Graco Husky 1050 Series User manual

Repair/Parts
Husky®1050 Air-Operated
Diaphragm Pump 313435H
ENG
1-inch pump with modular air valve for fluid transfer applications.
For professional use only.
See page 3 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
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
1050S Stainless Steel
1050H Hastelloy
ti14342a
1050A Aluminum
ti13946a
Center
Flange
ti13844a
ti13843a
End
Flange
1050P Polypropylene
1050C Conductive
Polypropylene
1050F PVDF
Patents Pending
0359

Related Manuals
2313435H
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Pump Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ATEX Certifications . . . . . . . . . . . . . . . . . . . . . . . 3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Pressure Relief Procedure . . . . . . . . . . . . . . . . . 8
Repair or Replace Air Valve . . . . . . . . . . . . . . . . 8
DataTrak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Check Valve Repair . . . . . . . . . . . . . . . . . . . . . . 11
Diaphragms and Center Section . . . . . . . . . . . . 12
Torque Instructions . . . . . . . . . . . . . . . . . . . . . . 15
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Parts/Kits Quick Reference . . . . . . . . . . . . . . . . 17
Center Section . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Air Valve and Data Monitoring . . . . . . . . . . . . . . 20
Fluid Covers and Manifolds . . . . . . . . . . . . . . . . 24
Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Check Balls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Diaphragms . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Manifold O-rings . . . . . . . . . . . . . . . . . . . . . . . . 29
DataTrak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Graco Standard Husky Pump Warranty . . . . . . . . 32
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 32
Related Manuals
Manual Description
312877 Husky 1050 Air-Operated Diaphragm Pump, Operation
313597 Husky 1050A UL-Listed Diaphragm Pump, Operation
313598 Husky 1050A CSA-Certified Diaphragm Pump, Operation
313840 DataTrak, Instructions/Parts
406824 Pulse Count Kits, Instructions
406825 Reed Switch with Solenoid Kits, Instructions
406826 Torque Instructions (Manifolds and Fluid Covers)

Pump Matrix
313435H 3
Pump Matrix
Check the identification plate (ID) for the 20-digit part number of your pump. Use
the following matrix to define the components of your pump. For example, pump
number 1050A-A01AA1SSBNBNPT represents a Husky 1 inch, 50 gpm alumi-
num pump (1050A), with aluminum center section (A01), a standard air valve
(A), aluminum fluid covers (A) and manifolds with standard ports in inches (1).
The pump has stainless steel seats (SS), buna-N check balls (BN), buna-N dia-
phragms (BN), and PTFE manifold o-rings (PT).
NOTE: Available options for seats, check balls, diaphragms, and seals vary
based on pump model (1050A-1050S). To build a pump, use the selector tool at
www.graco.com or speak with your distributor.
ATEX Certifications
CONFIGURATION NO.PART NO. SERIAL NO.
SERIESDATE CODE MAX WPR PSI-bar MADEIN
Pump ID
Pump Model
(1 inch ports, 50 gpm)
Center Section and
Air Valve Material
Air Valve/Monitoring Fluid Covers and Manifolds
1050A★
Aluminum
1050C★
Conductive
Polypropylene
1050F
PVDF
1050H‡
Hastelloy
1050P
Polypropylene
1050S‡
Stainless Steel
Aluminum
A01A Standard A1
A2
C1
C2
F1
F2
H1
H2
P1
P2
S1
S2
Aluminum, standard ports, inch
Aluminum, standard ports, metric
Conductive polypropylene, center flange
Conductive polypropylene, end flange
PVDF, center flange
PVDF, end flange
Hastelloy, standard ports, inch
Hastelloy, standard ports, metric
Polypropylene, center flange
Polypropylene, end flange
Stainless steel, standard ports, inch
Stainless steel, standard ports, metric
A01B Pulse Count✖
A01C DataTrak✖
A01D Remote
Conductive
Polypropylene
C01A Standard
C01B Pulse Count✖
C01C DataTrak✖
C01D Remote
Polypropylene
P01A Standard
P01B Pulse Count✖
P01C DataTrak✖
P01D Remote
★, ‡, or ✖: See ATEX Certifications below.
Check Valve Seats Check Valve Balls Diaphragm Manifold O-Rings
AC
AL
BN
FK
GE
PP
PV
SP
SS
TP
Acetal
Aluminum
Buna-N
FKM Fluoroelastomer
Geolast®
Polypropylene
PVDF
Santoprene®
316 Stainless Steel
TPE
AC
BN
CR
CW
FK
GE
PT
SP
SS
TP
Acetal
Buna-N
Polychloroprene Standard
Polychloroprene Weighted
FKM Fluoroelastomer
Geolast
PTFE
Santoprene
316 Stainless Steel
TPE
BN
CO
FK
GE
PO
PT
SP
TP
Buna-N
Polychloroprene Overmolded
FKM Fluoroelastomer
Geolast
PTFE/EPDM Overmolded
PTFE/EPDM Two-Piece
Santoprene
TPE
—
PT
None
PTFE
★
All 1050A (Aluminum) and
1050C (Conductive Polypropylene)
p
umps 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
II 1 G
EEx ia IIA T3
Nemko
06ATEX1124
✖DataTrak and Pulse Count
are certified:
ti14103a

