Pentair Hypro 9915-DP803 User manual

pentair.com
INSTALLATION AND
OPERATION MANUAL
L-1600 (04/01/21) ©2021 Pentair. All Rights Reserved.
DIAPHRAGM PUMPS

2L-1600 (04/01/21)
TABLE OF CONTENTS
Safety Information................................................................................................................................................................................ 3
General Information.............................................................................................................................................................................. 5
Installation and Operations ................................................................................................................................................................... 6
Maintenance ......................................................................................................................................................................................... 8
Low Pressure 15 Bar
 Performance&Specications ..................................................................................................................................................10
Installation ................................................................................................................................................................................ 11
Replacement Parts List.............................................................................................................................................................12
Medium Pressure 20-40 Bar
 Performance&Specications ..................................................................................................................................................18
Installation ...............................................................................................................................................................................20
Replacement Parts List............................................................................................................................................................ 24
High Pressure 50 Bar
 Performance&Specications ................................................................................................................................................. 32
Installation ............................................................................................................................................................................... 33
Replacement Parts List............................................................................................................................................................ 34
Troubleshooting.................................................................................................................................................................................. 38
Warranty.............................................................................................................................................................................................40

3
L-1600 (04/01/21)
SAFETY INFORMATION
Save these instructions: This manual contains important
instructions that should be followed during installation,
operation, and maintenance of the product.
SAFETY SYMBOLS
Caution is used to indicate the presence of a
hazard, which will or may 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.
This is the safety alert symbol. When you see this symbol on
your pump or in this manual, look for one of the following signal
words and be alert to the potential for personal injury.
The word NOTE indicates special instructions that are
important but not related to hazards
CALIFORNIA PROPOSITION 65 WARNING
This product and related accessories contain
chemicals known to the State of California to cause cancer,
birth defects or other reproductive harm.
PACKAGING INSPECTION
When the unit is received, look for any product damage as you
unpack the item. If any damage is present or parts are missing,
do not attempt to operate pump. Use this manual to determine
that all parts are properly installed. If you are in doubt, do not
operate the pump.
Before you start first, refer to local codes to ensure safety and
regulatory compliance.
GENERAL SAFETY
Carefully read and follow all safety instructions in this manual
and on the unit itself. Failure to comply with the safety
instructions could result in personal injury and/or property
damage!
Know the pump application, limitations, and potential hazards.
Follow all applicable local and state codes and regulations.
Keep safety labels in good condition, replacing any missing or
damaged labels.
Personal Safety:
 Wear safety glasses at all times when working with pumps.
 Keep work area clean, uncluttered and properly lighted.
Replace all unused tools and equipment.
 Keep visitors at a safe distance from work area.
 Make workshop child-proof with padlocks, master
switches, and by removing starter keys.
Do not pump flammable or explosive fluids such
as gasoline, fuel oil, kerosene, etc. Do not use in explosive
atmospheres. Do not pump asphalt sealer, roofing compounds,
concrete sealers, or any two-step curing products. 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.
Never use your hand to check the condition of hydraulic lines
or hoses. If hydraulic fluid penetrates the skin, get medical
attention immediately. Failure to get proper medical attention
may result in loss of limb or life. The safest way to check
hydraulic lines is by holding a piece of cardboard next to the
hydraulic line or hose.
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.
Verify that pump shaft rotates freely prior to engaging the pump
drive.

