JEC Pumps JRZS Series Installation and operation manual

Operating & Maintenance Manual
J
JE EC C J JR RZ ZS S S Se er ri ie es s
Twin Screw Pumps

1
CONTENTS
GENERAL
General Information ….……………………………………………………………………………….....……………..
Intended Use .………………………………………………………………………………….....………………………
Construction ………………………………………………………………………………….....…………………………
Packaging & Transport ….……………………….…………………………………………………..……………......
Storage …….……………………………………….………………………………………….....…………………………
SAFETY
DO’S and DON’TS ………………………………………………………………………………………………………….
Warranty ……………………………………………………………………………….………………………………......
INSTALLATION
Installation …………………………………………………………………………………………………………………..
Start Up ……………………………………………………………………………………………………………………….
MAINTENANCE
Screw Case Disassembly ……………………………………………………………..…………………………………
Screw Case Assembly ………….……………………………………………………..…………………………………
Screw Rote Clearance ………….……………………………………………………..…………………………………
Gearbox Maintenance ……………………………………………………………………………………………….…
Integral Type Unit Assembly ……………………………………………………………………………………….…
OPERATION
Troubleshooting …………………………………………………………………………………………………………..
Cleaning ……………………………………………………………………………………………………………………..
TECHNICAL INFORMATION
Technical Data ……………………………………………………………………………………………………………..
Dimensional Drawing …………………………………………………………………………………………………….
PARTS LIST
Exploded View / Bare Shaft ……………………………………………………………………………………………
Part List ………………………………………………………………………………………………………………………
Exploded View / Integral Type Unit …………………………………………………………………………………
Part List ………………………………………………………………………………………………………………………
* APPENDIX
Lubrication …………………………………………….…………………….…………………………………………….
Power Lock Installation, Removal & Reusability ……………….………………………………………………
Certificates
3-A (3-A Sanitary Standards, Inc.) …………………………………….…………………………………………
EHEDG (European Hygienic Engineering & Design group) …………………………………………………
DOCs
ATEX (European Explosion Proof Certificate) ………………………………………………………………….
CE (Declaration Of Conformity) ……………………………………………………………………………………
1935/2004 (EC) …………………………………………………………………………………………………………
FDA ….…………………………………………………………………………………………………………….…………
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GENERAL
GENERAL INFORMATION
Thank you for your purchasing JEC products!
This manual is a part of the JRZS series Twin Screw Pumps describes safe and appropriate operation
during operating and in all life cycles.
This contains instructions for installation, operation, disassembly and assembly, maintenance
procedures, troubleshooting and a complete parts list for all.
Read and completely understand this manual to learn how to service these pumps prior to operating
or servicing product and observe to pay special attention to the warnings.
This must always be available at the installation location since no liability will be assumed for any
damage or operational malfunctions arising from non-compliance with these operating instructions.
INTENDED USE
The pump is only to be used for the media pumping agreed in the applicable data sheet or
specification. Any other application beyond the intended use or conversion of the pump without
written agreement with the manufacturer shall be deemed to be not in accordance with the intended
use.
The pump may only be started up for the first time if it has been ensured that all safety devices are
completely fitted and functional.
If any areas are subject to have the risk of explosion, the relevant explosion-proof designed pumps to
be used.
Intended use also covers compliance with the conditions of operation, servicing and maintenance
specified by the manufacturer.
The pump is only to be put into operation filled with medium to be pumped.
Before starting up ensure that;
- Open the valves on the suction side completely to avoid cavitation and,
- Open the valves on the discharge side open completely to avoid exceeding the permitted
differential pressure of the pump
-Discharge-side safety measures should be done (e.g. safety valve) to protect the pump from
non-permitted excess pressure
-Protection against contact for hot, cold and moving parts must not be removed during operation

3
CONSTRUCTION
JRZS series can be ordered with bare shaft, i.e. pumps without motor or common bed.
Or, can be ordered as an ‘Integral type unit with B5 type motor' including integral adaptor, Common
base and adjustable legs, motor cover & bracket. However, it can be changed optionally.
Example Layout of pumps with Integral type unit;
①Integral adaptor, ②Gearbox, ③Screw case with outlet port (typically),
④Front cover with Inlet port (typically), ⑤Adjustable leg, ⑥Common base,
⑦Motor cover
*Shaft length of Bare shaft and Integral type unit is different, therefore, please ask us before you
replace the shaft.

