ZUMEX Z-450 User manual

MANUAL DE INSTRUCCIONES - INSTRUCTION MANUAL 1/28
MANUAL DE INSTRUCCIONES
INSTRUCTION MANUAL
ESPACIO PARA LA ETIQUETA DE IDENTIFICACIÓN
235.0132.009 MANUAL Z- 450 380 V. 50 Hz 3F
POLIGONO INDUSTRIAL MONCADA III CALLE DEL MOLÍ, Nº2
46113 MONCADA (VALENCIA) - ESPAÑA - TELEFONO: 34-961 301 251/FAX:[phone]
Internet: www.zumex.com E-mail: [e-mail]

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GENERAL INDEX
1 TECHNICAL CHARACTERISTICS............................................................................................. Pg. 29
2.GENERAL ASSEMBLY INSTRUCTIONS………........................................................................
Pg. 29
2.1 LIFT ASSEMBLY.............................................................................................................. Pg. 3
2.2 HOPPER ASSEMBLY…………………………………………………………….....…………. Pg. 32
2.3 RETURN CHANNEL ASSEMBLY……………………………………………………….……. Pg. 32
2.4 TRANSPORTER ASSEMBLY…………………………………………………………….……
Pg. 33
3 INSTRUCTIONS FOR USE…………………………………………………………..............……… Pg. 35
3.1 OPERATION …………………………………………………………………....……………… Pg. 35
3.1.1 TURNING ON THE MACHINE……………......................................…………... Pg. 35
3.1.2 ADJUSTMENT ………………………………..................................…………….
Pg. 36
3.1.3 SAFETY ………………………………………..........................................……… Pg. 36
3.2 CLEANING ……………………………………………………………………………………... Pg. 37
3.2.1 DISASSEMBLING THE BLADE AND THE BLADE SUPPORT...................... Pg. 38
3.2.2 FILTER DISASSEMBLY……………………………………………….…............ Pg. 38
3.2.3 DISASSEMBLY OF THE PEEL OUTLET ……………………............………… Pg. 39
3.3 MAINTENANCE …………………………...……………………………..................……… Pg. 39
3.3.1 Z-45 JUICER HEAD UNIT ……………………………………………………. Pg. 4
3.3.2 Z-45 TRANSPORTER UNIT ……………............................………………… Pg. 44
3.3.3 Z-45 LIFTING UNIT ……………………………………………...................… Pg. 45
4 JUICER CHANGE KIT INSTRUCTIONS ……………………………….......…………………… Pg. 45
5 SCHEMATIC DIAGRAM OF THE MACHINE........................................................................ Pg. 47
6 TABLE OF PROGRAMMING VARIABLES ……….…………………………………..………….
Pg. 49
7 REPLACEMENT AND PARTS LIST ………………………………………………….......………
Pg. 5
8 BRIEF PREVENTIVE MAINTENANCE TABLE ………………………………....……………… Pg. 52
9 GUARANTEE…………………………....………………………………………………………….. Pg. 53

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1. TECHNICAL CHARACTERISTICS.
MODEL Z-45 (43.13 . 9)
JUICING ACTION GEAR MOTOR 15 r.p.m i=4 2. (CV)
FILTERING ACTION GEAR MOTOR 15 r.p.m i=1 .25 (CV)
LIFT ACTION GEAR MOTOR 15 r.p.m i=4 .25 (CV)
TRANSPORTER ACTION GEAR MOTOR 15 r.p.m i=4 .25 (CV)
POWER INSTALLED 2.75 (CV)  2. 1(Kw)
EXIT JUICE 1 ¼ GAS
SWITCH OPTIONS ON / OFF / CLEAN
VOLTAGE THREE PHASE 38 V
FREQUENCY 5 Hz
SAFETY SCREEN PRESENCE DETECTOR
JUICING SPEED
15 ORANGES / MINUTE 9 CAV.
134 ORANGES / MINUTE 8 CAV.
117 ORANGES / MINUTE 7 CAV.
2. GENERAL ASSEMBLY INSTRUCTIONS.
The Zumex Z-45 unit comes in two wooden containers which contain all of the pieces
for complete assembly. In order to remove the juicer, undo the upper clamping ring and the
lower clamp of the machine's frame.

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2.1. LIFT ASSEMBLY.
Screw the lift supports into the lift as indicated in Figures 1 and 2 using the screws and
washers which are located there.
Figure 1
Figure 2
Once the lift supports are mounted, raise the unit onto its supports and level it by
loosening the rubber support's lock nuts with a ratchet wrench.

