Dover PSG ALL-FLO A300 Owner's manual

IOM
INSTALLATION OPERATION
& MAINTENANCE
A300
METAL 3 INCH
AIR-OPERATED DOUBLE-DIAPHRAGM PUMP

ALF-12090-E-01 All-Flo2
TABLE OF
CONTENTS
SECTION 1 WARNINGS, DANGERS AND CAUTIONS 3
SECTION 2 MODEL DESIGNATION MATRIX & REPAIR KITS 4-5
SECTION 3 PRINCIPLES OF OPERATION 6
SECTION 4 DIMENSIONAL DRAWINGS 7-8
SECTION 5 PERFORMANCE CURVES
RUBBER DIAPHRAGMS ..........................................9
TPE DIAPHRAGMS ....................................................9
PTFE DIAPHRAGMS..................................................9
SECTION 6 INSTALLATION
INSTALLATION....................................................10-11
TROUBLESHOOTING...............................................12
OPERATION .................................................................13
MAINTENANCE ........................................................13
SECTION 7 REPAIR AND ASSEMBLY
PUMP WET END REMOVAL........................14-15
AIR VALVE REMOVAL......................................16-17
PILOT VALVE REMOVAL ............................... 18-19
TORQUE SPECIFICATION CHART......................19
SECTION 8 EXPLODED VIEWS & PARTS LIST
THREADED ALUMINUM.............................. 20-22
FLANGED STAINLESS STEEL..................23-25
SECTION 9 ELASTOMERS 26
SECTION 10 WARRANTY AND REGISTRATION 27

ALF-12090-E-01 All-Flo3
SECTION 1
CAUTIONS — READ FIRST!
WARNING
CAUTION
= Hazards or unsafe practices
which could result in severe
personal injury, death or
substantial property damage
= Hazards or unsafe practices
which could result in minor
personal injury, product or
property damage.
READ THESE WARNINGS AND SAFETY PRECAUTIONS PRIOR
TO INSTALLATION OR OPERATION. FAILURE TO COMPLY
WITH THESE INSTRUCTIONS COULD RESULT IN PERSONAL
INJURY AND OR PROPERTY DAMAGE. RETAIN THESE
INSTRUCTIONS FOR FUTURE REFERENCE.
This product can expose you to chemicals
including Nickel, Chromium, Cadmium, or Cobalt, which are
known to the State of California to cause cancer and/or birth
defects or other reproductive harm. For more information, go
to www.P65Warnings.ca.gov.
WARNING Pump, valves and all containers must be
properly grounded prior to handling flammable fluids and/or
whenever static electricity is a hazard.
WARNING Prior to servicing the pump, ensure that
the air and fluid lines are closed and disconnected. While
wearing personal protective equipment, flush, drain and
process liquid from the pump in a safe manner.
WARNING The TX marking refers to the maximum
surface temperature depending not on the equipment
itself, but mainly on operating conditions. In this case,
the maximum surface temperature depends upon the
temperature of the process fluids.
CAUTION The temperature of the process fluid
and air input must be no more than 36°F (20C) less of the
maximum temperature allowed for the appropriate non-
metallic material. See the list of temperatures below for each
material’s maximum recommended temperature:
Buna-N (Nitrile): 10°F to 180°F (-12°C to 82°C)
Geolast®: 10°F to 180°F (-12°C to 82°C)
EPDM: -40°F to 280°F (-40°C to 138°C)
Santoprene®: -40°F to 225°F (-40°C to 107°C)
FKM: -40°F to 350°F (-40°C to 177°C)
PTFE: 40°F to 220°F (4°C to 104°C)
Polyethylene: 32°F to 158°F (0°C to 70°C)
Polypropylene: 32°F to 180°F (0°C to 82°C)
PVDF: 0°F to 250°F (-18°C to 121°C)
Nylon: 0°F to 200°F (-18°C to 93°C)
Temperature limits are solely based upon mechanical stress
and certain chemicals will reduce the maximum operating
temperature. The allowable temperature range for the
process fluid is determined by the materials in contact with
the fluid being pumped. Consult a chemical resistance
guide for chemical compatibility and a more precise safe
temperature limit. Always use minimum air pressure when
pumping at elevated temperatures.
CAUTION Do not lubricate air supply.
CAUTION Do not connect a compressed air source to
the exhaust port of the pump.
WARNING Use only with liquid process fluid.
WARNING Maintenance must not be performed when
a hazardous atmosphere is present.
CAUTION Do not exceed 120 psig (8.3 bar)
air-inlet pressure.
CAUTION Do not exceed 10 psig (0.7 bar)
or 23 ft-H2O suction pressure.
CAUTION Ensure all wetted components are
chemically compatible with the process fluid and the cleaning
fluid.
CAUTION Ensure pump is thoroughly cleaned and
flushed prior to installation into a process line.
CAUTION Always wear Personal Protective
Equipment (PPE) when operating pump.
CAUTION Close and disconnect all
compressed air and bleed all air from the pump
prior to service. Remove all process fluid in a safe manner
prior to service.
CAUTION Blow out all compressed air
lines in order to remove any debris, prior to
pump installation. Ensure that the muffler is properly installed
prior to pump operation.
CAUTION Ensure air exhaust is piped to
atmosphere prior to a submerged installation.
CAUTION Ensure all hardware is set to
correct torque values prior to operation.
WARNING

