Bearcat BC-502/CRC User manual

INSTRUCTION MANUAL

Model BC-502/CRC

Asphalt Distributor

Revision 8/19

Unit Serial Number:

FCAL #

GCAL #

Date of Service:

Customer:

Training Performed By:

I Have Received Hours Training

Signature:

3

This manual describes the Bearcat Transport as it is normally

delivered to the user, at the time the manual is prepared. Due

to a continuing program of product improvement, changes

may

be made in equipment delivered at a later date. Every attempt is

made to keep users fully informed of such changes.

If you do not understand any part of this manual and need

assistance, please contact your BearCat dealer or BearCat

directly.

BearCat Mfg.

3650 Sabin Brown Road

Wickenburg, AZ 85390

Phone: (928) 684-7851

Fax: (928) 684-3241

[email protected]

Manuals can be accessed via the BearCat website at the following

address:

www.bearcatmfg.com

Please help up to continually improve this manual by contacting us

with your comments, ideas and improvements.

BC-502/CRC

4

California Proposition 65 Warning: Diesel engine exhaust and

some of its constituents are known to the State of California to

cause cancer, birth defect, and other reproductive harm.

RECOGNIZE SAFETY INFORMATION

This is a safety alert symbol. When seen on your machine,

or in this manual, be alert to the potential for personal

injury.

DANGER - Immediate hazards which will result in death or

serious injury.

WARNING - Hazards or unsafe practices which could

result in serious injury or death.

CAUTION - Hazards or unsafe practices which could result

in minor or moderate injury, product or property damage.

All of these warnings are listed below and they also appear

throughout the manual. In addition to these, you will find notes

throughout the manual.

NOTE – A note provides general information that the operator

should be aware of when performing an operation.

5

Introduction

Warranty and Claim Procedures

Limited Warranty

BearCat Mfg. (Here in after referred to as “BearCat”) extends to

the original purchaser-user of Bearcat equipment, the following

warranty covering goods manufactured by BearCat, subject to

the qualifications listed.

The warranty applies only when the product:

1. Is properly used and maintained in accordance with

BearCat instructions, governing agencies or

associations.

2. Is being operated under proper fuel and/or

cargo characteristics.

3. Is not subject to corrosive or abrasive

atmosphere or materials.

4. Has not been damaged through malice or ignorance.

5. Has not been subject to flood, lightning,

accidents, misuse, neglect or unauthorized

modification, repair or service.

Parts replaced under this warranty are warranted only through

the remaining time of the original warranty.

BearCat warrants that at the time of delivery, the product manufactured

by BearCat and delivered new to the original purchaser-user shall be free

from defects in material and workmanship for a period of one (1) year

on the Asphalt Distributor and five (5) years on the Product Tank, after

delivery when operated and maintained under normal use and service

and in accordance with the written instructions provided by BearCat.

BC-502/CRC

6

Warranty Claims

BearCat agrees at its option, to repair or replace F.O.B.

Wickenburg, Arizona, any part acknowledged by BearCat to be

defective when returned to BearCat; provided that:

1. The defective part is returned transportation charges

prepaid to BearCat for inspection.

2. BearCat determines that the defective part had

failed under the terms of the above warranty.

BEARCAT WILL NOT INSTALL AND WILL NOT PAY ANY

INSTALLATION COST, TRANSPORTATION COST, TRAVEL

TIME, MILEAGE, LABOR COSTS OR OTHER EXPENSES

OF ANY DEFECTIVE PARTS REPLACED OR REPAIRED

UNLESS THE USER HAS REACHED A PRIOR

AGREEMENT WITH BEARCAT.

The user shall notify BearCat of any defect within this warranty no later

than thirty (30) days after a defect is discovered.

No defective parts will be accepted for return or replacement without

the written authorization of BearCat, or verbal authorization from the

BearCat Service Department. Upon such authorization, the part should

be returned within thirty (30) days to BearCat, shipping charges

prepaid, at the following address:

BearCat Mfg.

3650 Sabin Brown

Road Wickenburg, AZ

85390

Phone: (928) 684-7851

Fax: (928) 684-3241

7

Exclusions

The provisions of the foregoing warranty are BearCat’s sole

obligation and exclude all other warranties express or implied.

BearCat shall not be responsible for any loss, damage,

incidental or consequential damages of any kind, whether

based upon warranty, contract or negligence, arising

concerning the sale, use, or repair of the product.

Components manufactured by any supplier other than BearCat shall

bear only the warranty made by the manufacturer of that product.

