Hydraulically-Driven Pressure Washer Models 1802C, 1803C, 1804C, 1805C, 1806C, 1807C, 1824C, 1825C, 1826C and 1827C Form L-0560PW

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1 Hydraulically-Driven Pressure Washer Models 80C, 803C, 804C, 805C, 806C, 807C, 84C, 85C, 86C and 87C Form L-0560PW Installation, Operation, Repair, and Parts Manual Description Hydraulically-Driven Pressure Washers Hydraulic Motor Model Max. Max. Estimated Requirements Number GPM PSI GPM PSI Description Weight Ea. 803C Forged Brass Head Triplex Pump with 8 lbs. hydraulic motor, adjustable unloader, gauge, " NPT input, 3 8" quick disconnect output 805C Forged Brass Head Triplex Pumps with 6 lbs. 807C hydraulic motor, chemical injector, 6 lbs. 85C adjustable unloader, gauge, 3 4" GH input, 33 lbs. 87C " quick disconnect output 33 lbs. Hydraulically-Driven Pressure Washers with Hose and Gun Assembly Hydraulic Motor Model Max. Max. Estimated Requirements Number GPM PSI GPM PSI Description Weight Ea. 80C Forged Brass Head Triplex Pump 38 lbs. with hydraulic motor, adjustable unloader, gauge, " NPT input, 3 8" quick disconnect output, and 50 ft. hose and gun assembly 804C Forged Brass Head Triplex Pumps with hydraulic 4 lbs. 806C motor, chemical injector, adjustable unloader, 6 lbs. 84C gauge 3 4" GH input, 3 8" quick disconnect output, 49 lbs. 86C and 50 ft. hose and gun assembly 49 lbs. General Safety Information 0/08 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. Warning denotes that a potential hazard exists and 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. 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. 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.

2 Do not pump at pressures higher than the maximum recommended pressure. Operate the Pump between a temperature range of 45 o to 40 o F [7 o to 60 o C]. 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. Disconnect the power before servicing. Release all pressure within the system before servicing any component. Secure the discharge line before starting the pump. An unsecured discharge line may whip, resulting in personal injury and/or property damage. Check all hoses for weak or worn condition before each use. Make certain that all connections are tight and secure. Periodically inspect the pump and the system components. Perform routine maintenance as required. 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. Drain all liquids from the system before servicing. Hazardous Substance Alert Do not use these pumps for pumping water or other liquids for human or animal consumption. 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. 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. Installation Requirements 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. The pump comes equipped with an unloader valve and bypass system rated for 000 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.

3 Fresh Water Flooded Section 3/4" Strainer 80 Mesh P/N , , A or equivalent Hydraulic Quick Disconnect matches female end on Kit & ,000 psi Gauge Hydraulic Input /" NPT (F) Municipal Water Supply Access 3/4" Hose Thermal Relief Valve Full-Flow, 3/4" Shut-Off Valve 3/4" Garden Hose Adapter Four 5/64 Dia. Holes Hi-Lo Spray Nozzle 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 5 ft. Never run the pump dry. If suction inlet hose is more than four feet long, use next larger size. Spray Gun and Hose Figure Hydraulically-Driven Pressure Washer Hookup Unloader Valve Instructions The Unloader is factory set to a maximum of 000 psi [38 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 000 psi [38 BAR]. The Unloader Valve is factory tested and preset to 000 psi [38 BAR]. Adjustment is necessary only if the unloader is not functioning properly.. For priming, the Spray Gun and Hose Assembly (Kit ) should be detached from the pump at the Quick Disconnect (See Figure ).. 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 ). 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,000 psi [38 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 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 Figure Check oil level Check that the oil is at the correct level using the Dipstick, and topping off if necessary (See Figure ). Use Hypro Oil (part no ). Hypro oil is specially formulated, high grade, non-detergent, SAE 30 weight oil designed to prolong Pump life.

