BJM Pumps KZN37 Instruction manual

Version 3-2-2016
INSTALLATION, OPERATION & MAINTENANCE MANUAL
KZN (R) SERIES
HEAVY DUTY AGITATOR
TOP DISCHARGE
Electric Submersible Pumps
CAST IRON
Three Phase
208V, 230V, 460V, & 575V
KZN37
KZN55CH
KZN37R
KZN55R
KZN55
KZN55CHR
Three Phase
230V, 460V & 575V
KZN75
KZN110H
KZN75R
KZN110R
KZN110
KZN110HR
Three Phase
460V & 575V
KZN150
KZN220
KZN150L
KZN220L
KZN150LR
KZN220LR
KZN150R
KZN220R
Read this manual carefully before installing, operating or servicing these pump models.
UObserve all safety information.UFailure to comply with instructions may result in personal
injury and/or property damage. Please retain these instructions.

TABLE OF CONTENTS
INTRODUCTION...........................................................................................................................................4
HSAFETY......................................................................................................................................................5
INSPECTION ................................................................................................................................................6
PRE-INSTALLATION INSPECTION ........................................................................................................6
OIL FILL QUANTITY/TYPE......................................................................................................................6
PUMP INSTALLATION.............................................................................................................................7
POSITIONING THE PUMP.......................................................................................................................7
PUMP ROTATION....................................................................................................................................7
PUMP OPERATION......................................................................................................................................9
TYPICAL MANUAL DEWATERING INSTALLATION...................................................................................9
STOPPING ...............................................................................................................................................9
TYPICAL AUTOMATIC DEWATERING INSTALLATION...........................................................................10
STOPPING .............................................................................................................................................11
INTENDED METHODS OF CONNECTION ...............................................................................................12
THREE PHASE WIRING INSTRUCTION..............................................................................................12
TROUBLE SHOOTING...............................................................................................................................14
PUMP WILL NOT RUN...........................................................................................................................14
PUMP RUNS BUT DOES NOT DELIVER RATED CAPACITY.............................................................14
SERVICING YOUR SUBMERSIBLE PUMP ..........................................................................................14
MAINTAINING YOUR PUMP .................................................................................................................14
CHANGING SEAL OIL ...........................................................................................................................15
CHANGING SEALS* ..............................................................................................................................16
EXPLODED VIEW OF KZN37, 55, 55R, 55CH, 55CHR, 75, 75R..............................................................17
EXPLODED VIEW OF KZN110, 110R, 110H, 110HR, 150, 150R, 150L, 150LR......................................18
EXPLODED VIEW OF KZN220, 220R, 220L, 220LR.................................................................................19
KZN SERIES PARTS LIST.........................................................................................................................20
KZN R PARTS LIST....................................................................................................................................22
THREE PHASE WIRING DIAGRAMS........................................................................................................24
230V (5 LEAD)........................................................................................................................................24
MODELS KZN37, 37R, 55, 55CH, 55R, 55CHR, 75, 75R, 110, 110H, 110R, 110HR ......................24
460V (5 LEAD)........................................................................................................................................25
MODELS KZN37, 37R, 55, 55R, 55CHR, 75, 75R, 110, 110H, 110HR, 150, 150L, 150L, 150LR,
150R, 220, 220L, 220LR, 220R..........................................................................................................25
575V (5 LEAD)........................................................................................................................................26
MODELS KZN37, 37R, 55, 55R, 55CHR, 75, 75R, 110, 110H, 110HR, 150, 150L, 150L, 150LR,
150R, 220, 220L, 220LR, 220R..........................................................................................................26
SEAL MINDER®.........................................................................................................................................27
WARRANTY AND LIMITATION OF LIABILITY......................................................................................29
START-UP REPORT FORM.......................................................................................................................30
NOTES:.......................................................................................................................................................33

