Hypro 1802C, 1803C, 1804C, 1805C, 1806C Installation, Operation, Repair And Parts Manual

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Hydraulically-Driven Pressure Washer Models 1802C, 1803C, 1804C, 1805C, 1806C, 1807C, 1824C, 1825C, 1826C and 1827C

Form L-0560PW

Installation, Operation, Repair, and Parts Manual

Description

Hydraulically-Driven Pressure Washers

Model Max. Max. Estimated Number GPM PSI

1803C 3.0 1000 5.0 1300 Forged Brass Head Triplex Pump with 28 lbs.

1805C 3.0 1500 8.0 1900 Forged Brass Head Triplex Pumps with 26 lbs.

1807C 3.0 2000 11.0 1300 hydraulic motor, chemical injector, 26 lbs.

1825C 4.0 1500 8.5 2000 adjustable unloader, gauge, 3⁄4" GH input, 33 lbs.

1827C 4.0 2000 8.5 2000

Hydraulic Motor

Requirements

GPM PSI

Description Weight Ea.

hydraulic motor, adjustable unloader, gauge,

⁄2" NPT input, 3⁄8" quick disconnect output

⁄8" quick disconnect output 33 lbs.

Hydraulically-Driven Pressure Washers with Hose and Gun Assembly

Model Max. Max. Estimated Number GPM PSI

1802C 3.0 1000 5.0 1300 Forged Brass Head Triplex Pump 38 lbs.

1804C 3.0 1500 8.0 1900 Forged Brass Head Triplex Pumps with hydraulic 41 lbs.

1806C 3.0 2000 11.0 1300 motor, chemical injector, adjustable unloader, 26 lbs.

1824C 4.0 1500 8.5 2000 gauge

1826C 4.0 2000 8.5 2000 and 50 ft. hose and gun assembly 49 lbs.

Hydraulic Motor

Requirements

GPM PSI

Description Weight Ea.

with hydraulic motor, adjustable unloader,

gauge,

⁄2" NPT input,3⁄8" quick disconnect output,

and 50 ft. hose and gun assembly

⁄4" GH input, 3⁄8" quick disconnect output, 49 lbs.

2/08

General Safety Information

Notes are used to notify of installation, operation, or maintenance information that is important but not safety related.

Caution is used to indicate the presence of a hazard, which will or can cause minor injury or property damage if the notice is ignored.

Do not pump flammable or explosive fluids such as gasoline, fuel oil, kerosene, etc. Do not use in explosive atmospheres unless the Pump is properly grounded and the proper drive is used. The Pump should only be used with liquids compatible with the Pump materials. Failure to follow this notice can result in severe personal injury and/or property damage and will void the product warranty

arning denotes that a potential hazard exists and

W indicates procedures that must be followed exactly to either eliminate or reduce the hazard, and to avoid serious personal injury

, or prevent future

safety problems with the product.

Danger is used to indicate the presence of a hazard that will result in severe personal injury

, death, or

property damage if the notice is ignored.

The sound pressure level of the Pump may exceed 80dBA. Observe all safety precautions when operating the Pump within close proximity for extended periods by wearing hearing protectors. Extended exposure to elevated sound levels will result in permanent loss of hearing acuteness, tinnitus, tiredness, stress, and other effects such as loss of balance and awareness.

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Do not pump at pressures higher than the maximum recommended pressure.

Operate the Pump between a temperature range of

45oto 140oF [7oto 60oC].

Make certain that the power source conforms to the requirements of your equipment.

Provide adequate protection in guarding around the moving parts such as shafts and pulleys.

Secure the discharge line before starting the pump. An unsecured discharge line may whip, resulting in

ersonal injury and/or property damage.

heck all hoses for weak or worn condition before

C each use. Make certain that all connections are tight and secure.

Periodically inspect the pump and the system components. Perform routine maintenance as required.

Disconnect the power before servicing.

Release all pressure within the system before servicing any component.

Drain all liquids from the system before servicing.

Hazardous Substance Alert

Always drain and flush the pump before servicing.

Always drain and flush the pump prior to returning the Pump to Hypro for repair.

Never store a pump containing hazardous materials.

Prior to returning a pump for service or repair, drain all liquids and flush the pump with a neutralizing fluid; then, drain the pump again, and attach a tag or written notice certifying that this procedure has been done.

Use only pipe, hose, and hose fittings rated for maximum rated pressure of the pump or the pressure at which the pressure relief valve is set at. Do not use used pipe.

Do not use these pumps for pumping water or other liquids for human or animal consumption.

It is illegal to ship or transport any hazardous chemical without United States Environmental Protection Agency licensing.

Never use your hand to check the condition of hydraulic lines or hoses. If hydraulic fluid penetrates the skin, get medical help immediately. Failure to get proper medical help may result in loss of limb or life. The safest way to check hydraulic lines or hoses is by holding a piece of cardboard next to the hydraulic line or hose.

Hypro’s Hydraulically-Driven Pressure Washer can be installed on tractors with Closed Center and Load Sensing Hydraulic Systems, or on Custom Open Center Hydraulic Systems.

