Dover PSG ALL-FLO S100 Owner's manual

IOM
INSTALLATION OPERATION
& MAINTENANCE
S100
PLASTIC 1 INCH
AIR-OPERATED DOUBLE-DIAPHRAGM PUMP

ALF-13150-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
RUBBER, TPE AND PTFE DIAPHRAGMS...........................7
SECTION 6 INSTALLATION,
INSTALLATION ...................................................................................... 8-9
TROUBLESHOOTING ..................................................................10
OPERATION......................................................................................11
MAINTENANCE .............................................................................11
SECTION 7 REPAIR AND ASSEMBLY
PUMP WET END REMOVAL............................................ 12-13
AIR VALVE REMOVAL ........................................................ 14-15
PILOT VALVE REMOVAL...................................................16-17
TORQUE SPECIFICATIONS.......................................................17
SECTION 8 EXPLODED VIEWS AND PARTS LISTS 18-20
SECTION 9 ELASTOMERS AND REPAIR KITS 21
SECTION 10 ATEX PROTECTION SUMMARY 22
SECTION 11 WARRANTY AND REGISTRATION 24

ALF-13150-E-01 All-Flo3
SECTION 1
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.
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 For pump models with non-metallic manifolds,
air valves, or chambers: When the relative humidity in the surrounding
atmosphere is above 30%, the equipment must not be touched by
personnel unless first wiped down with a damp cloth.
WARNING Maintenance must not be performed when a
hazardous atmosphere is present.
WARNING Use only with liquid process fluid.
WARNING This equipment’s ambient temperature range is
32°F (0°C) to 104°F (40°C)
WARNING Do not operate the pump with fluids or in
temperatures which are less than 32°F (0°C)
WARNING The T6-T3 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. Do not exceed the
maximum recommended process fluid temperature of the configured
materials.
CAUTION The temperature of the process fluid and
air input must be no more than 36°F (20°C) 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 and applicable ATEX temperature class:
Buna-N (Nitrile): 10°F to 180°F (-12°C to 82°C) T6
Geolast®: 10°F to 180°F (-12°C to 82°C) T6
EPDM: -40°F to 280°F (-40°C to 138°C) T4
Santoprene®: -40°F to 225°F (-40°C to 107°C) T5
FKM: -40°F to 350°F (-40°C to 177°C) T3
PTFE: 40°F to 220°F (4°C to 104°C) T6
Polyethylene: 32°F to 158°F (0°C to 70°C) T6
Polypropylene: 32°F to 180°F (0°C to 82°C) T6
PVDF: 0°F to 250°F (-18°C to 121°C) T4
Nylon: 0°F to 200°F (-18°C to 93°C) T6
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
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.
limit. Always use minimum air pressure when pumping at elevated
temperatures.
CAUTION It is the end user’s responsibility to maintain the
process fluid’s temperature during use.
CAUTION Do not connect a compressed air source to the
exhaust port of the pump.
CAUTION Do not lubricate air supply.
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.
CAUTION The equipment must be inspected for visible
damage prior to use.
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

