CONTENTS

I. ABOUT THE ZINGER HORIZONTAL MEDIA MILL 2

A. Concept 2
B. Principle of Operation 2

II. ZINGER MEDIA MILL SPECIFICATIONS 3

III. INSTALLATION 4
A. Receiving the Mill 4
B. Installing the Mill 4
1. Foundation 4
2. Electrical 5
3. Cooling Water 6
4. Product Connections 6

IV. OPERATION 7
A. Function Controls 7
1. Lubricator Pump 7
2. Product Pump 7
3. Mill 7
B. System Monitors 8
1. Operator Control Station 8
2. External Monitors 8
C. Media 9
1. Media Charge 9
2. Media Charging Procedure 10
3. Media Level Maintenance 11
D. Start-up Procedure 12
E. Stopping Procedure 13
F. Restart Procedure 14
G. Cleaning Procedure 15

V. MAINTENANCE 16
A. Vessel Inspection and Media Removal 16
B. Rotor Removal 17
C. Rotor Reinstallation 17
D. Vessel Reinstallation 18
E. Motor Bearing Lubrication 18
F. Mechanical Seal Replacement 19
G. Belt Drive Maintenance 20
H. Common Replacement Parts 21

VI. ASSEMBLY DRAWINGS 22

1
I. ABOUT THE ZINGER HORIZONTAL MEDIA MILL

A. Concept

Patented technology is used in this completely sealed, self-contained grinding and

dispersion mill to produce superior “fine” and “ultra-fine” dispersions. The Zinger uses
an exclusive rotor and vessel design to aggressively accelerate media. This patented
design requires less energy and allows the use of smaller media to do the work. Low to
extremely high viscosity slurries are easily and efficiently processed using this rotor and
vessel design.

B. Principle of Operation

Pre-mixed liquid/solid slurry is continuously pumped into a pressure-sealed horizontal

chamber. The chamber contains grinding media and several rotating, shaft-mounted
rotors. The rotors are manufactured with specially designed vanes to propel the media
and slurry with a controlled force for maximum impact and reduced “hydraulic packing”.
Media is aggressively accelerated at high velocity, through the slurry, toward the vessel
walls; consequently, impacting, shearing, and reducing the size of the solid slurry
particles. Typically, a single pass through the mill yields micron to submicron-sized
dispersion.

2
II. ZINGER MEDIA MILL SPECIFICATIONS

Top Assembly Number: 485495

Model: LV-40X

Approximate Weight: 3000 Lb.

Empty Vessel Volume: 10 Gal. (38 Liters)

Rotor Speed: 247 to 989 RPM

Main Drive Motor: 50 HP

Length: 62-1/4 Inches

Width: 40-1/4 Inches

Height: 70-1/2 Inches

Pump Output: 0 to 6.2 GPM, 50 PSIG

Pump Motor: 1.5 HP

Hydraulic Power Unit Output: 1.9 Gal/Min, 70 PSIG

Hydraulic Power Unit Motor: 1 HP

3
III. INSTALLATION

A. Receiving the Mill

Check the components delivered against the packing list before accepting the
shipment. If a unit arrives in a damaged condition or if there are missing items, show a
notation of damage or shortage on the receipt that you give the carrier or his
representative. Next, request the carrier’s representative to show a similar notation on
the freight bill. Failure to do so may negate the legal basis for a claim, since the carrier
will then have possession of a clear delivery receipt.

B. Installing the Mill

1. Foundation

a. All Zinger Horizontal Media Mills are completely assembled and test-operated
(without grinding media load) by the manufacturer prior to shipping.

b. The Zinger should be installed on a flat, firm surface with a normal loading capacity
of 500 pounds per square foot or greater. It is recommended that the unit be
anchored in place using the mounting holes located at its base. If the mounting
surface is not flat, shims should be placed appropriately under the base of the unit
before tightening the mounting bolts. It may be desirable to raise the entire unit by
1/2” to 1” off the mounting surface, use shims to level the mill, and then fill the void
area with a non-shrink grout to ensure a flat and level installation.

