Dover PSG ALL-FLO G Series Owner's manual

IOM
INSTALLATION OPERATION
& MAINTENANCE
G075 - G200
3/4, 1-1/4, AND 2 INCH FOOD GRADE
AIR-OPERATED DOUBLE-DIAPHRAGM PUMPS

ALF-13400-E-01 All-Flo2
TABLE OF
CONTENTS
SECTION 1 WARNINGS, DANGERS AND CAUTIONS 3
SECTION 2 MODEL DESIGNATION MATRIX 4
SECTION 3 PRINCIPLES OF OPERATION 5
SECTION 4 DIMENSIONAL DRAWINGS 6
SECTION 5 PERFORMANCE CURVES
G075, G125, G200 ..........................................................................7
SECTION 6 INSTALLATION,
INSTALLATION AND OPERATION ......................................................8
TROUBLESHOOTING ..................................................................12
SECTION 7 REPAIR AND ASSEMBLY
DISASSEMBLY...............................................................................14
ASSEMBLY ......................................................................................16
SECTION 8 EXPLODED VIEWS AND PARTS LISTS 17-19
SECTION 9 ELASTOMERS AND REPAIR KITS 20
SECTION 10 WARRANTY AND REGISTRATION 21

ALF-13400-E-01 All-Flo3
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 temperature 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 Material temperature limits is as follows:
Stainless Steel Housing with
Conductive Polyethylene Air Section: 176°F (80°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 100 psig (7 bar)
air-inlet pressure.
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.
CAUTION Do not operate with a positive 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 or nitrogen
gas installation.
CAUTION Ensure all hardware is set to
correct torque values prior to operation.
SECTION 1
WARNING

ALF-13400-E-01 All-Flo4
MODEL DESIGNATION MATRIX
SECTION 2
PRODUCT SERIES
FLUID CONNECTION TYPE
LIQUID SECTION
DIAPHRAGM
VALVE/BALL
VALVE SEAT
O-RINGS
SPECIAL (OTHER)
SPECIAL (PORTING)
AIR SECTION
SPECIAL (HARDWARE,
MUFFLER)
G X X X -1 2 3- 4 5 6 7 - 8 9 10
PUMP SIZE
075 = 3/4 in. (1 in. Tri-Clamp®)
125 = 1-1/4 in. (1-1/2 in. Tri-Clamp®)
200 = 2 in. (2 in. Tri-Clamp®)
FLUID
CONNECTION TYPE
T = Tri-Clamp®
AIR SECTION
J = Conductive Polyethylene
LIQUID SECTION
3 = 316 Stainless Steel
DIAPHRAGMS
P = Integral PTFE
M = FDA EPDM
VALVE/BALL
M = FDA EPDM
T = PTFE
VALVE SEAT
X = N/A (Part of Liquid Section)
O-RINGS
T = PTFE
PORTING
G = Suction Center Rear / Discharge Center Rear
SPECIAL OPTION (HARDWARE,
MUFFLER, LUG)
F = Stainless Steel Hardware, Standard Muffler,
Grounding M6 Port (ATEX Models)
J = Leak Detection Muffler
SPECIAL OPTION (OTHER)
0 = Standard
1 = Cycle Counter Sensor
N = Manual Drain Ball-Lifters
P = USP VI Certification (PTFE Only)
R = Manual Drain Ball-Lifters / USP VI
T = Cycle Counter / USP VI
W = Manual Drain Ball-Lifters / Cycle Counter
Y = Manual Drain Ball-Lifters / Cycle Counter /
USP VI
SIZE
1
2
4
5
7
9
10
3
8
6

ALF-13400-E-01 All-Flo5
PRINCIPLES OF OPERATION
HOW AN AIR OPERATED DOUBLE
DIAPHRAGM PUMP WORKS
SECTION 3
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-13400-E-01 All-Flo6
PUMP DIMENSIONS
SECTION 4
mm A B C D E F G H J K L N O P Q
G075 177 150 227 154 129 125 40 19 135 209 17 114 6.5 1/4"1" TC
G125 228 200 311 203 178 175 52 27 184 285 17 156 6.5 1/4"1-1/2" TC
G200 318 270 422 278 238 230 70 38 212 386 20 212 8.5 1/2"2" TC
inch A B C D E F G H J K L N O P Q
G075 7 6 9 6.1 5.1 5 1.6 0.7 5.3 8.2 0.7 4.5 0.2 1/4"1" TC
G125 9 7.9 12.2 8 7 6.9 2 1.1 7.2 11.2 0.7 6.1 0.2 1/4"1-1/2" TC
G200 12.6 10.6 16.6 11 9.4 9.1 2.8 1.5 8.3 15.2 0.8 8.3 0.3 1/2"2" TC

