Wilden PRO-FLO P1500 Instruction Manual

EOM
ENGINEERING OPERATION
& MAINTENANCE
P1500 Bolted
Plastic Pump
WIL-11160-E-09
Where InnovationFlows

WIL-11160-E-09 Wilden®
2
Contents
Section 1: Precautions - Read First! 4
Section 2: Wilden Pump Designation System 5
Section 3: How It Works—Pump & Air Distribution System 6
Section 4: Dimensional Drawings 7
P1500 Polypropylene 7
P1500 PVDF 7
Section 5: Performance 8
P1 500 P last ic R ed uc ed - S tr ok e PT F E- Fi t te d 8
P1 500 Pla st ic Fu ll - Strok e PT F E- F itt ed 8
Su ction- L i ft Curve s 9
Section 6: Suggested Installation, Operation, 10
Maintenance and Troubleshooting
Section 7: Disassembly / Reassembly 13
Pu mp D i sa ssemb ly 13
Ai r Va lve / Cente r Se ct ion Disa ssemb ly 16
Re a ssembly H i n ts & T i ps 18
Section 8: Exploded View and Parts List 19
P1 500 Plastic Air D istrib ution Sy stem . 19
P1 5 00 Pl ast i c L iq ui d P at h . 21

WIL-11160-E-09 Wilden®
3
Copyright
Copyright 2018 PSG®, a Dover Company. All rights reserved.
PSG reserves the right to modify the information and illustrations in this document without prior notice. The
product described in this document is furnished under a license agreement or nondisclosure agreement. No
part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or any
means electronic or mechanical, including photocopying and recording, without the written permission of PSG,
a Dover Company, except as described by the terms of those agreements.
This is a non-contractual document. 01-2019.
Trademarks
PSG and the PSG logo are registered trademarks of PSG. Wilden® is a registered trademark of PSG
California LLC. Pro-Flo® SHIFT and Pro-Flo® are registered trademarks of PSG California LLC. Wil-Flex® is a
trademark of PSG California LLC. Saniflex™ is a trademark of PSG California LLC.
All trademarks, names, logos and service marks (collectively "trademarks") in this document are registered
and unregistered trademarks of their respective owners. Nothing contained in this document should be
construed as granting any license or right to use any trademark without the prior written permission of the
trademark owner.
Warranty
Each and every product manufactured by Wilden is built to meet the highest standards of quality. Every pump
is functionally tested to insure integrity of operation. Wilden 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.
For more information, and to register your Wilden pump for warranty, please visit
https://www.psgdover.com/wilden/support/warranty-registration.
Certifications

WIL-11160-E-09 Wilden®
4
Precautions - 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
PTFE1
4°C to 104°C
40°F to 220°F
FKM
–40°C to 177°C
–40°F to 350°F
Wil-Flex™
–40°C to 107°C
–40°F to 225°F
14°C to 149°C (40°F to 300°F) - 13 mm (1/2”) and 25 mm (1”) models only.
NOTE: Not all materials are available for all models. Refer to Section 2 for
material options for your pump.
CAUTION: When choosing pump materials, be sure to
check the temperature limits for all wetted components.
Example: PTFE has a maximum limit of 104°C (220°F) but
polypropylene has a maximum limit of only 79°C (175°F).
CAUTION: Do not apply compressed air to the exhaust ports
—pump will not function.
CAUTION : Do not over-lubricate air supply —excess
lubrication will reduce pump performance. Pump is pre-lubed
with NLGI Grade 2 white EP grease.
CAUTION: Maximum temperature limits are based upon
mechanical stress only. Certain chemicals will significantly
reduce maximum safe operating temperatures. Consult
engineering 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: Prevention of static sparking —If static
sparking occurs, fire or explosion could result. Pump,
valves, and containers must be properly grounded when
handling flammable fluids and whenever discharge of
static electricity is a hazard.
NOTE: Do not exceed 6.9 bar (100 psig) air supply
pressure for P1500 polypropylene pumps.
CAUTION: Do not exceed 8.6 bar (125 psig) air
supply pressure for P1500 PVDF pumps.
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 recommend.
NOTE: When installing PTFE diaphragms, it is
important to tighten outer pistons simultaneously
(turning in opposite directions) to ensure tight fit.
WARNING: Tighten all bolts and retainers prior to
installation. Fittings may loosen during transportation.
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: 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: Pump is not rated for U.L. 79 service.
For U.L. 79 transfer use Wilden’s U.L.-approved
T Series pump.
NOTE: The elbows and tees have bosses that are
designed to be tapped with a 9.5 mm NPT (3/8”)
fitting for draining the pump during maintenance.
CAUTION: The P1500 pump is not submersible.
Section 1

