GORMAN-RUPP PUMPS 2D-X.75 1P, D Series, 2D-X.75 3P Installation, Operation And Maintenance Manual
Page 1
OM‐01478‐04
September 13, 2010
Rev. A 06‐27‐2019
INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
WITH PARTS LIST
D SERIES PUMP
MODEL
2D-X.75 1P
GORMAN‐RUPP PUMPS
www.grpumps.com
e2010 Gorman‐Rupp Pumps Printed in U.S.A.
Page 2
Register your new
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:
Page 3
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...................................................................
ELECTRICAL CONNECTIONS 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............................................................
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.............................................................
Plunger Rod Assembly PAGE E - 5....................................................
PUMP DISASSEMBLY AND REASSEMBLY PAGE E - 6.......................................
Suction And Discharge Check Valve Removal PAGE E - 7................................
Diaphragm and Plunger Rod Removal PAGE E - 7.......................................
i
Page 4
TABLE OF CONTENTS
(continued)
Plunger Rod and Diaphragm Removal PAGE E - 7.......................................
Suction And Discharge Check Valve Installation PAGE E - 8..............................
LUBRICATION PAGE E - 8................................................................
Plunger Rod Assembly PAGE E - 8....................................................
Gear Reducer PAGE E - 8............................................................
ii
Page 5
D SERIES
OM-01478
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 is a D Series, positive displacement pump,
utilizing a single‐action diaphragm to produce a
straight‐through flow of liquid. The pump is flex‐
coupled to a 3/4 HP explosion‐proof electric motor.
It is ideally suited to industrial and contractor's ap
plications since it will handle liquids ranging from
clear water to construction‐site muck. Since it is
driven by an explosion‐proof motor, the pump may
be operated in a hazardous‐duty environment; the
pump is not, however, designed to handle volatile,
flammable or corrosive liquids. The basic material
of construction for wetted parts is aluminum, with
neoprene flap valves and diaphragm.
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.
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.
For information or technical assistance on the mo
tor, contact the motor manufacturer's local dealer
or representative.
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
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.
PAGE I - 1INTRODUCTION
Page 6
D SERIES
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 and tag out incoming
power to the motor to ensure that
the pump will remain inoperative.
3. Allow the pump to completely cool
if overheated.
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.
OM-01478
All electrical connections must be in ac
cordance with the National Electric
Code. If there is a conflict between in
structions provided and N.E.C. specifi
cations, N.E.C. specifications shall take
precedence. All electrical equipment
supplied with this pump was in confor
mance with N.E.C. requirements in ef
fect on the date of manufacture. Failure
to follow applicable specifications, or
substitution of electrical parts not sup
plied or approved by the manufacturer,
can result in severe injury or death.
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 electrical power used to operate
this pump is high enough to cause inju
ry or death. Obtain the services of a
qualified electrician to make all electri
cal connections. Make certain the pump
and motor are properly grounded; never
use gas pipe as an electrical ground. Be
sure that the incoming power matches
the voltage and phase of the motor be
fore making motor connections. Do not
run the pump if the voltage is not within
limits.
PAGE A - 1SAFETY
Page 7
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
D SERIESOM-01478
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.
PAGE A - 2 SAFETY
Page 8
D SERIES OM-01478
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.
OUTLINE DRAWING
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.
Figure 1. Pump Model 2D‐X.75 1P
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
move the shipping plug from the top of the
gear reducer and replace it with the vented
plug shipped loose with the unit. Refer to LU
BRICATION in the MAINTENANCE AND RE
PAIR section of this manual and perform du
ties as instructed.
e. If the pump and motor have been stored for
more than 12 months, some of the compo
PAGE B - 1INSTALLATION
Page 9
OM-01478 D SERIES
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
Do not install and operate a non‐explo
sion proof motor in an explosive atmo
sphere.
Lifting
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.
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.
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
PAGE B - 2 INSTALLATION
Page 10
D SERIES OM-01478
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
AIR CHAMBERS
(18 TO 24 INCH LENGTHS OF
6 TO 8 INCH DIAMETER PIPE
WITH WELDED CAPS)
DISCHARGE
CHAMBER
DISCHARGE
FLEXIBLE JOINT
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.
1/2‐INCH VALVE FOR
RECHARGING AIR
CHAMBER WITH
COMPRESSED AIR
(ALSO ON DISCHARGE
CHAMBER)
SUCTION
CHAMBER
FLEXIBLE JOINT
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
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
PAGE B - 3INSTALLATION
Page 11
OM-01478 D SERIES
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.
