Dover PSG Wilden PS800 Engineering, Operation & Maintenance
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Dover PSG Wilden PS800 Engineering, Operation & Maintenance

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EOM
ENGINEERING OPERATION
& MAINTENANCE MANUAL
PS800
Bolted Plastic Pump
Where Innovation Flows
WIL-11440-E-07

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  • Page 1 ENGINEERING OPERATION & MAINTENANCE MANUAL PS800 Bolted Plastic Pump Where Innovation Flows WIL-11440-E-07...
  • Page 2 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.

  • Page 3: Table Of Contents

    PS800 Bolted Plastic CONTENTS SECTION 1: Precautions – Read First! ..................... 4 SECTION 2: Wilden Pump Designation System ..................5 SECTION 3: How It Works .......................... 6 SECTION 4: Dimensional Drawings ......................7 SECTION 5: Performance ........................... 8 PS800 Plastic Rubber-Fitted ........................8 PS800 Plastic EZ-Install TPE-Fitted ......................

  • Page 4: Section 1: Precautions - Read First

    PS800 Bolted Plastic SECTION 1 SECTION 1 PRECAUTIONS – READ FIRST! WARNING: Always wear safety glasses when operating CAUTION: Do not exceed 82°C (180°F) air inlet a pump to avoid eye injury. If diaphragm rupture occurs, temperature for all models. material being pumped may be forced out of the air exhaust.

  • Page 5: Section 2: Wilden Pump Designation System

    PS800 Bolted Plastic SECTION 2 WILDEN PUMP DESIGNATION SYSTEM PS800 PLASTIC LEGEND PS 800 / / X X X / X X / X X / X X X X 51 mm (2") Pump O-RINGS MODEL VALVE SEATS SPECIALTY Maximum Flow Rate: VALVE BALLS CODE (if applicable)
  • Page 6 PS800 Bolted Plastic SECTION 3 HOW IT WORKS – AIR-OPERATED DOUBLE-DIAPHRAGM PUMP The Wilden diaphragm pump is an air-operated, positive displacement, self-priming pump. These drawings show flow pattern through the pump upon its initial stroke. It is assumed the pump has no fluid in it prior to its initial stroke. FIGURE 1 The air valve directs pressurized air to FIGURE 2 When the pressurized diaphragm, FIGURE 3 At completion of the stroke, the air...
  • Page 7 PS800 Bolted Plastic SECTION 4 DIMENSIONAL DRAWING PS800 POLYPROPYLENE DIMENSIONS METRIC STANDARD ITEM (mm) (inch) 23.8 16.4 28.5 31.5 31.8 15.3 18.9 16.0 16.7 14.2 DIN FLANGE 125 DIA. 4.9 DIA. 165 DIA. 6.5 DIA. 18 DIA. 0.7 DIA. ANSI FLANGE 121 DIA.
  • Page 8 PS800 Bolted Plastic DIMENSIONAL DRAWING PS800 POLYPROPYLENE – CENTER PORT DIMENSIONS METRIC STANDARD ITEM (mm) (inch) 23.0 16.1 27.1 30.1 15.5 18.9 15.6 16.7 14.2 12.1 10.0 DIN/ANSI COMBO 121 DIA. 4.8 DIA. 152 DIA. 6.0 DIA. 21 DIA. 0.8 DIA. LW0201 REV.

  • Page 9: Section 5: Performance

    PS800 Bolted Plastic SECTION 5 PERFORMANCE PS800 PLASTIC RUBBER-FITTED Ship Weight……...Polypropylene 40 kg (89 lb) PVDF 52 kg (115 lb) Air Inlet……………………………………….3/4" Inlet…………………………………..51 mm (2") Outlet………………………………...51 mm (2") Suction Lift……………………5.9 m Dry (19.3') 8.3 m Wet (27.2') Disp. Per Stroke ………………2.5 L (0.66 gal) Max.

  • Page 10: Ps800 Plastic Full-Stroke Ptfe-Fitted

    PS800 Bolted Plastic PERFORMANCE PERFORMANCE PS800 PLASTIC FULL-STROKE PTFE-FITTED Ship Weight……...Polypropylene 40 kg (89 lb) PVDF 52 kg (115 lb) Air Inlet……………………………………….3/4" Inlet…………………………………..51 mm (2") Outlet………………………………...51 mm (2") Suction Lift……………………5.7 m Dry (18.7') 8.3 m Wet (27.2') Disp. Per Stroke ……………...2.4 L (0.63 gal) Max.

  • Page 11: Suction Lift Capability

    PS800 Bolted Plastic SUCTION LIFT CAPABILITY SUCTION LIFT CAPABILITY PS800 PLASTIC SUCTION LIFT CAPABILITY Suction-lift curves are calibrated for pumps operating at 305 m (1,000') above sea level. This chart is meant to be a guide only. There are many variables that can affect your pump's operating characteristics.

  • Page 12: Section 6: Suggested Installation, Operation, Maintenance, And Troubleshooting

    PS800 Bolted Plastic SECTION 6 SUGGESTED INSTALLATION, OPERATION, MAINTENANCE AND TROUBLESHOOTING Wilden pumps are designed to meet the performance requirements of be eliminated. In addition, pump efficiency can be adversely even the most demanding pumping applications. They have been affected if proper attention is not given to site location. designed and manufactured to the highest standards and are ...
  • Page 13 PS800 Bolted Plastic SUGGESTED INSTALLATION, OPERATION, MAINTENANCE AND TROUBLESHOOTING to control the pump from a remote location. When the pump discharge pressure equals or exceeds the air supply pressure, the NOTE: In the event of a power failure, close the shut- pump will stop.

