GORMAN-RUPP PUMPS D Series Application guide

OM−02699−OE01

June 3, 1987

Rev. E 11-18-08

OTS

THE GORMAN-RUPP COMPANY DMANSFIELD, OHIO

www.grpumps.com

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−13

Gorman-Rupp pump online at

www.grpumps.com/register.

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:

The engine exhaust from this

product contains chemicals

known to the State of California to

cause cancer, birth defects or

other reproductive harm.

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 − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Strainers PAGE B − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sealing PAGE B − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DISCHARGE LINES PAGE B − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Siphoning PAGE B − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valves 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

TABLE OF CONTENTS

(continued)

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 − 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diaphragm Installation PAGE E − 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Suction And Discharge Check Valve Installation PAGE E − 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATION PAGE E − 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Plunger Rod Assembly PAGE E − 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gearbox PAGE E − 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine PAGE E − 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D SERIES OM−02699−01

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.

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 positive displacement pump, util-

izing a single-action diaphragm to produce a

straight-through flow of liquid. The pump is close-

coupled to a 3.5 HP Briggs and Stratton gasoline

engine. It is ideally suited to industrial and contrac-

tor’s applications since it will handle liquids rang-

ing from clear water to construction-site muck. The

basic material of construction for wetted parts is

aluminum, with neoprene flap valves and a Dura-

Blue 1000tdiaphragm.

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

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

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−02699−01

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. Disconnect the spark plug wire to

ensure that the pump will remain

inoperative.

3. Close the discharge valve (if

used).

4. 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.

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.

The gearbox provided on this pump is

designed for operation at 2600 RPM

maximum synchronous input speed. If

operated at a higher rpm, pump compo-

nents may be destroyed.

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−02699−01

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−02699−01

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-13

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 engine 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−02699−01 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-

D SERIES OM−02699−01

PAGE B − 3INSTALLATION

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.

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-

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