Note: Tightening the mounting bolts on an uneven surface may distort the mill
structure, which could cause damage to the mill drive and mechanical seal.

c. Both the Product Pump Assembly and Seal Barrier Fluid Re-circulator should be
installed on a location optimal to the production process. Close proximity to the mill
is desirable since both units will be interconnected to the mill for fluid and electrical
transfer.

Refer to drawings 485495, 485497, 482434, and 483921 on the Assembly

Drawings section for installation and piping information.

4
2. Electrical

a. Control instrumentations and wirings are provided in conformance with the National
Electrical Manufacturer’s Association (NEMA) code requirements. The electrical
components for the Zinger comply with the standards for hazardous environment
(NEMA 7, Class I, Division 1, Group D). All electrical wiring at the customer’s site
should be in accordance with all applicable electrical codes. The owner assumes
full responsibility for all electrical connections done at their facility.

b. An operator control station mounted on the Zinger unit houses the function controls
for the mill, product pump, and seal lubricator. The control station also houses a
display window, which indicates the values for certain monitoring parameters. See
System Monitors.

c. In addition, (3) process parameters are controlled using interlock switching to

automatically shut off the mill and product pump motors once certain control limits
are breached. These parameters are as follows:

1) Seal Barrier Fluid Pressure - Automatic shut off is initiated once the seal fluid
pressure falls below the preset minimum (50 PSIG). This ensures a positive
differential of the seal barrier fluid pressure versus the internal vessel pressure.

2) Product Temperature - Automatic shut off is initiated once the maximum

temperature (set by user) is exceeded; therefore, preventing a thermal condition
that may be harmful to the product being processed.

3) Product Pressure - Automatic shut off is initiated once the maximum vessel
pressure is exceeded; therefore, preventing product from being forced into the
mechanical seal. Maximum vessel pressure is factory-set at 50 PSIG.

d. Fault lights are located on the electrical control station. The fault lights indicate
which condition(s) have triggered the interlock shut off. The indicator will remain lit
until the fault condition has been corrected. Once the fault condition has been
resolved, the indicator light needs be manually reset. See Function Controls
section.

Refer to drawing 485498 on the Assembly Drawings section for more information
regarding the electrical assembly.

5
3. Cooling Water

a. The Zinger Horizontal Media Mills comes equipped with a water-jacketed chamber
and discharge end for optimum product temperature control. All on-board coolant
lines are pre-plumbed by the manufacturer with an accessible supply and return
lines.

b. The inlet and outlet ports for the cooling water are located on the base of the mill
(opposite the operator side). Both inlet and outlet ports are 3/4 NPT female pipe
threads.

c. The water outlet line should be connected directly to the drain or chiller, and must
remain unrestricted at all times.

Refer to drawing 483920 on the Assembly Drawings section for more information
regarding the Cooling Water Piping Assembly.

4. Product Connections

a. The Product Piping Assembly includes a Teflon-lined, flexible hose with braided
stainless steel sheath for connection to the Product Pump Assembly. The hose and
the product piping connections on the mill are set up with stainless steel, sanitary
fittings that feature a “quick disconnect” design.

b. The customer provides the necessary plumbing from their product pre-mix tank to
the product inlet (1-1/2 NPT female thread) of the Product Pump Assembly.

c. The product outlet is located at the end of the mill chamber. The customer provides
all necessary plumbing from the product outlet (1 NPT female thread) to their
storage tank.

Note: It is recommended that the product outlet of the mill be connected back to the
pre-mix tank. This allows the product to continuously circulate the mill for a
more uniform dispersion.

Refer to drawings 482434 and 479605 on the Assembly Drawings section for more
information regarding the Product Piping Assembly.

6
IV. OPERATION

A. Function Controls

1. Lubricator Pump

a. START - Turns on the Hydraulic Power Unit; seal barrier fluid starts circulating.

b. STOP - Turns off the Hydraulic Power Unit; circulation of seal barrier fluid is
stopped.

c. RESET (LOW SEAL PRESSURE) - Initializes the automatic interlock switching after
a seal fluid pressure fault has been corrected.