  • Page 14: Section 7: Disassembly/Reassembly

    PS800 Bolted Plastic SUGGESTED INSTALLATION, OPERATION, MAINTENANCE AND TROUBLESHOOTING Troubleshooting Pump air valve freezes. Pump will not run or runs slowly. Check for excessive moisture in the compressed air. Remove plug from pilot spool exhaust. Either install a dryer or a hot air generator for compressed Ensure that the air inlet pressure is at least 0.4 bar (5 psig) air.

  • Page 15: Pump Disassembly

    PS800 Bolted Plastic SECTION 7 DISASSEMBLY / REASSEMBLY PUMP DISASSEMBLY Tools Required: CAUTION: Before attempting any maintenance or repair, disconnect the compressed  air line to the pump and allow all air pressure to bleed from the pump. Disconnect all 9/16"...
  • Page 16 PS800 Bolted Plastic DISASSEMBLY / REASSEMBLY DISASSEMBLY / REASSEMBLY Step 4 Step 5 Step 6 Using an appropriately-sized wrench, Inspect the ball cage area of the manifold Using an appropriate-sized wrench, remove the inlet manifold from the liquid for wear or damage. Remove the remove the liquid chamber fasteners that chambers.
  • Page 17 PS800 Bolted Plastic Figure 9a Figure 9b Step 9 Step 10 NOTE: Due to varying torque values, one of the following two situations may occur: To remove diaphragm assembly from 1) The outer piston, diaphragm and inner piston remain attached to the shaft and the entire shaft, secure shaft with soft jaws (a vise assembly can be removed from the center section (Figure 9a).

  • Page 18: Air Valve/Center Section Disassembly

    PS800 Bolted Plastic DISASSEMBLY / REASSEMBLY AIR VALVE / CENTER SECTION DISASSEMBLY Tools Required: CAUTION: Before attempting any maintenance or repair, disconnect the compressed  air line to the pump and allow all air pressure to bleed from the pump. Disconnect all 3/16"...
  • Page 19 PS800 Bolted Plastic DISASSEMBLY / REASSEMBLY Step 4 Step 5 Step 6 Remove air valve spool from air valve Remove the air chamber bolts with an Remove the air chamber and inspect the body by threading one air valve bolt into appropriately sized hex socket.
  • Page 20 PS800 Bolted Plastic DISASSEMBLY / REASSEMBLY Step 10 Step 11 Step 12 Remove and inspect the shaft bushings Once the air chambers have been Inspect the center block shaft and air (2). Replace if necessary. removed, the square air valve nuts (6) control spool Glyd™...

  • Page 21: Single-Point Exhaust

    PS800 Bolted Plastic DISASSEMBLY / REASSEMBLY SINGLE-POINT EXHAUST Step 1 Step 2 Remove the pilot exhaust muffler in the pilot Optional: Install a single-point exhaust gasket (04-2638-52). The single-point air valve bleed port located at the front of the center gasket can be purchased as a spare part or included with the purchase of a new block.
  • Page 22 PS800 Bolted Plastic DISASSEMBLY / REASSEMBLY SHAFT SEAL INSTALLATION Pre-Installation Tools After all the old seals have been removed, the inside of the bushing The following tools can be used to aid in the installation of should be cleaned to ensure no debris is left that may cause premature the new seals: damage to the new seals.

  • Page 23: Section 8: Exploded View And Parts List

    PS800 Bolted Plastic SECTION 8 EXPLODED VIEW AND PARTS LIST PS800 PLASTIC LW0203 REV. C ALL CIRCLED PART IDENTIFIERS ARE INCLUDED IN REPAIR KITS WIL-11440-E-07...
  • Page 24 PS800 Bolted Plastic EXPLODED VIEW AND PARTS LIST EXPLODED VIEW AND PARTS LIST EXPLODED VIEW AND PARTS LIST Model Description PS800/PKPPP PS800/KKPPP Item Description Qty. Air Distribution Components Air Valve Assembly, Pro-Flo ® Shift 04-2039-20 O-Ring, End Cap (-225, Ø1.859" x Ø.139") 04-2390-52-700 End Cap 04-2330-20-700...
  • Page 25 PS800 Bolted Plastic SECTION 9 ELASTOMER OPTIONS PS800 PLASTIC FULL-STROKE FULL-STROKE FULL-STROKE EZ-INSTSALL VALVE DIAPHRAGMS BACKUP VALVE VALVE MANIFOLD MATERIALS DIAPHRAGMS DIAPHRAGMS SEAT DIAPHRAGMS DIAPHRAGMS BALLS (4) SEATS (4) O-RING (4) O-RING (4) Polyurethane 08-1022-50 08-1080-50 Neoprene 08-1010-51 08-1080-51 Buna-N 08-1010-52 08-1080-52 08-1205-52...
  • Page 26 PS800 Bolted Plastic NOTES WIL-11440-E-07...
  • Page 27 PS800 Bolted Plastic NOTES NOTES WIL-11440-E-07...
  • Page 28 P: +1 (909) 422 -1730 psgdover.com Where Innovation Flows ® ® Copyright 2021 PSG , a Dover Company ® reserves the right to modify the information and illustrations contained in this document without prior notice. This is a non-contractual document. WIL-11440-E-07...

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