Operating & Maintenance Manual

JEC JRZL Series

Rotary Lobe Pump

JEC LTD.
408, Cheongyo-ri, Bibong-myun, Hwaseong-si, Gyeonggi-do, South Korea
Tel: +82 31 355 0316 Fax: +82 31 355 0319 www.jecpump.com E-mail:
[email protected]
 Description

This manual contains installation, operation, assembly, disassembly and repair instructions
for the JEC ZL series rotary lobe pumps.

JEC rotary lobe pumps are positive-displacement pumps with

non-contact rotors and EHEDG( European Hygienic Equipment
Design Group) certified.

JEC ZL series lobe pump design combines unique front-loading

mechanical seal, O-ring and lip seal for pumping efficiency. The
pump’s bi-wing rotor provides easy maintenance, clean ability,
gentle product handling and dependability.

The ZL series pump is available with any connection type

designated and may be mounted with the inlet/outlet connections
in a horizontal or vertical orientation.

The pump should be coupled to an electric-motor assembly

properly specified to give the desired performance for the
required application.

Safety Instructions

Think Safety
1. Do not operate the pump with safety devices (if fitted) or guards removed.

2. Only qualified personnel should operate this pump.

3. Do not start the pump until all personnel are clear.

4. Never attempt to carry out service or maintenance procedures whilst the pump is in
motion.

5. Do not run the pump with the Front Cover removed.

6. Before any work is carried out on the pump, the power to the prime mover must be
isolated and suitable precautions taken to ensure the power is not restored until it is safe
to do so.

7. Ensure that no internal pressure exists within the pumping chamber or inter-connecting
pipe-work before carrying out any maintenance work.

2
 Table of Contents
Description ------------------------------------------------------------------------- 2

Safety Instructions ---------------------------------------------------------------- 2

Table of Contents ----------------------------------------------------------------- 3

Description of pump ------------------------------------------------------------- 4

Principle of Operation
Direction of Rotation

Technical Information ------------------------------------------------------------ 5

Specifications
Materials of constructions
Shaft Seals

Pump Dimensions ---------------------------------------------------------------- 6

Installation -------------------------------------------------------------------------- 7
Unpacking
Installing
Start-up Check List

Recommended Preventive Maintenance ----------------------------------- 8

Recommended Seal Maintenance
Elastomer Inspection
Lubrication
Periodic Maintenance
Recommended Torque Values

Maintenance ----------------------------------------------------------------------- 9 - 14
General
Pump housing Disassembly
Seal Assembly
Pump housing Assembly
Rotor clearance
Rotor timing

Shaft and Bearing Replacement --------------------------------------------- 15 - 16

Tool Required
Gearbox Disassembly
Gearbox Assembly

Trouble Shooting ----------------------------------------------------------------- 17

Section View ---------------------------------------------------------------------- 18

Parts List --------------------------------------------------------------------------- 19

3
 Description of Pump

Principle of Operation
The pumps are of the positive displacement rotary type with lobed rotors. The volume at the
inlet increases when the rotors rotate and the product is drawn into the pump. It is then
transported in the space between the lobes and the periphery of the pump housing to the
discharge side. The volume between the rotors is reduced here and the product is forced out
through the outlet.

Direction of Rotation
The direction of flow is dictated by the direction of rotation of the drive shaft. Reversing the
direction of rotation will reverse the flow direction. Top and bottom shaft drive

Figure 1

4
 Technical Information

Specifications

Standard Max. Max.

