Graco Husky 3300 Use and care manual

Repair/Parts
Husky®3300 Air-Operated
Diaphragm Pump 3A0411A
EN
Heavy-duty 3-inch pump with large flow paths for fluid transfer applications, including
high-viscosity materials. For professional use only.
See page 4 for model information, including approvals.
125 psi (0.86 MPa, 8.6 bar) Maximum Working Pressure, Aluminum or Stainless Steel Pumps
with Aluminum Center Section
100 psi (0.7 MPa, 6.9 bar) Maximum Working Pressure, Polypropylene or Stainless Steel Pumps
with Polypropylene Center Section
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
ti16556a
ti16561a
Polypropylene
Aluminum
Stainless Steel
ti17454a

Related Manuals
23A0411A
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
To Order a New Pump . . . . . . . . . . . . . . . . . . . . . . . 3
To Order Replacement Parts . . . . . . . . . . . . . . . . . 3
Distributor Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Configuration Number Matrix . . . . . . . . . . . . . . . . . 4
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pressure Relief Procedure . . . . . . . . . . . . . . . . 10
Repair or Replace Air Valve . . . . . . . . . . . . . . . 10
Check Valve Repair . . . . . . . . . . . . . . . . . . . . . 12
Diaphragms and Center Section . . . . . . . . . . . . 14
Torque Instructions . . . . . . . . . . . . . . . . . . . . . . 20
Parts, 3300P, Polypropylene . . . . . . . . . . . . . . . . 22
Parts, 3300A, Aluminum . . . . . . . . . . . . . . . . . . . . 23
Parts, 3300S, Stainless Steel . . . . . . . . . . . . . . . . 24
Parts/Kits Quick Reference . . . . . . . . . . . . . . . . . . 25
Center Section . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Air Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Fluid Covers and Manifolds . . . . . . . . . . . . . . . . 32
Seats and Check Balls . . . . . . . . . . . . . . . . . . . 34
Diaphragms . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Manifold and Seat Seals . . . . . . . . . . . . . . . . . . 37
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Graco Standard Husky Pump Warranty . . . . . . . . 42
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 42
Related Manuals
Manual Description
3A0410 Husky 3300 Air-Operated Diaphragm Pump, Operation

To Order a New Pump
3A0411A 3
To Order a New Pump
Call your distributor.
OR
Go to www.gracohusky.com,and use the Husky Pump Selector in the Toolbox.
To Order Replacement Parts
Call your distributor.
OR
Use this Manual: Refer to pages 22-24 for the main Parts illustrations, and page 25 for the Parts/Kits Quick Refer-
ence. Follow the page references on these pages for further ordering information, as needed.
Distributor Note
Use the 20-digit number from the ID plate on the pump to order the necessary kits. If you have only the Graco 6-digit
part number, use the Husky Pump Selector at www.gracohusky.com to find the corresponding Graco 20-digit
part number.

