Graco Husky 1050 Series Use and care manual

Repair/Parts
Husky®1050 Air-Operated
Diaphragm Pump 313435ZAA
EN
1-inch pump with modular air valve for fluid transfer applications.
For professional use only.
See page 4 for model information, including approvals.
125 psi (0.86 MPa, 8.6 bar) Maximum Fluid Working Pressure
125 psi (0.86 MPa, 8.6 bar) Maximum Air Input Pressure
Center
Flange
ti13844a
ti13843a
End
Flange
1050P Polypropylene
1050C Conductive
Polypropylene
1050F PVDF
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
1050S Stainless Steel
1050H Hastelloy
ti14342a
1050A Aluminum
ti13946a

Related Manuals
2313435ZAA
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
To Find Your Nearest Distributor . . . . . . . . . . . . . . 3
To Specify the Configuration of a New Pump . . . . 3
To Order Replacement Parts . . . . . . . . . . . . . . . . . 3
Distributor Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pump Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ATEX Certifications . . . . . . . . . . . . . . . . . . . . . . . . . 5
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pressure Relief Procedure . . . . . . . . . . . . . . . . 10
Repair or Replace Air Valve . . . . . . . . . . . . . . . 10
DataTrak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Check Valve Repair . . . . . . . . . . . . . . . . . . . . . 14
Diaphragms and Center Section . . . . . . . . . . . . 15
Torque Instructions . . . . . . . . . . . . . . . . . . . . . . 18
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Parts/Kits Quick Reference . . . . . . . . . . . . . . . . 21
Center Section . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Air Valve and Data Monitoring . . . . . . . . . . . . . . 24
Fluid Covers and Manifolds . . . . . . . . . . . . . . . . 26
Seats and Check Ball . . . . . . . . . . . . . . . . . . . . 28
Diaphragms . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Seat, Check Ball, and Diaphragm Kits . . . . . . . 31
Manifold O-Rings . . . . . . . . . . . . . . . . . . . . . . . . 32
DataTrak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Graco Standard Husky Pump Warranty . . . . . . . . 36
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 36
Related Manuals
Manual Description
312877 Husky 1050 Air-Operated Diaphragm Pump, Operation
313597 Husky 1050A UL-Listed Diaphragm Pump, Operation
313598 Husky 1050A CSA-Compliant Diaphragm Pumps, Operation
313840 DataTrak, Instructions/Parts
406824 Pulse Count Kits, Instructions
406825 Reed Switch with Solenoid Kits, Instructions
406826 Torque Instructions (Manifolds and Fluid Covers)

To Find Your Nearest Distributor
313435ZAA 3
To Find Your Nearest Distributor
1. Visit www.graco.com.
2. Click on Where to Buy and use the Distributor Locator.
To Specify the Configuration of a New Pump
Please call your distributor.
OR
Use the Online Diaphragm Pump Selector Tool at www.graco.com.
To Order Replacement Parts
Please call your distributor.
Distributor Note
1. To find part numbers for new pumps or kits, use the Online Diaphragm Pump Selector Tool.
2. To find part numbers for replacement parts:
a. Use the configuration number from the ID plate on the pump. If you only have the Graco 6-digit part num-
ber, use the selector tool to find the corresponding configuration number.
b. Use the Configuration Number Matrix on the next page to understand which parts are described by each
digit.
c. Refer to the main Parts illustration and to the Parts/Kits Quick Reference. Follow the page references on
these two pages for further ordering information, as needed.
3. Please call Graco Customer Service to order.

