Trebor 610RC User Manual

Phone: [phone] or 801-561-0303
Fax: [phone]
e-mail: [email protected]

MAGNUM 610RC PUMP

Operation / Maintenance

Manual

1/30/2014 – M610RC-AA

PATENTS: U.S. 09642426, U.S. 06106246, U.S. 05971402, U.S. 05370507

CONTENTS

1 FORWARD .............................................................................................................................................. 3

2 SAFETY INFORMATION ........................................................................................................................ 4

2.1 GENERAL SAFETY GUIDELINES ............................................................................................... 4

2.1.a Safety Symbols ............................................................................................................................. 4

2.1.b Operating Personnel ..................................................................................................................... 4

2.1.c In the Event of Non-Compliance ................................................................................................... 4

2.1.d Safety at Work .............................................................................................................................. 4

3 WARRANTY ........................................................................................................................................... 5

4 INSTALLATION ...................................................................................................................................... 6

4.1 UNPACKING................................................................................................................................. 6

4.2 TIE BOLT TORQUE ..................................................................................................................... 6

4.3 UTILITIES / HOOK-UP ................................................................................................................. 6

4.4 CHECK MUFFLER OPERATION ................................................................................................. 7

4.4.a Purpose......................................................................................................................................... 7

4.4.b Adjustment .................................................................................................................................... 8

5 START-UP .............................................................................................................................................. 9

5.1 PERFORMANCE CHARTS .......................................................................................................... 9

6 MAINTENANCE .................................................................................................................................... 10

6.1 PREVENTIVE MAINTENANCE SCHEDULE ............................................................................. 10

6.2 RECOMMENDED SPARE PARTS ............................................................................................. 11

6.3 TOOLS ........................................................................................................................................ 11

6.4 PARTS ILLUSTRATION ............................................................................................................. 12

6.5 PARTS LIST ............................................................................................................................... 13

6.6 CLEAN-UP .................................................................................................................................. 13

6.7 DISASSEMBLY ........................................................................................................................... 13

6.7.a Body Disassembly ...................................................................................................................... 14

6.7.b Head Disassembly ...................................................................................................................... 14

6.8 ASSEMBLY ................................................................................................................................. 14

6.8.a Head Assemblies ........................................................................................................................ 14

6.8.b Body Assembly ........................................................................................................................... 15

6.8.c Final Assembly ............................................................................................................................ 16

7 TROUBLESHOOTING.......................................................................................................................... 17

M610RC Table of Contents

8100 South 1300 West, West Jordan, Utah 84088 USA Tel: [phone] Fax: [phone] www.treborintl.com

PUMP RECORDS

 Pump Model: _____________________________________________________________________

 Pump Serial Number: ______________________________________________________________

 Date: ___________________________________________________________________________

Maintain pump records whenever possible. This will provide ready access to information for ordering
spare parts and evaluating the performance of the pump. Information to be included in these records:

Fluid being pumped; Cycle rate; Service conditions, including frequency of operation; Maintenance
records, including parts usage.

DECLARATION OF CONFORMITY

We herewith declare that the pumps described in this Installation, Operation and Maintenance Manual
comply with the following provisions:

 Machinery Directive (98/37/EC)

 Applied harmonized standards: EN809, EN292, EN1050

 ATEX Directive (94/9/EC): Group I, Category M2; Group II, Category 2GD; T6; non-electrical

equipment; gas and dust

Method of compliance: prEN 13463-5 (Constructional Safety)

Technical File reference no.: 968/Ex-Ab501/04

Manufacturer:

Importer in Country of Use:

Trebor International

A Unit of IDEX Corporation

8100 South 1300 West

West Jordan, UT 84088, USA

Signature: ________________________________

1 FORWARD

THIS MANUAL CONTAINS INSTRUCTIONS FOR THE INSTALLATION, OPERATION AND
MAINTENANCE OF THE TREBOR PUMP. If you have any questions concerning the information
contained in this manual, contact your local Trebor pump distributor or contact Trebor direct at 800-669­1303 in the U.S., 801-561-0303 outside the U.S., or by email at [email protected].