The use of pipe couplings in the suction line is not
recommended.
Strainers
pipe dope. The pipe dope should be compatible
with the liquid being pumped.
DISCHARGE LINES
The discharge line must be the same size
as, or larger than, the suction line. Never in
stall or operate the pump with a discharge
line smaller than the suction; a restricted
discharge line will cause excessive friction
loss resulting in overloading and destruc
tion of pump and drive components.
Siphoning
Do not terminate the discharge line at a level lower
than that of the liquid being pumped unless a si
phon breaker is used in the line. Otherwise, a si
phoning action causing damage to the pump
could result.
If a strainer is furnished with the pump, be certain
to use it; any spherical solids which pass through a
strainer furnished with the pump will also pass
through the pump itself.
If a strainer is not furnished with the pump, but is
installed by the pump user, make certain that the
total area of the openings in the strainer is at least
three or four times the cross section of the suction
line, and that the openings will not permit passage
of solids larger than the solids handling capability
of the pump.
This pump is designed to handle up to 1‐1/2 inch
(38,1 mm) diameter spherical solids.
Sealing
Since even a slight leak will affect priming, head,
and capacity, especially when operating with a
high suction lift, all connections in the suction line
should be sealed with pipe dope to ensure an air
tight seal. Follow the sealant manufacturer's rec
ommendations when selecting and applying the
Valves
The pump is provided with integral suction and dis
charge check valves.
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.
ELECTRICAL CONNECTIONS
Before connecting the motor to the incoming
power, check that the electrical service available
PAGE B - 4 INSTALLATION
Page 12
D SERIES OM-01478
matches the pump motor requirements stamped
on the motor nameplate.
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
Motor Data
MODEL
2D-X.75 1P
VOLTAGE PHASE HP Hz RPM
115/230 1 .75 60 1750
connections. Make certain the pump
and motor are properly grounded; never
use gas pipe as an electrical ground. Be
sure that the incoming power matches
the voltage and phase of the motor be
fore making motor connections. Do not
run the pump if the voltage is not within
limits.
Refer to the following motor data before making
electrical connections.
PAGE B - 5INSTALLATION
Page 13
D SERIES
OM-01478
OPERATION - SECTION C
Review all SAFETY information in Section A.
Follow the instructions on all tags, labels and
decals attached to 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, se
cure the pump to prevent creeping.
Make certain that the pump and all pip
ing or hose connections are tight, prop
erly supported and secure before oper
ation.
Pump application will affect its performance, espe
cially discharge velocities. Consult the Gorman‐
Rupp factory for actual performance levels for the
pump.
ened diaphragm life. No positive shut‐off
valve should be installed in the discharge
line.
STARTING
Consult the operations manual furnished with the
motor before starting the pump. Open any valves
installed in the suction line and start the pump.
OPERATION
Priming
The pump may not prime immediately because the
suction line must first fill with liquid. If the pump fails
to prime within five minutes, stop the engine and
check the suction line for leaks.
OPERATION CHECKS
Gearbox Check
Check that the gearbox is properly lubricated (see
LUBRICATION in MAINTENANCE AND RE
PAIR).
Install the pump and piping as described in IN
STALLATION. Make sure that the piping connec
tions are tight, and that the pump is securely
mounted. Check that components are properly lu
bricated (see LUBRICATION in MAINTENANCE
AND REPAIR).
Make certain that any positive shut‐off
valve installed in the suction line is open
before operating the pump; excessive re
striction will cause incomplete filling of the
diaphragm chamber and result in short
OPERATION PAGE C - 1
Leakage Check
No leakage should be visible at pump mating sur
faces, connections or fittings. Keep all line connec
tions and fittings tight to maintain maximum pump
efficiency.
Strainer Check
If a suction strainer has been installed, check and
clean it as necessary. It should be cleaned if pump
flow begins to drop. If a vacuum suction gauge has
been installed, monitor and record the readings
regularly to detect strainer blockage.
Page 14
OM-01478 D SERIES
STOPPING
After stopping the pump, lock out and tag out in
coming power to the motor to ensure that the
pump will remain inoperative.
If the pump will be idle for more than a few hours, or
if it has been pumping liquids containing a large
amount of solids, flush it with clean water.
Cold Weather Preservation
The primary construction materials of this
pump are aluminum, with neoprene flap
valves and diaphragm. Do not attempt to
clean or flush this pump with any liquid
which would attack pump fittings or com
ponents. Avoid cleaning with cleaning sol
vent.