ALF-13400-E-01 All-Flo7
PERFORMANCE CURVES
G075 PERFORMANCE CURVE
G075 Performance Specifications
Max. Flow: 20 gpm (75 lpm)
Max. Air Pressure: 100 psi (7 bar)
Max. Solids: 7/20” (9 mm)
Max. Suction Lift Dry (EPDM): 6.6 ft-H2O (2 m-H2O)
Max. Suction Lift Dry (PTFE): 3.3 ft-H2O (1 m-H2O)
Max. Suction Lift Wet: 29.5 ft-H2O (9 m-H2O)
Weight: 13 lbs (6 kg)
Air Inlet: 1/4” FNPT
Nominal Size: 3/4”
Liquid Inlet Tri-Clamp®: 1”
Liquid Outlet Tri-Clamp®: 1”
5
SECTION
*Flow rates indicated on the chart(s) 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.
AIR CONSUMPTION (SCFM)
G125 PERFORMANCE CURVE
G125 Performance Specifications
Max. Flow: 40 gpm (150 lpm)
Max. Air Pressure: 100 psi (7 bar)
Max. Solids: 9/20” (12 mm)
Max. Suction Lift Dry (EPDM): 6.6 ft-H2O (2 m-H2O)
Max. Suction Lift Dry (PTFE): 5 ft-H2O (1.5 m-H2O)
Max. Suction Lift Wet: 29.5 ft-H2O (9 m-H2O)
Weight: 29 lbs (13 kg)
Air Inlet: 1/4” FNPT
Nominal Size: 1-1/4”
Liquid Inlet Tri-Clamp®: 1-1/2”
Liquid Outlet Tri-Clamp®: 1-1/2”
AIR CONSUMPTION (SCFM)
G200 PERFORMANCE CURVE
G200 Performance Specifications
Max. Flow: 106 gpm (400 lpm)
Max. Air Pressure: 100 psi (7 bar)
Max. Solids: 11/20” (14 mm)
Max. Suction Lift Dry (EPDM): 9.8 ft-H2O (3 m-H2O)
Max. Suction Lift Dry (PTFE): 6.6 ft-H2O (2 m-H2O)
Max. Suction Lift Wet: 29.5 ft-H2O (9 m-H2O)
Weight: 64 lbs (29 kg)
Air Inlet: 1/2” FNPT
Nominal Size: 2”
Liquid Inlet Tri-Clamp®: 2”
Liquid Outlet Tri-Clamp®: 2”
AIR CONSUMPTION (SCFM)

