Page 1
AC
OM-03604-OM14
December 28, 1990
Rev. E 07‐19‐12
INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
WITH PARTS LIST
D SERIES PUMP
MODEL
3D-E1.5 1P
3D-E1.5 3P
THE GORMAN‐RUPP COMPANY D MANSFIELD, OHIO
www.grpumps.com
GORMAN‐RUPP OF CANADA LIMITED D ST. THOMAS, ONTARIO, CANADA Printed in U.S.A.
e1990 The Gorman‐Rupp Company
3D-X1.5 1P
3D-X1.5 3P
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...................................................................
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 - 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........................................................
i
Page 4
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 - 13......................................
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 - 16................................................................
ii
Page 5
D SERIES
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,
utilizing a single‐action diaphragm to produce a
straight‐through flow of liquid. The pump is flex‐
coupled to a 1.5 HP electric motor. It is ideally
suited to industrial and contractor's applications
since it will handle liquids ranging from clear water
to construction‐site muck. The basic material of
construction for wetted parts is aluminum, with
neoprene flap valves and a DuraBlue 1000t dia
phragm.
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:
OM-03604
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.
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:
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-03604
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
Do not install and operate a non‐explo
sion 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.
D SERIESOM-03604
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.
PAGE A - 2 SAFETY
Page 8
D SERIES OM-03604
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 3D‐E/X1.5 All Voltages
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
PAGE B - 1INSTALLATION
Page 9
OM-03604 D SERIES
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
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.
The pump may have to be supported or shimmed
to provide for level operation or to eliminate vibra
tion.
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
PAGE B - 2 INSTALLATION
Page 10
D SERIES OM-03604
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
AIR CHAMBERS
(18 TO 24 INCH LENGTHS OF
6 TO 8 INCH DIAMETER PIPE
WITH WELDED CAPS)
DISCHARGE
CHAMBER
DISCHARGE
FLEXIBLE JOINT
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 and discharge ports and install the lines.
SUCTION
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.
PAGE B - 3INSTALLATION
Page 11
OM-03604 D SERIES
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.
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.
Strainers
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 2‐1/4 inch
(57,2 mm) diameter spherical solids.
Sealing
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.
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
pipe dope. The pipe dope should be compatible
with the liquid being pumped.
PAGE B - 4 INSTALLATION
ALIGNMENT
The alignment of the pump and motor is critical for
trouble‐free mechanical operation. The motor and
pump must be mounted so that their shafts are
aligned with and parallel to each other. The pump
and motor were aligned and secured at the factory,
Page 12
D SERIES OM-03604
but fastening hardware may have loosened during
shipment. It is imperative that alignment be
checked after the pump and piping are installed,
and before operation. Adjustments may be made
by loosening the securing hardware and shifting or
shimming components as required.
To check coupling alignment, use a feeler gauge or
taper gauge between the coupling halves every
_
. The coupling is in alignment when the hubs
90
are the same distance apart at all points.
To check parallel adjustment, lay a straightedge
across both coupling halves at the top, bottom,
and side. When the straightedge rests evenly on
both halves of the coupling, the coupling is in hori
zontal parallel alignment. If the coupling is
misaligned, use a feeler gauge between the cou
pling and the straightedge to measure the amount
of misalignment.
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
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.
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.
ELECTRICAL CONNECTIONS
Before connecting the motor to the incoming
power, check that the electrical service available
Motor Data
MODEL
3D-E1.5
VOLTAGE PHASE HP Hz RPM THERMAL
115/230
230/460
1
3
Do not install and operate a non‐explo
sion 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.
Refer to the following motor data before making
electrical connections.
OVERLOAD
1.5
1.5
60
60
1800
1800 N/A
N/A
3D-X1.5
115/230
230/460
1
3
1.5
1.5
60
60
1800
1800 YES
YES
PAGE B - 5INSTALLATION
Page 13
D SERIES
OM-03604
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, 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.
Pump application will affect its performance, espe
cially discharge velocities. Consult the Gorman‐
Rupp factory for actual performance levels for the
pump.
striction will cause incomplete filling of the
diaphragm chamber and result in short
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
The pump is designed to operate at ap
proximately 60 cycles per minute through
a gearbox with a 30.36:1 ratio at a maxi
mum input speed of 1800 RPM. Make cer
tain that the electric motor installed does
not exceed this RPM. Operation at higher
RPM can cause pump components to be
damaged or destroyed.
