Page 1
EOM
Engineering
Operation &
Maintenance
P400
Plastic Pump
Where Innovation Flows
wildenpump.com
Page 2
TABLE OF CONTENTS
SECTION 1 CAUTIONS—READ FIRST! .............................................1
SECTION 2 WILDEN PUMP DESIGNATION SYSTEM ................................2
SECTION 3 HOW IT WORKS—PUMP & AIR DISTRIBUTION SYSTEM. . . . . . . . . . . . . . . . 3
SECTION 4 DIMENSIONAL DRAWINGS .............................................4
SECTION 5 PERFORMANCE
P400 Plastic Rubber-Fitted .................................................5
P400 Plastic TPE-Fitted ....................................................5
P400 Plastic Reduced-Stroke PTFE-Fitted .....................................6
P400 Plastic Full-Stroke PTFE-Fitted .........................................6
SECTION 6 SUGGESTED INSTALLATION, OPERATION & TROUBLESHOOTING .......8
SECTION 7 DISASSEMBLY / REASSEMBLY ........................................11
Air Valve / Center Section Disassembly ......................................14
Reassembly Hints & Tips ..................................................16
SECTION 8 EXPLODED VIEW & PARTS LISTING
P400 Plastic .............................................................18
SECTION 9 ELASTOMER OPTIONS ................................................20
Page 3
Section 1
CAUTIONS—READ FIRST!
CAUTION: Do not apply compressed air to the
exhaust port — pump will not function.
CAUTION: Do not over-lubricate air supply —
excess lub rication will reduce pump perfor mance.
Pump is pre-lubed.
TEMPERATURE LIMITS:
Acetal –29°C to 82°C –20°F to 180°F
Buna-N –12°C to 82°C 10°F to 180°F
Geolast
®
–40°C to 82°C –40°F to 180°F
Neoprene –18°C to 93°C 0°F to 200°F
Nordel
®
EPDM –51°C to 138°C –60°F to 280°F
Nylon –18°C to 93°C 0°F to 200°F
PFA –7°C to 107°C 45°F to 225°F
Polypropylene 0°C to 79°C 32°F to 175°F
Polyurethane –12°C to 66°C 10°F to 150°F
PVDF –12°C to 107°C 10°F to 225°F
Saniflex™ –29°C to 104°C –20°F to 220°F
SIPD PTFE with EPDM-backed
SIPD PTFE with Neoprene-backed
PTFE
1
4°C to 104°C 40°F to 220°F
4°C to 137°C 40°F to 280°F
4°C to 93°C 40°F to 200°F
FKM –40°C to 177°C –40°F to 350°F
Wil-Flex™ –40°C to 107°C –40°F to 225°F
1
4°C to 149°C (40°F to 300°F) - 13 mm (1/2") and 25 mm (1") models only.
NOTE: Not all materials are available for all
models. Refer to Section 2 for material options
for your pump.
CAUTION: When choosing pump materials, be
sure to check the temperature limits for all wetted
components. Example: FKM has a maximum
limit of 177°C (350°F) but polypropylene has a
maximum limit of only 79°C (175°F).
CAUTION: Maximum temperature limits are
based upon mechanical stress only. Certain
chemicals will significantly reduce maximum
safe operating temperatures. Consult Chemical
Resistance Guide for chemical compatibility and
temperature limits.
WARNING : Prevent static sparking — If static
sparking occurs, fire or explosion could result.
Pump, valves, and containers must be grounded
to a proper grounding point when handling
flammable fluids and whenever discharge of
static electricity is a hazard.
CAUTION: Do not exceed 8.6 bar (125 psig) air
supply pressure.
CAUTION: The process fluid and cleaning fluids
must be chemically compatible with all wetted
pump components. Consult Chemical Resistance
Guide.
CAUTION: Pumps should be thoroughly flushed
before installing into process lines. FDA- and
USDA-approved pumps should be cleaned and/
or sanitized before being used.
CAUTION: Always wear safety glasses when
operating pump. If diaphragm rupture occurs,
material being pumped may be forced out air
exhaust.
CAUTION: Before any maintenance or repair is
attempted, the compressed air line to the pump
should be disconnected and all air pressure
allowed to bleed from pump. Disconnect all
intake, discharge and air lines. Drain the pump
by turning it upside down and allowing any fluid
to flow into a suitable container.
CAUTION: Blow out air line for 10 to 20 seconds
before attaching to pump to make sure all
pipeline debris is clear. Use an in-line air filter. A
5μ (micron) air filter is recommended.
NOTE: When installing PFTE diaphragms, it is
important to tighten outer pistons simultaneously
(turning in opposite directions) to ensure tight fit.
(See torque specifications in Section 7.)
NOTE: PVDF pumps come standard from the
factory with expanded PTFE gaskets installed
in the diaphragm bead of the liquid chamber,
in the T-section and in the ball and seat area.
PTFE gaskets cannot be re-used. Consult for
installation instructions during reassembly.
NOTE: Before starting disassembly, mark a line
from each liquid chamber to its corresponding air
chamber. This line will assist in proper alignment
during reassembly.
CAUTION: Pro-Flo® pumps cannot be used in
submersible applications.
CAUTION : Tighten all hardware prior to installation.