ALF-13400-E-01 All-Flo8
SECTION 6
INSTALLATION,
TROUBLESHOOTING
For inflammable liquids as well as for applications in
explosion-proof areas, All-Flo G Series pumps have
been equipped with a center section in conductive
polyethylene. The pump has to be grounded to one
of the tapping holes located in the side housings. All
other housing parts are connected to the side housing;
therefore it is not necessary to ground single parts.
Grounded G Series pumps with conductive center
section are suitable to be used in explosion areas of the
category 2 and 3, atmosphere G/D, which are liable to
the guideline 2014/34/EU. As well following electrostatic
reasons, conductive diaphragms (liquid side) are
suitable for transferring liquids of any explosion-group.
When using non-conductive diaphragm materials, the
following exemplary protection measures have to be
respected:
• The pump is always used for the transfer of
exclusively fluids which are conductive or soluble in
water or
• Dry-running is avoided by action steps within the
facility and/or its control or
• The system is inertisated in case of dry running by
nitrogen, water, carbon dioxide etc. when the fluid
transfer ends.
Piping systems and product connections have to be
grounded separately. To avoid ignition hazards the
formation of dust deposits on the pumps must be
prevented. In explosion-proof areas repair working only
after careful inspection of the practicability and only
with appropriate tools. For the ATEX marking according
to guideline 2014/34/EU please see the attached
conformity declaration and the according pump label.
INSTALLATION AND OPERATION
The number in brackets, which is added to every part
mentioned in the following explanations, refers to its
position in the spare part list and the exploded view.
In general, the pump has to be connected load free.
Neglecting this causes leakage and maybe even
damages. To avoid vibrations, pulsation dampers and
compensators are recommended. Before connecting
the pump, take the yellow blind plugs out of the suction
and discharge connections as well as the air inlet [18]
in the center block [16]. Use threadseal only sparingly,
otherwise the connections could be damaged.
The operator is responsible for an adequately stability
and an appropriate fixation of the piping according to
the state of the art. To facilitate the installation and
maintenance shut off valves should be installed right
before and after the pump. The nominal width of the
connection pipes has to be chosen in accordance to the
connections of the pump. A smaller piping can cause
cavitation (suction line) as well as a loss of performance
(suction and discharge line). In case the pipe is too big,
the dry suction capacity of the pump can decrease.
Connect the suction line to the lower manifold [2]
which can be swivelled carefully along its longitudinal
axis into the position required. Seal the suction line
diligently; hosepipes should be suitably armoured.
A suction line continuously rising will prevent the
formation of air locks in the line which would affect the
suction lift. The discharge line has to be connected to
the upper manifold [2] which can be swivelled along its
longitudinal axis as well.
The air inlet [18] is located in the middle of the center
block [16]. Before installation, make sure that the
air supply pipe is free of solids. To supply the pump
with driving air sufficiently, the pipe diameter should
match the size of the air inlet. Take care that no dirt
or particles can intrude into the pump during the
connection, as these can accumulate inside the pump
and can cause malfunctions. An air filter [19] directly
behind the air inlet [18] prevents the entry of bulk
particles.
The integrated air control system is a precision-control
that requires oil-free, dry and clean compressed air
for optimal function. If humidity is expected, a water
separator or air dryer has to be fitted to protect the
pump from blocking by ice. The ideal condition is the
dewpoint of air at -4°F (-20°C). In humid surroundings,
icing from the outside may occur despite the driving
air is dried. If so, a prolonged waste-air-exhaust (ca.
20 in. (500 mm) by pipe or hose) can be helpful. When
installing the pump into boards or cabinets, it has to
be ensured that cold air does not get caught behind
the muffler. In applications with a tendency to freezing
at the waste air exhaust, good experiences in practise
have been achieved by pre-heating the driving air to

ALF-13400-E-01 All-Flo9
increase the distance to the dew point of the air.
Doing so, it has to be considered that the driving air
temperature generally may not exceed 122°F (50°C)
to avoid expansion and sticking effects on the air side.
This max. air temperature is a well valid when using a
compressor producing warm air which is e.g. often true
for truck compressors.
The pressure of the driving air should be limited to the
amount required to meet the performance needed.
Excessive pressure increases both the air consumption
and the wear of the pump. The pump is regulated by
tuning the flow rate of the air. For a proper operation
at the lower performance range the regulation via a
needle valve is recommended. An empty pump has to
be driven slowly (e.g. via a needle-valve). The pump
starts automatically. Pumps of the G Series are self-
priming when dry, thus it is not necessary to fill the
suction line of the pump. The suction lift capacity of
a liquid-filled pump, however, is much higher. The
pump is appropriate for running dry during slow
operation. Dry running at high stroke frequency causes
premature wear. The pumps can briefly (up to max.
one hour) be operated against a closed discharge
line. Throttling on the suction side may damage the
pump. When the pump operation has been stopped
by a closed discharge, the pressure equilibrium of the
diaphragms must be ensured. This can be achieved
by keeping the pump connected to the air supply
pressure; for longer stoppage, the pump must be
released from the pressure within the system on both
fluid side and air supply side.
TORQUE VALUES
Before putting the pump into operation as well as after
some hours of operation, the housing bolts [8] have to
be fixed according to the torque data of the following
schedule, as the elements of construction “settle”.
Fixing the bolts is necessary as well after periods of
stoppage, at temperature variations, after transport
and dismantling the pump. In case of temperature
varying between extremes or high temperature
difference between the liquid and the surrounding, the
housing bolts should be controlled more frequently
(interval proposals are available on request).
Size Torque Value ft lbs (Nm)
G075 11.1 (15)
G125 17 (23)
G200 17 (23)
SUGGESTED INSTALLATION
This illustration is a generic representation of a
G Series air operated double-diaphragm pump.

