GORMAN-RUPP PUMPS D Series Application guide

COM-01636-O1
September 13, 2010
Rev. A 03‐20‐13
THE GORMAN‐RUPP COMPANY DMANSFIELD, OHIO
GORMAN‐RUPP OF CANADA LIMITED DST. THOMAS, ONTARIO, CANADA Printed in U.S.A.
ECopyright by the Gorman‐Rupp Company
INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
WITH PARTS LIST
D SERIES PUMP
MODEL
3D-GX160

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:

TABLE OF CONTENTS
i
INTRODUCTION PAGE I - 1.................................................
SAFETY SECTION A PAGE A - 1...........................................
INSTALLATION - SECTION B PAGE B - 1....................................
Pump Dimensions PAGE B - 1.....................................................
PREINSTALLATION INSPECTION PAGE B - 1............................................
POSITIONING PUMP PAGE B - 2.......................................................
Lifting PAGE B - 2.................................................................
Mounting PAGE B - 2.............................................................
SUCTION AND DISCHARGE PIPING PAGE B - 2.........................................
Materials PAGE B - 2..............................................................
Line Configuration PAGE B - 2......................................................
Fixed, Rigid Piping PAGE B - 2.....................................................
Gauges PAGE B - 3...............................................................
SUCTION LINES PAGE B - 3...........................................................
Fittings PAGE B - 4...............................................................
Strainers PAGE B - 4..............................................................
Sealing PAGE B - 4...............................................................
DISCHARGE LINES PAGE B - 4........................................................
Siphoning PAGE B - 4.............................................................
Valves PAGE B - 4................................................................
ALIGNMENT PAGE B - 4..............................................................
OPERATION - SECTION C PAGE C - 1......................................
STARTING PAGE C - 1................................................................
OPERATION PAGE C - 1..............................................................
Priming PAGE C - 1...............................................................
OPERATION CHECKS PAGE C - 1......................................................
Gearbox Check PAGE C - 1........................................................
Leakage Check PAGE C - 1........................................................
Strainer Check PAGE C - 1.........................................................
Accumulator Chamber Check PAGE C - 1...........................................
STOPPING PAGE C - 2................................................................
Cold Weather Preservation PAGE C - 2..............................................
GEARBOX TEMPERATURE CHECK PAGE C - 2..........................................
TROUBLESHOOTING - SECTION D PAGE D - 1..............................
PUMP MAINTENANCE AND REPAIR SECTION E PAGE E - 1.................
STANDARD PERFORMANCE CHART PAGE E - 1........................................
PARTS LISTS:
Pump Model PAGE E - 3..........................................................
Diaphragm Pot Assembly PAGE E - 5...............................................
Plunger Rod Assembly PAGE E - 7.................................................
Gearbox Assembly PAGE E - 9.....................................................

TABLE OF CONTENTS
(continued)
ii
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 - 10..................................
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 - 14..................................................
Suction And Discharge Flap Valve Installation PAGE E - 15.............................
LUBRICATION PAGE E - 15.............................................................
Plunger Rod Assembly PAGE E - 15.................................................
Gearbox PAGE E - 15..............................................................
Engine PAGE E - 15................................................................

D SERIES OM-01636
PAGE I - 1INTRODUCTION
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, engine‐driven, positive displace
ment pump utilizing a single‐action diaphragm to
produce a straight‐through flow of liquid. The
pump is close‐coupled to a single cylinder, air
cooled Honda gasoline engine.
The pump is ideally suited to industrial and con
tractor's applications since it will handle liquids
ranging from clear water to construction‐site
muck. The basic material of construction for wet
ted parts is aluminum, with neoprene flap valves
and a DURABLUE 1000tdiaphragm.
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 or Gorman‐Rupp of Canada Limited
P.O. Box 1217 70 Burwell Road
Mansfield, Ohio 44901-1217 St. Thomas, Ontario N5P 3R7
The following are used to alert maintenance personnel to procedures which require special attention, 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-01636
PAGE A - 1SAFETY
SAFETY ‐ SECTION A
This information applies to D Series en
gine driven diaphragm pumps. Refer to
the manual accompanying the engine
before attempting to begin operation.
Before attempting to open or service the
pump:
1. Familiarize yourself with this man
ual.
2. Shut down the engine and take
precautions to ensure that the
pump will remain inoperative.
3. 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 located in op
erating position, make certain that the
wheels have been blocked and secured
to prevent creeping before attempting
to operate the pump.
After the pump has been installed, make
certain that the pump and all piping or
hose connections 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 2600 RPM
maximum input speed. If operated at a
higher RPM, pump components may be
destroyed.
Never tamper with the governor to gain
more power. The governor establishes
safe operating limits that should not be
exceeded. The maximum continuous
operating speed for this pump is 2600
RPM.
Do not operate an internal combustion
engine in an explosive atmosphere.
When operating internal combustion
engines in an enclosed area, make cer
tain that exhaust fumes are piped to the
outside. These fumes contain carbon
monoxide, a deadly gas that is color
less, tasteless, and odorless.

D SERIESOM-01636
PAGE A - 2 SAFETY
Fuel used by internal combustion en
gines presents an extreme explosion
and fire hazard. Make certain that all
fuel lines are securely connected and
free of leaks. Never refuel a hot or run
ning engine. Avoid overfilling the fuel
tank. Always use the correct type of fuel.
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-01636
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. Pump Model 3D‐GX160
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 and engine 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 engine have been stored for
more than 12 months, some of the compo

OM-01636 D SERIES
PAGE B - 2 INSTALLATION
nents or lubricants may have exceeded their
maximum shelf life. These must be inspected
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 275 pounds (125
kg), not including accessories or options. Cus
tomer installed equipment such as suction and dis
charge hoses must be removed before attempting
to lift.
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.
To ensure sufficient lubrication and fuel supply to
the engine, do not position the pump and engine
more than 15_off horizontal for continuous opera
tion. The pump and engine may be positioned up
to 30_off horizontal for intermittent operation
only; however, the engine manufacturer should be
consulted for continuous operation at angles
greater than 15_.
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 pump to operate within the safe
operation range.