ALF-12090-E-01 All-Flo4
MODEL DESIGNATION MATRIX & REPAIR KITS - ALUMINUM
SECTION 2
PRODUCT SERIES
FLUID CONNECTION TYPE
LIQUID SECTION
DIAPHRAGM
VALVE/BALL
VALVE SEAT
O-RINGS
SPECIAL (OTHER)
PORTING
AIR SECTION
SPECIAL (HARDWARE,
MUFFLER, LUG)
A 3 0 0 -1 2 3- 4 5 6 7 - 8 9 10
FLUID CONNECTION TYPE
N = NPT
B = BSPT
AIR SECTION
A = Aluminum Intermediate Pneumatic Shift
LIQUID SECTION
A = Aluminum
DIAPHRAGMS
G = Geolast®
S = Santoprene®
T = PTFE
N = Buna-N
U = Urethane
V = FKM
VALVE/BALL
G = Geolast®
S = Santoprene®
T = PTFE
E = EPDM
N = Buna-N
V = FKM
VALVE SEAT
E = EPDM (Integral Valve & O-Ring)
N = Buna-N (Integral Valve & O-Ring)
Y = Nylon
A = Aluminum
V = FKM (Integral Valve & O-Ring)
ORINGS
E = EPDM
N = Buna-N
T = PTFE
V = FKM
PORTING
B = Default (Suction Center Front / Discharge
Center Rear)
A = Suction Center Front / Discharge Center Front
F = Suction Center Rear / Discharge Center Front
G = Suction Center Rear / Discharge Center Rear
SPECIAL OPTION
HARDWARE, MUFFLER, LUG
3 = Default (Zinc Plated Hardware, Plastic Muffler)
4 = Zinc Plated Steel Hardware, Premium Muffler
7 = Stainless Steel Hardware, Plastic Muffler
8 = Stainless Steel Hardware, Premium Muffler
B = PTFE Coated Stainless Steel Hardware, Plastic
Muffler
C = PTFE Coated Stainless Steel Hardware, Pre-
mium Muffler
D = Zinc Plated Steel Hardware, Plastic Muffler,
Grounding Lug Installed
E = Zinc Plated Steel Hardware, Premium Muffler,
Grounding Lug Installed
F = Stainless Steel Hardware, Plastic Muffler,
Grounding Lug Installed
G = Stainless Steel Hardware, Premium Muffler,
Grounding Lug Installed
H = PTFE Coated Stainless Steel Hardware,
Plastic Muffler, Grounding Lug Installed
I = PTFE Coated Stainless Steel Hardware,
Premium Muffler, Grounding Lug Installed
SIZE
WET END REPAIR KIT
Wet end kits are available and consist of 2 diaphragms,
(back-up diaphragms if required), 4 balls, 4 seats, and
4 seat O-rings (if required). See matrix below.
1
2
6
7
9
10
AIR SECTION
A = Aluminum
AIR END REPAIR KIT
Air end repair kit contains pilot
sleeve assembly and main air valve.
MATERIAL
AAK3002
PRODUCT
SERIES
PUMP SIZE
AIR END
REPAIR KIT
3
4
5
8
PRODUCT
SERIES
WET END
REPAIR KIT
METALLIC WET END
Bold indicates recommended options
DIAPHRAGM
VALVE/BALL
VALVE SEAT
O-RINGS
PUMP SIZE
AWE3004567M
Note: Equipment must be grounded to achieve
ATEX rating. It is recommended to configure
the pump with a grounding lug option for ATEX
applications.
SPECIAL OPTION OTHER
0 = Standard
1 = Cycle Counter Valve
A = Grease Free (No lubrication assembly)
B = Carrying Handles
C = Cycle Counter Valve, Carrying Handles
D = Grease Free, Carrying Handles