All Trebor pumps are designed to give a long and trouble-free service life. The life of the pump and
satisfactory operation are enhanced by correct application, installation, regular inspection and routine
maintenance. Misuse or improper installation, operation or maintenance of pumps may result in pump
damage.

This manual must be read and understood prior to installation and maintenance. All installation, operation
and maintenance works must be carried out by qualified personnel in strict accordance with this manual
and must comply with all local, state and national safety codes. Trebor shall not be liable for injury,
damage or delays caused by a failure to observe the instructions contained in this manual.

You are advised to read the warranty that was supplied with your pump. Warranty is valid only when
genuine Trebor parts are used.

M610RC Page 3

8100 South 1300 West, West Jordan, Utah 84088 USA Tel: [phone] Fax: [phone] www.treborintl.com

This caution symbol indicates a risk to personal safety, the pump, the nearby equipment or the
environment if instructions and recommended precautions are not followed.

2 SAFETY INFORMATION

2.1 GENERAL SAFETY GUIDELINES

This manual gives instructions about pump installation, operation and maintenance. It must be read and
understood by the personnel responsible for these duties prior to assembly and start-up. This manual
must be kept available at the installation site at all times.

2.1.a Safety Symbols

Safety instructions in this manual are marked by:

2.1.b Operating Personnel

The personnel responsible for operation, maintenance, inspection and assembly must be adequately
qualified.

The responsibilities of the operating personnel must be defined by the plant operator. If the staff does not
have the necessary knowledge, they must be trained and instructed.

2.1.c In the Event of Non-Compliance

If operating personnel do not comply with the safety instructions contained herein, they may place
themselves, the pump or the environment at risk, which may result in a loss of any right to claim damages.

2.1.d Safety at Work

The following safety apparel should be available and worn, where appropriate:

 Chemical resistant gloves when handling parts that have been in contact with chemistry.
 Safety glasses with side shields for eye protection, especially when working around chemicals.
 Other personal protective equipment as required by local regulations to protect against all hazards.

Page 4 M610RC

8100 South 1300 West, West Jordan, Utah 84088 USA Tel: [phone] Fax: [phone] www.treborintl.com

3 WARRANTY

MAGNUM 610RC PUMP

TREBOR International, Inc. warrants to the purchaser of new equipment manufactured by TREBOR to be
free from defects in material and workmanship when used for its intended purpose under normal
operating conditions, and maintained according to the Operation/Maintenance Manual.

TREBOR’s obligation under this warranty is limited to repairing or replacing, at TREBOR’s option and at

the TREBOR factory, any part or parts thereof which shall, within 1 year after delivery thereof to the

original purchaser, be demonstrated to TREBOR’s satisfaction to have been defective. This warranty is

transferable. The warranty period is based on the original ship date from the factory. All warranty related
freight costs shall be borne by the customer.

Excessive wear to pump components caused by pumping abrasive solutions or chemicals, as well as
damage caused by ingesting foreign objects shall not be covered by this warranty.

This warranty shall not apply to any equipment which, in the judgment of TREBOR, shall have been

repaired or altered outside TREBOR’s factory in any way, so as to affect its performance or reliability;

subjected to misuse, negligence or accident; or used other than in accordance with TREBOR’s printed
instructions.

There are no terms, conditions or warranties, expressed, implied or statutory, of merchantability,
fitness, capacity, or otherwise, of the goods ordered, other than, or different from, the warranty set
forth above. This warranty takes precedence over any other warranty, expressed or implied.

TREBOR neither assumes, nor authorizes any other party to assume for it, any liability in connection with
said equipment except as set forth above.

M610RC Page 5

8100 South 1300 West, West Jordan, Utah 84088 USA Tel: [phone] Fax: [phone] www.treborintl.com

Qty

Item

Description

1

610RC

Magnum 610RC Pump

1

M610RC

Operation/Maintenance Manual

1

C0135

Check Muffler Assembly

1

C0145

Conductive Connector Group

CAUTION: If pipe work is not properly installed, it may pose a risk to personnel, equipment or
environment, when operating in areas with explosion hazard.

4 INSTALLATION

4.1 UNPACKING

After unpacking, the pump should be checked for any damage that may have occurred during shipment.
Damage should be reported to the carrier immediately.