ALF-13400-E-01 All-Flo10
SAFETY INSTRUCTIONS
• Installation, operation, and maintenance by qualified
staff only.
• Before start-up of the pump anyone should acquaint
oneself with the explanations of the chapter
troubleshooting (see pages 12/13). Only by this the
defect quickly can be realized and eliminated in
case of trouble. Problems which cannot be solved or
with an unknown reason should be passed on to the
manufacturer.
• Before any maintenance and service procedures
arising on the pump or on the optional equipments,
the complete installation has to be turned off and
protected against accidental turn on. This is possible
by a lockable emergency stop for the air supply of the
pump. Additional a danger sign against restart should
be attached.
• Pressure tests of the plant a pump is included in may
only be carried out with the pump disconnected from
the pressure on both ports or by using the pressure the
pump develops while operating. The load of a pressure
in the plant may damage the pump.
• Pump must not be operated with a positive suction
pressure.
• Depending on the conditions of operation, the liquid
conveyed might escape from the pump through
the muffler in case of a diaphragm rupture (in this
case muffler has to be replaced). For further safety
requirements the optional equipment diaphragm
monitoring and barrier chamber system are
recommended.
• In case of a diaphragm rupture, it might be possible fort
he fluid pumped to intrude into the air side of the pump.
In very adverse conditions - e.g. pressure within the
fluid system during stopped air supply - the fluid might
as well find its way into the air supply lines. To protect
other devices like pulsation dampers or even pneumatic
valves, it is recommended to protect the air supply line
accordingly, e.g. via a non-return valve. This would as
well avoid polluting the air supply line.
• The state of the muffler has to be inspected regularly, as
a blocked muffler can be forced out of the pump. If this
happens, damages of properties and/or persons cannot
be excluded.
• If the product tends to settle, the pump has to be
flushed regularly. For larger solids a filter has to be
installed in the suction line.
• In case of delivery of hot liquids the wetted pump must
not standstill for a longer time, because it could lead to
temporary leaks in the valve area and to a blockade of
the air control system.
• The relevant effective security advises have to be
respected.
• Pools of liquid which appear in the near outer area of
the pump have to be inspected on danger potential, if
necessary safety measures are to be taken.
• Chemical and biological reactions in the product
chamber of the pump (mixture of different substances)
and the freezing of the liquid have to be avoided.
• Before starting to disassemble the pump, take care
that the pump has been emptied and rinsed. Both
ports piping are to be closed and drained if applicable.
Further the pump has to be cut off from any energy on
the air and product side. If the pump is being deported
from the plant, a reference about the delivered liquid
has to be attached.
• Please respect the relevant additional security advices,
if the pump has been used for aggressive, dangerous
or toxic liquids (e.g. suitable protective equipment
according to the safety data sheet of the liquid). In case
of a diaphragm rupture, it is possible that residues of
the liquid remain behind the diaphragms, in the area
of the air control system and at the muffler, despite of
several flushing processes. Hence, appropriate safety
equipment according to the safety data sheet of the
liquid is indispensable.
• Before putting the pump back into operation, the
tightness of the pump has to be checked.
• Air-operated diaphragm pumps can lead to bruises
when lifting, sinking or assembling them. Appropriate
accessories and safety equipments are to be used. Big
and heavy modules have to fixed and secured to lifting
gears when transporting/replacing them.
• Especially when deliver critical liquids, wear parts, like
diaphragms, should be replaced within a preventive
maintenance.
• The use of non-original All-Flo spare parts and
structural changes lead to the lapse of the warranty
immediately. When operating such a pump, damages of
properties and/or persons cannot be excluded.
• The operation of the pump with nitrogen as driving gas
is possible. In closed rooms sufficient ventilation must
be provided.
• Possible electrical connections (e.g. when using
optional equipment with controllers) may be executed
by a qualified person only. The regulations of the
respective manufacturers are to be followed.
• At any work arising it has to be made sure that no
explosive atmosphere can appear. Appropriate safety
equipment is recommended.
• The pump is tested with water before shipment. Water
residues inside the pump cannot be precluded. If the
liquid, which is wanted to be conveyed, potentially
interacts with water, please consult All-Flo.

