FLOJET G-57 Series Installation instructions

4.58
(116)
0.25
(6.4)
5.27
(134)
Air Exhaust
Muffler
2.20
(56)
1.84
(47)
0.92
(23)
0.71
(19)
3.21
(82)
4.52
(115) 5.81
(148)
Fluid OutFluid In
Air Inlet
PRODUCT DATA
Pump Design ............................................Duplex Diaphragm
Wetted Parts .... Diaphragm Material Santoprene ® or Viton ®
Check Valve Seat Material Santoprene ® or Viton ®
Housing and check valve material
................Polypropylene (Glass Reinforced)
Springs ..........................................Hastelloy
Ports ......................................Gas Inlet & Outlet 1/4” (6.3 mm)
Product Inlet 3/8” (9.5 mm) - 1/2” (12.7 mm) - 3/4” (19.1 mm)
Product Outlet 3/8” (9.5 mm) - 1/2” (12.7 mm) - 3/4” (19.1 mm)
Net Weight ..............................................1.2 Pounds (0.54kg)
®Aregistered trade mark of Monsanto Co.
®Aregistered trade mark of I.E. DuPont Co.
PERFORMANCE SPECIFICATIONS
PUMP
Liquid Temperature Min ............................................40°F (4.4°C)
............................Max ......................................120°F (48.9°c)
Priming ..............Dry ..........................................15 ft. (4.5 m)
............................Wet ..........................................20 ft. (6.1 m)
Flow Rates ........Max ....................Up to 5 GPM (18.9 L/min)
Gas Supply Pressure ..............20 to 100 PSI (1.4 to 6.9 bar)
Noise Level ........Max ......................................................87dB
DESCRIPTION
FLOJET Industrial G-57 Series Pumps are designed for
general commercial and industrial applications. These
pumps areconstructed from a selection of materials for
handling a broad range of chemicals.
Allowed fluids for Not Allowed fluids for
Santoprene ®materials Santoprene ®materials
Potable Water, Acids Oils, Solvents,Soaps with
Alkaline, Soaps Solvents, D-Limonene,
Alcohols, Ketones Aromatic Hydrocarbons
Allowed fluids for Not Allowed fluids for
Viton ®materials Viton ®materials
Oils, Solvents, D-Limonene, Ketones, Acetones,
Aromatic & Halogenated Automotive Brake Fluid,
Hydrocarbons, Acids Ammonia, Ethanol
Santoprene and Viton Material with 1/2” Ports
G-57 Series
Industrial Air Driven Pump
DIMENSIONAL DRAWING
Inches (millimeters)
Dimensional tolerances ± 0.06 inches
Consult factory if precise details are required.
40
(2.8)
20
(1.4)
60
(4.1)
80
(5.5)
100
(6.9)
Flow in GPM (l/min)
*Indicates Airlet Pressure
Pressure in PSI (Bar)
01.0
(3.8)
2.0
(7.6)
3.0
(11.4)
4.0
(15.1)
5.0
(18.9)
6.0
(22.7)
100*
80*
60*
40*
20*
INSTALLATION & OPERATION INFORMATION FOR MODELS G573XXX THROUGH G575XX

MOUNTING
The FLOJET G-57 Series self-priming pump should be
mounted in a dry and adequately ventilated area. This
pump can be mounted several feet from the tank, above
or below the fluid level. For most applications, no more
than 4 feet above the fluid level is recommended. This
is not a submersible pump.
Secure Dump to desired fixture by screws through the
rubber grommets in the baseplate of the pump. Ports
must be facing down. Contact factory for mounting
bracket and hardware options.
HOSE CONNECTIONS
Product In - Use 3/8”. 1/2” or 3/4”. reinforced hose or
equivalent. Avoid sharp bends that could restrict flow or
cause hose to collapse under vacuum.
Product Out - Use reinforced 3/8”. 1/2” or 3/4” I.D. hose
for discharge tube. 3/4” must use 90° elbows when
using large muffler.