Warnings
4313435H
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.
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.
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.

Warnings
313435H 5
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.
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.
• Always wear impervious gloves when spraying or cleaning equipment.
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.
• Wait until equipment/fluid has cooled completely.
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
6313435H
Troubleshooting
Problem Cause Solution
Pump cycles but will not prime. Check valve ball severely worn or
wedged in seat or manifold.
Replace ball and seat. See page 11.
Seat severely worn. Replace ball and seat. See page 11.
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 11.
Pump cycles at stall or fails to hold
pressure at stall.
Worn check valve balls, seats, or
o-rings.
Replace. See page 26.
Pump will not cycle, or cycles once
and stops.
Air valve is stuck or dirty. Disassemble and clean air valve. See
page 9. Use filtered air.
Check valve ball severely worn and
wedged in seat or manifold.
Replace ball and seat. See page 11.
Pilot valve worn, damaged, or
plugged.
Replace pilot valve. See page 12.
Air valve gasket damaged. Replace gasket. See page 8.
Check valve ball is wedged into seat
due to overpressurization.
Install pressure relief kit. See Acces-
sories, page 29.
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 11.
Diaphragm (and backup) ruptured. Replace. See page 12.
Restricted exhaust. Remove restriction.
Pilot valves damaged or worn. Replace pilot valves. See page 12.
Air valve damaged. Replace air valve. See page 8.
Air valve gasket damaged. Replace air valve gasket. See
page 8.
Air supply erratic. Repair air supply.
Exhaust muffler icing. Use drier air supply or use low ice
muffler (Graco part 102656).

Troubleshooting
313435H 7
Air bubbles in fluid. Suction line is loose. Tighten.
Diaphragm (and backup) ruptured. Replace. See page 12.
Loose manifolds, damaged seats or
manifold o-rings.
Tighten manifold bolts or replace
seats or o-rings. See page 11.
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 12.
Loose diaphragm shaft bolt. Tighten or replace. See page 12.
Diaphragm shaft bolt o-ring dam-
aged.
Replace o-ring. See page 12.
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 9.
Damaged air valve gasket. Replace gasket. See page 8.
Damaged pilot valve. Replace pilot valves. See page 12.
Worn shaft seals or bearings. Replace shaft seals or bearings. See
page 12.
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 12.
Air valve gasket damaged. Replace gasket. See page 8.
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 15.
Manifold o-rings worn out. Replace o-rings. See page 11.
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.
Problem Cause Solution

Repair
8313435H
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 15.
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.
Trapped air can cause the pump to cycle unexpectedly,
which could result in serious injury from splashing.
FIG. 1. Reed switch assembly and air line removal
ti14094a
FIG. 2. Solenoid removal
ti14095a
Aluminum Model
Shown
109

