R and V Pump Manual (300)
Contents
1. a E i 6 Bolt Circ Port Dimension 4 5 8 11 Thread All Hot Oil Port are 3 4 SAE O ring Ports 4 SAE Port Long Shaft Port Size Both ports are a 2 1 2 ANSI 150 Pipe flange For high performance requirements consult factory for weld on flanges for 3 pipe With this set up the pump and entire pipe system are now 3 throughout BEARCAT BearCat Pumps LLC PUMPS 623 587 1350 We2. AT BearCat Pumps LLC 8 PUMPS 623 587 1350 TROUBLESHOOTING Under each fault symptom given below is a list of recommended inspections that could indicate the cause most are elementary but are often overlooked The best aid to fault finding in the pump is a vacuum gauge as close as possible to the pump inlet This can readily indicate whether the imposed suction is within the pumps capability or if there has been a dramatic change from the conditions which will indicate a change in the viscosity of the pumping media resulting in higher pressure loss in the suction line or that a filter requires cleaning etc No liquid delivered or the pump will not prime Check Direction of shaft rotation Are suction line joints leaking in air Total suction condition is there sufficient N P S H available Has the pump been properly primed before start up Is suction port blocked Is filter clean All valves in system are open Is the discharge line vented Pressure build up will ultimately prevent suction vacuum If the vacuum gauge is reading over 20inHG there is almost certainly a blockage in the suction Is the material hot enough EVERYWHERE If you have a screen box add 3 gallons of suitable liquid to help establish prime Pump noisy when operating A low growling sound is normal for new pump The noise is attributed to the meshing of the hardened gears The pump will tend to be louder when turning empty and will q
3. BEARCAT www bearcatpumps com Service Manual 300R and 300V Pump 300R Rubber Pump 300V Virgin Pump BEARCAT BearCat Pumps LLC PUMPS 623 587 1350 Table of Contents General Safety Precautions Overview Relief Valve No Leak Lip Seal Installation Shaft Alignment System Piping Piping Strain Relief Valve Relief Valve Setting Start Up Routine Maintenance Bearing grease for R series pumps Shaft Seal Seal Replacement Procedure Troubleshooting No liquid delivered or the pump will not prime Pump noisy when operating Technical Data Maximum Operating Limitations Model Number and Configuration 300R Parts Diagram Dimensional Drawing 300V Parts Diagram Dimensional Drawing BEARCAT BearCat Pumps LLC g f PUMPS 623 587 1350 GO 10 1 12 14 GENERAL SAFETY PRECAUTIONS This manual should be read entirely prior to the commencement of installation and operation Only qualified personnel should install operate and maintain this pump and associated equipment Check pump for specific safety warnings labels Prior to start up ensure complete cleanliness and integrity of the system in which the pump is installed In most cases the relief valve is factory set during performance test In cases where the type of duty is not known such as distributors or stock orders or where the components containing the relief valve come from pre tested stock batches it is not possible to factory set the relief v
4. aced the bearings must be greased at the end of the day just after shut down but while the pump is still hot Grease with high temperature Mystik JT 6 This will aide in lubricating the bearings and displacing diluting the AR prior to the next start up Shaft Seal After a period of time based on pressure operating procedures material etc it will be necessary to change the shaft seal This is a fairly easy procedure If the pump is leaking more than a drop a minute or any amount deemed unacceptable insure the the a seal kit is on hand and follow the seal replacement procedure Seal Replacement Procedure 1 Turn pump off completely 2 Ensure that pump is isolated from system by closing suction and discharge valves 3 Remove any guards couplings bearings or companion flanges aft the dust seal item 16 Remove the dust seal bracket item 16 and use a flat head screw driver to pry out the old seal item 15 4 Clean the shaft surface and seal bore of any asphalt debris Inspect and remove any sharp burrs in the keyway and shaft body Also inspect for groove worn into shaft by the old seal An excessively deep groove will require shaft replacement 5 Clear plastic tape can be used to mask keyway prior to seal installation Once the keyway is taped lubricate with grease Gently slide main seal item 15 over shaft and into seal bore Install new dust seal bracket 6 Replace guards couplings etc BEARC
