Service Manual 600R, 600V and 600B Pump
Contents
1. 4 At ric ji Her Y i z Di gL i eo B N 7 j a 27 4 Va 2 7 mama a TAA u I Long Shaft o An N mD N ale L Se SIR os ACE U TR 575k Port Size Both ports are a 3 ANSI 150 Pipe flange For high performance requirements consult factory for weld on flanges for 4 pipe With this set up the pump and entire pipe system are now 4 throughout BEARCAT BearCat Pumps LLC PUMPS 623 587 1350 12. Hp BEARCAT WP PUMPS 100 200 300 400 Pump Speed RPM BearCat Pumps LLC 623 587 1350 500 VER Series B Series This graph is generalized Flow rate will vary with material and conditions 0 150 300 450 600 750 Pump Speed RPM Power neglecting viscosity 25 PSI 50 PSI 100 Psi 10 MODEL NUMBER AND CONFIGURATION fe sooves 1u By Examples Example 600RMX RH 60 R M X RH U Shaft Position H High 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 B Crude Oil bronze bushing Displacement 300 0 30 Gallon Rev 450 0 45 Gallon Rev 600 0 60 Gallon Rev BEARCAT BearCat Pumps LLC i S Punrs 623 587 1350 600R PARTS DIAGRAM DIMENSIONAL DRAWING To order specify model number ex 600RMX followed by item a D 3 a 5 6 u 8 9 10 an a2 13 Housing Gear Set End Plate Gasket Idler Shaft Drive Shaft End Plate Adjuster Nut Adjuster Nut O ring Relief Valve Assembly O ring RV plate Bearing Cap O ring Cover Plate Steel Sleeve BEARCAT Sp PUMPS Continued 17 Castle Nut and Cotter Pin 18 Bearing Heat
3. BEARCAT PUMPS www bearcatpumps com Service Manual 600R 600V and 600B Pump 600R Rubber Pump 600V Virgin Pump 600B Crude Oil Pump BEARCAT BearCat Pumps LLC 1 S 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 600R Parts Diagram Dimensional Drawing 600V amp 600B Parts Diagram Dimensional Drawing BEARCAT BearCat Pumps LLC S PUMPS 623 587 1350 11 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
4. 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 traced 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 Al
5. d entire pipe system are now 4 throughout BEARCAT DP PUMPS BearCat Pumps LLC 623 587 1350 13 600V amp 600B PARTS DIAGRAM DIMENSIONAL DRAWING To order specify model number ex 600VMX followed by item 1 Housing 2 Gear Set 3 End Plate Gasket 4 Idler Shaft 5 Drive Shaft 6 End Plate 7 Adjuster Nut 8 Adjuster Nut O ring 9 Relief Valve Assembly 10 O ring RV plate 11 Bearing Cap Modified Seal 14 M24 Housing Assembly 15 Shaft Seal 16 Dust Seal and Mount Bracket Heat fittings All tapped ports require a 12 O ring Fitting DO NOT USE PIPE THREAD FITTINGS 20 12 MB O ring Plug 21 12 MB O ring Straight 22 tube 23 12 MB O ring Elbow Packed Seal not shown in drawing 17 9 Ring Packing Set 18 Packing Gland 2 pe 19 Studs Clips Washers Nut 2 Hardware items can be obtained from a local hardware store A 1 4 Key stock 2 L B 1 2 Dowel pin 1 1 4 Lg 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 S Pumps 623 587 1350 14 BeorCat_600VMX RH Base Foot Shown RH Configuration smen meant ees ine
6. eads above the nut The internal relief valve will have been factory set However check for correct operation upon i ity Poppet Spring n Heat Tracing Adjuster blue By Pass Return Shaft Bushing Relief Valve cut away view BEARCAT BearCat Pumps LLC r Dp 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 guards are in place During initial run pump speed should be operated at minimum in order to insure all functions are normal 2 If heating is necessary turn on supply and n connections are leak free and rotation is smooth allow pump temperature to stabilize 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 7 WP PUMPS 623 587 1350 ROUTINE MAINTENANCE Bearing grease for
7. fittings All tapped ports require a 12 O ring Fitting DO NOT USE PIPE THREAD FITTINGS 20 12 MB O ring Plug 21 12 MB O ring Straight 22 tube 23 12 MB O ring Elbow Modified Lip Seal 14 Seal Housing 15 Shaft Seal 16 Dust Seal Mount Bracket BearCat Pumps LLC 623 587 1350 Hardware items can be obtained from a local hardware store A 3 8 Key stock 2 Lg B 1 2 Dowel pin 1 1 Lg C 3 8 16x3 4 Socket Head D 1 4 20x3 8 Socket Head E 3 8 16x1 2 Set Screw F 3 8 16x1 1 2 Socket Head 12 BeorCat SOORMX RH Bolt circ Bose Foot 0 75 Dio Shown RH Configuration S mount holes Ths eier Ze HH j in ea H N H o e i 3 if a eo 8 24 5 Lo H 28 8 Be TEE Front View Center to Center ay pat oa pot ve se ear eu Set ac ff 7 00 18 00 J 7 00 ea Port Size Both ports are a 3 ANSI 150 Pipe flange For high performance requirements consult factory for weld on flanges for 4 pipe With this set up the pump an
8. it is not possible to factory set 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 or operating the pump BEARCAT BearCat Pumps LLC 3 W PumPs 623 587 1350 OVERVIEW The BearCat 600 is an external gear positive displacement pump designed specifically for pumping asphalt It is entirely heat jacketed with relief valve in both flow directions Three different models are available 600V Bronze bushing and shaft design Works well for standard asphalt and emulsions 600R AR Spherical Bearing desig
9. n rebuildable pump Ruggedized model designed for Asphalt Rubber 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 6008 Bronze bushings nitride shafts hardened steel gears works well with all grades of crude oil condensate produced water brine iron sulfate and mixed byproducts Applications include loading and unloading of crude oil transport trucks and trailers fluid transfer for tank battery LACT units and refineries Relief Valve Tom lit valve One of the prominent features of the BearCat pump is its endplate relief valve design The modularity of the plate provides mounting on both ends of the init Passage Poppet Vale pump and thus pressure relief in both directions Because the forward flow is controlled by one end and the reverse flow by the other each can be adjusted independently The heat tracing offers a critically important benefit to start up Its balance en of heat in relation with that of the main body insure eat full function of the relief valve prior to pump rotation when full of asphalt Heat Tracing No Leak Lip Seal The standard 600 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
10. ntract considerably with the changes in temperature Ensure that the final system allows for this change BEARCAT BearCat Pumps LLC W PUMPS 623 587 1350 RELIEF VALVE Each endplate can relieve the pressure in one flow Caution direction only As such if the valves are set in opposing directions each direction is A relief valve is ne 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 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 V amp R Series 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 flat where the hex meets up with the threads of the adjuster bolt flush with the edge of the lock Re adjustment may be necessary due to vise nut Backing the bolt out from this setting will Variations lower the pressure Tightening it will increase pressure at which the valve will open B Series The standard setting for the 600B Crude Oil pump is 60 psi four thr
11. so 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 BEARCAT BearCat Pumps LLC 8 W 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
12. split ring packing can be specified if needed BEARCAT BearCat Pumps LLC S 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 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 co
13. 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 quiet 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 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 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 600 500 400 300 200 100 0 Flow Rate GPM 20 Horse Power
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