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Once the hoses are hooked up as indicated in the above figure, connect the hose pins as
shown.
The hoses should be connected by the thread of the pins, while taking care to line up the
numbering of the two pieces which make up each pair: 1-1, 2-2 and 3-3.

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2.2. HOPPER ASSEMBLY.
Mount the fruit-holding hopper on the lift as shown in Figure 4. Attach the hopper to the
lift with the six lock nuts and washers which are located on the lift.
Figure 4
2.3. RETURN CHANNEL ASSEMBLY.
Secure the fruit return channel to the hopper, as shown, with a screw and its
corresponding lock nut and washers. Attach the return to the lift support, which is located at the
back of the return channel, with the screws, lock nuts and washers which are located there.

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2.4. TRANSPORTER ASSEMBLY.
Connect the transporter unit as shown in the figures, using the screws located on the
case of the machine and the transporter unit.
First, mount the transporter support and secure it to the case with the four screws that
are located on it (DIN-933 M8x2 mm + washer), as shown in Figure 4. Afterwards, mount the
transporter on its support and secure it with the screws provided with the transporter set, as
shown in Figure 5.
Figure 4
Figure 5
After securing all of the screws, make sure that the mouths of the feeding tube are perfectly
positioned and flat on the feeding belt . The transporter support has rails so that this step can be
accomplished. If the mouths not aligned properly, there will be a bad feed to the machine and an
excessive return of oranges.

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Position the lifting unit sideways to the juicing head as shown in Figure 6. Make sure that
the lift scoop does not touch the upper part of the transporter.
Figure 6
CAUTION !!
(*) AFTER ALL OF THESE STEPS HAVE BEEN CARRIED OUT, THE ONLY OTHER THING
TO DO IS TO FILL THE CASE WITH APPROXIMATELY 4.5 LITRES OF SAE 80W-90 OIL UP
TO THE RED POINT OF THE LEVEL CHECKER

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3. INSTRUCTIONS FOR USE.
3.1. OPERATION.
3.1.1. TURNING ON THE MACHINE.
Once the machine has been assembled by following the steps described above, the
position of the extractors should be checked to make sure that they are in accordance with the
following figure . They should be positioned so that they rub neither at the sides nor with the
bottom of the slots of the hubs.
1. – The machine may now be turned on by switching the main on/off switch which is located on
the left side of the control panel. This will show whether the emergency push buttons on the
control panel or the button located on the right support of the juicing unit had been pushed.
2. – Push the “ I “ SQUEEZER button .
EXPRIMIDOR
SQUEEZER
3º.- Push the “ I “ CONVEYOR button .
ALIMENTADOR
CONVEYOR
The machine should now be operating perfectly.

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CAUTION !!
MAKE SURE THAT ALL OF THE PARTS TURN ACCORDING TO THE DIAGRAM BELOW.
IF THEY DO NOT, THEN CHANGE THE PHASE ON THE CONTROL PANEL.
Once the parts are checked to make sure that they are turning in the right direction, the
machine is ready to be used.
3.1.2. ADJUSTMENT.
This machine is equipped with a potentiometer located on the control panel, which
allows the user to adjust the speed by which the orange is raised by the lift. This adjustment is
made according to the size of the orange so that the
number of oranges that are returned will be at a
minimum.
VELOCIDAD ELEV.
SPEED LIFTER
3.1.3. SAFETY.
If at any moment it is necessary to stop the machine-feeder immediately, either of the red
emergency stop buttons may be pushed, one of which is located in the locker and the other on
the front of the machine's frame.
The machine is also equipped with a presence detector for the frontal protector, which in
the event that it is removed, the machine will immediately stop. In both cases, once the machine
stops, in order to restart it the machine must be restarted with the initial settings.
Potentiomet
er

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3.2. CLEANING.
The machine may be cleaned with pressurised water in the juicing area. In order to
facilitate cleaning in the juicing area, remove the frontal protector. Once the protecting cover
has been removed, turn the CLEANING switch to the ON position.
Do not use substances which contain chlorine or chlorine compounds for cleaning as
these substances produce corrosion marks on the stainless steel. Use of quaternary ammonias
is recommended for cleaning. ("Bayclin" or "Dimanin A" by BAYER, "Oasis-498" or "Oasis-144
by HENKLE, "Quacide MC7" or Dectocide SB5" KLEENCARE HIGIENE – BETELGEUX).
CAUTION !!
THE MACHINE IS COMPLETELY OPERABLE IN THIS POSITION BUT IT SHOULD ONLY BE
IN THIS STATE WHEN CLEANING AS THE MACHINE IS DEVOID OF ALL SAFETY
MEASURES. THEREFORE, OPERATING THE MACHINE WHILE IN THIS STATE SHOULD
BE CARRIED OUT WITH THE UTMOST CARE.
LIMPIEZA
CLEANING
MARCHA
START
PARO
STOP
A B
When the switch on the control panel is set at the cleaning position, its red light will start
blinking, indicating the lack of safety of the machine. One the machine has been cleaned IT IS
OBLIGATORY TO PUT THE MACHINE BACK INTO A SAFE STATE by turning the
CLEANING switch to the left.
CAUTION !
A
B