WIL-11160-E-09 Wilden®
5
LEGEND
MATERIAL CODES
MODEL
P1500 = PRO-FLO
®
WETTEDPATH
K = PVDF
P = POLYPROPLYENE
OUTERPISTON
K = PVDF
P = POLYPROPLYENE
S = STAINLESS STEEL
AIR CHAMBERS
P = POLYPROPYLENE
CENTER BLOCK
P = POLYPROPYLENE
AIR VALVE
P = POLYPROPYLENE
DIAPHRAGMS
TEU = PTFE W/EPDM
BACKUP (White)
TNU = PTFE W/NEOPRENE
BACK-UP (White)
TSS = FULL-STROKE PTFE
W/SANIFLEX™ BACKUP
TWS = FULL-STROKE PTFE
W/WIL-FLEX™ BACK
VALVE BALLS
TF = PTFE (White)
VALVE SEATS
K = PVDF
VALVE SEAT O-RINGS
TV = PTFE ENCAP. FKM
NOTE: Most Elastomeric materials use colored dots for identification.
NOTE: Not all models are available with all material options.
P1500 ADVANCED™
PLASTIC
76 mm (3") Pump
Maximum Flow Rate:
878 lpm (232 gpm)
Section 2
WILDEN PUMP DESIGNATION SYSTEM
SPECIALTY CODES
0100 Wil ‑ Gard II™ 110V
0564 Split manifold, inlet ONLY
0102 Wil ‑ Gard II™ sensor wires ONLY
0604 DIN flange, Wil ‑ Gard II™ 220V
0504 DIN flange
0660 Split manifold, Wil ‑ Gard II™ 110V
0560 Split manifold
0563 Split manifold, discharge ONLY
P1500
/
X
X
X
X
X
/
XXX
/
XX
/
X
XX
/
XXXX
O-RINGS
MODEL
VALVE SEAT
VALVE BALLS
SPECIALTY CODE
DIAPHRAGMS
(if applicable)
AIR VALVE
CENTER BLOCK
AIR CHAMBERS
OUTER PISTON
WETTED PATHS

WIL-11160-E-09 Wilden®
6
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.
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,
balancing the load and removing mechanical
stress from the diaphragm. 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 of the pump. The movement of
diaphragm B toward the center section 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.
Liquidisfreetomovepasttheinletvalveballand
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 airto
the back side of diaphragm B. The pressurized
air forces diaphragm B away from the center
section while pulling diaphragm Ato 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 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 section 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 conditions of the
application.
HOW IT WORKS —AIR DISTRIBUTION SYSTEM
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. 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.
Section 3
HOW IT WORKS —PUMP

WIL-11160-E-09 Wilden®
7
P1500 Polypropylene
P1500 PVDF
DIMENSIONS
ITEM
METRIC (mm)
STANDARD (inch)
A
914
36.0
B
160
6.3
C
691
27.2
D
1280
50.4
E
180
7.1
F
305
12.0
G
1181
46.5
H
693
27.3
J
584
23.0
K
681
26.8
L
335
13.2
M
15 DIA.
0.6 DIA.
N
150
5.9
FLANGES
DIN (mm)
ANSI (inch)
P
160 DIA.
6.0 DIA.
R
191 DIA.
7.5 DIA.
S
18 DIA.
0.8 DIA.
LW0404 REV. A
DIMENSIONS
ITEM
METRIC (mm)
STANDARD (inch)
A
914
36.0
B
160
6.3
C
694
27.3
D
1278
50.3
E
180
7.1
F
303
11.9
G
1183
46.6
H
694
27.3
J
584
23.0
K
681
26.8
L
335
13.2
M
15 DIA.
0.6 DIA.
N
142
5.6
FLANGES
DIN (mm)
ANSI (inch)
P
170 DIA.
6.0 DIA.
R
190 DIA.
7.5 DIA.
S
18 DIA.
0.8 DIA.
A
914
36.0
LW0405 REV. A
DIMENSIONAL DRAWING