ALF-13400-E-01 All-Flo11
SUBMERGED OPERATION
Consider the following advises when using a All-Flo
pump as a submersible pump: When immersing an
air- operated diaphragm pump, it must generally
be ensured that the waste air is deducted above the
fluid level with a pipe or similar. The pump must be
located vertically upright to guarantee proper function.
Minute leakage on the air inlet or outlet can block
the air valve. The pump must be disconnected from
the pressure within the system during standstill.
When choosing the pump type, it must be taken into
consideration that all external parts - even those non-
wetted during standard operation - like covers, shock
absorbers, connections etc. must be resistant to the
fluid pumped. Please consider as well that depending
on the material, the pump must be weight down resp.
fixed.
ADDITIONAL TEMPERATURE
CONSIDERATIONS
The temperature and pressure limitations listed on
page 3 are solely based on mechanical temperature
limits of the housing material used. Depending on
the fluid pumped, the maximum safe operating
temperature of the housing material can be reduced
significantly.
A general aspect of lower temperatures is, that below
32°F (0°C) cold-brittling of the elastomers used within
the pumps can results in accelerated wear. Regarding
the housing materials, please note that polyethylene
keeps its mechanical strengths at low temperatures.
All-Flo pumps can therefore be operated safely as well
within low-temperature installations: However, with
liquids below 32°F (0°C) accelerated wear of internal
parts has to be accepted. Moreover, freezing, bogging
or crystallisation of the fluid pumped must be avoided,
especially within the pump. Emptying the pump via the
drainage system (optional equipment code R) may be a
useful tool to assist this.
Please consider, that viscosity and specific gravity
of most fluids change with temperature (most often
increasing at lower temperature). Depending on the
application, this fact may not only result in result in a
reduced flow rate, the pump may even be unable to
prime the thicker and/or “heavier“ fluid any more.
In case of varying application temperatures, the
housing bolt tension has to be controlled very
thoroughly, as variations like these can change the
effective tension of the housing bolts via the different
thermal expansion characteristics of single.

ALF-13400-E-01 All-Flo12
TROUBLESHOOTING
Problem Possible Reason Solutions/Remarks
pump does not operate air supply line blocked/closed
muffler blocked
working chambers blocked
air control system defective
discharge line blocked/closed
open air supply
clean/replace muffler
remove blockage
replace air valve system
clean/open line
pump operates unsteadily piston rings worn
air control system worn
diaphragm rupture
air control system soiled
check valve blocked
icing
replace piston rings
replace air control system
replace diaphragm, clean pump
clean/replace air control system
cleaning, removal of bulk particles
improve air processing
air within liquid suction line leaky
container with liquid empty
diaphragm rupture
cavitation
seal suction line
fill/new container
replace diaphragm
adapt suction lift, possibly install
suction pressurized air chamber
insufficient discharge pressure insufficient pressure/amount of driving
air
air supply line leaky
air control system leaky
check valve worn
more air consuming components
increase air supply
check/repair air supply
replace air control system
check/replace check valve
increase pressure/amount of air
output decreases air control system soiled
icing
air pressure drop
suction line/inlet strainer soiled
discharge line/outlet strainer soiled
muffler blocked
check valve worn
change in viscosity
more air consuming components
clean/replace air control system
improve air processing: dryer/filter
ensure sufficient supply of air
cleaning
cleaning
replace the muffler
replace valve
change back/adjust pump
increase pressure/amount of air
pump stops itself icing of the air control system
air pressure to low
air pressure drop
discharge line blocked
air filter blocked
valve closed
air control system defective
wear/leaking of air control system
diaphragm rupture
check valve blocked/worn
Improve air processing: dryer/heater
etc.
increase air pressure
ensure sufficient air supply
clean discharge line
clean air filter
open valve
replace air control system
replace air control system
replace diaphragm, clean pump
clean/replace check valve

ALF-13400-E-01 All-Flo13
TROUBLESHOOTING
Problem Possible Reason Solutions/Remarks
pumps operates, however suction
capacity insufficient
pump operates too fast
operation beyond physical limits
cavitation
operation beyond pump capacity
air cushion within suction/discharge
line
dry suction against discharge pressure
valve filter within suction line closed
valve filter within discharge line closed
container with liquid empty
vacuum inside the container
wear of the check valves
suction line leaky
suction line blocked
air pressure cushion at discharge
check valve blocked
start more slowly
adjust installation
check, cool down
adjust installation resp. install bigger
pump
bleed the line
wet pump, start without pressure
open valve/clean filter
open valve/clean filter
fill/new container
bleed container
replace valves
seal suction line
clean suction line
bleed discharge line
clean/replace valve
insufficient suction capacity after
pump repair
connections tighten incompletely
check valves inserted falsely
tighten/seal connections
correct positioning of check valves
diaphragm overstrained pressure within the plant/system
inadmissible vacuum
icing
ensure that pressure is only developed
by the pump itself, check plant/valves,
replace diaphragms
check suction line, open valve
improve air processing
leaking between housing parts housing bolts loosened
O-rings sleeve damaged
diaphragms attacked chemically
diaphragms overstrained
tension installation/pipework
tighten bolts, check pump
replace O-rings
replace diaphragms
replace diaphragms
loosen, eliminate tension, use of a
compensator
muffler grey driving air too humid, icing improve quality of driving air
muffler black soiled, oily air improve quality of driving air, install
sensitive filter in suction line
pump is connected to air but does not
operate
air control system blocked bulk
particles/dirt
chemical influence (O-rings swollen)
valve closed in discharge line
clean/replace air control system
clean pump, replace necessary parts,
improve air quality
check, replace damaged parts
open valve
liquid leaves the pump via the muffler diaphragm rupture replace diaphragms, clean pump

