Gorman-Rupp Pumps 4D-B User Manual

ABCDH

OM-01505-OB01

January 20, 1981

Rev. D 10/27/99

INSTALLATION, OPERATION,

AND MAINTENANCE MANUAL

WITH P ARTS LIST

DSERIESPUMP

4D --- B

THE GORMAN-RUPP COMPANY D MANSFIELD, OHIO

GORMAN-RUPP OF CANADA LIMITED D ST. THOMAS, ONTARIO, CANADA Printed in U.S.A.

eCopyright by the Gorman-Rupp Company

TABLE OF CONTENTS

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

WARN ING S - SE CTI ON A PA GE A --- 1.........................................

IN STA L LAT ION --- S ECT ION B PA GE B --- 1.....................................

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

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

ELECTRIC MOTOR INSTALLATION PAGE B --- 2.............................................

POSITIONING PUMP PA GE B --- 2..........................................................

Lifting PA GE B --- 2....................................................................

Mounting PA GE B --- 2................................................................

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

Materials PA GE B --- 2.................................................................

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

Fixed, Rigid Piping P AGE B --- 3........................................................

Gauges PA GE B --- 3..................................................................

SUCTION LINES PAGE B --- 4..............................................................

Fittings PA GE B --- 4..................................................................

Strainers PA GE B --- 4.................................................................

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

DISCHARGE LINES PA GE B --- 4...........................................................

Siphoning PA GE B --- 4................................................................

Valves PA GE B --- 4...................................................................

ALIGNMENT PAGE B --- 5.................................................................

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

OPER AT IO N --- S EC T IO N C PA GE C --- 1.......................................

STARTING PA GE C --- 1...................................................................

Rotation PA GE C --- 1.................................................................

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

Priming PA GE C --- 2..................................................................

OPERATION CHE CKS PA GE C --- 2.........................................................

Gearbox Check PAGE C --- 2...........................................................

Leakage Check PAGE C --- 2...........................................................

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

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

STOPPING PA GE C --- 2...................................................................

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

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

TR OUB LES HOO TI NG --- SE C TIO N D PA GE D --- 1...............................

PUMP MAINTENANCE AND REPAI R - SECTION E PAGE E --- 1..................

STANDARD PERFORMANCE TEST DATA PAGE E --- 1.......................................

PARTS LISTS:

Pump Model PA GE E --- 3.............................................................

i

TABLE OF CONTENTS

(continued)

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

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

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

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

Suction And Discharge Flap 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 P AGE E --- 12......................................

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

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

Suction And Discharge Flap Valve Installation P AGE E --- 15...............................

LUBRICATION PA GE E --- 15...............................................................

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

Gearbox PA GE E --- 16................................................................

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

ii

DSERIES

OM--01505

INTRODUCTION

This Installation, Operation, and Maintenance
manual is designed to help you achieve the best
performance and longest life from your Gorman­Rupp pump.

This is a DSeries, positivedisplacement pumputil­izing a single-action diaphragm to produce a
straight-through flow of liquid. The pump is pro­vided with an explosion-proof electric motor and
ideallysuitedtoindustrial andcontractor’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 diaphragm.

If there are any questions regarding the pump or
its application which are not covered in this man­ual or in other literature accompanying this unit,
please contact your Gorman -Rupp distributor, or
write:

The Gorman-Rupp Company
P.O. Box 1217
Mansfield, Ohio 44901--1217

or

Gorman-Rupp of Canada Limited
70 Burwell Road
St. Thomas, Ontario N5P 3R7

The following are used to alert maintenance per­sonnel to procedures which requirespecial atten­tion, tothose whichcould damage equipment, and
to those which could be dangerous to personnel:

Immediate hazards whichWILL result in
severe personal injury or death. These
instructions describe the procedure re­quired and the injury which will result
from failure to follow the procedure.

Hazards or unsafe practices which
COULDresult in severe personal injury
or death. These instructions describe
the procedure required and the injury
which could result fromfailure to follow
the procedure.

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 re­sponsibility 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 norpumpintegrity arecom­promised by the installation. Pumps and related
equipment must be installed and operated ac-
cording to all national, local and industry stan ­dards.

HazardsorunsafepracticeswhichCOULD
result in minor personal injury or product
or property damage. These instructions
describe the requirements and the possi­bledamage which couldresult from failure
to follow the procedure.

NOTE

Instructions to aid in installation, operation,and
maintenance, or which clarify a procedure.