WIL-11160-E-09 Wilden®
8
PERFORMANCE
P1500 PLASTIC
REDUCED-STROKE
PTFE-FITTED
ShipWeight.. Polypropylene 138 kg (305 lb)
PVDF 161 kg (356 lb)
Air Inlet..................................19 mm (3/4")
Inlet....................................... 76 mm (3 " )
Outlet ...................................... 76 mm (3 " )
Suction Lift.................... 3.63 m Dry (12')
8.64 m Wet (28')
Disp.PerStroke
1
.................3.75 L (0.99 gal)
Max.FlowRate..........784 lpm (207 gpm)
Max. Size Solids....................13 mm (1/2")
1
Displacement per stroke was calculated
at 4.8 bar (70 psig) air inlet pressure
against a 2 bar (30 psig) head pressure.
Example: To pump 246 lpm (65 gpm)
against a discharge pressure head
of 5.5 bar (80 psig) requires 6.9 bar
(100 psig) and 212 Nm3/h (125 scfm)
air consumption. (See dot on chart.).
Caution: Do not exceed 6.9 bar (100 psig)
air supply pressure on P1500
polypropylene pumps.
Caution: Do not exceed 8.6 bar (125 psig)
air supply pressure on 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.
P1500 PLASTIC
FULL-STROKE
PTFE-FITTED
ShipWeight.. Polypropylene 138 kg (305 lb)
PVDF 161 kg (356 lb)
Air Inlet..................................19 mm (3/4")
Inlet.......................................76 mm (3 " )
Outlet ...................................... 76 mm (3 " )
Suction Lift................... 5.5 m Dry (18.2')
8.6 m Wet (28.4')
Disp.PerStroke
1
...................5.8 L (1.52 gal)
Max.FlowRate..........878 lpm (232 gpm)
Max. Size Solids.................12.7 mm (1/2")
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 636 lpm (168 gpm)
against a discharge head of 1.4 bar
(20 psig) requires 5.5 bar (80 psig) and
177 Nm³/h (112 scfm) air consumption
Caution: Do not exceed 6.9 bar (100 psig)
air supply pressure on P1500
polypropylene pumps.
Caution: Do not exceed 8.6 bar (125 psig)
air supply pressure on PVDF pumps.
Section 5
Flow rates indicated on chart were determined by pumping water.
For optimum life and performance, pumps should be specified so that daily
operation parameters will fall in the center of the pump’s performance curve.

WIL-11160-E-09 Wilden®
9
SUCTION LIFT CURVES
P1500 PLASTIC
SUCTION - LIFT
CAPABILITY
Suction-lift curves are calibrated for
pumps operating at 305 m (1,000’)
above sea level. This chart is meant
to be a guide only. There are many
variables 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.

