GORMAN-RUPP PUMPS D Series, 4D-E3 3P Installation, Operation, And Maintenance Manual With Parts List

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Page 1

OM‐01510-OM03

June 29, 1981

Rev. E 12/05/18

Supersedes: OM-03569

INSTALLATION, OPERATION,

AND MAINTENANCE MANUAL

WITH PARTS LIST

D SERIES PUMPS

MODEL

4D-E3 3P

GORMAN‐RUPP PUMPS

www.grpumps.com

e1981 Gorman‐Rupp Pumps Printed in U.S.A.

Page 2

TABLE OF CONTENTS

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

WARNINGS SECTION A PAGE A - 1........................................

INSTALLATION - SECTION B PAGE B - 1.....................................

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

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

POSITIONING PUMP PAGE B - 2..........................................................

Lifting PAGE B - 2....................................................................

Mounting PAGE B - 2................................................................

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

Materials PAGE B - 2.................................................................

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

Fixed, Rigid Piping PAGE B - 2........................................................

Gauges PAGE B - 3..................................................................

SUCTION LINES PAGE B - 3..............................................................

Fittings PAGE B - 3..................................................................

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

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

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

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 - 2............................................................

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

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

Page 3

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 - 12......................................

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 - 15................................................................

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

Page 4

D SERIES

OM-01510

INTRODUCTION

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

This is a D Series, positive displacement pump util izing a single‐action diaphragm to produce a straight‐through flow of liquid. The pump 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 diaphragm.

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 write:

The Gorman‐Rupp Company

P.O. Box 1217

Mansfield, Ohio 44901-1217

Gorman‐Rupp of Canada Limited

70 Burwell Road

St. Thomas, Ontario N5P 3R7

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.

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.

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 5

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 incoming power to the motor to ensure that the pump will remain inoperative.

3. Allow the pump to completely cool if overheated.

4. Close the discharge valve (if used).

5. 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.

OM-01510

Do not operate the pump without the ec centric and coupling guards in place over the rotating parts. Exposed rotat ing parts can catch clothing, fingers, or tools, causing severe injury to person nel.

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

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.

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.

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 that the pump and motor are properly grounded; never use gas pipe as an electrical ground. Be sure that the in coming power matches the voltage and

PAGE A - 1SAFETY

Page 6

D SERIESOM-01510

phase of the pump and motor before connecting the power source. Do not run the pump if the voltage is not within the limits.

Death or serious personal injury and damage to the pump or components can occur if proper lifting procedures are not observed. Make certain that hoists, chains, slings or cables are in good working condition and of suffi cient capacity and that they are posi tioned so that loads will be balanced and the pump or components will not be damaged when lifting. Suction and dis charge hoses and piping must be re moved from the pump before lifting. Lift the pump or component only as high as necessary and keep personnel away from suspended objects.

All electrical connections must be in ac

cordance with the National Electric Code. If there is a conflict between the instructions provided and N.E.C. speci fications, N.E.C. specifications shall take precedence. All electrical equip ment supplied with this pump was in conformance with N.E.C. requirements in effect on the date of manufacture. Failure to follow applicable specifica tions, or substitution of electrical parts not supplied or approved by the man ufacturer, can result in severe injury or death.

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 7

D SERIES OM-01510

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

4” N.P.T. DISCHARGE

3” (OR 4”) N.P.T. SUCTION

33.88

[860,6]

17.00

[431,8]

APPROX

26.62

[676,1]

16.88

[428,8]

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.

50.69

[1287,5]

[1370,1]

[185,7]

MOTOR FRAME 182T AND 184T

53.94 MOTOR FRAME 213 AND 215

32,31

MOTOR FRAME 182T AND 184T

[820,7]

34,94

MOTOR FRAME 213 AND 215

[887,5]

19.69

[500,1]

7.31

7.00

[177,8]

DIMENSIONS:

INCHES

[MILLIMETERS]

Figure 1. 4D Electric Motor Driven Pumps

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.

5,31

[134,9]

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 8

OM-01510 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

Lifting

This pump is designed to be easily positioned for operation using the drawbar and wheels. The total pump weight is approximately 370 pounds (167,8 kg), not including accessories. Customer installed equipment such as suction and discharge piping must be removed before attempting to lift.

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

SUCTION AND DISCHARGE PIPING

Pump performance is adversely effected by in creased suction lift, discharge elevation, and fric tion losses. See Page E‐1 to be sure your overall application allows the pump to operate within the safe operation range.