ALF-12090-E-01 All-Flo5
MODEL DESIGNATION MATRIX & REPAIR KITS - STAINLESS STEEL
PRODUCT SERIES
FLUID CONNECTION TYPE
LIQUID SECTION
DIAPHRAGM
VALVE /BALL
VALVE SEAT
O-RINGS
SPECIAL (OTHER)
PORTING
AIR SECTION
SPECIAL (HARDWARE,
MUFFLER, LUG)
A 3 0 0 -1 2 3- 4 5 6 7 - 8 9 10
FLUID CONNECTION TYPE
F = ANSI/DIN FLANGE
AIR SECTION
A = Aluminum Intermediate Pneumatic Shift
LIQUID SECTION
3 = Stainless Steel
DIAPHRAGMS
G = Geolast®
S = Santoprene®
T = PTFE
N = Buna-N
U = Urethane
V = FKM
VALVE/BALL
G = Geolast®
S = Santoprene®
T = PTFE
E = EPDM
N = Buna-N
V = FKM
VALVE SEAT
E = EPDM (Integral Valve & O-Ring)
N = Buna-N (Integral Valve & O-Ring)
3 = Stainless Steel
V = FKM (Integral Valve & O-Ring)
Y = Nylon
ORINGS
E = EPDM
N = Buna-N
T = PTFE
V = FKM
PORTING
B = Default (Suction Center Front /
Discharge Center Rear)
A = Suction Center Front / Discharge Center Front
F = Suction Center Rear / Discharge Center Front
G = Suction Center Rear / Discharge Center Rear
SIZE
WET END REPAIR KIT
Wet end kits are available and consist of 2 diaphragms,
(back-up diaphragms if required), 4 balls, 4 seats, and
4 seat O-rings (if required). See matrix below.
1
2
6
7
9
10
AIR SECTION
A = Aluminum
Bold indicates recommended options
AIR END REPAIR KIT
Air end repair kit contains pilot
sleeve assembly and main air valve.
DIAPHRAGM
O-RINGS
AWE3004567M
PRODUCT
SERIES
WET END
REPAIR KIT
PUMP SIZE
MATERIAL
AAK3002
PRODUCT
SERIES
PUMP SIZE
AIR END
REPAIR KIT
3
4
5
VALVE
VALVE SEAT
8
SPECIAL OPTION HARDWARE,
MUFFLER, LUG
7 = Default (Stainless Steel Hardware, Plastic
Muffler)
8 = Stainless Steel Hardware, Premium Muffler
B = PTFE Coated Stainless Steel Hardware, Plastic
Muffler
C = PTFE Coated Stainless Steel Hardware,
Premium Muffler
F = Stainless Steel Hardware, Plastic Muffler,
Grounding Lug Installed
G = Stainless Steel Hardware, Premium Muffler,
Grounding Lug Installed
H = PTFE Coated Stainless Steel Hardware,
Plastic Muffler, Grounding Lug Installed
I = PTFE Coated Stainless Steel Hardware,
Premium Muffler, Grounding Lug Installed
SPECIAL OPTION OTHER
0 = Standard
1 = Cycle Counter Valve
A = Grease Free (No lubrication assembly)
B = Carrying Handles
C = Cycle Counter Valve, Carrying Handles
D = Grease Free, Carrying Handles
METALLIC WET END
Note: Equipment must be grounded to achieve
ATEX rating. It is recommended to configure
the pump with a grounding lug option for ATEX
applications.

ALF-12090-E-01 All-Flo6
SECTION 3
PRINCIPLES OF OPERATION
HOW AN AIR OPERATED DOUBLE
DIAPHRAGM PUMP WORKS
The air-valve directs pressurized air behind the diaphragm on the right,
causing the diaphragm on the right to move outward (to the right).
Since both the right diaphragm and the left diaphragm are connected
via a diaphragm rod, when the right diaphragm moves to the right, the
left diaphragm (through the action of the diaphragm rod) moves to the
right also.
When the diaphragm on the left side is moving to the right, it is referred
to as suction stroke. When the left diaphragm is in its suction stroke,
the left suction ball moves upward (opens) and the left discharge ball
moves downward (closes). This action creates suction and draws liquid
into the left side chamber.
The air-valve directs pressurized air behind the left diaphragm, causing
the left diaphragm to move outward (to the left).
Since both the left diaphragm and the right diaphragm are connected
via a diaphragm rod, when the left diaphragm moves to the left, the
right diaphragm (through the action of the diaphragm rod) moves to
the left also.
When the diaphragm on the left side moves outward, the left discharge ball
moves upward (opens) and the left suction ball moves downward (closes).
This causes the liquid to leave the left side liquid outlet of the pump.
Simultaneously, the right diaphragm moves inward (to the left), which
causes the right suction ball to open and the right discharge to close,
which in turn causes suction, drawing liquid into the right chamber.
The process of alternating right suction / left discharge (and vice-versa)
continues as long as compressed air is supplied to the pump.