BC-502/CRC

8

Introduction

BearCat liquid asphalt distributors (Model BC-502/CRC) are

designed and manufactured to ensure personnel safety when the

equipment is operated properly and all safety precautions are

strictly followed.

Persons responsible for the operation and field maintenance of the

Model BC-502/CRC distributor should read this manual carefully

before attempting to operate the equipment or performing any

service or adjustment procedures on it.

NOTE: BearCat Manufacturing assumes no liability for accident or

injury incurred through improper use of this equipment.

WARNING: BEARCAT EQUIPMENT USES VOLATILE MATERIALS AT

HIGH TEMPERATURES AND PRESSURES. THIS

EQUIPMENT EMPLOYS HIGHLY COMBUSTIBLE OR

EXPLOSIVE FUELS. POTENTIALLY LIFE THREATENING

HAZARDS MAY EXIST DURING EQUIPMENT

OPERATION. PERSONNEL MUST BE TRAINED AND

FAMILIAR WITH SAFETY PRECAUTIONS BEFORE

OPERATING BEARCAT EQUIPMENT.

WARNING: POTENTIALLY LIFE-THREATENING HAZARDS MAY

EXIST DURING EQUIPMENT OPERATION. ONLY

QUALIFIED PERSONNEL SHOULD ATTEMPT TO

OPERATE, SERVICE OR MAKE ADJUSTMENTS TO

THE BEARCAT EQUIPMENT.

WARNING: THE MATERIALS USED IN THE TRANSPORT ARE

NORMALLY HEATED TO 300° F TO 400° F DURING

APPLICATION. MATERIALS USED AT THESE

TEMPERATURES CAN CAUSE SERIOUS OR FATAL

BURNS AND CAN BECOME EXPLOSIVE UNDER

CERTAIN CONDITIONS. DIESEL FUEL USED IN THE

BURNERS TO HEAT THESE MATERIALS IS HIGHLY

FLAMMABLE. EXTREME CARE MUST BE

EXERCISED AT ALL TIMES TO ENSURE THE

SAFETY OF PERSONNEL WORKING IN PROXIMITY

TO THESE POTENTIALLY HAZARDOUS

CONDITIONS.