In below freezing conditions, drain the water from
the pump and the lines when the pump is not in op
eration. Also, clean out any solids by flushing with a
hose.
GEARBOX TEMPERATURE CHECK
The gearbox runs higher than ambient tempera
tures because of heat generated by friction. Tem
peratures of approximately 200_ F (93_C) are con
sidered normal, and can operate intermittently at
250_F (121_C).
Checking gearbox temperatures by hand is inac
curate. Place a contact‐type thermometer against
the housing and record this temperature for future
reference.
A sudden increase in gearbox temperature is a
warning that the bearings are at the point of failing.
Make certain that the bearing lubricant is of the
proper viscosity and at the correct level (see LU
BRICATION in Section E). Bearing overheating
can also be caused by shaft misalignment and/or
excessive vibration.
When pumps are first started, the bearings may
seem to run at temperatures above normal. Con
tinued operation should bring the temperatures
down to normal levels.
OPERATIONPAGE C - 2
Page 15
D SERIES OM-01478
TROUBLESHOOTING - SECTION D
Review all SAFETY information in Section A.
Before attempting to open or service
the pump:
1. Familiarize yourself with this man
ual.
2. Lock out and tag out incoming
power to ensure that the pump will
remain inoperative.
3. Allow the pump to completely cool
if overheated.
4. Drain the pump.
TROUBLE POSSIBLE CAUSE PROBABLE REMEDY
PUMP FAILS TO
PRIME
PUMP STOPS OR
FAILS TO DELIVER
RATED FLOW OR
PRESSURE
Air leak in suction line. Correct leak.
Lining of suction hose collapsed. Replace suction hose.
Integral suction or discharge check Clean valves, check that flange nuts
valve clogged, binding, or not seating are tight.
properly.
Cracked or broken diaphragm. Replace diaphragm.
Diaphragm not securely in place. Secure diaphragm.
Strainer clogged. Check strainer and clean if necessary.
Air leak in suction line. Correct leak.
Suction intake not properly submerged. Check installation.
Lining of suction hose collapsed. Replace suction hose.
Cracked or broken diaphragm. Replace diaphragm.
Diaphragm not securely in place. Secure diaphragm.
Strainer clogged. Check strainer and clean if necessary.
Integral suction or discharge check Clean valves, check that flange nuts
valve clogged, binding, or not seating are tight.
properly.
TROUBLESHOOTING PAGE D - 1
Page 16
OM-01478 D SERIES
TROUBLE POSSIBLE CAUSE PROBABLE REMEDY
PUMP REQUIRES
TOO MUCH
POWER
PUMP CLOGS
FREQUENTLY
EXCESSIVE NOISE
BEARINGS RUN
TOO HOT
Liquid solution too thick. Dilute if possible.
Integral discharge check valve clogged Clean valve.
or binding.
Bearings in motor or gearbox Check bearings.
worn or binding.
Integral suction or discharge check Clean valves, check that flange nuts
valve clogged, binding, or not seating are tight.
properly.
Liquid solution too thick. Dilute if possible.
Pump, gearbox, or motor not Check and tighten mounting bolts.
securely mounted.
Gearbox or motor not properly See LUBRICATION in MAINTE‐
lubricated. NANCE AND REPAIR.
Bearing temperature is high, but within Check bearing temperature regularly
limits. to monitor any increase.
Low or incorrect lubricant. Check for proper type and level of
lubricant.
Drive misaligned. Align drive properly.
TROUBLESHOOTINGPAGE D - 2
Page 17
D SERIES OM-01478
PUMP MAINTENANCE AND REPAIR ‐ SECTION E
MAINTENANCE AND REPAIR OF THE WEARING PARTS OF THE PUMP WILL MAINTAIN PEAK
OPERATING PERFORMANCE.