Repair
313435H 9
Replace Seals or Rebuild Air Valve
NOTE: Repair kits are available. See page 21 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 8.
2. See FIG. 4. Use a Torx screwdriver (T8 for aluminum
centers, T9 for plastic centers) to remove two
screws (209). Remove the valve plate (205),
cup (212), spring (211), and detent assembly (203).
3. 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).
4. 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.
FIG. 3. Air valve u-cup installation
Lips face down
Lips face up
208◆†
208◆†
202◆
ti12754a

Repair
10 313435H
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.
7. Grease and install the detent assembly (203) into
the piston. Install the spring (211). Grease the side
of the air valve cup (212) that will contact the valve
plate (205). Install the air valve cup (212). Align the
small round magnet with the air inlet.
8. 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✠
ti14026a
201
Apply lithium-based grease.
1
1
1
1
1
1
1
U-cup lips must face piston.
2
2
2
210✠
206◆†✠
DataTrak Models
with Runaway
Protection
207✠
1
1
1
air
inlet
FIG. 5. Air valve cup and plate installation
magnet
ti14097a
205 212
small
hole

Repair
313435H 11
DataTrak
NOTE: See DataTrak manual, 313840, for all DataTrak
service and repair information.
Check Valve Repair
NOTE: Kits are available for new check valve balls and
seats in a range of materials. See page 26 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 8.
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. 6.
4. Remove the o-rings (12, not used on some models),
seats (10), and balls (11).
5. Turn the pump over and remove the inlet manifold.
Remove the o-rings (12, not used on some 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. 6. 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. 6. Ball check valve assembly
Torque to 100 in-lb (11.3 N•m). See Torque Instructions,
page 15.
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
12 313435H
Diaphragms and Center Section
Disassembly
NOTE: Diaphragm kits are available in a range of mate-
rials and styles. See page 27 to order the correct dia-
phragms for your pump. A Center Rebuild Kit also is
available. See page 19. 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 8.
2. Remove the manifolds and disassemble the ball
check valves as explained on page 11.
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. 7.
Metal Pumps: Remove the bolt (304) from one
side of the diaphragm shaft, then remove all
parts of that diaphragm assembly. See FIG. 7.
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
313435H 13
FIG. 7. 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
2
2
28
26
7
7
2
6
2
113 7
28
(remote air control)

Repair
14 313435H
Reassembly
Follow all notes in FIG. 7. 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 15.
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. 7.
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 15. 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. 7.
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 15.

Repair
313435H 15
7. To ensure proper seating and extend diaphragm life,
attach the second fluid cover with air pressure on
the pump.
a. See FIG. 8. 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 15.
e. Remove the air valve and the tool (302), replace
the gasket (108), and reattach the air valve. See
Torque Instructions, page 15.
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 11.
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. 8. Fluid cover tool
302 A
ti14120a
FIG. 9. Torque sequence
ti13845a
ti13846a
9
10
11
1213
14
15
16
V
2
3
5
7
1
4
6
8

Parts
16 313435H
Parts
ti14023a
1
2
9
4
6
18
15
11
10
3
7
12
5
8
13
1
1
1
Not used on some models.