4
INTRODUCTION
This Installation, Operation and Maintenance manual provides important information on
safety and the proper inspection, disassembly, reassembly and testing of the BJM
Pumps® KZN Series submersible pump. This manual also contains information to
optimize performance and longevity of your BJM Pumps submersible pump.
The submersible KZN Series pumps are designed to pump water and water based
slurries. The KZN Series pumps are not explosion-proof. They are not designed to
pump volatile or flammable liquids.
Note: Consult chemical resistance chart for compatibility between pump
materials and liquid before operating pump.
If you have any questions regarding the inspection, disassembly, assembly or testing
please contact your BJM Pumps distributor, or BJM Pumps, LLC.
BJM Pumps, LLC
123 Spencer Plain Rd.
Old Saybrook, CT 06475, USA
Fax: [phone]
Phone: [phone]
Phone: [phone]
Information, including pump data sheets and performance curves, is also available on
our web site: HUwww.bjmpumps.comU
For assistance with your electric power source, please contact a certified electrician.
Please pay attention to the following alert notifications. They are used to notify
operators and maintenance personnel to pay special attention to procedures, to avoid
causing damage to the equipment, and to avoid situations that could be dangerous to
personnel.
NOTE: Instructions to aid in installation, operation, and maintenance or which
clarify a procedure.
Immediate hazards that WILL result in severe personal injury or
death. These instructions describe the procedure required and the injury which will
result from failure to follow the procedure.
Hazards or unsafe practices that COULD result in severe personal
injury or death. These instructions describe the procedure required, and the injury which
could result from failure to follow the procedure.
Hazards or unsafe practices which COULD result in personal injury
or product or property damage. These instructions describe the procedure required and
the possible damage which could result from failure to follow the procedure.

5
HSAFETY
Pump installations are seldom identical. Each installation and application can vary due
to many different factors. It is the owner/service mechanics responsibility to repair,
service, and test to ensure that the pump integrity is not compromised according to this
manual.
Risk of electric shock –this pump has not been investigated for use
in swimming pool areas.
Do not pump flammable, inflammable or volatile liquids. UDeath
or serious injury will result.
Before attempting to open or service the pump:
1) Familiarize yourself with this manual.
2) Unplug or disconnect the pump power cable to ensure that the pump will remain
inoperative.
3) Allow the pump to cool if overheated.
Do not operate the pump with a worn or damaged electric power
cable. Death or serious injury could occur.
Never attempt to alter the length or repair any power cable with a
splice. The pump motor and pump motor and cable must be completely waterproof.
Damage to the pump or personal injury may result from alterations.
After the pump has been installed, make sure that the pump and all
piping are secure before operation.
Do not lift the pump by the power cable piping or discharge hose.
Attach proper lifting equipment to the lifting handle (or lifting rings) fitted to the pump. Do
not suspend the pump by the power cable.
Obtain the services of a qualified electrician to troubleshoot, test
and/or service the electrical components of this pump.
Pumps and related equipment must be installed and operated
according to all national, local and industry standards.

6
INSPECTION
Review all safety information before servicing pump.
The following are recommended installation practices/procedures for the pump. If there
are questions in regards to your specific application, contact your local BJM Pumps
distributor or BJM Pumps, LLC.
PRE-INSTALLATION INSPECTION
1) Check the pump for damage that may have occurred during shipment.
2) Inspect the pump for any cracks, dents, damaged threads, etc.
3) Check power cord (and seal minder cord, if installed) for any cuts or damage.
4) Check for, and tighten any hardware that appears loose.
5) Carefully read all tags, decals and markings on the pump.
6) Important: Always verify that the pump nameplate, amps, voltage, phase, and
HP ratings match your control panel and power supply.
Warranty does not cover damage caused by connecting pumps and controls to an
incorrect power source (voltage/phase supply). Record the model numbers and serial
numbers from the pumps and control panel on the front of this instruction manual for
future reference. Give it to the owner or affix it to the control panel when finished with
the installation.
If anything appears to be abnormal, contact your BJM Pumps distributor or BJM
Pumps, LLC. If damaged, the pump may need to be repaired before use. Do not install
or use the pump until appropriate action has been taken.
Lubrication:
No additional lubrication is necessary. The shaft seal and bearings are fully lubricated
from the factory. Seal oil should be checked one per year. See table below.
OIL FILL QUANTITY/TYPE
Qty. oil in seal chamber
Models
U.S. fl. oz.
C.C.
Type of oil
KZN37, 37R, 55, 55CH, 55R, 55CHR,
75, 75R
49
1450
ISO 32 NSF Food Grade Mineral Oil
KZN110, 110H, 110R, 110HR, 150,
150L, 150LR, 150R
125
3700
ISO 32 NSF Food Grade Mineral Oil
KZN220, 220L, 220LR, 220R
213
6300
ISO 32 NSF Food Grade Mineral Oil

