960 Technical Service Manual
Contents
1. lubricate with grease Gently slide main seal over shaft and into seal bore Install new dust seal bracket 6 Packed Pump SET 83695 skip if using modified seal Replace packing washer Install new packing Offset each ring so that split is 180 deg off previous ring 7 Replace guards couplings etc WARRANTY BearCat Pumps warrants all products manufactured by it to be free from defects in workmanship or material for a period of one year from date of shipment Due to the inconsistencies in blend formulas and operating methods BearCat Pumps does not assume responsibility for pump wear life After material has entered a pump all warranty claims will be determined by factory authorized personal BearCat Pumps assumes no liability for consequential damages of any kind and the purchaser by acceptance of delivery assumes all liability for the consequences of the use or misuse of BearCat products by the purchaser his employees or others BearCat Pumps will assume no field expenses for service or parts unless authorized by it in advance This is BearCat sole warranty and is in lieu of all other warranties expressed or implied which are hereby excluded including in particular all warranties of merchantability or fitness for a particular purpose BEARCAT BearCat Pumps L L C Page 3 PUMPS 960 Technical Service Manual Figure 4 Exploded View Description Gear Set Drive Shaft short Drive Shaft long Idle Sha2. 960 Technical Service Manual CONTENTS Introduction How it Works Relief Valve Packing Box Warranty Parts Diagram Pump Curves OAU kh WN DANGER Before starting pump be sure all drive equipment guards are in place Failure to properly mount guards may result in serious injury or death Figure 2 Rotation and Flow pumps and must have some sort of pressure protection This may be a relief valve mounted to Figure 1 BearCat 960P INTRODUCTION This manual deals exclusively with the 960 series Pumps Included in this manual are most general issues pertaining to this pump For special applications not covered in the manual please refer to the factory or authorized service personnel HOW IT PUMPS Pumping The pumps operate equally in clockwise or counter clockwise rotation The rotational direction determines which port is suction and which discharge Figure 2 shows how the liquid travels the outside of the gears to get from inlet to outlet Pressure Relief Valve BearCat Pumps are positive displacement the backside of the pump The Pressure Relief Valve is made up of a plate that is held against a port by a spring The spring tension can be adjusted for varying pressures When the pressure exceeds the adjusted amount it pushes the plate Inner Poppet back allowing the liquid to flow back to the inlet side of the pump If a pump is rotated in reverse of normal operation the end plate with the relief valve m
3. any Material Safety Data Sheets MSDS for the liquid to be sure these precautions are understood Failure to follow the above listed precautionary measures may result in injury or death BEARCAT BearCat Pumps L L C Page 2 a PUMPS 960 Technical Service Manual Routine Maintenance Warning 7 1 Bearing grease for R series pumps Every Day If product is hot ensure adequate safety The bearings on an R series rubber pump should be precautions are taken and safety gear worn grease with high temperature axle grease just after the pump has been shut down but while it is still hot This will aide in not only lubricating the bearings but also displacing the asphalt rubber prior to start up the next time 5 8 pumps each bearing 7 2 Shaft seal replacement 1 Turn pump off completely 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 Remove the dust seal then worn main seal or remove packing if packed pump 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 grove worn into shaft by old seal An excessively deep groove will require shaft replacement 5 Lip Seal RNG 83600 skip this step if packed pump Clear plastic tape can be used to mask keyway prior to seal installation Once the keyway is taped
4. ft Housing Body Port Gasket 2 End Plate Gasket 2 End Plate 2 Piston Ring Bracket 4 Piston Ring 4 Bearing 4 Belleville Washer 2 Cotter Pin 2 Part Number GER 83680 PTM 83643 PTM 83644 PTM 83640 HSG 83601 RNG 89071 RNG 69993 HSG 83603 MSC 83666 FAS 83614 PTM 83612 N A GER 64502 Description Castle Nut 2 Cap O ring Domed Bearing Cap 2 Packing Housing Blind Bearing Cap Packing Washer Packing Set Packing Gland Retainer Clip 12 13 x 1 5 Hex Bolt 16 3 8 16x1 75 SHCS 6 3 8 16x1 25 Hex Bolts 4 1 8 NPT Grease Zerk 4 Part Number FAS 88678 RNG 83614 HSG 83605 HSG 83611 HSG 83606 N A SET 83695 BRK 83689 BRK 83725 N A N A N A N A BEARCAT PUMPS BearCat Pumps L L C Page 4 960 Technical Service Manual 960 PUMP CURVES Praia Paseo lle Elta i Pee E Input Horse P Pump Speed RPM BEARCAT BearCat Pumps L L C Page 5 W PUMPS
5. ust be rotated 180 degrees Pressure relief valves cannot be used to control flow or regulate pressure BEARCAT W PUMPS BearCat Pumps L L C Page 1 960 Technical Service Manual Description _ RV Housing Box Inner Poppet Outer Spring Inner Spring Outer Poppet Cap O ring Adjuster Cap Bolt O ring Adjuster Lock Nut 2 3 4 5 6 7 8 9 Pressure Adjuster Bolt bi i Inlet Cap RELIEF VALVE It may become necessary to access the inside of the pressure relief valve If the Relief Plate is removed for repairs be sure to replace it in the proper orientation in relation to the outlet port See Figure 6 REMOVAL 1 Measure the Pressure adjuster bolt distance from back of the Cap to the end of the Adjuster Bolt before proceeding 2 Release spring compression by Figure 6 Relief Valve loosening the Adjuster Lock Nut and Bolt Remove 2 bolts securing the Adjuster Cap Remove items 2 6 Fig 6 Clean and inspect Re assemble in reverse order 5 Set Adjuster Bolt to distance measurement established in step 1 n DANGER Before servicing any BearCat Pump liquid chamber or Relief Valve ensure that e Pressure inside pump has been completely vented through appropriate openings or connections e The drive system has been locked out so that it cannot be started while work is being done e Sufficient time has expired for the liquid to cool sufficiently inside the pump Observe
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