ZIRPE60 - Vibratory plate Zipper - Free user manual and instructions

USER MANUAL ZIRPE60 Zipper

EC-CONFORM: This product complies with the EC-directives.

Follow the instructions!

No open flame, fire, open source of ignition and smoking prohibited!

Danger of Intoxication! Only use outdoors and far from open windows and vents!

Wear personal protective equipment!

Warning signs and/or stickers on the machine which are illegible or have been removed must be replaced immediately!

This manual is part of the machine and must not be removed. Save it for later reference and if you let other people use the machine, add this manual to the machine. Please read and note the safety instructions! Before first use read this manual carefully. It eases the correct use of the machine and prevents misunderstanding and damages of machine. Due to constant advancements in product design, construction, illustrations and contents may deviate slightly. If you notice any errors, please inform us. We reserve the right to make technical changes! Check the goods immediately after receipt and note any complaints on the consignment note when taking over the goods from the deliverer! Transport damage must be reported to us separately to us within 24 hours. ZIPPER MASCHINEN GmbH cannot accept any liability for transport damage that has not been reported.

Copyright © 2023 This documentation is protected by copyright. All rights reserved! In particular, the reprint, translation and extraction of photos and illustrations will be prosecuted. The place of jurisdiction is the regional court Linz or the court responsible for 4170 Haslach is valid. Customer service contact

For your safety, read this manual carefully before commissioning. This will enable you to handle the machine safely and thus prevent misunderstandings as well as personal injury and damage to property. Pay special attention to the symbols and pictograms used on the machine as well as the safety information and danger warnings!

14.1 Intended use of the machine

The machine is designed exclusively for the following activities: For compacting (e.g. granular soils consisting of gravel and sand or mixtures of both) and for vibrating paving stones, bricks, etc. on small to medium-sized surfaces. The rubber mat should only be used to vibrate paving stones, bricks and the like! Other materials such as gravel, chippings etc. must be processed without a rubber mat. ZIPPER-MASCHINEN assumes no responsibility or warranty for any other use or use beyond this and for any resulting damage to property or injury.

14.1.1 Technical restrictions

The machine is designed for the work under the following conditions: Relative humidity max. 65 % Temperature (operation) +5 °C to +40 °C Temperature (storage, transport) -20 °C to +55 °C

14.1.2 Prohibited applications / Dangerous misuse

Operation of the machine without adequate physical and mental aptitude Operating the machine without appropriate knowledge of the operating instructions (machine + motor). Changes in the design of the machine Operating the machine in wet and rainy conditions Operating the machine in a potentially explosive environment Operating the machine indoors or in closed areas Operation of the machine without functioning or missing guards Operation of the machine in hard soil, frozen soil and mixed soil containing fragments of bricks. Compaction of asphalt or sticky soils with a high clay content. Remove the safety markings attached to the machine. Modify, circumvent or disable the safety devices of the machine. Use of the machine for the transport of persons The prohibited/hazardous use or disregard of the information and instructions presented in this manual will result in the voiding of all warranty and damage claims against Zipper Maschinen GmbH.

14.2 User requirements

Prerequisite for the use / operation of the machine is a corresponding physical and mental aptitude as well as knowledge and understanding of the instruction Manual. Please note that local laws and regulations may determine the minimum age of the operator and restrict the use of this machine! Put on your personal protective equipment before working on the machine. Work on electrical components or equipment may only be carried out by a qualified electrician or carried out under the guidance and supervision of a qualified Electrician.SAFETY ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 30 ZI-RPE60_ZI-RPE90

14.3 General safety instructions

In order to avoid malfunctions, damage and health hazards when working with this machine, in addition to the general rules for safe working, the following measures in particular must be observed UNCONDITIONALLY: Check that the machine is in perfect condition before each use. Ensure that all guards are in place and working properly and that all nuts, bolts, etc. are securely tightened. Do not take the machine into operation if you notice that parts are missing or damaged! Ensure sufficient lighting conditions in the working and surrounding areas of the machine. Keep hands and feet away from moving machine parts and always ensure a safe stand when working. Ensure that the area to be tamped does not contain any electric cables, gas or water lines which could be damaged by vibration. Remove the adjustment tool from the machine before operation. Never leave the running machine unattended (always stop the machine before leaving it). Ensure that unauthorised persons maintain a safe distance from the machine and keep children away from the machine. The machine may only be operated, serviced or repaired by persons who are familiar with it and who have been informed of the dangers arising during this work. Always wear suitable personal protective equipment (ear protection, gloves, safety shoes, close-fitting protective clothing, etc.)! Do not work with the machine if you are tired, not concentrated or under the influence of medication, alcohol or drugs! Never operate the unit in the presence of flammable liquids or gases (danger of explosion!). Carry out maintenance, adjustment and cleaning work only when the engine is switched off. Only use spare parts and accessories recommended by Zipper machines.

