GASER SUPER-MAXI User manual

HAMBURGER FORMING MACHINE
Mod. SUPER-MAXI

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INDEX
1. INDUSTRIAS GASER .............................................................................................4
2. EC DECLARATION OF CONFORMITY ..................................................................5
3. HYGIENE CERTIFICATE ........................................................................................6
4. INTRODUCTION.....................................................................................................7
4.1 Safety................................................................................................................7
4.2 Hygiene.............................................................................................................7
5. TECHNICAL SPECIFICATIONS..............................................................................8
6. RECEIPT AND START-UP ......................................................................................9
6.1 Receipt..............................................................................................................9
6.2 Start-up..............................................................................................................9
6.3 Notes...............................................................................................................10
6.3.1 Changing patty shape..............................................................................10
6.3.2 Compacting..............................................................................................11
6.3.3 Paper dispenser.......................................................................................11
7. CLEANING............................................................................................................13
8. MAINTENANCE ....................................................................................................18
9. TROUBLESHOOTING...........................................................................................19
10. GENERAL DIAGRAM..........................................................................................21
10.1 Overview ......................................................................................................21
10.2 Chassis overview ..........................................................................................22
10.3 Former shaft overview...................................................................................24
1 Overview complete former bearing housing...................................................25
10.3.1.1 Mechanical fuse overview...............................................................26
10.4 Tank overview................................................................................................27
10.4 Overview complete tank bearing housing .................................................29
10.4.2 Gear motor.............................................................................................30
10.4.3 Connecting rod overview........................................................................31
10.6 General overview ..........................................................................................33
10.6.1 Electrical cabinet overview.....................................................................35
10.6 Air pump overview.....................................................................................36
10.7 Belt overview.................................................................................................37

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10.8 Safety mechanism overview..........................................................................38
10.9 Ejector overview............................................................................................39
10.10, Paper dispenser overview..........................................................................41
11. HAMBURGER FORMERS...................................................................................42
11.1 Standard shape..............................................................................................42
11.2 Single shape (on request)..............................................................................42
11.3 Mini-double shapes (on request) ...................................................................42
11.4 Special shapes (on request)..........................................................................43
13. WIRING DIAGRAMS...........................................................................................44

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1. INDUSTRIAS GASER
Since its foundation in 1969, INDUSTRIAS GASER has specialised in manufacturing a range of
stainless-steel machinery for the meat industry.
Since 1985 we have constantly developed technology for GASER-brand hamburger-forming
machines, developing a distinctive system based on a SIMPLER, MORE EFFECTIVE AND MORE
ECONOMICAL TECHNIQUE.
In the 1990s, INDUSTRIAS GASER expanded into markets in various countries around the world, and
not just in the hamburger sector.
We are aware that our work would be of no value without the trust of our existing clients and partners
or the interest shown by those who wish to join them.
We thank them all.
INDUSTRIAS GASER GASER EUROPA
Salt, Girona, SPAIN L’viv, UKRAINE
INDUSTRIAS GASER Ctra, Bescanó, 15, Pol. Torre Mirona 17190 Salt (Girona) - Spain
Tel. [phone] | Fax [phone] | Whatsapp: [phone]
email: [email protected]
GASER EUROPA вул.Б.Лепкого,1 81160 смт.Щирець Пустомитівский р-н Львівська область
Украіна - Ukraine
Tel. [phone]
Fax [phone]
email: [e-mail]
For more information about the company and its products: www.gaser.com

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2. EC DECLARATION OF CONFORMITY
We declare under our responsibility that the following machine:
Brand: GASER
Model: SUPER-MAXI
Serial no.
Year of construction:
is in conformity with the following regulations
UNE-EN ISO 12100:2012
UNE-EN ISO 14120:2016
UNE-EN ISO 14121-1:2008
UNE-EN 60204-1:2007 60204-1:2007 CORR. 2010 60204-1:2007/A1:2009
UNE-EN ISO 13849-1:2008/AC:2009
and is in conformity with the following directives
Machinery directive: 2006/42/CE
Low voltage directive: 2014/35/UE
Electromagnetic compatibility directive: 2014/30/UE
It is forbidden to make any change or modification to the machine without the prior written permission
of our technical department. Use of the machine in these conditions could cause accidents, in which
case INDUSTRIAS GASER S.L. accepts no liability for the improper use of the machine.
Salt,
CARLOS GARGANTA SERRAMITJA
TECHNICAL DIRECTOR INDUSTRIAS GASER S.L.