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BEFORE HANDLING AND
DISASSEMBLING ANY PA
RT, FOR EXAMPLE THE
PRESSING
UNITS OR THE BLADES, THE MACHINE SHOULD BE DISCONNECTED FROM ALL
POWER SOURCES.
3.2.1. DISASSEMBLING THE BLADE AND THE BLADE SUPPORT.
Unscrew and remove the plastic securing
knob along with the washer and remove the blade in
the direction of the arrow, as indicated in the figure.
Take out the blade in the direction indicated.
CAUTION !
HANDLE THE BLADE WITH CARE. BEFORE
HANDLING THE BLADE THE MACHINE SHOULD
BE DISCONNECTED FROM ALL POWER
SOURCES.
3.2.2. DISASSEMBLY OF THE FILTER .
Take the cap off of the filter by unscrewing the three knobs. Ref. 13.23 . . If it is
necessary to remove the rotating pulp extractor, remove the screw and washer located at the
centre of the axle and take it straight out.
If removal of the strainer is required for more thorough cleaning, unscrew the four screws
which secure the filter clamp to the body of the case and proceed with its removal. When
reinstalling this piece into its proper place, soak the threads of the screws with VMQ silicone.

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CAUTION !
BEFORE HANDLING AND DISASSEMBLING ANY PART, FOR EXAMPLE THE PRESSING
UNITS OR THE BLADES, THE MACHINE SHOULD BE DISCONNECTED FROM ALL
POWER SOURCES.
3.2.3. DISASSEMBLY OF THE PEEL OUTLET.
Unscrew the two plastic knobs Ref. 2 .33 6. 1, then take the peel outlet straight out
(place the new knobs in their respective positions to keep them from being lost).
Perform the same operation on the peel outlet located on the other side of the juicer (on
the side of the transporter).
3.3. MAINTENANCE.
Preventive maintenance of the Zumex Z-45 Juicer is divided into three different areas of
the machine :
1. – Z-45 Juicer Head Unit ( Ref. 24. 22. ).
2. – Z-45 Transporter Unit ( Ref. 24. 21. 2 ).
3. – Z-45 Lifting Unit ( Ref. 24. 2 . 1 ).
NOTE : For any other eventuality contact your ZUMEX distributor.

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CAUTION !
BEFORE HANDLING OR DISASSEMBLING ANY PART, FOR EXAMPLE THE PRESSING
UNITS OR THE BLADES, THE MACHINE SHOULD BE DISCONNECTED FROM ALL
POWER SOURCES.
3.3.1. HEAD UNIT OF THE Z450 JUICER REF. 24.022.000.
A) OIL CHANGE ( Fig. 7 ) : The oil in the case should be changed every six months with a 5-
litre container of BESLUX GEAR-ATOX 22 (22 cST).
CAUTION !
BEFORE HANDLING OR DISASSEMBLING ANY PART, THE MACHINE SHOULD BE
DISCONNECTED FROM ALL POWER SOURCES.
Procedure : Unscrew the upper fill cap, then unscrew the lower draining cap located below the
level indicator. Make sure a container with a capacity of 4.5 litres or more is placed under the
draining outlet for collecting the used oil. Allow all of the oil to drain from the case, then check
the state of the silicone gasket Ref. 171.2618. 2 and remove the traces of the teflon band
which are found in the draining cap, screwing in the new one in a clockwise direction. After the
new draining cap is in place begin filling from the upper part of the machine.
Figure 7 Figure 8
B) REAR AXLE SUPPORTS ( Fig. 8 ) : Lubrication of the four rear UCFC 2 8 ball bearing units
should be carried out every six months using lithium grease with mineral oil as its base. Make
sure that the sealing caps for the ball bearings are not dried out or that the cast boxes are not
broken. Once the ball bearings have been lubricated, connect the machine for 5 minutes to test
that their temperature is not too high.
Procedure : Connect the output nozzle of a manual grease pump to the greaser of the ball
bearing unit.

