Zoom DB2100 Instruction Manual
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Zoom DB2100 Instruction Manual

Zoom DB2100 Instruction Manual

Double barrel leaf-cutting machine
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Zoom Double Barrel
Model DB2100
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Instruction Manual

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Summary of Contents for Zoom DB2100

  • Page 1 Technologies Instruction Manual Zoom Double Barrel Model DB2100...

  • Page 2: Table Of Contents

    Table of Contents Warnings & Notice 1 Safety Instructions 2 Operation 5 Machine startup 10 Cleaning 12 Maintenance 14 Adjustments 15 Suggested cutting tips 20 Troubleshooting 21 Specifications 23 Warranty 25 www.doublebarrelzoom.us ...
  • Page 3 WARNING!!!! This machine is a high-speed commercial double barrel leaf-cutting machine, all safety precautions must be observed to eliminate and reduce the risk of personal injury. Improper or careless use may result in serious or fatal injury. Notice Make sure that all people running this machine fully understand the operation and safety precautions before using. All maintenance needs to be followed to ensure safety and proper use. First time users will need to read and understand the instruction manual for proper and safe use. Make sure this instruction manual is always supplied to other operators who are not familiar with this specific machine operation for the first time.

  • Page 4: Safety Instructions

    IMPORTANT SAFETY INSTRUCTIONS READ THESE INSTRUCTIONS CAREFULLY Read all instructions completely before machine is operated KEEP THESE INSTRUCTIONS Retain instructions for future reference for all users. PAY ATTENTIONS TO ALL WARNING LABELS All warnings on the machine and in the instruction manual should be precisely followed. WARINING: To reduce risk of fire or electrical shock, do not expose this machine to water while plugged in. The machine must have a properly grounded receptacle to meet local code. Refer to machine labeling to determine correct electrical requirements. The machine requires a 15A circuit breaker. Observe all electrical codes and regulations for your area. This machine requires a minimum of 12AWG copper conductor. Maximum cord length should not exceed 50ft/15meters. An undersized cord will result in loss of power, overheating and possible fire. The machine must be unplugged before any protective covers are removed. Do not attempt to service electrical components on this machine, as there is a high risk of dangerous voltage, possible fire and electrical shock. Page 2...
  • Page 5 Zoom Double Barrel Trimmer WARNING! Never put objects into barrel that cannot be processed by the machine. Hard objects that the operator does not notice can cause extensive damage and/or bodily harm and will void the warranty. Abide by all warning labels. Never plug in the machine with shrouds, covers or guards removed. DO NOT change or modify any part of the machine or accessories. Never run the machine unattended. Only service this machine as directed in the manual. Do not make any changes to the machine that is not listed in the manual as this may expose you to dangerous voltage and/or other hazards. Only qualified service personal should service this machine if not covered in instruction manual. If machine does not operate normally by following operating instruction, adjust only the controls that are covered in the instruction manual and seek a qualified service technician for other issues. Only original replacement parts supplied by the original manufacture must be used on this machine. Warranty will be void if using other non-certified parts. WARNING! Careless or improper use of this machine may cause serious or fatal injury. Follow all safety guidelines listed in manual and on machine. Safety glasses must be worn to reduce risk of injury. To reduce the risk of injury, keep all body parts, long hair and loose clothing away from moving parts. Do not wear long sleeves or gloves, as this will be a hazard. Page 3...
  • Page 6 Read all WARNINGS listed below DO NOT operate this machine without all the protective covers installed. Do not operate the machine while tired or under the influence of drugs, alcohol or other medications. Do not reach inside barrels while the machine is plugged in for safety. Keep visitors a safe distance from the work area and children away at all times. Do not allow lubricants to build up around the machine. This could cause a slipping hazard for the operator and others. Replace warning labels if they become obscured, unreadable or removed. Request new labels from your retailer. Page 4...