14.4 Special safety instructions for the operation of ZI-REP60 and ZI-RPE90

The machine is designed to be operated by one person. Always operate the machine from behind. Never stand next to or in front of the machine when the engine is running. Longer continuous use of the vibratory plate can lead to circulatory disturbances, especially of the hands, caused by vibration. Therefore, take regular breaks from work! Wear suitable protective gloves to reduce the vibration intensity. The hardness of the surface to be treated, personal predisposition to circulatory disorders and low outside temperatures considerably reduce the permitted period of use. When working in or near excavations or building pits, make sure that the walls are stable and do not run the risk of collapsing due to vibration. Keep away from edges and trenches and avoid situations where the vibratory plate could tip over. Excessive noise can cause hearing damage and temporary or permanent hearing loss. Wear hearing protection certified to health and safety regulations to limit noise exposure. Do not increase the regulated idle speed of the engine above 3,500 rpm. This could result in damage to the machine or personal injury.

14.5 Safety instructions for machines with combustion engine

Do not touch the engine and/or muffler during operation or immediately after switching off! These areas become hot during operation and can cause burns. Do not touch the spark plug connector when the engine is running (electric shock!). Do not operate the unit in closed areas or in poorly ventilated rooms unless there is adequate ventilation through exhaust fans or hoses. (Risk of suffocation from carbon monoxide!) Do not smoke while the machine is in operation. Do not smoke when refuelling the machine. Refuel the machine only in a well ventilated area. Do not refuel the machine when the engine is running or the machine is still hot. Do not refuel the machine near naked flames. Do not spill fuel when refuelling. Do not crank a gas flooded engine as long as the spark plug is removed- fuel in the cylinder sprays out of the spark plug opening.ASSEMBLY ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 31 ZI-RPE60_ZI-RPE90 Do not carry out an ignition spark test on engines if the engine is flooded or gas can be smelled. A stray spark could ignite the vapours. Do not use fuel to clean machine parts, especially indoors. Vapours from fuels may explode. Always keep the area around the muffler free of foreign substances such as leaves, paper, cardboard, etc. A hot muffler could ignite these substances and cause a fire. Close the filler cap after refuelling. Check the fuel line and tank regularly for leaks and cracks. Do not operate the machine if leaks in the fuel system are known. Store fuel only in designated and approved containers.

14.6 Hazardous situations

Despite intended use, certain residual risks remain. Due to the design and construction of the machine, hazardous situations may occur which are identified as follows in these operating instructions: DANGER

A safety instruction designed in this way indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

A safety instruction designed in this way indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

A safety instruction designed in this way indicates a possibly hazardous situation which, if not avoided, may result in minor or moderate injury.

A safety notice designed in this way indicates a potentially hazardous situation which, if not avoided, may result in property damage. Regardless of all safety regulations, your common sense and your appropriate technical aptitude/training are and remain the most important safety factors in the error-free operation of the machine. Safe working depends on you! 15 ASSEMBLY

15.1 Check scope of delivery

After delivery, check the machine immediately for transport damage and missing Parts.

The machine is delivered pre-assembled. The parts that have been dismantled for transport must be assembled before commissioning / use.

Do not forget to tighten the springs (2).

Fasten the retaining bracket to the machine body using screws, washers and nuts (3).

Aattach the lifting frame first to the front and then to the rear (each with screw, spring washer and washer) (4).

Install the transport device using two screws (5).

Take the throttle cable which is rolled up on the engine and fix the throttle clamp on the handle (6). Make sure that the upper throttle lever is set to minimum ("turtle" symbol). Finally, secure the throttle cable to the retaining bracket with two cable ties.

The use of paint thinners, petrol, aggressive chemicals or abrasives leads to material damage to the surfaces! Therefore use only mild detergents for cleaning! Clean the machine and remove dirt and dust if necessary. If the air filter is dirty, blow the filter cartridge from the inside by moving a jet of dry compressed air up and down. Continue until all dust has been removed. Replace the air filter with a new one if necessary. Check the carburettor for external dirt and dust and clean it with dry compressed air if necessary. Check the nuts and bolts for tightness. (Screws or bolts loosened by vibrations can lead to accidents!)OPERATION ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 33 ZI-RPE60_ZI-RPE90

15.3.1 Checking the engine oil level

Too low an oil level will damage the engine and shorten the life of the machine. Therefore, check the engine oil level before every start and top up the engine oil if necessary.

