VERDER JEC JRZW Series User manual

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Operation and maintenance manual
JEC_ZW_man rev01-2019_(uk)
JEC HYGIENIC PUMP SOLUTIONS
JEC JRZW SERIES
Hygienic wine processing pump

2
Contents
Thank you for purchasing a 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.)--------------------------------------------------------------
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
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 -------------------------------------------------------------------------------------
Single & Double mechanical seal----------------------------------------------------------------
3
4
5
6
7
8
8
9
10
11
12
12
13
14
15
17
18
19
22

3

4

5

6

7
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 exceed.
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 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 check pump rotation with liquid in the pump.
DO NOT run the pump with the front cover removed. The rotors and rotor 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.

8
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.

9
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 and pressure of
product higher than expected.
Rotor contact to housing or cover
Reduce pump speed, increase
piping size,
Adjust clearance
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.

10
MAINTENANCE
PUMP HOUSING 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 many harden, crystallize or freeze in the pump it
should be thoroughly drained and cleaned immediately after use. Similar attention must
apply to the seal flush system. Remove power before servicing to prevent unintended start of
the pump by an authorized electrician.
Loosen and remove the four wrench bolts from
the cover. Remove the cover. If it is stuck, tap on
the cover with a soft hammer.
Remove rotor-retaining bolts. Use a wrench. To
remove rotor-retaining bolts, place the plastic dowel
between the rotors as shown in Figure 2. Turn the
first rotor bolt counter- clockwise. Remove the rotor
bolts and spring washers
The rotors can be removed from the pump housing by
pulling straight together with top and bottom. 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.

11
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 pump housing away from the gear box. In this time, handle the shims 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.
Please handle the shims with care to avoid
lost and damage when assemble and
disassemble.
The seal ring can be easy removed from rotor use such
like a small screw driver (-) or a pin as shown.
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.

12
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.
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
When install the ceramic shaft sleeve onto the pump shaft fit care in
to pin as shown in Figure 15.
Assemble a rotor onto shaft engaging the shallow groove with small
spline in rotor and seal side first in to the shaft together with top
and bottom rotors.
Place the plastic dowel between the rotors. Tighten the first rotor bolt with a wrench to the
recommended torque. To tighten the second rotor place the plastic dowel on the opposite
side of the rotor and tighten the second rotor bolt to the properly.
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.

13
ROTOR CLEALANCE
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
Standard Rotor Clearances (mm)
Model
Back Face
Front Face
Radial Sides
Radial Top &
Bottom
Rotor to
Rotor
JRZW120-031-06
0~0.05
0~0.05
0~0.05
0~0.05
0~0.05
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 (60).
2. Check that the rotor housing is tight to gearbox (1). And check the rotor bolts (6) 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 (60) from behind the pump housing.
5. Check each rotor and adjust as necessary.

14
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:
1. Assemble each rotor in its normal location on the drive shaft and the idle shaft. Assemble each
rotor bolt and tighten hand tight.
2. 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.
3. The Rotors are correctly timed when the gap measured at both locations are equal. If the gap is
unequal, adjust the timing as follows.
4. Rotor timing is determined by the relative
location of the two helical gears (14) on
the shafts. Gear spacers (16) are used to
adjust the location and the timing.
When adjusting timing, move only
one of the two gears.
5. Place the wooden dowel between
the rotors.
6. Bend away the tab of the lock washer
(12) 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 18
* 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.
7. Repeat above procedures until the timing gap is equal after gear spacers are in place and gear nuts
are tightened to correct torque.
8. Reassemble pump.

15
SHAFT AND BEARING REPLACEMENT
Gearbox Disassembly
1. Remove the oil drain plug and drain the oil.
2. Remove the gear box cover bolts (6) from the rear cover (4).
3. Pull the rear 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 rear cover and
dowel (4).
4. Remove the rear cover oil seal (11) from the rear cover.
5. Remove the paper gasket from the rear cover or gear box.
6. Straighten the locking tab of the bearing lock washer. Reinstall the rotors (38) on the drive
and idle shafts. Lock the rotor with a plastic dowel. Remove the lock nut (12-1) and lock
nut washer from the drive shaft (8) and idle shaft (9).
7. Pull the two helical-gears (14) off the pump shafts. Remove the gear keys (7).
8. Remove the front bearing gland set bolts (23).
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.

16
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 oil seals (22) 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 cover (24) into gear box (1).
9. Place the gear spacer (16) 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 gear keys (7) to the 12:00 position.
12. Place the gear, lock washer (12) and lock nut (12-1) 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 (38) 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 (12) on the idle shaft, following the previous steps.
16. Install the paper gasket to rear cover (26) and mount the rear cover 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.