ALF-13400-E-01 All-Flo14
SECTION 7
REPAIR AND ASSEMBLY
DISASSEMBLY
When dismantling a pump the mentioned procedures and safety notes on the pages 3 and 10 have to be considered generally.
The general design of the G Series pumps is simple. A plastic tool designed for the mounting of the air-valve [22] is delivered
along with every pump. Further special tools are not required. Please find the part number for any part in the spare part list.
Loosen nuts of the housing bolts
on one side of the pump.
Remove side housing [1] and
suction/discharge ports [2].
Draw the O-rings port outside [7]
off the side housings [1].
Remove the inner O-rings [6]
out of the ports [2].
Remove the valve stops [3] and the ball valves [15] out of the side housings [1].
For the G125 and G200 the use of a screwdriver to remove the valve stops maybe is more convenient.

ALF-13400-E-01 All-Flo15
SECTION 7
REPAIR AND ASSEMBLY
Remove the center block [16] by
gently pulling apart.
Screw one diaphragm [14] counter
clockwise off the shaft [13].
Pull the other diaphragm [14]
together with the shaft [13] out of
the center block [16].
For pumps with draining systems only:
Take out the locking handle of the black flushing system [30]; draw off the pressure plate and the outer O-Ring and take out
the ball lifter from inside the side housings [1]; withdraw inner O-ring.
Screw out the set screws, shaft
[13a].
Remove both parts of the shaft
piston rings [17] from
their grooves carefully
(do not damage the edges in the
center block; a re-assembly of the
same piston rings is impossible;
they have to be replaced).
Unscrew the muffler [20], the air
inlet [18] and the air filter [19] out
of the center block [16].
To remove the air control system,
screw off both end caps using the
plastic mounting tool delivered
with the pump. Take out main and
pilot piston.
Push out the air-valve housing with
the mounting tool turned around.
The disassembled air control
system.
Complete air valve assembly.

ALF-13400-E-01 All-Flo16
ASSEMBLY
The re-assembly of the components is principally carried out vice-versa to the
dismantling. Here are some additional references.
For the installation of the air control system, first screw in one end cap flushly into
the center block [16]. Insert one of the six O-rings, air-valve housing [24] into the
end cap from the inside. Moisture the four O-rings [24] of the air-valve housing with
a bit of water and push the housing into the center block [16] using the mounting
tool. Take care that it slips in softly. Do never insert the housing violently with a
hammer. In case the housing cocks or hardly gets in, take it out again completely
and start again. Insert the main piston and the pilot piston. Lay the sixth O-Ring [24]
on the edge of the air-valve housing and screw in the second end cap.
To install a new piston ring [17], carefully shape it like a kidney (see picture on the
right) and with locking ring pliers and insert the ring into the groove in the center
block [16]; completely press the rings into the grooves smoothly using some
round tool.
Insert the inner O-rings [6] in the manifolds [2] carefully (bending the rings
absolutely has to be avoided! Moisturising the rings and twisting them carefully may
be helpful). Mount the outer O-rings [7] onto the ledges of the side housings [1].
Screw in set screws, shaft [13a] into the diaphragms [14] and tighten them. Fix one diaphragm [14] with set screw [13a]
onto into the shaft [13], shove it into the center block [16], lay on a side housing [1] and fix the position with the housing
bolts [8]. Fit the second diaphragm to the other end of the shaft and push the housing bolts [8] carefully (if necessary,
rotate the bolt smoothly while pushing) through the bore holes of the diaphragm without damaging the diaphragm and
its surfaces. Set the manifolds [2] on the side housings slightly rotating them. Adjust the second side housing [1]. Fix the
housing bolts [8] crosswise evenly according to the given torque values until the side housings [1] are situated on the
center block [16]. Any further tightening of the bolts does not improve sealing but can deform the housing! Before putting
the pump back into operation, the tightness of the pump has to be checked.
The sealing surfaces of the diaphragms [14] and the side housings [1] have to be absolutely clean and undamaged; mere
small scratches can cause leaking (if necessary, smoothen the housing surfaces carefully with fine sandpaper). Moisture
all O-rings for assembly, push them in carefully, do not bend any ring.
REPAIR AND ASSEMBLY

ALF-13400-E-01 All-Flo17
EXPLODED VIEW & PARTS LIST
SECTION 8
Item 8 housing bolt, cpl.: pump sizes G075/G125: 6 pieces pump size G200: 8 pieces Item 30 only for pumps with optional draining system equipment.

