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- Page 1 OM-01516-01 June 29, 1981 Rev. E 08‐25‐15 INSTALLATION, OPERATION, AND MAINTENANCE MANUAL WITH PARTS LIST DIAPHRAGM PUMP MODEL 4D-X3 3P GORMAN‐RUPP PUMPS www.grpumps.com 1981 Gorman‐Rupp Pumps Printed in U.S.A.
- Page 2 Register your new Gorman‐Rupp pump online at www.grpumps.com Valid serial number and e‐mail address required. RECORD YOUR PUMP MODEL AND SERIAL NUMBER Please record your pump model and serial number in the spaces provided below. Your Gorman‐Rupp distributor needs this information when you require parts or service. Pump Model: Serial Number:...
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Page 3: Table Of Contents
TABLE OF CONTENTS INTRODUCTION ........... PAGE I - 1 WARNINGS SECTION A... - Page 4 TABLE OF CONTENTS (continued) PUMP AND SEAL DISASSEMBLY AND REASSEMBLY ......PAGE E - 10 Suction And Discharge Check Valve Removal .
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Page 5: Introduction
D SERIES OM-01516 INTRODUCTION Thank You for purchasing a Gorman‐Rupp pump. HAZARD AND INSTRUCTION Read this manual carefully to learn how to safely DEFINITIONS install and operate your pump. Failure to do so could result in personal injury or damage to the The following are used to alert maintenance per... - Page 6 D SERIES OM-01516 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 Do not operate the pump without the ec centric and coupling guards in place begin operation.
- Page 7 OM-01516 D SERIES phase of the pump and motor before not supplied or approved by the man connecting the power source. Do not ufacturer, can result in severe injury or run the pump if the voltage is not within death. the limits.
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Page 8: Installation - Section B
See Figure 1 for the approximate physical dimen range the pump and piping. sions of this pump. OUTLINE DRAWING Figure 1. Model 4D-X3 3P PREINSTALLATION INSPECTION c. Carefully read all tags, decals, and markings on the pump assembly, and perform all duties indicated. -
Page 9: Positioning Pump
OM-01516 D SERIES or replaced to ensure maximum pump serv Materials ice. Either pipe or hose maybe used for suction and discharge lines; however, the materials must be If the maximum shelf life has been exceeded, or if compatible with the liquid being pumped. If hose is anything appears to be abnormal, contact your used in suction lines, it must be the rigid‐wall, rein... -
Page 10: Gauges
D SERIES OM-01516 AIR CHAMBERS (18 TO 24 INCH LENGTHS OF 1/2‐INCH VALVE FOR 6 TO 8 INCH DIAMETER PIPE RECHARGING AIR WITH WELDED CAPS) CHAMBER WITH COMPRESSED AIR (ALSO ON DISCHARGE DISCHARGE CHAMBER) CHAMBER DISCHARGE SUCTION CHAMBER FLEXIBLE JOINT FLEXIBLE JOINT NOTE: INSTALL AIR CHAMBERS OFF FLOW LINE TEES SUCTION... -
Page 11: Strainers
OM-01516 D SERIES The use of pipe couplings in the suction line is not recommended. Strainers Never install a positive shut‐off valve in the discharge line; discharge restrictions will If a strainer is furnished with the pump, be certain cause excessive friction loss resulting in to use it;... -
Page 12: Electrical Connections
D SERIES OM-01516 90_. The coupling is in alignment when the hubs are the same distance apart at all points. To check parallel adjustment, lay a straightedge The pump must be operated in the direc across both coupling halves at the top, bottom and tion indicated by the arrow on the gearbox sides. -
Page 13: Operation - Section C
OM-01516 D SERIES OPERATION - SECTION C Review all SAFETY information in Section A. ened diaphragm life. No positive shut‐off valve should be installed in the discharge Follow the instructions on all tags, labels and line. decals attached to the pump. STARTING Consult the operations manual furnished with the motor before starting the pump. -
Page 14: Accumulator Chamber Check
OM-01516 D SERIES flow begins to drop. If a vacuum suction gauge has ponents. avoid cleaning with cleaning sol been installed, monitor and record the readings vent. regularly to detect strainer blockage. In below freezing conditions, drain the water from the pump and the lines when the pump is not in op... -
Page 15: Troubleshooting - Section D
D SERIES OM-01516 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. - Page 16 OM-01516 D SERIES TROUBLE POSSIBLE CAUSE PROBABLE REMEDY PUMP REQUIRES Liquid solution too thick. Dilute if possible. TOO MUCH POWER Integral discharge check valve clogged Clean valve. or binding. Bearings in motor or gearbox Check bearings. worn or binding. PUMP CLOGS Integral suction or discharge check Clean valves, check that flange nuts FREQUENTLY...
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Page 17: Pump Maintenance And Repair Section E
D SERIES OM-01516 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 STATIC DISCHARGE HEAD IN FEET LIFT IN FEET IN LITERS PER MINUTE AT 52 STROKES PER MINUTE... - Page 18 OM-01516 D SERIES SECTION DRAWING PARTS PAGE Figure 1. 4D-X3 3P PAGE E - 2 MAINTENANCE & REPAIR...
