GORMAN-RUPP PUMPS 4D-X3 3P Application guide

OM-01516-01
June 29, 1981
Rev. E 08‐25‐15
GORMAN‐RUPP PUMPS
www.grpumps.com
e1981 Gorman‐Rupp Pumps Printed in U.S.A.
INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
WITH PARTS LIST
DIAPHRAGM PUMP
MODEL
4D-X3 3P

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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:

TABLE OF CONTENTS
i
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........................................................

TABLE OF CONTENTS
(continued)
ii
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...................................................................

D SERIES OM-01516
PAGE I - 1INTRODUCTION
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.
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.
If there are any questions regarding the pump or
its application which are not covered in this man
ual or in other literature accompanying this unit,
please contact your Gorman‐Rupp distributor, or
The Gorman‐Rupp Company:
The Gorman‐Rupp Company
P.O. Box 1217
Mansfield, Ohio 44901-1217
Phone: [phone]
or:
Gorman‐Rupp of Canada Limited
70 Burwell Road
St. Thomas, Ontario N5P 3R7
Phone: [phone]
For information or technical assistance on the
power source, contact the power source manufac
turer's local dealer or representative.
HAZARD AND INSTRUCTION
DEFINITIONS
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.
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.

D SERIES OM-01516
PAGE A - 1SAFETY
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.
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.
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.
Install and operate only an explosion
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.
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

D SERIESOM-01516
PAGE A - 2 SAFETY
phase of the pump and motor before
connecting the power source. Do not
run the pump if the voltage is not within
the limits.
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.

D SERIES OM-01516
PAGE B - 1INSTALLATION
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.
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.
OUTLINE DRAWING
Figure 1. Model 4D-X3 3P
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

OM-01516 D SERIES
PAGE B - 2 INSTALLATION
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
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.
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
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
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
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.

D SERIES OM-01516
PAGE B - 3INSTALLATION
AIR CHAMBERS
(18 TO 24 INCH LENGTHS OF
6 TO 8 INCH DIAMETER PIPE
WITH WELDED CAPS)
DISCHARGE
CHAMBER
DISCHARGE
FLEXIBLE JOINT FLEXIBLE JOINT
SUCTION
CHAMBER
1/2‐INCH VALVE FOR
RECHARGING AIR
CHAMBER WITH
COMPRESSED AIR
(ALSO ON DISCHARGE
CHAMBER)
SUCTION
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.
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.
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.