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3. HYGIENE CERTIFICATE
We declare the machine:
Brand: GASER
Model: SUPER-MAXI
Serial no.
Year of construction:
is in conformity with the following regulations
Regulation (EC) 1935/2004, materials and articles in contact with food, repealing Directives
80/590/EEC and 89/109/EEC.
This means that all of the types of steel and plastic from which the machine is constructed and which
are in contact with the meat comply with the hygiene rules and regulations in force.
* Plastic material: polyethylene terephthalate (PETP), white, density 1.37 g/cm3,
Manufactured in accordance with DIN 50014.
* Stainless steel: AISI 304, manufactured in accordance with European regulations EN-10088,
Chemical composition: C≤0.07% Si≤0.75% Mn≤2% Cr=18-19% Ni=8-10%
Salt,
CARLOS GARGANTA SERRAMITJA
TECHNICAL DIRECTOR INDUSTRIAS GASER S.L.

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4. INTRODUCTION
Before using or handling the machine, you must read this manual carefully.
The instructions in this document are, whenever possible, accompanied by illustrations to help with
understanding of how to start, use and clean the machine.
This manual is subject to amendment.
4.1 Safety
It is forbidden to make any change or modification to the machine without the prior written permission
of our technical department. Use of the machine in these conditions could cause accidents, in which
case INDUSTRIAS GASER S.L. accepts no liability for improper use of the machine.
The machine has been designed for use with food products and must be used in the way described in
this manual. Any use other than the specified one will involve risk for the user and for the machine.
INDUSTRIAS GASER S.L. accepts no liability either for damage to the machine or personal injury or
injury to third parties that this use might cause.
4.2 Hygiene
All of the materials used in the manufacture of the machine and which come into contact with food
comply with Regulation 1935/2004. Consequently, the machine has the CE mark.
It is not recommended to use detergents containing chlorine, any of its derivatives or any other product
that could damage the construction materials of the machine.

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5. TECHNICAL SPECIFICATIONS
1. Table-top machine
2. Can be dismantled for ease of cleaning
3. Easy maintenance
4. Made from stainless steel and plastics suitable for use with food
5. Frequency inverter
6. Atmospheric-air patty ejection
7. Capable of placing paper on one side
8. Patented system
9. 800 m output belt
10. Produces round hamburgers of 50 to 120 mm diameter and other shapes (these must be
concentric with a circle and of the measurements mentioned above)
11. Maximum thickness 25 mm with interchangeable moulds
12. Produces up to 55 patties/minute and 110 patties per minute with double moulds
13. Capacity: 20 kg mixture
14. Motor power (single-phase) 1,250 W, 220 V, 50 Hz.
15. Dimensions of assembled machine: 650 × 450 × 800 mm
16. Machine weight: 85 kg

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6. RECEIPT AND START-UP
6.1 Receipt
When you receive the machine, you must first check that it is in perfect conditions, without any
damage, dents or knocks.
If there is any problem, we advise you notify the distributor or INDUSTRIAS GASER S.L. directly.
6.2 Start-up
1. These machines essentially comprise 5 parts: chassis, former unit, tank unit, ejector unit and belt.
Image 1. Main parts
2. It is important that when the machine starts working, it is completely clean to ensure it works
properly.
3. The SUPER-MAXI model hamburger former runs on single phase 220 V 50 Hz electrical current.
4. When working on the machine, whether for maintenance, cleaning or any other situation, the
machine must be fully disconnected from the electricity supply.
5. Put the ON-OFF switch (Pos. 14, electrical cabinet overview) in the ON position. The red and
green pilot lights will come on. This switch is located in the electrical cabinet.
6. Put the MANUAL-AUTOMATIC switch (Pos. 17, electrical cabinet overview) in the AUTOMATIC
position. This switch is located in the electrical cabinet. In MANUAL the former plate only turns if

