PSG Wilden P200 Instruction Manual

EOM
Engineering
Operation &
Maintenance
P200
Plastic Pumps
wildenpump.com
Where Innovation Flows

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
A. P200 Performance Curves
Rubber-Fitted ..............................................................5
TPE-Fitted .................................................................5
Reduced-Stroke PTFE-Fitted .................................................6
Full-Stroke PTFE-Fitted......................................................6
B. Suction-Lift Curves ...........................................................7
SECTION 6 SUGGESTED INSTALLATION, OPERATION & TROUBLESHOOTING.........8
SECTION 7 DISASSEMBLY / REASSEMBLY .............................................11
Disassembly, Cleaning, & Inspection .............................................14
Reassembly Hints &Tips ........................................................17
SECTION 8 EXPLODED VIEW & PARTS LISTING
P200 Plastic Full-Stroke Diaphragm-Fitted ........................................18
P200 Plastic Reduced-Stroke Diaphragm-Fitted ...................................20
SECTION 9 ELASTOMER OPTIONS ......................................................22
TABLE OF CONTENTS

WIL-11070-E-12 1 WILDEN PUMP & ENGINEERING, LLC
Section 1
CAUTIONS—READ FIRST!
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 4°C to 137°C 40°F to 280°F
SIPD PTFE with Neoprene-backed 4°C to 93°C 40°F to 200°F
PTFE
14°C to 104°C 40°F to 220°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
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 the Chemical
Resistance Guide for chemical compatibility and
temperature limits.
CAUTION: Always wear safety glasses when
operating pump. If diaphragm rupture occurs,
material being pumped may be forced out air
exhaust.
WARNING: Prevent static sparking — If static
sparking occurs, fire or explosion could
result. Proper grounding of pump, valves, and
containers is critical when handling flammable
fluids or whenever discharge of static electricity
is a hazard.
NOTE: Do not exceed 5.2 bar (75 psig) air supply
for PFA pumps.
CAUTION: Do not exceed 8.6 bar (125 psig) air
supply on polypropylene and PVDF pumps.
CAUTION: Bolted plastic pumps are made with
plastic that is not UV-stabilized. Direct sunlight
for prolonged periods can cause deterioration of
plastics.
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 pipe
line debris is clear. Use an in-line air filter. A 5µ
(micron) air filter is recommended.
NOTE: Tighten all bolts prior to installation.
Fittings may loosen during transportation. See
torque specifications on page 17.
NOTE: When installing polytetrafluoroethylene
(PTFE) diaphragms, it is important to tighten
outer pistons simultaneously (turning in opposite
directions) to ensure tight fit.
CAUTION: Verify the chemical compatibility of
the process and cleaning fluid to the pump’s
component materials in the Chemical Resistance
Guide.
CAUTION: When removing the end cap using
compressed air, the air valve end cap may come
out with considerable force. Hand protection
such as a padded glove or rag should be used to
capture the end cap.
CAUTION: Do not over-tighten the air inlet
reducer bushing. Additionally, too much torque
on the muffler may damage the air valve muffler
plate. Do not exceed 0.9 N·m (8 in-lb).
NOTE: When reinstalling the outer pistons, apply
two (2) drops of Loctite®246 to the shaft internal
threads before the diaphragm assembly.
1
4°C to 149°C (40°F to 300°F) - 13 mm (1/2") and 25 mm (1") models only.