5. alve In this case it is the installers responsibility to set the relief valve in accordance with the specific application Pumps with heat tracing or jacketing necessary to prevent solidification of the product should be brought up to working temperature prior to start up All electrical work must be done in accordance with the manufacturers recommended procedures by qualified personnel Ensure all guards are securely in place before operating the equipment Do not remove guards at any time during operation For pumps operating under flooded suction when venting the pump through a plug or valve care should be taken not to completely remove vent plugs or completely open any vent as this could result in liquid being discharged from the openings under pressure Prior to start up ensure that the system valves and associated equipment are correctly set Wear appropriate safety attire including long sleeves face shield and gloves whenever starting or operating the pump BEARCAT BearCat Pumps LLC 3 g f PUMPS 623 587 1350 OVERVIEW The BearCat 300 is an external gear positive displacement pump designed specifically for pumping asphalt It is entirely heat jacketed with adjustable relief valve Two different models are available 300V Bronze bushing and shaft design Works well for standard asphalt and emulsions Relief valve in both directions 300R AR Spherical Bearing design rebuildable pump Ruggedized model designe
6. d for Asphalt Rubber It has a forward only relief valve Applications include the primary pump of an Asphalt Distributor Plant supply through a Micro Motion Coriolis Mass Flow meter Blend transfer or as an unloading pump Relief Valve One of the prominent features of the BearCat pump 4 outlet is its endplate relief valve design The modularity of the plate provides mounting on both ends of the pump and thus pressure relief in both directions 300V only Because the forward flow is controlled by one end and the reverse flow by the other each can be adjusted independently The heat tracing deg offers a critically important benefit to start up Its spg balance of heat in relation with that of the main body insure full function of the relief valve prior to pump rotation when full of asphalt ae P agia Heat Tracing Relief Valve Inlet Passage Poppet Valve No Leak Lip Seal The standard 300 comes with a high temperature no leak low maintenance seal design Supported internally by a roller bearing the drive shaft runs precise thus prolonging seal life Packed Seal available upon request Graphite impregnated split ring packing can be specified if needed BEARCAT BearCat Pumps LLC PUMPS 623 587 1350 INSTALLATION Shaft Alignment In the case of a belt driven system care should be taken to insure proper alignment and tension of the drive belts and pulleys A pillow block must be used in order
7. ds are in place and all appropriate 1 Pump should turn freely by hand Ensure all safety gear is worn prior to starting pump guards are in place eee During initial run pump speed should be operated at 2 If heating is necessary turn on supply and minimum in order to insure all functions are normal allow pump temperature to stabilize connections are leak free and rotation is smooth 3 Gradually open appropriate valves and check Cautiously increase to normal operating speed for signs of leakage 4 If pump is above the level of liquid in the tank suction lift prime the pump by pouring a few gallons of liquid Do not use water in the strainer housing or adjacent piping particularly on the suction side 5 Check the pump rotation by flicking motor starter on then off Correct rotation indicated by diagram on pump cover plate 6 Start pump check system for leaks Rotation and Flow Flow is reversible from what is shown BEARCAT BearCat Pumps LLC P PUMPS 623 587 1350 ROUTINE MAINTENANCE Bearing grease for R series pumps For optimal service life in an R model pump the bearings need one of two things prior to start up each day Heat or Grease Cold Asphalt Rubber AR is extremely tough on the bearings and castle nut assembly inside the pump If the pump is traced with heat transfer oil then the bearing areas will receive adequate heat that will soften the AR However if the pump is not tr
8. er All Hot Oil Port are 3 4 SAE 4 5 8 11 Port Dimension O ring Ports Thread 18 00 Long Shaft Port Size Both ports are a 2 1 2 ANSI 150 Pipe flange For high performance requirements consult factory for weld on flanges for 3 pipe With this set up the pump and entire pipe system are now 3 throughout BEARCAT BearCat Pumps LLC PUMPS 623 587 1350 e 300V PARTS DIAGRAM DIMENSIONAL DRAWING To order specify model number Modified Seal Heat fittings All tapped ports require a ex 300VMX followed by item 14 M24 Housing Assembly 12 O ring Fitting DO NOT USE 1 Housing 15 Shaft Seal PIPE THREAD FITTINGS 2 Gear Set 16 Dust Seal and Mount 20 12 MB O ring Plug 3 End Plate Gasket Bracket 21 12 MB O ring Straight 4 Idler Shaft 22 J tube 5 Drive Shaft 23 12 MB O ring Elbow 6 End Plate 7 Adjuster Nut Packed Seal not shown in drawing Hardware items can be obtained from 8 Adjuster Nut O ring 17 9 Ring Packing Set a local hardware store 9 Relief Valve Assembly 18 Packing Gland 2 pc A 1 4 Key stock 2 Lg 10 O ring RV plate 19 Studs Clips Washers Nut 2 B 1 2 Dowel pin 1 1 4 Lg 11 Bearing Cap C 3 8 16x3 4 Socket Head 12 O ring Cover Plate D 1 4 20x3 8 Socket Head 13 Bushing E 3 8 16x1 2 Set Screw BEARCAT BearCat Pumps LLC 14 PUMPS 623 587 1350 BearCat 3O0O0VMX RH Shown RH Configuration 6 Bolt Circ 4 5 8 11 Thread