WIL-11160-E-09 Wilden®
10
Suggested Installation, Operation, Maintenance and Troubleshooting
The P1500 plastic pump has a 76 mm (3") inlet and 76 mm (3") outlet and is
designed for flows to 784 lpm (207 gpm). The P1500 plastic pump is
manufactured with wetted parts of polypropylene and PVDF. The center block
of the P1500 plastic pump is constructed of polypropylene. PTFE diaphragms,
valve balls, and o-rings are employed to satisfy chemical compatibility
concerns.
The suction pipe size should be at least 76 mm (3") diameter or larger if highly
viscous material is being pumped. The suction hose must be non-collapsible,
reinforced type as the P1500 is capable of pulling a high vacuum. Discharge
piping should be at least 76 mm (3"); 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.
For P1500 plastic models, Wilden offers 150 lb. standard flanges (ANSI or
DIN). The following details should be noted when mating these to pipe works:
• A 60–80 shore gasket that covers the entire flange face should be used.
• The gasket should be between 0.075”and 0.175”thickness.
A non-raised surfaced-flange adapter should be utilized when mating to the
pump’s inlet and discharge manifolds for proper sealing.
CAUTION: All fittings and connections must be airtight. Otherwise,
pump suction capability will be reduced or lost.
Months of careful planning, study and selection efforts can result in
unsatisfactory pump performance if installation details are left to chance.
You can avoid premature failure and long-term dissatisfaction by exercising
reasonable care throughout the installation process.
Location
Noise, safety and other logistical factors usually dictate where equipment
will be situated on the production floor. Multiple installations with conflicting
requirements can result in congestion of utility areas, leaving few choices
for additional pumps.
Within the framework of these and other existing conditions, every pump
should be located in such a way that several key factors are balanced
against each other to maximum advantage.:
• Access: First of all, the location should be accessible. If it’s easy to
reach the pump, maintenance personnel will have an easier time
carrying out routine inspections and adjustments. Should major repairs
become necessary, ease of access can play a key role in speeding the
repair process and reducing total downtime.
•Air Supply: Every pump location should have an air line large enough to
supply the volume of air necessary to achieve the desired pumping rate.
Use air pressure up to a maximum of 8.6 bar (125 psig) depending on
pumping requirements.
For best results, the pumps should use a 5μ (micron) air filter, needle
valve and regulator. The use of an air filter before the pump will ensure
that the majority of any pipeline contaminants will be eliminated.
•Solenoid Operation: When operation is controlled by a solenoid valve in
the air line, three-way valves should be used. This valve allows trapped air
between the valve and the pump to bleed off which improves pump
performance. Pumping volume can be estimated by counting the number
of strokes per minute and then multiplying the figure by the displacement
per stroke.
• Muffler: Sound levels are reduced below OSHA specifications
using the standard Wilden muffler. Other mufflers can be used to
further reduce sound levels, but they usually reduce pump
performance .
• Elevation: Selecting a site that is well within the pump’s
dynamic-lift capability will assure that loss-of-prime issues will be
eliminated. In addition, pump efficiency can be adversely affected
if proper attention is not given to site location .
• Piping: Final determination of the pump site should not be
made until the piping challenges of each possible location have
been evaluated. The impact of current and future installations
should be considered ahead of time to make sure that inadvertent
restrictions are not created for any remaining sites.
The best choice possible will be a site involving the shortest and
straightest hook-up of suction and discharge piping. Unnecessary
elbows, bends and fittings should be avoided. Pipe sizes should be
selected to keep friction losses within practical limits. All piping should
be supported independently of the pump. In addition, the piping
should be aligned to avoid placing stress on the pump fittings.
Flexible hose can be installed to aid in absorbing the forces created
by the natural reciprocating action of the pump. If the pump is to be
bolted down to a solid location, a mounting pad placed between the
pump and the foundation will assist in minimizing pump vibration.
Flexible connections between the pump and rigid piping will also
assist in minimizing pump vibration. If quick-closing valves are
installed at any point in the discharge system, or if pulsation within a
system becomes a problem, a surge suppressor (SD Equalizer®)
should be installed to protect the pump, piping and gauges from
surges and water hammer.
If the pump is to be used in a self-priming application, make sure
that all connections are airtight and that the suction lift is within
the model’s ability.
NOTE: Materials of construction and elastomer material have
an effect on suction-lift parameters. Please refer to the
performance section for specifics.
When pumps are installed in applications involving flooded suction or
suction-head pressures, a gate valve should be installed in the
suction line to permit closing of the line for pump service.
NOTE: The elbows and tees have bosses that are designed
to be tapped with a 9.5 mm
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 model P1500 will pass 13 mm (1/2") 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 6.9 bar (100 psig) air supply pressure on
p1500 polypropylene pumps.
Pumps should be thoroughly flushed with water before installing into
process lines
Section 6