IN GALLONS PER MINUTE AT 60 STROKES PER MINUTE
STATIC
LIFT
IN FEET
5272624 22
15
IN LITERS PER MINUTE AT 60 STROKES PER MINUTE
STATIC
LIFT
IN METERS
3,0
4,6 68,1
6,1 64,3
STANDARD PERFORMANCE TEST DATA FOR 2D ELECTRIC MOTOR DRIVEN PUMP
0
2510 24 21 20
21 20
0
102,2 98,4 90,8 83,31,5
94,6 90,8 79,5 75,7
79,5 75,7 71,9 68,1
STATIC DISCHARGE HEAD IN FEET
510 15 20
20
19
19202122
1920 18
STATIC DISCHARGE HEAD IN METERS
1,5 3,0 4,6 6,1
75,779,583,3
71,9
18
17
75,7
71,9
Based on 70_ F (21_ C) clear water at sea level
with minimum suction lift, using 2 inch (50 mm)
suction hose and 2 inch (50 mm) non‐collapsible
discharge hose. Since pump installations are sel
dom identical, your performance may be differ
ence due to such factors as specific gravity, eleva
MAINTENANCE & REPAIR PAGE E - 1
tion and temperature.
If your pump serial number is followed by an “N”,
your pump is NOT a standard production model.
Contact the Gorman‐Rupp Company to verify per
formance or part numbers.
Page 18
PARTS PAGE
D SERIESOM-01478
SECTION DRAWING
32
4 5
3
3031
6 8 7
19
9 10 11
294 5
12
13
SUCTION VALVE
WEIGHT
20
28
1
27
SUCTION
17
2
2526
14 15
24
18 19 5
16 17
20
DISCHARGE VALVE
DISCHARGE
1723
2122
WEIGHT
Figure 1. 2D-X.75 1P Pump Model
MAINTENANCE & REPAIRPAGE E - 2
Page 19
D SERIES OM-01478
PARTS LIST
2D-X.75 1P Pump Model
(From S/N 1462001 Up)
If your pump serial number is followed by an “N”, your pump is NOT a standard production model. Contact
the Gorman‐Rupp Company to verify part numbers.
ITEM
NO.
1 CONDUIT BOX 27144-122 1
2 REDUCER FITTING 27144-131 1
3 MOTOR .75 HP 1 PH 28272-340 1
4 HEX HEAD CAP SCREW B0604 15991 8
5 LOCK WASHER J06 15991 12
6 CARRYING HANDLE ASSY 44724-007 24150 1
7 VENTED PIPE PLUG 4823 15079 1
8 SHIPPING PLUG 11495 15079 1
9 GEAR HEAD REDUCER 24572-011 1
10 ROTATION DECAL 2613BM 1
11 PLUNGER ROD LUBRICATION DECAL 38816-085 1
12 PLUNGER ROD ASSEMBLY 46181-004 1
13 RETAINER RING 26812-702 1
14 KEY N0403 15990 1
15 ECC GUARD ASSY 42381-140 24150 1
16 HEX HEAD CAP SCREW B0508 15991 4
17 HEX NUT D05 15991 10
18 HEX HEAD CAP SCREW B0606 15991 4
19 HEX NUT D06 15991 8
20 HEX HEAD CAP SCREW B0503 15991 6
21 DISCHARGE FLANGE 26812-707 1
22 DISCH VALVE ASSY 26812-708 1
23 HEX HEAD CAP SCREW B0505 15991 2
24 DIAPHRAGM POT 38234-006 10010 1
25 HEX HEAD CAP SCREW B0506 15991 4
26 LOCK WASHER J05 15991 4
27 SUCT VALVE ASSY 26812-705 1
28 SUCTION FLANGE 26812-704 1
29 TAPSCREW 1/4 X 1/2 21281-472 4
30 NAMEPLATE 38818-004 13990 1
31 DRIVE SCREW BM#04-03 17000 4
32 BASE ASSEMBLY 41547-026 24150 1
NOT SHOWN:
PART NAME
SUCTION STICKER 6588AG 1
G-R DECAL 3 IN GR-03 1
INSTRUCTION TAG 38817-030 1
STRAINER 9026D 24001 1
KEY N0305 15990 1
WARNING DECAL 2613FF 1
DISCHARGE STICKER 6588BJ 1
PART
NUMBER
QTY
INDICATES PARTS RECOMMENDED FOR STOCK
MAINTENANCE & REPAIR PAGE E - 3
Page 20
ILLUSTRATION
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1
2
D SERIESOM-01478
3
4
5
6
5.69 ±.03
14
3.00
REF
7
8
9
10
11
13
12
Figure 2. 46181-004 Plunger Rod Assembly
MAINTENANCE & REPAIRPAGE E - 4
Page 21
D SERIES OM-01478
PARTS LIST
46181-004 Plunger Rod Assembly
ITEM
NO.