3
1
2
6
7
8
9
10
4
5
ALF-13150-E-01 All-Flo4
MODEL DESIGNATION MATRIX-PLASTIC SOLIDS
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)
S 1 0 0 -1 2 3- 4 5 6 7 - 8 9 10
FLUID CONNECTION TYPE
F = ANSI / DIN FLANGE
C = Combination ANSI / DIN FLANGE & NPT
E = Combination ANSI / DIN FLANGE & BSPT
AIR SECTION
P = Polypropylene Intermediate-Pneumatic Shift
LIQUID SECTION
K = PVDF
P = Polypropylene
DIAPHRAGMS
G = Geolast®
S = Santoprene®
T = PTFE with Santoprene®Backup
V = FKM
VALVE/BALL
N = Buna-N
E = EPDM
V = FKM
VALVE SEAT
K = PVDF
P = Polypropylene
3 = Stainless Steel
O-RINGS
E = EPDM
N = Buna-N
T = PTFE
V = FKM
PORTING
S = Default (Suction Right/ Discharge Right)
T = Suction Right / Discharge Left
X = Suction Left / Discharge Right
Y = Suction Left / Discharge Left
A = Suction Center Front / Discharge Center Front
B = Suction Center Front / Discharge Center Rear
D = Suction Center Front / Discharge Right
E = Suction Center Front / Discharge Left
F = Suction Center Rear / Discharge Center Front
G = Suction Center Rear / Discharge Center Rear
I = Suction Center Rear / Discharge Right
J = Suction Center Rear / Discharge Left
P = Suction Right / Discharge Center Front
Q = Suction Right / Discharge Center Rear
U = Suction Left / Discharge Center Front
V = Suction Left / Discharge Center Rear
4 = All Ports Open (Standard ports will be
left un-plugged)
SPECIAL OPTION (HARDWARE,
MUFFLER, LUG)
7 = Stainless Steel Hardware, Standard Muffler
8 = Stainless Steel Hardware, Premium Muffler
B = PTFE Coated Stainless Steel Hardware,
Standard Muffler
C = PTFE Coated Stainless Steel Hardware,
Premium Muffler
F = Stainless Steel Hardware, Standard Muffler,
Grounding Lug Installed
G = Stainless Steel Hardware, Premium Muffler,
Grounding Lug Installed
H = PTFE Coated Stainless Steel Hardware,
Standard Muffler, Grounding Lug Installed
I = PTFE Coated Stainless Steel Hardware,
Premium Muffler, Grounding Lug Installed
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
2 = Solenoid Adaptor Valve 110/50 Volt AC, 120/60
Volt AC, DIN 43650B Connector
3 = Solenoid Adaptor Valve 110/50 Volt AC, 120/60
Volt AC Explosion Proof
4 = Solenoid Adaptor Valve 220/50 Volt AC, 240/60
Volt AC, 12 Volt DC, DIN 43650B Connector
5 = Solenoid Adaptor Valve 220/50 Volt AC, 240/60
Volt AC, 12 Volt DC Explosion Proof
6 = Solenoid Adaptor Valve 220/50 Volt AC, 240/60
Volt AC, 125 Volt DC, DIN 43650B Connector
7 = Solenoid Adaptor Valve 220/50 Volt AC, 240/60
Volt AC, 125 Volt DC Explosion Proof
8 = Solenoid Adaptor Valve 24 Volt DC, DIN
43650B Connector
9 = Solenoid Adaptor Valve 24 Volt DC, Explosion
Proof
A = Grease Free (No lubrication assembly)
SIZE
WET END REPAIR KIT
Wet end kits are available and
consist of 2 diaphragms, (back-up
diaphragms if required), MaxPass™
valves and 4 seat O-Rings.
See matrix below.
Bold indicates recommended options
AIR END REPAIR KIT
Air end repair kit contains pilot sleeve
assembly and main air valve.
DIAPHRAGM
VALVE/BALL
O-RINGS
SWE-100-45X7-P
PRODUCT
SERIES
WET END
REPAIR KIT
PUMP SIZE
MATERIAL
SAK-100-P
PRODUCT
SERIES
PUMP SIZE
AIR END
REPAIR KIT
MATERIAL

ALF-13150-E-01 All-Flo5
PRINCIPLES OF OPERATION
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.
HOW AN AIR OPERATED DOUBLE
DIAPHRAGM PUMP WORKS
SECTION 3
Note: The graphics show ball valves, which are replaced with Max-Pass™
valves for these pump models.

ALF-13150-E-01 All-Flo6
1” PUMP DIMENSIONS
PLASTIC SOLIDS
SECTION 4

ALF-13150-E-01 All-Flo7
PERFORMANCE CURVES
PERFORMANCE CURVE Performance Specifications
Max. Flow: 41 gpm (155.8 lpm)
Max. Air Pressure: 120 psi (8.3 bar)
Max. Solids: 3/4” (19 mm)
Max. Suction Lift Dry: 15 ft-H2O (4.6 m-H2O)
Max. Suction Lift Dry w/PTFE: 10 ft-H2O (3.0 m-H2O)
Max. Suction Lift Wet: 26 ft-H2O (7.9 m-H2O)
Weight Polypropylene: 20 lbs (9.1 kg)
Weight PVDF: 30 lbs (13 kg)
Air Inlet: 1/4” FNPT
Liquid Inlet: 1” ANSI/DIN Flanged,
1” FNPT or 1” FBSPT
Liquid Outlet: 1” ANSI/DIN Flanged,
1” FNPT or 1” FBSPT
Height: 16.32” (414.5 mm)
Width: 17.26” (438.4 mm)
Depth: 8.88” (225.6 mm)
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.

ALF-13150-E-01 All-Flo8
SECTION 6
INSTALLATION, TROUBLE-
SHOOTING 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-13150-E-01 All-Flo9
SUGGESTED INSTALLATION
This illustration is a generic
representation of an air operated
double-diaphragm pump.