Priming
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
OPERATION PAGE C - 1
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).
Page 14
OM-03604 D SERIES
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.
Accumulator Chamber Check
Check periodically to ensure that there is sufficient
air in the integral suction accumulator chamber.
Replenish as required (see Fixed, Rigid Piping in
Section B for details).
Cold Weather Preservation
The primary construction materials of this
pump are aluminum, with neoprene flap
valves and a DuraBlue 1000t diaphragm.
Do not attempt to clean or flush this pump
with any liquid which would attack pump
fittings or components. Avoid cleaning
with cleaning solvent.
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.
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.
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-03604
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-03604 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-03604
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
5786766 68
10 73 64 66 62
20 64 59 65 59
IN LITERS PER MINUTE AT 60 STROKES PER MINUTE
STATIC
LIFT
IN METERS
1,5 295,2 253,6 249,8 257,4
3,0 276,3 242,2 249,8 234,7
4,6 257,4 227,1 242,2 223,3
6,1 242,2 223,3 246,0 223,3
51015 20
1,5 3,0 4,6 6,1
STATIC DISCHARGE HEAD IN FEET
5964606815
5660565625
STATIC DISCHARGE HEAD IN METERS
7,6 212,0 212,0 227,1 212,0
STANDARD PERFORMANCE TEST DATA FOR 3D ELECTRIC MOTOR DRIVEN PUMP
Based on 70_F (21_C) clear water at sea level
with minimum suction lift, using 3 inch (7,62 cm)
suction hose and 4 inch (10,16 cm) non‐collapsible
discharge hose. Since pump installations are sel
dom identical, your performance may be differ
ence due to such factors as viscosity, specific grav
MAINTENANCE & REPAIR PAGE E - 1
ity, elevation, temperature, and impeller trim.
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-03604
SECTION DRAWING
Figure 1. 3D Electric Motor Driven Pump
MAINTENANCE & REPAIRPAGE E - 2
Page 19
D SERIES OM-03604
PARTS LIST
Pump Model 3D‐E1.5 1P And 3D-E1.5 3P
Bill of Material Issue 14 (From S/N 883504 up
Pump Model 3D‐X1.5 1P And 3D-X1.5 3P
Bill of Material Issue 14 (From S/N 883504 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
PART NAME PART
NO.
NUMBER
MAT'L
CODE
QTY ITEM
NO.
PART NAME PART
NUMBER
MAT'L
CODE
QTY
1 ECCENTRIC GUARD 38861-501 23200 1
2 NYLOCK CAPSCREW BT0403 15991 1
3 WASHER S157 --- 1
4 FLAT WASHER K04 15991 1
5 LUBRICATION DECAL 38817-066 --- 1
6 SNAP RING 5385 --- 1
7 GUARD WARNING DECAL 38816-063 --- 1
8 GEAR BOX ASSY 8981 --- 1
9 COUPLING GUARD 34613-005 15020 1
10 GUARD WARNING DECAL 38816-063 --- 1
11 3/4” COUPLING HALF 24355-035 --- 1
12 7/8” COUPLING HALF 24355-037 --- 1
13 SPIDER 24355-262 --- 1
14 KEY N0304 15990 1
15 HEX HD CAPSCREW B0504 15991 4
16 FLANGED HEX NUT 21765-312 --- 4
17 U‐BOLT 5495 15991 2
18 FLANGED HEX NUT 21765-314 --- 4
19 AXLE 4607AD 15990 1
20 SPACE WASHER 5382 15990 4
21 HAIRCLIP PIN 21183-010 --- 4
22 HEX HD CAPSCREW B0403 15991 2
23 FLANGED HEX NUT 21765-310 --- 2
24 BASE 13583 24000 1
25 HEX HD CAPSCREW B0608 15991 5
26 FLANGED HEX NUT 21765-314 --- 5