4 Change the oil after 40 hours of break-in operation. Thereafter, change the oil every year or 500 hours, whichever comes first. Care 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 the pump with a 50/50 solution of automotive-type antifreeze and water. Bypass Operation During Bypass Operation (when water is diverted back to the pump inlet side) a temperature rise occurs. A Thermal Relief Valve is provided to maintain the maximum water temperature at 45 F [63 C]. Hydraulic System Operation 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-6 hydraulic oil at a temperature of 40 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. Pump Repair Instructions Plunger Replacement.. Using a metric allen wrench, remove the Socket Head Cap Screws securing the Pump Head to the Pump Body (See Figure 3).. 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 Washer (See Figures 5). 4. Slide the Plungers off the Piston Guides (See Figure 5). 5. Remove and discard the s (See Figure 5). 6. Remove the Slinger Ring (See Figure 5). Figure 3 Figure 4 Remove Socket Head Cap Screws While turning the crankshaft, use screwdrivers to pry the pump head off. 4

5 Apply a thin film of oil to the new s and Plungers before installing them. 7. Inspect the Plungers for cracking and replace them if damaged installing new s and Slinger Rings at the same time. 8. 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). Plunger Plunger Retaining Nut Figure 5 Plunger Retaining Nut Washer Slinger Ring If you are replacing the Packings, proceed with Packing Replacement. 0. Lubricate the Plungers and install the Pump Head onto the Plungers: then, push the Pump Head against the Pump Body.. Install the Socket Head Cap Screws removed in Step ; then tighten them as shown in Figure 6 to 88 in. lbs. [9.8 Nm] torque. Figure 6 Alternately and evenly tighten the Socket Head Cap Screws 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.. Using a metric allen wrench, remove the socket head Cap Screws securing the pump head to the pump body (See Figure 3).. 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 7 Using Extractor Pliers to remove Seal Retainers and Seals Models 806C & 807C Packing Replacement Support Ring Piston Guide Seal Seal Seal 5. Lightly lubricate and install new seal kit items in the order shown in Figures 8 and Lightly lubricate the plungers and install the pump head onto the plungers: then push the pump head against the pump body. 7. Install the socket head Cap Screws removed in Step ; then tighten them as shown in Figure 6 to 88 in. lbs. [9.8 Nm] torque. Figure 8 Models 86C & 87C Packing Replacement Seal Retainer Seal Gasket Seal Seal Retainer 5 Figure 9

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 0). Plug. Remove and discard the old (See Figure 0). 3. Inspect the Valves for signs of debris and/or wear. If worn or damaged, replace the Valves and install new s (See Figure 0). Valve 4. Install the Plugs and tighten them to 5 ft. lbs. [33.9 Nm] torque (See Figure 0). Figure 0 Valve Plug Hydraulic Motor Repair Instructions Hydraulic Motor Disassembly The work area should be kept as clean as possible to prevent contamination of parts. Pressure Port Adapter Tank Port Adapter. Place the Hydraulic Motor in a vise (See Figure ).. Using a large crescent or -/6" box wrench, loosen but do not remove the Tank Port Adapter and Pressure Port Adapter (See Figure ). Socket Head Cap Screws Bypass Adjusting Screw Nut Bypass Adjusting Screw 3. Using a 9/6" box wrench, loosen the Nut on the Bypass Adjusting Screw (See Figure ). Figure 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.) 5. Using a /4" allen wrench, remove the Socket Head Cap Screws from the Motor End Plate (See Figure ). 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 ). 7. Remove the Gerotor Housing and both components of the Gerotor (See Figure 3). Figure Gerotor Housing Gerotor Motor End Plate 8. Remove both components of the Gerotor from the Gerotor Housing (See Figure 3). Roll Pin 9. Using a flat instrument, such as a knife, remove the from the Motor End Plate and Body (See Figure 3). 6 Figure 3 Motor Body