Configuration Number Matrix
43A0411A
Configuration Number Matrix
Check the identification plate (ID) for the 20-digit Configuration Number
of your pump. Use the following matrix to define the components of your
pump.
Sample Configuration Number: 3300A-A01AA1TPACTPBN
3300A A01A A1 TP AC TP BN
Pump
Model
Center
Section and
Air Valve
Fluid
Covers and
Manifolds
Seats Balls Diaphragms Manifold
and Seat
Seals
&21),*85$7,21123$5712 6(5,$/12
6(5,(6'$7(&2'( 0$;:3536,EDU
Pump Configuration
Number
ti17770a
Pump
Center Section and Air
Valve Material For Use With Fluid Covers and Manifolds
3300A★
Aluminum
Aluminum A01A Standard Diaphragms A1 Aluminum, center flange, npt
A01E Optional FKM seals with
Standard Diaphragms
A2 Aluminum, center flange, bspt
3300P†
Polypropylene
A01G Overmolded Diaphragms P1 Polypropylene, center flange
Polypropylene†P01A Standard Diaphragms S1 Stainless steel, center flange, npt
3300S★
Stainless Steel
P01G Overmolded Diaphragms S2 Stainless steel, center flange, bspt
★3300A (aluminum) and 3300S (stainless steel) pumps with aluminum center sections are certified:
†Pumps with polypropylene fluid or center sections are not ATEX certified.
II 2 GD c IIC T4
Check Valve Seats Check Valve Balls Diaphragm Manifold and Seat Seals
AC Acetal AC Acetal BN Buna-N --- Models with Buna-N,
FKM Fluoroelastomer
or TPE seats do not use
o-rings.
AL Aluminum BN Buna-N CO Polychloroprene
Overmolded
BN Buna
BN Buna-N CR Polychloroprene
Standard
CR Polychloroprene PT PTFE
FK FKM Fluoroelasto-
mer
CW Polychloroprene
Weighted
FK FKM Fluoroelastomer
GE Geolast®FK FKM Fluoroelasto-
mer
GE Geolast
PP Polypropylene GE Geolast PO PTFE Overmolded
SP Santoprene®PT PTFE PT PTFE/Santoprene
Two-Piece
SS 316 Stainless
Steel
SP Santoprene SP Santoprene
TP TPE TP TPE TP TPE

Warnings
3A0411A 5
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. Do not use pail liners unless they
are antistatic or conductive.
•Stop operation immediately if static sparking occurs or you feel a shock.Do not use equipment
until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
• Route exhaust away from all ignition sources. If diaphragm ruptures, fluid may be exhausted with air.
Static charge may build up on plastic parts during cleaning and could discharge and ignite flammable
vapors. To help prevent fire and explosion:
• Clean plastic parts only in a well ventilated area.
• Do not clean with a dry cloth.
• Do not operate electrostatic guns in equipment work area.
PRESSURIZED EQUIPMENT HAZARD
Fluid from the equipment, leaks, or ruptured components can splash in the eyes or on skin and cause
serious injury.
• Follow the Pressure Relief Procedure when you stop spraying/dispensing 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.

Warnings
63A0411A
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 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. Alterations or modifications may void agency approvals and create
safety hazards.
• Make sure all equipment is rated and approved for the environment in which you are using it.
• 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.
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 property 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 sup-
plier for compatibility.
PLASTIC PARTS CLEANING SOLVENT HAZARD
Many solvents can degrade plastic parts and cause them to fail, which could cause serious injury or
property damage.
• Use only compatible water-based solvents to clean plastic structural or pressure-containing parts.
•SeeTechnical Data in this and all other equipment instruction manuals. Read fluid and solvent
manufacturer’s MSDSs and recommendations.
WARNING

Warnings
3A0411A 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 MSDSs to know the specific hazards of the fluids you are using.
• Route exhaust away from work area. If diaphragm ruptures, fluid may be exhausted into the 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
Wear appropriate protective equipment when in the work area to help prevent serious injury, including
eye injury, hearing loss, inhalation of toxic fumes, and burns. This equipment includes but is not limited
to:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.
WARNING

Troubleshooting
83A0411A
Troubleshooting
Problem Cause Solution
Pump cycles but will not prime. Pump is running too fast, causing
cavitation before prime.
Reduce air inlet pressure.
Check valve ball severely worn or
wedged in seat or manifold.
Replace ball and seat. See page 12.
Seat severely worn. Replace ball and seat. See page 12.
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 12.
Pump cycles at stall or fails to hold
pressure at stall.
Worn check valve balls, seats, or
o-rings.
Replace. See page 12.
Pump will not cycle, or cycles once
and stops.
Air valve is stuck or dirty. Disassemble and clean air valve.
See page 10. Use filtered air.
Check valve ball severely worn and
wedged in seat or manifold.
Replace ball and seat. See page 12.
Pilot valve worn, damaged, or
plugged.
Replace pilot valve. See page 14.
Air valve gasket damaged. Replace gasket. See page 10.
Dispensing valve clogged. Relieve pressure and clear valve.
Pump operates erratically. Clogged suction line. Inspect; clear.
Sticky or leaking check valve balls. Clean or replace. See page 12.
Diaphragm (or backup) ruptured. Replace. See page 14.
Restricted exhaust. Remove restriction.
Pilot valves damaged or worn. Replace pilot valves. See page 14.
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..
Air bubbles in fluid. Suction line is loose. Tighten.
Diaphragm (or backup) ruptured. Replace. See page 14.
Loose manifolds, damaged seats or
o-rings.
Tighten manifold bolts or replace
seats or o-rings. See page 12.
Diaphragm shaft bolt o-ring dam-
aged.
Replace o-ring.
Pump cavitation. Reduce pump speed or suction lift.
Loose diaphragm shaft bolt. Tighten.