2. Product Pump

a. START - Turns on the Product Pump Motor; product feeding is started.

b. STOP - Turns off the Product Pump Motor; product feeding is stopped.

c. SPEED - A dial on the control panel that regulates the product pump speed (RPM).
Turn clockwise to increase speed and counterclockwise to decrease speed.

Note: Increasing the product pump speed produces greater product flow rate. Make
certain that the product pressure does not exceed the allowable chamber
pressure (50 PSIG).

d. RESET (HIGH PRODUCT PRESS) - Initializes the automatic interlock switching

after a product pressure fault has been corrected.

e. RESET (HIGH PRODUCT TEMP) - Initializes the automatic interlock switching after
a product temperature fault has been corrected.

3. Mill

a. START - Turns on the Mill Motor; rotor shaft rotation is started.

b. STOP - Turns off the Mill Motor; rotor shaft rotation is stopped.

c. SPEED - A dial on the control panel that regulates the rotor shaft speed (RPM).
Turn clockwise to increase speed and counterclockwise to decrease speed.

d. JOG - Powers the Mill Motor, turning the rotor shaft while it is depressed. Releasing
the push button instantly switches off the Mill Motor. This is primarily used to
provide short bursts of mill rotation.

Refer to drawings 485498, 382376, and 485501 on the Assembly Drawings section
for more information regarding the Operator Control Station.

7
B. System Monitors

1. Operator Control Station

a. MAIN AMP - Displayed on the control box window, this value indicates the amount
of electrical current (AMPS) flowing through the Mill Motor. A low AMP reading
could be an indication that the mill is not exerting optimal work into the product;
otherwise, a high AMP reading is an indication that the Mill Motor is exerting too
much work. Excessive Media loads or a clogged screen usually causes high AMP
readings.

Note: The AMP reading on the Zinger Mill must never exceed the full load AMP
rating specified on the motor nameplate. The warranty on this Mill will not be
valid should this amperage be exceeded.

b. MAIN RPM - Displayed on the control box window, this value indicates the (main)
mill rotor shaft speed in Revolutions Per Minute (RPM). The Zinger Mill has an
operating speed of 989 RPM at 60 Hertz.

c. PUMP RPM - Displayed on the control station box window, this value indicates the
pump motor shaft speed in Revolutions Per Minute (RPM). The Product Pump
Assembly is set to produce a flow rate of 6.2 Gallons Per Minute (GPM) at 359
RPM.

d. PRODUCT TEMP - Displayed on the control station box window, this value
indicates the temperature of product that is flowing through the discharge outlet. A
thermometer on the outlet tube is integrated into the electrical system for
temperature reading, and also for automatic system shut off once the maximum
product temperature (set by user) is exceeded.

Refer to drawings 382376, 479605 and 482434 on the Assembly Drawings section
for more information regarding the Operator Control Station Monitors.

2. External Monitors

a. PRODUCT PRESSURE - Integrated into the product inlet, this gauge indicates the
product pressure inside the mill vessel. This gauge is incorporated into the electrical
system for automatic system shut off once the maximum vessel pressure (50 PSIG)
is exceeded.

b. WATER TEMP IN - Located on the operator side of the mill base, this gauge
continuously monitors the temperature of the cooling water being supplied to the
mill.

c. WATER TEMP OUT - Located next to the “WATER TEMP IN”, this gauge
continuously monitors the temperature of the cooling water exiting the mill.

Refer to drawings 485498, 482434, and 483920 on the Assembly Drawings section
for more information regarding the External Monitors.

8
C. Media

1. Media Charge

a. The Zinger Mill was designed to operate with a Media charge in the range of 70% to
80% of the vessel’s empty volume. To assist in grinding media selection and
determining correct media charge, refer to the table below:
MEDIA CHARGE TO OCCUPY 80% OF VESSEL VOLUME

MEDIA GLASS MODIFIED HIGH ALUMINA ZIRCONIA ZIRCONIA CAST STEEL

TYPE ALUMINA DENSITY OXIDE SILICATE OXIDE STEEL BALLS
GLASS SHOT

DENSITY 2.5 g/cc 2.8 g/cc 3.0 g/cc 3.5 g/cc 3.8 g/cc 5.4 g/cc 7.1 g/cc 7.8 g/cc

CHARGE 71.6 lbs 80.3 lbs 83.1 lbs 109.6 lbs 110.0 lbs 154.4 lbs 200.7 lbs 217.9 lbs
AMOUNT