Materials

Either pipe or hose maybe used for suction and discharge lines; however, the materials must be compatible with the liquid being pumped. If hose is used in suction lines, it must be the rigid‐wall, rein forced type to prevent collapse under suction. Us ing piping couplings in suction lines is not recom mended.

Line Configuration

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.

Keep suction and discharge lines as straight as possible to minimize friction losses. Make mini mum use of elbows and fittings, which substan tially increase friction loss. If elbows are necessary, use the long‐radius type to minimize friction loss.

Never pull a line into place by tightening connec tions at the pump. Lines near the pump must be in dependently supported to avoid strain on the pump which could cause excessive vibration and increased diaphragm and gear train wear. If hose‐ type lines are used, they should have adequate support to secure them when filled with liquid and under pressure.

Fixed, Rigid Piping

This pump is equipped with an integral suction ac cumulator chamber which promotes an efficient flow of liquid and acts as an air cushion against shock. Since the air in this chamber will leak away during pump operation, the air must be replen ished periodically. To introduce air into the cham ber, stop the pump and remove the suction accu mulator plug and integral gasket; this will break prime and allow the liquid in the chamber to drain away through the suction line.

If the pump is mounted in a system with fixed, rigid piping, it is recommended that a flexible connec

PAGE B - 2 INSTALLATION

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D SERIES OM-01510

tion be installed at or near the suction and dis charge ports to absorb shock which would other wise be transmitted through the drive train and greatly accelerate pump wear.

In a fixed piping installation, properly sized surge

AIR CHAMBERS (18 TO 24 INCH LENGTHS OF 6 TO 8 INCH DIAMETER PIPE WITH WELDED CAPS)

DISCHARGE CHAMBER

DISCHARGE

FLEXIBLE JOINT

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

SUCTION

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.

If discharge pressure and vacuum suction gauges are desired, drill and tap the suction and discharge lines not less than 18 inches (457,2 mm) from the suction and discharge ports and install the lines. Installation closer to the pump may result in erratic readings.

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.

PAGE B - 3INSTALLATION

Page 10

OM-01510 D SERIES

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

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.

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.

Valves

The pump is provided with integral suction and dis charge check valves.

ALIGNMENT

This pump is designed to handle up to 2‐1/4 inch (57 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 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

Before attempting to open or service the pump:

1. Familiarize yourself with this man ual.

2. Shut off incoming power to the mo tor and lock it out to ensure that the pump will remain inoperative.

3. Allow the pump to completely cool if overheated.

4. Close the discharge valve (if used).

5. Drain the pump.

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

PAGE B - 4 INSTALLATION

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D SERIES OM-01510

The pump and motor were aligned and secured at the factory, but fastening hardware may have loos ened during shipment. It is imperative that this hardware and the alignment be checked after the pump is installed and before operation. Adjust ments 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 90_. The coupling is in alignment when the hubs are the same distance apart at all points.

To check parallel adjustment, lay a straightedge across both coupling halves at the top, bottom and sides. The horizontal parallel adjustment is correct when the straightedge rests evenly on both halves of the coupling at all points. Use a feeler gauge be tween the coupling to measure any misalignment.

ELECTRICAL CONNECTIONS

Before connecting the motor to the incoming pow er, check that the electrical service available matches the pump motor requirements stamped on the motor nameplate.

The pump must be operated in the direc tion indicated by the arrow on the gearbox and on the accompanying decals. Reverse rotation could cause pump components to be destroyed.

Never install a non‐explosion proof motor in an ex plosive atmosphere. Be sure the motor is compat ible with the intended application.

PAGE B - 5INSTALLATION

Page 12

D SERIES

OM-01510

OPERATION - SECTION C

Review all SAFETY information in Section A.

Follow the instructions on all tags, labels and decals attached to the pump.

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

The pump is designed to operate at ap proximately 52 cycles per minute through a gearbox with A 33.34:1 ratio and a 1750 RPM maximum input drive. Make certain that the electric motor installed does not exceed this rpm; otherwise, pump compo nents may be destroyed.

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 motor and check the suction line for leaks.

OPERATION CHECKS

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

Gearbox Check

Check that the gearbox is properly lubricated (see

LUBRICATION in MAINTENANCE AND RE PAIR).

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

Page 13

OM-01510 D SERIES

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).