9

Abbreviation/Definition Table

ABBREVIATION DEFINITION

BTU British Thermal Units

CCW Counter Clockwise

CFM Cubic Feet per Minute

CRC Computerized Rate Control

CW Clockwise

FCAL Footage Calibration

FPM Feet per Minute

GCAL Gallons Calibration

GPM Gallons per Minute

KgSM Kilograms per Square Meter

LPM Liters per Minute

LSM Liters per Square Meter

MPM Meters per Minute

PSI Pounds per Square Inch

PSY Pounds per Square Yard

PTO Power Take Off

RPM Revolutions per Minute

Wet Asphalt Emulsified asphalt or containing water

BC-502/CRC

10

Table of Contents

RECOGNIZE SAFETY INFORMATION 4

INTRODUCTION 5

Warranty and Claim Procedures 5

Limited Warranty 5

Warranty Claims 6

Exclusions 7

Introduction 8

Abbreviation/Definition Table 9

EQUIPMENT DESCRIPTION 17

Hydraulics 18

Pump Drive Options 18

Hydraulic Reservoir and Filter 19

Hydrostatic Pump 19

Hydrostatic Motor 21

Asphalt Plumbing 22

Asphalt Pump 22

Spread / Circulate Relief Valve 22

Auxiliary Hydraulic System 23

Spray Bar 24

Folding Wing Configurations 24

Circulation Control 25

Bar Movements 25

Wing Shear Pins 26

Controls 27

Cab Console 27

Side Control Panel 28

Rear Control Panel 28

Computerized Rate Control (CRC) System 29

11

Asphalt Heating System (option) 29

Wash Down Facilities 29

Spray Bar Flushing System 30

Hand Spray System 30

Pattern Spray Capability 30

Remote Curb side Mirror 31

Electric Heat (Option) 31

Specifications 32

SAFETY PRECAUTIONS 36

Personnel Safety 36

Pumping Operations 38

Burner Operations 39

Clean the Equipment 41

Safety Decals and Plates 41

GENERAL OPERATION 44

CONTROLS 45

Operator’s Panel, In Cab 46

GSY (switch) 46

PTO 46

Heat 46

Pump 46

Manual 46

Bar Latch 46

Beacon 46

Tank 46

Power 46

Error 47

Left Wing Un-Lock 47

Right Wing Un-Lock 47

L. Wing & R. Wing 47

Mirror 47

Spray Valve Switches 48

Left Wing 48

BC-502/CRC

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Main Bar 48

Right Wing 48

L. Marker & R. Marker 48

Master 48

Taper Cut 49

Valve Selector Dial 49

OFF 49

Spread Heat 49

Load Outside 49

Circulate Heat 49

Auto Flush 49

Display 50

Side Control Panel 50

Valve Selector Dial 50

Pump/Valves 50

Pump direction 51

Manual Increase Speed 51

Rear Control Panel 51

Hyd. Bar Lock 51

Swing 51

Lift 51

LH & RH Wing Locks 52

L. Wing & R. Wing 52

R. Burner 52

L. Burner 53

Asphalt Valve Locations and Functions 54

Asphalt Tank Gauge 56

Asphalt Temperature Gauge 57

Preparation 57

Selection of Correct Spray Nozzles 57

Spray Nozzle Removal and Installation 58

Initial Checkout of the Equipment 58

Check Hydraulic Controls: 59

Check the operation of the wing safety switches: 59

13

Flushing Tank 60

Loading Tank 63

Loading Through Valve A 63

Loading Through Optional Valve L 65

On Load Thru Spray Bar 66

Loading Through Manhole 68

OFF Load Thru Valve D 70

Through Pump Transfer 72

Gravity OFF Load (External Pump Transfer) 74

Heating Asphalt 75

Tank Circulation While Heating 76

Warm Asphalt 76

Cold Asphalt (too stiff to circulate) 77

Heating with Diesel Fired Burners 77

OPERATING INSTRUCTIONS 79

Spraying Operations with CRC Computerized Rate Control 79

Spraying Operations using the optional Front Suction 81

Setting Spread Rate Manually 82

Hand Spraying While Circulating Spray bar 83

Hand Spraying 84

Spray Bar Flushing 86

Stage 1 87

Stage 2 88

Stage 3 88

Empty Flush Tank 89

Shutting the Equipment Down 91

CONSOLE DISPLAY 92

Start Up 92

Home Page 94

GSY 94

FPM 94

PTO 95

GPM 95

BC-502/CRC

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Width 95

Nozzle Size 95

Taper Cut 95

Gallons 96

Total Gallons 96

Feet 97

Sq. Yards 97

Temp 97

Settings Menu 98

Setup 98

Settings Page 98

Circulate 98

Manual 98

Simulate FPM 99

Flush Time 100

Cal 1 100

Calibration Page 100

F-Cal 100

G-Cal 101

T-Cal 103

Auto Shutdown 103

Hyd/Elc/Rub 103

Cab-Exp-Box 103

Pump 104

Std/Metric 104

PTO 104

Speed Sensor 104

Heat 104

Ready Set Point 104

Spray Bar 105

Spray bar Settings 105

Tank 107

Defaults 107

Diagnostic Menu 107

Volts/Snsr 108

Vlv Cmds 108

15

Switches 109

Side Ctrl 109

Rear Ctrl 110

Burner 110

Pump Test 111

Pump T-1 111

Pump T-2 111

Pump T-3 111

Pump T-4 112

SPRAYING COMPLEX PATTERNS 113

Parking Lot 113

T - Intersection 121

FIELD MAINTENANCE 126

Flush the Spray Bar 126

Clear Spray Bar Clogged with Frozen Asphalt 126

Preferred Method: Clearing with Live Steam 126

Alternate Method: Clearing with a Torch 127

Clear Clogged Spray Nozzle 127

Clean Asphalt Intake Strainer 127

Clean Bar Screen 128

Replace Swing Joint Seal 128

Disassembly 128

Seal Replacement 129

Reassemble 129

Replace Asphalt Pump Seals 129

Replace Nozzle Valve Stem Seals 130

Adjust Actuators for Spray Nozzle Valves (Mechanical Linkage) 131

Adjust Remote Curbside Mirror 133

Lubrication 133

Preparation for Storage 133

Removal of Spray Bar 134

Hydraulic System Maintenance 134

Cargo Pump Operation 135

CRC System Calibration and Service Adjustments 136

Equalizer Valve Packing 136

BC-502/CRC

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K Valve (spread circulate) or “bypass valve” 137

Troubleshooting 139

Bolt Torque Chart 144

Conversion Chart 145

Calculate Area 145

Check Spread Rate 145

PARTS 146

17

Equipment Description

The Model BC-502/CRC Cab Operated Computer Controlled Liquid

Asphalt Distributor is pictured below. The following description of the

equipment should be read to familiarize yourself with the operating

features and capabilities of the Model BC-502/CRC asphalt distributor.

