Sunfab SCPD 70/36 DIN BY-PASS User manual

Sunfab Hydraulics AB, Box 1094, SE-824 12 Hudiksvall, Sweden. Tel: [phone], Fax: [phone], E-mail: [e-mail] Web: www.sunfab.com
L
R
200/200 bar 220 + 116 = 336 Nm
350/350 bar 385 + 203 = 588 Nm
400/400 bar 441 + 232 = 673 Nm
7019EN1809 REV 1.0 1/8
PUMP SCPD 70/36 DIN BY-PASS
EN
INSTRUCTION MANUAL
THANK YOU FOR CHOOSING SUNFAB
You have chosen SCPD 70/36 DIN, a dual flow pump with differentiated
flow suitable for combination vehicles with high power take off ratio and high
output speeds. Compact design and easy installation makes SCPD 70/36
one of the mainstays for powerful, trouble free hydraulic systems
REMEMBER
A trouble-free hydraulic system is created using selected components and
correct installation. Consequently, follow the instructions in this manual,
which includes checking the power take off, tank design, hose dimensions,
installation and start up. Failure to carry out the manufacturer’s installation
conditions will invalidate the warranty.
INSTALLATION REQUIREMENTS
POWER TAKE-OFF
• Pump mounting: Spline shaft DIN 5462 / ISO 14.
Mounting flange ISO 7653-D.
• The power take off can be engine, flywheel or gearbox mounted
• The output speed of the power take off must not exceed the pump’s max
speed, relieved = 2550 rpm
• The permitted torque output on the power take off must be higher than the
pump shaft’s torque at maximum pressure
• The power take off’s direction of rotation must correspond with the selected
pump, which is supplied in left-hand (L) or righthand (R) designs
NOTE! The cover must not be turned to change the direction of rotation.

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PUMP SCPD 70/36 DIN BY-PASS
1
2
3
4
5 6
Optional design, solid baffle plate.
Recommended design.
Non-recommended design.
di
7019EN1809 REV 1.0
Important by installation!
Engine mounted power take-off
requires an internal diameter of
64 mm (2.5”) on suction hose and
connection.
If the suction line is more than 2
m long the internal diameter must
be increased by 10 mm for each
meter extension.
Recommended design
Optional design, solid baffle plate
Non-recommended design
INSTALLATION REQUIREMENTS (Continued)
OIL TANK
The design of the tank is important so that air bubbles are not drawn into
the pump and on into the system. Here are two recommended designs:
1. Air bubbles from the return oil are guided by the oil flow up to the oil
surface (venting area) via an oil pipe mounted at the bottom of the tank.
Another option, yet not as reliable, is a tank with a solid baffle plate as
shown in the middle picture.
2. Eventual drainage hoses is connected close to the
bottom, as far as possible from the suction connection.
3. Large return filter corresponding to 4 x the pump flow.
4. Separate air filter, which is fitted protected from water and dirt.
5. Suction connection close to or in the bottom of the tank on the op-
posite side to the return filter.
6. The net volume of the tank should be at least 1.5 x the pump flow and
positioned so that the oil level lies above the pump.
A traditional tank fitted with a baffle plate with holes is not recommended
as this does not deaerate the oil satisfactorily.
SUNFAB OIL TANK
This tank is included in the Sunfab range of accessories. It incorporates the
latest advances in tank design to give trouble-free operation.
The tank is available in two material options: stainless steel and aluminium.
PRESSURE RELIEF VALVES
The hydraulic system must be equipped with a pressure relief valve for
each circuit if the flow is used for different functions.
RECOMMENDED LINE SIZE (di)
All dimensions, internal diameter
Max flow 120 lit/min 160 lit/min
Max speed 1 470 rpm 1 850 rpm
Suction hose 50 mm (2”) 64 mm (2½”)
Shut off valve 50 mm (2”) 64 mm (2½”)
Return hose 32 mm (1¼”) 38 mm (1½”)
Pressure hose 19 mm (¾””) 19 mm (¾”)