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Or, ordered as a ‘complete unit with B3 type drive motor, coupling & guard, common bed’and layout
described as below.
Example Layout of pumps with complete unit
①Common bed, ②Drive unit, ③Coupling & coupling guard, ④Gearbox,
⑤Screw case with outlet port (typically), ⑥Front cover with Inlet port (typically)
The name plate is fixed on the gearbox shown an example as below.

5
PACKAGING & TRANSPORT
JRZS series are shipped in non-returnable wooden packaging.
Unpack the pump/unit upon delivery and inspect it for visible transport damage.
Any damage occurred during the transporting has to be immediately reported to the transport agent
after receipt of the consignment. Do not put the damaged products into operation.
The pumps need to be transported and secured with care to ensure no damage caused. Lifting
equipment (hoist) and load securing straps must be placed with sufficient load capacity.
Make sure you sent the pump down on a sufficient table, horizontal surface.
Below picture of complete unit with drive & common bed is shown for the example.
Caution)
*Do lift after dismantling the motor cover.
*Do keep alignment between pump’s and motor’s shafts.
*Do not lift the pump by the screw case, gearbox or integral adaptor.
STORAGE
If the pumps need to be stored temporarily, it should be sufficiently preserved under normal
environmental conditions and must not be exposed to the weather for any significant period of time.
Heed below measures when required to be stored longer period.
1. Protect pumps with dust, dirt, water or any other harmful environmental factors. Coat all
non-painted surfaces with acid-free and resin-free grease.
2. Do not grease stainless steel parts and non-metallic parts.
3. Cover all openings of pressure and suction ports.
4. Drain water when using it as flushing/quench medium for shaft seal.

6
SAFETY
DO’S & DON’TS
DO read and understand these instructions before installing or using the pump.
DO use JEC spare parts when replacing a component of the pump.
DO NOT service the pump while it is running.
DO NOT place the pump in an application where the service ratings are exceeded.
DO NOT modify the pump. Modifying the pump creates unsafe conditions and voids all
warranties.
SAFETY PRECAUTIONS WHEN INSTALLING PUMP
DO use an authorized electrician when connecting the pump.
DO observe the mechanical limits of the pump (refer to the pump performance sheet).
DO install a throttling valve in the discharge line.
DO earth the base plate of pump to avoid the potential build up of static electricity.
DO NOT install a throttling valve in the suction line.
SAFETY PRECAUTIONS WHEN OPERATING PUMP
DO only qualified personnel should operate this pump.
DO NOT start the pump until all personnel are clear.
DO NOT touch the pump or the lines when pumping hot fluids or when performing Clean In Place
(CIP) procedures.
DO NOT run the pump with BOTH the suction inlet and discharge outlet blocked. Running the
pump with the inlet the blocked will cause serious damage to the pump.
DO NOT checks pump rotation with liquid in the pump.
DO NOT run the pump with the front cover removed. The screws and screw case could be
damaged or may cause severe injury.
DO NOT operate the pump with removed the safety guard or shroud.
SAFATY PRECAUTIONS WHEN SERVICING PUMP
DO ensure the pump is cool to touch before performing service.
DO relieve all pressure and drain all fluids from pump and connected piping before performing
service.
DO ENSURE POWER TO THE UNIT HAS BEEN UNPLUGGED PRIOR TO PERFORMING
ANY PUMP MAINTENANCE OR CLEANING.
DO exercise caution and wear protective clothing when using lye or acid for cleaning.

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WARRANTY
TERMS & CONDITIONS
All terms & conditions and prices of sale are based on the applicable JEC price list at the time an
order from Customer is received by JEC and are subject to change without notice. No assignment
of the purchaser’s rights may be made without consent of JEC.
JEC warrants its Product from defects in materials and workmanship for a period of one (1) year
from the shipment date, providing it has been used as recommended and in accordance with
recognized piping practice, and providing it has not been worn out due to severe service, normal
tea and wear or subjected to accident, misuse or improper maintenance. This warranty extends
only to the original Buyer.
This warranty is expressly in lieu of any other warranties expressed or implied, including but not
limited to any implied warranty of merchantability or fitness for a particular purpose.
All claims must be in writing and must be mailed or delivered by purchaser within thirty (30) days
after purchaser learns of the facts upon which such claim is based. Any claim not made in writing
and within the time period specified above shall be deemed waived.
Purchaser’s sole and exclusive remedy and JEC Ltd.’s maximum liability for claims arising
hereunder or for negligence for any and all losses and damages resulting from any cause shall be
either the repair or replacement of defective components or pumps verified by JEC.
In no event, including in the case of a claim for negligence, shall JEC Ltd. be liable for incidental
or consequential damages including loss of profits.
No person, including any representative, employee or agent of JEC, is authorized to assume on
behalf of JEC, any liability or responsibility in addition to or different from that described in this
provision. Any and all representations, promises, warranties or statements that are in addition to
or different from the terms of this provision are of no force or effects.
RECEIVING INSPECTION
Ports are rubber capped at the factory to keep out foreign objects. If covers are missing or
damaged, a thorough inspection of fluid head, by removing pump cover, is recommended. Be
sure pumping head is clean and free of foreign material before rotating shaft.
LOSS OR DAMAGE
If your pump has been lost or damaged in transit, immediately file a claim at once with the
delivering carrier and ask for an Inspector to call. The carrier has signed the Bill of Lading
acknowledging that the shipment has been received from us in good condition.
We shall assist you in every way in collecting claims for loss, or damage, however, we are not
responsible for the collection of claims or replacement of material.

