Zummo Z40 Troubleshooting guide

Z40 NATURE
011604-02 1
DATE:
SERIAL Nr:
LOCATION:
MAINTENANCE CHECKLIST 1st YEAR
1.- PRIOR INSPECTION BEFORE OPENING THE MACHINE
OK
NOK
1.1.- Check machine operation
1.2.- Check machine synchronization
1.3.- Check external spare parts, classifiers use and safety system
1.4.- Check ventilation and power input cable
1.5.- Note the cycles counter reading Reading:
2.- MACHINE DISMANTLING AND INTERNAL INSPECTION
OK
NOK
2.1.- Dismantle the hopper track (Check all the screws and gasket ring)
2.2.- Check the machine body screws
2.3.- Check wiring and interconnection plugs
2.4.- Check sliders cover
2.5.- Check pushing plate and both Torx 8x35 bolts
2.6.- Check ratchets condition. Replace rubber cover if necessary.
2.7.- Check wedges condition
2.8.- Check ratchet’s springs condition
2.9.- Check both cup shafts
2.10.- Check feeder condition
2.11.- Check automatic filter belt
2.12.- Check motor/gearbox assembly
2.13.- Internal cleaning and greasing
2.14.- Operation test while the machine is open
3.- MACHINE CLOSING
OK
NOK
3.1.- Machine closing and operation test
COMENTARIOS:
Technician’s name and signature:
Name and signature of the centre responsible:

Z40 NATURE
011604-02 2
DATE:
SERIAL Nr:
LOCATION:
MAINTENANCE CHECKLIST 2nd YEAR
1.- PRIOR INSPECTION BEFORE OPENING THE MACHINE
OK
NOK
1.1.- Check machine operation
1.2.- Check machine synchronization
1.3.- Check external spare parts, classifiers use and safety system
1.4.- Check ventilation and power input cable
1.5.- Note the cycles counter reading Reading:
2.- MACHINE DISMANTLING AND INTERNAL INSPECTION
OK
NOK
2.1.- Dismantle the hopper track (Check all the screws and gasket ring)
2.2.- Check the machine body screws
2.3.- Check wiring and interconnection plugs
2.4.- Check sliders cover
2.5.- Check pushing plate and both Torx 8x35 bolts
2.6.- Check ratchets condition. Replace rubber cover if necessary.
2.7.- Check wedges condition
2.8.- Check ratchet’s springs condition
2.9.- Check both cup shafts
2.10.- Check feeder condition
2.11.- Check automatic filter belt
2.12.- Check motor/gearbox assembly
2.13.- Internal cleaning and greasing
2.14.- Operation test while the machine is open
3.- MACHINE CLOSING
OK
NOK
3.1.- Machine closing and operation test
PARTS TO REPLACE
Ratchet caps 6 u.
Ratchet rubber 6 u.
COMENTARIOS:
Technician’s name and signature:
Name and signature of the centre responsible:

Z40 NATURE
011604-02 3
DATE:
SERIAL Nr:
LOCATION:
MAINTENANCE CHECKLIST 3rd YEAR
1.- PRIOR INSPECTION BEFORE OPENING THE MACHINE
OK
NOK
1.1.- Check machine operation
1.2.- Check machine synchronization
1.3.- Check external spare parts, classifiers use and safety system
1.4.- Check ventilation and power input cable
1.5.- Note the cycles counter reading Reading:
2.- MACHINE DISMANTLING AND INTERNAL INSPECTION
OK
NOK
2.1.- Dismantle the hopper track (Check all the screws and gasket ring)
2.2.- Check the machine body screws
2.3.- Check wiring and interconnection plugs
2.4.- Check sliders cover
2.5.- Check pushing plate and both Torx 8x35 bolts
2.6.- Check ratchets condition. Replace rubber cover if necessary.
2.7.- Check wedges condition
2.8.- Check ratchet’s springs condition
2.9.- Check both cup shafts
2.10.- Check feeder condition
2.11.- Check automatic filter belt
2.12.- Check motor/gearbox assembly
2.13.- Internal cleaning and greasing
2.14.- Operation test while the machine is open
3.- MACHINE CLOSING
OK
NOK
3.1.- Machine closing and operation test
PARTS TO REPLACE
Motor belt 1 u.
COMENTARIOS:
Technician’s name and signature:
Name and signature of the centre responsible:

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1.- PRIOR INSPECTION BEFORE OPENING THE MACHINE
1.1.- Check machine operation. The machine will be switched on with all external parts properly assembled to check
operation. It is necessary to double check if the cups go down rhythmic and symmetrical and that no obstacle is observed
when descending.
1.2.- Check machine synchronization. Check that the machine is
properly aligned by manually moving the motor with the Allen key,
placed on the machine´s base, until the outer centre rod of the basket
coincides with the hopper basket rod. At this point the cups should
remain in the vertical position.
Once the alignment has been verified, move the machine manually
until the cups start moving downwards and check if there is any play
in the cups shaft.
1.3.- Check all external parts and the classifiers use. Check that all the external parts are working properly (Double check
the errors messages on the display).

