PSG Wilden H1500 Saniflo HS Series Instruction Manual

H1500 HS
Metal Pump
EOM
Engineering
Operation &
Maintenance
wildenpump.com
Where Innovation Flows

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U.S. Clean Air Act
Amendments of 1990
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
H1500 HSTPE-Fitted .............................................................5
Suction-Lift Curves ..............................................................5
SECTION 6 SUGGESTED INSTALLATION, OPERATION & TROUWBLESHOOTING ......6
SECTION 7 DISASSEMBLY / REASSEMBLY ..............................................9
Air Valve/Center Section Disassembly ............................................12
Power Cylinder Reassembly.....................................................17
Reassembly Hints &Tips ........................................................18
Clean in Place - CIP .............................................................19
SECTION 8 EXPLODED VIEW & PARTS LISTING
H1500 Saniflo™ HS.............................................................20
H1500 Saniflo™ HS 1935/2004/EC................................................22
SECTION 9 ELASTOMER OPTIONS ......................................................24
TABLE OF CONTENTS

WIL-12350-E-05 1 WILDEN PUMP & ENGINEERING, LLC
CAUTION: Do not apply compressed air to the ex-
haust port — pump will not function.
CAUTION: Do not over-lubricate air supply — excess
lubrication will reduce pump performance. Pump is
pre-lubed.
TEMPERATURE LIMITS:
NOTE: Not all materials are available for all mod-
els. 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 compo-
nents. 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 proper ground-
ing point when handling flammable fluids and when-
ever discharge of static electricity is a hazard.
CAUTION: Do not exceed 5.9 bar (85 psig) air supply
pressure.
CAUTION: All piping, valves, gauges and other com-
ponents installed on the liquid discharge must have a
minimum pressure rating of 20.7 bar (300 psig).
CAUTION:The discharge pressure generated by this
pump is three times the inlet pressure supplied.
CAUTION:The process fluid and cleaning fluids must
be chemically compatible with all wetted pump com-
ponents. 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 oper-
ating pump. If diaphragm rupture occurs, material
being pumped may be forced out air exhaust.
CAUTION: Before any maintenance or repair is at-
tempted, 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: Before starting disassembly, mark a line from
each liquid chamber to its corresponding air cham-
ber.This line will assist in proper alignment during
reassembly.
CAUTION: Wilden®H1500 High Pressure pumps can-
not be used in submersible applications.
CAUTION:Tighten all hardware prior to installation.
NOTE: When installing PTFE diaphragms, it is impor-
tant to tighten outer pistons simultaneously (turning
in opposite directions) to ensure tight fit. (SeeTorque
Specifications in Section 7.)
CAUTION: Do not over-lubricate air supply – excess
lubrication will reduce pump performance. Pump is
pre-lubricated.
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
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)
14°C to 104°C 40°F to 220°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 with Neoprene-backed 4°C to 104°C 40°F to 220°F
SIPD PTFE with EPDM-backed 4°C to 137°C 40°F to 280°F
Polyethylene 0°C to 70°C 32°F to 158°F
Geolast®–40°C to 82°C –40°F to 180°F
1
4°C to 149°C (40°F to 300°F) - 13 mm (1/2") and 25 mm (1") models only.
Section 1
CAUTIONS—READ FIRST!