STOPPING

After stopping the pump, shut off incoming power to the motor and lock it out 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 within 20 minutes or less.

OPERATIONPAGE C - 2

Page 14

D SERIES OM-01510

TROUBLESHOOTING - SECTION D

Review all SAFETY information in Section A.

Before attempting to open or service the pump:

1. Familiarize yourself with this manual.

2. Shut off incoming power to the motor and lock it out to ensure that the pump will remain inoperative.

3. Allow the pump to completely cool if overheated.

4. Close the discharge valve (if used).

5. 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 15

OM-01510 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 16

D SERIES OM-01510

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 52 STROKES PER MINUTE

STATIC LIFT IN FEET

5 150 119 113 112

10 126 108 105 105

20 94 74 73 66

STATIC LIFT IN METERS

1,5 567,8 450,4 427,7 423,9

3,0 476,9 408,8 397,4 397,4

4,6 370,9 283,8 280,1 276,3

6,1 355,8 280,1 276,3 249,8

0101520

IN LITERS PER MINUTE AT 52 STROKES PER MINUTE

0 3,0 4,6 6,1

STATIC DISCHARGE HEAD IN FEET

125

118

STATIC DISCHARGE HEAD IN METERS

1,5

473,1

446,6

367,1

310,3

104

100

7374759815

6066707425

7,6

393,6

378,5

264,9

238,4

7,6 280,1 264,9 249,8 227,1

STANDARD PERFORMANCE TEST DATA FOR 4D ELECTRIC MOTOR DRIVEN PUMPS

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 different due to such factors as viscosity, specific gravity, elevation, temperature, and impeller trim.

MAINTENANCE & REPAIR PAGE E - 1

310,3

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.

196,8

Page 17

SECTION DRAWING

D SERIESOM-01510

Figure 1. 4D-E3 3P

MAINTENANCE & REPAIRPAGE E - 2

Page 18

D SERIES OM-01510

PARTS LIST

Pump Model 4D-E3 3P

(From S/N 504867 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

QTY ITEM

NO.

PART NAME PART

NUMBER

QTY

1 DRIVE SHAFT CPLNG 24355-105 1 2 MOTOR SHAFT CPLNG 24355-112 1 3 SPIDER 24355-267 1 4 COUPLING GUARD 34613-045 15020 1

5 KEY N0408 15990 1 6 MOTOR 28216-442 1 7 BASE 13485 24000 1 8 HEX HD CAPSCREW B0605 15991 4

9 HEX NUT D06 15991 4 10 LOCKWASHER J06 15991 4 11 AXLE 6619 15990 1 12 SPACER 6619A 15070 2 13 COTTER PIN M0306 15990 2 14 FLAT WASHER S1532 4 15 PNEUMATIC WHEEL S0263 2 16 U‐BOLT 6945 15000 2 17 HEX NUT D06 15991 4 18 LOCKWASHER J06 15991 4 19 HEX HD CAPSCREW B0404 15991 2 20 FLAT WASHER K04 15991 2 21 LOCKWASHER J04 15991 2 22 HEX NUT D04 15991 2 23 DIAPHRAGM RING 6621 13010 1 24 DRAW BAR 5438 15990 1

INDICATES PARTS RECOMMENDED FOR STOCK

25 PLUNGER ROD ASSY 6959 1 26 LUB FITTING S191 1 27 END CAP 6643 10010 1 28 GEARBOX ASSY 44161-009 1 29 HEX HD CAPSCREW B01010 15991 4 30 LOCKWASHER J10 15991 4 31 HEX NUT D12 15991 4 32 LOCKWASHER J12 15991 4 33 HEX HD CAPSCREW B1212 15991 4 34 DIAPHRAGM POT ASSY 46475-702 1 35 U‐BOLT 5495 15991 2 36 HEX NUT W/FLANGE 21765-314 4 37 HEX HD CAPSCREW B0402-1/2 15991 2 38 T TYPE LOCKWASHER AK04 15991 2 39 FLAT WASHER K04 15991 2 40 ECCENTRIC GUARD 38861-504 23200 1 41 LUBE DECAL 38817-066 1 42 NYLOCK CAPSCREW BT0403 15991 1 43 WASHER S157 1 44 FLAT WASHER K04 15991 1 45 GRD WARNING STCKR 38816-063 1

NOT SHOWN:

NAME PLATE 2613BP 13990 1 DRIVE SCREW BM#04-03 17000 4 STRAINER 4917 24001 1

MAINTENANCE & REPAIR PAGE E - 3

Page 19

D SERIESOM-01510

ILLUSTRATION

Figure 2. Diaphragm Pot Assembly

MAINTENANCE & REPAIRPAGE E - 4

Page 20

D SERIES OM-01510

PARTS LIST

Diaphragm Pot Assembly

ITEM NO.