27 PLUNGER ROD ASSY 5685 --- 1
28 DRAW BAR 5438 15990 1
29 U-BOLT 5495 15991 2
30 FLANGED HEX NUT 21765-314 --- 4
31 SUCTION STICKER 6588AG --- 1
32 FLAT WASHER K08 15991 4
33 HEX NUT D08 15991 4
34 HEX HD CAPSCREW B0811 15991 4
35 DIAPHRAGM POT ASSY 46475-701 --- 1
36 DIAPHRAGM RING 13582 13010 1
37 PNEUMATIC WHEEL S752 --- 2
38 DISCHARGE STICKER 6588BJ --- 1
39 HEX HD CAPSCREW B0604 15991 2
40 LOCKWASHER J06 15991 2
41 HEX HD CAPSCREW B0402 1/2 15991 2
42 T TYPE LOCKWASHER AK04 15991 2
43 FLAT WASHER K04 15991 2
44 MOTOR X1.5 HP 1P 28274-040 --- 1
MOTOR X1.5 HP 3P 28274-442 --- 1
MOTOR E1.5 HP 1P 28214-040 --- 1
MOTOR E1.5 HP 3P 28214-440 --- 1
45 WARNING DECAL 2613FF --- 1
46 WARNING DECAL 2613FE --- 1
NOT SHOWN:
NAME PLATE 2613BP 13990 1
DRIVE SCREW BM#04-03 15990 4
STRAINER 4917 24001 1
TRADEMARK DECAL 38812-049 --- 1
OPTIONAL:
STATIONARY BASE 8283 24000 1
INDICATES PARTS RECOMMENDED FOR STOCK
MAINTENANCE & REPAIR PAGE E - 3
Page 20
SECTION DRAWING
D SERIESOM-03604
Figure 2. 46475-701 Diaphragm Pot Assembly
MAINTENANCE & REPAIRPAGE E - 4
Page 21
D SERIES OM-03604
PARTS LIST
46475-701 Diaphragm Pot Assembly
ITEM
NO.
1 DISCHARGE FLANGE 5658 13040 1
2 STUD C0810 15991 2
3 HEX NUT D08 15991 2
4 FLAT WASHER KE08 15991 2
5 RD HD MACHINE SCREW X0404 17090 2
6 LOCKWASHER J04 15991 2
7 RD HD MACHINE SCREW X0404 17090 2
8 LOCKWASHER J04 15991 2
9 PLUG AND GASKET S519A --- 1
10 SUCTION STUB 5376 13010 1
11 RED PIPE BUSHING AP4832 11999 1
12 STUD C0810 15991 2
13 FLAT WASHER K07 15991 2
14 HEX NUT D08 15991 2
15 VALVE SEAT 5374 10010 1
16 GASKET 5374G 19100 1
17 DIAPHRAGM POT DRAIN PLUG P06 11990 1
18 DIAPHRAGM POT 5375 13010 1
19 GASKET 5374G 19100 1
20 STUD C0809 15991 2
21 FLAT WASHER K07 15991 2
22 HEX NUT D08 15991 2
23 DISCHARGE FLANGE 5377 13040 1
24 GASKET 5374G 19100 1
25 VALVE SEAT 5374 10010 1
26 FLAP VALVE ASSY 46413-013 --- 1
27 -VALVE WEIGHT 5428 15990 1
28 -RD HD MACHINE SCREW X0403 17090 4
29 -LOCKWASHER J04 17090 4
30 -VALVE WEIGHT 5426 15990 1
31 -FLAP VALVE 5427 19100 1
PART NAME
PART
NUMBER
MAT'L
CODE
QTY
INDICATES PARTS RECOMMENDED FOR STOCK
MAINTENANCE & REPAIR PAGE E - 5
Page 22
SECTION DRAWING
D SERIESOM-03604
Figure 3. STANDARD 5685 AND OPTIONAL 5685B Plunger Rod Assembly
MAINTENANCE & REPAIRPAGE E - 6
Page 23
D SERIES OM-03604
PARTS LIST
5685 Standard Plunger Rod Assembly And
5685B Optional Plunger Rod Assembly
ITEM
NO.
1 ECCENTRIC CAP 5373 13010 1
2 ECCENTRIC BEARING 5610 14000 1
3 T‐TYPE LOCK WASHER AK12 15991 1
4 JAM NUT AT12 15991 1
5 SPRING WASHER 5384 15991 1
6 SPRING 5398 16081 1
7 FLAT WASHER K20 15991 1
8 DIAPHRAGM PLATE 5381 10010 1
9 DIAPHRAGM (5685) 26844-041 --- 1
10 DIAPHRAGM PLATE ASSY 5394 --- 1
11 -DIAPHRAGM PLATE NOT AVAILABLE 1
12 -STUD NOT AVAILABLE 3
13 HEX NUT D08 15991 3
14 HEX HEAD CAPSCREW 21612-577 --- 1
15 LUBE FITTING S191 --- 1
16 LUBE FITTING S191 --- 1
INDICATES PARTS RECOMMENDED FOR STOCK
PART NAME
DIAPHRAGM (5685B) S1042 --- 1
PART
NUMBER
MAT'L
CODE
QTY
MAINTENANCE & REPAIR PAGE E - 7
Page 24
SECTION DRAWING
D SERIESOM-03604
Figure 4. 8981 Gearbox Assembly
MAINTENANCE & REPAIRPAGE E - 8
Page 25
D SERIES OM-03604
PARTS LIST
8981 Gearbox Assembly
ITEM
PART NAME PART
NO.