WILDEN PUMP & ENGINEERING, LLC 2 WIL-12350-E-05
MODEL
H1500 = HIGH-PRESSURE SANIFLO
HYGIENIC
WETTED PARTS/OUTER PISTON
SS = 316L STAINLESS STEEL /
316L STAINLESS STEEL
SZ = 316L STAINLESS STEEL /
NO PISTON
AIR CHAMBER
S = 316 STAINLESS STEEL
CENTER SECTION
I = POWDER-COATED
ALUMINUM
AIR VALVE
I = POWDER-COATED
ALUMINUM
DIAPHRAGMS
FWL = FULL-STROKE SANITARY
WIL-FLEX™ IPD 1,3
FWS= SANITARY WIL-FLEX™,
EZ-INSTALL [SANTOPRENE®
(TWO ORANGE DOTS)]
1,3
TSS = FULL-STROKE PTFE w/
SANIFLEX™ BACKUP 1,2,3
TSS = FULL-STROKE PTFE w/
SANIFLEX™ BACKUP 1,2,3
TWS= FULL-STROKE PTFE w/
WIL-FLEX™ BACKUP
[Santoprene®(Three Black
Dots)] 1,2,3
VALVE BALLS/MUSHROOM CHECK
FW = SANITARY WIL-FLEX™
[Santoprene®(Two Orange
Dots)] 1,3
TF = PTFE (White)1,2,3
TM = PTFE MUSHROOM CHECK
1,2,3
MANIFOLD GASKET
FE = SANITARY EPDM 1,3
(Green Dot)
FV = SANITARY FKM 1,3
(One White/One Yellow Dot)
TF = PTFE (White) 1,2,3
H1500 SANIFLO™
HYGIENIC SERIES
76 mm (3") Pump
Maximum Discharge
Pressure:
17.2 bar (250 psig)
LEGEND
MATERIAL CODES
SPECIALTY CODES
0770 Saniflo™ HS
0770E Saniflo™ HS (1935/2004/EC)
NOTE: MOST ELASTOMERIC MATERIALS USE COLORED DOT FOR IDENTIFICATION
MODEL SPECIALTY
CODE (required)
MANIFOLD GASKET
VALVE OPTIONS
DIAPHRAGMS
AIR VALVE
CENTER SECTION
AIR CHAMBER
WETTED PARTS/OUTER PISTON
H1500 / XXXXX / XXX / XX / XX / XXXX
Notes:
1 Meets Requirements of FDA CFR21.177
2 Meets Requirements of USPClass VI
3 Meets Requirements of 1935/2004/EC
Section 2
PUMP DESIGNATION SYSTEM

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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 The air valve directs pressur-
ized 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 sepa-
ration 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 oppo-
site 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 port
of the pump. The movement of diaphragm
B toward the center of the pump creates
a vacuum within chamber B. Atmospheric
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).
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 forces the inlet valve ball onto
its seat due to the hydraulic forces devel-
oped 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.
FIGURE 3 At completion of the stroke, the
air valve again redirects air to the back-side
of diaphragm A, which starts 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 condition of the applica-
tion.
The H1500 HS uses an integral power amplifier piston
together with two diaphragms to yield a pressure ratio
of 3:1 [e.g., 5.9 bar (85 psig) air inlet will develop pump
discharge pressures up to 17.2 bar (250 psig)]. Air is simul-
taneously directed behind the amplifier piston as well as
one of the diaphragms via specialized air manifold port-
ing. The sum of the two surface areas is three times that
of the diaphragm.Therefore, the discharge is amplified by
a 3:1 pressure output ratio.
Section 3
HOW IT WORKS—PUMP DISTRIBUTION SYSTEM
HOW IT WORKS—THE POWER PRINCIPLE
B B BA A A

WILDEN PUMP & ENGINEERING, LLC 4 WIL-12350-E-05
Section 4
DIMENSIONAL DRAWING
H1500 HS Vertically-Mounted, Center-
Ported with Ball/Mushroom Valve
DIMENSIONS
ITEM METRIC (mm) STANDARD (inch)
A 599 23.6
B 201 7.9
C 543 21.4
D 678 26.7
E 1156 45.5
F 1209 47.6
G 74 2.9
H 310 12.2
J 490 19.3
K 401 15.8
L 351 13.8
M 318 12.5
N 356 14.0
P 010 0.4
LW0115 REV. A

WIL-12350-E-05 5 WILDEN PUMP & ENGINEERING, LLC
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.
H1500 HS
FULL-STROKE
INTEGRAL PISTON
DIAPHRAGM-FITTED
Ship Weight ..........................115 kg (254 lb)
Air Inlet .................................. 19 mm (3/4")
Inlet ........................................... 76 mm (3")
Outlet ........................................ 76 mm (3")
Suction Lift ..................... 3.8 m Dry (12.5')
9.0 m Wet (29.5')
Disp. Per Stroke1................. 1.2 L (0.32 gal)
Max. Flow Rate ............ 291 lpm (77 gpm)
Max. Size Solids.................. 6.4 mm (1/4")
1Displacement per stroke was calculated at
4.8 bar (70 psig) air inlet pressure against a
9.6 bar (140 psig) head pressure.
Example: To pump 83.2 lpm (22 gpm)
against a discharge head of 9.6 bar (140
psig) requires 4.1 bar (60 psig) and 123
Nm3/h (72 scfm) air consumption. (See dot
on chart.)
Caution: Do not exceed 5.9 bar (85 psig)
air supply pressure.
H1500 HS
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.
Section 5
PERFORMANCE
SUCTION-LIFT CURVES