Displacement Connection Differential Speed
ZL Model No. Size Pressure
Series Int US
Liters/ Gal/ Gal/
rev 100rev 100rev mm Inches BAR PSI Rev/min
ZL110-005-20 0.05 1.10 1.32 25 1 20 300 1000
100 ZL115-012-12 0.12 2.64 3.17 40 1.5 12 175 800
ZL120-021-08 0.21 4.61 5.54 50 2 8 115 800
ZL220-041-12 0.41 9.01 10.81 50 2 12 175 700
200
ZL225-062-08 0.62 13.63 16.35 65 2.5 8 115 700
ZL330-102-12 1.02 22.42 26.90 80 3 12 175 600
300
ZL340-144-08 1.44 31.65 37.98 100 4 8 115 600
ZL440-227-12 2.27 49.90 59.88 100 4 12 175 500
400
ZL450-334-08 3.34 73.42 88.10 150 5 8 115 500

Materials of Construction
Primary Product contact AISI 316
Gear Box Cast Iron
Stainless steel/option
Gasket (O-ring) NBR
EPDM, VITON, PTFE /option
Shaft Sleeve Ceramic
Surface Finish for Product Contact surfaces (Ra) 0.8 μm/32 μin
Surface Finish for Shaft Sleeve surfaces (Ra) 0.1 μm/4 μin

Shaft Seals
Seal Types Mechanical Seal
Double mechanical Seal, O-ring, Lip Seal /option
Mechanical Seal Material Tungsten Carbide
Silicon Carbide/option
O-ring Material NBR
EPDM, VITON/option
Lip Seal Material PTFE

5
 Pump Dimensions

Dimension
Model no.
A B C D E F G I K L M N X Y Z

ZL110-005-20 255 152 200 218 96 84 134 12 141 77 109 23 30 8 9

ZL115-012-12 264 152 200 222 96 84 134 12 141 77 109 23 30 8 9

ZL120-021-08 284 152 200 230 96 84 134 12 141 77 109 23 30 8 9

264
ZL220-041-12 386 188
.5
305 129 132 180 15 185 101 143 32 50 10 11
264
ZL225-062-08 406 188
.5
315 129 132 180 15 185 101 143 32 50 10 11
347 243 128
ZL330-102-12 533 242
.5
390 159 160 242 22
.5 .5
186 45 60 14 13
347 243 128
ZL340-144-08 546 242
.5
402 159 160 242 22
.5 .5
186 45 60 14 13

ZL440-227-12 674 324 458 506 199 210 320 30 324 170 247 55 87 14 15

ZL450-334-08 709 324 458 523 199 210 320 30 324 170 247 55 87 14 15

Dimensions in millimeters

Dimension B1 Weight Volume

Model no.
Ports ISO BS DIN SMS FLANGE KG CBM
ZL110-005-20 1” 20 26 30 20 30 12 0.01
ZL115-012-12 1 ½” 20 26 30 20 30 19 0.01
ZL120-021-08 2” 22 26 30 20 30 23 0.01
ZL220-034-12 2” 26 26 35 24 35 45 0.03
ZL225-052-08 2 ½” 26 26 35 24 35 51 0.03
ZL330-102-12 3” 28 26 40 24 40 91 0.06
ZL340-144-08 4” 28 26 40 24 40 103 0.06
ZL440-227-12 4” 28 26 54 35 54 180 0.15
ZL450-334-08 5” 28 26 54 35 54 210 0.15

6
 Installation

Unpacking
Check the contents and all wrapping when unpacking the pump. Carefully inspect for any
damage that may have occurred during shipping. Immediately report any damage to the
carrier. Leave the protective caps over the pump inlet and outlet connections until you are
ready to install the pump.

Installing
Prior to actually installing the pump, ensure that:

- Power sources, such as electric, air and hydraulic should be installed by trained and
authorized personnel only. Installations must comply with all applicable codes and
standards.

- Close to liquid source to keep suction piping to a minimize head loss due to friction.

- Low in relation to product supply to provide maximum static suction head.

- The pump and drive will be accessible for inspection, cleaning and maintenance.

- Adequate ventilation is provided for drive cooling.

Start-up Check List

1. Check that piping and pump are clean and free of foreign material, such as welding slag,
gaskets, etc. Do not use pump to flush system.