For Reference: Empty Vessel Volume: 38 Liters, 80% of Empty Vessel Volume: 30.4 Liters

Note: Charging Media with densities greater than 3.5 g/cc may require reduced
rotor speeds.

b. It recommended that a media charge of 70% (of the empty vessel volume) be
initially used until the mill operator is familiar with the Zinger and how it functions
with the customer’s specific application.

c. Once the operator is comfortable with mill operation, and it has been determined
that the product can be processed with the ammeter (AMPS) readings at or below
the full load rating of the main drive motor, additions to the media charge may be
made.

d. Higher media loading sometimes results in increased milling efficiency; however,

caution should be exercised when increasing the media charge.

e. When increasing the media charge, it is recommended that additions of only 1.5%
to 2% be made at a time. The resulting product should also be monitored with every
addition.

f. Although the Zinger is designed to operate with a media charge of up to 80%,

optimum performance can be obtained using a charge of under 80% while also
increasing the useful life of the internal components of the mill.

Note: Media charges in excess of 80% (of the empty vessel volume) may cause
rapid wear of the mill and media, which may eventually damage the mill.

9
2. Media Charging Procedure

a. Disconnect the product outlet plumbing from the mill by removing the (1-1/2”)
sanitary clamp that holds it to the outlet tube. Set the Teflon gasket, in between
fittings, on a safe location.

b. Remove the (3”) sanitary clamp that locks the outlet tube to the discharge head.
Carefully lift the outlet tube/discharge screen assembly off the discharge head and
set it aside to a safe location, being careful not to damage the product thermometer.
Set the Teflon gasket, located in between fittings, in a safe location.

c. Media can now be poured directly into the mill (wet or dry) through the discharge
screen opening.

d. While charging media, it may be necessary to “JOG” (Ref: Function Controls) the
mill. This evenly dispenses the media inside the vessel; therefore, making room for
the remainder of the charge. Only short bursts of “JOG” is needed to sufficiently
distribute the media. During a “JOG” procedure, the opening must be covered to
prevent media from being thrown out from the vessel.

e. When the vessel is completely charged, make sure that the seat of the discharge
fitting is clean from any residual media, and then install the Teflon gasket on the
seat. Carefully lower the outlet tube/discharge screen assembly through the
opening, keeping it as vertical and centered as possible. The assembly will have to
be gently forced through the media until it seated properly on its mating gasket and
fitting. Once the outlet tube/discharge screen assembly is properly seated, reinstall
the (3”) sanitary clamp.

f. Align the mating seats on the outlet tube and the product outlet plumbing. Insert the
Teflon gasket in between seats, and then secure the connection by reinstalling the
(1-1/2”) sanitary clamp.

g. It is recommended that a fresh media charge be rinsed by flushing the mill with a
solvent that is compatible with the product. Solvent can be circulated to the mill for 5
to 10 minutes for rinsing. A mill “JOG” procedure during the rinsing process will
assist in conditioning a fresh media charge; however, extended rotor operation
should be avoided in order to minimize mill and media wear.

h. We recommend rinsing a fresh media charge by flushing the mill with a solvent
compatible with your first product. Several gallons of solvent can be recirculated
through the mill for 5 or 10 minutes for rinsing. Jogging the mill during the rinsing
process will assist in conditioning the new media charge, however, extended rotor
operation should be avoided in order to minimize mill and media wear.

Note: Measure and record the media level after rinsing (Ref: Media Level
Maintenance). Media levels should be measured and recorded after the initial
media charge and after every subsequent addition to provide a basis for
future comparison.

Refer to drawing 482434 on the Assembly Drawings section for more information
regarding the mill components for media charging.

