Wilden HS400S User Manual

EOM

Engineering

Operation &

Maintenance

HS400S

Advanced™ Metal Pump

Where Innovation Flows

wildenpump.com

USE

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 DRAWING ..............................................4

SECTION 5 PERFORMANCE

HS400S Performance

TPE-Fitted ..................................................... 5

Suction-Lift Curve ..................................................... 6

SECTION 6 SUGGESTED INSTALLATION, OPERATION & TROUBLESHOOTING ........7

SECTION 7 DISASSEMBLY / REASSEMBLY ........................................10

Air Valve / Center Section Disassembly ......................................15

Reassembly Hints & Tips ..................................................17

SECTION 8 EXPLODED VIEW & PARTS LISTING

HS400S Metal ...........................................................18

O

I

I

&

I

s

s

a

l

C

NON

U.S. Clean Air Act

Amendments of 1990

D

e

p

l

e

t

i

n

z

o

n

e

s

e

c

n

a

t

s

b

u

S

g

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 p erformance .
Pump is pre-lubed.

TEMPERATURE LIMITS:

Polypropylene 0°C to 79°C 32°F to 175°F
PVDF –12°C to 107°C 10°F to 225°F
PFA –7°C to 107°C 45°F to 225°F
Neoprene –18°C to 93°C 0°F to 200°F
Buna-N –12°C to 82°C 10°F to 180°F
EPDM –51°C to 138°C –60°F to 280°F
Viton

®

FKM –40°C to 177°C –40°F to 350°F
Wil-Flex™ –40°C to 107°C –40°F to 225°F
Saniflex™ –29°C to 104°C –20°F to 220°F
Polyurethane –12°C to 66°C 10°F to 150°F

Polytetrafluoroethylene (PTFE)1 4°C to 104°C 40°F to 220°F

Nordel

®

EPDM –51°C to 138°C –60°F to 280°F
Nylon –18°C to 93°C 0°F to 200°F
Acetal –29°C to 82°C –20°F to 180°F

SIPD PTFE
SIPD PTFE

Geolast

1

with Neoprene-backed

with

EPDM-backed 4°C to 137°C 40°F to 280°F

®

–40°C to 82°C –40°F to 180°F

4°C to 149°C (40°F to 300°F) - 13 mm (1/2") and 25 mm (1") models only.

4°C to 93°C 40°F to 200°F

NOTE: Not all materials are available for all
models. Refer to Section 2 for the material
options available for your pump.

CAUTION: The process fluid and cleaning fluids

must be chemically compatible with all wetted
pump components. Consult Chemical Resistance
Guide.

CAUTION: Do not exceed 82°C (180°F) air inlet

temperature for Pro-Flo® SHIFT models.

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 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.

CAUTION: When choosing pump materials, be

sure to check the temperature limits for all wetted
components. Example: Viton® 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.

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® SHIFT is available in

both single-point exhaust (submersible) and
standard (non-submersible) options. Do not use
standard Pro-Flo® SHIFT models in submersible
applications. Turbo-Flo™ pumps are also
available in a single-point exhaust (submersible)
configuration.

CAUTION : Tighten all hardware prior to installation.

WIL-11112- E- 01 1 WILDEN PUMP & ENGINEERING, LLC

Section 2

WILDEN PUMP DESIGNATION SYSTEM

HS400S METAL

38 mm (1-1/2”) Pump
Maximum Flow Rate:
227 lpm (60 gpm)

LEGEND

XHS400S / XXX XX / X XX / XX / XXX / XXXX

MODEL

MATERIAL CODES

MODEL

XHS400S= HIGH PRESSURE SIMPLEX/

WETTED PARTS
AND OUTER PISTON

AS = ALUMINUM / STAINLESS STEEL

AIR CHAMBERS

A = ALUMINUM

ATEX

DIAPHRAGMS

VALVE BALLS

AIR VALVE

CENTER BLOCK

AIR CHAMBERS

OUTER PISTON

WETTED PARTS

CENTER BLOCK

A = ALUMINUM

AIR VALVE

A = ALUMINUM

DIAPHRAGMS

FWS = SANITARY WIL-FLEX
[Santoprene® (Two Orange
Dots)]

™

O-RINGS

VALVE SEAT

SPECIALTY
CODE

(if applicable)

VALVE BALLS

WF = WIL-FLEX
[Santoprene® (Orange Dot)]

VALVE SEAT

A = ALUMINUM

VALVE SEAT O-RINGS

TF = PTFE (White)

™

SPECIALTY CODES

0320 Single-Point Exhaust
0504 DIN flange

NOTE: MOST ELASTOMERIC MATERIALS USE COLORED DOT FOR IDENTIFICATION.