The following items should be included within the shipping container:

4.2 TIE BOLT TORQUE

The tie bolts on the pump are tightened before leaving the factory. However, relaxation may occur due to
handling, material creep, or other unforeseen events. Trebor recommends that all eight tie bolts be re­tightened upon pump install. The following procedure should be used.

1. Remove black tie bolt caps (Item 5 in 6.4 Parts Illustration) from both sides of all 8 tie bolts.

2. Apply 42 in-lbs. of torque to each slave side bolt while holding the master side bolt stationary. A
star-pattern is advised.

a. The master side is the left side of the pump if you are looking at the fluid ports.

3. Replace tie bolt caps.

4.3 UTILITIES / HOOK-UP

The pump is mounted using four 1/4” bolts. It is recommended that the pump be mounted not more than
15° from level to maintain its self-priming ability and pumping efficiency.

Air Inlet: 1/4” NPTF (3/8” [8mm] supply tube minimum).
Air Supply: 20-60 PSIG (.14 – .41 MPa) clean dry air or nitrogen. (See Performance Charts, Section

5.1, for air consumption.)

Fluid Ports: IN/OUT: 3/4” NPT; IMPORTANT SUCTION (“IN”) LINE REQUIREMENTS: (for maximum

flow)

1. Maximize supply line diameter. Minimum 3/4” tubing or 1/2” pipe recommended.

2. Minimize supply line length.

3. Minimize supply line restrictions; valves, fittings, etc.

Grounding: Use the supplied Conductive Connector Group to attach the pump to an appropriate

facility ground. The pump attachment is located behind the mounting base (see Figure
4-1) and is tapped for this group. It is advised to ensure your pump is properly installed.
This can be done by measuring the resistance to ground which should be less than
1,000,000 ohms from either pump head.

ATTENTION: All Local codes must be followed during installation and operation of this pump.

Page 6 M610RC

8100 South 1300 West, West Jordan, Utah 84088 USA Tel: [phone] Fax: [phone] www.treborintl.com

Recommended Maximum Operating Levels: 60 PSIG (.41 MPa) air supply, 110°C fluid temperature

ATTENTION: The pump should be operated with clean dry air (CDA) or nitrogen. Particulate, water and

oils in the air supply can damage the pump.

NOTE: Although extensive efforts are made to deliver pumps to our customers completely dry, new
pumps may contain residual moisture from their final DI water test.

4.4 CHECK MUFFLER OPERATION

4.4.a Purpose

 Permits pump to operate reliably in systems with a discharge fluid “dead head” condition (discharge

port closed while pump air supply remains on), or in systems that have the pump located at an
elevation below the liquid supply level.

Figure 4-1

M610RC Page 7

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4.4.b Adjustment

 The Check Muffler is preset at the factory to a setting that makes the pump cycle at a slow constant

rate with the fluid discharge port closed, and the pump air supply at 45 PSIG. This setting also allows
the pump to operate with approximately 4 ft. (1 meter) of H2O positive fluid supply pressure.
“Deadheading” at other air supply pressure or with more positive fluid supply pressure (fluid source
above pump) may require user adjustment. The adjustment should control the pump to a slow,

steady cycle rate with no erratic cycling, “machine gunning”, evident.

NOTE: If pump application does not require operation in either of these conditions, loosen check muffler

adjustment screw by turning counter-clockwise for minimum restriction. Note: Pump capacity is reduced
as check muffler adjustment is increased in the clockwise direction.

Figure 4-2

 Loosen locking nut.
 Turn adjustment screw clockwise (CW) to increase backpressure.
 Turn adjustment screw counter-clockwise (CCW) to decrease backpressure.
 Tighten locking nut when done to maintain adjustment.

