VERDER JEC JRZLF Series User manual

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Operation and maintenance manual
JEC_ZLF_man rev01-2019_(uk)
JEC HYGIENIC PUMP SOLUTIONS
JEC JRZLF SERIES
Hygienic rotary lobe pumps with front bearing cover

2
Contents
Thank you for purchasing JEC Products!
This manual contains installation, operation, disassembly and assembly instructions,
maintenance procedures, troubleshooting and a complete parts list for all JP series
Centrifugal Pumps designed and manufactured by JEC Ltd. South Korea.
READ THIS MANUAL carefully to learn how to service these pumps. Failure to do so could
result in person injury or equipment damage.
Certificates
3-A (3-A Sanitary Standards, Inc.) --------------------------------------------------------------
EHEDG (European Hygienic Engineering & Design group) ----------------------------------
ATEX (European Explosion proof certification) ------------------------------------------------
1935:2004 (EC) -----------------------------------------------------------------------------------
CE (Declaration of conformity) ------------------------------------------------------------------
SAFETY
DO’S and DON’TS ---------------------------------------------------------------------------------
INSTALLATION
Installation -----------------------------------------------------------------------------------------
Start Up --------------------------------------------------------------------------------------------
TROUBLESHOOTING
Troubleshooting ----------------------------------------------------------------------------------
MAINTENANCE
Pump housing disassembly ---------------------------------------------------------------------
Inspection -----------------------------------------------------------------------------------------
Seal assembly -------------------------------------------------------------------------------------
Pump housing assembly -------------------------------------------------------------------------
Rotor clearance -----------------------------------------------------------------------------------
Rotor Timing ---------------------------------------------------------------------------------------
Shaft and bearing replacement -----------------------------------------------------------------
TECHNICAL INFORMATION
Technical Data ------------------------------------------------------------------------------------
Dimensional Drawing -----------------------------------------------------------------------------
PARTS LIST
Exploded view / ZLF120, ZLF200 and ZLF300 -------------------------------------------------
Part list / ZLF120, ZLF200 and ZLF300 ---------------------------------------------------------
Exploded view / ZLF400 --------------------------------------------------------------------------
Part list / ZLF400 ----------------------------------------------------------------------------------
3
4
5
6
7
8
9
9
10
11
14
15
15
16
17
18
20
21
22
23
40
41

3

4

5

6

7

8
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 services the pump while it is running.
DO NOT place the pump in an application where the service ratings are exceed.
DO NOT modifies 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 NOT installs 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 touches 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 runs the pump with the front cover removed. The rotors and rotor case could be
damaged or may cause severe injury.
DO NOT operates 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.

9
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 distortion.
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 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 rotation 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 inlet line.
3. Pumping temperature is too high.
4. Pump is oversized.

10
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 sped.
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.
Rotor-to-rotor 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
Time rotors, replace twisted shafts,
replace worn gears.
Pump overloads
Viscosity of product higher than
expected.
Higher pressure than expected.
Reduce pump speed, increase
piping 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.

11
MAINTENANCE
PUMP HOUSING DISASSEMBLY
This JRZLF series with front bearing cover high pressure application has a same
design and structure with JRZL series, except bearing applied front cover. Therefore,
except the maintenance for front cover side, all of procedure is same as standard
rotary pump.
Reference numbers are listed in parts list refer to the sectional view on pages 22~24
Loosen and remove the four cap nuts and two
wrench bolts (Figure 2) from the cover. And use
special ‘Jack bolt’to loose stick front bearing
cover. (Figure 3) And remove the cover. If it is
stuck, tap on the cover with a soft hammer.
Figure 1
Figure 2
Figure 3
To remove extended shaft (rotor bolt), place the plastic dowel between the rotors to fix rotor
rotation as shown in Figure 4 and turn the spanner Counter-Clock Wise for drive shaft.
Figure 4-1 Figure 4-2