NUMBER
MAT'L
CODE
QTY ITEM
NO.
PART NAME PART
NUMBER
MAT'L
CODE
QTY
1 GEAR HOUSING 5367 13010 1
2 SPACER SLEEVE S952 --- 1
3 HEX HD CAPSCREW B1004 15991 1
4 BEARING S702 --- 1
4A BEARING S702 --- 1
5 SPACER WASHER 5395 15990 1
HOUSING GSKT 5367G 18000 1
6
7 COVER PLATE 5396 13010 1
8 HEX HD CAPSCREW B0403 15991 7
9 LOCKWASHER J04 15991 9
10 HEX HD CAPSCREW B0407 15991 2
11 GEAR 5334 16060 1
12 HARDENED KEY 31811-040 15990 1
13 SNAP RING S1004 --- 1
14 GASKET S825 --- 1
15 INTERNAL GEAR S823 --- 1
16 BEARING HOUSING 5918 13010 1
17 STR DOWEL PIN AA0405 15990 2
18 PINION BRG BUSH S824 --- 1
19 WASHER 2M 15990 3
INDICATES PARTS RECOMMENDED FOR STOCK
20 KEY N0304 15990 1
21 OIL SEAL ASSY 14408 --- 1
22 -OIL SEAL ADAPTER 14407 15000 1
23 -OIL SEAL 25227-355 --- 1
24 SNAP RING S269 --- 1
25 BALL BEARING S1044 --- 1
25A BALL BEARING S1044 --- 1
26 DRIVE PINION 5917 16070 1
27 SLEEVE 5922 15070 1
28 WASHER 5921 15990 1
29 OIL CUP S617 --- 1
30 SPACER WASHER 5382 15991 1
31 PINION 5333 16020 1
32 BEARING S703 --- 1
33 ECCENTRIC CAM 5378A 10080 1
34 ADJ SHIM SET 13103A 15990 1
35 DRIVE SHAFT 5397 15020 1
36 HARDENED KEY 31811-040 15990 1
37 SNAP RING S700 --- 1
38 WASHER 6531 18040 1
MAINTENANCE & REPAIR PAGE E - 9
Page 26
D SERIESOM-03604
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, 2, 3 and 4) and
the accompanying parts lists.
Before attempting to service the pump, lock out
and tag out incoming power to the motor to ensure
that it will remain inoperative. Close all valves in the
suction and discharge lines.
Suction And Discharge Check Valve Removal
(Figure 2)
To service the suction and discharge check valves,
remove the suction and discharge piping.
To service the suction check valve assembly (26),
remove the suction accumulator (10) by removing
the hardware (13 and 14) securing it to the dia
phragm pot (18). Remove the hardware (7 and 8)
securing the valve seat (15) and check valve as
sembly to the diaphragm pot. Pull the check valve
assembly from the suction port.
To service the discharge check valve assembly
(26), loosen the hardware (3 and 4) and remove the
assembled discharge flange (1), valve seat (25)
and check valve assembly. Remove the gasket
(24).
Remove the hardware (5 and 6) securing the valve
seat and discharge check valve assembly to the
discharge elbow.
For motor disassembly and repair, consult the lit
erature supplied with the motor, or contact your lo
cal motor representative.
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.
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.
Before attempting to service the pump, drain the
pump by removing the drain plug (18, Figure 2).
Clean and reinstall the drain plug.
To remove the discharge flange (23), loosen the
hardware (21 and 22) securing the flange to the di
aphragm pot. Remove the gasket (19).
The suction and discharge check valve assemblies
are identical parts and operate in the same direc
tion. For removal and/or replacement, remove the
hardware (28 and 29) securing the check valve
weights (27 and 30) to the check valve (31). Inspect
and replace parts as required.
If no further disassembly is required, see Suction
And Discharge Check Valve Installation.
