960 Pump Manual
Contents
1. BEARCAT PUMPS www bearcatpumps com Service Manual 960 BEARCAT BearCat Pumps LLC PUMPS 623 587 1350 Table of Contents General Safety Precautions Overview R Model Bearing Design Complete Rebuild Installation Shaft Alignment System Piping Piping Strain Relief Valve Relief Valve Setting Inspection or Removal Start Up Routine Maintenance Bearing grease for AR series pumps Shaft Seal Seal Replacement Procedure Trouble Shooting liquid delivered or the pump will not prime Pump noisy when operating Model Number and Configuration Pump Dimensions Parts Diagram 960 Pump Parts Diagram 960 Full Mount Assembly Technical Data Maximum Operating Limitations 10 12 13 14 BEARCAT BearCat Pumps LLC PUMPS 623 587 1350 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 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 set2. IAGRAM 960 PUMP m a a 6 6 m an as To order specify model number ex 960 followed item Housing Gear Set End Plat Idler Shaft Drive Shaft End Plate Cap Oring Piston Bracket and Ring Seal Housing Shaft Seal Dust Seal Mount Bracket Castle Wash Pin Bearing jasket Continued 24 Port Gasket Packed Seal Assembly 20 Packed Housing Ql Packing Washer 7 Ring Set 22 Gland 2 pe 23 Clips StudsNuts Washers Hardware items A 38 Key stock 2 Lg B 2 Dowel pin 141414 V2 13x1 1 2 Hex Head 0 1 4 20x3 8 Socket Head E 38 16x1 Sq Hd Set Screw 38 16x1 1 2 Socket Head BEARCAT PUMPS BearCat Pumps LLC 623 587 1350 12 PARTS DIAGRAM 960 FULL MOUNT ASSEMBLY order specify model followed by iem 30 960 Pump 30 Top Plate 32 Side Plate 33 RV Elbow 34 Foot Bracket 35 Support Bracket 37 Pillow Block Bearing 38 Bearing Support 41 Main Poppet 42 Outer Spring onfiguration 960PX RS Continued 43 Top poppet 44 Oring Adjuster Bolt 45 Lock Nut 46 Cap Oring 47 Inner Spring em 49 Return Cover Hardware items 38 Key stock 2 Lg B 12 Dowel pin 1 1 4 Lg 1 2 13x1 1 2 Hex Head 0 1 4 20x3 8 Socket Head 3 8 16x1 Sq Hd Set Screw 3 8 16x1 1 2 Socket Head Heat Cell 81 FPT to 10 MB Stra
3. ardened gears The pump will tend to be louder when turning empty and will quite 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 MODEL NUMBER AND CONFIGURATION Example 960 PX RS 960 PX RS L Inlet Port T Top S Side Port Side R Right L Left Shaft Length 5 Short X Extended Shaft Seal Packed M Modified Lip Seal Displacement 960 960 Gallons Rev T BearCot Pumps LLC 10 PUMPS 623 587 1350 PUMP DIMENSIONS Bearcat 960PX Shown Low Configuration ar 1508 SAE Flonge 2 Pis Dm i es N Front View 3 Port Size Port size is a 5 pump port It is the equivalent bolt circle of 4 ANSI 150 Pipe flange and can be bolted directiy to that flange using standard size gaskets and fittings For high performance requirements consult factory for specification and weld on langes for 5 line size connections BEARCAT BearCat Pumps LLC Prunrs 623 587 1350 PARTS D
4. d at the end of each day just after shut down but while the pump is still hot Cold Asphalt Rubber AR is extremely tough on the bearings and castle nut assembly inside the pump Grease with high temperature Mystik JT 6 This will aide in lubricating the bearings and displacing diluting the asphalt rubber 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 grove worn into shaft by 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 n
5. ew dust seal bracket 6 Replace guards couplings etc BEARCAT BearCat Pumps LLC 8 PUMPS 623 587 1350 TROUBLE SHOOTING 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 d No liq 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 blockage in the suction li 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 h
6. ight 52 10MB Plug 53 10 MB to 410M 90 54 Aluminum Heat Cell BEARCAT PUMPS BearCat Pumps LLC 623 587 1350 13 TECHNICAL DATA Maximum Operating Li Pressure 100 PSI 7 BAR Speed 500 RPM 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 Please consult factory for high perfarmance parameters exceeding standard specifications Pump Graphs Flow Rate GPM 500 9 375 3 250 125 o 100 200 300 400 500 Pump Speed RPM Power neglecting viscosity 25 30 0 100 Pst N Horse Power Hp a 8 1 0 100 200 300 400 500 Pump Speed RPM BEARCAT BearCat Pumps LLC PUMPS 623 587 1350 1