7 0. Remove the Roll Pin from the Shaft (See Figure 3).. Inspect the Motor End Plate, Body, and Gerotor Housing for signs of wear and/or gouging. If signs of wear or gouging are present in both the Motor End Plate and Body, the Hydraulic Motor is not reparable. If gouging has occurred in the Motor End Plate, 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.. While the hydraulic Motor is disassembled, clean all parts in a solvent bath. Removing the Shaft Assembly from the Motor Body. Remove the Rubber Slinger Ring from the Motor Shaft (See Figure 4). Special attention should be exercised when working with retaining rings. Always wear safety goggles when working with spring or tension loaded fasteners or devices.. Remove the Internal Retaining Ring securing the Ball Bearing and Shaft Assembly to the Motor Body (See Figure 4). Internal Retaining Ring Slinger Ring Figure 4 Front Motor Body Ball Bearing and Shaft Assembly 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 5). Figure 5 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.. Remove the Large Retaining Ring from the Shaft (See Figure 6).. Remove the Thrust Bearing (Thrust Bearing and two Thrust Bearing Races) from the Shaft (See Figure 6). Retaining Ring Figure 6 Thrust Bearing and Races Seal Spacer Shaft Ball Bearing Shaft Large Retaining Ring 3. Remove the Retaining Ring next to the Shaft Ball Bearing (See Figure 6). 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 7 Figure 7

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 7 and 8). 5. Inspect the sealing area of the Shaft and other Shaft Assembly components for signs of wear and replace them if necessary. Shaft Ball Bearing Figure 8 Seal Seal Spacer Shaft Shaft Seal Installation Special attention should be exercised when working with retaining rings. Always wear safety goggles when working with spring or tension loaded fasteners or devices.. Install the Large Retaining Ring; then, slide the Thrust Bearing and Races, and Seal Spacer onto the Shaft (See Figure 9).. 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 0). 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 9 & 0). Seal Spacer Figure 9 Shaft Seal Figure 0 Large Retaining Ring Thrust Bearing and Races Shaft Seal Shaft Shaft Bearing Installation. Install the Spacer Ring and Ball Bearing onto the Shaft (See Figure ).. Insert the Shaft into the support fixture. Place the 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 ). Ball Bearing Shaft Spacer Ring Figure 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. 8 Figure

9 Installing the Shaft Assembly into the Motor Body. Place the Shaft Assembly into the Motor Body Bearing Bore (See Figure 3). The Shaft Assembly and Motor Body Bearing Bore must be aligned prior to pressing the Shaft Assembly into the Motor Body Bearing Bore. Misalignment will result in pinched Spacer Rings.. An unthreaded section of pipe (" 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 4). Figure 3 Figure 4 Reassembly of the Remaining Hydraulic Motor Parts. Place the Motor Body in a vise with the large end of the Shaft facing up.. Coat the new o-ring with a thin film of oil; then, install the o-ring in the Motor Body (See Figure 5). 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 5). 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. 4. Install the outer portion of the Gerotor, making sure the Gerotor is centered within the groove in the Motor Body (See Figure 5). 5. Lightly lubricate the area between the inner and outer Gerotor and Gerotor Housing with hydraulic or mineral oil. Roll Pin Figure 5 Socket Head Cap Screws Gerotor Housing Gerotor Motor Housing Motor End Plate Pressure Port Adapter Tank Port Adapter Bypass Adjusting Screw Nut Bypass Adjusting 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 with a thin film of oil; then, install the 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 /4" allen wrench, alternately and evenly tighten them to 5 ft. lbs. [0.3 Nm] torque (See Figure 6). 9 Figure 6 0. 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 6).. Install the Washer and Nut onto the Bypass Adjusting Screw; then, install the Bypass Adjusting Screw into the Motor Plate (See Figure 6). a. For Closed Center Hydraulic Systems, turn the bypass adjusting screw in until it bottoms out in the end plate; then, using a 9/6" box wrench, tighten the nut.