12
Note: JRZLF series has different screw thread for drive and idle shafts. (but ZL series
has same screw thread for CW: tightening, CCW: loosening) The standard screw
thread is CCW for loosening, and CW for tightening for drive shaft. But please check
pump specification before maintenance because based on flow direction, extended
shaft thread could be changed too.
Remove the extended shafts, rotors,
and seal ring in rotor casing as
shown in figure 5.
Figure 5-1 Figure 5-2
The rotors can be removed from the pump housing by pulling straight. If it is stuck tight,
alternately tap on the back of the inlet and outlet ports with soft hammer. Handle the rotors
with care to avoid damage.
The seal ring can be replaced without remove the pump housing and any pipe line by
pulling straight. Please check the seal ring from the shaft and front cover as shown in
Figure 6.
Figure 6-1 Figure 6-2

13
Remove the four stud bolt securing the pump housing to
the gearbox.
Figure 7
Figure 8
Slide the pump housing away from the gear box. In this
time, handle the shim(s) with care to avoid lost and
damage. If the housing is stuck, alternately tap on the
back of the inlet and outlet ports with a soft hammer.
Figure 9
Please handle the shims with care to avoid lost and damage when assemble and disassemble.
Figure 10 Figure 11 Figure 12
Clean and examine all of the pump components for damage. Replace damaged
components as required. JEC recommends replacing all of the wetted elastomers
during reassembly.

14
If you want replace the seal ring only, you can ease dismantle pull it off from
pump housing just after removed rotors without dismantle the pump housing.
And new one pushes in to pump housing.
The seal ring can be easily removed from rotor with
small screw driver (-) or a pin as shown in Figure 13.
Figure 13
Figure 14
Pull the seal ring off from the rotor.
With the rotor lying face down on a table and push
downward to press the seal ring in to the rotor in Figure
15.
Figure 15
INSPECTION
1. Inspect O-rings and seals for reuse. Worn O-rings and seals should be replaced.
2. Inspect seal faces for scoring or cracks. Replace any seal faces that are damaged.
3. Inspect shaft shoulder matched to rotors and other metal parts for wear or damage.
4. Inspect rotor galling sign among the rotor housing, front cover and rotors. Must be
remove it or replaced.
5. Inspect bur of the rotor bolt groove. Must be remove it or replaced.

15
Seal Assembly
Inspect each piece of your seal replacement kit for damage
before installing them.
Place the pump housing face down on a table, put new seal
in to the pump housing and bolts tighten. (Figure 16, 17)
Figure 16
Figure 17
Pump Housing Assembly
Before install the pump housing to the gearbox make sure that cleaning on the surface of
pump hosing and gear box and check to the shim plate between pump housing and gear box.
And Install the pump housing onto the gear box and secure the four housing set nuts.
Place the plastic dowel between the rotors.
Tighten the first rotor bolt with a spanner. To
tighten the second rotor place the plastic dowel
on the opposite side of the rotor and tighten the
second rotor bolt to the proper torque.
Before tight four front cover nuts, wrench bolts
should be loosen as shown arrow. After tighten
for cover nuts, wrench bolts should be tighten
slightly in order to avoid over load of bearing.
Use feeler gauges and depth micrometer to verify the back and redial clearances
between the rotors and the housing. A depth gauge should be used to verify the
front clearance.