ALF-12090-E-01 All-Flo7
SECTION 4
3” PUMP DIMENSIONS
ALUMINUM - THREADED
REV
DRAWN BY
DEFAULT
TOLERANCES
DRAWING NUMBER
DATE
TITLE
SCALE
ANGULAR
DECIMAL (INCHES)
DIMENSIONS IN INCHES
.XX 0.01
.XXX 0.005
0.5
7750 TYLER BLVD. MENTOR, OHIO 44060 [phone] FAX [phone]
THE ALL-FLO PUMP COMPANY, LLC
12.4" (315mm)
24.8" (630mm)
16.5" (420mm)
30.2" (767mm)
32.6" (827mm)
2.5" (64mm)
10.2" (258mm)11.2" (284mm)
5.8" (146mm)
16.8" (425mm)
12.1" (306mm)
14.3" (363mm)
7.7" (195mm)
3.9" (100mm)
3.3" (84mm)
0.6" (14mm)
BA300-xAA-ELEV12.17.15
A300 ALUMINUM 3" PUMP
ROBERT WOODS0.200SHEET 1 OF 1
DATEBYDESCRIPTIONREV
12.17.15RKWCREATED ELEVATION DRAWINGA
03-15-2016BASREVERTED BACK TO POLY MUFFLER & MUFFLER PLATEB
* Note - Suction Center Front / Discharge Center Rear are default ports. See part number matrix option code
for additional porting options.
REV
DRAWN BY
DEFAULT
TOLERANCES
DRAWING NUMBER
DATE
TITLE
SCALE
ANGULAR
DECIMAL (INCHES)
DIMENSIONS IN INCHES
.XX 0.01
.XXX 0.005
0.5
7750 TYLER BLVD. MENTOR, OHIO 44060 [phone] FAX [phone]
THE ALL-FLO PUMP COMPANY, LLC
12.4" (315mm)
24.8" (630mm)
16.5" (420mm)
30.2" (767mm)
32.6" (827mm)
2.5" (64mm)
10.2" (258mm)11.2" (284mm)
5.8" (146mm)
16.8" (425mm)
12.1" (306mm)
14.3" (363mm)
7.7" (195mm)
3.9" (100mm)
3.3" (84mm)
0.6" (14mm)
BA300-xAA-ELEV12.17.15
A300 ALUMINUM 3" PUMP
ROBERT WOODS0.200SHEET 1 OF 1
DATEBYDESCRIPTIONREV
12.17.15RKWCREATED ELEVATION DRAWINGA
03-15-2016BASREVERTED BACK TO POLY MUFFLER & MUFFLER PLATEB
REV
DRAWN BY
DEFAULT
TOLERANCES
DRAWING NUMBER
DATE
TITLE
SCALE
ANGULAR
DECIMAL (INCHES)
DIMENSIONS IN INCHES
.XX 0.01
.XXX 0.005
0.5
7750 TYLER BLVD. MENTOR, OHIO 44060 [phone] FAX [phone]
THE ALL-FLO PUMP COMPANY, LLC
12.4" (315mm)
24.8" (630mm)
16.5" (420mm)
30.2" (767mm)
32.6" (827mm)
2.5" (64mm)
10.2" (258mm)11.2" (284mm)
5.8" (146mm)
16.8" (425mm)
12.1" (306mm)
14.3" (363mm)
7.7" (195mm)
3.9" (100mm)
3.3" (84mm)
0.6" (14mm)
BA300-xAA-ELEV12.17.15
A300 ALUMINUM 3" PUMP
ROBERT WOODS0.200SHEET 1 OF 1
DATEBYDESCRIPTIONREV
12.17.15RKWCREATED ELEVATION DRAWINGA
03-15-2016BASREVERTED BACK TO POLY MUFFLER & MUFFLER PLATEB
3/4”-14 FNPT
(Air Inlet)
3/4”-14 FNPT (Exhaust Port)
1-1/4” - 11.5 FNPT (Premium/Optional Exhaust Port)

ALF-12090-E-01 All-Flo8
3” PUMP DIMENSIONS
STAINLESS STEEL - FLANGED
REV
DRAWN BY
DEFAULT
TOLERANCES
DRAWING NUMBER
DATE
TITLE
SCALE
ANGULAR
DECIMAL (INCHES)
DIMENSIONS IN INCHES
.XX 0.01
.XXX 0.005
0.5
7750 TYLER BLVD. MENTOR, OHIO 44060 [phone] FAX [phone]
THE ALL-FLO PUMP COMPANY, LLC
24.8" (630mm)
4.2" (106mm)
18.2" (463mm)
31.4" (798mm)
12.4" (315mm)
16.8" (425mm)
35.2" (893mm)
3.6" (90mm)
10.2" (258mm)11.2" (284mm)
12.0" (305mm)
14.2" (361mm)
3.9" (100mm)
7.7" (195mm)
5.8" (146mm)
0.7" (19mm)
BA300-FA3-ELEV12.17.15
A300 STAINLESS STEEL 3" PUMP
ROBERT WOODS0.200SHEET 1 OF 1
DATEBYDESCRIPTIONREV
12.17.15RKWCREATED ELEVATION DRAWINGA
03-15-2016BASREVERTED BACK TO POLY MUFFLER & MUFFLER PLATEB
SCALE 0.150
* Note - Suction Center Front / Discharge Center Rear are default ports. See part number matrix option code
for additional porting options.
REV
DRAWN BY
DEFAULT
TOLERANCES
DRAWING NUMBER
DATE
TITLE
SCALE
ANGULAR
DECIMAL (INCHES)
DIMENSIONS IN INCHES
.XX 0.01
.XXX 0.005
0.5
7750 TYLER BLVD. MENTOR, OHIO 44060 [phone] FAX [phone]
THE ALL-FLO PUMP COMPANY, LLC
24.8" (630mm)
4.2" (106mm)
18.2" (463mm)
31.4" (798mm)
12.4" (315mm)
16.8" (425mm)
35.2" (893mm)
3.6" (90mm)
10.2" (258mm)11.2" (284mm)
12.0" (305mm)
14.2" (361mm)
3.9" (100mm)
7.7" (195mm)
5.8" (146mm)
0.7" (19mm)
BA300-FA3-ELEV12.17.15
A300 STAINLESS STEEL 3" PUMP
ROBERT WOODS0.200SHEET 1 OF 1
DATEBYDESCRIPTIONREV
12.17.15RKWCREATED ELEVATION DRAWINGA
03-15-2016BASREVERTED BACK TO POLY MUFFLER & MUFFLER PLATEB
SCALE 0.150
REV
DRAWN BY
DEFAULT
TOLERANCES
DRAWING NUMBER
DATE
TITLE
SCALE
ANGULAR
DECIMAL (INCHES)
DIMENSIONS IN INCHES
.XX 0.01
.XXX 0.005
0.5
7750 TYLER BLVD. MENTOR, OHIO 44060 [phone] FAX [phone]
THE ALL-FLO PUMP COMPANY, LLC
24.8" (630mm)
4.2" (106mm)
18.2" (463mm)
31.4" (798mm)
12.4" (315mm)
16.8" (425mm)
35.2" (893mm)
3.6" (90mm)
10.2" (258mm)11.2" (284mm)
12.0" (305mm)
14.2" (361mm)
3.9" (100mm)
7.7" (195mm)
5.8" (146mm)
0.7" (19mm)
BA300-FA3-ELEV12.17.15
A300 STAINLESS STEEL 3" PUMP
ROBERT WOODS0.200SHEET 1 OF 1
DATEBYDESCRIPTIONREV
12.17.15RKWCREATED ELEVATION DRAWINGA
03-15-2016BASREVERTED BACK TO POLY MUFFLER & MUFFLER PLATEB
SCALE 0.150
3/4”-14 FNPT
(Air Inlet)
3/4”-14 FNPT (Exhaust Port)
1-1/4” - 11.5 FNPT (Premium/Optional Exhaust Port)