The required inlet conditions for the water pump can vary from the flooded suction of a water tank to pressure from a city water supply. The water supply must be capable of supplying more than 4.0 gpm of water flow to meet the pump requirements.

Installation Requirements

The pump comes equipped with an unloader valve and bypass system rated for 2000 psi. When the trigger of the gun is in the OFF position, the unloader allows water to recirculate back through the pump. A thermal relief valve is included to keep the pump from overheating when it is in the bypass mode with the gun trigger in the OFF position. For long pump life, do not allow the pump to run more than five minutes with the gun trigger in the OFF position.

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Fresh Water

Flooded Section

3/4" Strainer

80 Mesh

P/N 3350-0035,

3350-0045,

3350-0035A

or equivalent

Hydraulic Quick

Disconnect

matches

female end

on Kit 8000-0030 &

8000-0049

5,000 psi

Gauge

Hydraulic Input

1/2" NPT (F)

Municipal Water

Supply Access

3/4" Hose

• Gun, Lance, Nozzle & Hose Assembly includes 50' pressure hose, gun, wand, nozzle, and female quick disconnect.

• Tank is mounted even or above the pump. Mount the tank higher if the inlet hose length is over 15 ft.

• Never run the pump dry.

• If suction inlet hose is more than four feet long, use next larger size.

Full-Flow, 3/4"

Shut-Off Valve

Hi-Lo

Spray Nozzle

3/4" Garden Hose

Adapter

Figure 1 Hydraulically-Driven Pressure Washer Hookup

Unloader Valve Instructions

The Unloader is factory set to a maximum of 2000 psi [138 BAR]. Do not tamper with the Unloader Valve settings or with the Locking Ring. Hydraulic System damage may result if the Unloader is adjusted outside the range of 2000 psi [138 BAR].

The Unloader Valve is factory tested and preset to 2000 psi [138 BAR]. Adjustment is necessary only if the unloader is not functioning properly.

1. For priming, the Spray Gun and Hose Assembly (Kit 8000-0030) should be detached from the pump at the Quick Disconnect (See Figure 1).

Thermal Relief Valve

Four

25/64 Dia.

Holes

Spray Gun

and Hose

5. The standard Pressure Washer is equipped with an adjustable cleaning angle nozzle. The cleaning angle may be varied throughout its range by rotating the black outer body clockwise (CW) or counterclockwise (CCW).

6. Your Pressure Washer is equipped with the optional Detergent Injection System. The nozzle must be set in Low Pressure Mode to activate the injector and draw soap. For rinsing, the nozzle should be set in High Pressure Mode. Pushing the black nozzle body forward places the nozzle in the Low Pressure Mode. Pulling the black nozzle body back places the nozzle in the High Pressure Mode.

Before Starting Up

2. Start the Pump and run it until it is fully primed, with water flowing freely out of the Quick Disconnect. Then, stop the Pump and reattach the Spray Gun and Hose Assembly at the Quick Disconnect (See Figure 1).

3. Pull the Gun Trigger, restart the Pump, and observe the pressure. The Hydraulic System and/or Bleeder Bypass Screw may require adjustment to obtain the proper pressure of 2,000 psi [138 BAR] (Refer Hydraulic System Operation for further information).

4. Open and close the Pressure Wash Gun several times to check the unloading pressure and Unloader Valve function.

Check oil level

Figure 2

Check that the oil is at the correct level using the Dipstick, and topping off if necessary (See Figure 2). Use Hypro Oil (part no. 2160-0038). Hypro oil is specially formulated, high grade, non-detergent, SAE 30 weight oil designed to prolong Pump life.

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Change the oil after 40 hours of break-in operation.

hereafter, change the oil every year or 500 hours,

T whichever comes first.

are of the Pump

After each use, flush the pump with a neutralizing solution for the liquid pumped. Follow this with a clear water rinse. For storage under freezing conditions, flush

Hydraulic System Operation

the pump with a 50/50 solution of automotive-type

ntifreeze and water.

Bypass Operation

uring Bypass Operation (when water is diverted back to

D the pump inlet side) a temperature rise occurs. A Thermal Relief Valve is provided to maintain the maximum water temperature at 145° F [63° C].

Hydraulic Systems

There are three types of Hydraulic Systems: Open center, Closed Center (Pressure Compensated), and Closed Center Load Sensing (Flow and Pressure Compensated).

Open Center Systems

In an Open Center System, the hydraulic pump puts out a constant flow. If the Pump puts out more than the Motor can use, a portion of the oil must be bypassed around the Motor. The Bleeder Bypass Screw allows the fluid to bypass around the Motor. When the oil is bypassed around a loop and does no work, the energy put into it by the Pump turns into heat. Therefore, this should only be used on smaller Open Center Systems where the amount of oil that must be bypassed is minimal.

Closed Center (Pressure Compensated) Systems

Closed Center (Pressure Compensated) Systems have a Variable Displacement Pump that will deliver flow at the necessary rate to maintain a specified pressure. The Flow Control Valve should be installed at the Motor Inlet to control the flow according to the Model requirements.