Parts
313435H 17
Parts/Kits Quick Reference
Use this table as a quick reference for parts/kits. See pages indicated in table for full description of kit contents.
▲Replacement Warning labels, signs, tags, and cards
are available at no cost.
Ref. Part/Kit Description Qty.
1 Varies Center Section; not sold separately, see
page 18
Aluminum
Conductive Polypropylene
Polypropylene
1
2 Varies Air Valve; see page 20 1
3
24B653
24C051
24D347
24C050
24C052
24C061
Fluid Cover Kits; see page 24
Aluminum
Conductive Polypropylene
Hastelloy
Polypropylene
PVDF
Hastelloy
2
4
24B649
24B650
24C039
24C042
24D343
24D344
24C038
24C041
24C040
24C043
24C057
24C058
Outlet Manifold Kits; see page 24
Aluminum, npt
Aluminum, bspt
Conductive Poly, center flange
Conductive Poly, end flange
Hastelloy, npt
Hastelloy, bspt
Polypropylene, center flange
Polypropylene, end flange
PVDF, center flange
PVDF, end flange
Stainless Steel, npt
Stainless Steel, bspt
1
5
24B651
24B652
24C045
24C048
24D345
24D346
24C044
24C047
24C046
24C049
24C059
24C060
Inlet Manifold Kits; see page 25
Aluminum, npt
Aluminum, bspt
Conductive Poly, center flange
Conductive Poly, end flange
Hastelloy, npt
Hastelloy, bspt
Polypropylene, center flange
Polypropylene, end flange
PVDF, center flange
PVDF, end flange
Stainless Steel, npt
Stainless Steel, bspt
1
6
24B654
24C056
24C064
Manifold Fasteners; 8-pack, see page 24
Aluminum
Conductive Poly, Poly, and PVDF
Stainless Steel and Hastelloy
16
7
24B654
24C055
24C063
24C056
Fluid Cover Fasteners; 8-pack,
see page 24
Aluminum
Conductive Poly, Poly, and PVDF
Stainless Steel or Hastelloy, alumi-
num center
Stainless Steel or Hastelloy, plastic
center
16
8 24C617 Plug; 6-pack, aluminum pumps only 6
9 24B910 Pressure Relief Valve; fuel dispense
model only, see page 24
1
10
24B630
24B631
24B632
24B638
24B633
24B635
24B636
24B637
24B634
Seats; 4-pack, includes 8 o-rings where
needed, see page 26
Acetal
Aluminum
Buna-N
FKM Fluoroelastomer
Geolast
Polypropylene
Santoprene
Stainless Steel
TPE
4
11
24B639
24B640
24B643
24B644
24B648
24B641
24B645
24B646
24B647
24B642
Check Balls; 4-pack, includes 8 o-rings,
see page 26
Acetal
Buna-N
Neoprene
Neoprene with SST core
FKM Fluoroelastomer
Geolast
PTFE
Santoprene
Stainless Steel
TPE
4
12 24B655 Manifold O-Ring (not used on some mod-
els); ptfe, 8-pack, see page 29
8
13
24C035
24C036
24D342
24C036
24C037
24C062
Fluid Side Diaphragm Plate; included in
Air and Fluid Plate Kits, see page 28
Aluminum
Conductive Polypropylene
Hastelloy
Polypropylene
PVDF
Stainless Steel
2
14 ----- Air Side Diaphragm Plate (not visible);
included in Air and Fluid Plate Kits, see
Part 13 or page 28
2
15
24B622
24B629
24B623
24B628
24B624
24B625
24B626
24B627
24F926
Diaphragm Kits; see page 27
Buna-N Standard
FKM Fluoroelastomer Standard
Geolast Standard
Santoprene Standard
TPE Standard
Neoprene Overmolded
PTFE Overmolded
PTFE/EPDM Two-Piece
PTFE/Santoprene Two-Piece
2
18 112182 Muffler; 3/4 npt, plastic 1
19
116343
116344
Screw, ground, M5 x 0.8; not shown
Pumps with aluminum air valve
Pumps with conductive poly air valve
1
20▲188621 Label, warning (not shown) 1
Ref. Part/Kit Description Qty.

Parts
18 313435H
Center Section
* Included in Center Section Rebuild Kit 24B621
Pump Size
and Material
Fluid Covers
and Manifolds
Seats Check
Balls
Diaphragm Manifold
O-Rings
1050A XXXX A2 AL BN TP PT
*101 *102
*102
*103 103*
*104
*105
*105
*106
*106
108*
109*
ti14025a
2
Aluminum Center Section
(A01x, AC1x, AU1x, and AU3x)
110
air valve
detail, see
page 20
113
(remote air control)
Ref. Description Qty.
101* VALVE, pilot 2
102* CARTRIDGES, pilot valve receiver 2
103* O-RING, receiver cartridge 2
104* SHAFT, center 1
105* BEARING, center shaft 2
106* U-CUP, center shaft 2
108* GASKET, air valve 1
109* SCREW, M6 x 25, stainless steel, (for
aluminum center section models, Axxx)
4
110 HOUSING, center, not sold separately 1
112* NUTS (for plastic center section models,
C01x and P01x)
4
113 INSERT, remote pilot (for remote air
control models, xxxD)
2
Plastic Center Section
(C01x and P01x)
*112
2
*108
ti14104a
110

