Kyocera SDS INSTALLATION

SDS SERIES

DC SUBMERISIBLE PUMPS

REBUILD MANUAL

Kyocera Solar, Inc. / SOLARJACK, 7812 E. Acoma Drive, Scottsdale, AZ 85260 Telephone [phone] FAX [phone] E-mail [e-mail] www.kyocerasolar.com

SDS PUMP REBUILD INSTRUCTIONS

Rev.4/92

1.Remove cable guard screws (Item 1).

2.Remove 1/8” pipe plug (Old Style) or 3/8” NC set screw (New Style) (Item 5) using a 3/16" hex wrench. WARNING: PUMP HOUSING MAY BE UNDER

HIGH PRESURE. USE EXTREME CAUTION IN REMOVING END CAP PLUGS AND END CAP SCREWS.

3.Remove the two socket head screws (Item 26) from end cap (Item 6) 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 (Item 8) comes out, disconnect the two motor wires plugged into the end 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 (Item 25) from the discharge head using a 5/32", hex wrench.

8.Remove the bypass valves and springs (Items 19 & 20), suction 5creen (Item 24), check valve assembly (Item 21), and gasket (Item 22) from the discharge head. Note: Check valve removal may require a lite tap with a blunt tool through the discharge opening.

9.Remove the two motor adapter screws (Items 4) using a 5/32”, hex wrench. Remove the set screw from the cam assembly (Item 13) using a long 1/8”, hex wrench. This wrench must be inserted through the hole in the side of the motor adapter (Item 16). 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 two piston screws (Item 12), and then the cam assembly (Item 13).

11.Discard the support collars (Item 14), O-ring6 (Items 9), diaphragm (Item 17), check valve (Item 23), and gasket (Item 22).

12.Clean and inspect all remaining parts and make sure that the electrical studs protruding from the epoxy in the end cap are in good condition and the epoxy is still hard.

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SDS PUMP REBUILD INSTRUCTIONS

ASSEMBLY

1.Set the brass pistons (Items 18) flat side down on the pump assembly plate, positioning the two holes over the locating studs.

2.Place the diaphragm (Item-17), with the offsets up, over the pistons locating the piston shafts through the two holes.

3.On an SDS-D-128 use only the white santoprene diaphragm. 0n an SDS-D-228 use only the black EPDM diaphragm and install the Teflon wear washer (Item 15) around the piston shaft. CAUTIONNEVER USE ANY TYPE, OF GREASE ON EITHER DIAPHRAGM, IT MAY CALUSE DIAPHRAGM FAILURE.

4.Slip the support collars (Item 14) over the shafts with the radius side toward the diaphragm.

5.Set the motor adapter (Item i6) face down over the diaphragm assembly allowing the piston to protrude through the two holes being careful not to nick or cut the diaphragm.

6.Put the set screw into the cam and insert the cam assembly (Item 13) over the piston shaft making sure the piston shafts fit into the cam plate holes.

7.Insert the two piston screw (Item 12) 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.

8.Place the motor on the assembly board with the shaft up. Turn the motor shafts until the flat side faces you.

9.Coat the inside of the cam hole and the outside of the motor shaft with silver anti-seize (NAPP. part no. 765-1674, is recommended).

10.Insert a long 1/8”, hex wrench through the hole in the motor adapter and into the cam set screw.

11.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.

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