PAGE I -- 1INTRODUCTION

DSERIES

SAFETY- SECTION A

These warnings apply to D Series Basic
Diaphragm pumps. Gorman-Rupp has
no control over or particular knowledge
of the power source which will be used.
Refer to the manual accompanying the
power source before attemp ting to b e­gin operation.

Beforeattempting toopenorservic e the
pump:

1. Familiarize yourself with this man­ual.

2. Lock out incoming power to the
power source to ensure that the
pump will remain inoperative.

3. Allowthe pump to completelycool
if overheated.

4. Close the discharge valve (if
used).

5. Drain the pump.

This pump is designed to handle non­volatile non-flammable liquids contain­ing 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.

Afterthe pump hasbeeninstalled,block
the wheels and secure the pump to pre­vent creeping. Make certain that the
pump and all piping or hose connec­tions are tight, properly supported and
secure before operation.

OM--01505

Donot operate the pump without the ec­centric and coupling guards in place
over the rotating parts. Exposed rotat­ing parts can catch clothing, fingers, or
tools, causing severe injury to person­nel.

The gearbox provided on this pump is
designed for operation at 1750 RPM
maximum input speed. If operated at a
higher RPM, pump componentsmay be
destroyed.

Install and operate only an explosion
proof motor in an explosive atmo­sphere. Install, connect, and operate
the motor in accordance with the Na­tional Electric Code and all local codes.
Ifthereisa conflictbetween the instruc­tions in the manual accompanying the
unit and the National Electric Code or
the applicable local code, the National
or local code shall take precedence.

Never install a positive shut-off valve inthe
discharge line; discharge restrictions will
cause excessive friction loss resulting in
overloading and destruction of pump and
drive components. It is strongly recom­mended that unless absolutelynecessary,
nopositiveshut-off valvebe installedinthe
suction line; excessive restriction will
cause incomplete filling of the diaphragm
chamber and result in shortened dia­phragm life.

PAGE A -- 1WARNINGS

DSERIES OM--01505

INSTALLATION --- SECTION B

Review all SAFETY information in Section A.

Since pump installations areseldom identical,this
section offers only general recommendations and
practices required to inspect, position, and ar­range the pump and piping.

OUTLINE DRAWING

DISCHARGE - 4” NPT

16.88

[428,75]

SUCTION - 3” (OR 4”) NPT

33.88

[860,55]

17.00

[431,80]

Forfurther assistance,contact yourGorman-Rupp
distributor or t he Gorman-Rupp Company.

Pump Dimensions

SeeFigure1fortheapproximatephysicaldimen­sionsofthispump.

APPROX

26.62

[676,15]

7.31

[185,67]

[1370,08]

19..69

[500,13]

53.94

34.94

[887,48]

.44

[11,18]

7.25

[184,15]

5.50

[139,70]

4.25

[107,95]

8.25

[209,55]

-(6)HOLESDIA

7.00

[177,80]

1.00

[25.40]

16.25

[412,75]

7.00

[177,80]

DIMENSIONS: INCHES

[MILLIMETERS]

Figure 1. Pump Model 4D-B

PREINSTALLATION INSPECTION

Thepump assembly wasinspected and tested be­foreshipment fromthe factory. Beforeinstallation,
inspect the pump fordamage which may have oc­curred during shipment. Check as follows:

a. Inspect the pump forcracks,dents, damaged

threads, and other obvious damage.

b. Check for and tighten loose attaching hard-

ware. Since gaskets tend to shrink after dry­ing, check for loose hardware at mating sur ­faces.

5.31

[134,87]

[133,35]

.75 DIA SHAFT W/ .19 X .09 X 1..06 LONG

[19,05] [4,83][2,29][26,92]

USEABLE KEYWAY

c. Carefully read all tags, decals, and markings

onthepumpassembly,and performallduties
indicated.

d. Check levels and lubricate as necessary. Re-

fer to LUBRICATION in the MAINTENANCE
AND REPAIR section of this manual and per­form duties as instructed.

e. If the pump and motor have been stored for

more than 12 months, some of the compo­nents or lubricants may have exceeded their
maximumshelflife.Thesemustbeinspected
or replaced to ensure maximum pump serv­ice.

5.25

PAGE B -- 1INSTALLATION

OM--01505 DSERIES

If the maximum shelf life has been exceeded, or if
anything appears to be abnormal, contact your
Gorman-Rupp distributor or the factory to deter­minethe repairor updating policy. Donotputthe
pump into service until appropriate action has
been taken.

