GORMAN-RUPP PUMPS D Series Application guide

COM-01636-O1

September 13, 2010

Rev. A 03‐20‐13

THE GORMAN‐RUPP COMPANY DMANSFIELD, OHIO

GORMAN‐RUPP OF CANADA LIMITED DST. THOMAS, ONTARIO, CANADA Printed in U.S.A.

ECopyright by the Gorman‐Rupp Company

INSTALLATION, OPERATION,

AND MAINTENANCE MANUAL

WITH PARTS LIST

D SERIES PUMP

MODEL

3D-GX160

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.................................................

SAFETY 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 - 4...............................................................

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

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

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

Siphoning PAGE B - 4.............................................................

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

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

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 - 1.........................................................

Accumulator Chamber Check PAGE C - 1...........................................

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 Flap Valve Removal PAGE E - 10...............................

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

Plunger Rod Removal And Disassembly PAGE E - 10..................................

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 - 14..................................................

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

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

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

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

Engine PAGE E - 15................................................................

D SERIES OM-01636

PAGE I - 1INTRODUCTION

INTRODUCTION

This Installation, Operation, and Maintenance

manual is designed to help you achieve the best

performance and longest life from your Gorman‐

Rupp pump.

This is a D Series, engine‐driven, positive displace

ment pump utilizing a single‐action diaphragm to

produce a straight‐through flow of liquid. The

pump is close‐coupled to a single cylinder, air

cooled Honda gasoline engine.

The pump is ideally suited to industrial and con

tractor's applications since it will handle liquids

ranging from clear water to construction‐site

muck. The basic material of construction for wet

ted parts is aluminum, with neoprene flap valves

and a DURABLUE 1000tdiaphragm.

If there are any questions regarding the pump or its application which are not covered in this manual or in

other literature accompanying this unit, please contact your Gorman‐Rupp distributor, or write:

The Gorman‐Rupp Company or Gorman‐Rupp of Canada Limited

P.O. Box 1217 70 Burwell Road

Mansfield, Ohio 44901-1217 St. Thomas, Ontario N5P 3R7

The following are used to alert maintenance personnel to procedures which require special attention, 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-01636

PAGE A - 1SAFETY

SAFETY ‐ SECTION A

This information applies to D Series en

gine driven diaphragm pumps. Refer to

the manual accompanying the engine

before attempting to begin operation.

Before attempting to open or service the

pump:

1. Familiarize yourself with this man

ual.

2. Shut down the engine and take

precautions to ensure that the

pump will remain inoperative.

3. 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 located in op

erating position, make certain that the

wheels have been blocked and secured

to prevent creeping before attempting

to operate the pump.

After the pump has been installed, make

certain that the pump and all piping or

hose connections 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 2600 RPM

maximum input speed. If operated at a

higher RPM, pump components may be

destroyed.

Never tamper with the governor to gain

more power. The governor establishes

safe operating limits that should not be

exceeded. The maximum continuous

operating speed for this pump is 2600

RPM.

Do not operate an internal combustion

engine in an explosive atmosphere.

When operating internal combustion

engines in an enclosed area, make cer

tain that exhaust fumes are piped to the

outside. These fumes contain carbon

monoxide, a deadly gas that is color

less, tasteless, and odorless.

D SERIESOM-01636

PAGE A - 2 SAFETY

Fuel used by internal combustion en

gines presents an extreme explosion

and fire hazard. Make certain that all

fuel lines are securely connected and

free of leaks. Never refuel a hot or run

ning engine. Avoid overfilling the fuel

tank. Always use the correct type of fuel.

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-01636

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. Pump Model 3D‐GX160

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 and engine 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 engine have been stored for

more than 12 months, some of the compo

OM-01636 D SERIES

PAGE B - 2 INSTALLATION

nents or lubricants may have exceeded their

maximum shelf life. These must be inspected

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

This pump is designed to be easily positioned for

operation using the drawbar and wheels. The total

pump weight is approximately 275 pounds (125

kg), not including accessories or options. Cus

tomer installed equipment such as suction and dis

charge hoses must be removed before attempting

to lift.

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.

To ensure sufficient lubrication and fuel supply to

the engine, do not position the pump and engine

more than 15_off horizontal for continuous opera

tion. The pump and engine may be positioned up

to 30_off horizontal for intermittent operation

only; however, the engine manufacturer should be

consulted for continuous operation at angles

greater than 15_.

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 pump to operate within the safe

operation range.

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