WIL-11241- E-03 1 WILDEN PUMP & ENGINEERING, LLC
Page 4
Section 2
WILDEN PUMP DESIGNATION SYSTEM
P400
Plastic
38 mm (1-1/2") Pump
Maximum Flow Rate:
450 lpm (119 gpm)
LEGEND
P400 / XX XXX / XXX / XX / XXX / XXXX
MODEL
MATERIAL CODES
MODEL
P400 = PRO‑FLO
WETTED PARTS & OUTER PISTON
KK = PVDF / PVDF
KZ = PVDF / NO OUTER PISTON
PP = POLYPROPYLENE /
POLYPROPYLENE
PZ = POLYPROPYLENE / NO
OUTER PISTON
AIR CHAMBERS
P = POLYPROPYLENE
CENTER BLOCK
P = POLYPROPYLENE
AIR VALVE
P = POLYPROPYLENE
®
DIAPHRAGMS
VALVE BALLS
AIR VALVE
CENTER BLOCK
AIR CHAMBERS
WETTED PARTS & OUTER PISTON
DIAPHRAGMS
BNS = BUNA‑N (Red Dot)
EPS = EPDM (Blue Dot)
FSS = SANIFLEX™
[Hytrel® (Cream)]
FWL = SANITARY WIL‑FLEX™,
IPD
FWS = SANITARY WIL‑FLEX™,
EZ‑INSTALL [Santoprene®
(Two Black Dots)]
NES = NEOPRENE (Green Dot)
PUS = POLYURETHANE (Clear)
TEU = PTFE W/EPDM
BACK‑UP (White)
TNU = PTFE W/NEOPRENE
BACK‑UP (White)
TSS = FULL STROKE PTFE
W/SANIFLEX™ BACK‑UP
TSU = PTFE W/SANIFLEX™
BACK‑UP (White)
TWS = FULL STROKE PTFE
W/WIL‑FLEX™ BACK‑UP
VTS = FKM (White Dot)
WFS = WIL‑FLEX™ [Santoprene®
(Three Black Dots]
ZGS = GEOLAST®, EZ‑INSTALL
ZPS = POLYURETHANE,
EZ‑INSTALL
ZSS = SANIFLEX™, EZ‑INSTALL
ZWL = WIL‑FLEX™, INTEGRAL
PISTON
ZWS = WIL‑FLEX™, EZ‑INSTALL
O-RINGS
VALVE SE ATS
VALVE BALLS
BN = BUNA‑N (Red Dot)
EP = EPDM (Blue Dot)
FS = SANIFLEX™
FW = SANITARY WIL‑FLEX™
NE = NEOPRENE (Green Dot)
PU = POLYURETHANE (Clear)
TF = PTFE (White)
VT = FKM (White Dot)
WF = WIL‑FLEX™ [Santoprene®
VALVE SEATS
K = PVDF
P = POLYPROPYLENE
VALVE SEAT O-RINGS
BN = BUNA‑N
TV = PTFE ENCAP. FKM
WF = WIL‑FLEX™ (Santoprene®)
SPECIALT Y
CODE
(if applicable)
[Hytrel® (Cream)]
[Santoprene® (Two Black
Dots)]
(Three Black Dots)]
SPECIALTY CODES
0100 Wil‑Gard II™ 110V
0102 Wil‑Gard II™, sensor wires ONLY
0103 Wil‑Gard II™ 220V
0502 PFA‑coated hardware
0504 DIN flange
0506 DIN flange, PFA coated hardware
0604 DIN flange Wil‑Gard II™ 220V
NOTE: Most elastomeric materials use colored dots for identification.
WILDEN PUMP & ENGINEERING, LLC 2 WIL-11241- E-03
Page 5
Section 3
HOW IT WORKS—PUMP
The Wilden diaphragm pump is an air-operated, positive displacement, self-priming pump. These drawings show flow pattern
through the pump upon its initial stroke. It is assumed the pump has no fluid in it prior to its initial stroke.
FIGUR E 1 The air valve dire cts pre ssurized
air to the back side of diaphragm A. The
compressed air is applied directly to the
liquid column separated by elastomeric
diaphragms. The diaphragm acts as
a separation membrane between the
compressed air and liquid; a balanced
load removes mechanical stress from the
diaphragm. The compressed air moves
the diaphragm away from the center
of the pump. The opposite diaphragm
is pulled in by the shaft connected to
the pressurized diaphragm. Diaphragm
B is on its suction stroke; air behind
the diaphragm has been forced out to
atmosphere through the exhaust por t of
the pump. The movement of diaphragm
B toward the center of the pump creates
a vacuum within chamber B. Atmos pheric
pressure forces fluid into the inlet
manifold forcing the inlet valve ball off its
seat. Liquid is free to move past the inlet
valve ball and fill the liquid chamber (see
shaded area).
HOW IT WORKS—AIR DISTRIBUTION SYSTEM
FIGURE 2 When the pressurized
diaphragm, diaphragm A, reaches the limit
of its discharge stroke, the air valve redirects
pressurized air to the back side of diaphragm
B. The pressurized air forces diaphragm
B away from the center while pulling
diaphragm A to the center. Diaphragm B is
now on its discharge stroke. Diaphragm B
forc es the inlet valve b all onto its se at due to
the hydraulic forces developed in the liquid
chamber and manifold of the pump. These
same hydraulic forces lift the discharge
valve ball off its seat, while the opposite
discharge valve ball is forced onto its seat,
forcing fluid to flow through the pump
discharge. The movement of diaphragm A
toward the center of the pump creates a
vacuum within liquid chamber A. Atmospheric pressure forces fluid into the inlet
manifold of the pump. The inlet valve ball
is forced off its seat allowing the fluid
being pumped to fill the liquid chamber.
The Pro-Flo
moving parts: the air valve spool and the pilot spool. The heart of
the system is the air valve spool and air valve. This valve design
incorporates an unbalanced spool. The smaller end of the spool
is pressurized continuously, while the large end is alternately
pressurized then exhausted to move the spool. The spool directs
pressurized air to one air chamber while exhausting the other.
The air causes the main shaft/diaphragm assembly to shif t to
one side — discharging liquid on that side and pulling liquid in
on the other side. When the shaf t reaches the end of its stroke,
the inner piston actuates the pilot spool, which pressurizes and
exhausts the large end of the air valve spool. The repositioning
of the air valve spool routes the air to the other air chamber.
®
patented air distribution system incorporates two
FIGURE 3 At completion of the stroke,
the air valve again redirec ts air to the
back side of diaphragm A, which star ts
diaphragm B on its exhaust stroke. As
the pump reaches its original starting
point, each diaphragm has gone through
one exhaust and one discharge stroke.
This constitutes one complete pumping
cycle. The pump may take several cycles
to completely prime depending on the
conditions of the application.
WIL-11241- E-03 3 WILDEN PUMP & ENGINEERING, LLC
Page 6
Section 4
DIMENSIONAL DRAWINGS
P400 Polypropylene
DIMENSIONS
ITEM METRIC (mm) STANDARD (inch)
A 476 18.8
B 81 3.2
C 348 13.7
D 602 23.7
E 665 26.2
F 677 26.6
G 131 5.2
H 138 5.4
J 300 11.8
K 351 13.8
L 324 12.8
M 268 10.6
N 208 8.2
P 176 6.9
R 12 0.5
S 91 3.6
DIN FLANGE
T 110 DIA. 4.3 DIA.
