Sun Pumps SPB 10-16C-1.0 User Manual

SUNPUMPS SPB-SERIES

PISTON PUMP SERVICE MANUAL

Caution: Piston pumps are positive displacement pumps. Therefore, a properly

designed pressure RELIEF OR SAFETY VALVE MUST BE INSTALLED in the
discharge piping. Failure to install such a relief mechanism could result in personal
injury or damage to the pump or system. SunPumps does not assume any liability or
responsibility for the operation of a customer’s high-pressure system.

INSTALLATION AND START-UP INFORMATION

Optimum performance of the pump is dependent upon the entire fluid system and will be
obtained only with the proper selection, installation of plumbing and operation of the
pump.

LUBRICATION: Fill crankcase with special hydraulic oil per pump specifications.

DO NOT RUN PUMP WITHOUT OIL IN CRANKCASE. Change initial fill after 50
hours running period. Thereafter, change oil every three months or at 500 hour

intervals.

PUMP ROTATION: Pump was designed for forward rotation to allow optimum

lubrication of the crosshead area. Reverse rotation is acceptable if the crankcase oil level
is increased slightly above center dot to assure adequate lubrication.

To minimize piping stress, use appropriate flexible hose to inlet and discharge ports.
Use the correct belt; make sure pulleys are aligned. Excessive belt tension may be
harmful to the bearings. Hand rotate pump before starting to be certain shaft and
bearings are free moving.

LOCATION: If the pump is used in extremely dirty or humid conditions, it is

recommended pump be enclosed. Do not store or operate in excessively high
temperature areas or without proper ventilation.

INLET CONDITIONS: Refer to complete Inlet Condition Check-List in this

manual before starting system. DO NOT STARVE THE PUMP OR RUN DRY.

DISCHARGE PLUMBING: OPEN ALL VALVES BEFORE STARTING

SYSTEM to avoid deadhead overpressure condition and severe damage to the pump or
system.

Install a Pulsation Dampening device mounted directly to the discharge line. Optimum
precharge should be calibrated at 30-50% of the operating system.

A reliable Pressure Gauge should be installed near the discharge outlet of the high­pressure manifold.

The pump is rated for a maximum pressure; this is the pressure, which would be read at

the discharge manifold of the pump.

An Unloader or Relief Valve must be installed to prevent over pressurizing the
pump in the event the discharge or downstream plumbing becomes plugged or is turned

off. Severe damage to the pump will result if this condition occurs without a relief valve
in the line. CAUTION: Failure to install such a safety valve will void the warranty

on the pump. Discharge regulating devices should be at minimum pressure setting
at start-up. On systems over 2000-PSI SECONDARY PROTECTION is recommended

by installing a pop-off valve, safety valve or rupture disc. START SYSTEM WITH ALL
VALVES OPEN OR IN THE LOW PRESSURE SETTING.

Use PTFE liquid (sparingly) or tape to connect accessories or plumbing. Exercise
caution not to wrap tape beyond the last thread to avoid tape from becoming lodged in the
pump or accessories. This condition will cause a malfunction of the pump or system.

STORING: For extended storing or between use in cold climates, drain all pumped

fluids from the pump and flush with antifreeze solution to prevent freezing and
damage to the pump. DO NOT RUN PUMP WITH FROZEN FLUID.

SERVICING THE VALVE ASSEMBLIES

DISASSEMBLY

1. Remove the fasteners securing the discharge manifold to the crankcase of the pump.

2. Support the discharge manifold and tap from the backside with soft mallet. Gradually

work free from cylinders.

3. Valve assemblies will remain in the manifold. Pump models with the o-ring groove

on the outside of the valve seat require the assistance of a Valve Seat Removal
Tool to remove the valve seat. The valve, spring and retainer will then fall out

when the manifold is inverted.

Pump models without the o-ring groove on the outside of the valve seat permit the seat,
valve,
spring and retainer all to fall out when manifold is inverted.

REASSEMBLY

1. Examine Retainer for wear and replace as needed. Place Retainer in manifold

chamber with nylon tab down.

2. Examine springs for fatigue and replace as needed. Insert spring into center of

retainer.

3. Inspect the Valves for wear, ridges or pitting and replace as needed.
Note: Seating side of Flat Valves may be lapped on flat surface using 240 grit paper.
Quiet Valves due to their shape must be replaced. Insert valve over spring with
dimpled side up.
Note: Do not mix Quiet Valve and Flat Valve Assemblies.