Closed Center Load Sensing Systems (Flow and Pressure Compensating)

The Closed Center Flow Compensated System is a variation of the Pressure Compensated System, designed primarily for more efficient operation and the generation of less heat. It works on the principle of maintaining a constant pressure drop from the pump to the working port of the Selector Valve. Any variation in demand at the Motor will cause a change in flow. The system senses this change in flow due to the change in pressure drop across the Valve and causes the pump to compensate by varying the Pump flow

Do not bypass oil. Use a Flow Control at the Motor Inlet to control the flow and speed of the motor.

Hydraulic Oil

The specifications for the Hydraulic-Driven Pressure Washer where compiled using Mobil DTE-26 hydraulic oil at a temperature of 140° F [60° C]. Using other type of oil and different temperatures will result in different flow requirements to replicate these Pressure Washer performance specifications. These specifications are a guide for initial start-up.

Plunger Replacement.

Using a metric allen wrench, remove the Socket

1. Head Cap Screws securing the Pump Head to the Pump Body (See Figure 3).

2. While turning the Crankshaft, use two screwdrivers to carefully pry between the Pump Head and Pump Body to remove the Pump Head (See Figure 4).

3. Remove the plunger Retaining Nut and the Plunger Retaining Nut W

asher (See Figures 5).

4. Slide the Plungers off the Piston Guides (See Figure 5).

5. Remove and discard the O-rings (See Figure 5).

Remove the Slinger Ring (See Figure 5).

Pump Repair Instructions

Remove

Socket Head Cap

Screws

Figure 3

While turning the

crankshaft, use

screwdrivers to pry

the pump head off.

Figure 4

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pply a thin film of oil to the new O-rings and

lungers before installing them.

7. Inspect the Plungers for cracking and replace them if damaged installing new O-rings and Slinger Rings at

he same time.

. Install the Plunger Retaining Nut Washers: then,

apply a drop of blue thread locking compound to the threads of the Plunger Retaining Nuts and install them.

9. Tighten the Plunger Retaining Nuts to 88 in. lbs. [9.8 Nm] torque (See Figure 5).

If you are replacing the Packings, proceed with Packing Replacement.

Plunger

Plunger Retaining

Nut

Figure 5

linger Ring

Plunger Retaining

Nut Washer

10. Lubricate the Plungers and install the Pump Head onto the Plungers: then, push the Pump Head against the Pump Body.

11. Install the Socket Head Cap Screws removed in Step 1; then tighten them as shown in Figure 6 to 88 in. lbs. [9.8 Nm] torque.

Packing Replacement

Water leakage between the pump head and pump body indicates the plunger packings require replacement.

1. Using a metric allen wrench, remove the socket head Cap Screws securing the pump head to the pump body (See Figure 3).

2. While turning the crankshaft, use two screwdrivers to carefully pry between the pump head and pump body to remove the pump head (See Figure 4).

3. Using Extractor Pliers, remove the Seal Retainers and Seals (See Figure 7).

4. Using a small blade knife, remove the Seals from the Seal Retainers.

Figure 6

Using Extractor

Pliers to remove

Seal Retainers

and Seals

Figure 7

Models

1806C & 1807C

Packing placement

Alternately and evenly tighten the

Socket Head Cap Screws to

88 in. lbs. [9.8 Nm] torque

Seal

Piston Guide

Suppor

t Ring

Seal

O-ring

5. Lightly lubricate and install new seal kit items in the order shown in Figures 8 and 9.

Lightly lubricate the plungers and install the pump

6. head onto the plungers: then push the pump head against the pump body.

7. Install the socket head Cap Screws removed in Step

1; then tighten them as shown in Figure 6 to

88 in. lbs. [9.8 Nm] torque.

Figure 8

1826C & 1827C

Figure 9

Models

Packing placement

Seal Retainer

Seal

Gasket

Seal

O-ring

Seal Retainer

O-ring

Page 6

Valve Replacement

Erratic or low-pressure operation may be the result of debris in the Valves or Worn Poppets and/or Seats.

. Remove the Plugs; then using needle nosed pliers,

remove the Valves (See Figure 10).

2. Remove and discard the old O-ring (See Figure 10).

3. Inspect the Valves for signs of debris and/or wear. If worn or damaged, replace the Valves and install new O-rings (See Figure 10).

4. Install the Plugs and tighten them to 25 ft. lbs. [33.9 Nm] torque (See Figure 10).

Hydraulic Motor Repair Instructions

Hydraulic Motor Disassembly

The work area should be kept as clean as possible to prevent contamination of parts.

Plug

O-ring

Figure 10

Valve

O-ring

Valve

Plug

Pressure Port

Adapter

O-ring

Tank Port

Adapter

1. Place the Hydraulic Motor in a vise (See Figure 11).

2. Using a large crescent or 1-1/16" box wrench, loosen but do not remove the Tank Port Adapter and Pressure Port Adapter (See Figure 11).

