GORMAN-RUPP PUMPS 4D-X3 3P Application guide

OM-01516-01

June 29, 1981

Rev. E 08‐25‐15

GORMAN‐RUPP PUMPS

www.grpumps.com

e1981 Gorman‐Rupp Pumps Printed in U.S.A.

INSTALLATION, OPERATION,

AND MAINTENANCE MANUAL

WITH PARTS LIST

DIAPHRAGM PUMP

MODEL

4D-X3 3P

Gorman‐Rupp pump online at

www.grpumps.com

Valid serial number and e‐mail address required.

RECORD YOUR PUMP MODEL AND SERIAL NUMBER

Please record your pump model and serial number in the

spaces provided below. Your Gorman‐Rupp distributor

needs this information when you require parts or service.

Pump Model:

Serial Number:

TABLE OF CONTENTS

INTRODUCTION PAGE I - 1...................................................

WARNINGS SECTION A PAGE A - 1........................................

INSTALLATION - SECTION B PAGE B - 1.....................................

Pump Dimensions PAGE B - 1........................................................

PREINSTALLATION INSPECTION PAGE B - 1...............................................

POSITIONING PUMP PAGE B - 2..........................................................

Lifting PAGE B - 2....................................................................

Mounting PAGE B - 2................................................................

SUCTION AND DISCHARGE PIPING PAGE B - 2............................................

Materials PAGE B - 2.................................................................

Line Configuration PAGE B - 2.........................................................

Fixed, Rigid Piping PAGE B - 2........................................................

Gauges PAGE B - 3..................................................................

SUCTION LINES PAGE B - 3..............................................................

Fittings PAGE B - 3..................................................................

Strainers PAGE B - 4.................................................................

Sealing PAGE B - 4..................................................................

DISCHARGE LINES PAGE B - 4...........................................................

Valves PAGE B - 4...................................................................

ALIGNMENT PAGE B - 4.................................................................

ELECTRICAL CONNECTIONS PAGE B - 5..................................................

OPERATION - SECTION C PAGE C - 1.......................................

STARTING PAGE C - 1...................................................................

OPERATION PAGE C - 1.................................................................

Priming PAGE C - 1..................................................................

OPERATION CHECKS PAGE C - 1.........................................................

Gearbox Check PAGE C - 1...........................................................

Leakage Check PAGE C - 1...........................................................

Strainer Check PAGE C - 2............................................................

Accumulator Chamber Check PAGE C - 2..............................................

STOPPING PAGE C - 2...................................................................

Cold Weather Preservation PAGE C - 2.................................................

GEARBOX TEMPERATURE CHECK PAGE C - 2.............................................

TROUBLESHOOTING - SECTION D PAGE D - 1...............................

PUMP MAINTENANCE AND REPAIR SECTION E PAGE E - 1..................

STANDARD PERFORMANCE CHART PAGE E - 1...........................................

PARTS LISTS:

Pump Model PAGE E - 3.............................................................

Diaphragm Pot Assembly PAGE E - 5..................................................

Plunger Rod Assembly PAGE E - 7....................................................

Gearbox Assembly PAGE E - 9........................................................

TABLE OF CONTENTS

(continued)

PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE E - 10...........................

Suction And Discharge Check Valve Removal PAGE E - 10...............................

Diaphragm Removal PAGE E - 10......................................................

Plunger Rod Removal And Disassembly PAGE E - 11....................................

Gearbox Removal And Disassembly PAGE E - 11........................................

Gearbox Reassembly And Installation PAGE E - 12......................................

Plunger Rod Reassembly And Installation PAGE E - 14...................................

Diaphragm Installation PAGE E - 15....................................................

Suction And Discharge Check Valve Installation PAGE E - 15.............................

LUBRICATION PAGE E - 15...............................................................

Plunger Rod Assembly PAGE E - 15...................................................

Gearbox PAGE E - 15................................................................

Motor PAGE E - 16...................................................................

D SERIES OM-01516

PAGE I - 1INTRODUCTION

INTRODUCTION

Thank You for purchasing a Gorman‐Rupp pump.

Read this manual carefully to learn how to safely

install and operate your pump. Failure to do so

could result in personal injury or damage to the

pump.

Because pump installations are seldom identical,

this manual cannot possibly provide detailed in

structions and precautions for every aspect of

each specific application. Therefore, it is the re

sponsibility of the owner/installer of the pump to

ensure that applications not addressed in this

manual are performed only after establishing that

neither operator safety nor pump integrity are com

promised by the installation. Pumps and related

equipment must be installed and operated ac

cording to all national, local and industry stan

dards.

If there are any questions regarding the pump or

its application which are not covered in this man

ual or in other literature accompanying this unit,

please contact your Gorman‐Rupp distributor, or

The Gorman‐Rupp Company:

The Gorman‐Rupp Company

P.O. Box 1217

Mansfield, Ohio 44901-1217

Phone: (419) 755-1011

or:

Gorman‐Rupp of Canada Limited

70 Burwell Road

St. Thomas, Ontario N5P 3R7

Phone: (519) 631-2870

For information or technical assistance on the

power source, contact the power source manufac

turer's local dealer or representative.