1 ECCENTRIC 38555-505 11060 1
2 SOCKET HD CAPSCREW BD0504 15990 1
3 ROD END 23924-005 1
4 HEX HD CAPSCREW B0807 15991 1
5 CAP PLUG 25141-151 1
6 HEX JAM NUT AT08S 15991 1
7 SPRING CENTERING WASHER 31513-001 15030 1
8 COMPRESSION SPRING 38571-603 17110 1
9 DIAPHRAGM PLATE - UPPER 38583-003 10010 1
10 LUBE FITTING S186 1
11 DIAPHRAGM 26812-711 1
12 DIAPHRAGM PLATE - LOWER 42111-314 24150 1
13 PLUNGER ROD ASSEMBLY 46181-003 24150 1
14 HEX NUT D04 15991 3
NOT SHOWN:
INDICATES PARTS RECOMMENDED FOR STOCK
PART NAME
CAP PLUG 25141-151 2
PART
NUMBER
QTY
MAINTENANCE & REPAIR PAGE E - 5
Page 22
D SERIESOM-01478
PUMP DISASSEMBLY AND REASSEMBLY
Review all SAFETY information in Section A.
Follow the instructions on all tags, label and de
cals attached to the pump.
This pump requires little service due to its rugged,
minimum‐maintenance design. However, if it be
comes necessary to inspect or replace the wearing
parts, follow these instructions which are keyed to
the sectional views (see Figures 1 and 2) and the
accompanying parts lists.
NOTE
The gear reducer used on this pump is a model
F842B-28K-B5, manufactured by Boston Gear. A
complete gear reducer can be ordered from Gor
man‐Rupp using the part number shown in the
parts list on Page E-3. Gorman‐Rupp does not,
however, stock or furnish any component parts for
the gear reducer. Replacement parts may be ob
tained by contacting Boston Gear at
www.bostongear.com.
This manual will alert personnel to
known procedures which require spe
cial attention, to those which could
damage equipment, and to those which
could be dangerous to personnel. How
ever, this manual cannot possibly antici
pate and provide detailed instructions
and precautions for every situation that
might occur during maintenance of the
unit. Therefore, it is the responsibility of
the owner/maintenance personnel to
ensure that only safe, established main
tenance procedures are used, and that
any procedures not addressed in this
manual are performed only after estab
lishing that neither personal safety nor
pump integrity are compromised by
such practices.
Most service functions may be performed without
separating the pump and gearbox from the motor.
If major repair is required, the pump, gearbox and
motor must be disconnected.
For motor disassembly and repair, consult the lit
erature supplied with the motor, or contact your lo
cal motor representative.
Before attempting to open or service the
pump:
1. Familiarize yourself with this man
ual.
2. Disconnect the incoming power to
the motor and lock it out to ensure
that the pump will remain inopera
tive.
3. Allow the pump to completely cool
if overheated.
4. Check the temperature before
opening any covers, plates, or
plugs.
5. Close the suction and discharge
valves.
6. Vent the pump slowly and cau
tiously.
7. Drain the pump.
Use Only Genuine Gorman-Rupp re
placement parts. Failure to do so may cre
ate a hazard and damage the pump or di
minish optimal pump performance. Any
such hazard, damage or diminished per
formance is not covered by the warranty.
MAINTENANCE & REPAIRPAGE E - 6
Page 23
OM-01478D SERIES
NOTE
When appropriate recycling facilities are available,
the user should recycle components and fluids
when doing any routine maintenance / repairs and
also at the end of the pump’s useful life. All other
components and fluids shall be disposed of ac
cording to all applicable codes and regulations.
Suction and Discharge Check Valve Removal
(Figure 1)
To service the suction and discharge check valves,
remove the suction and discharge piping.
To service the suction check valve assembly (27),
remove the hardware (20) securing the suction
flange (28) and check valve assembly to the dia
phragm pot (24). Pull the check valve assembly
from the suction port.
(Figure 2)
Loosen the socket head cap screw (2) and slide
the eccentric (1) off the motor shaft. Lift the as
sembled plunger rod assembly and diaphragm out
of the diaphragm pot.
Inspect the diaphragm for excessive wear or tears.
To replace the diaphragm, disengage the nuts (14)
and remove the diaphragm plate (12) and dia
phragm (11).
If the eccentric (1) requires replacement, remove
the capscrew (4) and separate the eccentric from
the rod end (3).
If the rod end or spring (8) requires replacement,
use a socket wrench to hold the plunger rod (13)
securely and unscrew the rod end.
To remove the spring, remove the jam nut (6),
spring centering washer (7) and spring (8).