Pump Matrix
4313435ZAA
Pump Matrix
Check the identification plate (ID) for the Configuration Number of your
pump. Use the following matrix to define the components of your pump.
Sample Configuration Number: 1050A-PA01AA1SSBNBNPT
1050 A P A01A A1 SS BN BN PT
Pump
Size Wetted Section
Material
Drive
Identifier Center Section and
Air Valve
Fluid
Covers and
Manifolds
Seats Balls Diaphragms Manifold
O-Rings
Pump
Size Wetted Section Material Drive Identifier Center Section and Air Valve Material Air Valve/Monitoring Fluid Covers and Manifolds
1050 AAluminum P
Pneumatic
Aluminum
A01A Standard A1 Aluminum, standard ports, inch
1050 CConductive
Polypropylene A01B Pulse CountA2 Aluminum, standard ports, metric
A01C DataTrakC1 Conductive polypropylene,
center flange
1050 F PVDF A01D Remote
1050 H‡Hastelloy A01E Optional FKM Seals C2 Conductive polypropylene, end
flange
1050 P Polypropylene AC1A CSA-Compliant
1050 S‡Stainless Steel AU1A UL-Listed; Fuel
transfer F1 PVDF, center flange
AU3A UL-Listed; Fuel
dispenseF2 PVDF, end flange
Conductive
Polypropylene
C01A Standard H1 Hastelloy, standard ports, inch
C01B Pulse CountH2 Hastelloy, standard ports, metric
C01C DataTrakP1 Polypropylene, center flange
C01D Remote P2 Polypropylene, end flange
Polypropylene
P01A Standard S1 Stainless steel, standard ports,
inch
P01B Pulse Count
P01C DataTrakS2 Stainless steel, standard ports,
metric
P01D Remote S5-1 Stainless steel, center flange,
horizontal outlet port
, ‡, or : See ATEX Certifications, on page 5.
 Contains pressure relief valve
S5-2 Stainless steel, center flange,
vertical outlet port
CONFIGURATION NO.PART NO. SERIALNO.
SERIESDATE CODE MAX WPR PSI-bar MADE IN
ID
ti14103a
Check Valve Seats Check Valve Balls Diaphragm Manifold O-Rings
AC Acetal AC Acetal BN Buna-N —Models with
Buna-N, FKM
Fluoroelasto-
mer or TPE
seats do not
use o-rings.
AL Aluminum BN Buna-N CO Polychloroprene Overmolded
BN Buna-N CR Polychloroprene Standard FK FKM Fluoroelastomer
FK FKM Fluoroelastomer CW Polychloroprene Weighted GE Geolast
GE Geolast®FK FKM Fluoroelastomer PO PTFE/EPDM Overmolded
PP Polypropylene GE Geolast PS PTFE/Santoprene Two-Piece PT PTFE
PV PVDF PT PTFE PT PTFE/EPDM Two-Piece
SP Santoprene®SP Santoprene SP Santoprene
SS 316 Stainless Steel SS 316 Stainless Steel TP TPE
TP TPE TP TPE

ATEX Certifications
313435ZAA 5
ATEX Certifications
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-
tion point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risk. When
these symbols appear in the body of this manual, refer back to these Warnings. Additional, product-specific warnings
may be found throughout the body of this manual where applicable.
All 1050A (Aluminum) and
1050C (Conductive Polypropylene)
pumps are certified:
II 2 GD c IIC T4
‡ 1050S (Stainless Steel) and 1050H
(Hastelloy) pumps with aluminum or
conductive polypropylene centers are
certified:
II 2 GD c IIC T4
DataTrak and Pulse Count are
certified:
0359 II 1 G
Ex ia IIA T3 Ga
ITS13ATEX27862X
9902471
Class I, Div. 1,
Group D T3A
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent
fire and explosion:
• Use equipment only in well ventilated area.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop
cloths (potential static arc).
• Keep work area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes
are present.
• Ground all equipment in the work area. See Grounding instructions.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail.
• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment
until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
Static charge may build up on plastic parts during cleaning and could discharge and ignite flammable
materials and gases. To help prevent fire and explosion:
• Clean plastic parts in a well ventilated area.
• Do not clean with a dry cloth.
• Do not operate electrostatic guns in equipment work area.