U 150 DIA. 5.9 DIA.
V 18 DIA. 0.7 DIA.
ANSI FLANGE
T 98 DIA. 3.9 DIA.
U 127 DIA. 5.0 DIA.
V 16 DIA. 0.6 DIA.
LW0324 REV. A
P400 PVDF
DIMENSIONS
ITEM METRIC (mm) STANDARD (inch)
A 471 18.5
B 83 3.2
C 345 13.6
D 596 23.4
E 659 25.9
F 670 26.4
G 130 5.1
H 137 5.4
J 300 11.8
K 348 13.7
L 319 12.6
M 264 10.4
N 205 8.1
P 174 6.9
R 12 0.5
S 91 3.6
DIN FLANGE
T 110 DIA. 4.3 DIA.
U 149 DIA. 5.9 DIA.
V 18 DIA. 0.7 DIA.
ANSI FLANGE
T 98 DIA. 3.9 DIA.
U 126 DIA. 5.0 DIA.
V 16 DIA. 0.6 DIA.
LW0325 REV. A
WILDEN PUMP & ENGINEERING, LLC 4 WIL-112 41- E- 03
Page 7
Section 5
P400 PLASTIC
RUBBER-FITTED
PERFORMANCE
Ship Weight .......Polypropylene 19 kg (41 lb)
PVDF 27 kg (59 lb)
Air Inlet ................................... 13 mm (1/2")
Inlet ...................................... 38 mm (1-1/2")
Outlet ................................... 38 mm (1-1/2")
Suction Lift ....................... 5.5 m Dry (18.2')
9.0 m Wet (29.5')
Disp. per Stroke1 .............. 1.25 L (0.330 gal)
Max. Flow Rate ............ 454 lpm (120 gpm)
Max. Size Solids ................... 6.4 mm (1/4")
1
Displacement per stroke was calculated at
4.8 bar (70 psig) air inlet pressure against a
2 bar (30 psig) head pressure.
Example: To pump 227 lpm (60 gpm)
against a discharge head pressure of 5.0
bar (73 psig) requires 6.9 bar (100 psig)
and 136 Nm3/h (80 scfm) air consumption.
Caution: Do not exceed 8.6 bar (125 psig)
air supply pressure.
Flow rates indicated on chart were determined by pumping water.
For optimum life and performance, pumps should be specified so that daily operation
parameters will fall in the center of the pump's performance curve.
P400 PLASTIC
TPE-FITTED
Ship Weight .......Polypropylene 19 kg (41 lb)
PVDF 27 kg (59 lb)
Air Inlet ................................... 13 mm (1/2")
Inlet .............................. 38 mm (1-1/2")
Outlet ........................... 38 mm (1-1/2")
Suction Lift ....................... 4.8 m Dry (15.9')
9.3 m Wet (30.6')
Disp. per Stroke1 ............ 1.34 L (0.353 gal)
Max. Flow Rate ............ 454 lpm (120 gpm)
Max. Size Solids .................... 6.4 mm (1/4")
1
Displacement per stroke was calculated at
4.8 bar (70 psig) air inlet pressure against a
2 bar (30 psig) head pressure.
Example: To pump 151 lpm (40 gpm)
against a discharge head pressure of 4.3
bar (63 psig) requires 5.5 bar (80 psig) and
68 Nm3/h (40 scfm) air consumption.
Caution: Do not exceed 8.6 bar (125 psig)
air supply pressure.
Flow rates indicated on chart were determined by pumping water.
For optimum life and performance, pumps should be specified so that daily operation
parameters will fall in the center of the pump's performance curve.
WIL-11241- E-03 5 WILDEN PUMP & ENGINEERING, LLC
Page 8
PERFORMANCE
P400 PLASTIC
REDUCED-STROKE PTFE-FITTED
Ship Weight .......Polypropylene 19 kg (41 lb)
PVDF 27 kg (59 lb)
Air Inlet ................................... 13 mm (1/2")
Inlet ...................................... 38 mm (1-1/2")
Outlet ................................... 38 mm (1-1/2")
Suction Lift ....................... 3.3 m Dry (10.8')
9.7 m Wet (31.8')
Disp. per Stroke
Max. Flow Rate .............. 318 lpm (84 gpm)
Max. Size Solids .................... 6.4 mm (1/4")
1
Displacement per stroke was calculated at
4.8 bar (70 psig) air inlet pressure against a
2 bar (30 psig) head pressure.
Example: To pump 178 lpm (47 gpm)
against a discharge head pressure of 3.4
bar (50 psig) requires 5.5 bar (80 psig) and
136 Nm3/h (80 scfm) air consumption.
Caution: Do not exceed 8.6 bar (125 psig)
air supply pressure.
1
............ 0.59 L (0.155 gal)
Flow rates indicated on chart were determined by pumping water.
For optimum life and performance, pumps should be specified so that daily operation
parameters will fall in the center of the pump's performance curve.
P400 PLASTIC
FULL-STROKE PTFE-FITTED
Ship Weight .... Polypropylene 19 kg (41 lb)
PVDF 27 kg (59 lb)
Air Inlet ................................... 13 mm (1/2”)
Inlet ......................................38 mm (1-1/2”)
Outlet ...................................38 mm (1-1/2”)
Suction Lift ............................5.7 Dry (18.7’)
9.3 m Wet (30.6’)
Disp. Per Stroke
Max. Flow Rate ...........424 lpm (111.9 gpm)
Max. Size Solids ....................6.4 mm (1/4”)
1
Displacement per stroke was calculated at
4.8 bar (70 psig) air inlet pressure against a
2.1 bar (30 psig)head pressure.
Example: To pump 337 lpm (89 gpm)
against a discharge head of 1.4 bar (20
psig) requires 5.5 bar (80 psig) and 147
Nm³/h (93 scfm) air consumption.
Caution: Do not exceed 8.6 bar (125 psig)
air supply pressure.
1
....................1.1 L (.30 gal)
20[34]
40[68]
60[102]
80[136]
100[170]
10 20 30 40 50 60 70 80 90 100 110 120
[38] [76] [114] [151] [189] [227] [265] [303] [341] [379] [416] [454]
Flow rates indicated on chart were determined by pumping water.