Diaphragm Removal
(Figure 1)
To remove the diaphragm (9, Figure 3), disengage
the hardware (32, 33 and 34) and remove the dia
phragm pot assembly (35). Inspect the diaphragm
ring (36) for wear or damage. If replacement is re
quired, the gearbox assembly (8) must be re
moved.
(Figure 3)
Remove the nuts (13). Separate the lower dia
phragm plate assembly (10) from the diaphragm
(9) and the upper diaphragm plate (8). Inspect the
diaphragm and replace a required.
MAINTENANCE & REPAIRPAGE E - 10
Page 27
OM-03604D SERIES
If no further disassembly is required, see Dia
phragm Installation.
Plunger Rod Removal And Disassembly
(Figure 1)
With the diaphragm pot assembly and diaphragm
removed, disengage the hardware (2, 3, 4, 41, 42
and 43) and remove the eccentric guard (1).
Removing the snap ring (6) and slide the plunger
rod assembly (27) off the eccentric cam (33, Figure
4).
(Figure 3)
Use a socket wrench to hold the plunger rod (14)
securely and unscrew the eccentric cap (1). Re
move the T‐type lockwasher (3), jam nut (4), spring
washer (5) and spring (6). Remove the flat washer
(7) and slide the plunger rod out of the upper dia
phragm plate (8).
Inspect the eccentric bearing (2) for excessive
wear. If replacement is necessary, use a suitable
tool to cut the bearing and remove it from the ec
centric cap. Be careful not to damage the eccen
tric cap.
ring for wear or damage and replace as necessary.
It is not necessary to remove the drawbar (28) from
the diaphragm ring unless replacement is re
quired. Disengage the hardware (30) from the U‐
bolts (29) to remove the drawbar.
Disengage the hardware (22 and 23) and remove
the coupling guard (9). Loosen the attaching hard
ware, separate the coupling halves (11 and 12)
and remove the spider (13). Remove the gearbox
assembly, and slide the coupling half off the pinion
drive shaft (26, Figure 4).
(Figure 4)
Before attempting to disassemble the gearbox as
sembly, drain the lubricant by removing the oil cup
(29) and turning the gearbox on its side. Clean and
reinstall the oil cup.
Remove the two lower and the five upper pieces of
hardware (8, 9 and 10) securing the cover plate (7)
to the gear housing (1). Pull the bearing housing
(16) and cover plate from the pinion shaft (31) and
gear (15). Remove the gasket (6) and clean the
mating surfaces. Replace the gasket as necessary.
Remove the remaining two pieces of hardware (9
and 10) and separate the cover plate from the bear
ing housing. Remove the gasket (14) and clean the
mating surfaces. Replace the gasket as necessary.
Gearbox Removal And Disassembly
(Figure 1)
When properly operated and maintained, the gear
box assembly (8) should not require disassembly.
Disassemble the gearbox only when there is evi
dence of wear or damage.
Shaft and bearing disassembly in the field
is not recommended. These operations
should be performed only in a properly
equipped shop by qualified personnel.
Support the diaphragm ring (36) with wooden
blocks. Disengage the hardware (25 and 26) se
curing the gearbox to the diaphragm ring, and re
move the diaphragm ring. Inspect the diaphragm
To disassemble the pinion drive shaft components,
remove the key (20) and pry the oil seal assembly
(21) from the bearing housing. Press the oil seal
(23) from the seal adaptor (22).
Remove the washer (19) and slide the assembled
pinion drive shaft (26), bearings (25 and 25A) and
sleeve (27) from the bearing housing.
After removing the shaft and bearings, clean and
inspect the bearings in place as follows.
To prevent damage during removal from
the shaft, it is recommended that bearings
be cleaned and inspected in place. It is
strongly recommended that the bearings
be replaced any time the shaft and bear
ings are removed.
MAINTENANCE & REPAIR PAGE E - 11
Page 28
D SERIESOM-03604
Clean the bearing housing, shaft and all compo
nent parts (except the bearings) with a soft cloth
soaked in cleaning solvent. Inspect the parts for
wear or damage and replace as necessary.
Most cleaning solvents are toxic and
flammable. Use them only in a well‐ven
tilated area free from excessive heat,
sparks, and flame. Read and follow all
precautions printed on solvent contain
ers.
Clean the bearings thoroughly in fresh cleaning
solvent. Dry the bearings with filtered compressed
air and coat with light oil.
Bearings must be kept free of all dirt and
foreign material. Failure to do so will great
ly shorten bearing life. Do not spin dry
bearings. This may scratch the balls or
races and cause premature bearing fail
ure.
other tool to pry the bushing from the bearing
housing.