3. Using a 9/16" box wrench, loosen the Nut on the Bypass Adjusting Screw (See Figure 11).

4. Using a small screwdriver, remove the Bypass Adjusting Screw from the Hydraulic Motor. (This will remove the Adjusting Screw, Lock Nut, Washer, and Gasket.) (See Figure 11.)

5. Using a 1/4" allen wrench, remove the Socket Head Cap Screws from the Motor End Plate (See Figure 11).

6. Grasp the Motor End Plate and Gerotor Housing by the Tank Port Adapter and Pressure Port Adapter, and with a rocking motion, remove the Motor End Plate and Gerotor Housing; then, remove the Tank Port Adapter and Pressure Port Adapter (See Figure 12).

7. Remove the Gerotor Housing and both components of the Gerotor (See Figure 13).

8. Remove both components of the Gerotor from the Gerotor Housing (See Figure 13).

Bypass Adjusting

Screw Nut

Socket Head

Cap Screws

Bypass Adjusting

Screw

Figure 11

Figure 12

Motor End

Plate

O-ring

Gerotor

Housing

Roll

Using a flat instrument, such as a knife, remove the

9. O-ring from the Motor End Plate and Body (See Figure 13).

Figure 13

O-ring

Motor Body

Page 7

10. Remove the Roll Pin from the Shaft (See Figure 13).

11. Inspect the Motor End Plate, Body, and Gerotor Housing for signs of wear and/or gouging. If signs of

ear or gouging are present in both the Motor End

w Plate and Body, the Hydraulic Motor is not reparable. If gouging has occurred in the Motor End Plate,

emoving the Shaft Assembly from the Motor Body

1. Remove the Rubber Slinger Ring from the Motor Shaft (See Figure 14).

Special attention should be exercised when working with retaining rings. Always wear safety goggles when working with spring or tension loaded fasteners or devices.

Body, or Gerotor Housing, the part that is worn must be replaced. If the Gerotor Housing is damaged, the Gerotor parts must also be replaced.

2. While the hydraulic Motor is disassembled, clean all

parts in a solvent bath.

Internal

Retaining

Ring

Slinger

Ring

Front

Motor

Body

2. Remove the Internal Retaining Ring securing the Ball Bearing and Shaft Assembly to the Motor Body (See Figure 14).

If the Ball Bearing is binding against the internal retaining ring so that the internal retaining ring cannot be easily removed, place the motor body on the arbor press support fixture with the ball bearing side up. Gently press against the shaft to relieve pressure of the ball bearing pressing against the internal retaining ring.

3. Place the body in the support fixture and position it on the arbor press; then press the Shaft Assembly out of the Motor Body (See Figure 15).

Hydraulic Motor Shaft Disassembly and Repair

Special attention should be exercised when working with retaining rings. Always wear safety goggles when working with spring or tension loaded fasteners or devices.

1. Remove the Large Retaining Ring from the Shaft (See Figure 16).

2. Remove the Thrust Bearing (Thrust Bearing and two Thrust Bearing Races) from the Shaft (See Figure 16).

Figure 14

Figure 15

Retaining

Ring

Figure 16

Thrust Bearing

and Races

Seal

Spacer

Shaft

Ball Bearing

Ball Bearing and

Shaft Assembly

Large

Retaining

Ring

Shaft

3. Remove the Retaining Ring next to the Shaft Ball Bearing (See Figure 16).

4. Remove the Bearing from the Shaft by placing the Shaft in the pipe support fixture. Place the two bars provided in the repair kit opposite each other and

Figure 17

Page 8

between the Seal on the Shaft and the support fixture. Using an arbor press, press the Shaft through the bearing, seal spacer, and seal (See Figures 17 and 18).

5. Inspect the sealing area of the Shaft and other Shaft Assembly components for signs of wear and replace them if necessary.

Shaft Seal Installation

Shaft

Ball Bearing

Figure 18

Seal

Shaft

Seal Spacer

Special attention should be exercised when working with retaining rings. Always wear safety goggles when working with spring or tension loaded fasteners or devices.

1. Install the Large Retaining Ring; then, slide the Thrust Bearing and Races, and Seal Spacer onto the Shaft (See Figure 19).

2. The sealing lips on the new Seal must be expanded to fit on the Shaft. Press the Seal onto the large end of the Shaft with the Seal Lip facing out. Do not push the Seal past the keyway on the Shaft (See Figure 20).

3. Once the Seal Lip has been expanded, remove the Seal from the Shaft.

4. With the Seal Lip facing the large end of the Shaft, slide the Seal over the smaller end of the Shaft, and gently push it onto the large end of the Shaft until it is seated against the Seal Spacer (See Figures 19 & 20).

Seal

Spacer

Figure 19

Shaft

Seal

Figure 20

Large

Retaining

Ring

Shaft

Thrust Bearing

and Races

Seal

Shaft

Shaft Bearing Installation

Install the Spacer Ring and Ball Bearing onto the

1. Shaft (See Figure 21).

Insert the Shaft into the support fixture. Place the

2. two support bars opposite each other and between the Bearing and the fixture. Place them on an arbor press and carefully press the Shaft down allowing just enough room for the Retaining Ring next to the Bearing to be installed (See Figure 22).