4L-1600 (04/01/21)
SAFETY INFORMATION
 Do not pump at pressures higher than the maximum
recommended pressure.
 Operate the pump between a temperature ranges of 45° to
140°F [7° to 60°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.
 Drain all liquids from the system before servicing.
 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.
Keep free of debris and foreign objects.
 Perform routine maintenance as required (see
maintenance).
 When wiring an electrically driven pump, follow all
electrical and safety codes, as well as the most recent
National Electrical Code (NEC) and the Occupational Safety
and Health Act (OSHA) requirements.
 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.
 Do not pressure feed pump inlet.
 Do not touch an operating motor. Modern motors can
operate at high temperatures.
 Do not handle pump or pump motor with wet hands or when
standing on wet or damp surface, or in water.
HAZARDOUS SUBSTANCE ALERT
1. Always drain and flush pump before servicing or
disassembling for any reason (see instructions).
2. Always drain and flush pumps prior to returning unit for
repair.
3. Never store pumps containing hazardous chemicals.
4. Before returning pump for service/repair, drain out all
liquids and flush unit with neutralizing liquid. Then, drain
the pump. Attach tag or include written notice certifying
that this has been done.Please note that it is illegal to
ship or transport any hazardous chemicals without United
States Environmental Protection Agency Licensing

5
L-1600 (04/01/21)
DESCRIPTION AND USES
Hypro Diaphragm pumps are intended for creating or boosting
dynamic pressure for non-food purposes with clean and
approved fluids in a watery solution which are compatible with
the materials of the pump at temperatures between 45° to 140°F
[7° to 60°C].
INTENDED USES
Hypro pressure diaphragm pumps are recommended for
spraying herbicides, pesticides, liquid fertilizers, and many
other hard to handle fluids. Low-cost maintenance and almost
wear-free operation make these pumps ideal for a wide variety
of spraying jobs. Pressure and output are designed for optimum
performance of small to large-sized sprayers.
Any uses outside of those specified in this manual are
considered misuses and are prohibited. Contact Hypro technical
service with any questions regarding specific acceptable uses.
The pump cannot be used with:
 Watery solutions whose viscosity and density exceed those
of water.
 Chemical solutions for which compatibility with the
materials the pump is made is not known.
 Sea water or water with a high concentration of salt.
 Fuels and lubricants of all kinds and types.
 Inflammable liquids or liquefied gases.
 Food-grade liquids.
 Solvents and diluents of all kinds and types.
 Paints of all kinds and types.
 Liquids at temperatures lower than 7°C or higher than 60°C.
 Liquids containing granules or solids in suspension.
 The pump must not be used in places where there are
particular conditions, such as corrosive or explosive
atmospheres, for example.
MISUSES
Hypro centrifugal pumps are designed to operate effectively
within the specified speed, pressure and environmental ranges.
Going outside of these ranges will void the warranty and could
cause damage to property, serious injury, or death.
 Do not run the pump faster than the maximum specified
speed.
 Do not run the pump higher than the maximum specified
pressure.
 Do not run pumps when the liquid has exceeded the
maximum or minimum temperature limit.
 Do not pump non-approved liquids.
 Do not pump water or other liquids for human consumption.
 Do not operate any Hypro pump under the influence of
drugs or alcohol.
 Do not run the pump dry.
 Do not run the pump hydraulic motor higher than the
specified RPM, pressure or flow.
 Do not run the pump without adequate suction filter.
GENERAL INFORMATION

6L-1600 (04/01/21)
INSTALLATION AND OPERATION
PUMP PLUMBING
Use only pipe, fittings, accessories, hose, etc. rated for the
maximum pressure rating of the pump.
1. Always mount pump with oil sight tube in upright position
(See Figure 1).
2. The proper selection of hose type and size is vital to optimal
performance
 Use good quality inlet hose, compatible with the fluids
being pumped and with good elasticity to reduce inlet
water hammer or pulsation. Be sure that hose is not
too rigid but capable of operating at low vacuums
without collapsing. The diameter of the inlet hose
should be at least that of the pump inlet port size and
preferably one size larger if the inlet line is longer than
6 feet [1.8meters].
 Use only approved high pressure hose on the discharge
side of pump.
3. Most ports are provided with hose barb connections. Use
good quality hose clamps and tighten them securely.
4. It is recommended to install strainer of 32 Mesh size
having double flowrate of the pump at the suction side, to
prevent diaphragm failures.
SHAFT ADAPTER KIT INSTALLATION
Order the appropriate shaft kit according to the chart on Spec
Sheet.
1. Mount shaft adapter (Ref. 1A for 9915-KIT1201, Ref 1B for
9915-KIT1202 and Ref. 1B for 9915-KIT1203) onto the pump
shaft and secure with 3 bolts (Ref. 2) and 3 washers (Ref. 3).
2. Mount pump/base assembly securely to prevent movement.
3A
2A
3
2
1A
FIGURE 1
FIGURE 2