WILDEN PUMP & ENGINEERING, LLC 2 WIL-11112- E- 01

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.

FIGURE 1 When air pre ssure is supplied
to the pum p, the air valve dir ects pr essure
to the back side of the diaphragm A. The
compressed air moves the diaphragm
away from the center section 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
the atmosphere through the exhaust
port. The movement of diaphragm B
towards the center section of the pump
creates a vacuum within the chamber B.
Atmospheric pressure forces fluid into
the inlet manifold forcing the inlet valve
ball off of 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 Once the shaft has reached
the end of its stroke, the air valve redirects
pressurized air to the back side of the
diaphragm B. This pressurized air is
also directed to the opposite side of the
diaphragm A through a passageway that
is routed through the common shaft and
outer piston. The pressurized air forces
diaphragm B away from the center
section while also pushing diaphragm
A to the center section. Diaphragm B is
now on its discharge stroke. Diaphragm B
forces the inlet valve ball onto its seat due
to the hydraulic forces developed in the
liquid chamber and manifold of the pump.
These same hydraulic forces lift the
discharge valve ball of f of its seat, forcing
fluid to flow through the pump discharge.
The pressure on diaphragm A creates a
force on the shaft that is combined with
the pressure from diaphragm B. This total
load is transferred to the liquid creating a
liquid pressure that is two times greater
than the supplied air pressure.

The heart of the patented Pro-Flo® SHIFT Air Distribution System
(ADS) is the air valve assembly. The air valve design incorporates
an unbalanced spool with the small end of the spool being
pressurized continuously while the large end of the spool is
alternately pressurized, then exhausted to move the spool. The
air valve spool directs pressurized air to one chamber while
exhausting the other. The air forces the main shaf t /diaphragm
assembly to move to one side – discharging liquid on that side
and pulling liquid in on the other side. When the shaf t reaches
the end of the stroke, the inner piston ac tuates the pilot spool,
which controls the air to the large end of the air valve spool. The
repositioning of the air valve spool routes the air to the other air
chamber. The air control spool allows air to flow freely into the air
chamber for the majority of each pump stroke, but it significantly
restricts the flow of air into the air chamber when activated by the
inner piston near the end of the each stroke.

FIGURE 3 At completion of the stroke,
the air valve again redirects air to the
back side of the diaphragm A, which
star ts diaphragm B on its exhaust s troke.
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
condition of the application.

WIL-11112- E- 01 3 WILDEN PUMP & ENGINEERING, LLC

Section 4

DIMENSIONAL DRAWINGS

HS400S ALUMINUM

DIMENSIONS

ITEM METRIC (mm) STANDARD (inch)

A 343 13.5
B 79 3.1
C 335 13.2
D 531 20.9
E 605 23.8
F 122 4.8
G 325 12.8
H 48 1.9
J 132 5.2
K 320 12.6

L 531 20.9
M 244 9.6
N 206 8.1

P 152 6.0

R 170 6.7

S 10 0.4

DIN (mm) ANSI (inch)
T 150 DIA. 5.0 DIA.
U 110 DIA. 3.9 DIA.
V 18 DIA. 0.6 DIA.

LW0287 REV. A

WILDEN PUMP & ENGINEERING, LLC 4 WIL-11112- E- 01

Section 5

PERFORMANCE

HS400S ALUMIMUM

TPE-FITTED

Height ................................. 605 mm (23.8")

Width .................................. 343 mm (13.5")

Depth .................................. 320 mm (12.6")

Ship Weight ............................27 kg (60 lbs)

Air Inlet ................................... 19 mm (3/4”)

Inlet ...................................... 38 mm (1-1/2")

Outlet ................................... 38 mm (1-1/2")

Suction Lift ..........................1.1 m Dry (3.6')

9.0 m Wet (29.5')

Disp. per Stroke ............... 0.26 L (0.07 gal)¹

Max. Flow Rate .............. 227 lpm (60 gpm)

Max. Size Solids .................. 8.0 mm (5/16")

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 45 lpm (12 gpm) against
a discharge head of 4.8 bar (70 psig) requires

4.1 bar (60 psig) and 59 Nm3/h (35 scfm) air
consumption.