Warnings
6313435ZAA
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information
about your material, request MSDS from distributor or retailer.
• Do not leave the work area while equipment is energized or under pressure. Turn off all equipment
and follow the Pressure Relief Procedure in this manual when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manu-
facturer’s replacement parts only.
• Do not alter or modify equipment.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
PRESSURIZED EQUIPMENT HAZARD
Fluid from the gun/dispense valve, leaks, or ruptured components can splash in the eyes or on skin and
cause serious injury.
• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,
checking, or servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.
THERMAL EXPANSION HAZARD
Fluids subjected to heat in confined spaces, including hoses, can create a rapid rise in pressure due to
the thermal expansion. Over-pressurization can result in equipment rupture and serious injury.
• Open a valve to relieve the fluid expansion during heating.
• Replace hoses proactively at regular intervals based on your operating conditions.
PRESSURIZED ALUMINUM PARTS HAZARD
Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical
reaction and equipment rupture. Failure to follow this warning can result in death, serious injury, or prop-
erty damage.
• Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or
fluids containing such solvents.
• Many other fluids may contain chemicals that can react with aluminum. Contact your material
supplier for compatibility.
PLASTIC PARTS CLEANING SOLVENT HAZARD
Use only compatible water-based solvents to clean plastic structural or pressure-containing parts. Many
solvents can degrade plastic parts and cause them to fail, which could cause serious injury or property
damage. See Technical Data in this and all other equipment instruction manuals. Read fluid and solvent
manufacturer’s warnings.
WARNING

Warnings
313435ZAA 7
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
• Read MSDS’s to know the specific hazards of the fluids you are using.
• Route exhaust away from work area. If diaphragm ruptures, fluid may be exhausted with air.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
BURN HAZARD
Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe
burns:
• Do not touch hot fluid or equipment.
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the operating
area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic
fumes, burns, and hearing loss. This equipment includes but is not limited to:
• Clothing and respirator as recommended by the fluid and solvent manufacturer
• Protective eyewear, gloves, and hearing protection.
WARNING

Troubleshooting
8313435ZAA
Troubleshooting
Problem Cause Solution
Pump cycles but will not prime. Pump is running too fast, causing
cavitation before prime Lower air inlet pressure.
Check valve ball severely worn or
wedged in seat or manifold. Replace ball and seat. See page 14.
Seat severely worn. Replace ball and seat. See page 14.
Outlet or inlet clogged. Unclog.
Inlet or outlet valve closed. Open.
Inlet fittings or manifolds loose. Tighten.
Manifold o-rings damaged. Replace o-rings. See page 14.
Pump cycles at stall or fails to hold
pressure at stall. Worn check valve balls, seats, or o-rings. Replace. See page 28.
Pump will not cycle, or cycles once
and stops. Air valve is stuck or dirty. Disassemble and clean air valve. See page 11. Use filtered air.
Check valve ball severely worn and
wedged in seat or manifold. Replace ball and seat. See page 14.
Pilot valve worn, damaged, or
plugged. Replace pilot valve. See page 15.
Air valve gasket damaged. Replace gasket. See page 10.
Check valve ball is wedged into seat
due to overpressurization. Install pressure relief kit. See Acces- sories, page 32.
Dispensing valve clogged. Relieve pressure and clear valve.
Air tubing is plugged
(remote air control models). Clear tube.
Pump operates erratically. Clogged suction line. Inspect; clear.
Sticky or leaking check valve balls. Clean or replace. See page 14.
Diaphragm (and backup) ruptured. Replace. See page 15.
Restricted exhaust. Remove restriction.
Pilot valves damaged or worn. Replace pilot valves. See page 15.
Air valve damaged. Replace air valve. See page 10.
Air valve gasket damaged. Replace air valve gasket. See
page 10.
Air supply erratic. Repair air supply.
Exhaust muffler icing. Use drier air supply or use low ice
muffler (Graco part 102656).