7
L-1600 (04/01/21)
OPERATION
1. Before start up check that oil is halfway up to the clear
oil sight tube. If necessary, fill to the correct level with
Hypro oil (part number 2160-0038). Hypro oil is a specially
formulated, high-grade, non-detergent, SAE 30 weight oil
formulated to prolong pump life.
2. Make sure the suction hose barb is tightly screwed onto
the suction union and that there are no air leaks on the inlet
side of the pump.
3. Check the charge pressure on the pulsation dampener
before starting the pump. The pressure is checked with a
standard automotive air gauge. The pressure should be at
approximately 20% of the maximum pressure that you will
be operating the pump at. Exercise caution when checking
pressure to avoid losing pre-charge.
4. The relief valve bypass port should be connected back to
the liquid tank without restrictions. Do not hook bypass line
back to the inlet port or inlet hose.
5. Allow the pump to start under low pressure by removing
restrictions on the outlet of the pump. The restriction on
the pump is removed by rotating the Pressure Release
knob on the control unit, fully toward bypass arrow
direction.
6. Check oil level daily while pump is running. Start the pump
and let it run for approximately one minute at low pressure.
Adjust Pressure Release knob to run pump at operating
pressure and check the oil sight tub level again to be sure
the oil level is correct. Add Hypro oil if necessary.
7. Adjust the pump to the desired pressure by changing
the relief valve setting on the control unit, relief valve or
unloader. All the outlet valve must be closed as shown in
Figure 3.
INSTALLATION AND OPERATION
First back out the pressure regulator adjustment knob to zero.
Then rotate the Pressure Release knob to Pressure arrow
direction. Adjust the pressure by rotating the relief valve
adjustment knob to the desired pressure.
For all discharge hoses, use hose with an operating pressure
rating equal to or greater than the maximum pressure rating of
the pump. High pressure clamping should be used on all outlet
hose connections.
The bypass return outlet on all control units must
be connected directly to the tank without restrictions or ball
valves.
Always wear safety goggles when working with
spring-loaded fasteners or devices.
During the first step, you are strongly advised to
start the pump with the regulating valve knob turned to 0
pressure and with the lever in the by-pass position. Maintain
this configuration for a couple of minutes so as to lubricate the
internal components of the pump and allow the diaphragms to
set in position before the pressure is increased.
FIGURE 3
OUTLET
OUTLET PRESSURE REGULATOR
ADJUSMENT KNOB