Slide the pinion shaft (31) and gear (15) out of the
pinion bearing (32). Remove the spacer washer
(30).
Inspect the pinion shaft and gear for wear or bro
ken teeth. If replacement is required, use an harbor
(or hydraulic) press to remove the shaft from the
gear.
Use an arbor (or hydraulic) press to remove the
pinion bearing from the gear housing.
NOTE
It is not necessary to remove the drive shaft (35),
drive gear (11), shaft bearings (4 and 4A) or eccen
tric cam (33) unless wear or damage is obvious. In
spect the parts, and if replacement is necessary,
proceed as follows.
Remove the snap ring (37) from the drive shaft. Us
ing a bearing puller, remove the eccentric cam and
key (36) from the drive shaft. Remove the eccentric
cam shim set (34) and washer (38). Tie and tag the
shims or measure and record their thickness for
ease of reassembly.
Slide the drive shaft and gear out of the gear hous
ing. Slide the spacer washer (5) off the drive shaft.
Rotate the bearings by hand to check for rough
ness or binding and inspect the bearing balls. If ro
tation is rough or the bearing balls are discolored,
replace the bearings.
The bearing tolerances provide a tight press fit
onto the shaft and a snug slip fit into the bearing
housing. Replace the bearings, shaft, or bearing
housing if the proper bearing fit is not achieved.
Inspect the sleeve (27) and replace as necessary.
If bearing and sleeve replacement is required, re
move the snap ring (24). Using a bearing puller, re
move the outboard bearing (25) from the drive pin
ion. Remove the sleeve and pull the inboard bear
ing (25A) from the shaft. Remove the washer (28)
from the shaft.
Inspect the pinion bushing (18) for excessive wear.
If replacement is required, use a screwdriver or
Remove the snap ring (13). Use an arbor (or hy
draulic) press to remove the gear (11) and key (12)
from the shaft.
To remove the drive shaft bearings (4 and 4A), the
spacer sleeve (2) must be coiled into a smaller di
ameter to allow passage through the I.D. of the
bearings.
NOTE
After the spacer sleeve in compressed, it will be
permanently damaged and require replacement.
To remove the spacer sleeve, remove the caps
crew (3) and use a pointed tool to rotated the perfo
rated steel sleeve until the seam is visible through
the tapped holed. Apply pressure on one side of
the seam until one edge overlaps the other. Reach
though the I.D. of the bearings and continue to coil
the spacer sleeve until is can be removed. Reinstall
the capscrew (3).
MAINTENANCE & REPAIRPAGE E - 12
Page 29
OM-03604D SERIES
Use an arbor (or hydraulic) press to remove the
bearings (4 and 4A) from the gear housing..
It is not necessary to remove the locating pins (17)
from the gear housing unless they are bent or dam
aged. If replacement is required, press the pins
from the housing.
Gearbox Reassembly And Installation
(Figure 4)
Inspect the shafts (26, 31 and 35) for distortion,
nicks or scratches. Dress small nicks and burrs
with a fine file or emery cloth. Replace the shaft if
defective.
NOTE
Do not heat the needle bearings (4, 4A and 32).
These bearings are designed to be pressed into the
gear housing, not onto the shafts.
tinuous motion, to prevent the bearings from cool
ing and sticking on the shaft.
Use caution when handling hot bear
ings to prevent burns.
After the bearings have been installed and allowed
to cool, check to ensure that they have not moved
out of position in shrinking. If movement has oc
curred, use a suitably sized sleeve and a press to
reposition the bearings.
If heating the bearings is not practical, use a suit
ably sized sleeve and an arbor (or hydraulic) press
to install the bearings on the shaft.
When installing the bearings onto the
shaft, never press or hit against the outer
race, balls, or ball cage. Press only on the
inner race.
To prevent damage during removal from
the shaft (26), it is recommended that the
bearings (25 and 25A) be cleaned and in
spected in place. It is strongly recom
mended that the bearings be replaced any
time the shaft and and bearings are re
moved.
The bearings may be heated to ease installation.
An induction heater, hot oil bath, electric oven, or
hot plate may be used to heat the bearings. Bear
ings should never be heated with a direct flame or
directly on a hot plate.
NOTE
If a hot oil bath is used to heat the bearings, both the
oil and the container must be absolutely clean. If
the oil has been previously used, it must be thor
oughly filtered.