WIL-11160-E-09 Wilden®
11
Suggested Installation, Operation, Maintenance and Troubleshooting
This illustration is a generic
representation of an air-operated
double-diaphragm pump.
NOTE: In the event of a power failure, the shut-off
valve should be closed, if the restarting of the pump is
not desirable once power is regained.
Air-Operated Pumps: To stop the pump from operating in an
emergency situation, simply close the shut-off valve (user-
supplied) installed in the air supply line. A properly functioning
valve will stop the air supply to the pump, therefore stopping
output. This shut-off valve should be located far enough away
from the pumping equipment such that it can be reached safely
in an emergency situation.
Operation
The P1500 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 internal lubrication may be flushed out. If the pump is then
moved to a nonlubricated location, it may need to be
disassembled and re-lubricated as described in the
DISASSEMBLY / REASSEMBLY INSTRUCTIONS.
Pump discharge rate can be controlled by limiting the volume and/or
pressure of the air supply to the pump. An air regulator is used
to regulate air pressure. A needle valve is used to regulate volume.
Pump discharge rate can also be controlled by throttling the pump
discharge by partially closing a valve in the discharge line of the pump. This
action increases friction loss which reduces flow rate. (See Section 5.) This is
useful when the need exists to control the pump from a remote location. When
the pump discharge pressure equals or exceeds the air supply pressure, the
pump will stop; no bypass or pressure relief valve is needed, and pump
damage will not occur. The pump has reached a “deadhead” situation and can
be restarted by reducing the fluid discharge pressure or increasing the air inlet
pressure. Wilden Pro-Flo® pumps run solely on compressed air and do not
generate heat; therefore, your process fluid temperature will not be affected.
Maintenance and Inspections
Since each application is unique, maintenance schedules may be different for
every pump. Frequency of use, line pressure, viscosity and abrasiveness of
process fluid all affect the parts life of a Wilden pump. Periodic inspections
have been found to offer the best means for preventing unscheduled pump
downtime. Personnel familiar with the pump’s construction and service should
be informed of any abnormalities that are detected during operation.

WIL-11160-E-09 Wilden®
12
Suggested Installation, Operation, Maintenance and Troubleshooting
Troubleshooting
Pump will not run or runs slowly.
1. Ensure that the air inlet pressure is at least 0.4 bar (5 psig) above
startup pressure and that the differential pressure (the difference
between air inlet and liquid discharge pressures) is not less than
0.7 bar (10 psig).
2. Check air inlet filter for debris (see SUGGESTED
INSTALLATION).
3. Check for extreme air leakage (blow by) that would indicate
worn seals/bores in the air valve, pilot spool 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. Checkforstickingballcheckvalves.Ifmaterialbeing pumped is
not compatible with pump elastomers, swelling may occur.
Replace ball check valves and seals with proper elastomers.
Also, as the check valve balls wear out, they become smaller
and can become stuckinthe seats.Inthis case, replaceballs
and seats.
6. Check for broken inner piston that will cause the air valve
spool to be unable toshift.
7. Remove plug from pilot spool exhaust.
Pump runs but little or no product flows.
1. Check for pump cavitation; slow pump speed down to allow
thick material to flow into liquid chambers.
2. Verify that vacuum required to lift liquid is not greater than
the vapor pressure of the material being pumped (cavitation).
3. Checkforstickingballcheckvalves.Ifmaterialbeing 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 becomestuckintheseats. Inthiscase,replaceballs
and seats.
Pump air valve freezes.
1. Check for excessive moisture in compressed air. Either
install a dryer or hot-air generator for compressed air.
Alternatively, a coalescing filter may be used to remove
the water from the compressed air in someapplications.
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 toshaft.