8L-1600 (04/01/21)
MAINTENANCE
MAINTENANCE INSTRUCTIONS
1. After usage, flush the pump with clean water.
2. Hypro diaphragm pumps come with oil in the crankcase.
Hypro recommends changing oil after 40 hours of break-in
operation and every three months or 500 hours, whichever
comes first. Use Hypro oil (part number 2160-0038). Hypro
oil is a specially formulated, high-grade, non-detergent,
SAE 30 weight oil formulated to prolong pump life.
To drain the oil:
1. Remove the drain plug and the oil sight glass covers, and
rotate shaft until the oil stops flowing out. Re-install the
drain plug.
2. For DP252 and DP302 Series, Remove the oil fill cap, turn
the pump upside down and rotate the shaft until oil stops
flowing out
3. To fill the pump with oil, slowly pour oil into sight tube while
turning the pump shaft. Turning the pump shaft purges
all the air out of the crankcase. Always change oil when
replacing diaphragms.
4. For winter storage or if a freezing condition will been
countered, flush the pump with a 50/50 mixture of water
and antifreeze.
REGULAR SERVICE PERIOD
Performed at every indicated month or operating hour interval,
whichever comes first.
First Use Each Use First month
or 40 hours
Every 3
months or
500 hours
Every 6
months or
1000 hours
Crankcase Oil
Check Level X X
Replace X X
Gearbox Oil
Check Level X X
Replace X X
Pulsation Dampener Pressure
(in models with dampeners)
Set to 20% of working PSI X
Replace X X
Diaphragms Replace X
Valves
Check X
Replace X
O-rings
Check X
Replace X
MAINTENANCE SCHEDULE
Fill oil to proper level in sight glass. Always make
sure all the air is purged out of crankcase prior to operating.
VALVE REPLACEMENT
Occasionally debris may cause improper seating of the valves
or damage to the O-rings. To check for this problem, follow
these steps.
Remove the pump manifolds or valve retainer. With removal of
that, the valves can easily be removed and inspected for debris
and wear. Replace valves, O-rings and manifolds.

9
L-1600 (04/01/21)
MAINTENANCE
DIAPHRAGM REPLACEMENT
Change diaphragms every 500 hours or three months,
whichever comes first.
1. Drain oil from crankcase as instructed previously.
2. Remove pump head bolts and heads.
3. Remove the bolt securing the diaphragm (See Figure 4).
4. Remove the old diaphragm and the washer (See Figure 4).
5. Install a new diaphragm. Then turn the crankshaft to bring
the piston to its mid-stroke and seat the diaphragm into the
sleeve groove.
6. Install the washer and bolts removed in steps 3 and 4.
7. Replace the pulsation dampener diaphragm by first
bleeding the air from the dampener. Remove the bolts
from the dampener cover and replace the diaphragm.
Reassemble the cover in place and charge the dampener to
20% of the operating pressure.
8. Refill the crankcase with Hypro oil (part number 2160-
0038).Rotate the shaft to distribute the oil, and fill to proper
level.
FIGURE 4

10 L-1600 (04/01/21)
DIAPHRAGM PUMP: LOW PRESSURE RANGE 15BAR
Model Number "Max. Flow
USGPM [LPM]"
"Max. Pressure
PSI [BAR] "
"Max. Speed
RPM"
"Power
HP [KW]"
No. of
Diaphragm
9915-DP803 21.7 [82] 218 [15] 550 3.2 [2.4] 3
Model Number "Max. Flow
USGPM [LPM]"
"Max. Pressure
PSI [BAR] "
"Max. Speed
RPM"
"Power
HP [KW]"
No. of
Diaphragm
9915-DP2505 6 3.9 [242] 218 [15] 550 9.5 [7.1] 5
Control Unit Model Number "Max. Flow USGPM [LPM]" "Max. Pressure PSI [BAR]" Pump Model
9915-KIT1004 42 [160] 29 0 [20] DP803/DP1003
9915-KIT1005 69 [260] 218 [15] DP2505
Crankcase Oil Capacity
Pump Model Series "Capacity oz. [Litre]"
DP803 24 [0.7]
DP1003 24 [0.7]
DP2505 110 [3.25]
Model Number "Max. Flow
USGPM [LPM]"
"Max. Pressure
PSI [BAR] "
"Max. Speed
RPM"
"Power
HP [KW]"
No. of
Diaphragm
9915-DP1003 26.8 [102] 218 [15] 550 4.0 [3.0] 3
CONTROL UNITS
Control units are available for easy flow and pressure control of
your sprayer system. These units include a manual dump valve
and adjustable pressure relief valve to control pressure, a liquid-
filled pressure gauge to monitor pressure, and shut-off valves
to control flow. Control unit 9915-KIT1004 and 9915-KIT1005 can
be remote mounted. Refer to the adjoining chart to select the
proper control unit for your pump.
Oil Capacity: Oil crankcase capacities are approximate. Fill
oil to proper level in sight glass. Always make sure all the air is
purged out of crankcase prior to operating