7
PUMP INSTALLATION
KZN Series pumps have been evaluated for use with water or water based solutions.
Please contact the manufacturer for additional information.
Risk of electric shock. KZN Series pump models do not come
with electric plug connectors. To reduce the risk of electric shock, be certain that it is
connected only to a properly grounded, grounding-type receptacle or control panels.
Lifting:
Attach a rope or lifting chain (not included) to the handle (or lifting rings) on the top of
the pump.
Do not lift the pump by the power cable or discharge hose/piping.
Proper lifting equipment (rope/chain) must be used.
POSITIONING THE PUMP
BJM Pumps, KZN Series pumps are designed to operate fully or partially submerged.
Do not run the pump dry. Refer to data sheet for minimum submersion depth for your
particular model. Data sheets can be obtained online at HUwww.bjmpumps.comUH or by
calling BJM Pumps, LLC at 860-399-5937. As a general rule, KZN Series top discharge
pumps can pump down to a level above the suction screen. Pumping lower than screen
will permit air to enter the pump and cavitate, lose prime or become air bound.
Do not run pump dry.
Pump liquid should not exceed a maximum temperature of 104°F.
Never place the pump on loose or soft ground. The pump may sink, preventing
water from reaching the impeller. Place on a solid surface or suspend the pump
with a lifting rope/chain. The KZN Series pumps are provided with a suction
strainer to prevent large solids from clogging the impeller. Any spherical solids
which pass through the strainer should pass through the pump.
For maximum pumping capacity, use the proper size non-collapsible hose or rigid
piping. A check valve may be installed after the discharge to prevent back flow
when the pump is shut off.
PUMP ROTATION
Two ways to check the correct pump rotation:

8
1. By looking at the impeller; the rotation of the impeller should be counter
clockwise as shown in the picture below.
2. By looking from the top of the pump. Since the impeller cannot be seen, the best
way to check the rotation is to check the kick back motion of the pump when the
pump just starts. The kick back motion of the pump should be counter clockwise
as shown in the picture below.

9
PUMP OPERATION
This pump is designed to handle dirty water that contains some
solids. It is not designed to pump volatile or flammable liquids. Do not attempt to pump
any liquids which may damage the pump or endanger personnel as a result of pump
failure.
Do not operate this pump where explosive vapors or
flammable material exist. Death or Serious injury will result.
TYPICAL MANUAL DEWATERING INSTALLATION
NOTE: Maximum recommended starts should not exceed 10 times per hour.
All KZN models are provided with a 50’(10m) power cord. UNEVERUsplice the power
cable due to safety and warranty considerations. Always keep the plug end dry.
Note: 208V, 230V, 460V & 575V three phase units do not have a plug and have to
be provided separately.
Do not alter the length or repair any power cable with a splice. The
pump motor and cable must be completely waterproof. Damage to the pump or
personal injury may result from alterations.
For manual operation: 208, 230, 460 & 575 volt: Attach the proper plug or connect
directly to the power source or control box. KZN model pumps are supplied with two
grounding wires; one green for grounding to the panel; the other is orange and is to be
used for grounding check systems or can be also connected to the grounding point on
the control. Check the direction of the rotation. Tilt the pump and start it. It should twist
in the opposite direction of the arrow (on pump). It is recommended that a Ground Fault
Interrupter (GFI) type receptacle (or equivalent) be used.
STOPPING
To stop the pump (manual and automatic mode), unplug it from the power source, turn
off the breaker, or turn the power source off (generator).