2. Check to see that pump and drive are tight and leak-free. Where possible, check system
with “non-hazardous” fluid.

3. Check that all guards are in place and secure.

4. See that all valves are open on discharge system, and that free flow path is open to
destination.

5. See that all valves are open on inlet side, and that fluid can reach pump.

6. Check direction of pump and drive rotation (jogging is recommended).

7. Start pump drive. Where possible, start at slow speed, or jog.

“Do not rotate the shafts with the cover removed. Rotors and
housing could be damaged.”

7
 Recommended Preventive Maintenance

Recommended Seal Maintenance

Visually inspect the shaft seal regularly for leakage.

Annually replace the shaft seal under normal conditions.

Replace the shaft seal as often as required under severe conditions (abrasive product, dry
running, etc…).

Elastomer Inspection
Inspect all elastomers when performing pump maintenance. We recommend replacing
elastomers (O-rings) during shaft seal replacements.

Lubrication
The pump will be supplied oil filled with Omala 150 of the Shell or equivalent. The oil level
should be maintained in the center of the oil window on the side of the gear housing. The oil
should be primal changed after 200 hours of operation and be changed every 4000 hours
under normal conditions.

Periodic Maintenance
Periodically inspect the pump housing, cover and rotors for any signs of wear or damage. If
wear is present this could be a sign of over pressurization, incorrect or bearing wear.

Recommended Torque values:

*Front cover nuts 100 ft-lbs *Rotor bolts 60 ft-lbs
*Gear/rotor housing bolts 100 ft-lbs *Gear lock nuts 140 ft-lbs

8
 Maintenance

General

WARNING The pump, when operating, can cause SEVERE INJURY to anyone in
contact with the rotating parts. Turn off the energy source and LOCK OUT
before dismantling pump. Use a locking device for which only the person doing the
dismantling has the key.

Tool Required:
- Special tool for rotor bolt - 1/2” plastic dowel
- Spanner - Soft Hammer
- Allen wrench set - Feeler gauge
- Torque wrench - Depth Micrometer

Pump Housing Disassembly

Drain all products from the pump head prior to disassembly. The pump head may be isolated
with inlet and outlet valves. Disconnect the suction and discharge piping from the pump.

Reference numbers are listed in part list refer to the section view on pages 18-19

Loosen and remove the four-cover dome nuts

(26) from the cover. Remove the cover (4). If it
is stuck, tap on the cover with a soft hammer.
Remove the cover O-ring (42).

Figure 2

Remove rotor-retaining bolts (6). Use the special

tool supplied with pump. To remove rotor-retaining
bolts, place the plastic dowel between the rotors as
shown in Figure 3. Turn the first rotor bolt (6)
counter- clockwise.

Figure 3

9
 Remove the rotor bolts and spring washers.

Figure 4

The rotors can be removed from the pump housing

(3) by pulling straight. If it is stuck tight, alternately
tap on the back of the inlet and outlet ports with soft
hammer as shown in Figure 8. Handle the rotors with
care to avoid damage. Figure 5

The seal ring can be replaced without remove

the pump housing (3) and any pipe line by
pulling straight.

Figure 6

Remove the four housing nuts (25) 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 shims (50) 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

10
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.

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 easy removed from rotor use

such like a small screw driver (-) or a pin as shown
in Figure 13.

Figure 13

Pull the sea seal ring off from the rotor (5).

Figure 14

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

11
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 (3) 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 (3) onto the gear box (1) and secure the four housing set nuts
(6)

When install the ceramic shaft sleeve onto the pump

shaft fit care in to pin as shown in Figure 18.

Assemble a rotor onto shaft engaging the shallow

groove with small spline in rotor and seal side first in to
the shaft.

Figure 18

Place the plastic dowel between the rotors as shown

in Figure 10. Tighten the first rotor bolt with a special
tool 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 proper torque.

Install the cover (4) and tighten the dome nuts (26).

Figure 19

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.