11
L-1600 (04/01/21)
LOW PRESSURE 15 BAR PERFORMANCE AND SPECIFICATIONS
CONTROL UNIT KIT INSTALLATION
The control units are designed for control of pressure and flow
rate. Use appropriate model (as specified in chart on page 10) to
use with particular pump model and pressure/flow ranges.
NOTE: Hypro recommends a blue thread locking compound on
all threaded fasteners that do not require lock washers.
Remote Mounting
1. Locate control unit at desired position with mounting holes
provided and secure with the bolts and nuts.
2. Use the high pressure hose to connect pump discharge
port hose barb to the control unit inlet port.
3. Connect the bypass hose to the bypass hose barb, then run
it unrestricted to the supply tank.
4. Connect the desired number of high pressure hoses to the
outlet ports on the control valve. Unused Ports can be shut
off with ball valves provided.
Outlet
Outlet
Pressure Release
Knob
Inlet
Pressure Regulator
Adjustment Knob
Pressure
Regulator
Adjustment
Knob
Pressure Gauge
Pressure
Gauge
Bypass Hose Barb (Connect directly
to the tank without restriction or ball valves)
Bypass Hose Barb
(Connect directly to the
tank without restriction
or ball valves)
For all discharge hoses, use hose with an operating pressure
rating equal to or greater than the maximum pressure rating of
the pump. High pressure clamping should be used on all outlet
hose connections.
Always wear safety goggles when working with
spring-loaded fasteners or devices.
During the first step, you are strongly advised to
start the pump with the regulating valve knob turned to 0
pressure and with the lever in the by-pass position. Maintain
this configuration for a couple of minutes so as to lubricate the
internal components of the pump and allow the diaphragms to
set in position before the pressure is increased.
The restriction on the pump is removed by rotating the Pressure
Release knob on the control unit, fully toward bypass arrow
direction. First back out the pressure regulator adjustment
knob to zero. Then rotate the Pressure Release knob to
Pressure arrow direction. Adjust the pressure by rotating the
relief valve adjustment knob to the desired pressure
FIGURE 5: MODEL 9915-KIT1004 FIGURE 6: MODEL 9915-KIT1005

12 L-1600 (04/01/21)
LOW PRESSURE 15 BAR REPLACEMENT PARTS
FIGURE 7: MODEL DP803

13
L-1600 (04/01/21)
LOW PRESSURE 15 BAR REPLACEMENT PARTS
TORQUE CHART DP803
REF. No. Qty. N-m ft.Lbs
3 3 25 18.5
43 120 14.8
47 3"5
(LOXEAL 55-14)"
"3.7
(LOXEAL 55-14)"
24 2 5 3.7
37 910 7.4
17 444 32.5
36 6 3 2.2
11 344 32.5
75 140 29.5
28 12 30 22
Tolerance on Torque value: +0/-10%
9915-KIT2004
KIT DIAPHRAGM DP803 DP1003
REF. No. DESCRIPTION QTY.
1PRE-SET DURAMAX PISTON
DIAPHRAGM 3
35 O-RING 3.53X28.17 6
ACCUMULATOR PRESSURE DP803
“OPERATING PRESSURE
PSI [Bar]”
“ACCUMULATOR PRESSURE
PSI [Bar]”
29-73 [2-5] 29 [2]
73-145 [5-10] 29-73 [2-5]
145-290 [10-20] 73 -102 [5 -7]
9915-KIT2104
KIT SERVICE VALVE DP803 DP1003
REF. No. DESCRIPTION QTY.
2VALVE ASSY 6
35 O-RING 3.53X28.17 6
9915-KIT2204
KIT REPAIR PUMP DP803 DP1003
REF. No. DESCRIPTION QTY.
16 O-RING 4.0x82 1
20 OIL SEAL DIA.35X52X7 1
35 O-RING DIA.3.53X28.17 6