Troubleshooting
313435ZAA 9
Air bubbles in fluid. Suction line is loose. Tighten.
Diaphragm (and backup) ruptured. Replace. See page 15.
Loose manifolds, damaged seats or
manifold o-rings. Tighten manifold bolts or replace seats or o-rings. See page 14.
Diaphragm shaft bolt o-ring dam-
aged. Replace o-ring.
Pump cavitation. Reduce pump speed or suction lift.
Loose diaphragm shaft bolt. Tighten.
Exhaust air contains fluid being
pumped. Diaphragm (and backup) ruptured. Replace. See page 15.
Loose diaphragm shaft bolt. Tighten or replace. See page 15.
Diaphragm shaft bolt o-ring dam-
aged. Replace o-ring. See page 15.
Moisture in exhaust air. High inlet air humidity. Use drier air supply.
Pump exhausts excessive air at
stall*. Worn air valve cup or plate. Replace cup and plate. See page 11.
Damaged air valve gasket. Replace gasket. See page 10.
Damaged pilot valve. Replace pilot valves. See page 15.
Worn shaft seals or bearings. Replace shaft seals or bearings. See
page 15.
Air tubing is damaged or loose
(remote air control models). Replace tubing or secure connection.
Remote air pressure is higher than
pump air pressure (remote air control
models).
Regulate remote pilot air pressure to
be equal to or less than main air.
Pump leaks air externally. Air valve or fluid cover screws loose. Tighten.
Diaphragm damaged. Replace diaphragm. See page 15.
Air valve gasket damaged. Replace gasket. See page 10.
Remote air pressure is higher than
pump air pressure (remote air control
models).
Regulate remote pilot air pressure to
be equal to or less than main air.
Pump leaks fluid externally from
joints. Loose manifold screws or fluid cover screws. Tighten manifold screws or fluid cover screws. See page 18.
Manifold o-rings worn out. Replace o-rings. See page 14.
Pump leaks fluid externally through
manifold or fluid cover. Excessive pump speed or inlet starvation. Replace manifold and reduce pump speed or improve pump feed.
* A small amount of air will exhaust during stall if the pump is stopped while in the process of changing over. This is
normal. If desired, Valve Upgrade Kit 24K224 can be installed to minimize air exhausting.
Problem Cause Solution

Repair
10 313435ZAA
Repair
Pressure Relief Procedure
1. Shut off the air supply to the pump.
2. Open the dispensing valve, if used.
3. Open the fluid drain valve to relieve fluid pressure.
Have a container ready to catch the drainage.
Repair or Replace Air Valve
Replace Complete Air Valve
1. Stop the pump. Relieve the pressure. See Pressure
Relief Procedure in previous section.
2. Disconnect the air line to the motor.
3. For motors with Pulse Count or DataTrak:
Remove screw to disconnect the reed switch
assembly from the air valve.
4. For motors with DataTrak: Remove two screws
and the solenoid bracket. Pull the solenoid out of
the air valve.
5. Remove screws (109, metal pumps) or nuts (112,
plastic pumps). Remove the air valve and gasket
(108).
6. To repair the air valve, go to Disassemble the Air
Valve, step 1, in next section. To install a replace-
ment air valve, continue with step 7.
7. Align the new air valve gasket (108) on the center
housing, then attach the air valve. See Torque
Instructions, page 18.
SPECIAL CONDITIONS FOR SAFE USE
Equipment must comply with the following
conditions to avoid a hazardous condition
which can cause fire or explosion.
• All label and marking material must be
cleaned with a damp cloth (or equiva-
lent).
• The electronic monitoring system is
required to be grounded. See Grounding
instructions in your pump operation man-
ual.
Trapped air can cause the pump to cycle unexpect-
edly, which could result in serious injury from splash-
ing.
WARNINGWARNINGWARNING
WARNING
FIG. 1. Reed switch assembly and air line removal
FIG. 2. Solenoid removal
ti14094a
ti14095a
Aluminum Model
Shown 109