Troubleshooting
3A0411A 9
Exhaust air contains fluid being
pumped.
Diaphragm (or backup) ruptured. Replace. See page 14.
Loose diaphragm shaft bolt. Tighten or replace. See page 14.
Diaphragm shaft bolt o-ring dam-
aged.
Replace o-ring. See page 14.
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 10.
Damaged air valve gasket. Replace gasket. See page 10.
Damaged pilot valve. Replace pilot valves. See page 14.
Worn shaft seals or bearings. Replace shaft seals or bearings. See
page 14.
Pump leaks air externally. Air valve or fluid cover screws loose. Tighten.
Diaphragm damaged. Replace diaphragm. See page 14.
Air valve gasket damaged. Replace gasket. See page 10.
Air cover gasket damaged. Replace gasket. See page 14.
Pump leaks fluid externally from
joints.
Loose manifold screws or fluid cover
screws.
Tighten manifold screws or fluid
cover screws. See page 20.
Manifold o-rings worn out. Replace o-rings. See page 12.
Problem Cause Solution

Repair
10 3A0411A
Repair
Pressure Relief Procedure
Follow the Pressure Relief Procedure when-
ever you see this symbol.
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. Remove screws (104, metal pumps) or nuts (116,
plastic pumps). Remove the air valve and gasket
(113).
4. 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 5.
5. Align the new air valve gasket (113*) on the center
housing, then attach the air valve. See Torque
Instructions, page 20.
6. Reconnect the air line to the motor.
Replace Seals or Rebuild Air Valve
NOTE: Repair kits are available. See page 31 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 1-3 under Replace Complete Air
Valve, page 10.
2. See FIG. 2. Use a Torx screwdriver (T8 for alumi-
num centers, T10 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. 2. Remove the retaining ring (210) from
each end of the air valve. Use the piston (202) to
push the end cap (207) out of one end. Remove the
u-cup seal (208). Pull the piston out the end and
remove the other u-cup seal (208). Remove the
other end cap (207) and the end cap o-rings (206).
5. Remove the detent cam (204) from the air valve
housing (201).
This equipment stays pressurized until pressure is
relieved manually. To help prevent serious injury from
pressurized fluid, such as splashing in the eyes or on
skin, follow the Pressure Relief Procedure whenever
you stop pumping and before you clean, check, or ser-
vice the equipment.

Repair
3A0411A 11
Reassemble the Air Valve
NOTE: Apply lithium-based grease whenever instructed
to grease. Order Graco PN 111920.
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 the
housing bore. Install the piston in the housing (201),
with the flat side toward the cup (213◆). Be careful
not to tear u-cups (208◆†) when sliding piston into
housing.
5. Grease new o-rings (206◆†✠) and install on the end
caps (207✠). 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. Grease and install the o-ring (214◆) on
the cup (213◆), then install the cup (213◆) on the
base (212◆). Install the spring (211◆) onto protru-
sion on cup. Install the cup assembly. Align the
small round magnet in the base with the air inlet.
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. 1. Air valve u-cup installation
Lips face down
Lips face up
208◆†
208◆†
202◆
ti12754a
FIG. 2. Air valve assembly
210✠
210✠
207✠
206◆†✠
206◆†✠
208◆†
202◆
209◆†
205◆
212◆
◆211
203 ◆
204◆
ti17765a
201
Apply lithium-based grease.
1
1
1
1
1
1
U-cup lips must face piston.
2
2
207✠
1
1
214◆
213◆
1
Apply lithium-based grease to contact surface.
3
3
3