14 L-1600 (04/01/21)
LOW PRESSURE 15 BAR REPLACEMENT PARTS
FIGURE 8: MODEL DP1003

15
L-1600 (04/01/21)
LOW PRESSURE 15 BAR REPLACEMENT PARTS
TORQUE CHART DP1003
REF. No. Qty. N-m ft.Lbs
3 3 25 18.5
47 35
(LOXEAL 55-14)
3.7
(LOXEAL 55-14)
24 2 5 3.7
37 910 7.4
17 444 32.5
36 6 3 2.2
11 344 32.5
75 140 29.5
28 12 30 22
Tolerance on Torque value: +0/-10%
9915-KIT2004
KIT DIAPHRAGM DP803 DP1003
REF. No. DESCRIPTION QTY.
1PRE-SET DURAMAX PISTON
DIAPHRAGM 3
35 O-RING 3.53X28.17 6
ACCUMULATOR PRESSURE DP1003
“OPERATING PRESSURE
PSI [Bar]”
“ACCUMULATOR PRESSURE
PSI [Bar]”
29-73 [2-5] 29 [2]
73-145 [5-10] 29-73 [2-5]
145-290 [10-20] 73 -102 [5 -7]
9915-KIT2104
KIT SERVICE VALVE DP803 DP1003
REF. No. DESCRIPTION QTY.
2VALVE ASSY 6
35 O-RING 3.53X28.17 6
9915-KIT2204
KIT REPAIR PUMP DP803 DP1003
REF. No. DESCRIPTION QTY.
16 O-RING 4.0x82 1
20 OIL SEAL DIA.35X52X7 1
35 O-RING DIA.3.53X28.17 6

16 L-1600 (04/01/21)
LOW PRESSURE 15 BAR REPLACEMENT PARTS
FIGURE 9: MODEL DP2505

17
L-1600 (04/01/21)
LOW PRESSURE 15 BAR REPLACEMENT PARTS
TORQUE CHART DP2505
REF. No. Qty. N-m ft.Lbs
9 5 25 18.4
40 220 14.8
18 25
(LOXEAL 24-18)"
3.7
(LOXEAL 24-18)"
55 1 8 5.9
46 640 29.5
64 222 16.3
31 20 22 16.3
53 310 7.4
820 40 29.5
91 440 29.5
83 20 10 7.4
84 20 10 7.4
Tolerance on Torque value: +0/-10%
9915-KIT2005
KIT DIAPHRAGM DP2505
REF. No. DESCRIPTION QTY.
1PRE-SET DURAMAX PISTON
DIAPHRAGM 5
3 O-RING 4.5x40 VITON 10
ACCUMULATOR PRESSURE DP2505
“OPERATING PRESSURE
PSI [Bar]”
“ACCUMULATOR PRESSURE
PSI [Bar]”
29-73 [2-5] 29 [2]
73-145 [5-10] 29 -73 [2-5]
145-290 [10-20] 73 -102 [5 -7]
9915-KIT2105
KIT SERVICE VALVE DP2505
REF. No. DESCRIPTION QTY.
2 S.S. AISI 316 VALVE ASSY (STD.) 10
3 O-RING 4.5x40 VITON 10
5 O-RING 2.62x42.52 VITON 5
9915-KIT2205
KIT REPAIR PUMP DP2505
REF. No. DESCRIPTION QTY.
3 O-RING 4.5x40 10
5 O-RING 2.62x42.52 VITON 5
38 O-RING 3.53x31.34 VITON 10
48 COVER GASKET 1
49 OIL SEAL DIA.35x52x7 2