12
Rotor Clearance

CAUTION 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 &

Back Face Front Bottom
Face

Rotor to
Rotor

Radial
Sides

Figure 20

Standard Rotor Clearances

Radial Top & Rotor to
Model Back Face Front Face Radial Sides
Bottom Rotor
ZL110-005-20 0.15 0.15 0.15 0.12 0.12
ZL115-012-12 0.15 0.15 0.27 0.12 0.15
ZL120-021-08 0.15 0.15 0.3 0.15 0.15
ZL220-040-12 0.2 0.2 0.3 0.15 0.2
ZL225-062-08 0.2 0.2 0.4 0.2 0.2
ZL330-102-12 0.3 0.3 0.4 0.2 0.3
ZL340-144-08 0.3 0.3 0.5 0.3 0.3
ZL440-227-12 0.45 0.45 0.55 0.3 0.4
ZL450-334-08 0.45 0.45 0.7 0.45 0.4
Rotor clearances in millimeters

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 plate (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 filler 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.

13
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. Te 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

(20) 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.

14
 Shaft and Bearing Replacement

WARNING The pump, when operating, can cause SEVERE INJURY to anyone in
contact with the rotating parts. Turn off the energy source and LOCK OUT
before dismantling pump. Use a locking device for which only the person doing the
dismantling has the key.

Tools required for Bearing Replacement

- Liquid gasket
- Bearing heater

Gearbox Disassembly

Remove the oil drain plug (36) and drain the oil.

Remove the gear box cover bolts (33) from the rear cover (2).

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 (28).

Remove the rear cover oil seal (22) from the rear cover and discard.

Remove the liquid or paper gasket from the rear cover.

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).

Pull the two gears (18) off the pump shafts. Remove the gear keys (14).

Remove the front bearing set bolt (32).

Place the gearbox (1), wet end down, on an arbor press.

Protect the shaft ends with a wood block and press the drive and idle shaft out of the gearbox.

Remove the rear bearing assemblies (17) from the rear cover (2) and discard.

Heat the front bearing (16) on the drive and idle shafts until they expand and drop off.
Remove the bearing from the pump shafts.

15
Gearbox Assembly

Place the rotor (5) on a flat surface. Lubricate the front and rear bearing areas of the drive
and idle shafts with oil. Insert the shafts into the rotor splines, for support. Heat the front
bearing to 250oF. Place the bearing over the shaft, after the bearing cooled.

Lubricate and install the front bearing oil seals (21).

Place the gearbox over the shafts.

Position the gearbox (1) with wet end up. Insert the front bearing with shaft perpendicularly to
the gearbox. There should be a tight sliding fit between the gearbox and the bearing outer
rings. Press or soft hammer could be used.

Place the front bearing set bolt and washer and tightened.

Lubricate and install the rear cover oil seal (22) into the rear cover (2).

Rear bearing assemblies (17) insert into the rear cover. There should be tight sliding fit.

Heat the inner ring of the rear bearing to 250oF. Place the inner ring over the shafts with the
flange end sliding over the shaft first.

Place the spacer (13) over the shafts.

Lubricate the gear area of the shaft and the face of the lock washer, with oil.

Position both shaft gear keys (14) to the 12:00 position.

Place the gear, lock washer (20) and lock nut (19) onto the shafts and hand tighten.

After the gears are installed, turn the shafts to make sure they turn freely and that the rotors
(5) are timed correctly.

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.

Measure rolling torque with no load on bearing. Set the torque wrench to zero while rotating,
this will remove the load caused by the lip seal.

The bearing locknut should be tightened until the rolling torque on the shaft measures the
values in the following table.

Tighten the locknut (19) on the idle shaft, following the previous steps.
Measure the shaft endplay to be sure it is zero. If the endplay is not zero, repeat the
tightening steps. To repeat these steps, the locknut (19) will have to be backed off and the
bearing will have to be tapped to remove the loadings.
Install the liquid gasket to rear cover (2) and mount the rear cover assembly over the drive
shaft extension onto the gearbox.