Repair
313435ZAA 11
8. For motors with DataTrak: Remember to reattach
the solenoid bracket and the solenoid.
9. For motors with Pulse Count or DataTrak: Use
screw to attach the reed switch assembly to the new
air valve. Reconnect cable.
10. Reconnect the air line to the motor.
Replace Seals or Rebuild Air Valve
NOTE: Repair kits are available. See page 25 to order
the correct kit(s) for your pump. Air Valve Seal Kit parts
are marked with a †. Air Valve Repair Kit parts are
marked with a . Air Valve End Cap Kit parts are
marked with a .
Disassemble the Air Valve
1. Perform steps 1-5 under Replace Complete Air
Valve, page 10.
2. See FIG. 4. Use a Torx screwdriver (T8 for alumi-
num centers, T9 for plastic centers) to remove two
screws (209). Remove the valve plate (205),
cup assembly (212-214), spring (211), and detent
assembly (203).
3. Pull the cup (213) off of the base (212). Remove the
o-ring (214) from the cup.
4. See FIG. 4. Remove the retaining ring (210) from
each end of the air valve. Use the piston (202) to
push the end caps (207, 217) out of the ends.
Remove end cap o-rings (206). If pump model is
equipped with a runaway protection solenoid, also
remove the solenoid release button (218) and
o-ring (219).
5. Remove the u-cup seals (208) from each end of the
piston (202), then remove the piston. Remove the
detent cam (204) from the air valve housing (201).
Reassemble the Air Valve
NOTE: Apply lithium-based grease whenever instructed
to grease.
1. Use all parts in the repair kits. Clean other parts and
inspect for damage. Replace as needed.
2. Grease the detent cam (204) and install into hous-
ing (201).
3. Grease the u-cups (208) and install on the piston
with lips facing toward the center of the piston.
4. Grease both ends of the piston (202) and install it in
the housing (201), with the flat side toward the cup
(212). Be careful not to tear u-cups (208) when slid-
ing piston into housing.
5. Standard or Pulse Count models (no runaway
protection solenoid): Grease new o-rings (206)
and install on the end caps (207). Install the end
caps into the housing.
DataTrak models (with runaway protection sole-
noid): Orient the air valve so the air inlet faces for-
ward. Grease and install new o-ring (206) on
right-side end cap (207). Grease and install new
o-ring (206) and the solenoid release button (218)
and o-ring (219) on left-side end cap (217). Install
the end caps into the housing.
6. Install a retaining ring (210) on each end to hold end
caps in place.
FIG. 3. Air valve u-cup installation
Lips face down
Lips face up
208†
208†
202
ti12754a

Repair
12 313435ZAA
7. Grease and install the detent assembly (203) into
the piston. Install the o-ring (214) on the cup (213).
Apply a light film of grease to the outside surface of
the o-ring and the inside mating surface of the base
(212).
Orient the end of the base that has a magnet toward
the end of the cup that has the larger cutout.
Engage the opposite end of the parts. Leave the
end with the magnet free. Tilt the base toward the
cup and fully engage the parts, using care so that
the o-ring remains in place. Install the spring (211)
onto the protrusion on the cup. Align the magnet in
the base with the air inlet and install the cup assem-
bly.
8. Grease the cup side and install the valve plate
(205). Align the small hole in the plate with the air
inlet. Tighten the screws (209) to hold it in place.
FIG. 4. Air valve assembly
210
210
207
217
206†
206†
208†
202
208†
209†
205
212
211
203
204
218
219
ti14026b
201
Apply lithium-based grease.
1
1
1
1
1
1
3
U-cup lips must face piston.
2
2
2
210
206†
DataTrak Models
with Runaway
Protection 207
1
1
1
air
inlet
2141
213
3
Apply lithium-based grease to
contact surface.
3
FIG. 5
211
213
212
214
ti19675a
FIG. 6. Air valve cup and plate installation
magnet ti14097b
205 212
small
hole