Repair
12 3A0411A
Check Valve Repair
NOTE: Kits are available for new check valve balls and
seats in a range of materials. See page 34 to order kits
in the material(s) desired. O-ring 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 seat o-rings, replace the o-rings every
time the manifold is removed.
Disassembly
1. Follow the Pressure Relief Procedure on page 10.
Disconnect all hoses.
NOTE: The pump is heavy. Always use two people or a
lift to move it.
2. Remove the pump from its mounting.
NOTE: For plastic pumps (3300P), use hand tools
until thread-locking adhesive patch releases.
3. Use a 3/4 in. (19 mm) socket wrench to remove the
outlet elbow fasteners (8), then remove the manifold
assembly. See FIG. 3.
4. Remove the o-rings (13, not used on some models),
seats (11), and balls (12).
5. Turn the pump over and remove the inlet manifold.
The mounting brackets will remain attached.
6. Remove the o-rings (13, not used on some models),
seats (11), and balls (12).
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. 3. Put the inlet manifold on first. Be sure the
ball checks (11-13) and manifolds are assembled
exactly as shown. The arrows (A) on the fluid cov-
ers must point toward the outlet manifold.

Repair
3A0411A 13
FIG. 3. Ball check valve assembly
Torque to 40-45 ft-lb (54-61 N•m) for Polypropylene models.
Torque to 55-60 ft-lb (75-81 N•m) for Aluminum models.
Torque to 40-45 ft-lb (54-61 N•m) for Stainless Steel models.
See Torque Instructions, page 20.
1
Not used on some models.
3
ti17808a
8
3
23
10
Arrow (A) must point toward outlet manifold.
2
1
3
Polypropylene
pump shown
7
1
9
9
12
11
13
13
10
9
8
9
12
13
13
11
A
3
2
3
3

Repair
14 3A0411A
Diaphragms and Center Section
Disassembly
NOTE: Diaphragm kits are available in a range of mate-
rials and styles. See page 35 to order the correct dia-
phragms for your pump. A Center Rebuild Kit also is
available. See page 29. 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 12.
NOTE: You may wish to remove the inner fluid cover
bolts (37) as you remove each manifold, for conve-
nience.
3. Overmolded Diaphragms (PO and CO models)
a. Orient the pump so one of the fluid covers faces
up. Use a 3/4 in. (19 mm) socket wrench to
remove the fluid cover bolts (36, 37), then pull
the fluid cover (2) up off the pump.
b. The exposed diaphragm (20) will screw off by
hand. The shaft will either release and come off
with this diaphragm, or remain attached to the
other diaphragm. If the diaphragm shaft bolt
(16) remains attached to the shaft (108),
remove it. Remove the air side diaphragm plate
(14) and washer (18).
c. Turn the pump over and remove the other fluid
cover. Remove the diaphragm (and the shaft, if
necessary).
d. If the shaft is still attached to either diaphragm,
grasp the diaphragm firmly and use a wrench
on the flats of the shaft to remove. Also remove
the air side diaphragm plate (14) and washer
(18). Continue with Step 5.
4. All Other Diaphragms
a. Orient the pump so one of the fluid covers faces
up. Use a 3/4 in. (19 mm) socket wrench to
remove the fluid cover screws (36, 37), then pull
the fluid cover (2) up off the pump. Turn the
pump over and remove the other fluid cover.
b. Plastic Pumps: Hold the hex of one fluid side
diaphragm plate (15) with a 1-5/8 socket or box
end wrench. Use another wrench (same size)
on the hex of the other plate to remove. Then
remove all parts of the diaphragm assembly.
See FIG. 6.
Metal Pumps: Turn the pump on its side. Hold
one diaphragm shaft bolt (16) with a wrench,
then use a 15/16 socket to remove the other
bolt. Remove all parts of the diaphragm assem-
bly. See FIG. 6, page 17.
c. Disassemble the other diaphragm assembly.
5. Use an o-ring pick to remove the u-cup packings
(101) from the center housing. Bearings (109) can
remain in place.
6. If necessary, use a socket wrench to remove the
pilot valves (110).
Air Covers
Remove air covers only if a serious air leak suggests
that the gaskets need to be replaced.
1. Remove pilot valves (110).
2. Use a 3/8 allen wrench (aluminum) or a 5/8 socket
(polypropylene) to remove two bolts (103), then
remove one air cover (105). Repeat for the other air
cover.
3. Remove and replace the gasket (107).
4. Inspect the diaphragm shaft (108) for wear or
scratches. If it is damaged, inspect the bearings
(109) in place. If they are damaged, use a bearing
puller to remove them.
NOTE: Do not remove undamaged bearings.