Page 8 M610RC

8100 South 1300 West, West Jordan, Utah 84088 USA Tel: [phone] Fax: [phone] www.treborintl.com

Air Supply

Pressure

(PSIG)

Discharge Fluid

Pressure (PSIG)

Air Used

(SCFM)

Cycles

Per Minute

Displacement
IN3 Per Cycle

20 0 3.9

170

10.4

20

10

2.8

105

9.3

30 0 5.6

190

10.5

30

15

4.0

120

9.4

40 0 7.0

198

10.5

40

20

5.4

125

9.6

50 0 8.4

205

10.5

50

25

7.2

130

9.7

60 0 10.2

208

10.6

60

30

8.4

128

9.4

5 START-UP

 Pump air supply pressure should be regulated.
 Open the fluid suction (IN) line valve, if necessary.
 Open the fluid discharge (OUT) line valve, if necessary.
 Start with air regulator at low pressure setting. Increase or decrease pressure to attain desired flow,

up to 60 PSIG (.41 MPa) at the pump.

 Table 1: Consumption / Efficiency can be used to determine approximate air consumption.
 Refer to Troubleshooting, Section 0, if pump fails to start.

ATTENTION: Prolonged periods of dry running will damage critical internal pump parts.

5.1 PERFORMANCE CHARTS

Pumping capacity is a function of air supply pressure and volume, suction head, suction line restrictions,
discharge head, discharge line restriction, and fluid specific gravity and viscosity.

Table 1: Consumption / Efficiency

NOTE: Specification to be used to size regulators and control valves.

Figure 5-1: Pressure & Capacity Chart

M610RC Page 9

8100 South 1300 West, West Jordan, Utah 84088 USA Tel: [phone] Fax: [phone] www.treborintl.com

CAUTION: Be aware that the pump will contain residual liquid when it is removed from service.
Please follow the instructions in the Pump Return Data Sheet for proper decontamination
before returning the pump to Trebor.

MAGNUM 610RC PUMP

Replacement

Inspection

Component / Comments

6 Month

1 Year

2 Year

3 Month

6 Month

1 Year

2 Year

X

Shuttle Spool System

X

Tie Bolt Retorque

X

Check Balls and O-Rings

X

Check Balls and O-Rings (High Suction Applications)

X

Shaft Seal and Shaft

X

Shaft Seal and Shaft (High Suction Applications)

X

Diaphragms and Main Seals

X

Diaphragms and Main Seals (HF)

X

Diaphragms and Main Seals (ACT 935 & TMAH)

Recommended tie bolt torque is 42 in-lbs.

6 MAINTENANCE

Trebor pump maintenance can be divided into two categories: air system maintenance and fluid system
maintenance. The purpose of air system maintenance is to prevent air system failures such as stalling or
erratic cycling. The purpose of fluid system maintenance is to maintain suction lift and maximum fluid
capabilities.

PUMP REBUILD SERVICE
Trebor provides a factory rebuild service for customers using Trebor products. Trebor will rebuild any

standard pump (exclusive of options). Please contact Trebor’s Sales Department for current rebuild

pricing. The fixed rebuild price includes a factory rebuild and parts equivalent to the standard rebuild kit.
Each factory rebuild comes with a new one-year warranty. Repairs requiring more extensive part
replacements will be quoted prior to proceeding with the pump rebuild. If the pump has exceeded its
useful life and cannot be rebuilt, the customer may elect to purchase a new Trebor pump. If the customer
chooses not to rebuild or replace the pump, a $150.00 evaluation charge will be required.

All returned pumps are to be shipped freight prepaid with a valid purchase order for the cost of rebuild
service. Please contact Trebor prior to returning your pump to obtain an RMA Number and Pump Return
Data Sheet to ensure proper safety precautions. Each pump will be evaluated and repaired within 5
working days of the receipt of pump at Trebor facility.

6.1 PREVENTIVE MAINTENANCE SCHEDULE

The following maintenance schedule is recommended to optimize pump performance and minimize
failures. Tie bolt torque should be checked prior to installation and every twelve months thereafter.

Adhering to the recommended preventative maintenance schedule along with periodic inspection of the
pump will ensure continued efficient operation and overall reliable pump performance.