WILDEN PUMP & ENGINEERING, LLC 6 WIL-12350-E-05
Wilden®pumps are designed to meet the performance
requirements of even the most demanding pumping appli-
cations. 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 analy-
sis of the performance characteristics of your pump. Wilden®
offers the widest variety of elastomer options in the indus-
try to satisfy temperature, chemical-compatibility, abrasion-
resistance and flex concerns.
The suction pipe size should be equivalent or larger than
the diameter 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 equivalent or larger than the diameter
of the pump discharge to minimize 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 selec-
tion 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 advan-
tage.
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. Do not exceed the maximum rated
air pressure.
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 contami-
nants 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 specifi-
cations 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 loca-
tion.
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 instal-
lations 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 short-
est 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 minimiz-
ing pump vibration. Flexible connections between the pump
and rigid piping will also assist in minimizing pump vibra-
tion. 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 capability.
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 effi-
cient 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.
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 5.9 BAR (85 PSIG) AIR SUPPLY
PRESSURE.
Section 6
SUGGESTED INSTALLATION

WIL-12350-E-05 7 WILDEN PUMP & ENGINEERING, LLC
NOTE: In the event of a power failure, the air shut-off valve
should be closed if 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 air shut-off
valve (user-supplied) installed in the air supply line. A prop-
erly functioning valve will stop the air supply to the pump,
therefore stopping output. This air shut-off valve should be
located far enough away from the pumping equipment such
that it can be reached safely in an emergency situation.
This illustration is a generic
representation of an air-operated
double-diaphragm pump.
SUGGESTED INSTALLATION

WILDEN PUMP & ENGINEERING, LLC 8 WIL-12350-E-05
OPERATION: The H1500 HS pumps 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 exter-
nal 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 regula-
tor 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 restarted by reducing
the fluid discharge pressure or increasing the air inlet pressure.
The H1500 HS 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 prevent-
ing 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 iden-
tify pumps that are poorly suited to their applications.
TROUBLESHOOTING
SUGGESTED OPERATION & MAINTENANCE
Pump will not run or runs slowly.
1. With the use of the flow curve located in the perfor-
mance section of this EOM, verify air pressure and
volume required for your application. If inlet air pres-
sure is too low, the H1500 HS pump will not operate.
2. Check air inlet filter for debris (see SUGGESTED
INSTALLATION).
3. Disassemble pump and check for obstructions in the
air passageways or objects that would obstruct the
movement of internal parts.
4. 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 balls
wear out, they become smaller and can become stuck
in the seats. In this case, replace the balls and seats.
5. CInspect the inlet pressure relief valve for damage.
Replace if necessary with genuine Wilden® parts.
6. Inspect the center block seals for damage. Replace if
necessary.
7. Check for broken inner pistons which will cause the
air valve spool to be unable to shift.
8. 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 greater
than the vapor pressure of the material being pumped.
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.
4. Check tightness of inlet and discharge connections.
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 the
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.
3. Check tightness of fasteners that connect the inner
piston to the outer piston.

WIL-12350-E-05 9 WILDEN PUMP & ENGINEERING, LLC
Step 2
Loosen the fasteners for the clamp band using an appropri-
ate-sized wrench.
Step 3
Remove the clamp band assemblies on discharge manifold.
TOOLS REQUIRED:
• Combination wrench set
and/or adjustable wrench-
es
• Vise equipped with soft
jaws (such as plywood,
plastic or other suitable
materials)
Step 1
Prior to assembly, place alignment marks on the liquid cham-
bers and air chambers to assist with proper alignment during
reassembly.
• Hex wrenches
• Ratchet and socket set
• O-ring pliers
• Snap-ring pliers
• Torque wrench
Step 4
Remove the discharge manifold and manifold gaskets.
CAUTION: Before any maintenance or repair is attempted,
the compressed air line to the pump should be discon-
nected 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.
Section 7
PUMP DISASSEMBLY