For optimum life and performance, pumps should be specified so that daily operation
parameters will fall in the center of the pump's performance curve.
WILDEN PUMP & ENGINEERING, LLC 6 WIL-112 41- E- 03
Page 9
SUCTION-LIFT CURVES
P400 PLASTIC
SUCTION-LIFT
CAPABILITY
Suction-lift curves are calibrated for
pumps operating at 305 m (1,000')
above sea level. This chart is meant
to be a guide only. There are many
variables that can affect your
pump's operating characteristics.
The number of intake and discharge
elbows, viscosity of pumping fluid,
elevation (atmospheric pressure)
and pipe friction loss all affect the
amount of suction lift your pump will
attain.
WIL-11241- E-03 7 WILDEN PUMP & ENGINEERING, LLC
Page 10
Section 6
SUGGESTED INSTALLATION
Wilden pumps are designed to meet the performance
requirements of even the most demanding pumping
applications. They have been designed and manufactured
to the highest standards and are available in a variety of
liquid path materials to meet your chemical resistance
needs. Refer to the performance section of this manual for
an in-depth analysis of the performance characteristics of
your pump. Wilden offers the widest variety of elastomer
options in the industry to satisfy temperature, chemical
compatibility, abrasion resistance and flex concerns.
The suction-pipe size should be at least the equivalent or
larger than the diameter size of the suction inlet on your
Wilden pump. The suction hose must be non-collapsible,
reinforced type as these pumps are capable of pulling a high
vacuum. Discharge piping should also be the equivalent
or larger than the diameter of the pump discharge which
will help reduce friction losses. It is critical that all fittings
and connections are airtight or a reduction or loss of pump
suction capability will result.
INSTALLATION: Months of careful planning, study,
and selection efforts can result in unsatisfactory pump
performance if installation details are left to chance.
Premature failure and long term dissatisfaction can be
avoided if reasonable care is exercised throughout the
installation process.
LOCATION: Noise, safety, and other logistical factors usually
dictate where equipment will be situated on the production
floor. Multiple installations with conflicting requirements
can result in congestion of utility areas, leaving few choices
for additional pumps.
Within the framework of these and other existing conditions,
every pump should be located in such a way that several
key factors are balanced against each other to maximum
advantage.
ACCESS: First of all, the location should be accessible. If
it’s easy to reach the pump, maintenance personnel will
have an easier time carrying out routine inspections and
adjustments. Should major repairs become necessary, ease
of access can play a key role in speeding the repair process
and reducing total downtime.
AIR SUPPLY: Every pump location should have an air line
large enough to supply the volume of air necessary to
achieve the desired pumping rate. Use air pressure up to
a maximum of 8.6 bar (125 psig) depending on pumping
requirements.
For best results, the pumps should use a 5µ (micron) air
filter, needle valve and regulator. The use of an air filter
before the pump will ensure that the majority of any pipeline
contaminants will be eliminated.
SOLENOID OPERATION: When operation is controlled by a
solenoid valve in the air line, three-way valves should be
used. This valve allows trapped air between the valve and
the pump to bleed off which improves pump performance.
Pumping volume can be estimated by counting the number
of strokes per minute and then multiplying the figure by the
displacement per stroke.
MUFFLER: Sound levels are reduced below OSHA
specifications using the standard Wilden muffler. Other
mufflers can be used to further reduce sound levels, but
they usually reduce pump performance.
ELEVATION: Selecting a site that is well within the pump’s
dynamic-lift capability will assure that loss-of-prime issues will
be eliminated. In addition, pump efficiency can be adversely
affected if proper attention is not given to site location.
PIPING: Final determination of the pump site should not be
made until the piping challenges of each possible location
have been evaluated. The impact of current and future
installations should be considered ahead of time to make
sure that inadvertent restrictions are not created for any
remaining sites.
The best choice possible will be a site involving the
shortest and straightest hook-up of suction and discharge
piping. Unnecessary elbows, bends, and fittings should
be avoided. Pipe sizes should be selected to keep friction
losses within practical limits. All piping should be supported
independently of the pump. In addition, the piping should
be aligned to avoid placing stress on the pump fittings.
Flexible hose can be installed to aid in absorbing the forces
created by the natural reciprocating action of the pump. If the
pump is to be bolted down to a solid location, a mounting
pad placed between the pump and the foundation will assist
in minimizing pump vibration. Flexible connections between
the pump and rigid piping will also assist in minimizing
pump vibration. If quick-closing valves are installed at any
point in the discharge system, or if pulsation within a system
becomes a problem, a surge suppressor (SD Equalizer
should be installed to protect the pump, piping and gauges
from surges and water hammer.
If the pump is to be used in a self-priming application, make
sure that all connections are airtight and that the suction lift is
within the model’s ability. NOTE: Materials of construction and
elastomer material have an effect on suction lift parameters.
Please refer to the performance section for specifics.
When pumps are installed in applications involving flooded
suction or suction head pressures, a gate valve should be
installed in the suction line to permit closing of the line for
pump service.
Pumps in service with a positive suction head are most efficient
when inlet pressure is limited to 0.5–0.7 bar (7–10 psig).
Premature diaphragm failure may occur if positive suction
is 0.7 bar (10 psig) and higher.
NOTE: Pro-Flo
ALL WILDEN PUMPS ARE CAPABLE OF PASSING SOLIDS.
A STRAINER SHOULD BE USED ON THE PUMP INTAKE TO
ENSURE THAT THE PUMP'S RATED SOLIDS CAPACITY IS
NOT EXCEEDED.
CAUTION: DO NOT EXCEED 8.6 BAR (125 PSIG) AIR
SUPPLY PRESSURE.
®
pumps are not submersible.
®
)
WILDEN PUMP & ENGINEERING, LLC 8 WIL-11241- E-03
Page 11
SUGGESTED OPERATION & MAINTENANCE
This illustration is a generic
representation of an air-operated
double-diaphragm pump.
NOTE: In the event of a power failure, the shut off
valve should be closed, if the restarting of the pump is
not desirable once power is regained.