HAZARD AND INSTRUCTION

DEFINITIONS

The following are used to alert maintenance per

sonnel to procedures which require special atten

tion, to those which could damage equipment, and

to those which could be dangerous to personnel:

Immediate hazards which WILL result in

severe personal injury or death. These

instructions describe the procedure re

quired and the injury which will result

from failure to follow the procedure.

Hazards or unsafe practices which

COULD result in severe personal injury

or death. These instructions describe

the procedure required and the injury

which could result from failure to follow

the procedure.

Hazards or unsafe practices which COULD

result in minor personal injury or product

or property damage. These instructions

describe the requirements and the possi

ble damage which could result from failure

to follow the procedure.

NOTE

Instructions to aid in installation, operation, and

maintenance or which clarify a procedure.

D SERIES OM-01516

PAGE A - 1SAFETY

SAFETY ‐ SECTION A

This information applies to D Series

electric motor driven diaphragm

pumps. Refer to the manual accompa

nying the motor before attempting to

begin operation.

Before attempting to open or service the

pump:

1. Familiarize yourself with this man

ual.

2. Lock out incoming power to the

motor to ensure that the pump will

remain inoperative.

3. Allow the pump to completely cool

if overheated.

4. Close the discharge valve (if

used).

5. Drain the pump.

This pump is designed to handle non‐

volatile non‐flammable liquids contain

ing specified entrained solids. Do not

attempt to pump volatile, corrosive, or

flammable liquids which may damage

the pump or endanger personnel as a

result of pump failure.

After the pump has been installed, block

the wheels and secure the pump to pre

vent creeping. Make certain that the

pump and all piping or hose connec

tions are tight, properly supported and

secure before operation.

Do not operate the pump without the ec

centric and coupling guards in place

over the rotating parts. Exposed rotat

ing parts can catch clothing, fingers, or

tools, causing severe injury to person

nel.

The gearbox provided on this pump is

designed for operation at 1750 RPM

maximum input speed. If operated at a

higher RPM, pump components may be

destroyed.

Install and operate only an explosion

proof motor in an explosive atmo

sphere. Install, connect, and operate

the motor in accordance with the Na

tional Electric Code and all local codes.

If there is a conflict between the instruc

tions in the manual accompanying the

unit and the National Electric Code or

the applicable local code, the National

or local code shall take precedence.

The electrical power used to operate

this pump is high enough to cause inju

ry or death. Obtain the services of a qu

alified electrician to make all electrical

connections. make certain that the

pump and motor are properly

grounded; never use gas pipe as an

electrical ground. Be sure that the in

coming power matches the voltage and

D SERIESOM-01516

PAGE A - 2 SAFETY

phase of the pump and motor before

connecting the power source. Do not

run the pump if the voltage is not within

the limits.

All electrical connections must be in ac

cordance with the National Electric

Code. If there is a conflict between the

instructions provided and N.E.C. speci

fications, N.E.C. specifications shall

take precedence. All electrical equip

ment supplied with this pump was in

conformance with N.E.C. requirements

in effect on the date of manufacture.

Failure to follow applicable specifica

tions, or substitution of electrical parts

not supplied or approved by the man

ufacturer, can result in severe injury or

death.

Never install a positive shut‐off valve in the

discharge line; discharge restrictions will

cause excessive friction loss resulting in

overloading and destruction of pump and

drive components. It is strongly recom

mended that unless absolutely necessary,

no positive shut‐off valve be installed in the

suction line; excessive restriction will

cause incomplete filling of the diaphragm

chamber and result in shortened dia

phragm life.

D SERIES OM-01516

PAGE B - 1INSTALLATION

INSTALLATION - SECTION B

Review all SAFETY information in Section A.

Since pump installations are seldom identical, this

section offers only general recommendations and

practices required to inspect, position, and ar

range the pump and piping.

For further assistance, contact your Gorman‐Rupp

distributor or the Gorman‐Rupp Company.

Pump Dimensions

See Figure 1 for the approximate physical dimen

sions of this pump.

OUTLINE DRAWING

Figure 1. Model 4D-X3 3P

PREINSTALLATION INSPECTION

The pump assembly was inspected and tested be

fore shipment from the factory. Before installation,

inspect the pump for damage which may have oc

curred during shipment. Check as follows:

a. Inspect the pump for cracks, dents, damaged

threads, and other obvious damage.

b. Check for and tighten loose attaching hard

ware. Since gaskets tend to shrink after dry

ing, check for loose hardware at mating sur

faces.

c. Carefully read all tags, decals, and markings

on the pump assembly, and perform all duties

indicated.

d. Check levels and lubricate as necessary. Re

fer to LUBRICATION in the MAINTENANCE

AND REPAIR section of this manual and per

form duties as instructed.

e. If the pump and motor have been stored for

more than 12 months, some of the compo

nents or lubricants may have exceeded their

maximum shelf life. These must be inspected

OM-01516 D SERIES

PAGE B - 2 INSTALLATION

or replaced to ensure maximum pump serv

ice.

If the maximum shelf life has been exceeded, or if

anything appears to be abnormal, contact your

Gorman‐Rupp distributor or the factory to deter

mine the repair or updating policy. Do not put the

pump into service until appropriate action has

been taken.