WILDEN PUMP & ENGINEERING, LLC 10 WIL-12350-E-05
Step 5
Next, remove the clamp bands that secure the ball valve
housing to the liquid chamber. Remove the ball valve hous-
ing, valve ball and gasket. After removing ball valve housing,
inspect for abrasion in the ball cage area.
NOTE: If your pump is fitted with a mushroom valve, remove
the mushroom valve housing, mushroom valve and gasket.
Step 6
Loosen the nut and remove the inlet manifold clamp bands.
Next, remove the clamp bands that secure the valve hous-
ing to the liquid chamber. After removing ball valve housing,
inspect for abrasion in the inlet manifold area.
Step 7
Next, remove the ball valve housing, valve ball and gasket
from liquid chamber.To ensure proper alignment during reas-
sembly of manifold/liquid chamber interface, turn off-set
portion of valve housing to the left or to the right.This proce-
dure works for the inlet and discharge manifold connections.
Step 8
Inspect the ball valve housing and valve ball for signs of
abrasion.
PUMP DISASSEMBLY

WIL-12350-E-05 11 WILDEN PUMP & ENGINEERING, LLC
Step 10
Next, remove the liquid chamber from the center section
assembly.
Step 9
Using the appropriate-sized wrenches, disconnect the inlet
manifold from the center section.
Step 11 (if applicable)
If your pump is fitted with an integral piston diaphragm (IPD),
when you remove the liquid chamber you will notice that
there is no outer piston.
Step 12
Using appropriate-sized wrenches, turning in the opposite
direction, loosen and remove one of the two (2) outer pistons.
NOTE:With an IPD, the procedure for removing the diaphragm
is slightly different. In this case, simply grasp the diaphragm
in two locations and turn in a counter-clockwise direction.
PUMP DISASSEMBLY

WILDEN PUMP & ENGINEERING, LLC 12 WIL-12350-E-05
Step 13
After loosening, remove the outer piston and diaphragm
assembly.
NOTE: If using an IPD, un-thread from the shaft.
Step 14
Loosen tubing nuts located at each pressure relief valve. Next,
loosen pipe fitting and elbow. This will allow easy access to
the relief valve. Using the appropriate-sized wrench, remove
each pressure relief valve.
Step 15
Using the appropriate-sized wrench, remove the fasteners
that connect the air valve and air valve gasket to the center
section.
Step 16
Lift air valve and isolator cover away from pump.
AIR VALVE/CENTER-SECTION DISASSEMBLY

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Step 17
Inspect air valve gasket for nicks,
gouges, chemical attack and replace if
necessary with genuine Wilden®parts.
Step 19
Using a hex wrench, remove the two (2) air-valve manifold
fasteners.
Step 18
Using a pair of snap-ring pliers, remove one snap-ring from the the air valve body.
Inspect air piston, air valve body and air valve end cap for nicks, gouges, chemical
attack or abrasive wear.
HINTS & TIPS: Using an air nozzle, alternately pressurize top and bottom bleeder
holes until the top end cap is forced from air valve body.
CAUTION: End cap may come out with considerable force. Position a shop rag or
equivalent over the top end cap to ensure that the end cap doesn’t harm the pump
technician or anyone else in the immediate area of the pump.
Step 20
Located behind the air valve manifold are four (4) tubes [two
short (2) and two (2) longer]. Remove all four (4) tubes from
pump.
AIR VALVE/CENTER-SECTION DISASSEMBLY

WILDEN PUMP & ENGINEERING, LLC 14 WIL-12350-E-05
Step 21
After removing tubes inspect or replace the O-rings as needed.
Step 23
Remove the air chamber fasteners and gasket.
Step 24
Using a socket wrench, unbolt the power cylinder cover from
the center section.
Step 22
Using the appropriate-sized wrench, remove the air chamber
fasteners.
AIR VALVE/CENTER-SECTION DISASSEMBLY

WIL-12350-E-05 15 WILDEN PUMP & ENGINEERING, LLC
Step 25
Using an air nozzle with a rubber tip, apply air to the air mani-
fold tube port.
Step 26
This will force the power cylinder cover away from the power
cylinder body. Inspect shaft bushing seals and O-ring on
power cylinder cover for damage.
Step 27
Using two appropriate-sized wrenches,
turning in the opposite direction, loosen
and remove shaft diaphragm assembly.
Step 28
Remove the outler piston, diaphragm and shaft assembly from the air chamber.
AIR VALVE/CENTER-SECTION DISASSEMBLY