AIR-OPERATED PUMPS: To stop the pump from
operating in an emergency situation, simply close
the shut-off valve (user-supplied) installed in the air
supply line. A properly functioning valve will stop the
air supply to the pump, therefore stopping output. This
shut-of f valve should be located far enough away from
the pumping equipment such that it can be reached
safely in an emergency situation.
WIL-11241- E-03 9 WILDEN PUMP & ENGINEERING, LLC
Page 12
SUGGESTED OPERATION & MAINTENANCE
OPERATION: The P400 are pre-lubricated, and do not
require in-line lubrication. Additional lubrication will
not damage the pump, however if the pump is heavily
lubricated by an external source, the pump’s internal
lubrication may be washed away. If the pump is then
moved to a non-lubricated location, it may need to be
disassembled and re-lubricated as described in the
DISASSEMBLY/REASSEMBLY INSTRUCTIONS.
Pump discharge rate can be controlled by limiting
the volume and/or pressure of the air supply to the
pump. An air regulator is used to regulate air pressure.
A needle valve is used to regulate volume. Pump
discharge rate can also be controlled by throttling
the pump discharge by partially closing a valve in
the discharge line of the pump. This action increases
friction loss which reduces flow rate. (See Section 5.)
This is useful when the need exists to control the pump
from a remote location. When the pump discharge
pressure equals or exceeds the air supply pressure,
the pump will stop; no bypass or pressure relief valve
is needed, and pump damage will not occur. The
pump has reached a “deadhead” situation and can be
TROUBLESHOOTING
restarted by reducing the fluid discharge pressure or
increasing the air inlet pressure. Wilden P400 pumps
run solely on compressed air and do not generate
heat, therefore your process fluid temperature will not
be affected.
MAINTENANCE AND INSPECTIONS: Since each
application is unique, maintenance schedules may
be different for every pump. Frequency of use, line
pressure, viscosity and abrasiveness of process fluid
all affect the parts life of a Wilden pump. Periodic
inspections have been found to offer the best
means for preventing unscheduled pump downtime.
Personnel familiar with the pump’s construction and
service should be informed of any abnormalities that
are detected during operation.
RECORDS: When service is required, a record should
be made of all necessary repairs and replacements.
Over a period of time, such records can become a
valuable tool for predicting and preventing future
maintenance problems and unscheduled downtime. In
addition, accurate records make it possible to identify
pumps that are poorly suited to their applications.
Pump will not run or runs slowly.
1. Ensure that the air inlet pressure is at least 0.4 bar
(5 psig) above startup pressure and that the differential
pressure (the difference between air inlet and liquid
discharge pressures) is not less than 0.7 bar (10 psig).
2. Check air inlet filter for debris (see SUGGESTED
INSTALLATION).
3. Check for extreme air leakage (blow by) that would
indicate worn seals /bores in the air valve, pilot
spool, main shaft.
4. Disassemble pump and check for obstructions in
the air passageways or objects that would obstruct
the movement of internal parts.
5. Check for sticking ball check valves. If material being
pumped is not compatible with pump elastomers,
swelling may occur. Replace ball check valves and
seals with proper elastomers. Also, as the check
valve balls wear out, they become smaller and can
become stuck in the seats. In this case, replace balls
and seats.
6. Check for broken inner piston that will cause the air
valve spool to be unable to shift.
7. Remove plug from pilot spool exhaust.
Pump runs but little or no product flows.
1. Check for pump cavitation; slow pump speed down
to allow thick material to flow into liquid chambers.
2. Verify that vacuum required to lift liquid is not
WILDEN PUMP & ENGINEERING, LLC 10 WIL-11241- E-03
greater than the vapor pressure of the material
being pumped (cavitation).
3. Check for sticking ball check valves. If material being
pumped is not compatible with pump elastomers,
swelling may occur. Replace ball check valves and
seats with proper elastomers. Also, as the check
valve balls wear out, they become smaller and can
become stuck in the seats. In this case, replace balls
and seats.
Pump air valve freezes.
1. Check for excessive moisture in compressed
air. Either install a dryer or hot air generator for
compressed air. Alternatively, a coalescing filter
may be used to remove the water from the
compressed air in some applications.
Air bubbles in pump discharge.
1. Check for ruptured diaphragm.
2. Check tightness of outer pistons (refer to Section 7).
3. Check tightness of fasteners and integrity of
O-rings and seals, especially at intake manifold.
4. Ensure pipe connections are airtight.
Product comes out air exhaust.
1. Check for diaphragm rupture.
2. Check tightness of outer pistons to shaft.
Page 13
Section 7
PUMP DISASSEMBLY
Tools Required:
• 9/16” Wrench
• Adjustable Wrench
• Vise equipped with
soft jaws (such as
plywood, plastic
or other suitable
material)
CAUTION: Before any maintenance or repair is attempted, the compressed air line
to the pump should be disconnected and all air pressure allowed to bleed from the
pump. Disconnect all intake, discharge, and air lines. Drain the pump by turning it
upside down and allowing any fluid to flow into a suitable container. Be aware of
any hazardous effects of contact with your process fluid.
NOTE: The model photographed for these instructions incorporates PTFE
diaphragms, balls, and seats. Models with Rubber diaphragms, balls and seats are
the same except where noted.
Step 1
Please note alignment marks on
liquid chambers. Use to properly
align center section with liquid
chamber.
WIL-11241- E- 0 3 11 WILDEN PUMP & ENGINEERING, LLC
Step 2
Using a 9/16" wrench, loosen the
discharge manifold from the liquid
chambers.
Step 3
Remove the discharge manifold to
expose the valve balls, valve seats
and valve seat O-rings.
Page 14
PUMP DISASSEMBLY
Step 4
Inspect valve balls, valve seats, and
valve seat O-rings for nicks, gouges,
chemical attack or abrasive wear.
Step 5
Using a 9/16” wrench, loosen the
inlet manifold from the liquid
chambers.
Step 6
Remove the inlet manifold, valve
balls, valve seats and valve seat
O-rings and inspect for nicks,
gouges, chemical attack or abrasive
wear.
Step 7
Using a 9/16” wrench, remove
the liquid chamber fasteners that
secure the liquid chamber to the
center section.
WILDEN PUMP & ENGINEERING, LLC 12 WI L-1124 1- E-03
Step 8
Remove the liquid chamber to
expose the diaphragm and outer
piston.