  • Page 7: Operation

    Zoom Double Barrel Trimmer Operation The Zoom double barrel machine has been adjusted and tested by the manufacture before shipping. Dried material buildup and normal wear and tear will require you to check the machine each day before initial startup for the proper settings. Please refer to the startup section on page 10. Before you start using your Zoom machine you should familiarize yourself with all the components and operation of this machine. To do this you will need to go through the entire instruction manual. Anticipate disassembly/assembly for cleaning will need to be done once or more per day depending on cutting materials and usage. WARNING! The following should only be done when the power is disconnected. *Pages 6 - 14 Routine checking and cleaning procedures that should be followed daily. Page 5...
  • Page 8 Removing the barrels: Warning!!! The following should only be done when the power is off and disconnected. Barrel belt removal Unlock the barrel motor lever and pull the belt towards you (raising the motor) and lightly tighten the handle. Then remove the belt from around the idler pulley and barrels. Figure 1.1 Barrel belt handle lever Figure 1.2 Barrel bearing guide assembly Pull the top slider block out and swing the barrel guide bearings up out of the way for barrel removal. With the belt removed you can then proceed to remove the barrels one at a time. Page 6...
  • Page 9 Removing Barrels continued Pull from the pulley side and slide one barrel out at a time by pulling and rotating. As the barrel is being pulled out keep them as parallel as possible to the machine to reduce any damage. Be EXTREMELY CAREFUL not to damage the barrels. Any damage to the barrels will directly affect cutting performance. Figure 1.4 Shroud cover removal Upper shroud latches 1 & 2 To removing the top shroud cover to access the reel blades, unlatch the (2) slide pins to remove the top sheet metal shroud cover and set aside. Page 7...
  • Page 10 Figure 1.5 Shrouds removed To remove the lower shroud cover first remove the 2 vacuum hoses on shroud then proceed by lifting the shroud up and over the guides while pulling it out. This will give you exposure to clean the reel. If necessary you can also remove the lower shroud but this is not suggested, as it will protect the electrical box and motors from water spray. Inspection of the blades WARNING!! The following should only be done when the power is disconnected. Never slide your fingers across the reel blades as they are very sharp and may injure you. With all the shroud covers removed visually check for any damage on the cutting edges. To rotate the reels blades use a small block of wood (2x2 or 2x4) and never your fingers. Refer to Figure 1.6 If there is damage to the blades this must be corrected before further assembly and operation. Page 8...
  • Page 11 Figure 1.6 Reel blades Remove the barrel and front guard with the latches. It’s best to use a block of wood to rotate the blades as they are very sharp and may very easily cut your hands or fingers. Make sure the reel spins freely. The reel blades will have light contact with the knife blade. This will ensure proper cutting action and will help maintain a sharp edge. Please refer to the adjustment section if the reel blades need to be adjusted. Note: If there is damage to the reel blades that will not allow for smooth rotation, the machine will need to be serviced by an authorized service technician. Damage from rocks and other hard objects are not covered under warranty. New parts must be purchased and installed properly. Page 9...

  • Page 12: Machine Startup

    Machine startup Before plugging the machine into the power receptacle it’s very important to make sure the reel blade spins freely each day. Please refer to page 8 and 9 of this manual then continue with this procedure. Move the Zoom into position on a somewhat flat surface and adjust the jacks accordingly on each side with the hand cranks to get the correct barrel slope and levelness from side to side for the hopper. This will anchor the machine in place and allow you to set the speed of travel with the machine angle and barrel rotation speed control. Refer to figure 1.9 below. Figure 1.9 On/Off & Barrel Speed Control Note: Make sure the cord is a minimum of 12/3 AWG and less then 50ft in length. Using 14/3, 16/3 or 18/3 cords will void the warranty and damage the motors. Do not overload electrical outlets. Failure to comply with electrical code could result in fire or electrical shock. It’s best to have a dedicated circuit for the machine. Consult an electrical contractor for assistance. Page 10...
  • Page 13 Machine startup: continued Once the machine is installed correctly make sure the reel spins freely. With the power disconnected remove the reel v-belt guard and rotate the belt by hand to make sure it spins freely. Reinstall the belt guard with the two screws. Connect the vacuum hose(s) up to the machine discharge outlet and the vacuum side. Fewer corners in the vacuum hose will increase overall suction. Connect the machine cord to the correct circuit. Plug the vacuum on a separate circuit. Note: We have equipped this machine with a 220V 3hp vacuum for the best performance and lowest amperage. You may need to consult a qualified electrician for making a 220V connection. Make sure hands and other objects are clear of the machine before beginning startup. Step 1: Toggle the REEL switch motor ON/OFF. (Labeled REEL) to make sure it’s running smoothly before proceeding. Press the switch again and leave the reel blades running. (Refer to figure 1.9). Step 2: Proceed with the BARREL switch drive motor (Labeled BARREL) by toggling the switch ON/OFF. Press the switch again and leave the barrels running. (Refer to figure 1.9). Step 3: Adjust the barrel speed knob to the slow-medium position for beginning. Step 4: Turn on the vacuum(s). Page 11...