16
Rotor Clearance
Rotor clearance must be precisely maintained to provide maximum pumping efficiency, yet prevent
contact between rotors, rotor housing, and front cover during operation. If pumping efficiency is
below expectations, or if parts contact has occurred during operation (Within rated differential
pressure), check, rotor clearances and adjust if incorrect.
Shims Rotor to Housing
Radial Top & Bottom
Back Face Front
Face
Rotor to
Rotor
Radial Sides
Figure 20
Standard Rotor Clearances (Millimeters)
Model
Back Face
Front Face
Radial Sides
Radial Top &
Bottom
Rotor to
Rotor
ZLF120-021-21
0.15
0.15
0.3
0.15
0.15
ZLF220-040-25
0.2
0.2
0.3
0.15
0.2
ZLF225-062-21
0.2
0.2
0.4
0.2
0.2
ZLF330-102-25
0.3
0.3
0.4
0.2
0.3
ZLF340-144-21
0.3
0.3
0.5
0.3
0.3
ZLF440-227-25
0.45
0.45
0.55
0.3
0.4
ZLF450-334-21
0.45
0.45
0.7
0.45
0.4
ZLF580-700-12
0.45
0.45
0.7
0.45
0.4
ZLF5100-1000-08
0.45
0.45
0.7
0.45
0.4
ZLF5120-1200-06
0.45
0.45
0.7
0.45
0.4
There are two areas of rotor clearances as illustrated following:
Rotor tip clearance –not adjustable set by manufacturer
Front and back face clearance –adjustable by shim
Rotor width and body depth are fixed at manufacture. Therefore, with the correct rotor size selected,
the only maintenance adjustment that can be made is the proportion of front and rear clearance.
Measure the front clearance as follows:
1. The rotor to rotor housing back face clearance is maintained by the shim.
2. Check that the rotor housing is tight to gearbox. And check the rotor bolts are tight.
3. Measure the clearance between the back face of the pump housing and the back of the rotor with
a feeler gauge. Check the reading with the recommended back face clearance.
4. If incorrect, adjust by adding or removing shim plates from behind the pump housing.
5. Check each rotor and adjust as necessary.

17
Rotor Timing
Rotor timing must be precisely maintained to provide maximum pumping efficiency, yet prevent
contact between rotors during operation. If pumping efficiency is below expectations, or if rotors
contact during operation (within rated differential pressure), check rotor timing and adjust if incorrect.
Also check rotor timing after any gearbox dismantling when the gears are removed and/or replaced.
Check Rotor timing as follows:
2. Assemble each rotor in its normal location on the drive shaft and the idle shaft. Assemble each
rotor bolt and tighten hand tight.
3. Rotate the shafts 30 degrees and measure gap as illustrated by arrows. Rotate the shafts 60
degrees the opposite direction and measure gap as illustrated.
4. The Rotors are correctly timed when the gap measured at both locations are equal. If the gap is
unequal, adjust the timing as follows.
5. Rotor timing is determined by the relative
location of the two helical gears (18) on
the shafts. Gear spacers (13) are used to
adjust the location and the timing.
When adjusting timing, move only
one of the two gears.
6. Place the wooden dowel between
the rotors.
7. Bend away the tab of the lock washer
(19) on one shaft. Loosen the lock
nut and temporarily insert shim stock
between the gear and gear spacer.
Tighten the lock nut, reassemble the
rotor in its correct location, and
recheck rotor timing. Figure 21
* If Rotor timing is correct, remove the gear and replace added other spacer or add a shim equal in
thickness to the shim stock temporarily added. Reassembly the gear and gear nut, tighten to the
correct torque, and check rotor timing again to confirm that it is correct.
* If rotor timing is incorrect, but closer to equal than original measurement, repeat previous step
adding addition shim stock.
* If rotor timing is incorrect and more unequal than original measurement, remove temporary shim
stock from one shaft and add instead to the other shaft.
8. Repeat above procedures until the timing gap is equal after gear spacers are in place and gear nuts
are tightened to correct torque.
9. Reassemble pump.

18
Shaft and Bearing Replacement
Gearbox Disassembly
1. Remove the oil drain plug and drain the oil.
2. Remove the gear box cover bolts (33) from the gear box cover (2).
3. Pull the gear box cover off the drive shaft extension. If the cover stuck use a soft hammer
carefully to loosen it. Heavy hitting the hammer may be cause damage to gear box cover
(2) and dowel (27).
4. Remove the rear cover oil seal (22) from the gear box cover (2)
5. Remove the paper gasket from the gear box cover (2) or gear box (1).
6. Straighten the locking tab of the bearing lock washer. Reinstall the rotors (5) on the drive
and idle shafts. Lock the rotor with a plastic dowel. Remove the lock nut (19) and lock nut
washer from the drive shaft (7) and idle shaft (8).
7. Pull the two helical-gears (18) off the pump shafts. Remove the gear keys (14).
8. Remove the front bearing gland set bolts.
9. Place the gearbox (1), wet end (rotor side) down, on an arbor press.
10.Protect the shaft ends with a wood block and press the drive and idle shaft out of the
gearbox.
11. Remove the bearings and spacers together by press the shaft out from the shafts.
12. Or remove bearings by puller.
13.The taper roller bearings for 400 series must be keep together with in-outside spacer and
separated for drive and idle shafts.