Repair
313435ZAA 13
DataTrak
NOTE: See DataTrak manual, 313840, for all DataTrak
service and repair information.
Replace DataTrak Battery or Fuse
To reduce the risk of fire and explosion, the
battery and fuse must be replaced in a
non-hazardous location. Follow all instruc-
tions in your pump operation manual.
Use only an approved replacement battery,
and an approved fuse (see pump operation
manual). Use of an unapproved battery or
fuse will void Graco’s warranty and Intertek
and Ex approvals.
WARNINGWARNINGWARNING
WARNING

Repair
14 313435ZAA
Check Valve Repair
NOTE: Kits are available for new check valve balls and
seats in a range of materials. See page 28 to order kits
in the material(s) desired. An o-ring kit and fastener kits
also are available.
NOTE: To ensure proper seating of the check balls,
always replace the seats when replacing the balls. Also,
on models with manifold o-rings, replace the o-rings.
Disassembly
1. Follow the Pressure Relief Procedure on page 10.
Disconnect all hoses.
2. Remove the pump from its mounting.
NOTE: For plastic pumps (1050P, 1050C, and
1050F), use hand tools only until thread-locking
adhesive patch releases.
3. Use a 10 mm socket wrench to remove the outlet
manifold fasteners (6). See FIG. 7.
4. Remove the o-rings (12, not used onsome models),
seats (10), and balls (11).
5. Turn the pump over and remove the inlet manifold.
Remove the o-rings (12, not used onsome models),
seats (10), and balls (11).
Reassembly
1. Clean all parts and inspect for wear or damage.
Replace parts as needed.
2. Reassemble in the reverse order, following all notes
in FIG. 7. Be sure the ball checks (10-12) and mani-
folds (4, 5) are assembled exactly as shown. The
arrows (A) on the fluid covers must point toward the
outlet manifold (4).
FIG. 7. Ball check valve assembly
Torque to 100 in-lb (11.3 N•m). See Torque Instructions,
page 18.
1
Not used on some models.
3
ti14098a
6
4
11
12
10
12
3
6
5
Arrow (A) must point toward outlet manifold.
2
1
1
2
A
10
12
12
3
3
3
3
11
Aluminum pump
shown
7

Repair
313435ZAA 15
Diaphragms and Center Section
Disassembly
NOTE: Diaphragm kits are available in a range of mate-
rials and styles. See page 29 to order the correct dia-
phragms for your pump. A Center Rebuild Kit also is
available. See page 23. Parts included in the Center
Rebuild Kit are marked with an *. For best results, use
all kit parts.
1. Follow the Pressure Relief Procedure on page 10.
2. Remove the manifolds and disassemble the ball
check valves as explained on page 14.
3. Overmolded Diaphragms
a. Orient the pump so one of the fluid covers faces
up. Use a 10 mm socket wrench to remove the
fluid cover screws (7), then pull the fluid cover
(3) up off the pump.
b. The exposed diaphragm (15) will screw off by
hand from the diaphragm shaft (104). The dia-
phragm shaft bolt will remain attached to the
diaphragm. Remove the air side diaphragm
plate (14).
c. Turn the pump over and remove the other fluid
cover. Pull the diaphragm and shaft up through
the center housing.
d. Grasp the diaphragm firmly and use a wrench
on the flats of the shaft to remove. Also remove
the air side diaphragm plate (14). Continue with
Step 5.
4. All Other Diaphragms
a. Orient the pump so one of the fluid covers faces
up. Use a 10 mm socket wrench to remove the
fluid cover screws (7), then pull the fluid cover
up off the pump. Turn the pump over and
remove the other fluid cover.
b. Plastic Pumps: Use a 1-1/4 socket or box end
wrench on the hex of a fluid side diaphragm
plate to remove. Then remove all parts of the
diaphragm assembly. See FIG. 8.
Metal Pumps: Remove the bolt (304) from one
side of the diaphragm shaft, then remove all
parts of that diaphragm assembly. See FIG. 8.
c. Follow the same procedure to disassemble the
other diaphragm assembly.
5. Inspect the diaphragm shaft (104) for wear or
scratches. If it is damaged, inspect the bearings
(105) in place. If they are damaged, use a bearing
puller to remove them.
NOTE: Do not remove undamaged bearings.
6. Use an o-ring pick to remove the u-cup packings
(106) from the center housing. Bearings (105) can
remain in place.
7. If necessary, use a socket wrench to remove the
pilot valves (101) or pilot inserts (113, remote air
control models).
8. Remove the pilot valve cartridges only if necessary
due to a known or suspected problem. After remov-
ing pilot valves, use a hex to remove the cartridges
(102), then remove cartridge o-rings (103). If
stripped, use two screwdrivers to screw out the car-
tridge.
NOTE: Do not remove undamaged pilot valve
cartridges.