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1.3.1 Verify magnet’s condition on all parts:
1.3.2 Check filter tray and pulp scraper status double check when the machine
is completely assembled that it moves properly. It can be checked looking by
the hole underneath the filter tray.
1.3.3 Check squeezing tray condition. Unscrew both balls and check if we have
both Teflon washers underneath the balls. Verify both threads status and that
there is no separation between the ball base, the washer and the thread base.
1.3.4 Check if we have the Allen key to unblock the machine and move it
manually. It must be underneath the machine.
FRONT COVER
FILTER TRAY
SIDE COVER
BINS /CHUTES
BASKET
SELF-SERVICE TRAY

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1.3.5 Check the properly use of both classifiers, the upper and lower one. If working with the medium size cups (53 /
76) we must use the upper classifier with the same size and lower separator at the same position show on picture
below.
Classifier 53/76 Lower classifier
1.4.- Check ventilation. Must be checked that the fan turns on every time the motor is operating.
Check power input plug, cable and fuse holder (Verify if there is one 6A fuse in backup).
1.5.- Note cycles Reading. The number of cycles must be note to have the
count of the cycles done since the last inspection. To view them, the
machine must be properly assembled then press STOP and the number of
cycles will be shown on the screen.

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2.- MACHINE DISMANTLING AND INTERNAL INSPECTION
2.1.- Check all the hopper track screws condition. Dismantle the machine following point 3 of the technical instructions.
Double check all screws condition while being removed. Once the Hopper track has been removed, we will be able to
disassemble the machine front.
2.1.1 Check the ring gasket of the basket shaft. When removing the caps (3/9/1G), unscrew the 4 cross head screws
and check the rubber washer condition of each one, considering that when re-screwing them don’t forget the washer.
2.2.- Check machine body bolts. Unscrew both hexagon bolts (I-933-M6X10) which fixes the front (210239) to the chassis
(210101). Loosen one turn each one of the four legs in order to remove the front and then the rear.
CESTA EXTERIOR
CESTA Z40 COMPLETA
TUERCA

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2.3.- Check the wiring and interconnection plugs. Once the hopper track is released, lift it carefully and unplug both from
the interconnections box. Double check both plugs and wiring status. To be able to remove the machine we must
disconnect the power input, ground connection and fan cables.
2.4.- Check the slide cover set. Get loose the 6 screws which fix the slide cover
set and double check its status.
2.5.- Check the pushing plate set (210447). Verify both hexagon socket countersunk Allen screws (I-7991-M6X16). The
hexagonal bolt (T-933-M8X20) which fixes the connecting rod (210411) to the pushing plate set must be also checked
and verify if its properly tight.

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2.6.- Check both ratchets condition. We must check if
both are well greased, if the four safety rings (T-471-
E14) are in good condition and if both ratchets have all
their soundproof plugs (blue arrows).
With the connecting rod on its vertical position verify
that the chassis closure screws (I-933-M8X35) are
securely tight. Then verify if the shafts have any play, in
case they have, both bolts must be adjusted.
2.7.- Check both wedges (R-210449A / L–210448A) condition. We must release
the spring and check if the four wedges rotate freely without any rub, if they are
properly greased and check the four E-18 safety rings (T-471-E14).
Check the pushing plate supplement (210430) condition. If it’s damaged proceed
to replace by a new one.
2.8.- Check both ratchet springs. Double check with the connecting rod on its higher vertical position that there is a
distance higher than 1,5 mm. between the wedge and the ratchet. *
*Check the pushing plate play. To check it take the pushing plate down until the ratchets don’t touch it.

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2.9.- Verify both cup shafts (210504A). Check that we haven’t got any play in both shafts
and that they have the safety rings (I-471-E28) in good condition. Release the safety ring.
2.9.1 Once we have removed the safety rings of both cup shafts, push each shaft inwards, as seen in the pictures and
grease the part which is inserted inside the slider.
2.10.- Check feeder condition. We must check that the feeder safety ring (I-471-E20) which fixes the conical crown set
and that the chain (210323) is not loose. Remove the safety ring (I-471-E20), release the crown and check that the crown
wheel base washer (210353) below is in good condition.

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2.11.- Check the automatic filter belt.
2.12.- Check the motor / gear box assembly condition. Check the hexagonal bolt (I-
933-M6x16) on the gear box rear is well tight.
Check that the belt tension is correct and check that both pulleys, motor one and gear
box one, are in perfect condition.
Check that there is no oil residue in the base of the machine.
2.13.- Finally clean any residues accumulated in the motor fan and inner the machine.
Once the machine has been cleaned up proceed to grease it following next points:
2.13.1 Move the machine manually until the sliders set arrive to the lowest
point and grease the part of the chassis shown on the picture beside.

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2.13.2 Grease both ratchets and wedges set. We will
also grease both springs, put them back and check its
tension.
2.13.3 Grease the feeder conical crown and check that the
E-20 safety ring is on its place.
2.13.4 Grease the bearing of the cup slider set and he copier surface which is in
contact with the bearing.

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2.14.- Operation test while the machine is open. Use the Allen wrench to move
manually the machine, double check the ratchets sets and verify if the greasing has
been done properly.
3.- MACHINE CLOSING
3.1.- Firstly we need to connect again all the cables disconnected before. We will place the stainless-steel rear and front
and then the hopper track following point 14 on the technical instructions.
Finally place all the external parts in their place to make the machine able to operate. Then turn on the machine and be
sure that the filter moves and that the fan runs at the same time as the motor does.