ALF-12090-E-01 All-Flo9
5
SECTION
PERFORMANCE CURVES
PERFORMANCE CURVE (3” RUBBER)*
PERFORMANCE CURVE (3” TPE)*
PERFORMANCE CURVE (3” PTFE)*
*Flow rates indicated on all three charts shown were determined by pumping water at flooded suction.
For optimum life and performance, pumps should be specified so that daily operation parameters will fall in the center of the pump performance curve.
Performance Specifications
Max. Flow: 235 gpm (890 lpm)
Max. Air Pressure: 120 psi (8.3 bar)
Max. Solids: 7/16” (11 mm)
Max. Suction Lift Dry: 17 ft-H2O (5.2 m-H2O)
Max. Suction Lift Wet: 31 ft-H2O (9.4 m-H2O)
Weight: AL-135 lbs (62 kg) / SS-300 lbs (136 kg)
Air Inlet: 3/4” FNPT
Liquid Inlet: 3” FNPT, 3” FBSPT, or ANSI/DIN Flanged
Liquid Outlet: 3” FNPT, 3” FBSPT, or ANSI/DIN Flanged
Height: 32.6” (827 mm) AL / 35.2” (893mm) SS
Width: 24.8” (630 mm)
Depth: 16.8” (425 mm)
Performance Specifications
Max. Flow: 235 gpm (890 lpm)
Max. Air Pressure: 120 psi (8.3 bar)
Max. Solids: 7/16” (11 mm)
Max. Suction Lift Dry: 20 ft-H2O (6.1 m-H2O)
Max. Suction Lift Wet: 31 ft-H2O (9.4 m-H2O)
Weight: AL-135 lbs (62 kg) / SS-300 lbs (136 kg)
Air Inlet: 3/4” FNPT
Liquid Inlet: 3” FNPT, 3” FBSPT, or ANSI/DIN Flanged
Liquid Outlet: 3” FNPT, 3” FBSPT, or ANSI/DIN Flanged
Height: 32.6” (827 mm) AL / 35.2” (893mm) SS
Width: 24.8” (630 mm)
Depth: 16.8” (425 mm)
Performance Specifications
Max. Flow: 235 gpm (890 lpm)
Max. Air Pressure: 120 psi (8.3 bar)
Max. Solids: 7/16” (11 mm)
Max. Suction Lift Dry: 20 ft-H2O (6.1 m-H2O)
Max. Suction Lift Wet: 31 ft-H2O (9.4 m-H2O)
Weight: AL-135 lbs (62 kg) / SS-300 lbs (136 kg)
Air Inlet: 3/4” FNPT
Liquid Inlet: 3” FNPT, 3” FBSPT, or ANSI/DIN Flanged
Liquid Outlet: 3” FNPT, 3” FBSPT, or ANSI/DIN Flanged
Height: 32.6” (827 mm) AL / 35.2” (893mm) SS
Width: 24.8” (630 mm)
Depth: 16.8” (425 mm)
AIR CONSUMPTION (SCFM)
AIR CONSUMPTION (SCFM)
AIR CONSUMPTION (SCFM)