  • Page 14: Cleaning

    Machine startup: continued Keep in mind that the machine will have specific noises when it’s has been properly adjusted from factory but could change in shipping. The operator should become familiar with these noises and characteristics to identify abnormal noises that can be corrected before they become serious. The operator can now proceed to feed the hopper with material. Both barrels can receive material at the same time. The material will consistently travel through at the proper speed and exit the opposite side. You may need to adjust the machine angle with the jacks as the machine is running to find the proper angle for material flow. All materials cut differently so we have designed this machine to be finely tuned by the barrel speed adjustment. The barrel motor speed knob for the RPM can be adjusted to find the proper speed for the material being cut. Refer to page 20 for Suggested Cutting Tips. Cleaning instructions A thorough cleaning of the machine should be done every time the machine is used and possibly 2-4 times daily depending on what is being cut. Material buildup can cause poor performance, overheating and hard startup for later use. Recommended cleaning will ensure proper performance and extend the life of the machine. As the residue dries it will become hard and more difficult to remove. Be extremely careful and never slide your fingers along the reel edges or blade lengthwise. Warning! All cleaning must be done when the machine power is disconnected and unplugged. Page 12...
  • Page 15 High pressure water cleaning (< 2,000psi) High pressure water cleaning (under 2,000psi) is the most efficient way to clean the machine for speed and ease. Remove the barrels, top shroud with the 2 latches and leave the bottom shroud in place. This will help keep the motors from getting wet. Cover motors with plastic bags and start spraying the brushes first then move down to the reel blades and lower shroud. Use a block of wood to rotate the blade for complete cleaning then spay the lower shroud. Keep direct hard spray away from the motors and electrical box. These items can get wet but should not be directly sprayed. You can then remove the lower shroud and clean completely. Proceed and clean the inside of the shroud with the latches. Carefully spray the barrels inside and out and reassemble all parts in reverse order. Cleaning without high pressure water Remove all three shrouds and spray Simple Green on inside surface of shrouds for presoaking. You can then take a good quality 1-2” wide putty knife or paint scraper and remove material residue buildup. Reel blades Remove the barrels and shrouds. Spray reel blades and barrels with Simple Green or denatured alcohol and let stand for 1 hour. Wipe the reel blades with a rag being extremely careful not to touch the blades with your fingers. Rotate the reel blades with a block of wood and continue to wipe carefully. Barrels Barrels can be sprayed or soaked in a garbage can with Simple Green and water. After soaking for 1 hour wipe the barrels inside and out with a rag being careful to not cut yourself on the barrel slots or damage the barrels. You can also take a garden hose and spray the barrels down. Be extremely careful with handling the barrels, as they are precision made and any damage with greatly effect the cutting performance of the machine. Barrel brushes The brushes can be spayed with Simple Green or bathroom cleaner then hosed off. High-pressure sprayer may damage bristles if sprayed to close. Page 13...