Heat the bearings to a uniform temperature no
higher than 250_F (120_C) and slide the bearings
onto the shaft (26), one at a time, until they are fully
seated. This should be done quickly, in one con
If removed, install the snap ring (28) in the groove
on the pinion drive shaft (26). Install the bearing
(25A) on the pinion drive shaft against the snap
ring. Install the sleeve (27). Install the bearing (25)
onto the pinion drive shaft until squarely seated
against the sleeve. Secure the bearing with the
snap ring (24). Wrap the shaft and bearings in a
clean cloth until reassembly in the bearing hous
ing.
Install the bearing (4A) in the gear housing until it is
flush with the outer machined face of the housing.
Install a new spacer sleeve (2) through the open
bearing bore, then press the bearing (4) into the
bore until it is flush with the inner machined face on
the housing.
When installing the bearings into the bear
ing bore, push against the outer race. Nev
er hit the balls or ball cage.
Install the gear key (12) in the keyway in the drive
shaft (35). Press the drive gear (11) onto the drive
MAINTENANCE & REPAIR PAGE E - 13
Page 30
D SERIESOM-03604
shaft and secure it with the snap ring (13). Be sure
the drive gear seats against the snap ring.
Install the washer (5) onto the drive shaft and slide
the assembled drive shaft and gear through the
bearings in the gear housing. Install the same
thickness of shims (34) as previously removed. In
stall the washer (38) and drive shaft key (36). Press
the eccentric cam (33) onto the shaft and secure
with the snap ring (37).
Press the pinion bearing (32) into the gear housing
until the closed end is flush with the outer face of
the bore.
Press the internal gear (15) onto the pinion shaft
until it seats squarely against the pinion shoulder.
Position the spacer washer (30) in the gear hous
ing and slide the pinion shaft through the washer
and into the pinion bearing.
Press the pinion bushing (18) into the bearing
housing until fully seated.
Slide the assembled pinion drive shaft and bear
ings (25, 25A and 26) into the bearing housing (16)
until the bearing (25A) is fully seated against the
bore shoulder.
Press the oil seal (23) into the adaptor (22) with the
lip positioned as shown in Figure 4. The outer face
of the oil seal should be just flush with the face of
the adaptor.
Secure the cover plate and bearing housing to the
gear housing with the remaining attaching hard
ware (8, 9 and 10).
NOTE
The two longer capscrews (10) must be installed in
the two lower holes in the gear housing.
Install the drive key (20) in the drive pinion.
(Figure 1)
Install the coupling half (12) on the drive pinion (26,
Figure 4).
Secure the gearbox assembly (8) to the diaphragm
ring (36) with the hardware (25 and 26). Connect
the coupling halves and check alignment as de
scribed in Section B.
Secure the coupling guard (9) to the base with
hardware (22 and 23).
Lubricate the gearbox as described in LUBRICA
TION.
Plunger Rod Reassembly And Installation
(Figure 3)
If the eccentric bearing (2) was removed, clean the
bore of the eccentric cap (1) with a cloth soaked in
cleaning solvent.
Install the washer (19) in the bearing housing.
Press the oil seal assembly (21) into the bearing
housing until fully seated. Be careful not to roll or
damage the oil seal lip on the pinion keyway.
Install the housing gasket (6) and secure the cover
plate (7) to the bearing housing with two of the
capscrews and lockwashers (8 and 9).
If the locating pins (17) were removed, press new
pins into the gear housing (1). Install the gasket
(14) and position the bearing housing (16) over the
internal gear (15) and against the cover plate so
that the locating pins align with the holes in the cov
er plate. Be sure the teeth on the drive pinion (26)
mesh with those on the internal gear (15). Tap
against the bearing housing with a soft‐faced mal
let or wood block until the pinion bushing (18) fully
engages the pinion shaft (31).
Most cleaning solvents are toxic and
flammable. Use them only in a well‐ven
tilated area free from excessive heat,
sparks, and flame. Read and follow all
precautions printed on solvent contain
ers.
Use a suitably sized dowel and an arbor (or hy
draulic) press to install a new eccentric bearing (2)
into the eccentric cap until fully seated.
Slide the plunger rod (14) through the upper dia
phragm plate (8). Install the flat washer (7), spring
(6), spring washer (5) and jam nut (4). Compress
the spring to the dimension shown in Figure 3 by
tightening the jam nut.