1 POT-DIAPHRAM 6622 13010 1 2 ACCUMULATOR & SUCTION FLANGE 6625 13010 1 3 DISCHARGE FLANGE 6627 13040 1 4 PIPE PLUG P06 15079 1 5 DISCHARGE ELBOW 6626 13040 1 6 VALVE SEAT 6635 10010 2 7 FLAP VALVE ASSY 46413-007 2 8 REDUCER PIPE BUSHING AP6448 11990 1

9 LOCK WASHER J05 15991 4 10 HEX HEAD CAP SCREW B0504 15991 4 11 STUD C1013 15991 4 12 WASHER SAE 5/8 21161-442 6 13 HEX NUT D10 15991 6 14 GASKET 6625G 19100 3 15 DRUM PLUG W/ GASKET 25142-010 1 16 STUD C1010 15991 2

INDICATES PARTS RECOMMENDED FOR STOCK

PART NAME

PART NUMBER

QTY

MAINTENANCE & REPAIR PAGE E - 5

Page 21

D SERIESOM-01510

SECTION DRAWING

234

8.00 REF

10.78 HOLD

Figure 3. 6959 Plunger Rod Assembly

6789

MAINTENANCE & REPAIRPAGE E - 6

Page 22

D SERIES OM-01510

PARTS LIST

6959 Plunger Rod Assembly

ITEM NO.

1 BEARING CAP 6560 10010 1

2 -HEX HD CAPSCREW B0813S 15991 2

3 -HEX NUT D08S 15991 2

4 -LOCKWASHER J08 15991 2

5 PLUNGER ROD ASSEMBLY 6633 15990 1

6 DIAPHRAGM S1017 1

7 LUBRICATION FITTING S194 1

8 DIAPHRAGM PLATE 6629 15990 1

9 DIAPHRAGM PLATE 6628 10010 1

10 HEX NUT D08 15991 4 11 SPRING WASHER 6639 15000 1 12 SPRING 6547 16080 1 13 SPRING RETAINING NUT 6638 11000 1

INDICATES PARTS RECOMMENDED FOR STOCK

PART NAME

PART NUMBER

QTY

MAINTENANCE & REPAIR PAGE E - 7

Page 23

SECTION DRAWING

D SERIESOM-01510

Figure 4. Gearbox Assembly

MAINTENANCE & REPAIRPAGE E - 8

Page 24

D SERIES OM-01510

PARTS LIST

Gearbox Assembly

ITEM

PART NAME PART

NO.

NUMBER

QTY ITEM

NO.