Gas In - Make sure gas regulator is set at zero. Use
reinforced 1/4” hose. connect “Gas In” to gas supply
fitting on regulator. If pumps are installed in an enclosed
area, it is recommended to connect a hose to the gas
discharge port (exhaust) and vent gas to atmosphere.
(Requires ‘small’ exhaust port)
PLUMBING
Use a flexible hose to avoid excess stress on pump
ports. DO NOT crimp or kink hose. All hose should be
the same size as the pump port fittings.
All fittings must be compatible with fluid being pumped.
It is recommended to use plastic fittings only.
The use of check valves in the plumbing system could
interferewith the priming ability of the pump. If
unavoidable, check valves in the pumping system must
have a cracking pressure of 2 PSI or less.
Use a minimum 40 mesh strainer or filter in the tank or
pump inlet line to keep large foreign particles out of the
system.
OPERATION
At start-up, regulate gas pressure to desired setting. For
most installations 20 PSI (1.4 bar) inlet will be adequate,
although DO NOT go below 20 PSI. Pump will operate
according to air supply. Flow and pressure can be
adjusted by increasing or decreasing gas pressure to
accommodate varying product viscosities, length of
lines or other installation conditions. Review flow curves
located on page 1 for further assistance. High viscosity
fluids and hose length will limit priming distance.
IF PUMP IS T0 BE USED IN HIGH FLOW, LOW
PRESSURE APPLICATIONS, ADJUST GAS PRESSURE
TO 20 PSI (1.38 BAR) ABOVE DISCHARGE PRESSURE.
CAUTION: DO NOT EXCEED 100 PSI (6.9 bar) GAS INLET
PRESSURE.
CONTINUOUS OPERATION AT 120°F (48.9°C) WILL
REDUCE PUMP LIFE.
AIR MUST BE DRY AND OIL FREE.
Compressors must have dryers and/or a water
separator in the air distribution system. Pumps that fail
due to water in the air chamber will not be covered
under the limited warranty.
GENERAL SAFETY INFORMATION
Protect yourself and others by observing all safety
information. Follow all safety codes and the
Occupational Safety and Health Act (OSHA).
DO NOT PUMP GASOLINE OR
FLAMMABLE LIQUIDS OR USE WHERE
FLAMMABLE VAPORS ARE PRESENT.
If used with C02or N2be surethe area is
well ventilated.
CAUTION:
Do not clean or service FLOJET pumps, hoses or valves
while the system is pressurized. Plastic CO2air inlet
ports do not have a check valve. Prior to cleaning or
servicing, purge the pump by carefully tilting the pump
so ports are facing up and remove suction line from
source. Turn air off and disconnect air inlet line. (Brass
air inlet ports have a check valve)
PREVENTIVE MAINTENANCE TIPS
Tips to help prolong your pump’s life.
• If pumping liquid other than water. pump should be
flushed with water (if applicable) after every use.
•
Before freezing conditions occur. pump must be liquid free.
• If mounting pump in an outdoor environment. shield
pump from environmental extremes (i.e. sunlight.
water from washdown spray, rain, etc.).
• When using an air compressor. use an inline air dryer
before the pump to limit water build-up.
WARNING
FLEXIBLE
HOSE
RIGID
PIPE

G57 DISASSEMBLYPROCEDURE
First, remove all gas (air in) lines and suction/discharge fittings
from me pump. This is accomplished by using a flat-bladed
screwdriver to slide the retaining clips away from the gas (air in)
and suction/discharge fittings and pulling the fittings away from
the pump body. Now remove the muffler by sliding the retaining
clip away from the muffler base and pulling the muffler out of the
pump body.
UsIng a Phillips screw driver remove the seven (7) screws from the
front end cap followed by the (7) screws from the rear end cap.
With the front end cap facing up and the rear end cap facing down
on the workbench, position a flat bladed screw driver into the slot
located above the muffler port and just below the pad marked
Air/C02and lift off the front end cap. The rear end cap can be
removed by placing the flat bladed screwdriver under the fully
opened port retaining clip and lifting off.