Sunfab Hydraulics AB, Box 1094, SE-824 12 Hudiksvall, Sweden. Tel: [phone], Fax: [phone], E-mail: [e-mail] Web: www.sunfab.com
3/8
PUMP SCPD 70/36 DIN BY-PASS
A B CD
A
0-20 20 40 60 80 100 C
68
46
32
BCD
A B CD
7019EN1809 REV 1.0
INSTALLATION REQUIREMENTS (Continued)
HYDRAULIC OILS
Quality:
• Mineral oil
Use a high quality oil whose technical properties conform, as a
minimum, to the following requirements:
ISO type HM VG 32-68 depending on the ambient air temperature.
Alternatively DIN 51524-2 HLP.
• Environment oil
Use synthetic ester that conforms to the same technical requirements
as the standards above.
Oil filling - Oil changing:
• New hydraulic oil has a too high impurity level. Filling should therefore
be done with the help of a filter unit or through the oil tank’s return
filter.
• Do not mix oil of a different quality, viscosity or brand. This will impair
the technical properties of the oil.
Viscosity:
The viscosity of the hydraulic oil drops (the oil becomes thinner) when the
temperature rises. An ideal choice is an oil with a high viscosity index (VI).
A higher VI gives less viscosity variation when the temperature changes
• At a viscosity higher than 1500 cSt (limit for cold start) the pump cannot
suck in oil
• At a viscosity lower than 10 cSt the lubrication capacity is insufficient.
System efficiency will also be impaired
• When there is a risk of the oil temperature in oil tank to exceed 60 °C, an
oil cooler must be used
Refers to oil temperature in pump
E.g. Hydraulic oil 32: The designation “32” denotes the viscosity is 32
cSt at 40 °C. Lowest start temperature is -23 °C and highest working
temperature 82 °C. Ideal working temperature is 35 - 55 °C.
A
B
C
D
NOTE! The diagram concerns hydraulic oil with viscosity index VI ≈ 180
The hydraulic system can be started but not loaded. Only circulation pumping
at idling speed 1500-700 cSt.
The system can be loaded 700-40 cSt.
Ideal working range 40-20 cSt.
Highest recommended operating temperature 20-10 cSt.
=
=
=
=

Sunfab Hydraulics AB, Box 1094, SE-824 12 Hudiksvall, Sweden. Tel: [phone], Fax: [phone], E-mail: [e-mail] Web: www.sunfab.com
4/8
PUMP SCPD 70/36 DIN BY-PASS
18/16/13
Directional
control valve
A
B
D
S
By-pass valvePump Directional
control valve
7019EN1809 REV 1.0
INSTALLATION REQUIREMENTS (Continued)
FILTERING:
To invest in cleanliness is worthwhile:
• Halving of the amount of particles doubles component life
• Halving of the amount of particles reduces the degree of malfunction by
half.
To conform to most market demands on operating reliability and life span
the impurity level of the oil should correspond to class 18/16/13 as set out
in ISO 4406.
Consequently, the hydraulic system is equipped with a return filter and air
ilter with a degree of filtration equal to 10 μm absolute.
Furthermore, the hydraulic system should be equipped with a pressure
filter if necessary.
CHANGING THE FILTER:
First change after 50 hours of operation. Then whenever the filter pressure
indicates too high a pressure at the normal operating temperature for
hydraulic oil.
A good rule is to change the air filter at the same time.
Contamination level 18/16/13
Max 64,000 particles > 5 μm/100 ml.
Max 8,000 particles > 15 μm/100 ml.
10 μm
absolute
After changing the filter,
run with the lowest possible
flow for at least 5 minutes to
ensure the filter functions.
INSTALLATION
Installing By-Pass valve
Clean the contact surfaces. Install the valve with the necessary seals and
banjo bolts.
Cooling pipe/drainage pipe
If the flow through the system in by-pass mode is less than 10% of the
theoretical pump flow, caused by high pressure drop in the system, or if
the system is equipped with a closed-centre valve, an external cooling
line must be installed from the drain port directly to tank.
The line must be routed directly from the By-Pass valve to a connection
below the oil level of the tank.
Connection G¼
to cooling pipe/
drainage pipe.
30 Nm