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C) PRESSING UNIT AND BLADE AXLES ( Fig. 9 and 10 ) : The pressing unit-carrier axles of
the retainers should be changed every two years. Periodically (every 6 months) check the state
of the retainer lips Ref. 17 . 3. 1. Check the blade sharpness every 3 days Ref.
2 . 92. 2.
Procedure : In order to facilitate disassembly, remove the peg, then remove the retainer of the
ball bearing box ( by its outside ring ), then replace. Ref. 17 . 3. 1.
Figure 9
Figure 10
D) FILTER BRUSH AND FILTER RETAINER ( Fig. 11, 12 and 13 ) : The filter brush should be
changed every three months Ref. 2 . 98. 2 . The wear on this part depends on how the
machine is used. Therefore, this amount of time refers to average use.
Procedure : In order to disassemble the filter blade unit, remove the three knobs Ref.
13.23 . taking off the juice tray cover by loosening the screws which loosens the brush
clamps. Proceed with replacement and then put the clamps back as they were.

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Figure 11
Figure 12
The retainer should be changed every 2 years.
Pressing unit axles should also be changed every 2
years. Periodically (every 6 months) check the state of
the retainer lips Ref. 17 . 2. 1.
Procedure : Disassemble the axle by loosening the
screw located in the rear part of the reducer, taking
special care to not lose the control pin, take out the
retainer and replace it with a new one Ref.
17 . 2. 1
Figure 13
E) JUICING HEADS ( Fig. 14 ) : The retainers in all of the heads should be changed every 13
months Ref. 17 . 4. 1 . Periodically check the state and alignment of the hub slots with
respect to the extractors.
Procedure : Disassemble the two male heads and the two female heads. Remove the VA-12
V-Ring retainers Ref. 17 . 4. 1 and replace them with new ones. Check the state of
alignment of the hubs with respect to the extractor blades. If there is any misalignment, free the
stud bolts of each hub and set it into the correct position for operation with a metal ruler, then
reset the stud bolts.

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Figure 14
Use the tool supplied to remove the drums
Pomegrana e Version: In order to remove the female squeezing drums you have to
disassemble the peel
ejectors

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The squeezing kit is composed by four drums and squeezing kits. Please use the correct feeding
pipes..
Top peel ejectors
Bottom peel ejectots
F) MOTORS AND REDUCERS : Check to make sure that the reducers are not losing oil at the
clamps. Make sure that the crosspieces of the fan rotate together with the axle of the motor and
that the electrical connections to the terminal boxes and that their protectors are in good
condition.

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G) CONNECTION PANEL AND CONTROL PANEL : Take off the connection cover and make
sure that the different parts are in good condition. Also make sure that the case remains
stopped and that the
Connections to the distributor case are not oxidised or defective. Proceed in the same way for
the control panel of the machine. Check all of the controls, the condition of the buttons and the
speed regulator as well as the protecting parts for safety.
CAUTION !
Pay special attention to the grounds and make sure that the electrical installation of the machine
does not have any shunts.
H) GENERAL APPEARANCE OF THE MACHINE : Check the general appearance of the
machine, paying special attention to the protection profile Ref. 145. . 2 pertaining to the
cover, making sure it is in good condition and that the cover lock is fixed. Make sure the control
panel cover is in good condition Ref. 2 . 25. 2 as well as the locks for the peel cart doors
Ref. 2 . 69. 1.
3 fase
s
+ neutro + tierra

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3.3.2. Z - 450 TRANSPORTER UNIT ( REF. 24.021.002 ).
Check the tension of the transporter belt as well
as its condition Ref. 2 . 8 . 1. For adjusting the
tension of the belt, loosen the lock nuts and screws of
the slack adjusters, tighten the belt with the screws
located just in front of the support plate. Once the belt
has been adjusted, tighten the lock nuts.
Make sure that there is no slippage between the slack adjustor axle and the transporter
roller and make sure that the axles are aligned. Make sure that the bearings and their retainers
are in good condition.
Lubricate the rollers (  ) of the tensor supports
and the bearing box located on the opposite side of
the driving axle of the regulator every six months by
connecting the output nozzle of a manual grease
pump to the greaser of the ball bearing unit.
Mo or and Reducer : Make sure that the reducers are not losing oil at the clamps and that the
screw of the driving axle is tight. Make sure that the blades of the fan rotate together with the
axle of the motor and that the electrical connections to the terminal boxes and that their
protectors are in good condition.