Caution: Do not exceed 8.6 bar (125 psig)
air supply pressure.

250

120

20[34]

200

150

psig

100
psig

80
psig

60
psig

40[68]

60[102]

80[136]

16

14

12

10

500

400

300

8

100

6

200

4

100

2

50

40
psig

20
psig

00

10 20 30 40 50 60

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.

[38] [76] [114] [151] [189] [227]

WIL-11112- E- 01 5 WILDEN PUMP & ENGINEERING, LLC

SUCTION—LIFT CURVES

HS400S ALUMIUM
SUCTION-LIFT CAPABILITY

Aluminum Wetted Path (HS400S)

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.

WILDEN PUMP & ENGINEERING, LLC 6 WIL-11112- E- 01

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
wetted-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 six key factors
are balanced against each other to maximum advantage.

ACCESS: First of all, the location should be accessible. If
it is 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.

WIL-11112- E- 01 7 WILDEN PUMP & ENGINEERING, LLC

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 ensure 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 hookup 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 options 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.

SUBMERSIBLE APPLICATIONS:
used for submersible applications. Pro-Flo® SHIFT pumps
are also available in a single-point exhaust (submersible)
configuration.

NOTE: Accu-Flo™ pumps do not have a single-point exhaust
option and are not submersible.

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 [3.4 BAR (50 PSIG) FOR UL-LISTED MODELS.

Turbo-Flo™ pumps can be

®

)

NOTE: This illustration is a generic representation
of an air-operated double-diaphragm pump.

SHUT-OFF VALVE

RELIEF VALVE

(SET TO 250 PSI)

FLEXIBLE

CONNECTION

PRESSURE
GAUGE

SHUT-OFF
VALVE

MUFFLER

PRESSURE OR

VACUUM GAUGE

SHUT-OFF VALVE

SUCTION
LINE

SHUT-OFF VALVE

NOTE: In the event of a power failure, the shut-off
valve should be closed, if restarting of the pump is not
desirable once power is regained.

DISCHARGE

LINE

AIR INLET

RETURN TO TANK

AIR SUPPLY

AIR SHUT-OFF VALVE

COMBINATION
FILTER & REGULATOR

NEEDLE VALVE

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.

WILDEN PUMP & ENGINEERING, LLC 8 WI L-11112- E-01

SUGGESTED OPERATION & MAINTENANCE

OPERATION: The HS400S is pre-lubricated, and does
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. Pump­discharge 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

TROUBLESHOOTING

be restarted by reducing the fluid discharge pressure
or increasing the air inlet pressure. The Wilden
Pro-Flo
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.

®

SHIFT pumps run solely on compressed air

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) which would
indicate worn seals/bores in the air valve, pilot spool
and 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 check valves. If material being
pumped is not compatible with pump elastomers,
swelling may occur. Replace check valves with
proper elastomers.

6. Check for broken inner piston, which 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; decrease pump speed to
allow thick material to flow into liquid chambers.

2. Verify that vacuum required to lift liquid is not
greater than the vapor pressure of the material being
pumped (cavitation).

3. Check for sticking check valves. If material being
pumped is not compatible with pump elastomers,
swelling may occur. Replace check valves with
proper elastomers.

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.

WIL-11112- E- 01 9 WILDEN PUMP & ENGINEERING, LLC

Section 7

PUMP DISASSEMBLY

TOOLS REQUIRED:

• 9/16" Wrench

• 3/4" Wrench

• Adjustable Wrench

• Vise equipped w/soft jaws (such
as plywood, plastic or other
suitable material)

Step 1

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: All O-rings used in the pump are made of special material and at any

of sign of hardness should be replaced with only factory-supplied parts.

Step 2

Step 3

Before starting disassembly, mark
a line from each liquid chamber to
its corresponding air chamber. This
line will assist in proper realignment
during reassembly.

Step 4

Remove the discharge valve ball,
valve seat and valve seat O-ring
from the left liquid chamber and
inspect for nicks, gouges, chemical
attack or abrasive wear. Replace
worn parts with genuine Wilden
parts for reliable performance.

WIL-11112- E- 01 10 WILDEN PUMP & ENGINEERING, LLC

Using a 3/4" wrench, loosen the
discharge manifold from the liquid
chambers.