PART NAME PART

NUMBER

QTY

1 GEAR HOUSING 6624 13040 1 2 CRANKSHAFT BEARING S374 1

CRANKSHAFT GEAR 6641 15060 1

3 4 GEAR HOUSING GSKT 6624G 18000 1 5 AIR VENT FITTING S2162 1

6 HEX HD CAPSCREW B0803 15991 1 7 GEAR COVER 6623 13010 1

8 CRANKSHAFT GEAR KEY N0605 15990 1

9 CRANKSHAFT BEARING S1080 1 10 HEX HD CAPSCREW B1004 15991 1 11 FLAT WASHER 21161-442 1 12 WASHER 6637 15000 1

13 PINION BUSHING S1016 1 14 GEAR COVER PLUG S1053 1 15 HEX HD CAPSCREW B0504 15991 4 16 LOCKWASHER J05 15991 4

17 DRIVE SHAFT KEY N0304 15990 1 18 DRIVE SHAFT 6631 15010 1 19 OIL SEAL S1012 1 20 ECCENTRIC HOUSING 6632 10010 1

21 ECC HOUSING GSKT 6632G 18000 1 22 DRAIN PLUG P04 15079 1

23 DRIVE SHAFT BEARING S1044 2 24 RETAINING RING S204 1

INDICATES PARTS RECOMMENDED FOR STOCK

25 DRIVE GEAR 6558 16040 1 26 SNAP RING S1004 1

27 PINION GEAR S1014 1 28 PINION SHAFT 6634 16070 1 29 GEAR HOUSING PLUG S1054 1 30 PINION SHAFT BUSHING S1015 1 31 SPACER 6636 15990 1 32 SNAP RING S244 1 33 ROLLER BEARING S1011 1 34 RETAINING RING S442 1 35 CRANKSHAFT 6550 11000 1 36 SNAP RING S1010 1 37 HEX HD CAPSCREW B0511 15991 5 38 LOCKWASHER J05 15991 5 39 HEX NUT D05 15991 5 40 SHOULDER BOLT S1018 1 41 LOCKWASHER J05 15991 1 42 HEX NUT D05 15991 1 43 HEX HD CAPSCREW B0518 15991 3 44 LOCKWASHER J05 15991 3 45 HEX NUT D05 15991 3 46 OIL CUP S617 1 47 SHOULDER BOLT S1019 1 48 LOCKWASHER J05 15991 1 49 HEX NUT D05 15991 1

MAINTENANCE & REPAIR PAGE E - 9

Page 25

OM-01510

PUMP AND SEAL DISASSEMBLY AND REASSEMBLY

D SERIES

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 thru 4) and the accompanying parts lists.

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.

Before attempting to open or service the pump:

1. Familiarize yourself with this man ual.

2. Shut off incoming power to the mo tor and lock it out to ensure that the pump will remain inoperative.

3. Allow the pump to completely cool if overheated.

4. Close the discharge valve (if used).

5. 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.

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.

Before attempting to service the pump, drain the pump by removing the drain plug (11, Figure 2). Clean and reinstall the drain plug.

Suction And Discharge Check Valve Removal

Before attempting to service the pump, shut off in coming power to the motor and lock it out to ensure that it will remain inoperative. Close all valves in the suction and discharge lines.

For motor disassembly and repair, consult the lit erature supplied with the motor, or contact your lo cal motor representative.

(Figure 2)

To service the suction and discharge check valves, remove the suction and discharge piping.

To service the suction check valve assembly (7), re move the suction accumulator (2) by loosening the hardware (12 and 13) securing it to the diaphragm pot (1). Remove the hardware (9 and 10) securing

MAINTENANCE & REPAIRPAGE E - 10

Page 26

OM-01510D SERIES

the valve seat (6) and check valve assembly to the diaphragm pot. Pull the check valve assembly from the suction port.

To service the discharge check valve assembly (7), loosen the hardware (12 and 13) and remove the assembled outboard discharge elbow (5), check valve, and seat (6). Remove the gasket (14).

Remove the hardware (9 and 10) securing the valve seat (6) and discharge check valve assembly to the discharge elbow.

To remove the inboard discharge flange (3), loosen the hardware (12 and 13) securing the flange to the diaphragm pot. Remove the gasket (14).

If no further disassembly is required, see Suction

And Discharge Check Valve Installation.

Diaphragm Removal

(Figure 1)

Use a socket wrench to hold the plunger rod (5) se curely, and unscrew the bearing cap assembly (1). Unscrew the spring retaining nut (13). Use caution when unscrewing the retaining nut; tension on the spring (12) will be released.

Remove the spring (12) and spring washer (11). Slide the plunger rod assembly (5) out of the upper diaphragm plate (9).

Inspect the component parts for excessive wear and replace as required.

Gearbox Removal And Disassembly

(Figure 1)

When properly operated and maintained, the gear box assembly (28) should not require disassembly. Disassemble the gearbox only when there is evi dence of wear or damage.

To remove the diaphragm (6, Figure 3), disengage the hardware (31, 32 and 33) and remove the dia phragm pot assembly (34). Inspect the diaphragm ring (23) for wear or damage. If replacement is re quired, the gearbox assembly (28) must be re moved.

(Figure 3)

Remove the nuts (10). Separate the lower dia phragm plate assembly (8) from the diaphragm (6) and the upper diaphragm plate (9). Inspect the dia phragm and replace a required.

If no further disassembly is required, see Dia

phragm Installation.

Plunger Rod Removal And Disassembly

(Figure 3)

With the diaphragm pot assembly and diaphragm removed, disengage the hardware (38, 39, 40, 43, 44, and 45, Figure 1) and remove the eccentric guard (41, Figure 1).