ALF-13400-E-01 All-Flo18
PARTS LIST
PUMP SIZE G075 G125 G200
ITEM PC. DESCRIPTION MATERIAL PART NUMBER
1 2 PUMP HOUSING, LIQUID SECTION 3 316 STAINLESS STEEL 5 20 210 26 5 32 210 26 5 50 210 26
2 2 TRI-CLAMP SUCTION/DISCHARGE PORT, LIQUID SECTION 3 316 STAINLESS STEEL 5 20 211 26 5 32 211 26 5 50 211 26
3 4 VALVE STOP 1.4571 5 20 216 24 5 32 216 24 5 50 216 24
6 4 O-RING, PORTS, INSIDE, O-RINGS T PTFE 9 24 537 60 9 36 539 60 9 54 542 60
7 4 O-RING, PORTS, OUTSIDE EPDM 9 28 512 72 9 42 540 72 9 62 543 72
8 * HOUSING BOLT WITH NUTS 1.4301 5 20 020 22 5 32 020 22 5 50 020 22
9 4 SHOCK ABSORBER NR 1 15 022 85 1 15 022 85 1 40 022 85
10 4 NUT 1.4305 9 06 106 22 9 06 106 22 9 08 106 22
13
13A
1
2
SHAFT
SET SCREW, SHAFT
1.4301
1.4305
2 15 030 22
9 10 220 22
2 25 030 22
9 12 221 22
2 40 030 22
9 16 222 22
14 2 DIAPHRAGM, DIAPHRAGMS P
DIAPHRAGM, DIAPHRAGMS M
PTFE
EPDM
1 15 031 67
1 15 031 73
1 25 031 67
1 25 031 73
1 40 031 67
1 40 031 73
15 4
VALVE BALL, VALVE/BALL M
VALVE BALL, VALVE/BALL T
VALVE BALL, VALVE/BALL T + OPTION USP
EPDM
PTFE
1 15 032 73
1 15 032 60
1 15 032 60U
1 25 032 73
1 25 032 60
1 25 032 60U
1 40 032 73
1 40 032 60
1 40 032 60U
16 1 CENTER BLOCK PE CONDUCTIVE 1 15 240 55 1 25 240 55 1 40 240 56
17 2 SHAFT PISTON RING, CPL. PTFE 1 15 041 64 1 25 041 64 1 40 041 64
18 1 AIR INLET PETP 1 15 047 84 1 15 047 84 1 40 047 84
19 1 AIR FILTER PE 1 15 043 51 1 15 043 51 1 40 043 51
20 1 MUFFLER BZ 1 15 244 34 1 15 244 34 1 40 244 34
22 1 AIR CONTROL SYSTEM PETP 2 15 001 84 2 15 001 84 2 40 001 84
24 1 O-RING, AIR VALVE HOUSING (INCLUDED IN 22) NBR 9 35 504 71 9 35 504 71 9 46 515 71
*G075 AND G125: 6 PIECES, G200: 8 PIECES PER PUMP
OPTIONS PARTS LIST
PUMP SIZE G075 G125 G200
CODE ITEM PC. DESCRIPTION MATERIAL PART NUMBER
1 16 1 CENTER BLOCK, CONDUCTIVE FOR SENSOR PE CONDUCTIVE 1 15 340 55 1 25 340 55 1 40 340 56
N1
30
2
4
PUMP HOUSING FOR DRAINING SYSTEM
BALL-LIFTER, CPL.
1.4408
1.4571
5 20 310 26
5 20 033 24
5 32 310 26
5 32 033 24
5 50 310 26
5 50 033 24

ALF-13400-E-01 All-Flo19
EPDM
is a general purpose elastomer with good resistance
to many acids and bases.
SECTION
9
ELASTOMERS
WETTED ELASTOMERS
Warning: The temperature 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.
All wetted elastomers used in G Series pumps
are FDA-approved. A material-certificate stating
FDA-conformity can be ordered.
PTFE (POLYTETRAFLUOROETHYLENE)
is a thermoplastic polymer that is inert to most
chemicals.
Stainless Steel Housing with PE-conductive Air Section: II 2GDc IIB T80°C
REPAIR KIT
Nomenclature Guide / Models G075 G125 G200
GXXX - 1 2 3 - 4 5 6 7 - 8 9 10 PART NUMBER
GXXX - TJ3 - MMXT SG075MMXT SG125MMXT SG200MMXT
GXXX - TJ3 - PTXT SG075PTXT SG125PTXT SG200PTXT
Spare part kits include everything needed to replace worn O-rings, ball valves,
diaphragms, shaft seals, muffler and air control system that are required for a single pump.