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Page 19: Parts List
D SERIES OM-01516 PARTS LIST Pump Model 4D-X3 3P (From S/N 377791 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... -
Page 20: Diaphragm Pot Assembly
OM-01516 D SERIES SECTION DRAWING NOTE: CHECK VALVE ASSEMBLY SHOWN IN POSI TION ON DISCHARGE SIDE. SUCTION SIDE TO OPEN IN SAME DIRECTION. DISCHARGE SUCTION Figure 2. 46475-702 Diaphragm Pot Assembly PAGE E - 4 MAINTENANCE & REPAIR... - Page 21 D SERIES OM-01516 PARTS LIST 46475-702 Diaphragm Pot Assembly ITEM PART MAT'L PART NAME NUMBER CODE DIAPHRAGM POT 6622 13010 SUCT ACCUMULATOR PLUG AND GASKET S591A SUCTION ACCUMULATOR 6625 13010 REDUCER PIPE BUSHING AP6448 11990 HEX HD CAPSCREW B0504 15991 LOCKWASHER 15991 STUD...
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Page 22: Plunger Rod Assembly
OM-01516 D SERIES SECTION DRAWING 2 3 4 8.00 REF 10.78 HOLD Figure 3. 6959 Plunger Rod Assembly PAGE E - 6 MAINTENANCE & REPAIR... - Page 23 D SERIES OM-01516 PARTS LIST 6959 Plunger Rod Assembly ITEM PART MAT'L PART NAME NUMBER CODE BEARING CAP 6560 10010 -HEX HD CAPSCREW B0813S 15991 -HEX NUT D08S 15991 -LOCKWASHER 15991 PLUNGER ROD ASSEMBLY 6633 15990 DIAPHRAGM S1017 LUBRICATION FITTING S194 DIAPHRAGM PLATE 6629...
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Page 24: Gearbox Assembly
OM-01516 D SERIES SECTION DRAWING Figure 4. 44161-009 Gearbox Assembly PAGE E - 8 MAINTENANCE & REPAIR... - Page 25 D SERIES OM-01516 PARTS LIST 44161-009 Gearbox Assembly ITEM PART NAME PART MAT'L ITEM PART NAME PART MAT'L NUMBER CODE NUMBER CODE GEAR HOUSING 6624 13040 SNAP RING S1004 CRANKSHAFT BEARING S374 PINION GEAR S1014 CRANKSHAFT GEAR 6641 15060 PINION SHAFT 6634 16070 GEAR HOUSING PLUG...
- Page 26 OM-01516 D SERIES PUMP AND SEAL DISASSEMBLY 2. Shut off incoming power to the mo AND REASSEMBLY tor and lock it out to ensure that the pump will remain inoperative. Review all SAFETY information in Section A. 3. Allow the pump to completely cool if overheated.
- Page 27 D SERIES OM-01516 Diaphragm Removal Disassemble the gearbox only when there is evi dence of wear or damage. (Figure 1) 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 Shaft and bearing disassembly in the field ring (23) for wear or damage.
- Page 28 OM-01516 D SERIES maining hardware (37, 38, 39, 41, 42, 43, 44, 45, 48 After removing the shafts and bearings, clean and and 49). inspect the bearings in place as follows. NOTE The shoulder bolts and capscrews securing the gearbox cover to the gearbox housing are of differ ent lengths.
- Page 29 D SERIES OM-01516 If the bearings require replacement, remove the NOTE bearing retaining ring (34). Remove the bearing The crankshaft bearing (9) must be installed after snap ring (32) and use a bearing puller to remove the crankshaft gear (3). the bearings (2, 23 and 33).
- Page 30 OM-01516 D SERIES Install the drive gear (25) on the drive shaft, and se the bearing bore, push against the outer cure with the snap ring (26). race. Never hit the balls or ball cage. Clean the mating surface of the eccentric housing Install the crankshaft gear key (8) in the shaft key...
- Page 31 D SERIES OM-01516 free from excessive heat, sparks, and flame. (26, 28, 33 and 34) and check valves (27 and 37) Read and follow all precautions printed on sol with the hardware (29, 30, 35 and 36). vent containers. If the inboard discharge flange (18) was removed, clean the mating surfaces and install the gasket Inspect the bearing cap for wear or damage and (12).
- Page 32 OM-01516 D SERIES Apply No. 2 lithium base grease to the upper lubri level hole. Clean and reinstall the vented plug and cation fitting (26) until grease escapes from the end the oil level plug. cap (27). Under normal conditions, drain the gearbox every 500 hours of operation or every six months and re...
- Page 33 For Warranty Information, Please Visit www.grpumps.com/warranty or call: U.S.: 419-755-1280 Canada: 519-631-2870 International: +1-419-755-1352 GORMAN‐RUPP PUMPS...
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