Parts
313435H 19
Kit 24B621, Center Section Rebuild (*)
All models
Kit includes:
• 2 pilot valves (101)
• 2 pilot cartridges (102)
• 2 cartridge o-rings, buna-N (103)
• 1 center shaft (104)
• 2 center shaft bearings (105)
• 2 center shaft u-cups (106)
• 1 air valve gasket (108)
• 4 bolts, M6 x 25, for A01x pumps (109)
• 4 nuts, for P01x and C01x pumps (112)
• 8 o-rings, PTFE (12)
Kit 24B657, Pilot Valve Assembly
Standard, Pulse Count, and DataTrak with
runaway protection models (xxxA, xxxB,
and xxxC)
Kit includes:
• 2 pilot valve assemblies (101)
• 2 pilot valve receiver cartridges (102)
• 2 receiver cartridge o-rings (103)
Kit 24D043, Remote Pilot Inserts
Remote air control models (xxxD)
Kit includes:
• 2 remote pilot inserts
Kit 24B656, Center Shaft Kit
All models
Kit includes:
• 1 center shaft (104)
• 2 center shaft bearings (105)
• 2 center shaft u-cups (106)
Kit 24B658, Center Shaft Bearing Kit
All models
Kit includes:
• 2 center shaft bearings (105)
• 2 center shaft u-cups (106)
The center housing (110) is not sold separately.
Ground Screws
Center Section Material
Ground
Screw (19)
A01A-A01D,
AU1A, AU3A, and
AC1A
Aluminum 116343
C01A-C01D Conductive
Polypropylene
116344
P01A-P01D Polypropylene None

Parts
20 313435H
Air Valve and Data Monitoring
◆Parts included in Air Valve Repair Kit 24B768.
† Parts included in Air Valve Seals Kit 24B769.
✠Parts included in Air Valve End Cap Kit. See page 21.
Kit 24B769, Air Valve Seals (†)
All Models
Kit includes:
• 2 end cap o-rings (206)
• 2 piston u-cups (208)
• 2 screws, M3, shorter (209, for metal pumps)
• 2 screws, #4, longer (209, for plastic pumps)
• 1 solenoid release button o-ring (219)
• 1 air valve gasket (108)
202◆
◆203
◆204
◆205
206◆†✠
206◆†✠
208◆†
◆†209
◆211
◆212 218✠
ti14027a
210✠
217✠
208◆†
210✠
207✠
219◆†✠
201
210✠
206◆†✠
207✠
201
(Compatible with DataTrak
with runaway protection)
Standard (no reed switch) or
Pulse Count (with reed switch) 220
Ref. Description Qty.
201 HOUSING, not sold separately 1
202◆PISTON 1
203◆DETENT PISTON ASSEMBLY 1
204◆CAM, detent 1
205◆PLATE, air valve 1
206◆†✠O-RING 2
207✠CAP, end
Standard (xxxA), Pulse Count (xxxB), or
Remote (xxxD)
DataTrak (xxxC)
2
1
208◆† U-CUP 2
209◆†SCREW 2
210◆✠ RETAINING RING 2
211◆DETENT SPRING 1
212◆CUP 1
217✠CAP, end (for DataTrak models with runaway
protection, xxxC)
1
218✠BUTTON, solenoid release (for DataTrak
models with runaway protection, xxxC)
1
219◆†✠O-RING (for DataTrak models with runaway
protection, xxxC)
1
220 REED SWITCH ASSEMBLY (for Pulse
Count models, xxxB, includes fastener)
1
Ref. Description Qty.