WILDEN PUMP & ENGINEERING, LLC 2 WIL-11070-E-12
P200 PLASTIC
25 mm (1") Pump
Maximum Flow Rate:
220 lpm (58 gpm)
MATERIAL CODES
MODEL
P200 = PRO-FLO®
WETTED PARTS & OUTER PISTON
KK = PVDF / PVDF
PK = POLYPROPYLENE / PVDF
CENTER SECTION
PP = POLYPROPYLENE
AIR VALVE
P = POLYPROPYLENE
DIAPHRAGMS
BNS = BUNA-N (Red Dot)
FSS = SANIFLEX™
[Hytrel®(Cream)]
EPS = EPDM (Blue Dot)
NES = NEOPRENE (Green Dot)
PUS = POLYURETHANE (Clear)
TEU = PTFE W/EPDM
BACK-UP (White)
TNU = PTFE W/NEOPRENE
BACK-UP (White)
TSU = PTFE W/SANIFLEX™
BACK-UP (White)
VTS = VITON®(White Dot)
WFS = WIL-FLEX™ [Santoprene®
(Orange Dot)]
TSS = FULL-STROKE PTFE
W/SANIFLEX™ BACK-UP
TWS = FULL-STROKE PTFE
W/WIL-FLEX™ BACK-UP
VALVE BALLS
BN = BUNA-N (Red Dot)
FS = SANIFLEX™
[Hytrel®(Cream)]
EP = EPDM (Blue Dot)
NE = NEOPRENE (Green Dot)
PU = POLYURETHANE (Brown)
TF = PTFE (White)
VT = VITON®(White Dot)
WF = WIL-FLEX™ [Santoprene®
(Orange Dot)]
VALVE SEATS
K = PVDF
P = POLYPROPYLENE
T = PTFE PFA
VALVE SEAT O-RINGS
BN = BUNA-N
PU = POLYURETHANE (Brown)
TV = PTFE ENCAP. VITON®
WF = WIL-FLEX™ (Santoprene®)
SPECIALTY CODES
0100 Wil-Gard II™ 110V
0102 Wil-Gard II™ sensor wires Only
0103 Wil-Gard II™ 220V
0206 PFA coated hardware,
Wil-Gard II™ sensor wires ONLY
0480 PCM I™ (Sensor & wires only)
0502 PFA coated hardware
0504 DIN flange
0506 DIN flange, PFA coated hardware
0603 PFA coated hardware, Wil-Gard II™ 110V
0604 DIN flange, Wil-Gard II™ 220V
0608 PFA coated hardware, Wil-Gard II™ 220V
LEGEND
P200 / XXXXX / XXX /XX / XXX /XXXX
O-RINGS
MODEL VALVE SEATS
VALVE BALLS
DIAPHRAGMS
AIR VALVE
CENTER SECTION
WETTED PARTS & OUTER PISTON
SPECIALTY
CODE
(if applicable)
Viton®is a registered trademark of DuPont Dow Elastomers.
Maximum Operating
Pressure for PFA
is 5.2 bar (75 psig)
Section 2
WILDEN PUMP DESIGNATION SYSTEM

WIL-11070-E-12 3 WILDEN PUMP & ENGINEERING, LLC
The Wilden diaphragm pump is an air-operated, positive displacement, self-priming pump. These drawings show the flow
pattern through the pump upon its initial stroke. It is assumed the pump has no fluid in it prior to its initial stroke.
The Pro-Flo®patented air distribution system
incorporates three moving parts: the air valve spool,
the pilot spool, and the main shaft/diaphragm
assembly. The heart of the system is the air valve
spool and air valve. As shown in Figure A, 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 shift to
one side — discharging liquid on that side and pulling
liquid in on the other side. When the shaft 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.
Figure A
Section 3
HOW IT WORKS
HOW IT WORKS—AIR DISTRIBUTION SYSTEM
FIGURE 1 The air valve directs pressurized 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 mechani-
cal stress from the diaphragm. The compressed
air moves the diaphragm away from the center
block 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 of the
pump. The movement of diaphragm B toward the
center of the pump creates a vacuum within cham-
ber 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 developed in the liquid chamber and mani-
fold 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 consti-
tutes one complete pumping cycle. The pump may
take several cycles to completely prime depending
on the conditions of the application.