9. h Drive L Low Drive Port Configuration R Right L Left Shaft Length S Short X Extended Shaft Seal M Modified Lip P Packed Bearing Type R Rubberized Asphalt spherical bearing V Virgin Asphalt bronze bushing Displacement 300 0 30 Gallon Rev 450 0 45 Gallon Rev 600 0 60 Gallon Rev BEARCAT BearCat Pumps LLC WP PUMPS 623 587 1350 11 300R PARTS DIAGRAM DIMENSIONAL DRAWING To order specify model number Continued Heat fittings All tapped ports require a ex 300RMX followed by item 17 Castle Nut and Cotter Pin 12 O ring Fitting DO NOT USE 1 Housing 18 Bearing PIPE THREAD FITTINGS 2 Gear Set 20 12 MB O ring Plug 3 End Plate Gasket 21 12 MB O ring Straight 4 Idler Shaft 22 J tube 5 Drive Shaft 23 12 MB O ring Elbow 6 End Plate 7 Adjuster Nut Modified Lip Seal Hardware items can be obtained from 8 Adjuster Nut O ring 14 Seal Housing a local hardware store 9 Relief Valve Assembly 15 Shaft Seal A 3 8 Key stock 2 Lg 10 O ring RV plate 16 Dust Seal Mount Bracket B 1 2 Dowel pin 1 1 4 Lg 11 Bearing Cap C 3 8 16x3 4 Socket Head 12 O ring Cover Plate D 1 4 20x3 8 Socket Head 13 Steel Sleeve E 3 8 16x1 2 Set Screw F 3 8 16x1 1 2 Socket Head BEARCAT BearCat Pumps LLC 19 PUMPS 623 587 1350 BearCat SOORMX RH Shown RH Configuration 5 1 2 Bolt Circ 4 5 8 11 Thread Pie de SE BALINE Front View Center to Cent
10. ions each direction is A relief valve is necessary to protect the pump and independently adjustable So it is possible to system from potentially dangerous over pressure pressure relieve at 80 PSI in one direction while 30 PSI in reverse It is important for the operator to understand which valve controls each flow direction Note 300R relieves in forward only The relief valve will operate in the event of a restriction in the discharge line or the inadvertent closure of a downstream valve The valve must not be used as a flow control device Relief Valve Setting If the pump is supplied without an internal relief valve a suitable external relief to the system must be supplied The standard factory setting for the forward flow in the pump is 80 psi This is done by setting the The internal relief valve will have been factory set flat where the hex meets up with the threads of However check for correct operation upon installation the adjuster bolt flush with the edge of the lock nut Backing the bolt out from this setting will Re adjustment may be necessary due to viscosity variations lower the pressure Tightening it will increase pressure at which the valve will open Poppet Spring Adjuster Bolt Heat Tracing blue By Pass Return Pressure Inlet Shaft Bushing Relief Valve cut away view BEARCAT BearCat Pumps LLC 6 W PUMPS 623 587 1350 START UP Caution Be sure all guar
11. to support the side load from the belts Insure that the belts and pulleys are free and clean from oil and debris In the case of a direct drive system proper care must be used to insure that the coupled shafts are accurately aligned Failure to do so may result in rapid wear of the seal and or reduced pump life System Piping Pump should be positioned as near as possible to source feeding it Suction piping must be no smaller in diameter than the pump intake port and designed to avoid sharp bends changes in sections or undue restrictions Pressure drops due to an accumulation of valves flex lines etc can be considerable and must be taken into consideration Certain designs such as a low level drop are designed in order to maintain a minimum amount of liquid at the pump After evacuating the lines this remaining liquid can significantly improve Start up priming Piping Strain To ensure undue forces are not present flange bolts suction and discharge should be completely slackened If flanges are observed to spring apart twist or move out of parallel excessively remedial action must be taken The piping system can expand and contract considerably with the changes in temperature Ensure that the final system allows for this change BEARCAT BearCat Pumps LLC 5 T PUMPS 623 587 1350 RELIEF VALVE Each endplate can relieve the pressure in one flow a Caution direction only As such if the valves are set in opposing direct
12. uiet down once liquid prime is established A loud clacking can be an indication that the pump is cavitating Look for signs of inlet flow restrictions or lower than normal material temperature As a last resort slow pump speed until noise goes away Pump internals are worn Debris in material Add screen box Misalignment of drive system BEARCAT BearCat Pumps LLC PUMPS 623 587 1350 TECHNICAL DATA Maximum Operating Limitations e Pressure 130 PSI 9 BAR e Speed 500 RPM e Temperature 500 F 260 C Actual flow can be limited by any number of parameters Line flow restrictions viscosity material type etc The standard maximum RPM is based on ideal conditions As a general rule we recommend reducing speed RPM limits by 25 when handling viscous materials such as rubberized asphalt When certain conditions are met the pumps may be used in excess of the limitations Please consult factory for high performance parameters exceeding standard specifications Pump Graphs Flow Rate GPM D 150 O 113 2 75 Se 38 2 0 em 0 100 200 300 400 500 Pump Speed RPM Power neglecting viscosity e 10 8 S CN 5 o 3 Tr oO 0 100 200 300 400 500 Pump Speed RPM BEARCAT BearCat Pumps LLC PUMPS 623 587 1350 Wi MODEL NUMBER AND CONFIGURATION e Geen Examples 600VPS LL Example 600RMX RH 600 R M X RH L Shaft Position H Hig
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