ALF-12090-E-01 All-Flo10
SECTION 6
INSTALLATION, TROUBLESHOOTING
AND MAINTENANCE
INSTALLATION
PIPING
Whenever possible ensure the pump is installed using
the shortest possible pipe lengths with the minimum
amount of pipe fittings. Ensure all piping is supported
independent of the pump.
Suction and discharge piping should not be smaller
than the connection size of the pump. When pumping
liquids of high viscosity, larger piping may be used, in
order to reduce frictional pipe loss.
Employ flexible hoses in order to eliminate the vibration
caused by the pump. Mounting feet can also be used to
reduce vibration effects.
All hoses should be reinforced, non-collapsible and be
capable of high vacuum service. Ensure that all piping
and hoses are chemically compatible with the process
and cleaning fluid.
For processes where pulsation effects should be
reduced, employ a pulsation dampener on the discharge
side of the pump.
For self-priming applications, ensure all connections
are airtight and the application is within the pumps
dry-lift capability. Refer to product specifications for
further details.
For flooded suction applications, install a gate valve
on the suction piping in order to facilitate service.
For unattended flooded suction operation, it is
recommended to pipe the exhaust air above the liquid
source. In the event of a diaphragm failure this will
reduce or eliminate the possibility of liquid discharging
through the exhaust onto the ground.
LOCATION
Ensure that the pump is installed in an accessible
location, in order to facilitate future service and
maintenance.
AIR
Ensure that the air supply is sufficient for the
volume of air required by the pump. Refer to product
specifications for further details. For reliable
operation, install a 5 micron air filter, air-valve and
pressure regulator. Do not exceed the pumps
maximum operating pressure of 120 psig.
REMOTE OPERATION
Utilize a three way solenoid valve for remote
operation. This ensures that air between the solenoid
and the pump is allowed to “bleed off,” ensuring
reliable operation. Liquid transfer volume is estimated
by multiplying displacement per stroke times the
number of strokes per minute
NOISE
Correct installation of the muffler reduces sound
levels. Refer to product specifications for
further details.
SUBMERGED OPERATION
For submersible operation, pipe the air exhaust to
atmosphere
GROUNDING THE PUMP
Loosen grounding screw and install a grounding wire.
Tighten grounding screw. Wire size should be a 12
gauge wire or larger. Connect the other end of the wire
to a true earth ground. Equipment must be grounded
to achieve ATEX rating and it is recommended to
configure the pump with a grounding lug option.

ALF-12090-E-01 All-Flo11
6
SECTION
SUGGESTED INSTALLATION
This illustration is a generic
representation of an air operated
double-diaphragm pump.

ALF-12090-E-01 All-Flo12
SECTION 6
TROUBLESHOOTING
PROBLEM EFFECT/SOLUTION
Pump Will Not Cycle
Discharge line closed or plugged
Discharge filter blocked
Check valve stuck
Air filter blocked
Air supply valve closed
Air supply hooked up to muffler side of pump
Compressor not producing air or turned off
Muffler iced or blinded
Diaphragm ruptured
Plant air supply line ruptured
Air valve wear/debris
Pilot sleeve wear/debris
Diaphragm rod broken
Diaphragm plate loose
Pumped Fluid Coming Out of Muffler
Diaphragm ruptured
Diaphragm plate loose
Inlet liquid pressure excessive (above 10 psig)
Pump Cycles but no Flow
Inlet strainer clogged
Suction valve closed
Suction line plugged
No liquid in the suction tank
Suction lift excessive
Debris stuck in valves
Excessive wear of check valves
Air leak on suction side with suction lift
Pump Cycles with Closed Discharge Valve
Debris stuck in check valve
Excessive wear of check valves
Pump Running Slowly/Not Steady
Air compressor undersized
Leak in air supply
Air-line, filter regulator or needle valve undersized
Muffler partially iced or blinded
Air valve gasket leak or misalignment
Air valve wear/debris
Pilot sleeve wear/debris
Liquid fluid filter blocked
Pump may be cavitating, reduce speed of operation
Suction strainer clogged
Pump Will Not Prime
Air leak in suction pipe
Air leak in pump manifold connections
Suction strainer and lines clogged
Excessive lift conditions
Check valve wear
Debris in check valve