Repair
3A0411A 15
Reassembly of Housing Parts and Air
Covers
Follow all notes in FIG. 6. These notes contain
important information.
NOTE: Apply lithium-based grease whenever instructed
to grease. Order Graco PN 111920.
1. Clean all parts and inspect for wear or damage.
Replace parts as needed.
2. Grease and install the diaphragm shaft u-cup pack-
ings (101*) so the lips face out of the housing.
3. If removed, insert the new bearings (109*) 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.
4. Assemble air covers, if removed:
a. Put one air cover on the bench. Install the align-
ment pins (112*) and a new gasket (107*).
b. Carefully place the center section on the air
cover.
c. Install second set of alignment pins (112*) and
gasket (107*) in the center section. Lower the
second air cover onto the center housing.
d. Aluminum Centers: Apply medium-strength
(blue) thread locker on the bolts (103). Install
two bolts and torque to 30-40 ft-lb (41-54 N•m).
Turn the pump over on the bench and install
and torque the other two bolts.
Polypropylene Centers: Apply
medium-strength (blue) thread locker on the
bolts (103) and install a washer (119) on each
bolt. Turn the assembly on its side. The align-
ment pins will help hold it together. Slide one
bolt (103) through from one air cover to the
other. Install a washer (119) and nut (118),
hand tight. Repeat for the other three bolts, then
torque to 25-35 ft-lb (34-47 N•m).
5. Grease and install the pilot valves (110*). Torque to
20-25 in.-lb (2.3-2.8 N•m). Do not over-torque.
NOTICE
Unwanted pressurized air due to worn seals can
lead to reduced diaphragm life.
FIG. 4. Assemble Center Section.
113*
101*
110*
116*
106
117
118
111
119
Lips must face out of housing.
6
ti17769a
2
2
7
2
6
109*
107*
108*
119
103
112*
105
Polypropylene
Model Shown
Torque to 20-25 in.-lb (2.3-2.8 N•m).
8
8
Aluminum: Torque to 30-40 ft-lb. (41-54 N•m).
Poly: Torque to 25-35 ft-lb. (34-47 N•m).
7
Apply lithium-based grease.
2