10
Typical 3 phase manual control 1
TYPICAL AUTOMATIC DEWATERING INSTALLATION
NOTE: Maximum recommended starts should not exceed 10 times per hour.
Float switches (wired into the pump motor or piggy-back style) are available from the
factory as an option.
Note: 208V, 230V, 460V & 575V pumps do not have a plug installed.
Three phase pumps need a separate control box with float(s) for automatic
operation.

11
STOPPING
To stop the pump (manual and automatic mode), unplug it from the power source, turn
off the breaker, or turn the power source off (generator).

12
Typical 3 phase Auto Control 1
INTENDED METHODS OF CONNECTION
Use with approved motor control that matches motor input in full
load amperes. “UTILLISER UN DÉMARREAR APPROUVÉ CONVENANT AU
COURANT Á PLEINE CHARGE DU MOTEUR.”
BJM Pumps submersible pumps have been evaluated for use with water or water
based solutions. Please contact the manufacturer for additional information.
THREE PHASE WIRING INSTRUCTION
FOR YOUR PROTECTION, ALWAYS DISCONNECT PUMP
FROM ITS POWER SOURCE BEFORE HANDLING.
“Risk of electrical shock” Do not remove power supply cord and
strain relief or connect conduit directly to the pump.

13
Installation and checking of electrical circuits and hardware should
be performed by a qualified licensed electrician.
To automatically operate a non-automatic three phase pump, a control panel is
required. UFollow the instructions provided with the panel to wire the system.UFor
automatic three phase pumps see automatic three phase wiring diagram.
Before installing a pump, check the pump rotation to insure that wiring has been
connected properly to power source, and that the green lead of power cord (See wiring
diagram), is connected to a valid ground, momentarily energize the pump, observing the
directions of kick back due to starting torque. Rotation is correct if kick back is in the
opposite direction of rotation arrow on the pump casing. If rotation is not correct,
switching of any two power leads other than ground will provide the proper rotation.
Three phase pumps have integral motor overload protection. It is recommended that all
three phase pumps using a motor starting device also incorporate motor overload
protection. Pumps must be installed in accordance with the National Electrical Code
and all applicable local codes and ordinances. Pumps are not to be installed in locations
classified as hazardous in accordance with National Electrical Code, ANSI/NFPA 70.
Connect pump to a junction box, outlet box, control box, enclosure with a wiring
compartment that meets NEC and local codes. The provision for supply connection
shall reduce the risk of water entry during temporary, limited submersion and shall
comply with the applicable requirements of the Standard for Enclosures for Electrical
Equipment, UL 50, or the standard for Metallic Outlet Boxes, UL 514A, and the standard
for Motor-Operated Water Pumps. UL 778.

14
TROUBLE SHOOTING
Disconnect the power source to the pump BEFORE attempting
any type of trouble shooting, service or repair.
PUMP WILL NOT RUN
1. Check power supply (fuses, breaker). Reset power.
2. Blocked impeller. Remove strainer, check and clean.
3. Defective cable or incorrect wiring.
4. Strainer clogged. Check and clean as necessary.
5. Float switch tangled/obstructed. Clean and free float switch from obstruction.
6. Float switch defective. Replace float switch.
7. Pump overheated or temperature of liquid exceeds pump operating
temperature.
UWarning: Pump will restart automatically when motor over-heat protection switch
cools.
PUMP RUNS BUT DOES NOT DELIVER RATED CAPACITY
1. Discharge line clogged, restricted or hose kinked. Check discharge hose/pipe.
2. Worn impeller and/or suction cover. Inspect and replace as necessary.
3. Pump overloaded due to liquid pumped being too thick.
4. Pumping air. Check liquid level and position of pump.
5. Excessive voltage drops due to long cables.
6. Three phase only; pump running backwards, check rotation.
SERVICING YOUR SUBMERSIBLE PUMP
Pump should be disconnected from the electric power supply before proceeding to do
any service or maintenance.
To service or repair your pump, please contact your local BJM Pumps distributor.
Service should only be performed by a qualified electrician.
MAINTAINING YOUR PUMP
Pump should be disconnected from the electric power supply before proceeding
to do any service or maintenance.
Pump should be inspected at regular intervals.