WIL-11160-E-09 Wilden®
13
Disassembly / Reassembly
Pump Disassembly
Tools Required:
• (2 qty.) 5/8" Box Wrench
• (2 qty.) 3/4" Box Wrench
• 1-1/8" Box Wrench
• Adjustable Wrench
• Vise equipped with soft jaws
(such as plywood, plastic or
other suitable material)
CAUTION: Before any maintenance or repair is attempted, the compressed air
line to the pump should be disconnected and all air pressure allowed to bleed
from the pump. Disconnect all intake, discharge, and air lines. Drain the pump
by turning it upside down and allowing any fluid to flow into a suitable container.
Be aware of any hazardous effects of contact with your process fluid.
The Wilden P1500 has a 76 mm (3”) inlet and outlet and is designed for flows
up to 878 lpm (232 gpm). Its air distribution system is based on a revolutionary
design which increases reliability and performance. The model P1500 is
available in injection molded polypropylene and PVDF.
NOTE: Replace worn parts with genuine Wilden parts for reliable performance.
Step 1
Take the proper safety precautions to
work on the pump.
Step 2
Utilizing the two 5/8” adjustable wrenches,
remove bolts that fasten the discharge
manifold to the liquid chambers .
Step 3
Remove the discharge manifold to expose the
valve balls, valve seats, and O-rings. Inspect
the O-rings for nicks, gouges, or chemical
attack. Replace with genuine Wilden parts if
needed. Inspect the ball cage area of manifold
for excessive wear or damage .
Section 7

WIL-11160-E-09 Wilden®
14
Disassembly / Reassembly
Step 4
Rotate the ball cage counterclockwise to
remove the threaded ball seat.The ball
cage has feet that interlock with the seat to
facilitate this operation.
Step 5
After removing the discharge valve seat,
remove the valve seat O-ring and inspect
valve seat, valve seat O-ring, valve balls
and ball cage for nicks, gouges, chemical
attack or abrasive wear . Replace worn
parts with genuine Wilden parts for reliable
performance.
Step 6
Remove the bolts that secure the liquid
chambers and center section to the
intake manifold.
Step 7
Lift intake manifold from liquid chambers
and center section to expose intake valve
balls and seats. Inspect the ball cage area
of manifold for excessive wear or damage.
Repeat Steps 4–6.
NOTE: Two people or a jib crane is
recommended to perform Step 8.
Step 8
Lift one side of the intake manifold, then
slide out the other side to remove the
manifold from the mounting stand.
Normally inlet and discharge manifolds
should not be disassembled during regular
pump maintenance. Should this be
necessary, completely remove the bolts
and inspect O-rings for nicks, cuts and
chemical attack.
Step 9
With the adjustable wrenches, remove the
bolts that secure the liquid chamber to the air
chamber. Using an adjustable wrench, or by
rotating the diaphragm by hand, remove the
diaphragm assembly (Figure 10a).

WIL-11160-E-09 Wilden®
15
Disassembly / Reassembly
Step 10
NOTE: Due to varying torque values, one of the following two situations
may occur:
1) The outer piston, diaphragm and inner piston remain attached to the shaft and the
entire assembly can be removed from the center section (Figure 10a);
2) The outer piston, diaphragm and inner piston separate from the shaft which remains
connected to the opposite side diaphragm assembly (Figure 10b). Repeat disassembly
instructions for the opposite liquid chamber. Inspect diaphragm assembly and shaft for
signs of wear or chemical attack. Replace all worn parts with genuine Wilden parts for
reliable performance. Rubber/TPE are not available.
Step 11
To remove diaphragm assembly from 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.

WIL-11160-E-09 Wilden®
16
Disassembly / Reassembly
Air Valve / Center Section Disassembly
Tools Required :
• 3/8" Hex-Head
Wrench
• 3/4" Hex Socket
• 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 into a suitable container. Be aware of hazardous effects of contact with
your process fluid.
The Wilden P1500 pump utilizes a revolutionary Pro-Flo®air distribution system. A 19 mm (3/4") air inlet
connects the air supply to the center section. Proprietary composite seals reduce the coefficient of
friction and allow the P1500 to run lubefree. Constructed of polypropylene, the Pro-Flo®air distribution
system is designed to perform in on/off, non-freezing, non-stalling, tough duty applications.
NOTE: Replace worn parts with genuine Wilden parts for reliable performance .
Step 1
Loosen the air valve bolts utilizing a 3/8" hex-
head wrench.
Step 2
Remove muffler plate and air valve bolts
from air valve assembly exposing muffler
gasket for inspection. Replace if necessary.
Step 3
Lift away air valve assembly and remove
air valve gasket for inspection. Replace if
necessary.
Step 4
Remove air valve end cap to expose air valve spool by
simply lifting up on end cap once air valve bolts are
removed