WILDEN PUMP & ENGINEERING, LLC 4 WIL-11070-E-12
DIMENSIONS
ITEM METRIC (mm) STANDARD (inch)
A 457 18.0
B 66 2.6
C 259 10.2
D 381 15.0
E 434 17.1
F 99 3.9
G 104 4.1
H 122 4.8
J 259 10.2
K 231 9.1
L 353 13.9
M 310 12.2
N 124 4.9
P 157 6.2
R 10 0.4
DIN FLANGE
S 85 DIA. 3.3 DIA.
T 115 DIA. 4.5 DIA.
U 14 DIA. 0.6 DIA.
ANSI FLANGE
S 79 DIA. 3.1 DIA.
T 108 DIA. 4.3 DIA.
U 16 DIA. 0.6 DIA.
LW0XXX REV. A
Section 4
DIMENSIONAL DRAWINGS
P200 Plastic

WIL-11070-E-12 5 WILDEN PUMP & ENGINEERING, LLC
Ship Weight ........Polypropylene 10 kg (22 lb)
PVDF 15 kg (32 lb)
PFA 18 kg (40 lb)
Air Inlet......................................6 mm (1/4")
Inlet............................................ 25 mm (1")
Outlet ......................................... 25 mm (1")
Suction Lift ........................ 3.6 m Dry (11.9')
9.1 m Wet (30.0')
Disp. per Stroke1................. 0.32 L (.086 gal)
Max. Flow Rate................. 220 lpm (58 gpm)
Max. Size Solids .................4.76 mm (3/16")
1Displacement per stroke was calculated at 4.8 bar
(70 psig) air inlet pressure against a 2 bar (30 psig)
head pressure.
Example: To pump 68 lpm (18 gpm) against
a discharge head pressure of 3.4 bar (50 psig)
requires 4.1 bar (60 psig) and 34 Nm3/h (20
scfm) air consumption. (See dot on chart.)
Caution: Do not exceed 5.2 bar (75 psig) air
supply pressure on PFA pumps.
Caution: Do not exceed 8.6 bar (125 psig) air
supply pressure on polypropylene and PVDF
pumps.
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.
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.
Ship Weight ........Polypropylene 10 kg (22 lb)
PVDF 15 kg (32 lb)
PFA 18 kg (40 lb)
Air Inlet......................................6 mm (1/4")
Inlet............................................ 25 mm (1")
Outlet ......................................... 25 mm (1")
Suction Lift ........................ 3.5 m Dry (11.4')
9.8 m Wet (32.0')
Disp. per Stroke1................. 0.33 L (.088 gal)
Max. Flow Rate................. 216 lpm (57 gpm)
Max. Size Solids .................4.76 mm (3/16")
1Displacement per stroke was calculated at 4.8 bar
(70 psig) air inlet pressure against a 2 bar (30 psig)
head pressure.
Example: To pump 76 lpm (20 gpm) against
a discharge head pressure of 3.1 bar (45 psig)
requires 4.1 bar (60 psig) and 34 Nm3/h (20
scfm) air consumption. (See dot on chart.)
Caution: Do not exceed 5.2 bar (75 psig) air
supply pressure on PFA pumps.
Caution: Do not exceed 8.6 bar (125 psig) air supply
pressure on polypropylene and PVDF pumps.
Section 5A
PERFORMANCE
P200 PLASTIC
TPE-FITTED
P200 PLASTIC
RUBBER-FITTED

WILDEN PUMP & ENGINEERING, LLC 6 WIL-11070-E-12
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.
Section 4
PERFORMANCE
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.
P200 PLASTIC
FULL-STROKE PTFE-FITTED
P200 PLASTIC
REDUCED-STROKE PTFE- FITTED
Ship Weight ........Polypropylene 10 kg (22 lb)
PVDF 15 kg (32 lb)
PFA 18 kg (40 lb)
Air Inlet......................................6 mm (1/4")
Inlet............................................ 25 mm (1")
Outlet ......................................... 25 mm (1")
Suction Lift .......................... 2.4 m Dry (7.9')
9.4 m Wet (31.0')
Disp. per Stroke1............... 0.22 L (0.057 gal)
Max. Flow Rate................. 174 lpm (46 gpm)
Max. Size Solids .................4.76 mm (3/16")
1Displacement 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 76 lpm (20 gpm) against
a discharge head pressure of 4.5 bar (65 psig)
requires 6.9 bar (100 psig) and 37 Nm3/h
(40 scfm) air consumption. (See dot on chart.)
Caution: Do not exceed 5.2 bar (75 psig) air
supply pressure on PFA pumps.
Caution: Do not exceed 8.6 bar (125 psig) air
supply pressure on polypropylene and PVDF
pumps
Ship Weight ........Polypropylene 10 kg (22 lb)
PVDF 15 kg (32 lb)
Air Inlet......................................6 mm (1/4”)
Inlet............................................ 25 mm (1”)
Outlet ......................................... 25 mm (1”)
Suction Lift ......................... 3.5m Dry (11.4’)
8.6 m Wet (28.4’)
Disp. Per Stroke1................... 0.5 L (0.13 gal)
Max. Flow Rate.............. 195 lpm (51.4 gpm)
Max. Size Solids .................4.76 mm (3/16”)
1Displacement 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 20 GPM against a
discharge head of 60 psigrequires 80 psig
and 29 scfm air consumption.
Caution: Do not exceed 5.2 bar (75 psig) air
supply pressure on PFA pumps.
Caution: Do not exceed 8.6 bar (125 psig) air
supply pressure on polypropylene and PVDF
pumps