ALF-13150-E-01 All-Flo10
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-13150-E-01 All-Flo11
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.
WARNING For pump models with non-metallic
manifolds, air valves, or chambers: When the relative
humidity in the surrounding atmosphere is above 30%,
the equipment must not be touched by personnel
unless first wiped down with a damp cloth.
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-13150-E-01 All-Flo12
SECTION 7
REPAIR AND ASSEMBLY
PUMP WET END REMOVAL
STEP 1
Using the 1/2 inch wrenches
remove eight “Hex-Head Cap
Screws”, sixteen “Washers” and
eight “Nuts” from the “Discharge
Manifold”.
STEP 2
Remove the “Discharge Manifold”.
STEP 3
Remove the “O-Ring”,
“Max-Pass™ Backup” and
“Max-Pass™ Valve” from the
“Discharge Manifold”.
TOOLS NEEDED
1) One Wrench, 7/16 Inch
2) Two Wrenches, ½ Inch
3) Two Wrenches, 9/16 Inch
4) Two Wrenches, 11/8Inch
WARNING Prior to servicing the pump, ensure that the air and fluid
lines are closed and disconnected. While wearing personal protective equip-
ment, flush, drain and process liquid from the pump in a safe manner.
WARNING Maintenance must not be performed when a hazardous atmo-
sphere is present.
WARNING For pump models with non-metallic manifolds, air valves, or
chambers: When the relative humidity in the surrounding atmosphere is above
30%, the equipment must not be touched by personnel unless first wiped down
with a damp cloth.
STEP 4
Using the 1/2 inch wrenches
remove eight “Hex-Head Cap
Screws”, sixteen “Washers” and
eight “Nuts” from the “Suction
Manifold”.
STEP 5
Remove the “Suction Manifold”.
STEP 6
Remove the “O-Ring”,
“Max-Pass™ Backup” and
“Max-Pass™ Valve” from the
“Outer Chambers”.

ALF-13150-E-01 All-Flo13
STEP 7
In order to remove both “Outer
Chambers”, using two 9/16 Inch
wrenches, remove eight “Hex
Head Cap Screws”, sixteen
“Washers” and eight “Nuts” from
each side.
STEP 8
Remove both “Outer Chambers”
from the “Intermediate”.
STEP 9
Using two 1-1/8 Inch wrenches,
remove “Outer Diaphragm
Plate”, “Diaphragm” and “Inner
Diaphragm Plate” from one side
of the pump.
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 17). Inverting one of the diaphragms during reassembly will
facilitate ease of assembly.
Note: When using pumps built with PTFE O-Rings, always replace with
new PTFE O-Rings, since the original O-Rings may not reseal the pump.
STEP 10
Placing the 1-1/8 inch wrench on the remaining “Outer Diaphragm Plate” and the 7/16 inch wrench on the
“Diaphragm Rod Assembly”, remove the remaining “Outer Diaphragm Plate”, “Diaphragm” and “Inner
Diaphragm Plate” from the other side of the pump.

ALF-13150-E-01 All-Flo14
AIR VALVE REMOVAL
STEP 1
Using the 7/16 Inch wrench,
remove four “Hex Head Cap
Screws”, four “Lock Washers”,
four “Flat Washers” and four “Hex
Nuts” (rear).
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 equip-
ment, flush, drain and process liquid from the pump in a safe manner.
WARNING Maintenance must not be performed when a hazardous atmo-
sphere is present.
WARNING For pump models with non-metallic manifolds, air valves, or
chambers: When the relative humidity in the surrounding atmosphere is above
30%, the equipment must not be touched by personnel unless first wiped down
with a damp cloth.
STEP 4
Remove the “Shuttle Plate” from
the main “Air-Valve Assembly”.
Note: The smooth shinny 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-13150-E-01 All-Flo15
STEP 7
Remove the “Air Valve Spool” from
the main “Air-Valve Assembly”.
Note: The longer piston is on the
plug side, insert larger chamfer
first.
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/shinny 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, larger chamfer side first, the spool’s longer
piston is to be on the plug side, ensure O-Ring is installed, and then the
air-valve end plug into position.