Step 9
Using two adjustable wrenches,
or rotating both diaphragms by
hand (counterclockwise), remove
the diaphragm assembly from the
center section assembly.
Page 15
PUMP DISASSEMBLY
Step 10
Due to varying torque values, one of
the following two situations may occur:
1) The outer piston, diaphragm and
inner piston remain attached to the
shaft and the entire assembly can
be removed from the center section.
2) The outer piston, diaphragm and
inner piston separate from the shaft,
which remains connected to the
opposite side diaphragm assembly.
Step 11
Remove diaphragm assembly from
shaft, secure shaft with soft jaws (a
vise fitted with plywood, plastic or
other suitable material) to ensure
shaft is not nicked, scratched or
gouged. Using an adjustable wrench
or rotating counterclockwise by
hand, remove diaphragm assembly
from shaft.
WIL-11241- E- 0 3 13 WILDEN PUMP & ENGINEERING, LLC
Page 16
AIR DISTRIBUTION SYSTEM (ADS) DISASSEMBLY
Tools Required:
• 3/16” Wrench
• O-ring Pick
CAUTION: Before any maintenance or repair is attempted, the compressed air line
to the pump should be disconnected and all air pressure allowed to bleed from the
pump. Disconnect all intake, discharge, and air lines. Drain the pump by turning it
upside down and allowing any fluid to flow into a suitable container. Be aware of
hazardous effects of contact with your process fluid.
Step 1
Using a 3/16” hex-head wrench,
loosen air valve bolts.
WILDEN PUMP & ENGINEERING, LLC 14 W IL-112 41 - E- 0 3
Step 2
Remove muffler plate and air valve
bolts from air valve assembly,
exposing muffler gasket for
inspection. Replace if necessary.
Step 3
Lift away air valve assembly
and remove air valve gasket for
inspection. Replace if necessary.
Page 17
Section 7B
AIR DISTRIBUTION SYSTEM (ADS) DISASSEMBLY
Step 4
Remove air valve end cap to expose
air valve spool by simply lifting up
on end cap once air valve bolts are
removed. NOTE: Pro-Flo V™ air
valve incorporates an end cap at
both ends of the air valve.
Step 5
Remove the air valve spool from the air
valve body by threading one air valve
bolt into the end of the air valve spool
and gently sliding the spool out of the
air valve body. Inspect seals for signs
of wear and replace entire assembly if
necessary. Use caution when handling
air valve spool to prevent damaging
seals.
removed from assembly. Seals are not
sold separately.
NOTE:
Seals should not be
Step 6
Remove pilot sleeve from center
section. To do so, the air chambers
must be removed from the center
block which will expose the pilot
spool sleeve.
Step 7
Using an O-ring pick, gently remove the O-ring from the opposite side
of the “notched end” on one side of the pilot spool. Gently remove the
pilot spool from pilot spool sleeve and inspect for nicks, gouges and
wear. Replace pilot sleeve or outer sleeve O-rings if necessary. During
re-assembly, never insert the pilot spool into the sleeve with the “notched
end” first, this end incorporates the urethane O-ring and will be damaged
as it slides over the ports cut in the sleeve. NOTE: Seals should not be
removed from pilot spool. Seals are not sold separately.
WIL-11241- E- 0 3 15 WILDEN PUMP & ENGINEERING, LLC
Step 8
Inspect center section seals for
signs of wear. If necessary, remove
seals with O-ring pick and replace.
Page 18
Section 7C
REASSEMBLY HINTS & TIPS
RE ASS E MB LY:
Upon performing applicable maintenance to the air
distrib ution system, t he pump can now be re assembled .
Please refer to the disassembly instructions for photos
and parts placement. To reassemble the pump, follow
the disassembly instructions in reverse order. The air
distribution system needs to be assembled first, then
the diaphragms and finally the wetted path. Please
find the applicable torque specifications on this page.
The following tips will assist in the assembly process.
• Lubricate air valve bore, center section shaft and
pilot spool bore with NLGI grade 2 white EP bearing
grease or equivalent.
• Clean the inside of the center section shaft bore to
ensure no damage is done to new seals.
• A small amount of NLGI grade 2 white EP bearing
grease can be applied to the muffler and air valve
gaskets to locate gaskets during assembly.
• Make sure that the exhaust port on the muffler plate
is centered between the two exhaust ports on the
center section.
• Stainless bolts should be lubed to reduce the
possibility of seizing during tightening.
PRO-FLO® MAXIMUM TORQUE SPECIFICATIONS
Description of Part Torque
®
Pro-Flo
Air Valve Bolts 5.1 N•m (45 in-lb)
Air Chamber to Center Block 27.1 N•m (20 ft-lb)
Outer Piston 47.5 N•m (35 ft-lb)
Manifolds to Liquid Chamber 9.6 N•m (85 in-lb)
Liquid Chamber to Air Chamber 9.6 N•m (85 in-lb)
SHAFT SEAL INSTALLATION:
PRE-INSTALLATION
• Once all of the old seals have been removed, the
inside of the bushing should be cleaned to ensure
no debris is left that may cause premature damage
to the new seals.
INSTALLATION
The following tools can be used to aid in the installation
of the new seals:
Needle-Nose Pliers
Phillips Screwdriver
Electrical Tape
• Wrap electrical tape around each leg of the needle-nose
pliers (heat shrink tubing may also be used). This is done
to prevent damaging the inside surface of the new seal.
• With a new seal in hand, place the two legs of the
needle-nose pliers inside the seal ring. (See Figure A.)
• Open the pliers as wide as the seal diameter will allow,
then with two fingers pull down on the top portion of
the seal to form kidney-shape. (See Figure B.)
• Lightly clamp the pliers together to hold the seal into
the kidney shape. Be sure to pull the seal into as tight
of a kidney shape as possible, this will allow the seal to
travel down the bushing bore easier.
• With the seal clamped in the pliers, insert the seal into
the bushing bore and position the bottom of the seal
into the correct groove. Once the bottom of the seal is
seated in the groove, release the clamp pressure on the
pliers. This will allow the seal to partially snap back to its
original shape.