Step 5

To ensure no excessive wear
or damage has occurred to the
amplification chamber plug O-rings,
remove plugs located between top
and bottom tee sections and elbows
(right side of pump only). Inspect and
replace seat plug O-rings if necessary.
Install Buna® O-ring on air side of plug
and the encapsulated Viton® O-ring on
liquid side of plug.

Remove the discharge manifold to
expose the top-left valve ball.

NOTE: The HS400S pump does not

use valve balls in the amplification
chamber.

Step 6

Using a 3/4" wrench, loosen the inlet
manifold from the liquid chambers.

PUMP DISASSEMBLY

Step 7

Lift liquid chambers and center
section away from inlet manifold
to expose left inlet valve ball, valve
seat and valve seat O-ring. Inspect
for nicks, gouges, chemical attack or
abrasive wear.

Step 10

Using an adjustable wrench,
remove the diaphragm assembly
from diaphragm shaft by turning
counter-clockwise.

Step 8

Using a 9/16" wrench, remove the
liquid chamber from the center
section.

Step 11

After loosening and removing
the diaphragm assembly, remove
opposite liquid chamber

.

Step 9

The liquid chamber should be
removed to expose the diaphragm
and outer piston.

Step 12

After removing the opposite liquid
chamber, the remaining diaphragm
assembly and diaphragm shaft can
be easily removed.

WILDEN PUMP & ENGINEERING, LLC 11 WIL-11112- E- 01

Step 13

To 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, remove diaphragm
assembly from shaft. Inspect all
parts for wear and replace with
genuine Wilden parts, if necessary.

PUMP DISASSEMBLY

AIR PASSAGEWAY

The outer piston on the side of
the amplification chamber has
an air passageway at the center
of the outer piston lug. This air
passageway allows air to flow
from the opposite air chamber to
the amplification chamber. This
principle is how the HS400S high­pressure pump achieves a 2:1 ratio
of inlet air pressure to discharge
pressure. When reassembling the
HS400S pump, the outer piston
(with the air passageway) has to be
positioned on the same side as the
amplification chamber. If it is not
reassembled correctly, the pump
will not operate and process fluid
will enter the air distribution system
through the air passageway located
at the shaft lug.

AIR PASSAGEWAYAIR PASSAGEWAY

This same air passageway continues through the diaphragm shaft, exits
out of the diaphragm shaft via a 90º turn and into the air chamber located
on the wetted side of the pump. The air passageway has to be positioned in
the air chamber on the wetted side of the pump, opposite the amplification
chamber.

WIL-11112- E- 01 12 WILDEN PUMP & ENGINEERING, LLC

AIR VALVE / CENTER SECTION DISASSEMBLY

TOOLS REQUIRED:

• 3/16” Hex-Head Wrench

• 1/4” Hex-Head 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
any hazardous effects of contact with your process fluid.

Step 1

Using a pair of snap-ring pliers,
remove the snap ring from pilot
sleeve.

WILDEN PUMP & ENGINEERING, LLC 13 WI L-1111 2-E- 01

Step 2

Using an O-ring pick, remove O-ring
from modulator spool.

Step 3

Using the appropriate-sized wrench,
loosen and remove the fasteners
that attach the air chamber to center
section.

AIR VALVE / CENTER SECTION DISASSEMBLY

Step 4

Lift away air chamber from center
section and remove center block
gasket. Replace gasket if necessary.

Step 5

Turn assembly over and remove the
pilot spool sleeve from the center
section.

Step 6

Using an O-ring pick, gently remove
the O-ring from the opposite side of
the dimpled end of the pilot spool.

Step 7

Gently remove the pilot spool from
the sleeve and inspect for nicks,
wear or damage. Replace the pilot
spool assembly or sleeve O-rings
if necessary. During reassembly,
never insert the dimpled end of the
pilot spool first, this will damage the
single urethane O-ring by passing it
over the ports in the pilot sleeve.

NOTE: Seals should not be removed
from the assembly. Seals are not
sold separately.

WIL-11112- E- 01 14 WILDEN PUMP & ENGINEERING, LLC

Step 8

Remove modulator spool from
center section. Check for wear to
spool or O-rings and replace if
necessary.

Step 9

Using the appropriate-sized wrench,
loosen the fasteners and lift away
remaining air chamber and center
block gasket from center section.
Replace gasket if necessary.