Note the position of the suction and discharge valves before
removing them from the pump body. The first diaphragm is
removed from the pump shaft by unscrewing in a counter clock-
wise direction. The second diaphragm is removed by placing the
flat tip of a screwdriver the exposed slot at the end of the pump
shaft and unscrewing me diaphragm from the shaft. To remove the
flange housing, place the tip of the flat bladed screw driver into the
air bleed hole on the lower side of the flange housing and lift up
the lower end separating the flange housing from the pump body.
The slide valve assembly and pump shaft can be removed by sim-
ply pulling them from the pump body. The pump shaft then can be
removed from the slide valve yoke assembly.
REASSEMBLE PROCEDURE
Assemble the slide valve and pump shaft with the yoke placed
between the (2) bumpers on the pump shaft. Install the slide
valve/pump shaft assembly into the pump body making surethe
O-rings in the slide valve arein place. Toinstall the flange housing,
prelube the o-ring with Parker Super “O” Lube and install on flange
housing and place housing over the pump body aligning the flange
housing with the pump body ribs pressing it into place.
Install the first diaphragm and O-ring on to the pump shaft by
threading on to shaft using a flat blade screwdriver to hold the
pump shaft until the diaphragm is tight. Install the second
diaphragm and O-ring on to the pump shaft turning clockwise until
tight.
Install the suction valves with springs facing into the pump body
and the discharge valves with the springs facing out. See arrows
on pump rear end cap below suction and discharge ports.
Install the port retainer clips (large) into the pump end cap
(mounting base) and install the seven (7) Phillips screws into pump
body and cross tighten until snug and then cross torque to 22-24
inch pounds. Install port retaining clips (small) into the pump body,
tabs facing out, position the front end cap and install the seven (7)
Phillips screws into pump body and cross tighten until snug and
then cross torque to 22-24 inch pounds.
Install the muffler in the center port by pushing it in and sliding the
retainer clip into place. Install the suction and discharge ports and
the (air in) port fitting and slide the retainer clips in place. Check
for leaks.
2B
2A
5
43A
6
3A
4
5
7
1A
1A
6
6
2B
2A
Key Part No. Description Qty
1A 20740-050A Kit, Check Valve, Assy., Santo ®,Hastelloy 4
1B 20740-020A Kit, Check Valve. Assy., Viton ®,Hastelloy 4
2A 20730-000A Kit, Diaphragm, Santo,&, w/“O” rings 2
2B 21000-209 Kit, Diaphragm, Viton ®2
3A 20751-000A Kit, Shaft & Slide Valve Assy. (Santo ®)2
3B 20751-002A Kit, Shaft & Slide Valve Assy.(Viton ®) 2
4 20896-000A Kit, Flange & Housing Assy. w/“O” Ring 2
5 20753-000A Kit End Caps 2
Key Part No. Description Qty
6 20793-100A Kit Hardware - Includes
Screws #10x1.5” Hi Low 14
Retainer Clip Small 2
Retainer Clip Large 2
Exhaust Port 1
Exhaust Muffler 1
720132-000 Kit, Grommets 2
MODEL G57 SERIES EXPLODED VIEW

Copyright 2006, ITT Industries Printed in U.S.A. All Rights Reserved Form: 82000-014 Rev. C 08/2006
WARRANTY
FLOJET warrants this product to be free of defects in material and/or
workmanship for a period of one year after purchase by the customer
from FLOJET. During this one year warranty period, FLOJET will at its
option, at no charge to the customer, repair or replace this product if
found defective, with a new or reconditioned product, but not to
include costs of removal or installation. No product will be accepted
for return without a return material authorization number. All return
goods must be shipped with transportation charges prepaid. This is
only a summary of our Limited Warranty. For a copy of our complete
warranty, please request Form No. 100-101.