Repair
16 3A0411A
Reassembly of Standard Diaphragms
NOTE: If your pump has overmolded diaphragms, see
page 19.
PTFE Diaphragms
1. Clean all parts and inspect for wear or damage.
Replace parts as needed.
2. Clamp the shaft flats in a vise.
3. For metal pumps, install the washer (18) and o-ring
(17) on the shaft bolt (16).
4. Assemble the fluid side plate (15), the diaphragm
(20), the backup diaphragm (305), the air side dia-
phragm plate (14), and the washer (18) on the bolt
exactly as shown in FIG. 6.
5. Apply medium-strength (blue) Loctite or equivalent
to the bolt (16) threads. Assemble into shaft. Torque
the bolt to 110 -120 ft-lb (149-163 N•m) at 100 rpm
maximum.
6. Grease the shaft u-cups (101*) and the length and
ends of the diaphragm shaft (108*). Slide the shaft
into the housing.
7. Repeat Steps 3 and 4 for the other diaphragm
assembly.
8. Apply medium-strength (blue) Loctite or equivalent
to the bolt (16) threads. Screw the bolt into the shaft
hand tight.
9. To keep the diaphragms properly aligned, place 4
bolts on the side that has been torqued. Screw into
the air cover just enough to engage two threads.
NOTE: The fluid cover bolts may work well, or use shop
bolts. Do not use bolts that are long enough to deform
the diaphragm manually.
10. Clamp the torqued side in a vise.
11. Again align the diaphragm and air cover holes on
the second side and place 4 more bolts.
12. Torque the shaft bolt on the second side to 110 -120
ft-lb (149-163 N•m) at 100 rpm maximum.
13. Remove the bolts used for alignment.
14. Reattach one fluid cover (2). Arrow (A) must point
toward the air valve. See Torque Instructions,
page 20.
15. Follow directions under Attach Second Fluid
Cover, page 19.
16. Reassemble the ball check valves and manifolds as
explained on page 12.
FIG. 5. Place bolts to keep PTFE diaphragms aligned.
ti18621a

Repair
3A0411A 17
FIG. 6. Assemble diaphragms and center section
ti17811a
104*
ti14037b
PO and CO
models
14
108*
ti17812a
PT models
(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 110-120 ft-lb. (149-163
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
TP, SP, BN,
FK, and GE
models
5
3
(Plastic pumps)
ti17813a
15
16
17
18
18
20
305
20
14 16
18
15
17
18
16
15
18 14 20
108
108
15
3

Repair
18 3A0411A
All Other Standard Diaphragms - Metal Pumps:
1. Install the washer (18) and o-ring (17) on the shaft
bolt (16).
2. Assemble the fluid side plate (15), the diaphragm
(20), the air side diaphragm plate (14), and the
washer (18) on the bolt exactly as shown in FIG. 6.
3. Apply medium-strength (blue) Loctite or equivalent
to the bolt (16) threads. Screw the bolt into the shaft
hand tight.
4. Grease the shaft u-cups (101*) and the length and
ends of the diaphragm shaft (108*). Slide the shaft
into the housing.
5. Repeat Steps 1-5 for the other diaphragm assem-
bly.
6. Hold one shaft bolt with a wrench and torque the
other bolt to 110-120 ft-lb (149-163 N•m) at 100 rpm
maximum. Do not over-torque.
7. Reattach one fluid cover (2). Arrow (A) must point
toward the air valve. See Torque Instructions,
page 20.
8. TP, SN, and GE Models: Follow directions under
Attach Second Fluid Cover, page 19.
CR, BN, and FK Models: Reattach the second fluid
cover (2). Arrow (A) must point toward the air valve.
See Torque Instructions, page 20.
9. Reassemble the ball check valves and manifolds as
explained on page 12.
All Other Standard Diaphragms - Plastic Pumps:
1. Assemble the diaphragm (20), the air side dia-
phragm plate (14), and the washer (18) on the fluid
side plate (15) exactly as shown in FIG. 6.
2. Apply medium-strength (blue) Loctite or equivalent
to the threads of the screw on the fluid side plate.
Screw the assembly into the shaft hand-tight.
3. Grease the shaft u-cups (101*) and the length and
ends of the diaphragm shaft (108*). Slide the shaft
into the housing.
4. Repeat for the other diaphragm assembly.
5. Hold one of the plates with a wrench, and torque the
other plate to 110-120 ft-lb (149-163 N•m) at 100
rpm maximum. Do not over-torque.
6. Reattach one fluid cover (2). Arrow (A) must point
toward the air valve. See Torque Instructions,
page 20.
7. TP, SN, and GE Models: Follow directions under
Attach Second Fluid Cover, page 19.
CR, BN, and FK Models: Reattach the second fluid
cover (2). Arrow (A) must point toward the air valve.
See Torque Instructions, page 20.
8. Reassemble the ball check valves and manifolds as
explained on page 12.