ALF-13400-E-01 All-Flo20
WARRANTY. All All-Flo products shall be covered by the standard All-Flo Limited Warranty in effect at the time
of shipment. This warranty (which may be modified by All-Flo at any time) provides:
MATERIALS SOLD ARE WARRANTED TO THE ORIGINAL USER AGAINST DEFECTS IN WORKMANSHIP OR
MATERIALS UNDER NORMAL USE (RENTAL USE EXCLUDED) FOR FIVE YEARS AFTER PURCHASE DATE. ANY
PUMP WHICH IS DETERMINED TO BE DEFECTIVE IN MATERIAL AND WORKMANSHIP AND RETURNED TO
ALL-FLO, SHIPPING COSTS PREPAID, WILL BE REPAIRED OR REPLACED AT ALL-FLO’S OPTION. CUSTOMER
SHALL NOTIFY ALL-FLO IN WRITING WITHIN 30 DAYS OF ANY CLAIMED DEFECTS. NO MATERIALS CAN BE
RETURNED WITHOUT THE PRIOR CONSENT OF ALL-FLO, AND IF APPROVED SHALL BE RETURNED TO
ALL-FLO FREIGHT PREPAID. ALL-FLO’S LIABILITY FOR ANY BREACH OF THIS WARRANTY SHALL BE
LIMITED TO EITHER REPLACEMENT OF THE MATERIALS OR, AT ALL-FLO’S SOLE OPTION, THE REFUND OF
THE PURCHASE PRICE. ALL-FLO SHALL NOT BE HELD LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL
DAMAGES CAUSED BY BREACH OF THIS WARRANTY. THIS EXCLUSION APPLIES WHETHER SUCH DAMAGES
WERE SOUGHT BASED ON BREACH OF WARRANTY, BREACH OF CONTRACT, NEGLIGENCE, STRICT LIABILITY
IN TORT, OR ANY OTHER LEGAL THEORY. FURTHER, ALL-FLO SHALL NOT BE LIABLE FOR LOSSES, DELAYS,
LABOR COSTS, OR ANY OTHER COST OR EXPENSE DIRECTLY OR INDIRECTLY ARISING FROM THE USE OF
MATERIALS. ALL-FLO’S LIABILITY IS EXPRESSLY LIMITED TO THE REPLACEMENT OR REPAIR OF DEFECTIVE
GOODS, OR THE TOTAL VALUE OF SUCH GOODS. THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES,
WHETHER EXPRESS, IMPLIED, OR ORAL INCLUDING THE IMPLIED WARRANTY OF MERCHANTABILITY, ANY
IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE, AND ANY IMPLIED WARRANTIES
OTHERWISE ARISING FROM A COURSE OF DEALING OR TRADE. All-Flo will not, in ANY event, be liable for any
loss of profit, interruption of business or any other special, consequential or incidental damages suffered or
sustained by Customer. All-Flo’s total maximum liability to the customer in respect of sale of materials or
services rendered by All-Flo is limited to the total monies received by All-Flo from the customer for the
particular materials described in Customer’s order.
All-Flo does not warrant any part or component that it does not manufacture, but will assign to the original
end-user purchaser of any warranty received by it from the manufacturer, to extent such pass through is
permitted by the manufacturer.
REGISTRATION FORM
Pump Model _________________________________ Pump Serial Number __________________________
Company Name _____________________________________________________________________________
Name ______________________________________ Email _______________________________________
Phone # ____________________________ City _____________________ State ______ Zip ___________
Qty of Pumps ________________________________ Fluid Pumping _______________________________
How did you hear about us? Existing All-Flo user,
Web, Distributor, Magazine…
______________________________________________________
www.all-flo.com/registration-form.html
WARRANTY AND REGISTRATION
Scan QR code and
complete form
on mobile phone
or visit
10
SECTION
MAIL TO: All-Flo | Attn: Product Registration
22069 Van Buren Street, Grand Terrace, CA 92313-5651