BC-502/CRC

18

Hydraulics

Pump Drive Options

Hydraulic power is used to drive the asphalt pump and move the spray

bar. Primary power for the hydraulic system is derived from a power

takeoff driven by the truck engine. Either a transmission PTO,

Crankshaft, REPTO, or an additional engine may be employed.

Transmission Power Take-Off

The transmission power take-off (PTO) consists of a gearbox mounted to

the truck transmission, from which a driveline connects to a hydrostatic

pump. The PTO gearbox operates only when the truck clutch is engaged

on manual transmission trucks. When the clutch is disengaged, the PTO

stops, in turn stopping the hydrostatic motor. Automatic transmission

generally have a live PTO that constantly operates once the PTO is

engaged. The transmission PTO is

engaged by use of a switch on the

Cab Console. In general, the PTO

can be switched on when the

truck arrives at the job site and

left on continuously until the shift

is finished for the day. All

configurations of the PTO can be

operated at highway speed. See your truck Operations Manual for

details on the PTO operation for your specific truck.

Crankshaft or REPTO Drive

The crankshaft and rear engine PTO (REPTO) are driven directly by the

truck crankshaft, allowing the hydrostatic pump and asphalt pump to be

operated independently of the truck clutch. Crankshaft or REPTO drives

are typically used in applications where the truck transmission is not

equipped with an adequate PTO, the end user prefers a live PTO with a

manual transmission and in applications where truck body can be

changed out on the truck, such as a swap loader.

19

Additional Engine

The additional engine option uses an engine mounted to the distributor

body to power the hydraulic system. The additional engine has the

hydraulic pumps direct mounted and is used primarily for applications

where the truck PTO or crank drive is not feasible or the horse power

required is in excess of truck engine capabilities. Distributors equipped

with an additional engine do not depend on the truck engine for

powering the hydraulic pump on the distributor.

Hydraulic Reservoir and Filter

Hydraulic fluid for the hydrostatic pump

and motor is stored in a 15 gallon tank

mounted to the frame. The system uses

ISO 46 Hydraulic Fluid. The tank includes

a sight glass that indicates the presence

of sufficient fluid to operate the system.

The tank has an internal 100 mesh

suction screen. A 10 micron return filter

is located immediately adjacent to the tank. A pressure gauge mounted

on the filter housing serves as an indication of the condition of the filter

element. When the element is clean and unobstructed, the gauge will

indicate pressure in the range 0 to 24 PSI.

Hydrostatic Pump

A heavy duty, variable displacement

hydrostatic pump is used to drive the

hydrostatic motor that turns the asphalt

pump through a 3.5 to 1 planetary gear

box. The hydrostatic pump is a sealed, self-

lubricating unit. It operates in either the

forward or reverse direction, at any speed within its operating range.

Control of the speed of the pump is determined in one of two ways:

a.

CRC control: Computerized Rate Control (CRC) automatically

adjusts the pump speed to achieve the desired spread rate at

BC-502/CRC

20

any truck speed. While in CRC, the system monitors the

vehicle speed and determines the proper pump parameters

to maintain the selected gallons per square yard (GSY) of

asphalt distribution. Automatic control occurs only when the

selector on the cab Console is in the ‘CRC’ position.

b.

Manual control: In manual control, the pump speed is

determined by setting the manual pump speed on the

second page of the display, or by using the GSY switch on the

Console. Manual control is possible only when the selector

is in the ‘MANUAL’ position. The pump control functions are

described further in the ‘Cab Console Controls’ section of

this manual.

CAUTION: INSUFFICIENT HYDRAULIC FLUID FLOW TO THE

HYDROSTATIC PUMP WILL CAUSE CATASTROPHIC

DAMAGE TO THE PUMP. INSUFFICENT HYDRAULIC

FLUID FLOW TYPICALLY INDICATES A CLOGGED FILTER,

BLOCKED HYDRAULIC LINE, OR LOW FLUID LEVEL.

The hydrostatic pump receives power directly from the PTO. It is a

quiet, smooth running unit under the conditions normally encountered

in asphalt circulation/heating operations. Excessive or unusual noise

from the pump may indicate a clogged filter, low fluid level or blocked

hydraulic line. The pump should never be operated under these

conditions.

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Bearcat BC-502/CRC User manual

Bearcat BC-502/CRC User manual

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