Page 10 M610RC

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KR610RC-00-A Spares Rebuild Kit, which includes:
Part No

Qty

Description

KD610-03-A

1

Diaphragm Kit

Includes:

(2)
(2)

98003600
C0100

O-Ring
Diaphragm Set

KM610RC-00-A

1

Maintenance Kit

Includes:

(1)
(1)

11001210
11001230

Shuttle Assembly
Detent Assembly

11001015

1

Protective Cap Set

11001220

2

Pilot Valve

1610B0022

1

Shaft

98001415

4

Check Ball

98001976

2

Shaft Seal

98002331

2

O-Ring

98002332

2

O-Ring

98002334

4

O-Ring, PTFE

AM084

2

Check Cap Seal

C0135

1

Check Muffler

KT610RC-00-A Tool Kit, which includes:
Part No

Qty

Description

98001225

2

3/8” Nut Driver

98001226

1

1/2” Nut Driver

98001230

1

5/32” Allen Wrench

98002327

1

Tool Case

98003225

1

3/8” Socket

98003305

1

Drive Handle

T000B0014

1

Check Sleeve Removal Tool

T000B0020

1

Check Sleeve Insertion Tool

T0123

1

Shuttle Sleeve Tool

T0146

1

3/4” Pin Tool

T0148

1

1/2” Pin Tool

T16002104

1

Shaft Bullet

6.2 RECOMMENDED SPARE PARTS

6.3 TOOLS

The following tool kit is recommended as standard service equipment.

M610RC Page 11

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6.4 PARTS ILLUSTRATION

Page 12 M610RC

8100 South 1300 West, West Jordan, Utah 84088 USA Tel: [phone] Fax: [phone] www.treborintl.com

ILL
NO

PART NO

QTY

DESCRIPTION

PM

YEAR #

MATERIAL

1

1100C0026

1

Shuttle Plug PP

2

11001230

1

Detent

1 & 2

Acetal, SS

3

11001210

1

Shuttle Assembly

1 & 2

SS410, Buna

4

C0135

1

Check Muffler Assembly

2

PP, NPRN

5

98001109

12

Tie Bolt Cap 2 PU

6

98002338

6

Nut, Flanged

SS18-8

7

C0142

1

Master Head

PP

8

11001220

2

Pilot Valve

Brass, SS, NBR

9

98003600

2

Main Seal 2 Viton

10

C0100

2

Diaphragm Set

2

PFA

11

C0095

2

Push Plate PTFE

12

1610B0022

1

Shaft 2 PFA

13

98001976

2

Shaft Seal 2 PTFE

14

C0141

1

Body PTFE

15

98002334

4

O-Ring, PTFE Check Valve

2

PTFE

16

98001415

4

Check Ball 2 PTFE

17

1610B0007

2

Suction Sleeve

PTFE

18

1610B0008

2

Discharge Sleeve

PTFE

19

AM084

2

Seal, Check Bore Cap

2

PTFE

20

C0144

2

Check Bore Cap

PTFE

21

C0143

1

Slave Head PP

22

1610B0010

6

Tie Bolt Assembly

SS416, PFA

23

AM022

1

Mounting Base

PP

24

98003207

4

Mounting Screw

PP

25

98003071

1

Locking Lever Screw

PP

26

AM023

1

Locking Lever

PP

27

C0102

1

Quick Release Base

PP

28

1610A0013

1

Pilot Transfer Tube

PFA

29

98002331

2

O-Ring, Transfer Tube

2

Viton

30

1110A0022

2

Main Transfer Tube

PFA

31

98002332

2

O-Ring, Transfer Tube

2

Viton

32

98003599

2

Conductive Pin

SS

33

C0145

1

Conductive Connector Group

SS

CAUTION: Pump assembly and disassembly must be performed by authorized and qualified
personnel who have fully read this manual. If not, the pump could be damaged and people and
the environment placed at risk when operating this pump in explosive hazard areas.

6.5 PARTS LIST

6.6 CLEAN-UP

The pump fluid cavities may be flushed clean by cycling with the suction (IN) and discharge (OUT) lines
connected to a DI water flushing or rinsing tank. Flushing using an external pressure source without
allowing the pump to cycle will result in incomplete removal of potentially dangerous chemicals.

6.7 DISASSEMBLY

During the life of the pump it will be necessary to perform certain preventative maintenance procedures to
ensure its continued high performance operation. This section and the next (6.8 Assembly) are provided
for the user’s convenience in disassembly and re-assembly procedures.