10 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 -/ turns. Tighten the Nut while holding the Bypass Adjusting Screw with a screwdriver; the hydraulic Motor will then have to be readjusted to the tractor system,. Replace the s in both Port Adapters. 4. 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. 6. Using the four Hex Head Bolts, secure the Hydraulic Motor to the Pump Mounting Flange. 3. Install and tighten the Pressure Port Adapter; then install and tighten the Tank Port Adapter (See Figure 5). Troubleshooting Symptom Low discharge. Hydraulic System overheating. The Air Probable Cause Pump is not primed. leaks in the Suction Line. Blocked Undersize or clogged Line Strainer. or collapsed Suction Line. Bypass Adjustment Screw in the Hydraulic Motor is not properly set. Bypass Adjustment Screw is set to bypass too much oil. Improper Metering Orifice has been installed in the Pressure Port. Hydraulic Hose size is too small. Prime the Pump. Check for Fittings. Corrective Action air leaks and reseal the Inlet Inspect the Strainer and remove debris from the Strainer Screen. any The Suction Line should be the same diameter or larger than the Inlet Port of the Pump. Turn the Bypass Adjustment Screw (located on the side of the Hydraulic Motor) clockwise until the desired output is attained. Turn the Bypass Adjustment Screw (located on the side of the Hydraulic Motor) clockwise until the desired output is attained. Install the proper size Metering Orifice. Hydraulic Hose must be at least / inch diameter. For large Open Center Systems it must be at least 3/4 inch diameter. 0

11 Typical Hydraulic Circuit Schematics for Hydraulic-Driven Pressure Washers Figure 7 Typical Hydraulic Circuit Schematics for Hydraulic-Driven Pressure Washers

12 Mounting Dimensions Figure 8 Mounting Dimensions

13 Models 80C, 803C, 804C, 805C, 806C and 807C Parts List Figure 9 Models 80C, 803C, 804C, 805C, 806C and 807C Exploded View Socket Head Cap Screw Plug Plug Valve Support Ring Gasket Piston Guide Gasket Seal Plug Retaining Ring (Internal) Bearing Bushing Pump Housing Oil Plug Nut Washer Piston Spacer Guiding Piston Piston Pin Socket Head Cap Screw Complete Cover Connecting Rod (Aluminum) Connecting Rod (Bronze) 806C/807C Gasket Plug B Pump Head Thermal Relief Valve Screw Base Seal Flange (Gas) Bolt Hollow Shaft 5/8" Dia Bearing Washer Socket Head Cap Screw Socket Head Cap Screw Cover Snap Ring Washer Elbow Pressure Gauge Denotes Valve Kit item. 990-KIT864 Denotes Piston Kit item. 990-KIT69 3 Denotes Oil Seal Kit item. 990-KIT860 4 Denotes Water Seal Kit item. 990-KIT874 3

14 Models 84C, 85C, 86C and 87C Parts List Figure 30 Models 84C, 85C, 86C and 87C Exploded View Plug Valve Plug Support Ring Gasket Piston Guide Pump Body Cap Retaining Ring (Internal) Retaining Ring (External) Bearing Oil Cap Piston Pin Socket Head Cap Screw Complete Cover Connecting Rod Guiding Piston Spacer Disc Piston Piston Washer 3 Denotes Valve Kit item. 990-KIT864 Denotes Piston Kit item. 990-KIT746 3 Denotes Oil Seal Kit item. 990-KIT787 4 Denotes Water Seal Kit item. 990-KIT747 5 Denotes Support Ring Kit item. 990-KIT Nut Base Plug Screw Seal Rear Piston Guide Gasket Thermal Relief Valve Head Washer Socket Head Cap Screw Bearing Snap Ring Seal Bushing Hollow Shaft Gas Engine Flange Bolt Elbow Pressure Gauge

15 Unloader/Bypass Valve Model (Models 80C/803C) Figure 3 Injector/Unloader Seat and Seal Kit Items Pressure Adjustment Nut Main Spring Spring Button Plunger Retainer Plunger 6 Cup Sleeve 8 Cup Valve Body Bypass Poppet Bypass Seal/Outlet Bypass Adapter Poppet Pin Check Valve Poppet Check Valve Spring Poppet Retainer Bypass Adapter Denotes Repair Kit item. Repair Kit No