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INSTALLATION
INSTALLATION
1. Mounting surface should be flat and level.
2. The suction line should be kept as short as possible and present minimum friction loss.
3. Suction and discharge lines must be fully supported and installed so that no expansion or
shock forces act on the pump which could lead to a bad influence.
4. Ensure sufficient clearance around the motor and pump.
START UP
1. Before connecting the suction and discharge pipe work the entire system must be thoroughly
cleaned to prevent damage from welding, grinding and other residues.
2. Before starting, bump the motor to check if the motor fan is rotating clockwise or
counterclockwise when seen from the motor back. If the motor fan cannot be seen, look
through the pump case adaptor after takeoff motor shroud. (Bump means to momentarily
apply power to the motor and then immediately remove power).
3. Direction of rotating must only be checked with a completely filed system. Where double
mechanical shaft seals are installed the flush supply must be operational. Any dry running will
result in seal damage.
4. The motor rating plate should be checked to ensure that it is in accordance with the available
electrical supply. It is essential that the full load current is not exceeded to prevent motor
overload.
5. Before start up any safety guards required by local statutory regulations should be fitted.
Pay attention to circumstances that could indicate pump cavitation;
1. Low pressure in the suction line due to bad suction conditions.
2. Air in the suction-line.
3. Pumping temperature is too high.
4. Pump is oversized.

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MAINTENANCE
SCREW CASE DISASSEMBLY
Prior to removal of pump, the shut-off valves in the suction and discharge pipe work must be closed.
If there is any risk that product may be hardened, crystallized or frozen in the pump it should be
thoroughly drained and cleaned immediately after use. Similar attention must be applied to the seal
flushing system. Remove power before servicing to prevent from any unintended start of the pump
by an authorized electrician.
Remove Front cover after removing the four cap nuts from the
cover. If it is stuck, tap on the front cover with a soft mallet as
shown Figure 6.
Extract screw bolts and spring washers.
Pull out the twin screws from the shaft and treat carefully the
screws to avoid damage. If it is stuck, can be pulled out by
extraction tool.
Pull out the both seal rings for stationary parts.
Fig. 1
Fig.2
Figure 1
Fig. 3
Fig. 4

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Release wrench bolts on the screw case to be separated from
gearbox.
If it is stuck tight, tap alternately on the rim of the screw case
with soft hammer.
Slide along the stud bolt carefully and pull out the screw case
from gearbox.
If you want replace the seal ring only, you can easily dismantle and pull them out from
screw case just after removing screws without dismantling screw case and replace new
one pushed into the screw case.
The seal ring for rotating parts can be easily removed by hand
from screw.
Pull out the seal ring from screw and replace the new one.
Fig. 8
Fig. 9
Fig. 5
Fig. 6
Fig. 7

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SCREW CASE ASSEMBLY
Before installation for screw case to the gearbox, make sure to clean the surface of screw case and
gearbox and check the shim plate surely between screw case and gearbox.
Assembly can be done reverse way against the disassembling procedure.
Slide and insert screw case along the stud bolt carefully to match
the gearbox.
Tighten bolts on the screw case using wrench with reference of
below torque set value to be fixed to the gearbox.
Series
ZS100
ZS200
ZS300
Bolt size
M8
M10
M14
Torque value for
bolt (N·m)
46
91
180
Insert the both seal rings for rotating parts into the screw case
matching the hole of seal rings to the pin of seal body in screw
case.
Assemble O-ring to seal ring and put on the screw by matching
the hole of seal ring to the pin of screw.
Fig. 10
Fig. 11
Fig. 12
Fig. 13