 Thoroughly clean / flush the pump using DI water (Refer to Section 6.6 Clean Up).
 Unlock pump from quick release base by pulling out locking lever on front of base. Then slide pump

forward until it stops. Lift pump off base.

 Remove check muffler assembly.
 Remove tie bolt caps from both heads.
 Remove flanged nuts from the tie bolt assemblies. (Master Head side.) Using both 3/8” nut drivers.

Leave tie bolts in place.

 Lay the pump on the slave head side.

M610RC Page 13

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 Remove the master head.
 Remove the main seal and diaphragms.
 Remove the main transfer tube and seal.
 Remove the pilot transfer tube seal.
 Remove the body assembly.
 Remove the pilot transfer tube and seal and the second main transfer tube and seal.
 Remove the slave side set of diaphragms and main seal.
 Remove tie bolts.

NOTE: All parts, when disassembled, should be thoroughly washed and be free from chemical residue for
handling purposes.

6.7.a Body Disassembly

 Remove check bore caps and seals.
 Remove sleeves, check balls and O-rings.
 Unthread one push plate from the shaft.
 Remove remaining push plate and shaft from body.
 Unthread push plate from shaft.
 Remove shaft seals from the shaft bore, taking care not to damage the shaft bore or shaft seal

grooves.

6.7.b Head Disassembly

 Remove the shuttle cap from the master head.
 Remove the detent and shuttle spool. See Section 6.4 for shuttle detail. (A small blast of air into the

air inlet port will normally cause the detent and shuttle spool to pop out.)

 Remove the shuttle sleeve from the shuttle bore.
 Remove the pilot valves from the master and slave heads, with 1/2” nut driver.

NOTE: The shuttle spool, sleeve and the exterior of the detent may be cleaned with isopropyl alcohol. Do
not disassemble or remove lubricant from detent. If lubricant is lost, it is necessary to replace the detent
to avoid damage to the shuttle spool.

6.8 ASSEMBLY

6.8.a Head Assemblies

Pilot Valve (Both Heads)
 Install the pilot valves with 2 wraps of TFE thread tape in each head.

Figure 6-1

Page 14 M610RC

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Shuttle Assembly (Master Head)

NOTE: Ensure that the shuttle spool moves freely inside the shuttle sleeve prior to installation.
 Check the shuttle assembly making sure it has notched O-rings on each end. (See Section 6.4 for

shuttle detail.)

 Insert shuttle sleeve into the shuttle bore.
 Insert shuttle spool.
 Insert detent.
 Install shuttle cap with 2 wraps of TFE tape.

6.8.b Body Assembly

NOTE: Body must be upside down with check port extending over a table edge so that parts remain

assembled during insertion of sleeves. (See Figure 6-2.)

Figure 6-2

 Insert suction sleeve, check ball and O-ring carefully into check bore.

NOTE: The suction sleeves have a shoulder diameter larger than their body diameter.

 Repeat insertion process with the discharge sleeve, check ball and O-ring.
 Repeat process for second check bore.
 Place seals and tighten check bore caps into check bores.
 Install shaft seals into shaft bore grooves.

M610RC Page 15

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CAUTION: If conductive pin is not properly installed, it may pose a risk to personnel, equipment
or environment, when operating in areas with explosion hazard.

CAUTION: If conductive pin is not properly installed, it may pose a risk to personnel, equipment
or environment, when operating in areas with explosion hazard.

CAUTION: A good validation of correct pump assembly is to check the resistance between
both pump heads to ground. Failure to assemble properly may pose a risk to personnel,
equipment or environment, when operating in areas with explosion hazard.

 Thread shaft into push plate, gently snug.
 Insert shaft through shaft bore using shaft bullet as shown (This prevents damage to the PTFE shaft

seals).

Figure 6-3

6.8.c Final Assembly

 Remove bullet and thread on remaining push plate, gently snug.
 Insert tie bolt assemblies through slave head and lay flat with tie bolts sticking up.
 Place main seal O-ring into the main seal groove in slave head.
 Install a diaphragm set, removing all air from between diaphragms, onto the tie bolts noting the

relative orientation of the formed main seal groove in the diaphragms with respect to conforming to
the main seal. Also note air transfer port hole alignment.