15
More frequent inspections are required if the pump is used in a harsh
environment.
Preventative maintenance should be performed to reduce the chance of
premature failure.
Worn impellers and lip seals should be replaced.
Cut or cracked power cords must be replaced. (Never operate a pump with a
cut, cracked or damaged power cord.)
Seal oil should be checked once per year.
Maintenance should always be done when taking a pump out of service before
storage.
1) Clean pump of dirt and other build up.
2) Check condition of oil around the shaft seals.
3) Check hydraulic parts: check for wear.
4) Inspect power cable. Make sure that it is free of nicks or cuts.
CHANGING SEAL OIL
Changing the seal oil in the KZN Series pumps is very easy.
1) Make sure that the pump cable is disconnected from the power source.
2) Lay the pump down on its side.
3) Remove the screws that hold the bottom plate in place.
4) Remove bottom plate.
5) Remove screws holding the suction cover.
6) Remove the suction cover.
7) Remove the impeller.
8) Remove the inspection screw for the oil chamber (pos#50-08). Pour out a
small sample of the oil. If it is milky white, or contains water, then the oil and
possible, the mechanical seal, should be changed. If an oil change is needed:
9) Remove the screws that hold the oil chamber cover in place & remove the oil.
10)Replace the mechanical seal if necessary.
11)Replace the oil.
12)Assemble the pump.

16
CHANGING SEALS*
1) Make sure that the pump cable is disconnected from the power source.
2) Lay the pump down on its side.
3) Remove the oil inspection bolt (pos#50-11) from the oil seal chamber.
4) Drain out all the inside the oil seal chamber.
5) Remove the bolts holding the stand.
6) Remove the stand.
7) Remove the bolts holding the suction cover.
8) Remove the suction cover.
9) Remove the agitator.
10)Remove the impeller, impeller key and shims.
11)Remove the bolts holding the pump housing.
12)Remove the pump housing.
13)Remove the shaft sleeve. Note the shaft sleeve direction.
14)Remove the bots holding the oil cover.
15)Remove the oil cover.
16)Remove the screws holding the seal retainer.
17)Remove the seal retainer.
18)Remove the mechanical seal.
19)Replace the mechanical seal, lip seal and o-rings.
20)Assemble the pump.
21)Fill with recommended new oil.
22)Replace the oil inspection bolt o-ring.
23)Secure the oil inspection bolt.
*Note: If there is excessive liquid found in the oil or mechanical seal damaged, please
contact BJM Pumps authorized service centers.

