Service Manual

450R and 450V Pump

450R Rubber Pump 450V Virgin Pump

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 Table of Contents
General Safety Precautions 3
Overview 4
Relief Valve
No-Leak Lip Seal
Installation 5
Shaft Alignment
System Piping
Piping Strain
Relief Valve 6
Relief Valve Setting
Start–Up 7
Routine Maintenance 8
Bearing grease for ‘R’ series pumps
Shaft Seal
Seal Replacement Procedure
Troubleshooting 9
No liquid delivered or the pump will not prime.
Pump noisy when operating
Technical Data 10
Maximum Operating Limitations
Model Number and Configuration 11
450R Parts Diagram / Dimensional Drawing 12
450V Parts Diagram / Dimensional Drawing 14

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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 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.

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OVERVIEW

The BearCat 450 is an external gear, positive

displacement pump designed specifically for
pumping asphalt. It is entirely heat jacketed with
relief valve in both flow directions.

Two different models are available;

450V: Bronze bushing and shaft design. Works

well for standard asphalt and emulsions.

450R: AR Spherical Bearing design, 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.

Relief 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
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
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.

No-Leak Lip Seal

The standard 450 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.

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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 contract considerably with the changes in temperature. Ensure
that the final system allows for this change.

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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 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
The relief valve will operate in the event of a restriction
30 PSI in reverse. It is important for the operator
in the discharge line or the inadvertent closure of a
to understand which valve controls each flow downstream valve.
direction.
The valve must not be used as a flow control device.
Relief Valve Setting
If the pump is supplied without an internal relief valve,
The standard factory setting for the forward flow a suitable external relief to the system must be supplied
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.

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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
2. If heating is necessary, turn on supply and minimum in order to insure all functions are normal,
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

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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 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. 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.

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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 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.

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TECHNICAL DATA

Maximum Operating Limitations

• 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

Flow Rate (GPM)

Flow Rate - GPM

300
225
150
75
0
0 100 200 300 400 500
Pump Speed (RPM)

Power (neglecting viscosity) 25 PSI

50 PSI
15
Horse Power (Hp)

100 PSI
11
8
4
0
0 100 200 300 400 500
Pump Speed (RPM)

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MODEL NUMBER AND CONFIGURATION

600RMX - RH 600VPS - LL

Examples

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450R PARTS DIAGRAM / DIMENSIONAL DRAWING

To order specify model number Continued Heat fittings. All tapped ports require a
(ex - 450RMX) 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

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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.

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450V PARTS DIAGRAM / DIMENSIONAL DRAWING

To order specify model number Modified Seal Heat fittings. All tapped ports require a
(ex - 450VMX) 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

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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.

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