17
TECHNICAL INFORMATION
TECHNICAL DATA
SPECIFICATIONS
Maximum Inlet Pressure ----------------------------------------------- 1 bar (100 kPa, 14.5 psi)
Maximum Differential Pressure ------------------------------------------ 6 bar (600 kPa, 87 psi)
Maximum Flow Rate ------------------------------------------------------- 15 m3/hr (66 US GPM)
---------------------------------------- Please consult to JEC over 15 m3/hr
Temperature Range ------------------------------------------------ -5 C to 120 C (23 F to 248 F)
Viscosity Range -------------------------------------------------------------------------- 100,000 cPs
Noise Level -------------------------------------------------------------------------------- 60 ~ 80 dB
MATERIALS
Product Wetted Parts -------------------------------------------------- EPDM, SUS316L (standard)
Product Wetted Seals -------------------------------------------------------------- EPDM (standard)
Alternative Seals ---------------------------- NBR, FPM, PTFE Encapsulated, Perfluor elastomer
SHAFT SEALS
Seal type ------------------------------------------ Single and Double Mech., O-ring and Lip-seal
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
Rubber Heli-lobe rotors.
OPTIONAL INFORMATION
Viton Heli-lobe rotor
Thermal jacket on rotor housing and front cover
Surface hardened rotor housing
Trolley version

18
DIMENSIONAL DRAWING

19
Parts list
EXPLODED VIEW

20
All orders for repair parts must contain the following;
1. Complete model number (located on nameplate).
2. Pump serial number (located on nameplate).
3. Description and part number from the parts list.
Please refer the ‘Parts list’ separately for further reference.
ITEM
PART NO.
Description
Material
Q'ty
Per
Ass'y
Per
Pump
1
ZL10-GB03-CS
Gear Box
FCD40
1
1
ZL10-GB03-SS
Gear Box
SUS304
1
1
2
ZL10-GB05-CS
Base, Gear Box
FCD40
1
1
ZL10-GB05-SS
Base, Gear Box
SUS304
1
1
3
ZL10-WB03-SS
Wrench Bolt, Base(M8x20L)
SUS304
1
4
4
ZL10-GB04-CS
Cover, Gear Box
FCD40
1
1
ZL10-GB04-SS
Cover, Gear Box
SUS304
1
1
5
ZL12-LD01-CS
Plug, Level, Drain
1
3
6
ZL10-WB02-CS
Wrench Bolt, Gear Box Cover (M6x45L)
S45C
1
4
7
ZL10-SK01-CS
Key, Shaft (8x7x34)
S45C
1
1
8
ZL10-SF03-SS
Shaft, Drive
SUS304
1
1
9
ZL10-SF04-SS
Shaft, Idle
SUS304
1
1
10
ZL10-GK01-CS
Key, Gear (8x7x21)
S45C
1
2
11
ZL10-OS02-L5
Oil Seal, Cover(23x43x7t)
NBR
1
1
ZL10-OS02-L2
Oil Seal, Cover(23x43x7t)
FPM
1
1
12
ZL10-LW01-CS
Lock Washer
S45C
1
2
12-1
ZL10-LN01-CS
Lock Nut
S45C
1
2
13
ZL12-RV01-PE
Valve, Relief
PE
1
1
14
ZL10-HG01-CS
Helical Gear
S45C
1
2
15
ZL10-PN05-SS
Dowel, Gear Box (Φ6)
SUS304
1
2
16
ZL10-GS01-CS
Spacer, Gear (Φ35x5L)
S45C
1
2
17
ZL10-BE02-CS
Bearing, Rear (#5205)
1
2
18
ZL10-BS01-CS
Spacer, Bearing
S45C
1
2
19
ZL10-IB04-SS
I-bolt / M8
SUS304
1
2
20
ZL10-BE01-CC
Bearing, Front (#5206)
1
2
21
ZL10-OR01-L2
O-ring, Oil seal gland (AN035)
FPM
1
2
22
ZL10-OS01-L5
Oil Seal, Gear Box (38x55x9t)
NBR
1
2
ZL10-OS01-L2
Oil Seal, Gear Box (38x55x9t)
FPM
1
2
23
ZL10-WB01-SS
Wrench Bolt, Oil Seal Gland (M6x10L)
SUS304
3
6
24
ZL10-OG01-SS
Gland, Oil Seal
SUS304
1
2
25
ZL10-PN01-SS
Pin, Double Seal
SUS304
1
2
26
ZL10-GG01-LL
Gasket
Paper
1
1
27
ZL10-PG01-LL
Plug (M8)
PE
1
8
28
ZL10-VA01-SS
Vertical adaptor
SUS304
1
4