AIR VALVE / CENTER SECTION DISASSEMBLY

Step 10

Using an O-ring pick, remove
the two (2) shaft bushings from
center block. Inspect and replace
if necessary. Using an O-ring pick,
gently remove the two (2) Glyd™
rings from the center block. Inspect
and replace if necessary.

Step 11

Using an O-ring pick, remove the
two (2) Glyd™ rings from modulator
spool bore. Inspect and replace if
necessary.

Step 12

Using an appropriate-sized wrench,
remove the pilot exhaust muffler.
Inspect for damage or contamination
and replace if necessary.

Step 13

Using an appropriate-sized hex
wrench, loosen and remove the
four (4) air valve bolts from center
section assembly.

WILDEN PUMP & ENGINEERING, LLC 15 WI L-11112- E-01

Step 14

Lift away muffler plate and muffler plate gasket from center block. Inspect
for wear and replace if necessary. Lift away the air valve assembly and
remove air valve gasket. Inspect the gasket and replace if necessary.

AIR VALVE / CENTER SECTION DISASSEMBLY

Step 15

Remove air valve end cap to expose
air valve spool by lifting up on end
cap. Inspect O-ring on end cap using
an O-ring pick. Replace O-ring(s)
if necessary. NOTE: The Pro-Flo
SHIFT air valve incorporates an end
cap at both ends of the air valve.

Step 16

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 the entire
air valve assembly if necessary. Re-insert the spool immediately into air

®

valve body after inspection as the seals expand and cannot be reinserted
after a length of time.

NOTE: Seals should not be removed from the assembly. Seals are not sold
separately.

SINGLE-POINT EXHAUST PRO-FLO® SHIFT

Step 1

Remove pilot exhaust muffler in
pilot bleed port located at the front
of the center block. Install 1/4" NPT
pipe plug (00-7010-08) into bleed
port.

WIL-11112- E- 01 16 WILDEN PUMP & ENGINEERING, LLC

Standard Single-Point Exhaust

Step 2

Next, install an optional single-point exhaust air
valve gasket (04-2638-52). The single-point air valve
gasket can be purchased as a spare part or included

®

with the purchase of a new Pro-Flo

SHIFT pump.

REASSEMBLY HINTS & TIPS

ASS EM B 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. 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 shaft seals.

• A small amount of NLGI grade 2 white EP bearing
grease can be applied to the muffler and air valve
gaskets to lubricate 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-steel bolts should be lubed to reduce the
possibility of seizing during tightening.

• Use a mallet to tap lightly on the large clamp bands
to seat the diaphragm before tightening.

HS400S MAXIMUM TORQUE SPECIFICATIONS

Description Torque

Air Valve 13.6 N•m (120 in-lb)

Center Block to Air Chamber 27.1 N•m (20 ft-lb)

Liquid Chamber to Air Chamber, Aluminum 47.5 N•m (35 ft-lb)

Manifolds, T-Section, Aluminum 27.1 N•m (20 ft-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.

INSTALLATI O N

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 a kidney shape. (See Figure B.)

• Lightly clamp the pliers together to hold the seal in 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 seals.

WILDEN PUMP & ENGINEERING, LLC 17 WI L-11112- E- 01

Figure A

TAPE

SHA FT SE AL

Figure B

SHA FT SE AL

NEEDLE-NOSE

PLIERS

TAPE

Section 8

EXPLODED VIEW & PARTS LISTING

HS400S ALUMINUM

EXPLODED VIEW

9

ALL CIRCLED PART IDENTIFIERS ARE INCLUDED IN CONVERSION KIT (See Section 9).

WILDEN PUMP & ENGINEERING, LLC 18 WI L-11112- E - 0 1

LW0288 REV.B

EXPLODED VIEW & PARTS LISTING

HS400S ALUMINUM

Item

Description Qty.