WILDEN PUMP & ENGINEERING, LLC 16 WIL-12350-E-05
Step 33
Using a hex wrench, remove the fasten-
ers that connect the inner piston to
the diaphragm assembly. Inspect
diaphragm for nicks, gouges, chemical
attack or abrasion. Replace if necessary
with genuine Wilden®parts.
Step 29
Using an air nozzle with a rubber tip, apply air to the air mani-
fold tube.This will force the power cylinder piston away from
the power cylinder body.
Continue to apply air pressure to the air manifold tube port
until the power cylinder piston is moved out of the power
cylinder body.
Step 30
Retain the shaft bushings for use in reassembly.
Step 31
Inspect the center section cover and
bushings. Replace if necessary with
genuine Wilden®parts.
Step 32
Inspect the O-ring cover for nicks,
gouges, chemical attack or abrasion.
Replace if necessary with genuine
Wilden®parts.
AIR VALVE/CENTER-SECTION DISASSEMBLY

WIL-12350-E-05 17 WILDEN PUMP & ENGINEERING, LLC
Step 1
After attaching the diaphragm shaft and
bushing to the power cylinder piston,
place power cylinder in vice with soft
jaws (careful to not damage piston).
Next, install new slipper seal.
HINTS & TIPS:Using a strip of material
(like an old O-ring), slide the material
back and forth until the slipper seal is
positioned above the center groove.
Step 2
Next, place the power cylinder and
power cylinder piston on top of the two
blocks of wood or equivalent.
Step 3
Insert new guide rings in outer grooves.
Very gently, begin to maneuver the
power cylinder piston into the power
cylinder body.
HINTS & TIPS:A conical (tapered) piece
of cylindrical sheet material or equiva-
lent can be used to hold the guide rings
in place as the power cylinder piston
slides in to the power cylinder body.
Step 4
Using a rubber mallet, lightly tap power
cylinder piston in a circular fashion until
piston is maneuvered completely into
power cylinder body. When performing
this task, use caution to not damage the
guide rings or slipper seal.
Step 5
As a last step, install power cylinder
cover and bushing to power cylin-
der body and secure with fasteners
provided.
POWER CYLINDER REASSEMBLY

WILDEN PUMP & ENGINEERING, LLC 18 WIL-12350-E-05
Description of Part H1500 HS Stainless Steel H1500 HS Ductile Iron
Inner Piston Bolts* 58.3 N•m (43 ft-lb) 58.3 N•m (43 ft-lb)
Outer Piston 140 N•m (103 ft-lb) 140 N•m (103 ft-lb)
Air Valve Bolts 9.5 N•m (84.1 in-lb) 9.5 N•m (84.1 in-lb)
Inlet/Discharge Manifold Bolts 17.6 N•m (13 ft-lb) 163 N•m (120 ft-lb)
Center Section Cover Bolts 54.0 N•m (40 ft-lb) 54.0 N•m (40 ft-lb)
Air Chamber Bolts* 88.1 N•m (65 ft-lb) 163 N•m (120 ft-lb)
Liquid Chamber Bolts 58.3 N•m (43 ft-lb) 163 N•m (120 ft-lb)
REASSEMBLY:
Upon performing applicable maintenance to the air distri-
bution system, the pump can now be reassembled. Please
refer to the disassembly instructions for photos and parts
placement. To reassemble the pump, follow the disassem-
bly 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 specifica-
tions on this page.The following tips will assist in the assem-
bly 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 lubri-
cate gaskets during assembly.
• Make sure that the exhaust port on the muffler plate is cen-
tered between the two exhaust ports on the center section.
• Stainless 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.
NOTE: To ensure proper
alignment during reas-
sembly of manif old/liquid
chamber interface, turn
off-set portion of valve
housing to the left or to
the right. This procedure
works for the inlet mani-
fold and discharge mani-
fold connections.
MAXIMUM TORQUE SPECIFICATIONS
OFF-SET
VALVE
HOUSING
TWIST
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 bean 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 with greater ease.
• 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 pos-
sible.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.
Figure A
SHAFT SEAL
TAPE
Figure B
SHAFT
SEAL TAPE
NEEDLE-NOSE
PLIERS
*Use #242 removable Loctite® on fastener threads.
REASSEMBLY HINTS & TIPS