10
3. Media Level Maintenance

a. For an accurate media level reading, the mill must be clean and free of product and
clean-up materials.

b. Residual solvent may be drained from the mill through the ball valve located on the
discharge head (opposite the discharge outlet). Also, an adequate container needs
to be positioned under the valve to avoid spillage.

c. Proceed to open the ball valve. At first, liquid may flow slowly due to residual
product in between the valve and grinding chamber. Do not leave the valve
unattended as liquid flow may suddenly increase. Close the valve after draining.

d. Media level is checked through the same port used for charging. Remove the outlet
tube/discharge screen assembly from the discharge head in the same way as when
charging (Ref: Media Charging Procedure).

e. Insert a tape measure through the opening, keeping it as vertical and as close to the
edge of the opening as possible, until it touches the grinding media. Read the
measurement from the end of the tape (media level) to the top edge of the
discharge screen seat.

f. Record this measurement and then compare with previous readings to determine
the media level.

g. Calculate the volume necessary to bring media up to the desired charge level.
Incrementally add media to the mill, checking the level after every addition, until
media is at the proper level.

h. Reinstall the outlet tube/discharge screen assembly in the same way as described
in the media charging section (Ref: Media Charging Procedure).

Note: Proper media level is a factor in maintaining the milling efficiency of the
Zinger. For maximum efficiency and repeatable performance, it is
recommended that media levels be checked and adjusted weekly.

Refer to drawing 482434 on the Assembly Drawings section for more information
regarding the mill components for media level maintenance.

11
D. Start-up Procedure

Note: The Zinger Mill requires pre-mixed product as feed material. The pre-mix must
be as homogenous as possible, and free of lumps and large agglomerates.
High-speed dispersion by a “Cowles”-type impeller blade is recommended for a
good pre-mix. Also, mild agitation during the mill processing is recommended to
maintain suspension.

1. Make sure that all electrical components are functional and properly connected.
Check all interconnecting piping to and from the Zinger Mill.

2. Activate the cooling water to be supplied to the vessel jacket. Adjust the water flow
rate to attain the desired product discharge temperature. Make sure that the water
outlet line is not restricted.

3. Start the hydraulic unit, by pushing the Lubricator Pump “START” button (Ref:
Function Controls), to initiate the circulation of the seal barrier fluid. Make sure that
the seal fluid circulating on the mechanical seal has a pressure above 70 PSIG.

4. Set the product pump speed to “0” (Ref: Function Controls) and then start the feed
pump. Slowly set the pump speed to a low setting. If necessary, prime the pump with
a compatible, low-viscosity fluid.

Note: If the vessel develops a rapid increase in pressure, reduce the pump speed to
maintain a pressure below 50 PSIG, and then “JOG” the mill to about 5 to 10
seconds to clear the product passage. If pressure continues to increase, stop
the product feed pump and inspect for possible blockages in the product feed
and discharge plumbing.

5. With product steadily exiting the mill discharge, start the mill motor by pushing the Mill
“START” button (Ref: Function Controls). Adjust the “MILL SPEED” dial according to
the product being processed and the media type used. Always keep the “AMPS”
reading just below the full load amp value. Adjust the product pump speed to provide
a more optimal flow of product if needed.

6. Recirculate the product processed from the mill back to the pre-mix tank until uniform
dispersion appears at the discharge port. Continue processing until the required
product grind is attained.

7. Follow the procedures for stopping the mill (Ref: Stopping Procedure).

Refer to drawings 485495, 485498, 483920, 483921, and 482434 on the Assembly
Drawings section for more information regarding the mill components for start-up.

12
E. Stopping Procedure

1. Begin the system shut off by gradually setting the “PUMP SPEED” control dial to “0”
(Ref: Function Controls), and then push the Product Pump “STOP” button.

2. Next, gradually set the “MILL SPEED” control dial to “0” (Ref: Function Controls), and
then push the Mill “STOP” button.

3. After shutting down both the pump and mill motors, push the Circulating Pump
“STOP” button (Ref: Function Controls).

4. Proceed to turn off the cooling water supplied to the vessel. Follow the procedures for
cleaning the mill (Ref: Cleaning Procedure).