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PUMP SCPD 70/36 DIN BY-PASS
80 Nm
80 Nm
Fill the pump with
hydraulic oil.
24 Nm
64
mm (2 ½")
G ¾, 150 Nm
Flow B
Flow A
Connection G¼
to cooling pipe/
drainage pipe.
30 Nm
7019EN1809 REV 1.0
INSTALLATION (Continued)
Pump installation
Lubricate the splined shaft before installation using assembly paste
intended for spline joints, e.g. Molykote G Rapid plus, or the like. Do
not hit the gear wheel/drive disc.
Use a M12 stud bolt and sleeve when assembling the gear wheel.
Use a M12 stud bolt and washer when assembling the drive disc.
Secure the gear wheel using a circlip or M12 bolt and locking fluid.
Secure the O-ring and fit the pump on the power take-off.
The manufacturer of the power take-off may have different
requirements.
Connections
Secure the O-ring and tighten the suction connection bolts crosswise.
Tighten the hose using two heavy-duty hose clips. To maintain the
speed characteristics do not use a strainer on the SCPD-pump. Use
pressure connections with flat seals against the pump for optimal
strength. Do not use connections with tapered threads.
Tank location and hose routing
The tank should be positioned as high and as close to the pump as
possible in order to create good suction conditions for the pump. The
suction pipe is routed so that air pockets cannot form, to prevent cavitation
and noise.
Electrical installation
Route the cables between the solenoids and the manoeuvre switch.
Start up
Start and run the pump unloaded at idling speed and allow the hydraulic
oil to circulate through the hydraulic system for at least five minutes before
the system’s functionality is tested.
The pump can be installed in 4 positions with the angle upwards, downwards
or to the side. When the angle is to the side it is an advantage if the pump can
be twisted so that the suction connection is highest.

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6/8
PUMP SCPD 70/36 DIN BY-PASS
7019EN1809 REV 1.0
TROUBLESHOOTING
Measures with malfunctioning hydraulic system
Cause
1. Pump not vented after installation.
2. Air leakage on the suction hose or pump.
3. Oil level too low.
4. Not optimal designed tank for separa-
tion of air from the oil.
5. Oil tank with too small air venting area.
1. Too small diameter on the suction hose.
2. Crushing or restriction of the suction
hose.
3. Oil too thick.
4. Underpressure in the oil tank.
1. Too small a diameter or restriction in
the pressure or return hoses.
2. Clogged pressure or return filter.
3. Oil flow too great.
4. Pressure relief valve tripped at too low
a pressure.
5. Oil too thin.
6. Oil tank too small.
7. Oil level too low.
8. High continuous power output.
1. Pressure relief valve tripped at too low
a pressure.
2. Defective directional control valve.
1. Pressure relief valve tripped at too
low a pressure.
2. Worn pump.
1. Too small diameter on the suction hose.
2. Crushing or restriction of the suction
hose.
3. Oil too thick.
4. Underpressure in the oil tank.
5. Worn pump.
1. Leakage from the suction connection.
2. Leakage from the shaft seal.
3. Leakage from the plugs/fittings.
1. Play on intermediate shaft.
2. Incorrect joint angle on intermediate
shaft.
3. Imbalance on intermediate shaft.
4. The universal joints are not in line with
each other.
Action
1. Vent the pump.
2. Repair the air leakage.
3. Fill with oil.
4. Replace the return filter with an oil
pipe or tank with solid baffle plate.
5. Change to a tank with a greater air
venting area.
1. Change to a suction hose with a
larger diameter.
2. Remove the restriction.
3. Change to an oil with a lower viscosity.
4. Change the air filter.
1. Change to hoses with a larger
diameter; rectify the restriction.
2. Replace the filter.
3. Lower the speed or change to a
smaller pump.
4. Adjust the valve or replace if necessary.
5. Change to an oil with a higher viscosity.
6. Change to a larger oil tank.
7. Fill with oil.
8. Fit an oil cooler.
1. Adjust the valve or replace if necessary.
2. Replace the directional control valve.
1. Adjust the valve or replace if necessary.
2. Replace the pump.
1. Change to a suction hose with a
larger diameter.
2. Remove the restriction.
3. Change to an oil with a lower viscosity.
4. Change the air filter.
5. Replace the pump.
1. Replace the O-rings and tighten the
hose clips.
2. Replace the shaft seals.
3. Replace the plugs/fittings and
tighten carefully (15 Nm).
1. Replace the intermediate shaft.
2. Ensure that the spindle on the power
take off and pump shaft are parallel.
3. Rectify the intermediate shaft.
4. Loosen and turn the spline coupling
so that the universal joints are
aligned with each other.
Troubleshooting
Check whether the flow in the pressure
hose from the pump pulsates. Oil spots
on the pump and suction hose can
indicate an air leakage.
Check the oil level in the tank.
Check whether the oil foams.
Check whether the pump cavitates.
This is noticeable through flow
pulsations and noise from the pump
stopping when the speed is lowered.
Run the pump unloaded at working
speed and measure the counter
pressure. Connect a pressure gauge to
the pressure hose close to the pump.
The pressure must not exceed 2 MPa.
Check whether the pressure rises to
the correct value when a function is run
towards the stop.
Check whether the pressure rises to
the correct value when a function is run
towards the stop.
Connect a flow meter close to the
pump. Check the flow.
1. The correct flow is obtained when
loaded.
2. Abnormally low flow obtained when
loaded.
1-5. Check whether the pump cavitates
This is indicated by the noise
stopping when the speed drops.
Check whether the noise
propagates in the hydraulic system.
6. Check whether the noise can be
heard at all speeds.
Localise the oil leakage.
Check whether the pump shakes,
despite the flow not pulsating, i.e. the
attachment does not jerk.
Fault
The equipment works
jerkily.
The equipment works
jerkily when starting and
at a high pump speed.
The oil has an abnormally
high temperature.
The equipment has a lack
of power.
The equipment runs
abnormally slowly when
loaded.
Noise from the pump.
Oil leakage from the
pump.
The pump shakes (inter-
mediate shaft assembly).
If oil leakage has occurred via a damaged shaft seal,
ensure that no hydraulic oil has entered the gearbox!

