SUNPUMPS SDS-Q Series User manual

SDS-Q SERIES PUMP REBUILD INSTRUCTIONS
Bottom Mounted Pistons
DISASSEMBLY
1. Remove cable guard screws and cable guard.
2. Loosen the 4 discharge head screws about 4 turns each but do not remove at
this time. With a rubber mallet tap the discharge head to break the bond between
the head and the diaphragm. This will relieve any pressure in the motor housing.
WARNING: PUMP HOUSING MAY BE UNDER HIGH PRESSURE. USE
EXTREME CAUTION IN REMOVING THE DISCHARGE HEAD.
3. Turn the pump over and remove the 3/8" set screw using 3/16" hex wrench
and the two socket head screws from end cap using a 5/32" hex wrench.
4. Clamp the pump in the puller and screw the proper threaded mandrel in the
end cap.
5. Pull the end cap out of the stainless housing. If the brass ends seem to be
stuck, warm the stainless housing slightly with a small propane torch, being
careful not to overheat and warp the housing. As the end cap comes out
disconnect the two motor wires plugged into the cap.
6. With the end cap removed from the housing turn the pump around, screw the
appropriate mandrel into the discharge head, and remove the pump assembly
from the stainless housing.
7. Remove the four socket head screws from the discharge head using a 5/32"
hex wrench.
8. Remove the suction screen, check valve assembly, relief valve assembly and
o-rings from the discharge head. Note: Check valve removal may require a
light tap with a blunt tool through the discharge opening.
9. Remove the four motor adapter screws using a 5/32" hex wrench. Remove the
set screw from the cam assembly using a long 1/8" hex wrench. This wrench
must be inserted through the hole in the side of the motor adapter. Before
inserting the wrench, visually align the set screw with the hole by turning the
motor adapter while holding the motor.
10. Pull the motor adapter and cam assembly away from the motor, remove the
four piston screws and then the cam assembly.
11. Clean and inspect all parts to be reused and make sure the electrical studs
protruding from the epoxy in the end cap are in good condition and the epoxy is
still hard.

SDS-Q SERIES PUMP REBUILD INSTRUCTIONS
ASSEMBLY
1. Set the brass pistons flat side down on the pump assembly plate, positioning
the two holes over locating studs.
2. Place the diaphragm face down over the pistons locating the piston shafts
through the four holes. CAUTION: NEVER USE ANY TYPE OF GREASE ON
THE DIAPHRAGM, IT MAY CAUSE DIAPHRAGM FAILURE.
3. Slip the support collars over the piston shafts with the round side toward the
diaphragm.
4. Set the motor adapter face down over the diaphragm assembly allowing the
piston to protrude through the four holes being careful not to nick or cut the
diaphragm.
5. Insert the cam assembly over the piston shaft making sure the piston shafts fit
into the cam plate holes.
6. Insert the four piston screws through the cam assembly, and tighten with a
5/32" hex wrench to 60 inch lbs. of torque. (Be careful not to allow the pistons to
slip off the locating studs while tightening the screws.) Each screw should be
tightened a little at a time alternating between each side. This will pull both
pistons into alignment before either piston clamps the diaphragm.
7. Place the motor on the assembly board with the shaft up. Turn the motor
shafts until the flat side faces you.
8. Coat the inside of the cam hole and the outside of the motor shaft with silver
anti-seize compound.
9. Insert a long 1/8" hex wrench through the hole in the motor adapter and into
the cam set screw.
10. Slip the cam assembly over the motor shaft aligning the set screw to the
center of the flat on the shaft. As the cam assembly is inserted over the motor
shaft tighten the set screw until it lightly touches the motor shaft and then back it
off 1/8 turn. Continue installing the cam assembly until the motor adapter butts up
to the motor. Then push on the pistons until the cam assembly bottoms on the
motor shaft. While holding the piston down firmly, tighten the set screw.
11. With the motor assembly still on the board, gently lift the diaphragm up on
each end and insert a bolt in each motor adapter hole.
12. Rotate the motor adaptor slowly until screws "drop" into place. Tighten the
screws while alternating between the four, to 40 inch lbs. of torque.
13. Lay the discharge head top side down on a flat surface. Install the relief valve
assembly and secure with the two Phillips head screws. Install suction screen
with the welded seam placed between the two cable guard screw holes.

14. Install the o-ring into the check valve and insert the check valve into the
discharge head making sure check valve assembly is flush with discharge head.
Turn the discharge head over and insert the four washers and the stainless head
bolts in the 4 countersunk holes.
15. With the motor assembly still held in a vertical position install the discharge
head on the motor adapter while carefully guiding the rings on the diaphragm into
the mating holes in the check valve assembly.
16. While holding the discharge head in position tighten the four screws a little at
a time, jumping to opposite sides, to 40 inch lbs. of torque.
17. Set the pump with the discharge end facing down on a flat table.
18. Install the two o-rings onto the motor adapter and lightly lubricate with a food
grade grease or petroleum jelly.
19. Lightly grease the inside of both ends of the stainless housing about one inch
deep and slip it over the pump assembly until it rests on the o-rings. With a small
block of wood or other soft flat object push the housing down over the o-rings
until it touches the brass lip on the motor adapter.
20. Screw a 10-32 X 3" stud into one of the coupling nuts on the back side of the
motor. This is used as a guide when installing the end cap assembly.
21. Install the two o-rings on the end cap assembly and lightly lubricate the o-
rings.
22. Connect the motor leads onto the electrical studs on the inside of the end
cap. (The positive red wire lead connects to the red wire side). Before seating
end cap in housing, be sure that the terminals on the wires are tight on the end
cap electrical studs. Slide the end cap over the guide stud, making sure that the
motor lead wires are not pinched between the end cap coupling nuts. Align the
cable guard screw holes on the same side as the screw holes in the discharge
head.
23. Push the end cap down inside the housing until it butts up against the brass
cap lip and then remove the guide stud.
24. Slip a #10 stainless steel washer and the small o-ring on each of the end cap
screws. Apply a small amount of non-outgasing silicone sealant around the o-
rings of the two screws. Insert the two screws into the end cap and tighten to 35
inch lbs. of torque. (DOW CORNING 3145 RTV ADHESIVE/SEALANT IS
RECOMMENDED).
25. Install the end cap plug and tighten with a 3/16" hex wrench. An anti-seize
should be used on the threads.
26. Install the cable guard over the motor lead using the four screws.