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the START button is kept depressed (Pos. 2, general overview). This function is for adjustment
and testing.
7. Press the START button (Pos. 2, general overview) and adjust the speed using the speed control
(Pos. 3, general overview) from 1 to 10. The red pilot light will go off and the green one will remain
illuminated.
8. The most appropriate setting on the speed control is between 3 and 8.
9. To stop the machine, press the emergency stop (Pos. 1, various overview); the red pilot light will
light up. At the end, set the 6-A switch to the OFF position.
10. To start production, first ensure there is nothing in the meat tank (Pos. 8, tank overview) as this
could cause irreparable damage.
11. With the machine stopped, fill the meat tank (Pos. 8, tank overview) to the level of its maximum
capacity marked on the sticker on the outside.
12. The appropriate mix must be cold, between 0 and 4 degrees centigrade, it must not have excess
water and must not have sinew or fibres of over 1 cm in length.
13. If you have to load the machine with the mix several times, it is better to do so before the mix in
the machine has been used up. This will prevent the patties from coming out incomplete.
6.3 Notes
6.3.1 Changing patty shape
To change the shape of the patties, first disassemble the machine as shown in point “7 CLEANING”.
Once the machine has been disassembled, you can change the former plate and reassemble the
machine by reversing the order of disassembly.

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6.3.2 Compacting
The machine leaves the factory set up for standard compacting.
However, as all mixtures are different, for the first 3 or 4 patties, we recommend using the manual
button and checking whether they come out with too much or too little mixture. If they do, the
compacting will have to be adjusted.
To adjust the amount of mixture, use the adjustment nut (Pos. 6, chassis overview) which is below the
former plate (Pos. 2, former shaft overview), by turning it by hand clockwise to increase the amount of
mixture and anti-clockwise to reduce it (see red arrow in image 2). Underneath this nut there is an
o-ring (Pos. 20, chassis overview) to fix it in the appropriate location.
Image 2, Adjusting compacting
6.3.3 Paper dispenser
If the paper dispenser is used (Pos. 12, overview), it must be adjusted differently for the different types
of patties so that is centred on them.
To place the paper on the patties, the paper dispenser must be set up with appropriate paper disks
and the metal plate (Pos. 7, Paper dispenser overview) placed on the top to weigh down the paper
discs.
Insert the paper discs so that the waxed side faces downwards in the dispenser, as this is the side that
will be in contact with the mixture.

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To centre the paper on the patties, the position of the dispenser can be adjusted by moving the length
and height control (Pos. 5, Paper dispenser overview) and the thickness control (Pos. 3, Paper
dispenser overview).
The height of the dispenser above the belt at its low position must be 5 mm less than the thickness of
the patties. For example: with 12 mm-thick patties, the distance between the dispenser and the mesh
belt must be 7 mm.
Image 3,Adjusting paper dispenser height

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7. CLEANING
When you have finished using the machine, it must be cleaned. To do so, follow these steps:
1. First of all, ensure the machine is fully disconnected from the power supply. Next, disassemble the
machine.
2. Remove the blower tube (Pos. 17, chassis overview). Only the part in contact with the ejector unit
(Pos. 11, overview).
Image 4, Disconnecting blower tube
3. Disconnect the counterweight (Pos. 11, chassis overview) from the ejector unit.
Image 5, Disconnecting the counterweight from the ejector unit

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4. Remove the ejector unit (Pos. 11, overview) and the paper dispenser unit (Pos. 12, overview).
Before doing so, remove the “safety screw” (Pos. 7, ejector overview) from the former unit.
Image 6, Extracting safety screw
Image 7, Ejector unit removal
Image 8, Dispenser unit removal
5. Remove the tank (Pos. 8, tank overview). To do this, lift the cover of the tank (Pos. 17, tank
overview), extract the safety mechanism guide tube (Pos. 9, safety mechanism overview) and
then turn the tank clockwise.
Image 9, Lifting lid
Image 10, Safety guide tube
Image 11, Turning tank anti-clockwise
Image 12, Removing tank