18 L-1600 (04/01/21)
DIAPHRAGM PUMP: MEDIUM PRESSURE RANGE 20 - 40BAR
Model Number "Max. Flow
USGPM [LPM]"
"Max. Pressure
PSI [BAR] "
"Max. Speed
RPM"
"Power
HP [KW]"
No. of
Diaphragm
9915-DP503
13.5 [51] 580 [40]
550
5.4 [4.0] 3
9915-DP503GRGI 3300
9915-DP503AP-A 550
Model Number "Max. Flow
USGPM [LPM]"
"Max. Pressure
PSI [BAR] "
"Max. Speed
RPM"
"Power
HP [KW]"
No. of
Diaphragm
9915-D303
8.1 [3 1] 580 [40]
650
3.2 [2.4] 3
9915-D303GRGI 3600
9915-D303AP-A 650
9915-D403 9.8 [37] 580 [40] 550 3.9 [2.9] 3
9915-D403GRGI 3000
9915-D503
13.5[51] 580 [40]
550
5.4 [4.0] 3
9915-D503GRGI 3300
9915-D503AP-A 550
Model Number "Max. Flow
USGPM [LPM]"
"Max. Pressure
PSI [BAR] "
"Max. Speed
RPM"
"Power
HP [KW]"
No. of
Diaphragm
9915-DP302
7.1 [27] 29 0 [20]
650
1.6 [1.2] 2
9915-DP302AP-A 3450
9915-DP302GRGI 3450
Model Number "Max. Flow
USGPM [LPM]"
"Max. Pressure
PSI [BAR] "
"Max. Speed
RPM"
"Power
HP [KW]"
No. of
Diaphragm
9915-DP252
6.3 [24] 290 [20]
650
1.4 [1.1] 2
9915-DP252GRGI 3450
9915-DP252GRGI58 3450

19
L-1600 (04/01/21)
MEDIUM PRESSURE 20-40 BAR PERFORMANCE AND SPECIFICATIONS
DRIVE OPTIONS
Order the appropriate shaft adapter kit or gear reduction unit
for the drive option requirements. Refer to the adjoining chart
for proper selection.
Oil Capacity: Oil crankcase capacities are approximate. Fill
oil to proper level in sight glass. Always make sure all the air is
purged out of crankcase prior to operating.
Control Units: Control units are available for easy flow and
pressure control of your sprayer system. These units include
a manual dump valve and adjustable pressure relief valve to
control pressure, a liquid-filled pressure gauge to monitor
pressure, and shut-off valves to control flow. Control unit can
be remote mounted with remote mounting kit.Refer to the
adjoining chart to select the proper control unit for your pump
and remote mounting kits.
Model Number 3/4" Solid Shaft 1" Solid Shaft W/Keyway 1-3/8" Male Splined Shaft Gear Reduction Unit for
Gas Drive Engine
9915-DP252 N/A N/A N/A Order gear reduced models
9915-DP302 9915-KIT1201 9915-KIT1202 9915-KIT1203 Order gear reduced models
9915-D303 9915-KIT1201 9915-KIT1202 9915-KIT1203 9915-KIT1103
9915-D403 N/A 9915-KIT1202 9915-KIT1203 9915-KIT1103
9915-D503 N/A 9915-KIT1202 9915-KIT1203 9915-KIT1105
9915-DP503 N/A 9915-KIT1202 9915-KIT1203 9915-KIT1105
Control Unit Model Number "Max. Flow
USGPM [LPM]"
"Max. Pressure
PSI [BAR] " Pump Model Remote Mounting Kits
9915-KIT1001 7.9 [30] 290 [20] DP252 9915-KIT1403
9915-KIT1002 10.5 [4 0] 580 [40] D303/D403 9915-KIT1404
9915-KIT1003 24 [9 0] 580 [40] DP503/D503 9915-KIT1405
9915-KIT1008 10.5 [40] 290 [20] DP302 9915-KIT1406
Crankcase Oil Capacity
Pump Model Series "Capacity oz. [Litre]"
DP252 24 [0.7]
DP302 24 [0.7]
D303 20 [0.6]
D403 20 [0.6]
D503 17 [0.5]
DP503 17 [0.5]