• After the pliers are removed, you will notice a slight
bump in the seal shape. Before the seal can be properly
resized, the bump in the seal should be removed as
much as possible. This can be done with either the
Phillips screwdriver or your finger. With either the side
of the screwdriver or your finger, apply light pressure
to the peak of the bump. This pressure will cause the
bump to be almost completely eliminated.
• Lubricate the edge of the shaft with NLGI grade 2
white EP bearing grease.
• Slowly insert the center shaft with a rotating motion.
This will complete the resizing of the seal.
• Perform these steps for the remaining seal.
Figure A
SHA FT SE AL
TAPE
WILDEN PUMP & ENGINEERING, LLC 16 WI L-1124 1- E-03
Figure B
SHA FT SE AL
NEEDLE-NOSE
PLIERS
TAPE
Page 19
NOTES
Page 20
Section 8
EXPLODED VIEW AND PARTS LISTING
P400 PLASTIC
EXPLODED VIEW
PLASTIC ADS
FULL-STROKE PTFE FULL-STROKE IPD
REDUCED-STROKE PTFE
LW0328 REV. A
ALL CIRCLED PART IDENTIFIERS ARE INCLUDED IN REPAIR KITS (see section 9).
WILDEN PUMP & ENGINEERING, LLC 18 WI L-1124 1- E-03
Page 21
EXPLODED VIEW AND PARTS LISTING
P400 PLASTIC
Item
Description Qty.
P400/PPPPP
P/N
AIR DISTRIBUTION COMPONENTS
1 Air Valve Assembly, Pro-Flo®
2 O-Ring, End Cap (-225, Ø1.859" x Ø.139") 2 04-2390-52-700 04-2390-52-700
3 End Cap 2 04-2330-20-700 04-2330-20-700
4 Screw, SHC, Air Valve (1/4"-20 x 4-1/2") 4 01-6000-03 01-6000-03
5 Screw, SHC, Air Valve (#10-16 x 1-3/4") 2 04-6351-03 04-6351-03
6 Nut, Square (1/4"-20) 4 00-6505-03 00-6505-03
7 Muffler Plate, Pro-Flo
8 Gasket, Muffler Plate, Pro-Flo
9 Gasket, Air Valve, Pro-Flo
10 Center Block Assembly, Pro-Flo
11 Sleeve, Threaded, Center Block 4 04-7710-08 04-7710-08
12 Removable Pilot Sleeve Assembly 1 04-3882-99 04-3882-99
13 Pilot Spool Retaining O-Ring (-009, Ø.204" x Ø.070") 2 04-2650-49-700 04-2650-49-700
14 Shaft Seal 2 08-3210-55-225 08-3210-55-225
15 Gasket, Center Block Pro-Flo
16 Air Chamber, Pro-Flo
17 Washer, Flat (Ø.406" x Ø.875" x .125") 8 04-6741-03 04-6741-03
18 Screw, HHC (3/8"-16 x 1-1/4") 8 04-6190-03 04-6190-03
19 Bushing Reducer 3/4" MNPT to 1/2" FNPT 1 04-6950-20-700 04-6950-20-700
20 Muffler 3/4" MNPT 1 04-3510-99 04-3510-99
1
®
®
®
® 2
®
®
1 04-2000-20-700 04-2000-20-700
1 04-3180-20-700 04-3180-20-700
1 04-3500-52-700 04-3500-52-700
1 04-2600-52-700 04-2600-52-700
1 04-3110-20 04-3110-20
2 04-3526-56 04-3526-56
2 04-3681-20 04-3681-20
WETTED PATH COMPONENTS
21 Chamber, Liquid 2 04-5005-20 04-5005-21
22 Washer, Plain (Ø.406" x Ø.812" x .065") 32 04-6740-03 04-6740-03
23 Screw, HHCS (3/8"-16 x 3-1/2") 16 04-6191-03 04-6191-03
24 Nut, Hex Flange (3/8"-16) 16 04-6435-03 04-6435-03
25 Screw, HHCS, (3/8"-16 x 1-3/4") 16 04-6181-03 04-6181-03
26 Manifold, Discharge (ANSI) 1 04-5030-20 04-5030-21
Manifold, Discharge (DIN) 1 04-5031-20 04-5031-21
27 Manifold, Inlet (ANSI) 1 04-5090-20 04-5090-21
Manifold, Inlet (DIN) 1 04-5091-20 04-5091-21
GASKETS/VALVE BALLS/VALVE SEATS/VALVE O-RINGS
28 Valve Ball 4
29 Valve Seat 4 04-1125-20 04-1125-21
30 Valve Seat O-Ring (-331, Ø2.225" x Ø.210") 4 *
31 Manifold O-Ring (-340, Ø3.350" x Ø.210") 4 *
* *
FULL-STROKE RUBBER/TPE/PTFE/FSIPD COMPONENTS
32 Shaft, Pro-Flo® Rubber Advanced 1 04-3811-03 04-3811-03
33 Shaft Stud (1/2"-20 x 1-7/8") 2 08-6150-08 08-6150-08
34 Piston, Inner, Full-Stroke Rubber/TPE/PTFE/FSIPD 2 04-3700-01-700 04-3700-01-700
35 Diaphragm, Primary 2 *
Diaphragm, Primary, Full-Stroke PTFE 2 04-1040-55 04-1040-55
Diaphragm, IPD Primary 2 *
36 Diaphragm, Backup, Full-Stroke PTFE 2 *
37 Piston, Outer, Full-Stroke Rubber/TPE/PTFE 2 04-4550-20-500 04-4550-21-500
REDUCED-STROKE PTFE COMPONENTS
32 Shaft, Pro-Flo
34 Piston, Inner, Reduced-Stroke PTFE 2 04-3752-01 04-3752-01
35 Diaphragm, Primary, Reduced-Stroke PTFE 2 04-1010-55 04-1010-55
36 Diaphragm, Backup, Reduced-Stroke PTFE 2 *
37 Piston, Outer, Reduced-Stroke PTFE 2 04-4600-20-500 04-4600-21-500
®
1 04-3842-03 04-3842-03
P400/KKPPP
P/N
*
*
*
*
*
*
LW0329 REV. A
PARTS LISTING
1
Air Valve Assembly includes item
numbers 2 and 3.
2
Center Block Assembly includes
items 10 and 14.