To check the engine oil level, place the machine on a safe, level surface. Switch off the engine and allow the machine to stand for ten minutes so that the circulating oil can collect in the oil pan. Unscrew the oil dipstick and wipe with a clean, lint-free cloth or a non-fibrous paper towel (1).

Push the dipstick into the opening, but do not screw it in (2). (Make sure that the dipstick has really been pushed in completely).

Pull out the oil dipstick again and read off the oil level. There are two markings for this - see illustration on the left. If the oil level is low, refill the recommended oil up to the upper edge (maximum filling volume: approx. 0.5 litres). Push in the oil dipstick again and tighten.

Observe the safety regulations for fuel control. Filter the fuel during refuelling to prevent foreign particles from entering the combustion chamber. Wipe up leaked fuel. Screw on the tank cap (sits on the fuel tank). Level check in the form of a visual inspection. If necessary, top up with fuel with the appropriate octane number (RON 95). Close the fuel filler cap tightly after refuelling. 16 OPERATION Save the working environment before you start compressing. Only put the machine into operation after you have read and understood the safety instructions and carried out the necessary measures before initial commissioning. The correct moisture content of the soil is very important for correct compaction. Compaction of dry materials is facilitated by moistening the material. Too much moisture, on the other hand, leaves water-filled cavities which weaken the load-bearing capacity of the soil. Wetness or excessive irrigation can lead to overloading and engine death.OPERATION ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 34 ZI-RPE60_ZI-RPE90

16.1 Information on Initial Start-up

Note that the machine is delivered without engine oil and fuel. Make sure that this equipment is filled up before the machine is put into operation for the first time. ATTENTION: The machine does not start until the engine oil has been refilled to the upper limit.

16.1.1 Test Run Initial Start-up

Let the machine run idle for about 3 minutes. Pay attention to abnormal noises. Pay attention to the exhaust fumes (too black, too white)?

16.1.2 Notes on the first 20 operating hours

In order to optimize the life expectancy of your machine, the following points should be observed: Do not operate the engine for the first 20 operating hours @ maximum load (this also applies to used engines after extensive maintenance). This means lower speed and lower maximum working load than during normal operation. Change the engine oil after the first 20 hours of operation.

16.2 Operating Instructions

Never use the recoil-starter while the engine is running. This will damage the engine. The pull mechanism for changing the engine speed is limited by an adjusting screw. This is factory set. Never change this setting on your own, you could overload the motor. Do not operate the machine on slopes of more than 20°, as even with an optimum oil level the engine may not be supplied with sufficient lubrication. In the direction of the vibratory plate and within a range of one meter around the vibrator, nobody but the operator must stand. During the compaction the soil should first be compacted about 10 to 15 cm inside the edge two to three times, then the edge should be compacted. When working inside the building, the vibrating plate or eccentric block must not attach the walls. If several vibrator plates are used simultaneously on one surface, the parallel distance between the machines should not be less than five metres and the distance between the front and rear machines should not be less than ten metres. If the machine is working in an environment e.g. on soft or uneven ground, make sure to reduce the horsepower to the lowest level to prevent the machine from sinking. On slopes (max. 20° allowed!!!), make sure that the machine does not tilt. Pay particular attention to the following particularly dangerous areas: o During tunnel work, good ventilation must be provided to prevent accidents. In addition, the ventilation must be monitored. o There is a risk of electric shock near overhead lines. Persons not in control of the machine should not be in the near or far working area. o The stability of the machine should be taken into account when working and parking the machine in order to avoid hazards. During tunnel work, good ventilation must be provided to prevent accidents. In addition, there must be a functioning control system for the functioning of the fresh air supply.

Turn the fuel valve (1) to the "On" position.

Set the engine ON/OFF switch (2) (ignition switch) also to the "On" position.

NOTE: The closed position of the choke lever (5) enriches the fuel mixture for starting a cold engine. The open position (4) provides the correct fuel mixture for normal operation after starting and for restarting a warm engine. Turn the choke lever (3) to the "Closed" position (5), only for cold engine.

Set the throttle lever (6) to "half throttle" (= middle position between "fast" (8) and "slow" (7)). NOTE:: Do not pull the starter rope through to the end and do not let it rewind after pulling, but only rewind it quickly.