Make sure the spacer ring between the seal and the bearing is free floating (not binding).

If the Main Needle Bearings in the Hydraulic Motor require replacement, a new body an/or end plate, with the main needle bearing already installed must be used. If this occurs, check other internal parts of the motor for damage or wear

Shaft

Ball Bearing

Spacer Ring

Figure 21

Figure 22

Page 9

Installing the Shaft Assembly into the Motor Body

. Place the Shaft Assembly into the Motor Body

Bearing Bore (See Figure 23).

he Shaft Assembly and Motor Body Bearing Bore

T must be aligned prior to pressing the Shaft Assembly into the Motor Body Bearing Bore. Misalignment will result in pinched Spacer Rings.

2. An unthreaded section of pipe (1" Dia X 4" long) is needed to support the Outer Bearing Race of the Shaft Ball Bearing. Place this pipe over the Shaft Assembly; then, using an arbor press, press the Shaft Assembly down until the Retaining Ring can be installed in its groove in the bearing bore of the Motor Body (See Figure 24).

Reassembly of the Remaining Hydraulic Motor Parts

1. Place the Motor Body in a vise with the large end of the Shaft facing up.

2. Coat the new o-ring with a thin film of oil; then, install the o-ring in the Motor Body (See Figure 25).

3. Install the Roll Pin on the Shaft. Place the Inner Gear of the Gerotor onto the Shaft, making sure the Gerotor Slot lines up with the Roll Pin in the Shaft (See Figure 25).

The Roll Pin Key can slide up behind the inner gear of the gerotor when the gear is installed. Make sure the key is visible in the slot after the gear is in place.

Install the outer portion of the Gerotor

, making sure the Gerotor is centered within the O-ring groove in the Motor Body (See Figure 25).

5. Lightly lubricate the area between the inner and outer Gerotor and Gerotor Housing with hydraulic or mineral oil.

Figure 23

Figure 24

Roll

Figure 25

Socket Head

Cap Screws

Gerotor

Housing

O-ring

Motor

Housing

Pressure Port

Motor End

Plate

O-ring

Adapter

Bypass Adjusting

Tank Port

Adapter

Bypass Adjusting

Screw Nut

Screw

6. Install the Gerotor Housing, making sure the Pins in the Gerotor Housing line up with their respective holes in the Motor Body

7. Coat the new O-ring with a thin film of oil; then, install the O-ring on the Motor End Plate.

8. Place the End Plate on the Gerotor Housing, making sure the holes in the End Plate line up with the Pins in the Gerotor Housing.

9. Install the four Socket head Cap Screws in the Motor End Plate; then, using a 1/4" allen wrench, alternately and evenly tighten them to 15 ft. lbs. [20.3 Nm] torque (See Figure 26).

Figure 26

10. Put the Thread Seal Gasket on from the slotted end of the Bypass Adjusting Screw leaving four threads showing beyond the

Thread Seal Gasket (See Figure

26).

11. Install the Washer and Nut onto the Bypass Adjusting Screw; then, install the Bypass Adjusting Screw into the Motor Plate (See Figure 26).

a. For Closed Center Hydraulic Systems, turn the

bypass adjusting screw in until it bottoms out in the end plate; then, using a 9/16" box wrench, tighten the nut.

Page 10

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b. For Open Center Hydraulic Systems, turn the

Bypass Adjusting Screw in until it bottoms out in the End Plate; then, turn it back out 1-1/2 turns.

ighten the Nut while holding the Bypass

T Adjusting Screw with a screwdriver; the hydraulic Motor will then have to be readjusted to the tractor system,

12. Replace the O-rings in both Port Adapters.

13. Install and tighten the Pressure Port Adapter; then install and tighten the Tank Port Adapter (See Figure 25).

Troubleshooting

14. Remove the Hydraulic Motor from the vise; then, turn the Motor Shaft by hand to check for binding, the Motor Shaft should turn freely.

5. Install the Slinger Ring over the Motor Shaft.

16. Using the four Hex Head Bolts, secure the Hydraulic Motor to the Pump Mounting Flange.

Page 11

Typical Hydraulic Circuit Schematics for Hydraulic-Driven Pressure Washers

Figure 27 Typical Hydraulic Circuit Schematics for Hydraulic-Driven Pressure Washers

Page 12

Mounting Dimensions

Figure 28 Mounting Dimensions

Page 13

Models 1802C, 1803C, 1804C, 1805C, 1806C and 1807C Parts List

Figure 29 Models 1802C, 1803C, 1804C, 1805C, 1806C and 1807C Exploded View

Ref. No. Part No. Description Qty.