AIR DISTRIBUTION COMPONENTS

1 Air Valve Assembly, Pro-Flo® SHIFT
2 O-Ring, End Cap (-225, Ø1.859" x Ø.139") 2 04-2390-52-700

3 End Cap 2 04-2340-01
4 Screw, SHC, Air Valve (1/4"-20 x 4 1/2") 6 01-6000-03
5 Muffler Plate, Pro-Flo

6 Gasket, Muffler Plate, Pro-Flo
7 Gasket, Air Valve, Pro-Flo

8 Center Block Assembly, Pro-Flo

9 Pilot Sleeve Assembly 1 04-3880-99
10 Pilot Spool Retaining O-Ring (-009, Ø.208" x Ø.070") 2 04-2650-49-700
11 Seal, Shaft 2 15-3210-55-225
12 Bushing, Shaft 2 15-3306-13
13 Gasket, Center Block Pro-Flo V™ 2 04-3529-52
14 O-Ring, (-210, Ø.734" x Ø.139") 2 04-3209-49
15 Air Control Spool 1 04-3859-03
16 Air Control Spool Retaining O-Ring (-114, Ø.612" x Ø.103") 2 04-3879-50

17 Air Chamber, Pro-Flo V™ 2 04-3694-01
18 Screw, HSFHS (3/8"-16 x 1") 8 71-6250-08
19 Retaining Ring 2 04-3890-03
20 Grounding Screw, (10-32 x 1/2") Self Tapping 1 04-6345-08
21 Muffler 1" MNPT 1 15-3510-99R
22 Bushing, Reducer, 1-1/2" MNPT to 1" FNPT 1 04-6959-08
23 Muffler, 1/4" MNPT 1 04-3240-07

®

SHIFT 1 04-3189-01

1

®

SHIFT 1 04-3509-52

®

SHIFT 1 04-2639-52

®

2

SHIFT

WETTED PATH COMPONENTS

24 Liquid Chamber 2 04-4980-01
25 Washer (3/8") 16 15-6740-08-50
26 Screw, HHC (3/8"-16 x 1-1/4") 16 04-6140-08
27 Discharge Elbow 2 04-5250-01
28 Washer (1/2") 40 04-6730-08
29 Screw, HHC (1/2"-13 x 1-1/2") 8 04-6180-08
30 Screw, HHC (1/2"-13 x 2") 16 04-6210-08
31 Hex Nut (1/2"-13) 16 15-6420-08
32 Tee, Section ANSI, XHS400S 2 04-5181-01

Tee, Section DIN, XHS400S 2 04-5186-01

33 Inlet Elbow 2 04-5210-01

GASKETS/VALVE BALLS/VALVE SEATS/VALVE O-RINGS

34 Manifold O-Ring (-237) (Ø3.359" x Ø.139") 4 04-1370-55
35 Valve Seat O-Ring (-232) (Ø2.734" x Ø.139") 2 04-1205-55
36 Seat, Valve 2 04-1125-01
37 Ball, Valve 2 04-1080-58
38 Gasket, Tee Section Manifold 2 04-1325-55
39 O-Ring (Ø1.484" x Ø.139") Viton

40 Seat, Plug, XHX400S 2 04-1135-01

41 O-Ring (Ø1.484" x Ø.139") Buna-N 2 02-1230-52

®

FULL-STROKE TPE COMPONENTS

42 Shaft 1 04-3845-08
43 Piston, Inner 2 15-3750-01

44 Diaphragm, Primary 2 04-1011-57

45 Piston, Outer 1 15-4600-03
46 Piston, Outer 1 04-4565-03

*See elastomer chart - Section 9

1

Air Valve Assembly includes items 2 and 3.

2

Center Block Assembly includes items 11, 12, 14, 15 and 16.

All boldface items are primary wear parts.

XHS400S/ASAAA

P/N

1 04-2039-01

1 15-3129-01

2 05-1370-60

PARTS LISTING

LW0289 REV. A

WIL-11112- E- 01 19 WILDEN PUMP & ENGINEERING, LLC

NOTES

WILDEN PUMP & ENGINEERING, LLC 20 WIL-11112- E- 01

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 Pos tal C ode Country

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

NOTE: WARRANTY VOID IF PAGE IS NOT FA XED TO WILDEN

Trade Journal

Trade Show

ONCE COMPLETE, FAX TO [phone]

WILDEN PUMP & ENGINEERING, LLC

Internet/ E-mail

Distributor

Where Innovation Flows

22069 Van Buren Street,

Grand Terrace, CA 92313-5607

Telephone: [phone]

Fax: [phone]

22069 Van Buren St., Grand Terrace, CA 92313-5607

P: [phone]

www.maag.com

• F: [phone]

wildenpump.com

PSG

PSG® reserves the right to modify the information and illustrations contained in this document without prior notice. This is a non-contractual document. 07-2015

Authorized PSG Representative:

Copyrigh t ©2015, PS G®, A Dover Compa ny

WI L- 11112 - E - 01