RETURN PROCEDURE
Prior to returning any product to FLOJET, call customer service for an
authorization number. This number must be written on the outside
of the shipping package. Place a note inside the package with an
explanation regarding the reason for return as well as the
authorization number. Include your name, address and phone number.
G57 PORTFITTINGS
MODEL NUMBERING MATRIX
TROUBLESHOOTING CHART
Symptom Possible Cause(s) Corrective Action
Pump will Pump will not start (stalls) 1. Inadequate air supply (20 PSI Min.) 1. Increase air inlet pressure
2. Contaminated air supply 2. An air dryer might be required
3. Ruptured diaphragm (2) 3. Replace diaphragm (2)
4. Check shuttle valve for wear (11) 4. Replace shuttle valve if necessary (11)
Pump runs, but no fluid 1. A leak or break in the product inlet line 1. Replace product line
2. A leak or break in the product discharge line 2. Replace product line
Pump leaks through exhaust port 1. Leak at upper exhaust port o-ring (13) 1. Replace exhaust port (13)
2. Shaft seal o-rings damaged or worn 2. Replace shaft seal o-rings
3. Inadequate slide lubrication 3. Replace with shuttle valve kit
Flow rate is low 1. Tubing or hose is damaged or blocked 1. Clean or replace
2. Check viscosity of medium being pumped 2. Reduce viscosity of medium, increase
hose diameter or contact factory for
recommendation
3. Check valves not seated correctly (6) 3. Reinstall check valves (6)
Pump leaks 1. Ruptured or wornout diaphragm (2) 1. Replace diaphragm (2)
2.
Pump housing screws not torqued adequately 2. Torque screws to 20 in lb
Elastomer/ Ports Air Inlet/ Packaging
Spring Material (Product in and out) Muffler Code
5SANTO Diaphragm 00 No Port Fittings 5 Straight brass 1/4” A (single pack)
SANTO Check Valve 20 Straight 3/8” HB 6 Elbow 90° brass 1/4” D (72 bulk pack)
EPDM O-Rings 21 Straight 1/2” HB 7 Tee brass 1/4”
Hastelloy Springs 22 Straight 3/4” HB 8 Straight Plastic 1/4”
23Elbow 90° 3/8” HB 9 Straight Plastic 1/4”*
3VITON ®Diaphragm 24 Elbow 90° 1/2” HB *(no muffler element)
VITON ®Check Valve Seat 25 Elbow 90° 3/4” HB
Hastelloy Springs
G57X XX X X
PART DESCRIPTION QTY
NUMBER
20381-010 3/4” HB, 90° Elbow, EPDM “O” Ring 2
20325-033 1/4” HB, Straight Plastic (Air In) 12
01510-000 1/4” HB, Straight Brass (Air In) 12
PART DESCRIPTION QTY
NUMBER
20381-002 1/2” HB, Straight, EPDM “O” Ring 2
20381-006 3/4” HB, Straight, EPDM “O”Ring 2
20381-009 1/2” HB, 90° Elbow, EPDM “O” Ring 2
For a complete port fitting list please request form No. F1 00-112.
www.flojet.com
U.S.A.
Flojet
666 E. Dyer Rd.
Santa Ana, CA 92705
Phone: [phone]
Fax: [phone]
UNITED KINGDOM
Flojet
Bingley Road, Hoddesdon
Hertfordshire EN11 OBU
Tel: [phone]
Fax: [phone]
CANADA
Fluid Products Canada
55 Royal Road
Guelph, Ontario N1H 1T1
Tel: [phone]
Fax: [phone]
JAPAN
NHK Jabsco Company Ltd.
3-21-10, Shin-Yokohama
Kohoku-Ku, Yokohama, 222
Tel: [phone]
Fax: [phone]
GERMANY
Jabsco GmbH
Oststrasse 28
22840 Norderstedt
Tel: [phone]
Fax: [phone]
ITALY
Jabsco Marine Italia
Via Tommaseo, 6
20059 Vimercate, Milano
Tel: [phone]
Fax: [phone]