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Before insert the twin screws, interdigitate carefully and
checking the key in screw and groove in shaft to be matched.
Slide and insert carefully the twin screws to the screw case and
treat carefully the screws to avoid damage.
Fasten screw bolts and spring washers with reference of below
torque set value using wrench spanner.
Series
ZS100
ZS200
ZS300
Bolt size
M8
M14
M18
Torque value for
Screw bolt (N·m)
22
40
53
Covering and fasten four cap nuts with reference of below torque
set value so that the Front cover and screw case can be
assembled.
Series
ZS100
ZS200
ZS300
Nut size
M8
M10
M14
Torque value for
Cap nut (N·m)
14
17
30
Fig. 14
Fig. 15
Fig. 16

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SCREW ROTOR CLEARANCE
Screw rotor clearance must be precisely maintained to provide maximum pumping efficiency, yet
prevent contact between screw rotors, screw case, and front cover during operation.
If pumping efficiency is lower than expected or if parts contact has occurred during operation (Within
rated differential pressure), check the screw rotor clearances and adjust, if incorrect.
Model
Clearances for Standard (mm)
Clearances for High Pressure (mm)
Screw to Screw
(A/B)
Screw to Housing
Screw to Screw
(B)
Screw to Housing
ZS100 SERIES
0.1
0.1
0.2
0.2
ZS200 SERIES
0.12
0.12
0.24
0.24
ZS300 SERIES
0.15
0.15
0.3
0.3
Fig. 17

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GEARBOX MAINTENANCE
Gearbox Disassembly
Remove the drain plug and drain the oil.
Remove the shaft key (7) on the drive shaft and gearbox cover bolts (6) from the rear cover (4).
Pull the cover off the drive shaft extension. If the cover stuck,
use a soft mallet carefully to loosen it. Heavy hitting by mallet
may be caused damage to the cover and dowel (15).
Remove the rear cover oil seal (11) from the rear cover if the
oil seal is needed to be replaced. Remove the paper gasket
from the cover or gearbox.
To replace the timing gears (14, 14-1) for drive & idle shaft
and power lock (181), straighten the locking tab of the
bearing lock washer at drive shaft.
Remove the lock nut (12-1) and lock nut washer (12) from the
drive shaft (8).
Release the setting wrench bolt and fasten jack bolts at power
lock (181) to remove power lock and pull out the gear on the
idle shaft (9).
See the detailed instruction of removal power lock in the
‘APPENDIX’.
Fig. 18
Fig. 20
Fig. 19

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Gearbox Assembly
1. Clean and lubricate the front & rear bearing areas of the drive & idle shafts with oil.
Fit the front bearing, spacer and rear bearing on the shaft sequentially by arbor press (or heat
120℃(250F) up by heater).
Position the gearbox (1) with wet end side facing up and be sure to place carefully for the gasket
face(downside) of cover during this time.
Clean and lubricate the front and rear bearing areas with oil.
Insert the shaft perpendicularly one by one to the gearbox properly. There should be a tight
sliding fit between the gearbox and the bearing outer rings. Press the shaft into gear case until
bearings are fully seated.
2. Lubricate and install the front bearing oil seals set
(21,22,24) on the gearbox.
Place the front bearing gland set on the both screws and
insert carefully for the Oil seal spring inside of the gland
set would not be deflected during insert. Set the Bolt &
washer, and tighten.
3. Place the gear spacer (5mm) and insert gear key on the
slots of drive shaft.
4. Place the gear (14), lock washer (12) and lock nut (12-1)
sequentially onto the drive shafts and hand tighten.
At this time, before insert lock washer, one sawtooth of
lock washer should be bent and inserted into the hole of
timing gear.
5. Insert helical gear and power lock on the idle shaft and
fasten power lock temporarily. Put the wedge between
timing gears and tighten the gear lock nut on the drive
shaft.
The other sawtooth also fitted in the lock nut to fasten
each other and release the power lock in order to insert
screws.
Fig. 21
Fig. 22
Fig. 23
Fig. 24