17
EXPLODED VIEW OF KZN37, 55, 55R, 55CH, 55CHR, 75, 75R

18
EXPLODED VIEW OF KZN110, 110R, 110H, 110HR, 150, 150R, 150L, 150LR

19
EXPLODED VIEW OF KZN220, 220R, 220L, 220LR

20
KZN SERIES PARTS LIST
Pump Model KZN37 KZN55 KZN55CH KZN75 KZN110 KZN110H KZN150 KZN150L KZN220 KZN220L
Pos. No. Part Description Item # Item # Item # Item # Item # Item # Item # Item # Item # Item #
01N-01 Stand w/ Strainer Plate 201982 201982 201983 201982 201981 201981 201981 201981 201984 201984
02 Wear Plate 202018 202018 202019 202018 202016 202016 202016 202867 202030 202030
02W Suction Cover 202869 202869 202870 202873 202874 202874 202874 202875 202876 202877
04 Lock Washer 202917 202917 202917 202917 202918 202918 202918 202918 202919 202919
05 Impeller 202976 202977 202979 202980 202981 202982 202972 202973 202974 202975
05W Agitator 202983 202983 202983 202983 202984 202984 202984 202984 202985 202985
06 Impeller Key 202146 202146 202146 202146 202147 202147 202147 202147 202986 202986
07 Pump Housing 202191 202191 203026 202191 202203 202203 202203 202203 203034 203034
07-3 Pump Housing Sleeve 202182 202182 202182 202182 202183 202183 202183 202183 202184 202184
08 Oil Chamber Cover 202225 202225 202225 202225 202227 202227 202227 202227 203049 203049
08 -1 O-Ring (Kit Only) Kit Kit Kit Kit Kit Kit Kit Kit Kit Kit
09 Lip Seal Buna N 202248 202248 202248 202248 202251 202251 202251 202251 202244 202244
10 Shaft Sleeve 203071 203071 203071 203071 203072 203072 203072 203072 203073 203073
12 Upper Lip Seal Buna N - - - - 202252 202252 202252 202252 203063 203063
13 Mech. Seals - Set FKM** 200419 200419 200419 200419 200433 200433 200433 200433 200433 200433
13-2 Mech. Seal Retainer - - - - 202272 202272 202272 202272 202272 202272
14 Lower Ball Bearing (* Qty 2 needed) 200963 200963 200963 200963 200964 200964 200964 200964 200965* 200965*
14-2 Lower Bearing Retainer 202276 202276 202276 202276 202277 202277 202277 202277 202278 202278
14-3 Retaining Locknut & Ring - - - - - - - - 202275 202275
15 Impeller Shim Kit (Required) 200475 200475 200475 200475 200476 200476 200476 200476 200477 200477
16 Motor Housing. 202295 202295 202295 203081 203082 203082 203082 203082 203083 203083
17 Rotor w/ Shaft, 3 phase 202349 202350 202350 202351 202352 202352 202353 202353 202354 202354
18 Stator 230V/460V 3 phase 200681 200683 200683 200685 200687 200687 - - - -
18 Stator 460V 3 phase - - - - - - 200689 200689 200691 200691
18 Stator 575V, 3 phase 200695 200697 200697 200699 200693 200693 200701 200701 200703 200703
20 Upper Ball Bearing 200968 200968 200968 200968 200968 200968 200968 200968 200962 200962
20-1 O-Ring (Kit Only) Kit Kit Kit Kit Kit Kit Kit Kit Kit Kit
20-2 Spring Washer 202361 202361 202361 202361 202362 202362 202362 202362 202363 202363
21A Lower Bearing Housing 202377 202377 202377 202377 - - - - - -
21A Oil Chamber - - - - 202371 202371 202371 202371 202372 202372
21A-1 O-Ring (Kit Only) - - - - Kit Kit Kit Kit Kit Kit
21A-1 O-Ring (Kit Only) Kit Kit Kit Kit - - - - - -
22 Cover Plate Upper - - - - - - - - 202381 202381
23 Overload 230V, 3PH 202392 202394 202394 202396 202397 202397 - - - -
23 Overload 460V, 3PH 202391 202393 202393 202394 202398 202398 202397 202397 202400 202400
23 Overload 575V, 3 PH 202389 202391 202391 202393 202394 202394 202398 202398 202397 202397
26 Pump Top Cover 203136 203136 203136 203136 203137 203137 203137 203137 203138 203138
26-1 O-Ring (Kit Only) Kit Kit Kit Kit Kit Kit Kit Kit Kit Kit
27 Power Cord Set (5 lead) 203452 203455 203455 203455 203456 203456 203456 203456 203457 203457
27-1 O-Ring (Kit Only) Kit Kit Kit Kit Kit Kit Kit Kit Kit Kit