1 9910-680570 Socket Head Cap Screw 6 2 9910-620301 Plug 1 7 9910-1260162 Plug 6

17 9910-1320320 Plug 1 18 9910-1320360 O-ring 1 19 20 9910-1320370 Bearing 1 21 9910-1320330 Bushing 1 22 9910-1320010 Pump Housing 1 23 9910-880130 Oil Plug 1

29 30 9910-1260080 Piston Pin 3

9910-960160 O-ring 6

3400-0133 Valve 6

9910-880830 O-ring 6

1830-0138 Support Ring 3

9910-1260220 Gasket 3

1830-0139

9910-1260420

9910-1260450 Gasket 3

9910-1260460

9910-1260790 Retaining Ring (Internal) 1

9910-1260110 Nut 3

9910-1260100 Washer 3

3500-0061 Piston 3

9910-480480 O-ring 3

9910-1260091 Spacer 3 9910-1260070

Piston Guide

O-ring 3

Seal

Guiding Piston

Ref. No. Part No. Description Qty.

31 9910-1260760 Socket Head Cap Screw 6 32 9910-1269101 Complete Cover 1 36 9910-1260060 Connecting Rod 36 9910-1320140 Connecting Rod (Bronze) 1806C/1807C 1

38 9910-740290 O-ring 2 39 9910-1980740 Plug 2 40 0203-2250B Pump Head 1 41 9910-180101 O-ring 1 42 3312-0004 Thermal Relief Valve 1 47 9910-1260470 Screw 4 48 9910-1263890 Base 2

69 9910-1320050 Flange (Gas) 1 70 9910-1200430 Bolt 4 73 0551-2255 Hollow Shaft 5/8" Dia. 1 74 9910-1321190 Bearing 1 79 80 9910-780060 Socket Head Cap Screw 1 81 82 9910-1321420 Cover 1 84 9910-1321080 Snap Ring 1 85 86 2400-0048 Elbow 1 87 2640-0005 Pressure Gauge 1

9910-1260040 Gasket 1

9910-1381550

9910-480671

9910-780230

2220-0069

Seal

asher 1

Socket Head Cap Screw

asher

(Aluminum) 3

Denotes Valve Kit item. 9910-KIT1864

Denotes Piston Kit item. 9910-KIT2629

Denotes Oil Seal Kit item. 9910-KIT1860

Denotes Water Seal Kit item. 9910-KIT1874

Page 14

Models 1824C, 1825C, 1826C and 1827C Parts List

Figure 30 Models 1824C, 1825C, 1826C and 1827C Exploded View

Ref. No. Part No. Description Qty.

1 9910-960160 O-ring 6 2 9910-1260162 Plug 6

5 9910-620301 Plug 1

8 9 9910-1780010 Pump Body 1

1 12 9910-1780550 Retaining Ring (External) 1 13 9910-1780490 Bearing 1 14 9910-880130 Oil Cap 1 15

17 9910-1200430 Socket Head Cap Screw 6 18 19 9910-1780040 Connecting Rod 3 20 21 22 9910-1260091 Spacer Disc 3

Denotes Valve Kit item. 9910-KIT1864

Denotes Piston Kit item. 9910-KIT2746

Denotes Oil Seal Kit item. 9910-KIT2787

Denotes Water Seal Kit item. 9910-KIT2747

Denotes Support Ring Kit item. 9910-KIT2745

3400-0133 Valve 6

9910-880830 O-ring 6

9910-1780140 Support Ring 3

9910-1260220 Gasket 3 9910-1780110 Piston Guide 3

9910-1266740 Cap 1 9910-1260790

9910-1780050

9910-1780510

9910-1789010

9910-1780060 Guiding Piston 3

9910-480480

9910-1780080 9910-1260100

Retaining Ring (Internal)

Piston Pin

O-ring 1

Complete Cover

O-ring 3

Piston

Piston W

asher

Ref. No. Part No. Description Qty.

25 9910-1260110 Nut 3 26 9910-1380141 Base 2 27 9910-740290 O-ring 2 28 9910-1980740 Plug 2 29 9910-1260470 Screw 4

34 3312-0004 Thermal Relief Valve 1

3 3

35 9910-180101 O-ring 1 36 37 9910-1381550 Washer 8 38 9910-1322730 Socket Head Cap Screw 8 40 41

62 9910-1780430 Bushing 1 63 64 9910-1780980 Gas Engine Flange 1 66 67 68 2640-0005 Pressure Gauge 1

9910-1260460 Seal 3 9910-1780120

9910-770260 O-ring 3

9910-1260450

9910-1780020

9910-1321190 Bearing 1 9910-1321080

9910-480671 Seal 1

9910-1780990

9910-180432 Bolt 4

2400-0048

Rear Piston Guide

Gasket

Head

Snap Ring 1

Hollow Shaft

Elbow

Page 15

Unloader/Bypass Valve Model 3390-0086 (Models 1802C/1803C)

Figure 31 Injector/Unloader Seat and Seal Kit Items

Ref. No. Part No. Description Qty.