20 L-1600 (04/01/21)
MEDIUM PRESSURE 20-40 BAR INSTALLATION
INSTALLATION INSTRUCTIONS FOR GEAR REDUCTION KIT
9915-KIT1103 (REFER TO FIGURE 10)
NOTE: Hypro recommends a blue thread locking compound on
all threaded fasteners that do not require lock washers. Shaft
key needs to be inspected occasionally and replaced if worn.
The 9915-KIT1103 gear reducer is designed for direct mounting
diaphragm pumps (listed in chart on page 19) onto a 5 hp gasoline
engine with a flange mounting and 3/4” solid shaft.
Assembly Instructions (Refer to Figure 10)
1. Take out from the pump the retaining ring sheet with the 4
corresponding fastening bolts.
2. Fasten the gear (Ref. 14) to the pump shaft by using the
corresponding 3 bolts (Ref. 13) with torque 16.2lbf [22Nm].
3. Install the O-ring (Ref. 15) in the corresponding slot on the
gear casing (Ref. 7), then fit the gear casing to the pump
tightening he bolts M10x20 (Ref. 11) with torque 29.5lbf
[40Nm].
4. Screw the oil drain plug (Ref. 9) with the proper washer (Ref.
8) and the oil sight (Ref. 12), then fill the gearbox casing with
oil SAE 80-W90 up to the middle of the oil sight. Then install
the oil filling plug (Ref. 10).
5. Insert the key (Ref. 2) the engine shaft and fit the centering
ring (Ref. 1) on the gear casing.
6. Install the “pump-gearbox assy” on the engine and tighten
the 4 corresponding bolts (Ref. 6) with torque 16.2lbf
[22Nm].
INSTALLATION INSTRUCTIONS FOR GEAR REDUCTION KIT
9915-KIT1105 (REFER TO FIGURE 11)
Hypro recommends a blue thread locking compound on all
threaded fasteners that do not require lock washers. Shaft key
needs to be inspected occasionally and replaced if worn.
The 9915-KIT1105 gear reducer is designed for direct mounting
the diaphragm pumps (listed in chart on page 19) onto an 8 hp
gasoline engine with a flange mounting and 1” solid shaft.
Assembly Instructions (Refer to Figure 11)
1. Take out from the pump the retaining ring locking sheet
with the 4 corresponding fastening bolts.
2. Install the O-ring (Ref. 9) in the half casing slot (pump side)
(Ref. 19), then fit to the pump with the 4 corresponding with
the 4 copper washer (Ref. 18) and bolts (Ref. 8) with torque
29.5lbf [40Nm].
3. Fit the ring gear (Ref. 17) to the pump shaft by using the
corresponding screws (Ref. 15) and the proper safety
washers (Ref. 16) with torque 29.5lbf [40Nm] along with
thread sealant. In case the gearbox is fixed by M8 screws
(ref. 20-21-22), tightening torque is 16.2 lbf [22Nm].
4. Screw the oil sight (Ref. 14) in the lateral part of the gearbox
casing (Ref. 12).
5. Apply sealant on the top of the 2 half casings and install the
engine side assembly on the pump side assembly. Fit the
paper gasket (Ref. 13) between the 2 assemblies and fasten
the whole system with corresponding bolts (Ref. 10) with
torque 16.2lbf [22Nm].
6. Insert the key (Ref. 1) onto the engine shaft, fit the pump-
gearbox assy to the engine and tighten the 4 corresponding
bolts 3/8” (Ref. 6) and spring washers (Ref. 5) with torque
29.5lbf [40Nm].
7. Fill the gearbox casing with SAE 80-W90 oil, up to the
middle of the oil sight, then install the oil vent plug (Ref. 11).