ELECTRIC MOTOR INSTALLATION

The pump is designed tobe flex-coupledto a1750
RPMsynchronousspeed electricmotor.The pump
basewillaccepteither a182Tor184T motorframe.
Be sure the motor tobe used meets these specifi­cations and is compatible with the intended appli­cation.

Install and operate only an explosion
proof motor in an explosive atmo­sphere. Install, connect, and operate
the motor in accordance with the Na­tional Electric Code and all local codes.
Ifthereisa conflictbetween the instruc­tions in the manual accompanying the
unit and the National Electric Code or
the applicable local code, the National
or local code shall take precedence.

POSITIONING PUMP

andmovetheunitareimproperlywrapped
around the pump.

Mounting

Locatethepumpinanaccessibleplaceascloseas
practicalto the liquid being pumped. Levelmount­ing is essential for proper operation.

The pump may have to be supported or shimmed
to provide for level operation or to eliminate vibra­tion.

After the pump has been positioned, block the
wheels and secure the pump t o prevent creeping.

SUCTION AND DISCHARGE PIPING

Pump performance is adversely effected by in­creased suction lift, discharge elevation, and fric­tion 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
compatiblewith theliquidbeingpumped.If hoseis
used insuction lines, it mustbe the rigid-wall, rein­forcedtype toprevent collapseunder suction.Us­ing piping couplings in suction lines is not recom­mended.

Lifting

This pump is designed to be easily positioned for
operationusing the drawbar and wheels. The total
pump weight is approximately295 pounds (133,8
kg), not including accessories or motor.Customer
installed equipment such as suction and dis­chargepipingmustberemovedbeforeattempting
to lift.

Thepumpassemblycanbeseriously
damaged ifthecables or chains used tolift

PAGE B -- 2 INSTALLATION

Line Configuration

Keep suction and discharge lines as straight as
possible to minimize friction losses. Make mini­mum use of elbows and fittings, which substan­tiallyincreasefriction loss.If elbowsarenecessary,
use the long-radius type to minimize friction loss.

Never pull a line into place by t ightening connec­tionsatthe pump.Lines near thepump mustbe in­dependently supported to avoid strain on the
pump which could cause excessive vibration and
increased diaphragm and gear train wear. If hose­type lines are used, they should have adequate
support to secure them wh en filledwith liquidand
under pressure.

DSERIES OM--01505

Fixed, Rigid Piping

This pump is equipped with an integral suction ac­cumulator 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 replen­ished periodically. To introduce air into the cham­ber, stop the pump and remove the suction accu­mulator plug and integral gasket; this will break
prime and allow the liquid in the chamber to drain
away through the suction line.

AIR CHAMBERS
(18TO24INCHLENGTHSOF
6 TO 8 INCH DIAMETER PIPE
WITH WELDED CAPS)

DISCHARGE
CHAMBER

If the pump is mounted in a system with fixed, rigid
piping, it is recommended that a flexible connec­tionbeinstalledatornearthesuctionanddis­charge ports to absorb shock which would other­wise be transmitted through the drive train and
greatly accelerate pump wear.

In a fixed piping installation, properly sized surge
suppressorsmust be installed in both suction and
discharge lines. If commercial surge suppressors
are not readilyavailable, air chambers may be fab­ricated from pipe as shown in Figure 2.

1/2-INCH VALVE FOR
RECHARGING AIR
CHAMBER WITH
COMPRESSED AIR
(ALSO ON DISCHARGE
CHAMBER)

DISCHARGE

FLEXIBLE JOINT

NOTE: INSTALL AIR CHAMBERS OFF FLOW LINE TEES

TO AVOID SURFACE TURBULENCE WITHIN CHAMBERS.

Figure 2. Fixed Piping Installation

Notethat the airchambers have not been installed
directly in the flow line, but have been installed off
tees to avoid turbulence within the chambers. The
airchambersarefittedwithvalvestopermitintro­ductionof small amounts of compressed air to fur­ther 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.

SUCTION
CHAMBER

FLEXIBLE JOINT

SUCTION

Gauges

Ifdischarge pressure and vacuum suction gauges
aredesired, drilland tapthesuctionanddischarge
lines not less than 18 inches (457,2 mm) from the
suction and discharge ports and install the lines.
Installationcloserto the pump may result in erratic
readings.