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7/8
PUMP SCPD 70/36 DIN BY-PASS
7019EN1809 REV 1.0
Theoretical oil flow A+B
at pump speed
Displacement A+B
Min pump speed A+B
Max pump speed A+B
Max pump speed A
Max pump speed B 1)
Max pump speed, relieved
Max working pressure 2)
Continous
Intermittent 3)
Max system oil temperature
Max inlet pressure (housing pressure)
Weight without valve
Weight with valve
Tare-weight torque without valve
Tare-weight torque with valve
Theoretical power at pressure and
pump speed
Theoretical torque on pump shaft
at different pressures
Direction of rotation
1) Port A relieved.
2) Do not only relieve port B if the pressure level of both ports is at the same time > 250 bar.
3) Max. 6 seconds per minute.
500
1000
1500
1800
69.2 + 36.4
500
1800
1800
2100
2550
350
400
70
2.0
22.4
27. 3
32.6
46.00
rpm
500
1000
1500
1800
34.6 + 18.2 = 52.8
69.2 + 36.4 = 105.6
103.8 + 54.6 = 158.4
124.6 + 65.5 = 190.1
l/minrpm
200 bar
11.5 + 6.1 = 17.6 kW
23.1 + 12.1 = 35.2 kW
34.6 + 18.2 = 52.8 kW
41.5 + 21.8 = 63.3 kW
350 bar
20.2 + 10.6 = 30.8 kW
40.4 + 21.2 = 61.6 kW
60.5 + 31.9 = 92.4 kW
72.7 + 38.2 = 110.9 kW
400 bar
23.1 + 12.1 = 35.2 kW
46.1 + 24.3 = 70.4 kW
69.2 + 36.4 = 105.6 kW
83.0 + 43.7 = 126.7 kW
200 bar
220 + 116 = 336 Nm
350 bar
385 + 203 = 588 Nm
400 bar
441 + 232 = 673 Nm
cm3⁄ rev
rpm
rpm
rpm
rpm
rpm
bar
bar
°C
bar
kg
kg
Nm
Nm
supplied in right or left-hand design
TECHNICAL DATA SCPD 70/36 DIN
If it is necessary to run a hydraulic function as an emergency operation
during a power cut, the pump flow can be started manually by screwing in
the By-Pass valve emergency screw.
For safety reasons the pump must not be running during the adjustment.
Do as follows:
1. Unscrew the protective cap.
2. Remove plastic spacer below the adjusting screw.
3. Screw in the adjusting screw until the pin bottoms
The valve is now activated and oil can be pumped into the hydraulic
system.
After emergency operation is completed the adjustment screw is reset to
the original position and the protective cap reinstalled.
EMERGENCY OPERATION OF THE BY-PASS VALVE

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PUMP SCPD 70/36 DIN BY-PASS
Sunfab reserves the right to make changes in design and dimensions without notice. Printing and typesetting errors reserved.
© Copyright 2018 Sunfab Hydraulics AB. All Rights Reserved.
7019EN1809 REV 1.0
When the pump is running:
1. Do not touch the pressure hose
2. Watch out for rotating parts
3. The pump and hoses may be hot
WARNING