1 3220-0039 Pressure Adjustment Nut 1 2 1900-0116 Main Spring 1 3 1900-0101 Spring Button 1 4 2404-0151 Plunger Retainer 1 5 2404-0016 Plunger 1

6 7 1400-0020 Sleeve 1

9 0117-3390 Valve Body 1 10 3260-0037 Bypass Poppet 1 11 1830-0140 Bypass Seal/Outlet 1 12 1720-0004 O-ring 1 13 2404-0164 Bypass Adapter 1 14 1600-0041 Poppet Pin 1

15 16 3260-0048 Check Valve Poppet 1 17

1900-0123 18 1830-0115 Poppet Retainer 1 19 1720-0004 O-ring 1 20 21 2404-0164 Bypass Adapter 1

Denotes Repair Kit item. Repair Kit No. 3430-0223

1720-0064 O-ring 1

Cup 1

Cup

O-ring 1

alve Spring

Check V

O-ring

Page 16

3390-0104/2B Unloader Assembly-Models 1804C/1805C, 1806C/1807C, 1824C/1825C, 1826C/1827C

Figure 32 Unloader Assembly Items

Ref. No. Part No. Description Qty.

14 15 3430-0483 Bolt Kit Assembly (NPT) 1 15 3430-0487 Bolt Kit Assembly (BSP) 1

Repair Kit Item W

Repair Kit Item O-ring 1

1720-0186 O-ring 1

Repair Kit Item O-ring 1

Repair Kit Item Washer 1

1720-0196 O-ring 1

1720-0163 O-ring 1

3210-0080

1720-0190 O-ring 1

3320-0035 Piston 1

1900-0161 Spring 1

Repair Kit Item O-ring 1

9900-38FPB

Quick Disconnect (Male End)

asher 1

Valve Seat 1

Denotes Parts Kit items. Parts Kit No. 3430-0484

Page 17

Model No. 2500-0015C Hydraulic Motor Parts List - Models 1802C/1803C, 1804C/1805C

Figure 33 Hydraulic Motor Exploded View 2500-0015C

Ref. No. Part No. Description Qty.

1 1820-0013 Retaining Ring (Internal) 1 2 1810-0014 Retaining Ring (External) 1

3 4 1410-0073 Spacer 1

5 6 1410-0074 Seal Spacer 1 7 2029-0014 Thrust Bearing Assembly 1 8

9 10 0610-0012 Key 1 11 1610-0031 Roll Pin (HM1C) 1 12 0152-2500C Motor Body & Main Bearing 1 13 14 15 1600-0044 Dowel Pin (HM1C) 1

Denotes Parts Kit item. Parts Kit No. 3430-0178

2000-0010 Ball Bearing 1

2104-0005

1810-0026 0512-2500

1720-0110 O-ring 1

0700-2500C1

Shaft Seal 1

Snap Ring

Shaft (HM1C)

Gerotor Housing (HM1C)

Ref. No. Part No. Description Qty.

16 1600-0047 Dowel Pin 1 17 3900-0022 Dowel Pin (HM1C) 1 18 0251-2500C2 Motor End Plate & Main Brg. 1 19 3220-0029 Bypass Adjusting Screw 1

21 22

1 1

23 2270-0039 Washer 4 24

1700-0047 2270-0027 Washer 1 2250-0038

2220-0021 Cap Screw 4 1720-0108

Gasket

Lock Nut

O-ring 2

26 3320-0016 Tank Port Adapter 1 27

3260-0039

Poppet

28 1820-0023 Retaining Ring (Internal) 1

29 3320-0015 Tank Check Valve Assy. 1 30

3360-0021

Pressure Port

Adapter 1

31 2500-0015C Complete Motor Assy. 1

Page 18

Model No. 2500-0020C Hydraulic Motor Parts List - M

odels 1806C/1807C, 1824C/1825C, 1826C/1827C

Figure 34 Hydraulic Motor Exploded View 2500-0020C

Ref. No. Part No. Description Qty.

1 1820-0013 Retaining Ring (Internal) 1 2 1810-0014 Retaining Ring (External) 1

4 1410-0073 Spacer 1

6 1410-0074 Seal Spacer 1 7 2029-0014 Thrust Bearing Assembly 1 8 9 0513-2500 Shaft 1

10 1610-0012 Key 1

1 1610-0055 Roll Pin 1

12 0152-2500C Motor Body & Main Bearing 1

14 0702-2500C1 Gerotor Housing (HM3C) 1 15 1600-0068 Dowel Pin 1

Denotes Parts Kit item. Parts Kit No. 3430-0178

2000-0010 Ball Bearing 1

2104-0005

1810-0026

1720-01

Shaft Seal 1

Snap Ring

O-ring 2

Ref. No. Part No. Description Qty.

16 1600-0052 Dowel Pin 1 17 3900-0024 Gerotor (HM3C) 1 18 0251-2500C2 Motor End Plate & Main Brg. 1 19 3220-0029 Bypass Adjusting Screw 1

22 2250-0038 Lock Nut 1 23 24 2220-0021 Cap Screw 4

26 3320-0016 Tank Port Adapter 1 27 3260-0039 Poppet 1 28 29 3320-0015 Tank Check Valve Assy. 1 30 3360-0021 Pressure Port Adapter 1 31 2500-0020C Complete Motor Assy. 1

1700-0047 Gasket 1

2270-0027 Washer 1

asher

2270-0039

1720-0108 O-ring 2

1820-0023

Retaining Ring (Internal) 1

Page 19

Gun, Lance, Nozzle and Hose Assembly Parts List

Figure 35 Gun, Lance, and Hose Replacement Components

Ref. No.