4. Examine Valve Seats for wear, pitting or grooves. Lap the Flat Valve Seats with 240
grit paper or replace if evidence of excessive wear. Quiet Valve Seats must be
replaced if worn. Install seats with dishside down.

5. Examine o-rings and back-up rings on the Valve Seat if used and replace if worn.

Always lubricate o-rings for ease of installation and to avoid damage.
Note: First install o-ring in groove on seat towards seating surface, then back-up ring.
Note: Models without outer groove on seat require the o-ring to be placed on lip of
retainer.

6. Lubricate o-rings on exposed cylinder. Exercise caution when slipping manifold over

Cylinders to avoid damaging cylinder o-rings. Completely press manifold over
cylinders.

7. Replace fasteners and torque per chart.

Note: Replace all original shims if used. When new manifold is used reshim pump.
When starting the pump, check to see that there is no cylinder motion, as this will
cause premature failure of the cylinder o-rings. Center cylinder motion indicates
improper shimming.

SERVICING THE PUMPING SECTION

STANDARD PISTON PUMP

DISASSEMBLY:

1. Remove the discharge manifold as described above.

2. Grasp cylinders by hand and with an up and down motion, pull cylinders from inlet

manifold.

3. Remove cotterpin, nut and washer from piston rod.

4. Next remove retainer, spacer, piston-cup assembly and inlet valve.

REASSEMBLY:

1. Examine inlet valve surface for pitting, scale or grooves. Reverse valves and sand

inlet side of valve using 240 grit paper for clean surface or replace if evidence of
excessive wear. Slip onto rod.

2. Examine Piston seating surface and lightly sand on flat surface using 240 grit paper.

If extreme pitting or sharp edges, replace piston.

3. Examine cup for wear, cracking, tearing or separation from the piston. If worn

replace and lubricate before installing on piston.
Note cup installation: Wipe cup inserter with oil. Slip back-up ring (when used)
onto piston. Push cup over inserter and square with all surfaces. Faulty cup
installation causes premature cup failure. Some models use a one-piece piston
assembly. The cup does not separate from the piston. Replace entire assembly.
Lubricate piston assembly and slip piston-cup assembly onto piston rod with lid

facing discharge.

4. Next replace Piston Spacer and Retainer on rod.

5. Replace washer; thread on nut and torque per chart.

Note: Always replace with new stainless steel cotterpin and turn ends under.

6. Examine cylinder walls for scoring or etching which causes premature wear of cups

and replace as needed.

7. Lubricate cylinder and replace o-rings and/or back-ups rings if worn or damaged.

Back-up rings go to low pressure side of the o-rings. Carefully slip cylinder
over rod ends and push into inlet manifold with back-up ring to the discharge,
stroke marking on the inside of cylinder to the crankcase.

8. Position discharge manifold onto pump as described, replace fasteners and torque

per specifications chart.

SLEEVED-TYPE PISTON MODELS

DISASSEMBLY

1. After removing the discharge manifold, slip cylinders off piston rods. It is best

to leave the cylinder adapters and springs in the inlet manifold as they may score
the sleeved-type pistons when removed. The V-packings will remain in the cylinders.

2. Press worn V-packings from cylinders.

3. Remove cotter pins, slotted nuts, washers and piston retainers. Pull sleeved-type

pistons from each piston rod. Next slip sleeved-type spacer and inlet valve from each
piston rod.

4. Lubricate and install new o-rings on cylinders and adapters.

5. Inspect inlet valve surfaces. If inlet valves are worn, lap with 240 grit paper or

replace if evidence of excessive damage. If sleeved-type piston inlet surface is worn
or the outer diameter is scored, replace it.

REASSEMBLY

1. First install inlet valve then sleeved-type piston onto piston rod with the lapped end

toward the inlet valve.

2. Next install the sleeved-type spacer.

3. Then install new V-packings in the cylinder in the following order:
a. Install all parts in one cylinder, and then move to the next cylinder.
b. Rotate crankshaft to extend one piston rod completely forward.
c. Lubricate V-packings and cylinder I.D. and place O-ring end of cylinder on

work surface.

d. Install into cylinder Female Packing Spacer, black Female Adapter, V-packings,

nylon Male Adapter and Male Packing Spacer with “V” side down.

e. Install spring in outer end of cylinder and slip cylinder assembly over piston rod

end. Press cylinder into manifold chamber. The spring in the cylinder will be in