Repair
16 313435ZAA
FIG. 8. Assemble diaphragms and center section
ti14022b
304
301
15
13
14
104* 15
104*
ti14037b
PO and CO
models
304
301
15 13
14
104*
305
14 303
ti14021b
PT models
13
13 (Metal pumps)
(Plastic pumps)
(Metal pumps)
1
Rounded side faces diaphragm.
1
1
1
1
1
Apply lithium-based grease.
2
2
2
2
Torque to 20-25 ft-lb (27-34 N•m)
at 100 rpm maximum.
3
3
3
AIR SIDE markings on diaphragm
must face center housing.
4
44
4
4
If screw comes loose or is
replaced, apply permanent (red)
Loctite®or equivalent to
diaphragm side threads. Apply
primer and medium-strength (blue)
Loctite®or equivalent to shaft side
threads.
5
101* 102*
102*
103*
103*
104*
105*
105*
106*
106*
110
Lips must face out of housing.
6
TP, SP, BN,
FK, and GE
models
5
3
3
ti14025b
2
2
Torque to 20-25 in.-lb (2.3-2.8 N•m).
8
7
(Plastic pumps)
Cartridges (102) must be installed
before pilot valves (101) or inserts
(113, for remote air controls).
7
2
2
22
28
26
7
7
2
6
2
113 7
28
(remote air control)

Repair
313435ZAA 17
Reassembly
Follow all notes in FIG. 8. These notes contain
important information.
NOTE: Apply lithium-based grease whenever instructed
to grease.
1. Clean all parts and inspect for wear or damage.
Replace parts as needed.
2. If removed, grease and install the new pilot valve
cartridges (102) and cartridge o-rings (103). Screw
in until seated.
NOTE: Cartridges (102) must be installed before pilot
valves (101).
3. Grease and install the pilot valves (101). Torque to
20-25 in.-lb (2.3-2.8 N•m). Do not over-torque.
4. Grease and install the diaphragm shaft u-cup pack-
ings (106) so the lips face out of the housing.
5. If removed, insert the new bearings (105) into the
center housing. Use a press or a block and rubber
mallet to press-fit the bearing so it is flush with the
surface of the center housing.
6. Overmolded Diaphragms:
a. Clamp the shaft flats in a vise.
b. If diaphragm setscrew comes loose or is
replaced, apply permanent (red) Loctite®or
equivalent to diaphragm side threads. Screw
into diaphragm until tight.
c. Assemble the air side plate (14) onto the dia-
phragm. The rounded side of the plate must
face the diaphragm.
d. Apply medium-strength (blue) Loctite or equiva-
lent to the threads of the diaphragm assembly.
Screw the assembly into the shaft as tight as
possible by hand.
e. Grease the shaft u-cups (106) and the length
and ends of the diaphragm shaft (104). Slide
the shaft into the housing.
f. Reattach the first fluid cover (3). See Torque
Instructions, page 18.
g. Repeat Steps b and c for the other diaphragm
assembly. Go to Step 7.
All Other Diaphragms - Metal Pumps:
a. Install the o-ring (301) on the shaft bolt (304).
b. Assemble the fluid side plate (13), the dia-
phragm (15), the backup diaphragm (305, if
present), and the air side diaphragm plate (14)
on the bolt exactly as shown in FIG. 8.
c. Apply medium-strength (blue) Loctite or equiva-
lent to the bolt (304) threads. Screw the bolt into
the shaft hand tight.
d. Grease the shaft u-cups (106) and the length
and ends of the diaphragm shaft (104). Slide
the shaft into the housing.
e. Repeat Steps a-c for the other diaphragm
assembly.
f. Hold one shaft bolt with a wrench and torque
the other bolt to 20-25 ft-lb (27-34 N•m) at 100
rpm maximum. Do not over-torque.
g. Reattach the first fluid cover (3). See Torque
Instructions, page 18. Go to Step 7.
All Other Diaphragms - Plastic Pumps:
a. Assemble the diaphragm (15), the backup dia-
phragm (305, if present), and the air side dia-
phragm plate (14) on the fluid side plate (13)
exactly as shown in FIG. 8.
b. Apply medium-strength (blue) Loctite or equiva-
lent to the threads of the screw on the fluid side
plate. Screw the assembly into the shaft
hand-tight.
c. Grease the shaft u-cups (106) and the length
and ends of the diaphragm shaft (104). Slide
the shaft into the housing.
d. Repeat for the other diaphragm assembly
e. Hold one of the plates with a wrench, and
torque the other plate to 20-25 ft-lb (27-34 N•m)
at 100 rpm maximum. Do not over-torque.
f. Reattach the first fluid cover (3). See Torque
Instructions, page 18.

