GORMAN-RUPP PUMPS D Series Application guide

OM−02699−OE01
June 3, 1987
Rev. E 11-18-08
OTS
THE GORMAN-RUPP COMPANY DMANSFIELD, OHIO
www.grpumps.com
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−13

Register your new
Gorman-Rupp pump online at
www.grpumps.com/register.
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:
The engine exhaust from this
product contains chemicals
known to the State of California to
cause cancer, birth defects or
other reproductive harm.

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 − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Strainers PAGE B − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sealing PAGE B − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISCHARGE LINES PAGE B − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Siphoning PAGE B − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valves 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE E − 10. . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS
(continued)
ii
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 − 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diaphragm Installation PAGE E − 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Suction And Discharge Check Valve Installation PAGE E − 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION PAGE E − 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plunger Rod Assembly PAGE E − 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gearbox PAGE E − 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine PAGE E − 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D SERIES OM−02699−01
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.
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 close-
coupled to a 3.5 HP Briggs and Stratton gasoline
engine. It is ideally suited to industrial and contrac-
tor’s applications since it will handle liquids rang-
ing from clear water to construction-site muck. The
basic material of construction for wetted parts is
aluminum, with neoprene flap valves and a Dura-
Blue 1000tdiaphragm.
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
P.O. Box 1217
Mansfield, Ohio 44901−1217
Phone: (419) 755−1011
or:
Gorman-Rupp of Canada Limited
70 Burwell Road
St. Thomas, Ontario N5P 3R7
Phone: (519) 631−2870
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−02699−01
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. Disconnect the spark plug wire to
ensure that the pump will remain
inoperative.
3. Close the discharge valve (if
used).
4. 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.
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.
The gearbox provided on this pump is
designed for operation at 2600 RPM
maximum synchronous input speed. If
operated at a higher rpm, pump compo-
nents may be destroyed.
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−02699−01
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−02699−01
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-13
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 engine 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−02699−01 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-

D SERIES OM−02699−01
PAGE B − 3INSTALLATION
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.
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-