FLOJET G257 Series Guide

10.06
(256)
5.19 (MAX)
(127) (MAX)
5.19 (MAX)
(127) (MAX)
4.00
(102)
0.84
(21)
10.06
(256)
4.00
(102)
0.84
(21)
0.75
(19)
5.84
(148)
2.06
(52)
1.84
(47)
2.72
(69)
2.00
(51)
12.88
(328)
12.88
(328)
12.88
(328)
2.06
(52)
1.84
(47)
0.75
(19)
5.84
(148)
2.72
(69)
2.00
(51)
PRODUCT DATA
Pump Design ......................Air Operated Double 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
Mounting Brackets and Manifolds ..................Polypropylene
Ports..........................................Gas Inlet/Outlet 1/4” (6.3 mm)
Product Inlet/Outlet (Dual) - 1/2” NPT (12.7 mm)
Product Inlet/Outlet (Quatro) - 3/4” NPT (19.1 mm)
Net Weight Dual ..............................3.5 Pounds (1.59kg)
Quatro ..........................7.0 Pounds (3.18kg)
®
A registered trade mark of Monsanto Co.
®
A registered 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 ..(Dual) Up to 10 GPM (37.8 L/min)
Flow Rates ........Max (Quatro) Up to 20 GPM (75.6 L/min)
Gas Supply Pressure ..........20 to 100 PSI (1.4 to 6.9 bar)
Noise Level ........Max ................................................90dB
DESCRIPTION
FLOJET Industrial G-57 Series Pumps are designed for
general commercial and industrial applications. These
pumps are constructed 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
Dual (10 GPM) and
Quatro (20 GPM)
Air Operated Diaphragm Pumps
DIMENSIONAL DRAWING
Inches (millimeters)
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 Air Inlet Pressure in PSI
Dual (10 GPM)
(Model G257XXX)
Quatro (20 GPM)
(Model G457XXX)
Head Pressure in PSI (Bar)
05.0
(18.9)
10.0
(37.8)
05.0
(18.9)
10.0
(37.8)
15.0
(56.6)
20.0
(75.5)
100*
80*
60*
40*
20*
100*
80*
60*
40*
20*
INSTALLATION & OPERATION INFORMATION FOR MODELS G257XXX AND G457XXX
Dual (10 GPM) and Quatro (20 GPM) Air Oper. Diaphragm Pumps
Dual Pump (Model G257xxx) Quatro Pump (Model G457xxx)

MOUNTING & PLUMBING
Flojet’s 10 GPM Dual and 20 GPM quatro pumps should be
mounted in a dry and adequately ventilated area. Since these
are self priming pumps they can be mounted several feet from
the tank above or below the liquid level. These can be
mounted either on the floor or on the wall. For most
applications, mounting at no more than 4 feet above the liquid
level. this is not a submersible pump.
Secure pump system to desired fixture by screws through the
baseplate of the pump bracket.
Use flexible hoses to avoid excess stress on the pump ports.
Do not crimp or kink hoses. All hoses should be the same size
as the pump port fittings. Fittings must be compatible with
liquid being pumped. Use plastic fittings. Avoid sharp bends
that could restrict flow or cause hose to collapse under
vacuum. Use reinforced hoses.
Make sure gas regulator is set at zero. Use reinforced 1/4” hose
to connect to gas supply from regulator to the ‘Gas In’ port.
The exhaust could be vented to atmosphere or through a muffler.
Use of check valves (especially with a cracking pressure >
2psi) could interfere with priming capability of the pumps. Use
a minimum 40 mesh strainer before the pump inlet.
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 sure the 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.
10 GPM (DUAL) AND 20 GPM (QUATRO)
DISASSEMBLY PROCEDURE
Remove the gas (AIR IN) lines and liquid suction and
discharge lines from the Dual or Quatro pump systems. You
can then disconnect the suction and discharge manifolds from
the pumps. For the Dual pump systems this is accomplished
simply by sliding the retainer clips on the pump and pulling the
manifolds away form the pump. For Quatro pump systems
you will have to take off the screws holding the pumps on any
one side. That will create room for the pumps to be pulled
away from the manifold after sliding the retainer clips on these
pumps. The AIR IN fitting can also be disengaged from each
of the pumps similary by sliding the retainer clip. The muffler
also can be removed by sliding its retainer clip.
ASSEMBLY PROCEDURE
In order to replace a pump you will then need to remove the
screws holding the pump to the bracket. PLEASE MAKE
ABSOLUTELY SURE THAT YOU REPLACE A PUMP WITH
ANOTHER PUMP WITH EXACTLY THE SAME PART
NUMBER. EVEN THOUGH THE PUMPS LOOK SIMILAR ON
THE OUTSIDE, THE INTERNAL PARTS ARE DIFFERENT.
When putting the system back together you go in the reverse
order by putting the pumps together first and the fittings in the
end. You need to make sure that each fitting/manifold port has
the O-ring in the groove and the retainer clip is pushed back
in the lock position. Also make sure the pumps are securely
fastened to the bracket. Ensure you have proper sealing on
the fittings that are threaded into the ports. Then you may
connect the gas/air in and liquid tubes.
If you want to repair the G-57 pumps, please refer to the
instructions on page 3 of this manual .
WARNING
FLEXIBLE
HOSE
RIGID
PIPE