WIL-11070-E-12 7 WILDEN PUMP & ENGINEERING, LLC
P200 PLASTIC
SUCTION-LIFT
CAPABILITY
Section 5B
SUCTION-LIFT CURVES
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 which
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.
26
24
22
20
18
16
14
12
10
8
6
4
2
0
7
6
5
4
3
2
1
0
0 10 20 30 40 50 60 70 80 90 100
[0.7] [1.4] [2.0] [2.7] [3.4] [4.1] [4.8] [5.5] [6.2] [6.9]

WILDEN PUMP & ENGINEERING, LLC 8 WIL-11070-E-12
The Pro-Flo®model P200 plastic pump has a 25 mm (1")
inlet and 25 mm (1") outlet and is designed for flows to 220
lpm (58 gpm). The P200 plastic pump is manufactured with
wetted parts of pure, unpigmented Polypropylene or PVDF.
The P200 plastic pump is constructed with a glass fiber filled
PP center section. A variety of diaphragms and O-rings
are available to satisfy temperature, chemical compatibility,
abrasion, and flex concerns.
The suction pipe size should be at least 25 mm (1") diameter
or larger if highly viscous material is being pumped. The
suction hose must be non-collapsible, reinforced type as
the P200 plastic pump is capable of pulling a high vacuum.
Discharge piping should be at least 25 mm (1"); larger
diameter can be used to 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 should 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 five
key factors are balanced against each other to maximum
advantage.
ACCESS: First, 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 (see Section 5). Do not exceed 5.2
bar (75 psig) air supply for PFA pumps. Use air pressure up
to a maximum of 8.6 bar (125 psig) for polypropylene and
PVDF pumps 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 insure 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, thus allowing trapped air to bleed off and improving
pump performance. Pumping volume can be set by counting
the number of strokes per minute and multiplying by
displacement per stroke.
SOUND: Sound levels are reduced using the standard
Wilden muffler element. Other mufflers can be used, but
usually reduce pump performance.
ELEVATION: Selecting a site that is well within the pump’s
dynamic-lift capability will assure that loss-of-prime troubles
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 problems 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 stresses 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 should be installed
to protect the pump, piping and gauges from surges and
water hammer.
The P200 plastic Pro-Flo®-equipped pump can be installed
in submersible applications only when both the wetted and
non-wetted portions are compatible with the material being
pumped. If the pump is to be used in a submersible appli-
cation, a hose should be attached to the air and pilot spool
exhaust ports of the pump. These should then be piped
above the liquid level. The exhaust area for the pilot spool is
designed to be tapped for a 1/8" NPT fitting.
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.
If the pump is to be used in a self-priming application, be
sure that all connections are airtight and that the suction-
lift is within the ability of the model. NOTE: Materials of
construction and elastomer material have an effect on
suction lift parameters. Please consult Wilden distributors
for specifics.
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.
THE P200 PLASTIC WILL PASS 4.76 mm (3/16") SOLIDS.
WHENEVER THE POSSIBILITY EXISTS THAT LARGER
SOLID OBJECTS MAY BE SUCKED INTO THE PUMP, A
STRAINER SHOULD BE USED ON THE SUCTION LINE.
CAUTION: DO NOT EXCEED 5.2 BAR (75 PSIG) AIR
SUPPLY FOR PFA PUMPS. DO NOT EXCEED 8.6 BAR (125
PSIG) AIR SUPPLY PRESSURE FOR POLYPROPYLENE
AND PVDF PUMPS.
Section 6
SUGGESTED INSTALLATION