1 2800-0023 Case (Right and Left) 1

3 1610-0049 Pin 1

4 1610-0050 Trigger Pin 1

6 0101-3381B Body (3381-0018) 1

7 Repair Kit Item Plunger Sleeve 1

8 Repair Kit Item O-ring (Viton) 1

9 Repair Kit Item Plunger 1

11 Repair Kit Item Seal 1

12 Repair Kit Item Retainer 1 13 13 14 1720-0163 O-ring 1 15 Repair Kit Item Ball 1 16 Repair Kit Item Spring 1 17 Repair Kit Item O-ring 1 18 19 2270-0068 Seal (Washer) 2 20 2404-0223 Tube (Inlet) 1 21 2404-0224 Tube (Adapter) 1 22 2200-0038 Screw 7

Part No.

2825-0023

3210-0082

Repair Kit Item

3210-0081 Seat (3381-0018) 1 3210-0083

Repair Kit Item

Description Qty.

rigger

ear Pin 1

rigger W

O-ring (V

Seat (3381-0018 Std.)

iton)

Retainer

Repair Kit No. 3430-0398

Gun Parts List

Figure 36 Gun Replacement Components

Page 20

Limited Warranty on Hypro Pumps

Hypro warrants to the original purchaser of its products (the “Purchaser”) that such products will be free from defects in material and workmanship under normal use for the period of one (1) year for all products except: oil crankcase plunger pumps will be free from defects in material and workmanship under normal use for the period of five (5) years, and accessories will be free from defects in

aterial and workmanship under normal use for the period of ninety (90) days. In addition, Hypro warrants to the purchaser all forged

m brass pump manifolds will be free from defects in material and workmanship under normal use and from damage resulting from

nvironmental conditions for the life of the pump.

“Normal use” does not include use in excess of recommended maximum speeds, pressures, vacuums and temperatures, or use requiring handling of fluids not compatible with component materials, as noted in Hypro product catalogs, technical literature, and

nstructions. This warranty does not cover freight damage, freezing damage, normal wear and tear, or damage caused by

i misapplication, fault, negligence, alterations, or repair that affects the performance or reliability of the product.

THIS WARRANTY IS EXCLUSIVE. HYPRO MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

Hypro’s obligation under this warranty is, at Hypro’s option, to either repair or replace the product upon return of the entire product to the Hypro factory in accordance with the return procedures set forth below.

BREACH OF WARRANTY.

IN NO EVENT SHALL HYPRO BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY KIND, WHETHER FOR BREACH OF ANY WARRANTY, FOR NEGLIGENCE, ON THE BASIS OF STRICT LIABILITY, OR OTHERWISE.

Return Procedures

All pumps or products must be flushed of any chemical (ref. OSHA Section 0910.1200 (d)(e)(f)(g)(h) and hazardous chemicals must be labeled before being shipped* to Hypro for service or warranty consideration. Hypro reserves the right to request a Material Safety Data sheet from the Purchaser for any pump or product Hypro deems necessary. Hypro reserves the right to “disposition as scrap” pumps or products returned which contain unknown substances, or to charge for any and all costs incurred for chemical testing and proper disposal of components containing unknown substances. Hypro requests this in order to protect the environment and personnel from the hazards of handling unknown substances.

THIS IS THE EXCLUSIVE REMEDY FOR ANY

For technical or application assistance, call the Hypro Technical/Application number: 800-445-8360. To obtain service or warranty assistance, call the Hypro Service and Warranty number: 800-468-3428; or call the Hypro Service and Warranty FAX: (651) 766-6618.

Be prepared to give Hypro full details of the problem, including the following information:

1. Model number and the date and from whom you purchased your pump.

2. A brief description of the pump problem, including the following:

• Liquid pumped. State the pH and any non-soluble • Drive type (gas engine/electric motor; direct/belt drive; materials, and give the generic or trade name. tractor PTO) and rpm of pump.

• Temperature of the liquid and ambient environment. • Viscosity (of oil, or other than water weight liquid).

• Suction lift or vacuum (measured at the pump). • Elevation from the pump to the discharge point.

• Discharge pressure. • Size and material of suction and discharge line.

• Size, type, and mesh of the suction strainer. • Type of spray gun, orifice size, unloader/relief valve.

Hypro may request additional information, and may require a sketch to illustrate the problem. Contact the factory to receive a return material authorization before sending the product. All pumps returned for warranty work should be sent shipping charges prepaid to:

HYPRO

Attention: Service Department

375 Fifth Avenue NW

New Brighton, Minnesota 55112

*Carriers, including U.S.P.S., airlines, UPS, ground freight, etc., require specific identification of any hazardous materials being shipped. Failure to do so may result in a substantial fine and/or prison term. Check with your shipping company for specific instructions.

Hypro 2008 Printed in the USA