POSITIONING PUMP

Lifting

Pump unit weights will vary depending on the

mounting and drive provided. Check the shipping

tag on the unit packaging for the actual weight, and

use lifting equipment with appropriate capacity.

Drain the pump and remove all customer‐installed

equipment such as suction and discharge hoses

or piping before attempting to lift existing, installed

units.

The pump assembly can be seriously

damaged if the cables or chains used to lift

and move the unit are improperly wrapped

around the pump.

Mounting

Locate the pump in an accessible place as close as

practical to the liquid being pumped. Level mount

ing is essential for proper operation.

The pump may have to be supported or shimmed

to provide for level operation or to eliminate vibra

tion.

After the pump has been positioned, block the

wheels and secure the pump to prevent creeping.

SUCTION AND DISCHARGE PIPING

Pump performance is adversely effected by in

creased suction lift, discharge elevation, and fric

tion losses. See Page E‐1 to be sure your overall

application allows the pump to operate within the

safe operation range.

Materials

Either pipe or hose maybe used for suction and

discharge lines; however, the materials must be

compatible with the liquid being pumped. If hose is

used in suction lines, it must be the rigid‐wall, rein

forced type to prevent collapse under suction. Us

ing piping couplings in suction lines is not recom

mended.

Line Configuration

Keep suction and discharge lines as straight as

possible to minimize friction losses. Make mini

mum use of elbows and fittings, which substan

tially increase friction loss. If elbows are necessary,

use the long‐radius type to minimize friction loss.

Never pull a line into place by tightening connec

tions at the pump. Lines near the pump must be in

dependently supported to avoid strain on the

pump which could cause excessive vibration and

increased diaphragm and gear train wear. If hose‐

type lines are used, they should have adequate

support to secure them when filled with liquid and

under pressure.

Fixed, Rigid Piping

This pump is equipped with an integral suction ac

cumulator chamber which promotes an efficient

flow of liquid and acts as an air cushion against

shock. Since the air in this chamber will leak away

during pump operation, the air must be replen

ished periodically. To introduce air into the cham

ber, stop the pump and remove the suction accu

mulator plug and integral gasket; this will break

prime and allow the liquid in the chamber to drain

away through the suction line.

If the pump is mounted in a system with fixed, rigid

piping, it is recommended that a flexible connec

tion be installed at or near the suction and dis

charge ports to absorb shock which would other

wise be transmitted through the drive train and

greatly accelerate pump wear.

In a fixed piping installation, properly sized surge

suppressors must be installed in both suction and

discharge lines. If commercial surge suppressors

are not readily available, air chambers may be fab

ricated from pipe as shown in Figure 2.

D SERIES OM-01516

PAGE B - 3INSTALLATION

AIR CHAMBERS

(18 TO 24 INCH LENGTHS OF

6 TO 8 INCH DIAMETER PIPE

WITH WELDED CAPS)

DISCHARGE

CHAMBER

DISCHARGE

FLEXIBLE JOINT FLEXIBLE JOINT

SUCTION

CHAMBER

1/2‐INCH VALVE FOR

RECHARGING AIR

CHAMBER WITH

COMPRESSED AIR

(ALSO ON DISCHARGE

CHAMBER)

SUCTION

NOTE: INSTALL AIR CHAMBERS OFF FLOW LINE TEES

TO AVOID SURFACE TURBULENCE WITHIN CHAMBERS.

Figure 2. Fixed Piping Installation

Note that the air chambers have not been installed

directly in the flow line, but have been installed off

tees to avoid turbulence within the chambers. The

air chambers are fitted with valves to permit intro

duction of small amounts of compressed air to fur

ther dampen shock; this compressed air will leak

away during operation, and should be replaced

from time to time. If the suction chamber floods,

open the suction chamber valve to break prime

and allow the liquid in chamber to drain through

the suction line.

Gauges

If discharge pressure and vacuum suction gauges

are desired, drill and tap the suction and discharge

lines not less than 18 inches (457,2 mm) from the

suction and discharge ports and install the lines.

Installation closer to the pump may result in erratic

readings.

SUCTION LINES

To avoid air pockets which could affect pump prim

ing, the suction line must be as short and direct as

possible. When operation involves a suction lift, the

line must always slope upward to the pump from

the source of the liquid being pumped; if the line

slopes down to the pump at any point along the

suction run, air pockets will be created.

NOTE

Maximum pump performance is realized at suction

lifts of 5 feet (1,5 m) or less. Use the shortest possi

ble length of suction hose or piping; lengths of 25

feet (7,6 m) or longer will reduce the capacity of the

pump.

It is strongly recommended that no positive shut‐

off valve be installed in the suction line; excessive

restrictions will cause incomplete filling of the dia

phragm chamber and result in short diaphragm

life.

Fittings

Suction lines should be the same size as the pump

inlet. If reducers are used in suction lines, they

should be the eccentric type, and should be in

stalled with the flat part of the reducers uppermost

to avoid creating air pockets. The suction line

should not be restricted more than 1 inch below the

nominal suction size.

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