5. If the mill is to remain idle for an extended period (ex: overnight) and cleaning is not
required:

a. Close the valve on the product feed tank.

b. Close the product discharge valve or plug the discharge opening to prevent the
curing of product in the process piping.

c. Cover any top process containers to avoid product contamination.

Refer to drawings 482434 and 483920 on the Assembly Drawings section for more
information regarding the mill components for stopping.

13
F. Restart Procedure

1. Open the valve on the product feed tank, and then open the product discharge valve
(or unplug the discharge opening).

2. Start the hydraulic power unit by pushing the Circulating Pump “START” button on the
operator control panel (Ref: Function Controls).

3. Loosen the media inside the vessel by pushing the Mill “JOG” button for a few
seconds. Do this until a constant AMPS reading below the full load rating is attained.

Note: Do not start the Product Feed Pump until media has been loosened.

4. Turn on the feed pump by pushing the Product Pump “START” button. Gradually set
the “PUMP SPEED” control dial to the normal operating speed.

5. Turn on the mill rotors by pushing the Mill “START” button. Gradually set the “MILL
SPEED” control dial to the normal operating speed.

6. Activate the cooling water to be supplied to the vessel jacket. Adjust the water flow
rate to attain the desired product discharge temperature. Readjustments might be
necessary after a few minutes of operation.

7. Observe the product discharge, and verify that the product flows as was previously
established.

8. It is recommended a product sample be collected for grind check and approval every
time the mill is restarted.

Refer to drawing 482434 and 483920 on the Assembly Drawings section for more
information regarding the mill components for restarting.

14
G. Cleaning Procedure

1. Remove the most amount of product from the vessel as ideally possible.

2. Prepare a mixture of vehicle (product) and compatible solvent that is approximately

equal to 6 times the volume of product retained in the vessel. The liquid mixture
should have enough vehicle to raise the viscosity for pumping (500-1000 cps), and to
lubricate the media.

Note: Volume of Product Retained = Empty Volume - 0.6 (Media Volume)

3. Wash down the side of the cleanup container with solvent, and then add
approximately 25% of the vehicle and solvent mixture into the tank.

4. Start the feed pump and mill (Ref: Start-up Procedure) and then circulate the mixture
through the mill at a medium pumping speed. Continue circulating until the mixture is
thoroughly saturated with the product, and then discharge the mixture into a separate
container.

Note: Reduced rotor speeds may be necessary during cleanup.

5. Repeat steps 3 and 4 until only about 25% of the vehicle-solvent mixture remains.

6. Add the final 25% of the vehicle-solvent mixture, and then pump it straight through the
mill. Discharge the final mixture without recirculating.

Refer to drawing 482434 on the Assembly Drawings section for more information
regarding the mill components for cleanup.

15
V. MAINTENANCE

Note: Shut off and lock out all electrical power supplied to the Zinger Mill prior to any
maintenance procedure. Contact with operating voltage may be fatal.

A. Vessel Inspection and Media Removal

1. Place an appropriate sized container under the stainless steel catch pan spout.

2. Drain any residual cleanup materials from the vessel through the drain valve
underneath the product discharge screen.

3. Remove the drain valve assembly by loosening the (3”) sanitary fitting that holds it in
place. A large quantity of wet grinding media will drop from this outlet. Set the Teflon
gasket, in between fittings, on a safe location.

4. Remove the (3”) sanitary clamp that locks the outlet tube to the discharge head.
Carefully lift the outlet tube/discharge screen assembly off the discharge head and set
it aside to a safe location, being careful not to damage the product thermometer. Set
the Teflon gasket, located in between fittings, in a safe location.

5. Disconnect the cooling water lines by detaching the “quick disconnect” couplers
located at the side of the mill base.

6. Remove the fasteners that secure the vessel flange to the mill head.

7. Insert (2) fasteners in the threaded holes provided on the vessel flange. Evenly torque
both fasteners to pull the vessel away from the mill head.

Note: Residual media and liquids will pour out on the catch pan as the vessel
separates from the mill head.

8. Pull the vessel away from the mill head; support rods running on the rollers will aid
this action. An internal retainer prevents the vessel from moving too far.