PAGE B -- 3INSTALLATION

OM--01505 DSERIES

SUCTION LINES

To avoidairpockets whichcould affect pumpprim­ing, the suction line must be as short and direct as
possible.When operationinvolvesasuctionlift,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

Maximumpumpperformanceis realized atsuction
lifts of 5 feet or less. Use the shortest possible
lengthof suction hose or piping; lengths of 25 feet
or longer will reduce the capacity of the pump.

It is strongly recommended that no positive shut­off valve be installed in the suction line; excessive
restrictions will cause incomplete filling of the dia­phragm chamber and result in short diaphragm
life.

Fittings

Suction lines shouldbe the same size as the pump
inlet. If reducers are used in suction lines, they
should be the eccentric type, and should be in­stalledwith the flat part ofthe reducers uppermost
to avoid creating air pockets. The suction line
shouldnot be restricted morethan 1 inch belowthe
nominal suction size.

The use of pipe couplings in the suction line is not
recommended.

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

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 air­tight seal. Follow the sealant manufacturer’s rec­ommendations when selecting and applying the
pipe dope. The pipe dope should be compatible
with the liquid being pumped.

DISCHARGE LINES

Thedischargelinemustbethesamesize
as,or largerthan,thesuctionline. Neverin­stall or operate thepump with a discharge
line smaller than the suction; a restricted
dischargeline will cause excessive friction
loss resulting in overloading and destruc­tion of pump and drive components.

Siphoning

Donot terminate the discharge lineat a level lower
than that of the liquid being pumped unless a si­phon breaker is used in the line. Otherwise, a si­phoning action causing damage to the pump
could result.

Valves

Strainers

If a strainer is furnished with the pump, be certain
touseit; any sphericalsolidswhichpass througha
strainer furnished with the pump will also pass
through the pump itself.

If a s trainer 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 crosssection of the suction
line,and that the openings will not permit passage

PAGE B -- 4 INSTALLATION

Thepumpisprovidedwithintegralsuctionanddis­charge check valves.

Never install a positive shut-off valve inthe
discharge line; discharge restrictions will
cause excessive friction loss resulting in
overloading and destruction of pump and
drive components. It is strongly recom-

DSERIES OM--01505

mended that unless absolutely necessary,
nopositiveshut-off valvebe installedinthe
suction line; excessive restriction will
cause incomplete filling of the diaphragm
chamber and result in shortened dia­phragm life.

ALIGNMENT

Beforeattempting toopenorservic e the
pump:

1. Familiarize yourself with this man­ual.

2. Shut off incoming powertothemo­torand lock itouttoensurethatthe
pump will remain inoperative.

3. Allowthe pump to completelycool
if overheated.

4. Close the discharge valve (if
used).

5. Drain the pump.

To check parallel adjustment, lay a straightedge
acrossbothcouplinghalvesatthe top, bottomand
sides. The horizontal parallel adjustment is correct
when the straightedge rests evenlyon both halves
ofthe couplingatall points.Use afeeler gaugebe­tween the coupling to measure any misalignment.

Donot operate the pump without the ec­centric and coupling guards in place
over the rotating parts. Exposed rotat­ing parts can catch clothing, fingers, or
tools, causing severe injury to person­nel.

ELECTRICAL CONNECTIONS

Beforeconnecting the motorto the incomingpow­er, check that the electrical service available
matches the pump motor requirements stamped
on the motor nameplate.

It is imperative that alignment be checked
before the pump is operated.

The pump and gearbox were aligned andsecured
at the factory, but fastening hardware may have
loosenedduring shipment. It is imperative thatthis
hardware and the alignment be checked after the
pump is installed and before operation. Adjust­ments may be made by loosening the securing
hardware and shifting or shimming components
as required.

This pump is designed to be driven by a flex­coupled electric motor.

Tocheck couplingalignment,use a feelergaugeor
taper gauge between the coupling halves every
90_. The coupling is in alignment when the hubs
are the same distance apart at all points.

The pump must be operated in the direc­tion indicated bythe arrow on thegearbox
andon the accompanying decals.Reverse
rotationcould causepumpcomponentsto
be destroyed.

Install and operate only an explosion
proof motor in an explosive atmo­sphere. Install, connect, and operate
the motor in accordance with the Na­tional Electric Code and all local codes.
Ifthereisa conflictbetween the instruc­tions in the manual accompanying the
unit and the National Electric Code or
the applicable local code, the National
or local code shall take precedence.

PAGE B -- 5INSTALLATION