  • Page 16: Maintenance

    General Maintenance Maintenance will depend on the amount of use the machine is operated. This will describe what you should do if the machine is used on a daily bases. Warning!!! General maintenance should only be done when the machine power is disconnected with no exceptions. Grease lubrication The brush bearings with grease fitting should be greased once per year. Adjustment The cutting reel and each barrel should be check for damage each day and adjustments made as necessary before cutting. Note: Operating the machine with damaged blades could result in further damage or personal injury. An authorized technician or the manufacture must repair damage. Cleaning A thorough cleaning of the machine should be done on a daily basis. Material buildup can cause poor performance, overheating and hard startup for later use. As the residue dries it will become hard and more difficult to remove. Be extremely careful to avoid sliding your fingers along the blade lengthwise. Refer to the cleaning section of this manual on pages 12 - 13. Vacuum maintenance Change or empty the bottom debris bag daily on the vacuum. Keeping the top bags clean for maximum airflow will give you the best performance possible. Disconnect power before cleaning around impeller for heavily used vacuums. Page 14...
  • Page 17 Machine cutting adjustments There are very few adjustments that will need to be made on this machine over time. These machines have been adjusted and tested at the factory before being shipped. You may need to check and readjust the blades as necessary over prolonged use. To do this it will need to be done by a person that understands how this works, as this is a very precision machine and can be damaged if done incorrectly. Warning! The following should only be done when the machine is disconnected from the power. Never slide fingers down edges of the blades lengthwise, as they are extremely sharp and dangerous. Blade adjustment Remove both barrels from the machine to access the 2 blades and then remove both of the shrouds covering the reel. The machine blades must be completely clean before any adjustments are made. Locate the adjustment blocks for each blade. Only attempt to adjust one blade at a time. It’s best to adjust the blade away from the reel to make sure it spins freely. To do this you will need to unloosen the lock nut and turn the adjustment wheel clockwise 3 or 4 notches on both sides of the same blade until the reel turns freely. Once it spins freely move onto the next step. Slowly turn the adjustment bolt counterclockwise one notch at a time on each end of the blade while checking for paper tightness while turning the reel. Refer to figure 2.1 for paper position. Once the paper is touching then tighten the lock nuts and proceed onto the next blade. Page 15...
  • Page 18 Figure 2.1 Paper inserted from the front side. Check for light contact force on both sides of the reel on the paper like in figure 2.1. Adjust each side until the paper is lightly pinched. Remove the paper and turn the blade with a block of wood. You should not feel or hear any contact with the reel blade. Assembly the guards, plug the machine into the power cord and turn on the reel motor. If you hear any ticking or noise adjust the side causing the contact until it goes away. This can be adjusted while the machine is running very carefully. Find the blade end, loosen lock nut and adjust the thumb wheel a few notches to move blade away from the reel blade then retighten lock nut. Repeat as necessary until machine runs quite. Page 16...
  • Page 19 Any damage to the blades may make proper adjustment not possible. The self-sharping blades cannot correct damage on the reel blades. Damage to the reel blades must be replaces by an authorized service technician. Once adjustment has been completed you will need to ensure the reel spins freely. There should be no drag or contact on the blades when running. Everything must be clean for proper adjustment. You may need to readjust it once you turn the motor on for no blade to reel contact. Replace the protective shrouds and barrels. Swing the barrel-bearing block down in place and install the lock pin. Proceed to the initial startup procedure. You should get no sounds of blade contact when running. Tumbler adjustment Tumbler adjustment has been set and tested at factory before shipping but may change in shipping. Warning!!! The tumbler adjustment should only be done when it is certain the power has been disconnected. The factory has made the closest cutting adjustment possible but you may want to readjust after transporting or lengthen the cut for different materials. You will need to adjust both ends so the barrel is parallel to the blade for even cutting action. Refer to figure 2.3 and begin loosening locknut labeled #6 & #7 on each end. Turn #5 counter clockwise to raise the tumbler. Once you have reached the desired space between reel and barrel re-tighten the #7 bolts (3 bolts per plate) on each end and #6 on each end of the adjustment block. Proceed to the opposite barrel side and follow the same procedure as you did on the first barrel. Page 17...
  • Page 20 Note: Make sure to turn the barrel by hand before applying power with the v-belt. This is a good check to see if there are any problems before applying power to make sure it spins freely. Once you have done so then turn the barrel power on and make sure it does not rub the reel or blade. Figure 2.3 Front view showing bolts Page 18...
  • Page 21 Notes: • Ensure that all loosened nuts and bolts are tight before applying power. • Make sure barrels spins freely before applying power. Lubrication This machine has been engineered to run as maintenance free as possible. The reel bearings have been designed and engineered with sealed bearings. Improper cleaners and cleaning procedures can damage seals and will void warranty. Simple Green (mild detergent) and denatured alcohol are the recommended cleaners. For cutting wet material we suggest a periodically very light water spray mist on material to help the metal surfaces resist the resin from adhering. Grease fittings Brushes The brush bearings with grease fitting should be lightly greased once every 8-12 months depending on usage. When you see grease coming out of the bearing seals stop pumping grease gun. Reel bearings These reel bearings are sealed (2) on the reel end plates and should not be pressure washed in this area. Make sure the reel spins freely to ensure the bearings are in good condition. Page 19...

  • Page 22: Suggested Cutting Tips

    Suggested Cutting Tips • Wet cutting - Keep high resin materials wet and fresh for cutting • Always use short top bags on vacuum for wet or dry trimming • Dry trimming use cloth or plastic bags on bottom of vacuum • Find the correct material flow rate to each material • Fast material flow may cause insufficient cutting • Make sure material is tumbled in cutting zone of barrel blades • Light material cuts differently then heaver material and may take 2 passes • Adjust speeds based on weight and leaf size to be trimmed • Loss in vacuum will greatly decrease your cutting ability • Clean barrels when leafs stick and block inside of barrel slots • Any foreign matter will damage reel blades • Listen for abnormal noises when the machine is running Reel belt replacement Remove the hex head bolts labeled #4 in figure 2.3. Then loosen bolts labeled #3 and figure 2.3. The motor is very heavy and may be difficult to lift by one person. Lift motor and remove belt. Reverse this procedure to install the new belt. Page 20...