19
Gearbox Assembly
1. Clean and lubricate the front and rear bearing areas of the drive and idle shafts with oil.
2. Fit the front bearing, spacer and rear bearing on the shaft by arbor press or heat 120C
(250F) up by heater.
3. Lubricate and install the front bearing (16) and oil seals (21) in to the bearing gland.
4. Position the gearbox (1) with wet end up. Must be carefully placed gasket face of cover.
5. Clean and lubricate the front and rear bearing areas with oil.
6. Insert the shaft perpendicularly to the gearbox properly. There should be a tight sliding fit
between the gearbox and the bearing outer rings. Press or soft hammer could be used.
7. Place the front bearing gland set bolt and washer and tightened.
8. Lubricate and install the rear oil seal gland (20) into gear box (1).
9. Place the gear spacer (13) over the shafts.
10. Clean and lubricate the gear area of the shaft and the face of the lock washer, with oil.
11. Position both shaft key (15) and gear keys (14) to the 12:00 position.
12. Place the gear, lock washer and lock nut (19) onto the shafts and hand tighten.
13. After the gears are installed, turn the shafts to make sure they turn freely and that the
rotors (5) are timed correctly. (rotor alignments are required)
14. Use a spanner wrench to tighten the gear lock nut on the drive shaft. You can install the
rotors to hold the shafts in place while you tighten the nut.
15. Tighten the locknut (19) on the idle shaft, following the previous steps.
16. Install the paper gasket (53) to gear box cover (2) and assembly over the drive shaft
extension onto the gearbox.
17. Set the cover bolts, oil window and pressure relieve valve.
18. Fill the oil reservoir with oil to the middle of the oil wind.

20
TECHNICAL INFORMATION
TECHNICAL DATA
SPECIFICATIONS
Maximum Inlet Pressure ---------------------------------------------- 10 bar (1,000 kPa, 145 psi)
Maximum Differential Pressure --------25 bar (363psi) is available with ‘Front bearing cover’
Maximum Flow Rate ----------------------------------------------------- 100 m3/hr (440 US GPM)
------------------ Please consult to JEC over 100 m3/hr up to 450 m3/hr
Temperature Range ----------------------------------------------- -10 C to 180 C (14 F to 356 F)
Viscosity Range ------------------------------------------------------------------------ 1,000,000 cPs
Noise Level -------------------------------------------------------------------------------- 60 ~ 80 dB
MATERIALS
Product Wetted Steel Parts ---------------------------------------------------- SUS316L (standard)
Product Wetted Seals -------------------------------------------------------------- EPDM (standard)
Alternative Seals ------------------------- NBR, VITON, PTFE Encapsulated, Perfluor elastomer
SHAFT SEALS
Seal type ------------------------------------------ Single mechanical seal/Double mechanical seal
----------------------------------------------------- Other seal option, please contact JEC
Maximum Flushing Water Pressure ------------------------------------- Maximum 0.5 bar (7 psi)
Flushing Water Consumption -------------------- 0.25~0.5 liter/min (30~60 cubic inches/min)
Stationary Seal ring Material ------------------------------------------------------ Tungsten Carbide
Rotating Seal Ring Material ---------------------Tungsten Carbide (standard) or Silicon Carbide
O-ring Material ----------------------------------------------------------------------- EPDM (standard)
Lip-seal Material ----------------------------------------------------- PTFE(Polytetrafluoroethylene)
ROTOR INFORMATION
Single/Bi-wing and Bi-lobe/Tri-lobe/Heli-lobe are interchangeable.
Multi-lobe, Spur Gear-lobe optional.
Peek, Teflon coated and hardened rotors optional.
Rubber Heli-lobe rotors interchangeable and optional.
OPTIONAL INFORMATION
Heating jacket on rotor case (front cover heating jacket is not available)
Rectangular inlet version
Surface hardening