Grab the starter handle (9) and pull it out slowly. The resistance becomes strongest at a certain point. This point corresponds to the compression point. Let the rope roll back a little from this point and then pull it out powerfully. Turn the choke lever to "Open when the engine is running. Open throttle further Machine to start compacting.

Set the upper throttle lever to "minimum" and let the engine run idle for approx. 3 minutes at low engine speed. Then set the engine ON/OFF switch (ignition switch) to the OFF position. Close the fuel switch. Wait until the engine has cooled down before storing the machine.

16.4.2 Emergency Stop

In case of danger and/or in an emergency situation, you can quickly switch off the machine with the speed governor by pushing it completely into the STOP position.MAINTENANCE ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 36 ZI-RPE60_ZI-RPE90 17 MAINTENANCE WARNING

Hot surfaces and rotating machine parts while the engine is running can cause serious injury or even death! Always stop the machine before carrying out any conversion, adjustment, cleaning or maintenance work and secure it against unintentional restarting.

17.1 Maintenance and Servicing Pan

The specified intervals refer to working under "normal" operating conditions. Depending on the load, a change/exchange may also be necessary at an earlier point in time. What to do? Frequency Check fuel level before each start-up Check engine oil level before each start-up Control of the operating elements before each start-up Check for damaged parts before each start-up Checking for loose or lost screws before each start-up Change engine oil first after 20 h, then every 100 h Check V-belt every 50 h; replacement after 300 h or 1 year Change exciter oil every 200 h Air filter cleaning every 50 h, replacement after 300 h or 1 year Spark plug test every 100 h; replacement after 300 h or 1 year

17.2 Changing the exciter oil

Waste oils are toxic and must not be released into the environment! Contact your local authorities for information on proper disposal.

To drain the exciter oil, remove the drain screw (2) from the exciter (1) and then tilt the machine. (Note that the oil can drain more easily when warm.) Then straighten the machine again and top up with fresh oil. Recommended oil is 20W20 or similar about 100ml is needed for a refill.

20W20 oder ähnliches es sind ca. 100ml einzufüllen. To drain the exciter oil, loosen the rubber cover (4) on the machine (3) and remove the drain screw (5) behind it. Then tilt the machine. (Note that the oil can drain more easily when warm.) Then straighten the machine again and top up with fresh oil. Recommended oil is 20W20 or similar about 100ml is needed for a refill.MAINTENANCE ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 37 ZI-RPE60_ZI-RPE90

17.3 Changing the engine oil

Waste oils are toxic and must not be released into the environment! Contact your local authorities for information on proper disposal.

Loosen oil drain plug (1) on the rear of the engine. Open oil tank cap (2). Collect the draining oil in a collecting container and dispose of it properly! Tighten oil drain plug again after emptying. Top up with fresh oil via the filling opening (2) (see section Checking the engine oil level). Only use high-quality engine oil, e.g. SAE30, 15W40 or similar!

17.4 Cleaning the air filter

A contaminated air filter can contribute to problems starting the machine, loss of performance during operation and shorten engine life. Zipper Machines does not accept any liability for engine damage caused by failure to clean the air filter regularly. To clean the air filter, first loosen the wing nut on the air filter housing, remove the cover (foam filter element (2)) and remove the air filter cassette (paper filter element (1)). Clean both elements mechanically with a soft brush. If only the air filter cassette is to be cleaned, blow a dry jet of compressed air from the inside against the filter until all dust has been removed. An air filter change is necessary when: The engine power drops and the fuel consumption increases at the same time. the oil consumption increases the starting of the engine becomes more difficult

17.5 Checking and replacing V-belt and coupling

Warning of danger of detection/trapping in! Never attempt to check the V-belt while the engine is running. Your hands could get caught between the V-belt and the clutch. Serious hand injuries are the result.Warnung vor Erfassungs-/Einzugsgefahr!

If the vibratory power of the machine - regardless of the number of operating hours - suddenly decreases or stops completely during normal operation, first of all check the V-belt and clutch. Loose or worn V-belts reduce power transmission efficiency, result in poor compaction performance and shorten the service life of the belt itself. Therefore, always check the V-belt tension at the specified intervals. WARNI NGMAINTENANCE ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 38 ZI-RPE60_ZI-RPE90

Loosen V-belt cover screws (1) and remove them. Check tension: V-belt tension is OK, if the belt (2) yields approx. 10 to 15 mm under pressure with thumb and index finger (3) (see illustration on the left). If the V-belt is too loose or too tight, adjust the tension! Remount V-belt cover after having checked/corrected V-belt tension!