MAINTENANCE & REPAIRPAGE E - 14
Page 31
OM-03604D SERIES
Install the T‐type lockwasher (3). Apply `Loctite No.
242 Threadlocker' or equivalent compound on the
plunger rod threads and screw the eccentric cap
on until tight.
NOTE
The lubrication fitting (15) in the diaphragm plate
must face the same direction as the lubrication fit
ting (16) in the eccentric cap.
Lubricate the eccentric bearing (2) with a thin coat
ing of No.2 lithium base grease.
Diaphragm Installation
(Figure 3)
Position the diaphragm (9) on the upper dia
phragm plate, making sure the lip is properly
seated. Slide the studs (12) in the lower diaphragm
plate (11) through the holes in the upper plate and
secure with the nuts (13).
(Figure 1)
Install the plunger rod assembly (21) onto the ec
centric cam (33, Figure 4) and secure with the snap
ring (6).
(19). Secure the flange to the diaphragm pot with
the hardware (21 and 22).
Subassemble the valve seat (25) and discharge
check valve (26) to the discharge elbow (1) with the
weights positioned as shown in Figure 2. Secure
with the hardware (3 and 4).
Clean the mating surfaces of the valve seat and dis
charge flange (23). Install the gasket (24) and se
cure the outboard discharge flange, check valve,
and seat to the inboard discharge flange with the
hardware (5 and 6).
Check the operation of the check valve to ensure
proper seating and free movement.
Clean the mating surfaces of the valve seat (5) and
suction accumulator (10). Position the suction
check valve, valve seat (15) and gasket (16)
against the diaphragm pot (19) with the weights
positioned as shown in Figure 2. Secure with the
hardware (7 and 8).
Check the operation of the check valve to ensure
proper seating and free movement.
Secure the suction accumulator (10) to the dia
phragm pot with the hardware (13 and 14).
Connect the suction and discharge piping as de
scribed in INSTALLATION, Section B.
Install the eccentric guard (1) and secure it with the
hardware (2, 3, 4, 41, 42 and 43).
Lubricate the plunger rod assembly as described
in LUBRICATION, Section E.
Secure the diaphragm pot assembly (35) to the di
aphragm ring (36) with the hardware (32, 33 and
34).
Suction And Discharge Check Valve
Installation
(Figure 2)
Inspect the check valve components and replace
as required. Subassemble the check valve weights
(27 and 30) and check valves (31) with the hard
ware (28 and 29).
If the inboard discharge flange (23) was removed,
clean the mating surfaces and install the gasket
Refer to OPERATION, Section C before starting
the pump.
LUBRICATION
Plunger Rod Assembly
(Figure 3)
The eccentric bearing should be lubricated
thoroughly after each 8 hours of operation.
Failure to do so may cause the bearing to
overheat and fail.
Before attempting to lubricate the plunger rod as
sembly, rotate the eccentric cam until the grease
fittings (15 and 16) can be accessed through the
holes in the eccentric guard (1, Figure 1).
MAINTENANCE & REPAIR PAGE E - 15
Page 32
D SERIESOM-03604
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 until grease escapes from the top of the
upper diaphragm plate inside the spring.
Gearbox
(Figure 4)
The gearbox was fully lubricated when shipped
from the factory. Change the oil in a new gearbox at
operating temperature after 100 hours of operation
or four weeks, whichever comes first. To drain the
oil, remove the oil cup (29) and position the pump
and gearbox on its side. After draining, reinstall the
oil cup and flush the case thoroughly with a light oil.
Remove the oil cup and drain the flushing oil. Rein
stall the oil cup.
To lubricate the gearbox, add SAE No. 30 non‐de
tergent oil through the oil cup (29) until the oil level
stabilizes at the middle of the oil cup. Check the oil
regularly and maintain it at this level.
Monitor the condition of the bearing lubri
cant regularly for evidence of rust or mois
ture condensation. This is especially im
portant in areas where variable hot and
cold temperatures are common.
MAINTENANCE & REPAIRPAGE E - 16
Page 33
For U.S. and International Warranty Information,
Please Visit www.grpumps.com/warranty
or call:
U.S.: 419-755-1280
International: +1-419-755-1352
For Canadian Warranty Information,
Please Visit www.grcanada.com/warranty
or call:
519-631-2870
THE GORMAN‐RUPP COMPANY D MANSFIELD, OHIO
GORMAN‐RUPP OF CANADA LIMITED D ST. THOMAS, ONTARIO, CANADA
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