ZISTE7500DSH - Generator Zipper - Free user manual and instructions

USER MANUAL ZISTE7500DSH Zipper

11.4 Special safety instructions for the operation of the machine ............................. 22

11.5 Safety instructions for machines with combustion engine ................................. 22

10 PREFACE (EN) Dear Customer! This manual contains information and important instructions for the installation and correct use of the ZIPPER generators ZI-STE6700DH and ZI-STE7500DSH. Following the usual commercial name of the machine (see cover) is substituted in this manual with the name "machine". This manual is part of the product and shall not be stored separately from the product. Save it for later reference and if you let other people use the product, add this instruction manual to the product. Please read and obey the security instructions!

Due to constant advancements in product design, construction pictures and content may diverse slightly. However, if you discover any errors, inform us please. Technical specifications are subject to changes! Please check the product contents immediately after receipt for any eventual transport damage or missing parts. Claims from transport damage or missing parts must be placed immediately after initial product receipt and unpacking before putting the product into operation. Please understand that later claims cannot be accepted anymore.

Copyright © 2018 This document is protected by international copyright law. Any unauthorized duplication, translation or use of pictures, illustrations or text of this manual will be pursued by law. Court of jurisdiction is the regional court Linz or the competent court for 4707 Schlüsslberg, Austria!

Customer service contact

11 SAFETY This section contains information and important notices for safe commissioning and handling of machine. For your own safety, read these operating instructions carefully before putting the machine into operation. This will enable you to handle the machine safely and prevent misunderstandings as well as possible damage to property and persons. Also observe the symbols and pictograms used as well as the safety instructions and hazard warnings!

11.1 Intended use of the machine

The machine is intended exclusively for the following activities: This power unit is designed exclusively for operating electric devices whose max. performance is within the specifications for the generator. A higher starting current of inductive loads must be considered. The generator is designed to operate from conventional resistive and inductive loads, such as Lights, electric hand tools (drills, electric chain saws, compressors) determined. When connecting to stationary systems such as heating, house supply, air conditioning or for the power supply of mobile homes, an electrician and the heating manufacturer must be consulted regarding the connection and grounding. ZIPPER-MASCHINEN assumes no responsibility or warranty for any other use or use beyond this and for any resulting damage to property or injury.

11.1.1 Technical Restrictions

The machine is intended for use under the following ambient conditions: Relative humidity: max. 65 % Temperature (for operation) +5° C bis +40° C Temperature (for storage and/or transport) -20° C bis +55° C

11.1.2 Prohibited Use / Forseeable 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

• Remove the safety markings attached to the machine.

• Modify, circumvent or disable the safety devices of the machine. 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.

11.2 User Requirements

The physical and mental suitability as well as knowledge and understanding of the operating instructions are prerequisites for operating the machine. Persons who, because of their physical, sensory or mental abilities or their inexperience or ignorance, are unable to operate the machinery safely must not use it without the supervision or instruction by a responsible person. 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 22

ZI-STE6700DH & ZI-STE7500DSH

11.3 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.

• 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 (eg. ear protection,.., 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.

11.4 Special safety instructions for the operation of the machine

• Do not use the generator if it is raining, wet or has high humidity. RISK OF ELECTRIC SHOCK. DANGER OF LIFE!.

11.5 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.

• 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.

11.6 Hazard warnings

Despite intended use, certain residual risks remain.

• Risk of burns: Touching the mufflers, exhaust and other machine components which can be hot after prolonged continuous operation or when the engine is hot cause severe burns.ASSEMBLY ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 23

ZI-STE6700DH & ZI-STE7500DSH

• Risk of fire and explosion: NEVER refuel fuel or engine oil while the machine is in operation or is hot. When refuelling and at places where fuel is stored not smoke or allow open flames or sparks. Do not overfill the fuel tank and avoid the spillage of gasoline during refuelling. If fuel is spilled, make sure the area is completely dry and cleaned before starting the engine. Make sure that the filler cap is tightly closed again after refuelling safely.

• Chemical risks Never use or refuel a gasoline or diesel engine in a closed area without adequate ventilation. Carbon monoxide emissions from the internal drive units of the engine can cause in confined spaces through inhalation health effects and death. Therefore, use the machine only in well- ventilated rooms or outdoors in operation. Liquid fuels can cause serious damage on the skin and the environment.