Repair
3A0411A 19
Attach Second Fluid Cover
To ensure proper seating and help attain expected dia-
phragm life, attach the second fluid cover with air pres-
sure on the pump. This procedure is needed for
overmolded diaphragms (PO and CO) and for the fol-
lowing standard diaphragms: TP, SN, GE, PT.
1. Place the supplied tool (302) where the air valve
gasket (113*) normally goes. Arrows (A) must face
toward the fluid cover that is already attached.
2. Reattach the air valve.
3. Supply the pump with low pressure air, just enough
to move the diaphragm. For standard diaphragms,
use about 10 psi (0.07 MPa, 0.7 bar); for over-
molded diaphragms use about 20 psi (0.14 MPa,
1.4 bar). 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.
4. Attach the second fluid cover (2). See Torque
Instructions, page 20.
5. Remove the air valve and the tool (302), replace the
gasket (113), and reattach the air valve. See
Torque Instructions, page 20.
NOTE: If you are replacing the diaphragms but not the
air valve, you still must remove the air valve, and
replace the gasket with the tool so the air valve can be
used for proper installation of the second fluid cover.
Remember to remove the tool and replace the gasket
when finished.
Reassembly of Overmolded Diaphragms
NOTE: If your pump has standard diaphragms, see
page 16.
1. Clamp the shaft flats in a vise.
2. If diaphragm setscrew comes loose or is replaced,
apply permanent (red) Loctite®or equivalent to dia-
phragm side threads. Screw into diaphragm until
tight.
3. Assemble the air side plate (14) and washer (18)
onto the diaphragm. The rounded side of the plate
must face the diaphragm.
4. Apply medium-strength (blue) Loctite or equivalent
to the threads of the diaphragm assembly. Screw
the assembly into the shaft as tight as possible by
hand.
5. Grease the shaft u-cups (101*) and the length and
ends of the diaphragm shaft (108*). Slide the shaft
into the housing.
6. Reattach the first fluid cover (2). Arrow (A) must
point toward the air valve. See Torque Instruc-
tions, page 20.
7. Repeat Steps 2 - 4 for the other diaphragm assem-
bly.
8. Follow directions under Attach Second Fluid
Cover, page 19.
9. Reassemble the ball check valves and manifolds as
explained on page 12.
To reduce the risk of serious injury, do not put your fin-
gers or hand between the air cover and the diaphragm.
FIG. 7. Diaphragm Installation Tool
302 A
ti18299a

Repair
20 3A0411A
Torque Instructions
See FIG. 8 for fluid cover and air valve fasteners. See
FIG. 9 for manifold fasteners.
NOTE: Fluid cover and manifold fasteners on the poly-
propylene pumps have a thread-locking adhesive patch
applied to the threads. If this patch is excessively worn,
the fasteners may loosen during operation. 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, then
torque the manifold pieces together, then torque the
assembled manifolds to the fluid covers.
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 fasteners:
Polypropylene and Stainless Steel: 40-45 ft-lb
(54-61 N•m)
Aluminum: 55-60 ft-lb (75-81 N•m)
Manifold fasteners:
Polypropylene: 40-45 ft-lb (54-61 N•m)
Aluminum:
Refs 1-8: 11-21 ft-lb (15-28 N•m)
Refs 9-16: 55-60 ft-lb (75-81 N•m)
Stainless Steel:
Refs 1-4: 110-120 in-lb (12-13 N•m)
Refs 5-12: 40-45 ft-lb (54-61 N•m)
Retorque the air valve fasteners in a crisscross pattern
to specified torque.
Air Valve fasteners
Plastic Center Sections: 45-55 in-lb (5-6.2 N•m)
Aluminum Center Sections: 75-85 in-lb
(8.5-9.6 N•m)
Also check and tighten the nuts or bolts (X) holding the
manifold feet to the mounting brackets.
FIG. 8. Torque instructions, Fluid Covers and Air Valve Fasteners (all models, aluminum shown)
Fluid Cover Screws Air Valve Screws
ti16558a
ti16560a
1
2
3
4
5
67
8
X
911
12 10
14
32