  • Page 23: Troubleshooting

    Trouble shooting Barrel makes grinding noises This could be due to damage to the tumbler barrel causing it to rub the reel blade. It may need to be adjusted further away from the reel and blade knife. Barrel motor shakes This may be due to something in the belt or pulleys causing it to be unbalanced. Check for material adhered to the drive system using proper safety. Reel drive motor is very hot The reel drive motor will get hot after prolonged use. It will shut off automatically if it overheats and will need to cool down before restarting. There is a high pitch squeal sound coming from the blades This can be due to the blade rubbing the protective shrouds or covers. Check for damage on shroud covers and if the machine needs cleaning. There is a high speed ticking sound coming from the blades There should be no sounds from the reel being turned on. If your hearing a ticking sound the stationary blade will need to be adjusted so the noise will go away. Debris is getting clogged up in the vacuum inlet Clean periodically due to debris buildup of wet or dried material from current or pervious use. The circuit breaker keeps tripping This is typically caused by an undersized cord, a cord that is to long or an circuit breaker that is to small. Also check to make sure the machine is not sharing a circuit breaker with other electrical items. Page 21 ...
  • Page 24 Trouble shooting continued: The reel motor stops on startup This is typically caused from using an undersized cord that is to long. This also may be caused by improper belt tension (to tight). Suction from the vacuum is weak The suction is critical for proper cutting. Check to make sure there is no blockage in shroud, hose and around the vacuum housing of the impeller. Clean or change the upper filter bag in the vacuum and make sure all connection are correct. Excess material buildup on the brush & tumbler barrel Clean brush and barrel more often and apply a light coat of cooking oil spray to brush to keep the cut material from sticking. The material comes out of the machine under processed This may be due to excessive machine angle causing the material to flow to fast through the barrel or not enough vacuum. Check for proper vacuum. Lower the jacks and reduce the machine angle to get the proper flow rate. You may also need to adjust for proper barrel speed for the material being cutting. The reel motor won’t start This is most likely due to hardened residue buildup, poor adjustment or lack of lubricant. Residue left on blades will harden and cause the motor. The start button for the blade lights the LED indicator however the motor will not start. This is a safety feature that protects the motors. The motor has overheated and needs to cool down to reset. The motor will overheat if the blades need to be cleaned/adjusted or possibly incorrect belt tension. Make sure the problem is resolved before continuing. It may take several minutes to reset. Page 22...

  • Page 25: Specifications

    Trimmer Specifications Input voltage 120V Current draw 12A Weight 300lbs / 136kgs Length 50.6” / 128.5cm Width 32.4” / 82.3cm Width – w/o wheels 25.8” / 65.6cm Height 37.2” / 94.5cm Discharge diameters 6” / 15.2cm Vacuum Specifications Input voltage 220V Current draw 14A Additional Requirements Extension cord 12/3 AWG (10 AWG or 12AWG) 50ft/15m (max length) Lubrication WD-40 for storage...
  • Page 26 Transporting & Storage Tie down The machine is easy to tie down to the tubular frame. Make sure you anchor low on the machine and your tie downs don’t slide making the machine loose in transportation. Have sufficient number of tie downs on the front and back to keep the machine of shifting during transport. Storage This machine is made with parts that resist corrosion. It’s recommended to be lightly sprayed down for additional protection. We recommend storing the machine in a dry place and to make sure to clean the machine thoroughly before storing. Any material left on the machine will harden and become harder to clean over time. Once cleaned and dry it is best to spray the reel blades and blade knives with a thin lubricant like WD-40. Following these steps will ensure smooth startup on the following use. Store the machine in a safe dry location with all guards and shields installed. Keep it out of reach of children and other unauthorized people.

  • Page 27: Warranty

    Manufacturer’s Warranty The manufacture will repair or replace without charge any parts that are proved defective in material or workmanship for a period of one year. The warranty period will begin from the date the machine is purchased from the initial retailer. You may be denied warranty coverage if your machine has failed due to abuse, improper maintenance, normal wear, accident or unapproved modifications. The manufacture assumes no risk and shall be subject to no liability for damages or loss resulting from the specific use or application made of the product. In no event will the manufacture be liable for any special, incidental or consequential damages (including loss of use, loss of profit and claims of third parties) however caused whether by negligence of the manufacture or otherwise. If warranty repair is required please contact the manufacture at info@doublebarrelzoom.us to obtain a repair authorization number with the following information. Model and serial number 1. Proof of purchase date 2. A copy of the original Warranty Registration Card Details of the defect or problem. The machine or defective parts must be returned to the manufacture for analysis and replacement. © 2018 Zoom - Double Barrel Trimmer All rights reserved. www.doublebarrelzoom.us Please contact the manufacture with any questions on warranty at info@doublebarrelzoom.us. Manual 2017 v3...

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