9. Remaining grinding media can now be manually removed from the vessel and rotors.

Refer to drawings 485495, 482434, 483920, and 472480 on the Assembly Drawings
section for more information regarding the mill components for vessel inspection and
media removal.

16
B. Rotor Removal

1. Follow the procedure for media removal (Ref: Vessel Inspection and Media Removal).

2. Make sure that all media has been removed from the vessel and rotors.

3. Note the arrangement of the rotors on the shaft. The rotors will have to be reinstalled
in the same manner.

4. Temporarily install an adequate device to support the end of the rotor shaft.

Note: Force or impact applied on an unsupported shaft may severely damage the
Zinger Mill. Never pull or hammer the rotors with the shaft unsupported.

5. Remove the spring pins that hold the each rotor to the shaft. If necessary, loosen the
rotors by lightly tapping with a non-metallic hammer.

6. Remove the temporary shaft support, and then slide each rotor off the shaft.

Note: Rotors may have sharp edges. It is recommended that protective gloves be
used when handling the rotors.

Refer to drawing 483922 on the Assembly Drawings section for more information
regarding the mill components for rotor removal.

C. Rotor Reinstallation

1. Wipe the rotor and shaft with a clean cloth to ensure that all surfaces are free from
product, media, and other foreign materials.

2. Successively slide the (8) single rotors on the shaft, aligning the pinholes on the rotor
hubs with the pinholes on the shaft. Next, slide the end rotor to the shaft, aligning the
pinhole on the rotor hub with the pinhole on the shaft.

Note: The rotors must be mounted with the vane side facing the mill head, and with
the rotor vanes offset from the vanes of the preceding rotor.

3. Install the spring pins to secure the rotors into position. Never apply force or
hammering without ample support to the rotor shaft.

Refer to drawing 483922 on the Assembly Drawings section for more information
regarding the mill components for rotor reinstallation.

17
D. Vessel Reinstallation

1. Remove the (2) fasteners, used to separate the vessel to the mill head, from the
tapped holes in the vessel flange.

2. Wipe the mounting flange on the seal housing and the mating flange on the vessel
with a clean cloth to remove any product, media, or any foreign materials.

3. Inspect the o-ring on the seal housing for wear or damage, and replace if necessary.
Lubricate the o-ring with compatible grease and then install.

4. Push the vessel back toward the mill head. Slowly slide the vessel over the seal-
housing flange until the vessel flange comes in contact with the mill head.

5. Install the fasteners through the clearance holes on the vessel flange and into the
threaded holes on the mill head.

6. Alternately tighten the fasteners in a crossing manner.

7. Reconnect the cooling water lines by reattaching the “quick disconnect” couplers to its
mating fitting located at the side of the mill base. Make sure that the hoses connect to
the correct ports.

8. Align the mating seats on the drain valve and the discharge head. Insert the Teflon
gasket in between seats, and then secure the connection by reinstalling the (3”)
sanitary clamp.

9. Follow the necessary steps for charging media (Ref: Media Charging Procedure).

Refer to drawings 472480, 483922, 483920, and 482434 on the Assembly Drawings
section for more information regarding the mill components for vessel reinstallation.

E. Motor Bearing Lubrication

1. Remove the grease relief plugs located on the opposite side of the grease fittings.

2. Using a grease gun, add about 1.5 cubic inches of Polyrex EM (Exxon Mobil) oil or
any equivalent grease through the grease fittings.

Note: Excessive lubrication causes overheating, which shortens the bearing life.

3. Let the motor to run for about 2 hours to allow any excess grease to drain from the
grease relief ports.

4. Reinstall the grease relief plugs.

5. Under normal conditions, lubricate the motor bearings every 2 years.

Refer to drawing 483905 on the Assembly Drawings section for more information
regarding the mill motor.

18
F. Mechanical Seal Replacement

1. Follow the necessary procedures for removing the mill rotors (Ref: Rotor Removal).

2. Disconnect the seal fluid lines on the mechanical seal. Have a container ready to
accommodate fluid spillage.

3. Loosen the setscrews that secure the bushing sub-assembly to the shaft. Uninstall
the bushing sub-assembly and wear washer.