BSP to NPT Air Line Reducer
Bushing (P/N 04-6950-23-702) is
available upon request.
0502 Specialty Code = PFA-Coated
Hardware
0504 Specialty Code = DIN Flange
*Refer to Elastomer Chart (see
Section 9).
All boldface items are primary
wear parts.
WIL-11241- E-03 19 WILDEN PUMP & ENGINEERING, LLC
Page 22
Section 9
ELASTOMER OPTIONS
P400 Plastic
MATERIAL DIAPHRAGMS (2)
Polyurethane 04-1010-50 N/A N/A 04-1022-50 N/A N/A
Neoprene 04-1010-51 N/A N/A N/A N/A N/A
Buna-N 04-1010-52 N/A N/A N/A N/A N/A
®
Geolast
EPDM 04-1010-54 N/A N/A N/A N/A N/A
FKM 04-1010-53 N/A N/A N/A N/A N/A
Saniflex™ 04-1010-56 N/A 04-1065-56 04-1022-56 N/A N/A
PTFE N/A 04-1040-55 N/A N/A N/A 04-1010-55
PTFE Encap. (FKM) N/A N/A N/A N/A N/A N/A
FDA Wil-Flex™ 04-1010-57 N/A 04-1065-57 04-1022-57 04-1031-57 N/A
Wil-Flex™ 04-1010-58 N/A N/A 04-1022-58 N/A N/A
Polypropylene N/A N/A N/A N/A N/A N/A
PVDF N/A N/A N/A N/A N/A N/A
MATERIAL
Polyurethane N/A 04-1080-50 N/A N/A N/A
Neoprene 04-1060-51 04-1080-51 N/A N/A N/A
Buna-N N/A 04-1080-52 N/A 08-1300-52-500 04-1371-52
®
Geolast
EPDM 04-1060-54 04-1080-54 N/A N/A N/A
FKM N/A 04-1080-53 N/A N/A N/A
Saniflex™ 04-1060-56 04-1080-56 N/A N/A N/A
PTFE N/A 04-1080-55 N/A N/A N/A
PTFE Encap. (FKM) N/A N/A N/A 08-1300-60-500 04-1371-60
FDA Wil-Flex™ N/A 04-1080-57 N/A N/A N/A
Wil-Flex™ N/A 04-1080-58 N/A 08-1300-58-500 04-1371-58
Polypropylene N/A N/A 04-1125-20 N/A N/A
PVDF N/A N/A 04-1125-21 N/A N/A
Backup diaphragms used with PTFE diaphragms only.
N/A N/A N/A 04-1022-15 N/A N/A
REDUCED-STROKE
BACKUP
DIAPHR AGMS (2) VALVE BALLS (4) VALVE SE ATS (4)
N/A N/A N/A N/A N/A
FULL-STROKE
DIAPHRAGMS (2)
FULL-STROKE
BACKUP
DIAPHR AGMS (2)
EZ-INSTSALL
DIAPHRAGMS (2)
VALVE SEAT
O-RINGS ( 4)
FULL-STROKE IPD
DIAPHRAGMS (2)
MANIFOLD
O-RINGS ( 4)
LW0329 REV. A
REDUCED-STROKE
DIAPHRAGMS (2)
WILDEN PUMP & ENGINEERING, LLC 20 WIL-112 41 - E- 0 3
Page 23
WARRANTY
Each and every product manufactured by Wilden Pump and Engineering, LLC is built to meet the highest
standards of quality. Every pump is functionally tested to insure integrity of operation.
Wilden Pump and Engineering, LLC warrants that pumps, accessories and parts manufactured or supplied by
it to be free from defects in material and workmanship for a period of five (5) years from date of installation or
six (6) years from date of manufacture, whichever comes first. Failure due to normal wear, misapplication, or
abuse is, of course, excluded from this warranty.
Since the use of Wilden pumps and parts is beyond our control, we cannot guarantee the suitability of any pump
or part for a particular application and Wilden Pump and Engineering, LLC shall not be liable for any consequential
damage or expense arising from the use or misuse of its products on any application. Responsibility is limited
solely to replacement or repair of defective Wilden pumps and parts.
All decisions as to the cause of failure are the sole determination of Wilden Pump and Engineering, LLC.
Prior approval must be obtained from Wilden for return of any items for warranty consideration and must be
accompanied by the appropriate MSDS for the product(s) involved. A Return Goods Tag, obtained from an
authorized Wilden distributor, must be included with the items which must be shipped freight prepaid.
The foregoing warranty is exclusive and in lieu of all other warranties expressed or implied (whether written or oral)
including all implied warranties of merchantability and fitness for any particular purpose. No distributor or other
person is authorized to assume any liability or obligation for Wilden Pump and Engineering, LLC other than expressly
provided herein.
PLEASE PRINT OR TYPE AND FAX TO WILDEN
PUMP INFORMATION
Item # Serial #
Company Where Purchased
YOUR INFORMATION
Company Name
Industry
Name Title
Street Address
City State Postal Code C ountry
Telephone Fax E-mail Web Address
Number of pumps in facility? Number of Wilden pumps?
Types of pumps in facility (check all that apply): Diaphragm
Media being pumped?
Other
Centrifugal
Gear
Submersible
Lobe
How did you hear of Wilden Pump?
Other
Trade Journal
Trade Show
Internet/ E-mail
Distributor
ONCE COMPLETE, FAX TO (909) 783-3440
OR GO TO PSGDOVER.COM > WILDEN > SUPPORT TO COMPLETE THE WARRANTY REGISTRATION ONLINE
NOTE: WARRANTY VOID IF PAGE IS NOT FAXED TO WILDEN OR SUBMITTED ONLINE VIA THE PSGDOVER.COM WEBSITE
WILDEN PUMP & ENGINEERING, LLC
Page 24
PSG
22069 Van Buren St., Grand Terrace, CA 92313-5607
P: +1 (909) 422-1730
• F: +1 (909) 783-3440
wildenpump.com
Where Innovation Flows
PSG® reserves the right to modify the information and illustrations contained in this document without prior notice. This is a non-contractual document. 11-2018
Authorized PSG Representative:
Copyrigh t ©2018, PS G®, A Dover Compa ny
REPLACES WIL-11241-E-02
WI L-11241 - E - 03
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