WIL-11070-E-12 9 WILDEN PUMP & ENGINEERING, LLC
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-off valve should be located far enough away from
the pumping equipment such that it can be reached safely in an emergency situation.
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.
SUGGESTED INSTALLATION

WILDEN PUMP & ENGINEERING, LLC 10 WIL-11070-E-12
Pump will not run or runs slowly.
1. Ensure that the air inlet pressure is at least 0.35 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. In addition, valve balls become
smaller as the wear. This may cause them to become
stuck in the seats. In this case, replace balls and seats.
6. Check for broken inner piston, that will prevent the air
valve spool from shifting.
7. Remove plug from pilot spool exhaust, check pilot spool
exhaust for blockage.
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
(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 seals
with proper elastomers. In addition, valve balls become
smaller as the wear. This may cause them to become
stuck in the seats. In this case, replace balls and seats.
Pump air valve freezes.
1. Check for excessive moisture in compressed air. Install
either 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.
3. Check torque of bolts 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.
OPERATION: Pump discharge rate can be controlled by
limiting the volume and/or pressure of the air supply to
the pump (preferred method). 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. 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 been "deadheaded." It can be restarted by reducing the
fluid discharge pressure, or increasing the air inlet pressure.
The Wilden P200 plastic pump runs solely on compressed
air and does not generate heat, therefore your process fluid
temperature will not be affected.
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.
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.
Section 4
SUGGESTED OPERATION & MAINTENANCE
TROUBLESHOOTING

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Section 7
PUMP DISASSEMBLY
Step 1. Figure 1
Please see pre-molded alignment
marks on the liquid chamber and
center section.
Step 2. Figure 2
Using the 13 mm (1/2”) box wrench,
loosen the discharge manifold from
the liquid chambers.
Step 3. Figure 3
Remove the discharge manifold to
expose the valve balls, valve seats
and valve seat O-rings.
Tools Required:
• 13 mm (1/2") Box
Wrench
• 2 – 25 mm (1") Sockets
or 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 used for these instructions incorporates PTFE diaphragms and
balls. Models with rubber diaphragms and balls are the same except where noted.

WILDEN PUMP & ENGINEERING, LLC 12 WIL-11070-E-12
Step 7. Figure 7
With a 13 mm (1/2") box wrench,
remove the liquid chambers from the
center section.
Step 8. Figure 8
The liquid chamber should be
removed to expose the diaphragm
and outer piston. Rotate center
section and remove the opposite
liquid chamber.
Step 9. Figure 9
Using two crescent wrenches
or 25 mm (1") sockets, remove
diaphragm assembly from center
section assembly.
Section 5C
PUMP DISASSEMBLY
Step 4. Figure 4
Remove the discharge valve balls,
seats and valve seat O-rings from
the discharge manifold and liquid
chamber, inspect for nicks, gouges,
chemical attack or abrasive wear.
Replace worn parts with genuine
Wilden parts for reliable performance..
Step 5. Figure 5
Using a 13 mm (1/2") box wrench,
remove the inlet manifold.
Step 6. Figure 6
Remove the inlet valve balls, seats
and valve seat O-rings from the
liquid chamber and discharge
manifold, inspect for nicks, gouges,
chemical attack or abrasive
wear. Replace worn parts with
genuine Wilden parts for reliable
performance.