Loosen the hardware (2, 3 and 4) and remove the end cap (27, Figure 1). Slide the bearing cap (1) off the crankshaft roller bearing (33, Figure 4), and re move the plunger rod assembly.

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 (23) with wooden blocks. Disengage the hardware (29 and 30) and remove the diaphragm ring. Inspect the dia phragm ring for wear or damage and replace as necessary. It is not necessary to remove the draw bar (24) from the diaphragm ring unless replace ment is required. Disengage the hardware (36 and

37) from the U‐bolts (35) to remove the drawbar.

Disengage the hardware (19, 20, 21 and 22) and remove the coupling guard (4). Loosen the hard ware securing the drive shaft coupling (1). Sepa rate the gearbox assembly from the coupling by pulling straight away. Remove the shaft key (17, Figure 4).

(Figure 4)

Before attempting to disassemble the gearbox as sembly, drain the lubricant by removing the drain plug (22) and turning the gearbox on its side. Clean and reinstall the drain plug.

Remove the hardware (15 and 16) securing the ec centric housing (20) and housing gasket (21) to the

MAINTENANCE & REPAIR PAGE E - 11

Page 27

OM-01510

D SERIES

gear cover (7). Pull the complete drive shaft sub‐ assembly from the gear cover.

To disassemble the drive shaft subassembly, re move the snap ring (26) and slide the drive gear (25) off the drive shaft (18). Remove the retaining ring (24), and press the drive shaft and assembled bearings (23) out of the eccentric housing. Press the oil seal (19) from the housing bore. Cover the shaft and bearing with a clean cloth until ready to clean and inspect the gearbox components.

For access to the remaining gearbox drive compo nents, the gear cover (7) and gear housing gasket (4) must be separated from the gear housing (1) by removing the two close‐tolerance shoulder bolts (40 and 47), which act as pilots to ensure accurate concentric positioning of the cover, and the re maining hardware (37, 38, 39, 41, 42, 43, 44, 45, 48 and 49).

NOTE

The shoulder bolts and capscrews securing the gearbox cover to the gearbox housing are of differ ent lengths. For ease of reassembly, record the po sitions of the shoulder bolts and capscrews at the time of removal.

Remove the gear housing gasket and clean all the mating surfaces.

Install two 5/8‐11 UNC capscrews in the tapped holes in the crankshaft gear (3), and use a gear puller to slide the gear off the crankshaft. Retain the crankshaft gear key (8). Remove the capscrews from the gear.

Remove the snap ring (36) and slide the crankshaft and crankshaft bearing (2) out of the gearbox housing.

To disassemble the pinion shaft and components, slide the shaft and assembled pinion gear (27) out of the shaft bushing (30). The pinion gear is re tained on the shaft by tight friction fit and does not normally require removal. If removal is required, press the pinion gear from the shaft.

Inspect the pinion shaft bushing and, if replace ment is required, remove the plug (29) and press the bushing from the gear housing bore.

After removing the shafts 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.

NOTE

If the gear cover does not readily separate from the housing, remove the hardware (10 and 11), install a 5/8‐11 UNC by 4‐inch long capscrew, and jack the cover from the housing. Remove the jacking screw and replace the hardware (10 and 11).

After the gear cover has been removed, inspect the pinion shaft bushing (13). If replacement is re quired, remove the cover plug (14) and press the pinion shaft bushing (13) from the cover bore. Slide the pinion shaft washer (12) off the pinion shaft (28) and tag it for reference during reassembly.

Use a bearing puller to remove the crankshaft bearing (9) from the crankshaft (35). Remove the spacer (31).

Clean the gear housing, shaft and all component 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.

MAINTENANCE & REPAIRPAGE E - 12

Page 28

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.

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 shafts and a snug slip fit into the gear housing. Replace the bearings, shafts, eccentric housing, or gear housing if the proper bearing fit is not achieved.

If the bearings require replacement, remove the bearing retaining ring (34). Remove the bearing snap ring (32) and use a bearing puller to remove the bearings (2, 23 and 33).

Gearbox Reassembly And Installation

(Figure 4)

OM-01510D SERIES

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 shafts, one at a time, until they are fully seated. This should be done quickly, in one con tinuous motion, to prevent the bearings from cool ing and sticking on the shaft.

Use caution when handling hot bear ings to prevent burns.

NOTE

The crankshaft bearing (9) must be installed after the crankshaft gear (3).

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 suitable sized sleeve and a press to reposition the bearings.