To service the discharge check valve assembly
(22), remove the hardware (17, 20, and 23) secur
ing the discharge flange (21) and check valve as
sembly to the diaphragm pot. Pull the check valve
assembly from the suction port.
Individual parts for the suction and discharge
check valve assemblies are not available. Replace
the complete assemblies if they are excessively
worn or damaged.
If no further disassembly is required, see Suction
And Discharge Check Valve Installation.
Diaphragm and Plunger Rod Removal and
Disassembly
(Figure 1)
Before attempting ro remove the diaphragm (11,
Figure 2), rotate the motor shaft until the eccentric
(1, Figure 2) is at the top of its stroke and the spring
(8, Figure 2) is decompressed.
Remove the tap screws (29) and eccentric guard
assembly (15).
Remove the hardware (16 and 17) securing the re
tainer ring (13) to the diaphragm pot (24).
Plunger Rod and Diaphragm Reassembly and
Installation
(Figure 2)
Slide the plunger rod (13) through the diaphragm
plate (9). Install the spring (8), spring centering
washer (7) and jam nut (6). Compress the spring to
the dimension shown in Figure 2 by tightening the
jam nut.
Screw the rod end (3) onto the plunger rod until
tight.
Position the eccentric (1) against the rod end. Ap
ply “Loctite Threadlocker No. 242” or equivalent
compound to the threads of the capscrew (4) and
secure the eccentric to the rod end with the caps
crew.
Position the diaphragm (11) on the diaphragm
plate (12). Slide the studs in the diaphragm plate
through the holes in the upper diaphragm plate
and secure with the nuts (14).
(Figure 1)
Position the retainer ring (13) over the diaphragm.
Position the diaphragm and plunger rod in the di
aphragm pot (24) with the grease fitting (10, Figure
2) facing away from the gear reducer (9).
MAINTENANCE & REPAIR PAGE E - 7
Page 24
D SERIESOM-01478
If removed, secure the key (14) in the gear reducer
keyway with “Loctite Retaining Compound No.
680” or equivalent and slide the eccentric over the
gear reducer shaft. Secure it by tightening the
socket head capscrew (2, Figure 2).
Secure the diaphragm and retainer ring to the dia
phragm pot by tightening the hardware (16 and 17)
in an alternating sequence.
Install the guard (15) over the plunger rod and se
cure it with the tapscrews (29).
Suction And Discharge Check Valve
Installation
(Figure 1)
Inspect the check valves and replace as required.
Individual parts for the suction and discharge
check valve assemblies are not available. Replace
the complete assemblies if they are excessively
worn or damaged.
Position the discharge check valve (22) against the
diaphragm pot with the weight positioned as
shown in Figure 1. Secure the discharge flange
(21) and diaphragm to the diaphragm pot with the
hardware (19, 20 and 23).
Refer to OPERATION, Section C before starting
the pump.
LUBRICATION
Plunger Rod Assembly
(Figure 2)
The rod end should be lubricated thor
oughly after each 8 hours of operation.
Failure to do so may cause the rod end
bearing to overheat and fail.
Before attempting to lubricate the plunger rod as
sembly, rotate the eccentric cam until the upper
grease fitting (5) can be accessed through the
slotted hole in the eccentric guard (15, Figure 1).
Use a grease gun to apply No. 2 lithium base
grease to the upper lubrication fitting until grease
escapes from the eccentric cap. Lubricate the low
er fitting (10) until grease escapes from the top of
the upper diaphragm plate inside the spring.
Position the suction check valve (27) against the di
aphragm pot with the weight positioned as shown
in Figure 1. Secure the suction flange (28) and dia
phragm to the diaphragm pot with the hardware
(20).
Check the operation of the check valves to ensure
proper seating and free movement.
Connect the suction and discharge piping as de
scribed in INSTALLATION, Section B.
Gear Reducer
(Figure 1)
The gear reducer used on this unit is lubricated for
life from the manufacturer. No additional lubrica
tion is required. If the gear reducer has been disas
sembled for maintenance, follow the lubrication in
structions provided by the gear reducer manufac
turer for the recommended type and quantity of lu
bricant.
MAINTENANCE & REPAIRPAGE E - 8
Page 25
For Warranty Information, Please Visit
www.grpumps.com/warranty
or call:
U.S.: 419-755-1280
Canada: 519-631-2870
International: +1-419-755-1352
GORMAN‐RUPP PUMPS
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