 Place one main transfer tube with seal into respective port.
 Place pilot transfer tube and one seal into slave head.
 Install one conductive pin in the slave head.

 Carefully place and press the body assembly onto the tie bolts, transfer tubes, seals, and slave head.
 Install the remaining diaphragm set onto the tie bolts and body, again noting formed main seal groove

and transfer port seals (O-rings).

 Install seal onto protruding pilot transfer tube.
 Place the master side main seal O-ring into the formed groove in the diaphragms as closely as

possible to ensure engagement into the main seal groove in the master head.

 Install one conductive pin in the master head.

 Place remaining main transfer tube and seal into body.
 Install the master head onto the bolts taking care not to jar or move any of the mating components.
 Install flange nuts onto tie bolts; tighten to 42 in-lbs. torque.
 Install tie bolt caps and check muffler assembly.
 Install pump onto base and slide back. Use locking lever to secure.
 Resistance between heads must be less than 1,000,000 ohms.

Page 16 M610RC

8100 South 1300 West, West Jordan, Utah 84088 USA Tel: [phone] Fax: [phone] www.treborintl.com

Pump Will Not Start, Fails to Operate

Cause:

Solution:



Insufficient air pressure.



Must be 10-15 PSIG greater than fluid discharge line
pressure.



Insufficient air volume.



See Performance Charts (Section 5.1) for requirements.



Dirty or damaged shuttle valve.



Clean shuttle spool/detent and sleeve until free movement is
assured; or replace (see 6.8.a).

Use clean dry air or nitrogen.



New diaphragm installed; not stretched
enough to allow contact with pilot valves.



Increase air pressure up to 60 psig until pump starts.
Decrease for proper flow if necessary.



Both diaphragms expanded into contact with
pilot valves due to excess fluid supply line
pressure.



Adjust check muffler assembly (see 4.4).



Fluid discharge line blocked. Downstream
valve closed, filter plugged or other
obstruction (dead head).



Remove obstruction. Refer to Section 4.4 for further
information on “Dead Head” condition.



Shuttle valve spool may be centered.



Turn off air supply. Disconnect supply tube at pump fitting to
bleed internal pressure. Reconnect and turn on air.

Remove shuttle cap and push the spool to end of travel.
Replace cap, start pump.

Bubbles in Fluid Discharge

Cause:

Solution:



Leaking fluid inlet fitting.



Tighten, or remove and wrap with PTFE thread tape prior to
tightening.

Replace seals (adapter port option only).



Leaking main seal.



Tighten tie bolt nuts to 42 in-lbs. Replace diaphragms if
damaged.



Ruptured (perforated) diaphragm. This is
easily detected by large amounts of air in the
discharge fluid during pump operation.



Replace Diaphragms.

Fluid Leaks

Cause:

Solution:



Tie bolt torque not enough to effect seal.



Tighten all nuts to 42 in-lbs.



Damaged main seal.



Replace. Check for irregularities in diaphragm groove on
pump body. Inspect for proper chemical compatibility.



Check bore cap.



Tighten, or remove and replace seal.



Ruptured diaphragm(s) can result in fluid
leaks through air exhaust port and shuttle
valve.



Replace diaphragms, and any parts that may have been
damaged by fluid exposure.

7 TROUBLESHOOTING

M610RC Page 17

8100 South 1300 West, West Jordan, Utah 84088 USA Tel: [phone] Fax: [phone] www.treborintl.com

Erratic Cycling

Cause:

Solution:



Leaking shuttle cap.



Tighten; or remove and wrap with PTFE thread tape prior to
tightening.



Fluid supply line restricted (cavitation).



Reduce fluid restriction.
Reduce distance, height of suction head.
Increase diameter of suction supply line (reduces restriction).



Fluid supply line pressure.



Adjust check muffler assembly.



Pilot valve not seating.



Check pilot valve function and seal.
Additional PTFE thread tape on pilot valve threads.



Pilot valve transfer O-rings leaking.



Check diaphragm hole alignment. Replace O-ring seals.



Check ball(s) not seating.



Replace check balls and O-ring seats.

Page 18 M610RC

8100 South 1300 West, West Jordan, Utah 84088 USA Tel: [phone] Fax: [phone] www.treborintl.com