Inspect the shafts (18, 28 and 35) for distortion, nicks or scratches. Dress small nicks and burrs with a fine file or emery cloth. Replace the shafts if defective.

If heating the bearings is not practical, use a suit able sized sleeve and an arbor (or hydraulic) press to install the bearings on the shaft.

When installing the bearings onto the

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.

MAINTENANCE & REPAIR PAGE E - 13

shaft, never press or hit against the outer race, balls, or ball cage. Press only on the inner race.

Secure the bearing (2) with the snap ring (34). Se cure the crankshaft roller bearing (33) with the snap ring (32).

If removed, press the pinion shaft bushing (30) into the gear housing until fully seated.

Use a hydraulic press to install the pinion gear (27) onto the pinion shaft (28).

Page 29

OM-01510

D SERIES

NOTE

The pinion gear is a tight interference fit on the pin ion shaft. To ease installation, the gear may be heated (and the shaft cooled) to a temperature dif ferential of 350_F (177_C). If the gear is heated, use caution when handling the gear to prevent burns.

Slide the assembled pinion shaft and gear into the pinion shaft bushing until fully seated.

Slide the crankshaft and assembled bearing (2) into the gear housing and secure with the snap ring (36).

When installing the shaft and bearings into the bearing bore, push against the outer race. Never hit the balls or ball cage.

Install the crankshaft gear key (8) in the shaft key way. Align the crankshaft gear teeth with those on the pinion shaft, and press the gear onto the crank shaft until fully seated against the shoulder. Install the spacer (31), and press the bearing (9) onto the shaft until fully seated against the spacer.

Tap the end of the crankshaft with a soft‐faced mal let to ensure that all components are fully seated.

Press the drive shaft and assembled bearings into the eccentric housing (20), and secure with the re taining ring (24).

When installing the shaft and bearings into the bearing bore, push against the outer race. Never hit the balls or ball cage.

Lubricate the lip of the oil seal (19) with light oil, and position it on the drive shaft with the lip positioned as shown in Figure 4. Press the oil seal into the ec centric housing bore until the face of the oil seal is

just flush with the face of the eccentric housing. Be careful not to roll or cut the lip of the oil seal on

the shaft keyway.

Install the drive gear (25) on the drive shaft, and se cure with the snap ring (26).

Clean the mating surface of the eccentric housing and replace the eccentric housing gasket (21). Po sition the assembled eccentric housing and drive shaft in the gear cover bore with the word “top” on the eccentric housing flange facing up. Slide the housing and drive shaft into the gearbox, making certain the drive gear teeth fully engage those of the pinion gear. Secure the eccentric housing to the gear housing with the hardware (15 and 16).

Install the drive shaft key (17).

If removed, press the pinion shaft bushing (13) into the gear cover (7). Slide the pinion shaft washer (12) onto the pinion shaft (28). Install the gear housing gasket (4). Position the gear cover so that the respective bores slip over the crankshaft bear ing and pinion shaft. Tap the cover into place with a soft‐faced mallet.

Install the two close‐tolerance shoulder bolts (40 and 47) (which act as pilots to ensure accurate concentric positioning of the cover) through their respective holes, and secure them with the hard ware (41, 42, 48 and 49). Secure the gear cover to the gear housing by tightening the remaining hard ware (37, 38, 39, 43, 44, 45 and 46) evenly.

Install the gear cover plug (14) and the gear hous ing plug (29).

(Figure 1)

Position the gearbox on the base (7). Position the diaphragm ring (23) under the base, and secure the gearbox and diaphragm ring with the hardware (29 and 30).

If the drawbar (24) was removed, secure it to the diaphragm ring with the U‐bolts (35) and hardware (36 and 37).

Secure the drive shaft coupling (1) to the drive shaft. Check the coupling alignment as described in ALIGNMENT, Section B. Install the coupling guard (4) and secure it with the hardware (19, 20, 21 and 22).

Lubricate the gearbox as described in LUBRICA

TION.

MAINTENANCE & REPAIRPAGE E - 14

Page 30

OM-01510D SERIES

Plunger Rod Reassembly And Installation

(Figure 3)

Slide the plunger rod (5) through the upper dia phragm plate (9). Slide the spring washer (11) and spring (12) down over the plunger rod. Install the spring retaining nut (13), and tighten it to obtain the dimension shown in Figure 3.