The V-belt is tensioned by moving the engine block on the vibratory plate. Remove the V-Belt protection cover. Loosen the four nuts securing the motor unit to the base plate until the motor can be moved forward on the base plate. Loosen the nut(s) (1) to adjust the motor position with the screw(s) (2). Screw in the screw(s) (turn to the right) = tighten the belt. Unscrew the screw(s) (turn to the left) = Loosen the belt. Once the belt has the correct tension, retighten the four nuts securing the motor unit to the base plate and retighten the motor position adjustment screw(s) (2) using the nuts (1). Fix the four nuts securing the motor unit to the base plate again. Finally, retighten the V-belt protection cover.

17.5.3 Changing the V-belt

Loosen the V-belt and move it to the maximum foremost position. Then pull over the V-belt over the pulleys. Clean the drive wheels including the V-groove and the inside of the protective cover. Install the new V-belt and tension the V-belt again. Finally, reattach the V-belt protective cover.TRANSPORT ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 39 ZI-RPE60_ZI-RPE90

17.5.4 Checking the clutch

Check the clutch at the same time as the V-belt. With the belt removed, visually check the outside for seizure and the "V" groove for wear and damage. Clean the V-groove as required. If the clutch shoe is worn, the power transmission becomes insufficient.

17.6 Cleaning the spark plug

Pull out the spark plug cap and remove impurities from the outside of the spark plug. Unscrew the spark plug using the spark plug wrench. Check the ceramic insulation, clean the electrodes (metal tips) and check the distance between the contacts. It should be 0.7 to 0.8 mm. Reinstall the cleaned (or replaced) spark plug and replace the spark plug cap. 18 TRANSPORT WARNING

Never lift or transport the machine with the engine running!

18.1 Transport over shorter distances

For transport over short distances, use the hand holder and the mounted transport wheels:

Release the transport wheels from the rubber holder and support the wheel axle on the ground. Pull the machine backwards until the base plate rests on the rubber supports of the wheel suspension. Press the handle vertically until the centre of gravity

Move the machine only on level and firm ground.

18.2 Lifting and transporting with separate devices

There are two persons required to lift and park the machine on another transporting devices. - one person to operate the hoist and one person to keep the machine in balance.

When transporting over long distances, fold the handle forward as far as possible (see illustration on the left). Ensure that the lifting equipment, including accessories, is suitable for loads greater than 90 kg. Before lifting, check the weld on the lifting ring and the fixing of the lifting frame. First lift the machine only a few centimetres to check the load capacity. Then lift the machine as gently as possible into the desired position. Secure the load properly for transport.STORAGE ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 40 ZI-RPE60_ZI-RPE90 19 STORAGE If the machine is not used for a longer period of time (>30 days): Empty the oil tanks or fuel tank. Remove the spark plug and pour a few drops of engine oil into the cylinder. Using a rope starter, turn the engine a few times so that the oil is well distributed inside the cylinder. Clean the spark plug and replace it. Cover the cooled machine and store it out of the reach of children and unauthorised persons in a well-ventilated, dry and frost-free environment. 20 DISPOSAL

Observe the national waste disposal regulations. Never dispose of the machine, machine components or operating equipment in the residual waste. If necessary, contact your local authorities for information regarding available disposal options. If you purchase a new machine or equivalent equipment from your specialist dealer, he is obliged in certain countries to dispose of your old machine properly. 21 TROUBLESHOOTING WARNING

Hot surfaces and rotating machine parts while the engine is running can cause serious injury or even death. Always stop the machine before carrying out troubleshooting work and secure it against unintentional restarting.

Fault Possible cause / remedy Motor does not start Check On/Off switch and make sure it is positioned to "On". Check fuel supply. Check engine oil level (a sensor prevents starting if oil level is too low). Make sure that the spark plug ignition cable is connected. Check spark plug Check carburettor and air filter and make sure they are clean. Motor stops Check fuel supply. Check that the fuel tap is open. Check oil levels. Check the condition of the air filter. Engine does not deliver enough power: Check fuel supply. Check that the fuel tap is open. Check the condition of the air filter. Check throttle position Insufficient vibration Check whether the V-belt slips or is lost. Check throttle position Machine does not move freely Check the underside of the disc for buildup.PREFACIO (ES) ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 41 ZI-RPE60_ZI-RPE90 22 PREFACIO (ES) Este manual contiene informaciones e instrucciones importantes para el uso correcto e instalación de las placas compactadoras de ZIPPER, ZI-RPE60 y ZI-RPE90, en lo sucesivo denominada "máquina".