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6. On the opposite shafts, interdigitate carefully for both
screws together with checking the key and groove in shaft
to be matched, and insert properly to the shaft shoulder.
7. Fasten the both screw bolts and insert ‘Feeler gauge’ with
reference of below value to each series to secure screw
timing.
Series
ZS100
ZS200
ZS300
Set Filler gauge
value (mm)
0.10
0.12
0.15
8. On the opposite timing gear after insert Feeler gauge,
fasten wrench bolt of the power lock (181) sequentially
with recommended below torque value.
Series
ZS100
ZS200
ZS300
Bolt size
M6
M6
M8
Torque value for
Cap nut (N·m)
16.7
16.7
40.2
See also in detail the installation manual of the power lock
in the ‘APPENDIX’.
9. Install the paper gasket (26) to the gasket face of the
gearbox and mount the rear cover assembly over the drive
shaft extension onto the gearbox.
10. Set the cover bolts, drain plug and fill the oil to the oil
reservoir.
The detail instructions of the lubrications are mentioned
on the ‘APPENDIX’.
Fig. 25
Fig. 26
Fig. 27
Fig. 28

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INTEGRAL TYPE UNIT ASSEMBLY
If ZS series ordered by ‘Integral type unit’, they will be provided with pump head with integral
adaptor, Common base with adjustable leg, motor, motor cover and bracket. However, the contents
can be changed optionally.
Seated the assembled pump head and integral adaptor on the
Common base. Assemble the motor bracket on the Common
base.
Insert and assemble motor to the integral adaptor by
adjusting between the motor shaft key and key way in integral
stud shaft (192).
Assemble integral adaptor flange and motor by fastening bolt
(198) and nut (199).
Fasten socket set screw (197) inside of the hole by L-wrench.
Fit the motor cover at the integral adaptor flange and cover
bracket. Fasten motor cover with bolt each side on the
bracket.
Finally adjust the height and balance of the pumps by using
adjustable legs. Fasten the nuts (203) of all adjustable legs.
Fig. 32
Fig. 29
Fig. 30
Fig. 31

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OPERATION
TROUBLESHOOTING
Problem
Cause
Solution
Pump not turning
Interruption of electrical power.
Key sheared or missing.
Coupler or belts are not connected.
Pump shaft or gears sheared.
Wrong rotation.
Relief valve not properly adjusted.
Reset circuit breaker, check fuses.
Replace.
Replace or adjust.
Replace.
Reverse.
Adjust valve.
Pump not priming
Valve closed in suction lines.
Suction line clogged or restricted.
Air leak in connections or seal.
Pump speed too slow.
Suction line does not remain flooded.
Air lock.
Excessive clearances in pump.
Net inlet pressure low.
Open valve.
Clear suction line.
Repair leak.
Increase speed.
Install foot valve.
Bleed suction line.
Replace out of tolerance parts
Increase suction pressure
Insufficient flow
Speed too low.
Air leak.
Adjust speed as required.
Repair leak.
Noisy operation
Cavitation.
Viscous product.
High vapor pressure, high temp.
Leaks in piping or pump.
Dissolved gas in product.
Mechanical noise.
Excessive weight from piping,
Pump body distorted.
Excessive discharge pressure.
Worn bearing.
Worn gears.
Screw-to-Screw contact.
Increase net inlet pressure.
Slow pump, reduce product.
Reduce temperature.
Repair leaks.
Reduce discharge pressure.
Check tolerances.
Support piping.
Check align and level
Reduce discharge pressure.
Replace bearing.
Replace gears
Timing screws, replace twisted shafts,
replace worn gears.
Pump overloads
Viscosity of product higher than
expected.
Higher pressure than expected.
Reduce pump speed, increase
pipe size,
Reduce pump speed, increase
pipe size,
Play between gears
Worn gear teeth.
Gear loose on shaft.
Replace gear.
Inspect gear key, keyway and shaft.
If all are undamaged, retighten the
gear retaining nut.
Check for backlash.
If assistance is required, please contact your local sales office with the following information:
1. Operating conditions.
2. Accurate description of default.
3. Model of pump and serial number.
4. If possible installations sketch of pump system.

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CLEANING
1. Before cleaning the pump, wear rubber gloves and protective glasses.
2. While CIP and SIP process, do not touch the pump and pipelines.
3. Ensure velocity rate of CIP solutions is adequate to clean entire circuit. For most applications
a velocity of 1.52 m/sec is sufficient. For the CIP solution to achieve the proper velocity, the
pump drive must have enough speed range and horsepower. The required inlet pressure also
must be satisfied. If the pump does not supply enough CIP solution velocity, a separate CIP
supply pump with an installed bypass may be used.
4. Refer to the below CIP and SIP process.