Clean the bearing cap (1) with a cloth soaked in cleaning solvent.

Diaphragm Installation

(Figure 3)

Position the diaphragm (6) on the upper dia phragm plate (9), making sure the lip is properly seated. Slide the studs in the lower diaphragm plate (8) through the holes in the upper diaphragm plate, and secure with the nuts (10).

(Figure 1)

Secure the diaphragm pot assembly (34) to the di aphragm ring (23) with the hardware (31, 32 and

33).

Suction And Discharge Check Valve Installation

(Figure 2)

Inspect the check valve components and replace as required.

If the inboard discharge flange (3) was removed, clean the mating surfaces and install the gasket (14). Secure the flange to the diaphragm pot (1) with the hardware (12 and 13).

Inspect the bearing cap for wear or damage and replace if necessary.

NOTE

The bearing cap consists of an upper and lower half secured with the hardware (2, 3 and 4). The cap is machined as one piece before being split to ensure concentricity of the bore, and is available only as an assembly.

Screw the bearing cap assembly onto the plunger rod until fully seated against the spring retaining nut.

Loosen the hardware (2, 3 and 4), and position the bearing cap over the crankshaft roller bearing (33, Figure 4). Secure the plunger rod assembly by tightening the hardware (2, 3 and 4).

Secure the eccentric guard (41, Figure 1) with the hardware (38, 39, 40, 43, 44, and 45, Figure 1).

Subassemble the valve seat (6) and discharge check valve (7) to the discharge elbow (5) with the weights positioned as shown in Figure 2, and se cure with the hardware (9 and 10).

Clean the mating surfaces of the valve seat and dis charge flange. Install the gasket (14) and secure assembled discharge elbow, check valve, and seat to the discharge flange with the hardware (12 and

13).

Check the operation of the check valve to ensure proper seating and free movement.

Subassemble the suction check valve (7). Clean the mating surfaces, and position the gasket (14), check valve assembly, and valve seat (5) against the diaphragm pot with the weights positioned as shown in Figure 2. Secure with the hardware (9 and 10).

Check the operation of the check valve to ensure proper seating and free movement.

Secure the suction accumulator (2) to the dia phragm pot with the hardware (12 and 13).

Lubricate the plunger rod assembly as described in LUBRICATION, Section E.

MAINTENANCE & REPAIR PAGE E - 15

Connect the suction and discharge piping as de scribed in INSTALLATION, Section B.

Page 31

OM-01510

D SERIES

Refer to OPERATION, Section C before starting the pump.

LUBRICATION

Plunger Rod Assembly

(Figure 1)

The crankshaft roller bearing (33, Figure 4) should be lubricated thoroughly after each 8 hours of operation. Failure to do so may cause the bearing to overheat and fail.

Apply No. 2 lithium base grease to the upper lubri cation fitting (26) until grease escapes from the end cap (27).

Apply No. 2 lithium base grease to the lower fitting (7, Figure 3) until grease escapes from the top of the upper diaphragm plate inside the spring.

of the proper grade (see the following reference) through the vented plug hole until it flows out the oil level hole. Clean and reinstall the vented plug and the oil level plug.

Under normal conditions, drain the gearbox every 500 hours of operation or every six months. Change the oil more frequently if the pump if oper ated under severe conditions, continuously or in stalled in an environment with rapid temperature change.

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.

The following lubricants are recommended:

Lubricant Manufacturer

Gearbox

(Figure 4)

The speed reducer 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 which ever comes first. To drain the oil, remove the oil drain plug at the bot tom of the gear housing cover and the vented plug at the top of the gear housing cover. Flush the case thoroughly with a light oil. Clean and reinstall the oil drain plug.

To fill the speed reducer, remove the oil level plug in the side of the gear housing cover, and add new oil

No. 4 Gear Oil AGMA Lubricant Meropa Lube No. 6 Texaco Mobilgear No. 634 Mobil Oil Sunep No 1150 Sun Oil Valvata Oil No. J78 Shell Oil

If none of the recommended lubricants are avail able, use SAE No. 90 multi‐purpose gear oil at am bient temperatures of +40 _F (4_C) to +120 _F (49_C, and SAE No. 80 multi‐purpose gear oil at temperatures below +40 _F (4_C).

Motor

Refer to the motor manufacturer's recommenda tions or contact your local motor representative.

MAINTENANCE & REPAIRPAGE E - 16

Page 32

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