ALF-13150-E-01 All-Flo16
PILOT VALVE REMOVAL
STEP 1
Using the screwdriver, remove
three “Phillips Pan-Head Screws”
in order to remove the “Retaining
Plate”. Repeat for other side of
the pump.
STEP 2
Remove the “Diaphragm Rod” and
the “Pilot Sleeve Assembly” from
the “Intermediate”.
STEP 3
Remove both “Lip Seals
(Diaphragm Rod)” and both “End
Spacers (Pilot Sleeve)” from the
“Pilot Sleeve Assembly”. Remove
both “O-Rings (End Spacer)” from
both “End Spacers (Pilot Sleeve)”.
TOOLS NEEDED
1) One Screwdriver, Phillips #2
2) Two Wrenches, 7/16 Inch
WARNING Prior to servicing the pump, ensure that the air and fluid
lines are closed and disconnected. While wearing personal protective equip-
ment, flush, drain and process liquid from the pump in a safe manner.
WARNING Maintenance must not be performed when a hazardous atmo-
sphere is present.
WARNING For pump models with non-metallic manifolds, air valves, or
chambers: When the relative humidity in the surrounding atmosphere is above
30%, the equipment must not be touched by personnel unless first wiped down
with a damp cloth.
STEP 4
Remove three “Inner Spacers
(Pilot Sleeve)” and four “O-Rings
(Pilot Sleeve)” from the “Pilot
Sleeve Assembly”.
STEP 6
Remove the “Pilot Sleeve” from
the disassembled “Diaphragm
Rod Assembly”.
REPAIR AND ASSEMBLY
STEP 5
Using two 7/16 inch wrenches,
disassemble the “Diaphragm Rod
Assembly” into its two parts.
Note: They are installed with
thread locker.

ALF-13150-E-01 All-Flo17
PILOT VALVE ASSEMBLY
To assemble the pilot valve, reverse the order of disassembly. 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
1” Pumps
Manifold Bolts 100-110 in-lbs (11.3-12.4 N-m)
Chamber Bolts 75-85 in-lbs (8.48 - 9.61 N-m)
Air Valve Bolts 40 in-lbs (4.52 N-m)
Diaphragm Plates 165 in-lbs (18.6 N-m)
Note: Always torque the chamber bolts prior to the manifold bolts. When reassembling, loosely tighten all
external fasteners adjusting and aligning gradually, in an alternating fashion, tighten to torque requirements
listed above.
Note: When using pumps built with PTFE O-Rings, always replace with new PTFE O-Rings, since the original
O-Rings may not reseal the pump.