ALF-12090-E-01 All-Flo13
OPERATION
The Air-Operated Double Diaphragm Pump requires
a minimum of 20 psig of air to operate, with some
variation according to diaphragm material. Increasing
the air pressure results in a more rapid cycling of the
pump and thus a higher liquid flow rate. In order to not
exceed 120 psig of inlet air pressure, and for accurate
control of the pump, it is suggested to use a pressure
regulator on the air inlet.
An alternate means of controlling the flow-rate of the
pump is to use an inlet air valve and partially open or
close accordingly. When the air valve is completely in
the closed position, the pump will cease to operate.
A third method of controlling the flow rate of the
pump is to use a liquid discharge valve. Closing the
liquid discharge valve will cause a decrease in the
flow rate since the pump will operate against a higher
discharge pressure.
Solenoid control of the inlet air may also be used in
order to facilitate remote operation. A three way
solenoid valve is recommended, in order to allow the
air to “bleed off” between the solenoid and the pump.
Do not use valves for flow control on the suction side
of the pump. (Closing or partially closing a liquid
suction valve restrict the suction line and may cause
damage to the diaphragms.) Suction strainers may
be employed to reduce or eliminate larger solids, but
routine maintenance is necessary in order to prevent
a restriction on the suction.
MAINTENANCE
Due to the unique nature of each application, periodic
inspection of the pump is the best method to determine
a proper maintenance schedule. A record should be
kept of all repairs made to an installed pump. This will
serve as the best predictor of future maintenance.
Typical maintenance involves replacing of “wear-
parts” such as the diaphragms, balls, valve seats and
O-rings. Proper maintenance can ensure trouble-free
operation of the pump. Refer to repair and assembly
instructions for further details.
WARNING Maintenance must not be performed
when a hazardous atmosphere is present.
MAINTENANCE SCHEDULE
WEEKLY (OR DAILY)
Make a visual check of the pump. If pumped fluid is
leaking out of the pump, pipe fittings or muffler turn
off pump and schedule maintenance.
EVERY THREE MONTHS
Inspect fasteners and tighten any loose fasteners to
recommended torque settings.
Schedule pump service based on pump’s service
history.

ALF-12090-E-01 All-Flo14
REPAIR AND ASSEMBLY
PUMP WET END REMOVAL
STEP 1
Using the 3/4 inch wrench remove
six “Hex-Head Cap Screws (1/2”-
13x2-1/2”)”, six “Flat & Lock
Washers (1/2”)” and six“Flanged
Hex Nuts (1/2”-13)” from the
“Discharge Manifold”.
STEP 2
Remove the “Discharge Manifold”.
STEP 3
Remove the “O-Ring”, “Valve Seat”
and “Ball”.
Note: some models have an
integral rubber seat and seal.
TOOLS NEEDED
1) Two Wrenches, 3/4 Inch
2) Two Adjustable Wrenches or Vice
3) One Socket Wrench, 9/16 Inch
4) One Socket Wrench, 1-1/16 Inch
5) One Spanner Wrench, 3/4 Inch
(May Be Required) - A vice may be
required
WARNING Prior to servicing the pump, ensure that the air and
fluid lines are closed and disconnected. While wearing personal
protective equipment, flush, drain and process liquid from the pump
in a safe manner.
WARNING Maintenance must not be performed when a hazardous
atmosphere is present.
STEP 4
Using the 3/4 inch wrench remove
six “Hex-Head Cap Screws (1/2”-
13x2-1/2”)”, six “Flat & Lock
Washers (1/2”)” and six “Flanged
Hex Nuts (1/2”-13)” from the
“Suction Manifold”.
STEP 5
Remove the “Suction Manifold”.
STEP 6
Remove the “O-Ring”, “Valve
Seat” and “Ball”.
Note: some models have an
integral rubber seat and seal.
SECTION 7

ALF-12090-E-01 All-Flo15
7
SECTION
STEP 7
In order to remove both “Outer
Chambers” use two ¾ Inch
wrenches. Remove eight “Hex-
Head Cap Screws (1/2”-13)”, eight
“Flat Washers (1/2”)” and eight
“Flanged Hex Nuts (1/2”-13)” from
each “Outer Chamber”.
STEP 8
Remove both “Outer Chambers”
from the “Intermediate.”
STEP 9
Using two adjustable wrenches (or
a wrench 1-5/32” and a vice),
remove “Outer Diaphragm Plate”,
“Diaphragm” & “Inner Diaphragm
Plate” from one side of the pump.
STEP 10
Remove the “Bumper” and large
“Washer” (2-3/8”) from the
threaded rod stud (Aluminum
models only).
STEP 11
Using the 9/16 inch socket
wrench, remove six “Hex-Head
Cap Screws (3/8”-16x1-1/4”) and
six “Washers” (3/8”). Remove
“Inner Diaphragm Plate” and
“Outer Diaphragm Plate” from
“Diaphragm.”
PUMP WET END ASSEMBLY
To assemble the wet end of the pump, reverse the order of disassembly.
Ensure all hardware is fastened in accordance with torque specifications
(see page 19). Inverting one of the diaphragms during reassembly will
facilitate ease of assembly.
Note: On pumps built before 2018, shorter bolts (1-1/2”) may have been
used at the 6 and 12 O’Clock position of the chamber bolt patterns and
thread directly into blind tapped holes (no nuts).