16 /B Unloader Assembly-Models 804C/805C, 806C/807C, 84C/85C, 86C/87C Figure 3 Unloader Assembly Items 4 Repair Kit Item Washer Repair Kit Item Repair Kit Item 5 Repair Kit Item Washer Valve Seat Piston Spring Repair Kit Item 3 Repair Kit Item FPB Quick Disconnect (Male End) Bolt Kit Assembly (NPT) Bolt Kit Assembly (BSP) Denotes Parts Kit items. Parts Kit No

17 Model No C Hydraulic Motor Parts List - Models 80C/803C, 804C/805C Figure 33 Hydraulic Motor Exploded View C Retaining Ring (Internal) Retaining Ring (External) Ball Bearing Spacer Shaft Seal Seal Spacer Thrust Bearing Assembly Snap Ring Shaft (HMC) Key Roll Pin (HMC) C Motor Body & Main Bearing C Gerotor Housing (HMC) Dowel Pin (HMC) Denotes Parts Kit item. Parts Kit No Dowel Pin Dowel Pin (HMC) C Motor End Plate & Main Brg Bypass Adjusting Screw Gasket Washer Lock Nut Washer Cap Screw Tank Port Adapter Poppet Retaining Ring (Internal) Tank Check Valve Assy Pressure Port Adapter C Complete Motor Assy. 7

18 Model No C Hydraulic Motor Parts List - Models 806C/807C, 84C/85C, 86C/87C Figure 34 Hydraulic Motor Exploded View C Retaining Ring (Internal) Retaining Ring (External) Ball Bearing Spacer Shaft Seal Seal Spacer Thrust Bearing Assembly Snap Ring Shaft Key Roll Pin C Motor Body & Main Bearing C Gerotor Housing (HM3C) Dowel Pin Denotes Parts Kit item. Parts Kit No Dowel Pin Gerotor (HM3C) C Motor End Plate & Main Brg Bypass Adjusting Screw Gasket Washer Lock Nut Washer Cap Screw Tank Port Adapter Poppet Retaining Ring (Internal) Tank Check Valve Assy Pressure Port Adapter C Complete Motor Assy. 8

19 Gun, Lance, Nozzle and Hose Assembly Parts List 4 3 Figure 35 Gun, Lance, and Hose Replacement Components Gun Parts List Case (Right and Left) Trigger Pin Trigger Pin Trigger Wear Pin B Body ( ) 7 Repair Kit Item Plunger Sleeve 8 Repair Kit Item (Viton) 9 Repair Kit Item Plunger 0 Repair Kit Item (Viton) Repair Kit Item Seal Repair Kit Item Retainer Seat ( ) Seat ( Std.) Repair Kit Item Ball 6 Repair Kit Item Spring 7 Repair Kit Item 8 Repair Kit Item Retainer Seal (Washer) Tube (Inlet) Tube (Adapter) Screw Figure 36 Gun Replacement Components Repair Kit No

20 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 () 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 material and workmanship under normal use for the period of ninety (90) days. In addition, Hypro warrants to the purchaser all forged brass pump manifolds will be free from defects in material and workmanship under normal use and from damage resulting from environmental 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 instructions. This warranty does not cover freight damage, freezing damage, normal wear and tear, or damage caused by 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. THIS IS THE EXCLUSIVE REMEDY FOR ANY 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 Limited Warranty on Hypro Pumps All pumps or products must be flushed of any chemical (ref. OSHA Section (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. For technical or application assistance, call the Hypro Technical/Application number: To obtain service or warranty assistance, call the Hypro Service and Warranty number: ; or call the Hypro Service and Warranty FAX: (65) Be prepared to give Hypro full details of the problem, including the following information:. Model number and the date and from whom you purchased your pump.. 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 55 *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 008 Printed in the USA