Note: Setting clips are usually shipped loose with the Zinger unit. If available, reinstall
the setting clips to the mechanical seal to ease the disassembly process.

4. Loosen the clamp ring setscrews that lock the seal to the shaft.

5. Remove the flat head screws (and o-rings) that secure the bearing housing to the mill
head.

6. Carefully slide the seal and seal housing assembly from the shaft. Set the product
inlet o-ring on a safe location.

7. Disassemble the existing seal from the housing.

8. Proceed to install the replacement seal to the seal housing.

9. Carefully slide the seal and housing assembly back to the shaft.

10. Secure the seal housing to the mill head by reinstalling the flat head screws (with o-
rings). Make sure that the o-ring between the product inlet tube and seal housing is
properly installed.

11. Secure the seal into the shaft by evenly tightening the setscrews on the clamp ring.

12. Check the alignment and rotation of the mechanical seal, and then remove the setting
clips that come with the replacement seal.

Note: Failure to remove the setting clips will cause damage to the mechanical seal.

13. Reinstall the wear washer and bushing sub-assembly to the shaft. Tighten the
setscrews on the bushing sub-assembly to secure it into position.

14. Reconnect the seal fluid lines. Make certain that the fluid suction and return lines are
on the correct ports.

15. Reinstall the mill rotors (Ref: Rotor Reinstallation).

Refer to drawings 483922, 483921, 482434, and 183506 on the Assembly Drawings
section for more information regarding the mill components for mechanical seal
replacement.

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G. Belt Drive Maintenance

Note: Satisfactory belt life depends on the proper alignment of belts and sheaves.
With the belts tensioned, the sheaves should be aligned within 1/16”.

1. V-belt replacement procedure:

a. Make certain that all electrical power to the machine is turned off.

b. Remove the appropriate covers from the mill head/frame assembly.

c. Slacken the belts by adjusting the fasteners on the top land of the motor plate.

d. Remove the bearing housing on the rear side of the mill head.

e. Proceed to replace the V-belts.

f. Slip the bearing housing over the rear bearing and then reassemble it to the mill
head.

g. Apply tension to the V-belts by evenly adjusting the fasteners on the top land of the
motor plate.

h. Reinstall the removed covers on the mill head/base assembly.

2. V-belt tensioning guidelines:

a. The ideal tension for a V-belt drive is the lowest tension at which it will not slip under
peak load conditions.

b. Frequently check the tension on a new drive during the first two days of operation.

c. Keep the belts and sheaves free from foreign materials that may cause slip.

d. Periodically inspect the tension on the V-belt drive.

e. Over-tensioning shortens the life of the belt and bearing.

f. If a V-belt slipping occurs--tighten it.

Refer to drawings 483905 and 483922 on the Assembly Drawings section for more
information regarding the mill components for belt maintenance.

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H. Common Replacement Parts

ZINGER HORIZONTAL MEDIA MILL

MODEL: LV-40
TOP ASSEMBLY: 485495

Description Part Number Quantity

Drive Belt 646433 5 Ea

Rotor 372556 8 Ea

Rotor (End) 372557 1 Ea

Spring Pin 649839 9 Ea

Wear Washer 275471 1 Ea

Discharge Screen 381021 1 Ea

Mechanical Seal 673043 1 Ea

Bearing (Front) 680035 1 Ea

Bearing (Rear) 680034 1 Ea

Gasket Kit (LV-20/40) 680348 1 Ea

O-ring Kit (LV-20/40) 680405 1 Ea

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VI. ASSEMBLY DRAWINGS

Description: Drawing Number:

Top Assembly 485495

Zinger Media Mill Model LV-40 485497

Electrical Assembly 485498

Operator Control Station 382376

Electrical Schematic 485501

Drive Assembly 483905

Vessel Assembly 472480

Shaft/Bearing/Rotor Assembly 483922

Product Piping Assembly 482434

Lube/Seal Piping Assembly 483921

Coolant Piping Assembly 483920

Product Pump Assembly 479605

Hydraulic Power Unit 285588

Wear Washer Instruction Sheet 183506

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