WIL-11160-E-09 Wilden®
17
Disassembly / Reassembly
Step 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
Remove pilot spool retaining O-rings
on both sides of center section with
O-ring pick.
Step 7
Remove air chamber bolts with 3/4"
hex socket.
Step 8
Remove pilot spool bushing from
center block.
Step 9
Gently remove pilot spool from bushing
and inspect spool and seals for nicks,
gouges or other signs of wear. Replace
pilot sleeve assembly or outer bushing
O-rings if necessary.
NOTE: Seals should not be
removed from pilot spool. Seals are
not sold separately. The end of the
pilot spool that has a “center hole”
in it should not be fed into the bore
first (see TB 1296).
Step 10
Check center section Glyd™ rings
for signs of wear. If necessary,
remove Glyd™ rings with o-ring pick
and replace.
.

WIL-11160-E-09 Wilden®
18
Disassembly / Reassembly
Reassembly Hints & Tips
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.
• Lubricate air valve bore, center section shaft and pilot spool
bore with NLGI grade 2 white EP grease or equivalent.
• Clean the inside of the center section shaft bushing to ensure
no damage is done to new glyd ring seals.
• A small amount of NLGI grade 2 white EP grease can be
applied to the muffler and air valve gaskets to locate gaskets
during assembly.
• Make sure that the exhaust port on the muffler plate is centered
between the two exhaust ports on the center section.
• Stainless bolts should be lubed to reduce the possibility of
seizing during tightening.
GLYD™ RING 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.
PRO-FLO
®
MAXIMUM TORQUE SPECIFICATIONS
Description of Part
Torque
AirValve
8.5 N•m (75 in-lb))
Outer Piston
136 N•m (100 ft-lb)
Air Chamber/Center Block
4.6 N•m (55 ft-lb))
Tee Section/Elbow
3.4 N•m (32 ft-lb)
Elbow/Liquid Chamber
3.4 N•m (32 ft-lb)
Liquid Chamber/Air Chamber
3.4 N•m (32 ft-lb)
Figure A
NSTALLATION
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 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 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 grease.
•Slowly insert the center shaft with a rotating motion. This will
complete the resizing of the seal.
•Perform these steps for the remaining seal.
Figure B

WIL-11160-E-09 Wilden®
19
Exploded View and Parts Listing
P1500 PLASTIC
AIR DISTRIBUTION SYSTEM
EXPLODED VIEW
.
Section 8

WIL-11160-E-09 Wilden®
20
Exploded View and Parts List
Item No.
Description
Qty.
P1500/P...
Part Number
P1500/K...
Part Number
1
Pro-Flo® Air Valve Assembly 1
1
15-2010-20
15-2010-20
2
O-Ring (-235), End Cap
1
71-1280-52
71-1280-52
3
End Cap, Pro-Flo®
1
15-2332-20
15-2332-20
4
Screw, SHCS, Air Valve (7/16-14 x 5-7/8")
6
15-6001-03
15-6001-03
5
Muffler Plate, Pro-Flo®
1
15-3181-20
15-3181-20
6
Gasket, Muffler Plate
1
15-3505-52
15-3505-52
7
Gasket, Air Valve
1
15-2615-52
15-2615-52
8
Nut, Square (7/16-14)
6
15-6506-03
15-6506-03
9
Center Block Assembly 2
1
15-3110-20
15-3110-20
10
Removable Pilot Sleeve Assembly
1
15-3882-99
15-3882-99
11
Shaft
1
15-3842-03
15-3842-03
12
Center Block Glyd™ Ring
2
15-3210-55-225
15-3210-55-225
13
Gasket, Center Block, Pro-Flo®
2
15-3525-52
15-3525-52
14
Air Chamber, Pro-Flo®
2
15-3681-20
15-3681-20
15
Air Chamber Screw 1/2-13 x 3-1/4"
12
15-6201-03
15-6201-03
16
Threaded Sleeve
6
15-7710-08
15-7710-08
1Air Valve Assembly includes items 2 and 3.
2Center Block Assembly includes item 12.
All boldface items are primary wear parts.