WIL-11070-E-12 13 WILDEN PUMP & ENGINEERING, LLC
Step 10. Figure 10
After loosening and removing the
outer piston the diaphragm assembly
can be disassembled.
Step 11. Figure 11
To remove the remaining dia-
phragm assembly from the shaft,
secure shaft with soft jaws (a vise
fitted with plywood 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.
Step 12. Figure 12
Inspect diaphragms, outer and
inner pistons for signs of wear.
Replace with genuine Wilden parts
if necessary.
Section 5C
PUMP DISASSEMBLY

WILDEN PUMP & ENGINEERING, LLC 14 WIL-11070-E-12
Step 1. Figure 1
Loosen the air valve bolts utilizing a
3/16" Allen wrench.
Step 2. Figure 2
Remove muffler plate and air valve
bolts from air valve assembly
exposing muffler gasket for
inspection. Replace if necessary.
Step 3. Figure 3
Lift away air valve assembly and
remove air valve gasket for
inspection. Replace if necessary.
Section 5C
AIR VALVE / CENTER-SECTION DISASSEMBLY
Tools Required:
• 3/16" Allen Wrench
• Snap-Ring Pliers
• 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.
The P200 plastic pump utilizes a revolutionary Pro-Flo®air distribution system.
A 6 mm (1/4") air inlet connects the air supply to the center section. Proprietary com-
posite seals reduce the coefficient of friction and allow the P200 to run lube-free. The
Pro-Flo®air distribution system is designed to perform in on/off, non-freezing, non-
stalling, tough duty applications.

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Step 4. Figure 4
Remove air valve end cap to expose
air valve spool by simply lifting up
on end cap once air valve bolts are
removed.
Step 5. Figure 5
Remove air valve spool from air
valve body by threading one air
valve bolt into the end of the 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.
NOTE: Seals should not be
removed from assembly. Seals are
not sold separately.
Step 6. Figure 6
Remove pilot spool sleeve retaining
snap-ring on both sides of center
section with snap-ring pliers.
Step 7. Figure 7
Remove pilot spool sleeve from center
section.
Step 8. Figure 8
With O-ring pick, gently remove the O-ring from the opposite side of the
“center hole” cut on the spool. Gently remove the pilot spool from sleeve
and inspect for nicks or gouges and other signs of wear. Replace pilot
sleeve assembly or outer sleeve o-rings if necessary. During re-assembly
never insert the pilot spool into the sleeve with the “center cut” side 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.
Section 5C
AIR VALVE / CENTER-SECTION DISASSEMBLY

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Section 5C
AIR VALVE / CENTER-SECTION DISASSEMBLY
Step 9. Figure 9
Check center section Glyd™ rings
for signs of wear. If necessary,
remove Glyd™ rings with O-ring
pick and replace.

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ASSEMBLY:
Upon performing applicable maintenance to the air distribution
system, the pump can now be reassembled. 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.
• Clean the inside of the center section shaft bore to ensure
no damage is done to new seals.
• Stainless bolts should be lubed to reduce the possibility of
seizing during tightening.
• Be sure to tighten outer pistons simultaneously on PTFE-
fitted pumps to ensure proper torque values.
• Apply two (2) drops of Loctite®246 to the shaft internal
threads before the diaphragm assembly.
• Concave side of disc spring in diaphragm assembly faces
toward inner piston.
MAXIMUM TORQUE SPECIFICATIONS
Part Description Torque
Pro-Flo®Air Valve 3.1 N•m (27 in-lb)
Air Inlet Reducer Bushing 0.9 N•m (8 in-lb)
Outer Piston (rubber, TPE, & PTFE
diaphragm-fitted) 27.1 N•m (20 ft-lb)
Top & Bottom Manifolds (Poly & PVDF) 5.6 N•m (50 in-lb)
Liquid Chamber (Poly & PVDF) 8.5 N•m (75 in-lb)
Top & Bottom Manifolds (PFA) 3.4 N•m (30 in-lb)
Liquid Chamber (PFA) 5.6 N•m (50 in-lb)
Section 5C
REASSEMBLY HINTS & TIPS

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P200 PLASTIC FULL-STROKE DIAPHRAGM-FITTED EXPLODED VIEW
30
29
15
14
16
17
FULL-STROKE PTFE-FITTED
Section 8
EXPLODED VIEW & PARTS LISTING