ALF-12090-E-01 All-Flo16
SECTION 7
AIR VALVE REMOVAL
STEP 1
Using the 7/16 inch wrench, remove
eight “Hex Head Cap Screws
(1/4”–20 x 3”)” , eight “Lock
Washers (1/4)” and eight “Flat
Washers (1/4)”.
STEP 2
Remove the main “Air-Valve
Assembly” from the pump.
STEP 3
Remove the “Air-Valve Gasket”
from the main “Air-Valve
Assembly”.
TOOLS NEEDED
1) One Wrench, 7/16 Inch
2) One Pick, General Purpose
3) One Pair of Pliers
WARNING Prior to servicing the pump, ensure that the air and
fluid lines are closed and disconnected. While wearing personal
protective equipment, flush, drain and process liquid from the pump
in a safe manner.
WARNING Maintenance must not be performed when a hazardous
atmosphere is present.
STEP 4
Remove the “Shuttle Plate” from
the main “Air-Valve Assembly”.
Note: The smooth shiny side of the
shuttle plate should be toward the
shuttle car.
STEP 5
Remove the “Shuttle” from the
main “Air-Valve Assembly”.
STEP 6
Using the pair of pliers, remove
the “Air Valve End Plug” from the
main “Air-Valve Assembly”.
Ensure the “O-Ring” is installed
when reassembling.
REPAIR AND ASSEMBLY

ALF-12090-E-01 All-Flo17
STEP 7
Remove the “Air Valve Spool” from
the main “Air-Valve Assembly”.
STEP 8
Using the pick, remove the “Lip
Seal (Air Valve)” from the main
“Air-Valve Assembly”.
STEP 9
Using the pick, remove the
second “Lip Seal (Air Valve)” from
the main “Air-Valve Assembly”.
AIR VALVE ASSEMBLY
To assemble the air valve, reverse the order of disassembly. During
assembly, ensure that the open side of the lip-seals are both facing each
other inward. Install the shuttle plate with the smooth/shiny side toward
the shuttle car. Lubrication of the air valve assembly, with a non-synthetic
lubricant, is recommended. Magna-Lube or Magna-Plate are recommended
for assembly lubrication (see detailed parts list for ordering information).
Note that if the lip-seals are installed incorrectly, they will be unable to
rotate. Insert the spool, the spool’s longer piston with leading chamfer is to
be on the top side of the air valve casting, ensure O-Rings are installed, and
then the air-valve end plugs into position.
STEP 10A
Air Valve Orientation
The longer piston with the
leading chamfer is to be on
the top facing up. Arrow
points up on the main air
valve casting.
STEP 10B
Spool Orientation

ALF-12090-E-01 All-Flo18
PILOT VALVE REMOVAL
STEP 1
Using the screwdriver, remove
three “Phillips Flat Head Mach
Screw (#6-32-x 3/4”)” in order to
remove the “Retaining Plate”.
Repeat for both sides of the pump.
STEP 2
Remove the “Diaphragm Rod” and
the “Pilot Sleeve Assembly” from
the “Intermediate”.
TOOLS NEEDED
1) One Screwdriver, Phillips #2
2) Two Wrenches, 3/4 Inch
The chambers do not need to be
removed for this procedure.
The graphics show the inner
chambers removed for clarity.
WARNING Prior to servicing the pump, ensure that the air and
fluid lines are closed and disconnected. While wearing personal
protective equipment, flush, drain and process liquid from the pump
in a safe manner.
WARNING Maintenance must not be performed when a hazardous
atmosphere is present.
STEP 3
Remove the “Lip Seal” and “End
Spacer”.
STEP 4
Remove “O-rings” and “Inner
Spacer”.
REPAIR AND ASSEMBLY
STEP 5
Remove “Pilot Sleeve” from
diaphragm rod. The two piece rod
must be disassembled to remove
the “Pilot Sleeve”. Use the 3/4
inch wrenches to separate the
rod. Note they are installed with
threadlocker.

ALF-12090-E-01 All-Flo19
PILOT VALVE ASSEMBLY
To assemble the pilot valve, reverse the order of disassembly. Thread locking
sealant should be applied to the inner diaphragm rod threads (red) and
the retainer plate screws (blue) when installed. Should process fluid have
contact with the pilot valve o-rings, they should be replaced as swelling
may occur and cause irregular operation. During assembly, ensure that
the open side of the lip-seals are facing outward. Lubrication of the pilot
sleeve assembly, with a non-synthetic lubricant, is recommended in order to
facilitate re-assembly into the intermediate. Magna-Lube or Magna-Plate are
recommended for assembly lubrication (see detailed parts list for ordering
information).
TORQUE SPECIFICATION CHART
RECOMMENDED TORQUE SPECIFICATIONS
3” Pumps Wrench Size
Manifold Bolts 50 ft-lbs (67.8 N-m) 3/4”
Chamber Bolts 30 ft-lbs (40.7 N-m) 3/4”
Air Valve Bolts 40 in-lbs (4.5 N-m) 7/16”
Inner/Outer Diaphragm Plate Bolts 12.5 ft-lbs (16.9 N-m) 9/16”
Chamber/Intermediate Bolts 100 in-lbs (11.3 N-m) 1/2”
Diaphragm Rod Tighten until mechanical interference (hard stop)
then 1/8 to 1/4 turn more

ALF-12090-E-01 All-Flo20
EXPLODED VIEW & PARTS LIST
ALUMINUM, A300-*AA-****-***
SECTION 8
210
190 OPTIONAL
40 OPTIONAL
220
10
180
30
20
170
323
321
160
385
371351
150
270
190
300
290
230
240
250
330
280
381
382
40 311
312
372
260
384
360
61
342
341
70 80 90 100 110 120 130 140
50
62
383
322
353
352
355
200