7. mer Spring G Outer Spring 5 Outer Poppet 11 7 Adjuster 8 Bolt Oring 9 Lock Nut IN do Adjuster Bolt T BearCat Pumps LLC PUMPS 623 587 1350 START UP Caution Be sure all guards are in place and all appropriate 1 Pump should turn freely by hand Ensure all safety gear is worn prior to starting pump juards are in place 2 During initial run pump speed should be operated at 2 Ifheating is necessary turn on supply and minimum in order to insure functions are normal allow pume temperature to stabilize connections are leak free and rotation is smooth Cautiously increase to normal operating speed 3 If pump is below level of liquid is tank flooded suction open appropriate system valves gradually and check for signs of leakage 4 If pump is above the level of liquid in the tank suction lift prime the pump by pouring as much liquid possible 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 7 PUMPS 1623 587 1350 ROUTINE MAINTENANCE Bearing grease for AR series pumps For optimal service life in an AR model pump the bearings need to be grease
8. mps in the discharge line or the inadvertent closure of a and must have some sort of pressure protection downstream valve This may be a relief valve mounted to the backside of the pump The Pressure Relief Valve is made up of a plate that is held against a port dhe pump is supplied without an internal relief valve by spring The spring tension can be adjusted a suitable external relief to the system must be supplied 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 Re adjustment may be necessary due to viscosity Tbe valve must not be used as a flow control device The internal relief valve will have been factory set However check for correct operation upon installation Inspection or Removal 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 l 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 loosening the Adjuster Lock Nut and Bolt 7 Remove bolts securing the Adjuster Cap t 4 Re assemble in reverse order 5 5 Set Adjuster Bolt to distance measurement 4 established In step 1 Se 3 2 1 RV Housing ovra 1 2 Inner Poppet i
9. ossible 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 be considerable and must be taken into consideration System Pi 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 Pi g 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 Re tighten All Bolts Once the pump reaches operating temperature all flange connecting bolts should be tightened At temperature green gaskets will softened and cause the connection to loasen retightening the bolts will prevent further leaks from developing BEARCAT BearCat Pumps LLC 5 PUMPS 623 587 1350 RELIEF VALVE essary to protect the pump and system from potentially dangerous ever pressure Relief Valve Setting The relief valve will operate the event ofa restriction BearCat Pumps are positive displacement pu
10. p for a number of different applications Applications include the primary pump of an Asphalt Rubber Distributor Plant supply through a Micro Mation Coriolis Mass Flow meter transfer pump from an mix blender or as an unloading pump R Model Bearing Design The R model pumps most prominent feature is the Heavy Duty AR bearings In abrasive high viscosity materials the bearings will significantly improve service life and predictability in the pump Complete Rebuild Probably the best feature of the 960 is that it is completely rebuildable To minimize downtime the program is structured as a core exchange In most cases the rebuild pump is delivered to the customer prior to removing the old pump from service A factory rebuilt pump is bored and sleeved It receives new gears shafts bearings end plates seals and hardware Contact the factory for more information about rebuilding a 960 pump 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 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 placed to insure that the coupled shafts are accurately aligned Failure to do so may result in rapid seal and or reduced pump life Pump should be positioned as near as p
11. the relief valve 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 operating the pump BEARCAT BearCat Pumps LLC 5 PUMPS 623 587 1350 OVERVIEW The BearCat 960AR is an external gear positive displacement pump designed specifically for rubberized and polymer modified asphalts The bare pump as shown in the picture to right is a bearing design with one of the key features being that it is completely rebuildable The pump can fitted with heating blocks relief valve extended or short shafts in order to fit the pum
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