G57 UNIT DISASSEMBLY PROCEDURE
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.
G57 UNIT 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 sure the
O-rings in the slide valve are in place. To install 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.
2A
5
43A
6
3A
4
5
7
1
6
62B
2A
2B
6
Shown in position
for Standard Pump
(Part No. G573000
and G575000)
1Shown in position
for Reverse Flow
Pump (Part No.
G577000 and
G578000)
Key Part No. Description Qty
1 20740-050A Kit, Check Valve, Assy., Santo ®, Hastelloy 4
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
7 20132-000 Kit, Grommets 4
MODEL G57 SERIES EXPLODED VIEW

UNITED KINGDOM
Jabsco/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]
U.S.A.
Flojet
20 Icon
Foothill Ranch, CA 92610-3000
Tel: [phone]
Fax: [phone]
GERMANY
Jabsco GmbH
Oststrasse 28
22844 Norderstedt
Tel: [phone]
Fax: [phone]
© Copyright 2002, ITT Industries Printed in U.S.A. All Rights Reserved Form: 81000-354 11/02
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.
TROUBLESHOOTING CHART
Symptom Possible Cause(s) Corrective Action
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 3. Replace diaphragm
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 manifold o-ring 1. Replace exhaust manifold
2. Shaft seal O-rings damaged or worn 2. Replace shaft seal O-rings
3. Inadequate slide lubrication 3. Replace with shuttle valve kit
4. Manifold port clip not correctly installed 4. Make sure clip is installed correctly
and fully seated
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 3. Reinstall check valves
Pump leaks 1. Ruptured or worn out diaphragm 1. Replace diaphragm
2.
Pump housing screws not torqued adequately 2. Torque screws to 20 in lb
WASHDOWN PUMP SERVICE PARTS
KEY# Pump System Flojet Part No. Description
1 2 & 4 Pump System G575000A Replacement Pump with Santoprene™, EPDM Elastomer
2 & 4 Pump System G573000A Replacement Pump with Viton™ Elastomer
2 2 & 4 Pump System G577000A Replacement Pump with Santoprene™, EPDM Elastomer, Reverse Flow
2 & 4 Pump System G578000A Replacement Pump with Viton™ Elastomer, Reverse Flow
3 2 & 4 Pump System 21000-324A Kit, Bracket with Two Screws
4 2 Pump System 20574-015A Kit, Gas Line Assembly, 2 Pump, 1/4” Barb
2 Pump System 20574-013A Kit, Gas Line Assembly, 2 Pump, for 1/4” Quick Connect
5 2 Pump System 21039-100A Kit, Manifold, EPDM, 2 Pump
2 Pump System 21039-101A Kit, Manifold, Viton™, 2 Pump
6 4 Pump System 20574-016A Kit, Gas Line Assembly, 4 Pump, 1/4” Barb
4 Pump System 20574-014A Kit, Gas Line Assembly, 4 Pump, for 1/4” Quick Connect
7 4 Pump System 21039-102A Kit, Manifold, EPDM, 4 Pump
4 Pump System 21039-103A Kit, Manifold, Viton™, 4 Pump
2
6
7
1
3
3
1
7
2
3
1
5
2
4
5