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6. Remove the vanes (Pos. 9, tank overview), loosening the shaft screw (Pos. 13, tank overview) by
turning it clockwise.
Image 13, Removing safety screw
Image 14, Removing vanes
7. Extract the 3 knobs (Pos. 14, tank overview) from the machine and remove the protection (Pos. 8,
various overview).
Image 15, Tank base knobs
Image 16, Lifting ramp supporting knob
Image 17, Removing protection
8. Next disassemble the base of the tank (Pos. 3, tank overview). The knurled nut must first be
removed from the former plate (Pos. 6, former shaft overview).
Image 18. Removing former plate knurled nut
Image 19, Removing tank base

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9. Remove the former plate (Pos. 2, former shaft overview).
Image 20. Removing former unit
10. Remove the compactor unit (Pos. 4. overview).
Image 21. Removing compactor unit
11. Finally, remove the conveyor belt unit (Pos. 6, overview) so that you can clean the belt (Pos. 18,
belt overview). To be able to remove it, first extract the two knobs (Pos. 13 chassis overview) that
hold it in place. Once removed from the machine, fold the belt chassis to remove the belt.
Image 22, Removing knobs
Image 23, Disconnecting belt from power

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Image 24, Conveyor belt unit removal
Image 25, Conveyor belt removal
12. Clean the disassembled components (except for the conveyor belt) with pressurised water and dry
well, if possible with air. Clean the machine’s chassis with a damp cloth. Never clean it with
pressurised water.
Image 26. Machine ready for cleaning

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8. MAINTENANCE
This machine requires virtually no maintenance. Even so, there are a few details that must be taken
into consideration.
1. Periodically check the condition of all moving parts: retainers, seals, gears and bearings.
2. Periodically check the condition of the gear motor.
3. Periodically check the condition of the safety elements.
4. Periodically check the general condition of the machine.

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9. TROUBLESHOOTING
The table below lists the problems that might occur with the machine, their potential causes and how to solve them.
Problem
Cause
Solution
The machine does not start
Machine unplugged
See manual “6.2. Start-up”, point XX
The safety elements have not been fitted
Fit safety elements.
The machine starts and stops because the speed
control blocks.
The mixture is too hard.
The mixture should be softer.
The machine is incorrectly assembled.
Check the assembly of any parts that have been
handled.
The machine still does not start.
Safety sensors have come lose.
Calibrate security sensors
Electrical connections or components in poor
condition
See manual “8. Maintenance”, point 4.
The former plate does not fill.
The mixture is too hard.
The mixture should be softer.
The compacting is poorly adjusted.
Adjust compacting with adjustment nut.
The patty does not stay in the former plate.
The compacting is poorly adjusted.
Adjust the compacting using the adjuster nut.
The mixture is too soft or warm.
Correct the flaw.
Excess mixture is wasted.
The compacting is poorly adjusted.
Adjust the compacting using the adjuster nut.
The machine is incorrectly assembled.
Check the assembly of any parts that have been
handled.
The paper is not centred on the patties.
The patties do not easily fall away.
The mixture has too much sinew.
The paper dispenser is poorly adjusted.
The mixture is too soft.
Move the dispenser to the appropriate location.

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The ejector does not eject the patties.
The ejector shaft and guides do not have enough oil.
Oil the points indicated in the instructions.
The ejector counterweight is not attached.
Hook on the counterweight.
The air tube is not connected.
Check whether the air tube is properly connected.
The machine does not place the paper.
The paper dispenser height is incorrect.
Adjust the height of the dispenser using the piece.
The mixture used does not stick to the paper.
Check whether the paper sticks to the patties.
The metal plate is not on top of the paper discs.
Put the plate in place.