Fill the oil reservoir with oil to the middle of the oil wind

16
 Troubleshooting

Problem Cause Solution

Pump not turning Interruption of electrical power Reset circuit breaker, check
fuses.
Key sheared or missing. Replace.
Coupler or belts are not connected. Replace or adjust.
Pump shaft or gears sheared. Replace.
Wrong rotation. Reverse.
Relief valve not properly adjusted. Adjust valve.

Pump not priming Valve closed in suction lines. Open valve.

Suction line clogged or restricted. Clear suction line.
Air leak in connections or seal. Repair leak.
Pump speed too slow. Increase sped.
Suction line does not remain flooded. Install foot valve.
Air lock. Bleed suction line.
Excessive clearances in pump. Replace out of tolerance parts
NIPA low. Increase suction pressure

Insufficient flow Speed too low. Adjust speed as required.

Air leak. Repair leak.

Noisy operation Cavitations. Increase NIPA.

Viscous product. Slow pump, reduce product.
High vapor pressure, high temp. Reduce temperature.
Leaks in piping or pump. Repair leaks.
Dissolved gas in product. Reduce discharge pressure.
Mechanical noise. Check tolerances.
Excessive weight from piping, Support piping.
pump body distorted.
Excessive discharge pressure. Reduce discharge pressure.
Worn bearing. Replace bearing.
Worn gears. Replace gears
Rotor-to-rotor contact. Time rotors, replace twisted
shafts, replace worn gears.

Pump overloads Viscosity of product higher than Reduce pump speed, increase
expected. piping size,
Higher pressure than expected. Reduce pump speed, increase
pipe size,

Play between gears Worn gear teeth. Replace gear.

Gear loose on shaft. Inspect gear key, keyway and
shaft. If all are undamaged,
retighten the gear retaining nut.
Check for backlash.

NIPA: Net Inlet Pressure Available at Pump

17
Section view

Figure 22

18
 Part list

Item Part Item Part

Description Q’ty Description Q’ty
No. No. No. No.
1 Gear Box 1 36 Oil Plug, Window/Drain 3
2 Gear Box Cover 1 37 Stop Pin, Double Seal 6
3 Rotor Housing 1 38 Seal, Single Mech. 2
4 Front Cover 1 39 Seal, Double Mech. 2
5 Rotor 2 40 Seal, Double O-ring 2
6 Rotor Bolt 2 41 Seal, Lip Seal, PTFE 2
7 Main Shaft 1 42 O-ring, Front Cover 1
8 Idle Shaft 1 43 O-ring, Rotor Housing 2
9 Shaft Sleeve, Ceramic 2 44 O-ring, Rotor 2
10 Stop Pin, Shaft 2 45 O-ring, Double Seal 2
11 Stop Pin, Rotor 4 46 O-ring, Rotor Bolt 2
12 Spacer, Bearing 2 47 O-ring, BRG. Retainer 2
13 Spacer, Gear 2 48 Nipple, Flush Water 2
14 Key, Gear 2 49 Plug, Gear Box 6
15 Key, Motor 1 50 Shim, Rotor Housing 2
16 Bearing, Front 2 51 Heating Jacket 2
17 Bearing, Rear 2 52 Name Plate 1
18 Timing Gear 2
19 Lock Nut 2
20 Bearing Retainer 2
21 Front Oil Seal 2
22 Rear Oil Seal 1
23 Retainer, Lip Seal
24 Stud, Rotor Housing 4
25 Nut, Stud 4
26 Dome Nut 4
27 Dowel Pin, Rotor Housing 2
28 Dowel Pin, Gear Box 2
29 Spring Washer, Rotor Bolt 2
30 Foot 1
31 Wrench Bolt, Foot 4
32 Wrench Bolt, Retainer 6
33 Wrench Bolt, G. B. Cover 4
34 Flat Washer, Seal 6
35 Relief Valve 1

19