Repair
18 313435ZAA
7. To ensure proper seating and extend diaphragm
life, attach the second fluid cover with air pressure
on the pump.
a. See FIG. 9. Place the supplied tool (302) where
the air valve gasket (108) normally goes.
Arrows (A) must face toward the fluid cover that
is already attached.
b. Reattach the air valve.
c. Supply a minimum of 20 psi (0.14 MPa, 1.4 bar)
air pressure to the air valve. Shop air may be
used. The diaphragm will shift so the second
fluid cover will seat properly. Keep air pressure
on until the second fluid cover is attached.
d. Attach the second fluid cover (3). See Torque
Instructions, page 18.
e. Remove the air valve and the tool (302), replace
the gasket (108), and reattach the air valve. See
Torque Instructions, page 18.
NOTE: If you are replacing the diaphragms but not the
air valve, you must remove the air valve and gasket, put
the tool in place of the gasket, and put the air valve back
on to get the air pressure needed for proper installation
of the second fluid cover. Remember to remove the tool
and replace the gasket when finished.
8. Reassemble the ball check valves and manifolds as
explained on page 14.
Torque Instructions
NOTE: Fluid cover and manifold fasteners have a
thread-locking adhesive patch applied to the threads. If
this patch is worn, the screws may loosen during opera-
tion. Replace screws with new ones, or apply medium-
strength (blue) Loctite or equivalent to the threads.
If fluid cover or manifold fasteners have been loosened,
it is important to torque them using the following proce-
dure to improve sealing.
NOTE: Always completely torque fluid covers before
torquing manifolds.
Start all fluid cover screws a few turns. Then turn down
each screw just until head contacts cover. Then turn
each screw by 1/2 turn or less working in a crisscross
pattern to specified torque. Repeat for manifolds.
Fluid cover and manifold fasteners:
100 in-lb (11.3 N•m)
Retorque the air valve fasteners (V) in a crisscross pat-
tern to specified torque.
Air valve fasteners:
55 in-lb (6.2 N•m) for plastic center sections
80 in-lb (9.0 N•m) for metal center sections
FIG. 9. Fluid cover tool
302 A
ti14120a

Repair
313435ZAA 19
FIG. 10. Torque sequence








 





 9
ti18448a
ti18449a

Parts
20 313435ZAA
Parts
ti14023a
8
1
1
Not used on some models.
1
see page 22
2
see page 24 3
see page 26
4
see page 26
5
see page 26
6
see page 27
7
see page 27
12
see page 32
13
see page 30
10
see page 28
11
see page 28
18
1
9
see page 27
15
see page 29