ALF-13150-E-01 All-Flo18
EXPLODED VIEW & PARTS LIST
S100-*P*-****-*** PLASTIC SOLIDS
SECTION 8

ALF-13150-E-01 All-Flo19
PARTS LIST - PLASTIC SOLIDS
S100-*P*-****-***
ITEM DESCRIPTION QTY PUMP MODEL PART NO. MATERIAL
1 AIR VALVE END PLUG 1 ALL MODELS 11703-60 Polypropylene
2 AIR VALVE SPOOL 1 ALL MODELS 10480-31 Acetal
4 AIR VALVE GASKET 1 ALL MODELS 12116-19 Nitrile
5 SHUTTLE PLATE 1 ALL MODELS 10416-77 Ceramic
6 SHUTTLE 1 ALL MODELS 10415-00 Special
7 AIR VALVE BODY 1 ALL MODELS 11614-60 Polypropylene
8 SLT WSHR (#8 X 1”) SCREW 8 ALL MODELS (NON-PTFE COATED) 12525-26 Stainless Steel
9 SPLIT LOCKWASHER (3/8”) 16 ALL MODELS (NON-PTFE COATED) 12316-26 Stainless Steel
10 FLAT WASHER (1/4”) 4 ALL MODELS (NON-PTFE COATED) 12300-26 Stainless Steel
11 CAP SCREW (1/4” X 5”) 4 ALL MODELS (NON-PTFE COATED) 12512-26 Stainless Steel
12 FLAT WASHER (3/8”) 64 ALL MODELS (NON-PTFE COATED) 12303-26 Stainless Steel
13 DIAPHRAGM ROD (Short) 1 ALL MODELS * Stainless Steel
14 END SPACER (Pilot Sleeve) 2 ALL MODELS 10204-40 Polypropylene
15 DIAPHRAGM ROD (Long) 1 ALL MODELS * Stainless Steel
16 BOLT (5/16” X 2-1/4”) 16 ALL MODELS (NON-PTFE COATED) 12547-26 Stainless Steel
17 HEX NUT (1/4” - 20) 4 ALL MODELS (NON-PTFE COATED) 12600-26 Stainless Steel
18 HEX NUT (5/16” - 18) 16 ALL MODELS (NON-PTFE COATED) 12601-26 Stainless Steel
19 O-RING (Manifolds) 4 S100-*P*-***N-*** 11940-11 Nitrile
S100-*P*-***E-*** 11940-15 EPDM
S100-*P*-***T-*** 11940-17 PTFE
S100-*P*-***V-*** 11940-82 FKM
20 BOLT (3/8” X 2-1/4”) 16 ALL MODELS (NON-PTFE COATED) 12544-26 Stainless Steel
21 HEX NUT (3/8” - 16) 16 ALL MODELS (NON-PTFE COATED) 12602-26 Stainless Steel
23 SUCTION MANIFOLD 1 S100-*PP-****-*** 10555-40 Polypropylene
S100-*PK-****-*** 10555-56 PVDF
24 SELF TAP SCREW (#6 X 1/2”) 6 ALL MODELS 12510-26 Stainless Steel
25 LOCK WASHER 4 ALL MODELS 12350-26 Stainless Steel
28 OUTER CHAMBER 2 S100-*PP-****-*** 10723-40 Polypropylene
S100-*PK-****-*** 10723-56 PVDF
29 OUTER DIAPHRAGM PLATE 2 S100-*PP-****-*** 11204-40 Polypropylene
S100-*PK-****-*** 11204-56 PVDF
30 OVERLAY (PTFE ONLY) 2 S100-*P*-T***-*** 11406-59 PTFE
31 DIAPHRAGM 2 S100-*P*-V***-*** 10605-13 FKM
S100-*P*-G***-*** 10605-19 Geolast®
S100-*P*-S***-*** 10605-23 Santoprene®
S100-*P*-T***-*** 10605-23 Santoprene®
32 DISCHARGE MANIFOLD 1 S100-*PP-****-*** 10567-40 Polypropylene
S100-*PK-****-*** 10567-56 PVDF
33 INNER DIAPHRAGM PLATE 2 ALL MODELS 11104-25 Plated Steel
34 INTERMEDIATE 1 ALL MODELS 11522-60 Polypropylene
36 MUFFLER PLATE 1 ALL MODELS 13111-60 Polypropylene

ALF-13150-E-01 All-Flo20
37 MUFFLER 1 ALL MODELS 13000-00 Polypropylene
39 GASKET (Muffler Plate) 1 ALL MODELS 12117-19 Nitrile
40 LIP SEAL (Diaphragm Rod) 2 ALL MODELS 12000-76 Nitrile
41 RETAINING PLATE 2 ALL MODELS 12708-54 Polypropylene
42 O-RING (End Spacer) 2 ALL MODELS 11923-11 Nitrile
43 LIP SEAL (Air Valve) 2 ALL MODELS 12003-76 Nitrile
44 O-RING (Air Valve End Plug) 1 ALL MODELS 11913-11 Nitrile
45 PILOT SLEEVE 1 ALL MODELS 10105-31 Acetal
46 O-RING (Pilot Sleeve) 4 ALL MODELS 11920-16 Urethane
47 INNER SPACER (Pilot Sleeve) 3 ALL MODELS 10203-40 Polypropylene
48 MAX-PASS™ VALVE 4 S100-*P*-*N**-*** 10911-11 Nitrile
S100-*P*-*E**-*** 10911-15 EPDM
S100-*P*-*V**-*** 10911-82 FKM
49 MAX-PASS™ BACK-UP 4 S100-*PP-**P*-*** 10912-40 Polypropylene
S100-*PK-**K*-*** 10912-56 PVDF
50 O-RING (Max-Pass™Valve) 4 S100-*P*-***N-*** 11936-11 Nitrile
S100-*P*-***E-*** 11936-15 EPDM
S100-*P*-***V-*** 11936-82 FKM
* Any Character
* NOTE: DIAPHRAGM ROD CAN ONLY BE PURCHSED AS AN ASSEMBLY.
DIAPHRAGM ROD ASSEMBLY 1 ALL MODELS 32000-00 Stainless Steel
Items 13 & 15
OPTIONAL ASSEMBLIES AVAILABLE
AIR VALVE ASSEMBLY 1 ALL MODELS SMK-100-P Various
Items 1, 2, 4, 5, 6, 7, 43, 44
PILOT VALVE ASSEMBLY 1 ALL MODELS SPK-100-P Various
Items 14, 40, 42, 45, 46, 47
ITEM DESCRIPTION QTY PUMP MODEL PART NO. MATERIAL
PARTS LIST - BOLTED PLASTIC
S100-*P*-****-***