• Risk of electric shock Direct electrical contact may cause electric shock. Never touch the unit with wet hands. Provide adequate grounding.

• Hearing damage A longer stay in the immediate vicinity of the running unit may cause hearing damage. Wear ear protectors! 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. WARNING

Such a safety instruction indicates a potentially hazardous situation which, if not avoided, may result in serious injury or even death. CAUTION A safety instruction designed in this way indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. NOTICE

A safety note designed in this way indicates a potentially dangerous situation which, if not avoided, may result in property damage. Irrespective of all safety regulations, their sound common sense and corresponding technical suitability/training are and remain the most important safety factor in the error-free operation of the machine. Safe working depends first and foremost on you! 12 ASSEMBLY

12.1 Check scope of delivery

After delivery, check the machine immediately for transport damage and missing Parts. ZI-STE6700DH: The machine is delivered almost fully assembled. If desired, the transport unit can be mounted and battery have to be connected.OPERATION ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 24

Assembly wheel shaft Fix the wheel shaft to the frame with 2 clamps and 4 screws.

Assembly wheels Place the wheel (1) on the stub shaft (3), add washers (4) and secure against axial movement by means of the cotter pin (3). Carry out that assembly steps on both sides.

Assembly Feet Attach the rubber feet (1) to the stand feet (29) and slide the stand foot (2) into the holder on the frame and secure it with the screw (3). Connecting the battery The battery is attached to the frame by means of a holding bracket (1) or can be removed after loosening. Clamp the (+) pole (3) red to the battery using a screw connection, then clamp the (-) pole (2) black to the battery using a screw connection. Put both pole covers (2a, 3a) back in place to protect the two poles. ZI-STE7500DSH: The machine is delivered fully assembled. There is no further assembly necessary, except connection of the battery. 13 OPERATION This power unit is designed exclusively for operating electric devices whose max. Performance within the performance specifications of the generator. A higher starting current of inductive loads must be considered.

13.1 Checklist before each use

13.1.1 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. NOTICE

Engine oil and fuels are toxic and must not be released into the environment! Follow the instructions of the supplier and, if necessary, contact your local authorities for information on proper disposal.OPERATION ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 25

1. 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.

2. Unscrew the oil dipstick and wipe with a clean,

lint-free cloth or a non-fibrous paper towel.

3. Push the dipstick into the opening, but do not

screw it in. (Make sure that the dipstick has really been pushed in completely).

4. Pull out the oil dipstick again and read off the oil

level. There are two markings for this - see illustration on the left.

5. If the oil level is low, refill the recommended oil

up to the upper edge

6. Push in the oil dipstick again and tighten.

To operate the generator, use engine oil that meets the following requirements: suitable for diesel engines 0W30 or 15W40 with classification CF/ CH-4/ or CI-4 For year-round operation, engine oil with SAE viscosity level 15W-40 is recommended.

13.1.2 Checking the fuel tank level

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.

1. Screw on the tank cap (sits on the fuel tank).

2. Level check in the form of a visual inspection or via display. If necessary, top up

with diesel fuel with the appropriate standard EN 590.

3. Close the fuel filler cap tightly after refuelling.

13.1.3 Check the air filter

Check the core of the air filter, ensuring that it is clean and performs well.

• Loosen the screw on the cover of the filter, and then dismantle the cover to check the filter.

• Please clean or change the filter if necessary. NOTICE

• Do not run the engine without the air filter, or else filth will enter the engine through carburetor, resulting in quick wear and tear of the engine.

• If the power output drops or the colour of the exhaust gases does not lock normal, renew the air filter immediately.

Before starting up the machine, have it grounded by a qualified electrician! If the machine is intended for mobile operation, get a grounding cable with sufficient cross section from your electrical retailer.OPERATION ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 26

Make sure to treat the machine with care, when using it for the first time. After starting, let the motor run for 5 minutes without connecting the generator with consumer load. Following points should be checked in the first 5 minutes:

• Is the sound of the generator normal?

• Are the vibrations not to strong?

• Exhaust gases should not look black or white.

• Is oil pilot light showing? If these points meet the demands, the generator can be used further. Otherwise stop the generator and find the cause of the problem.

Open fuel tap. Set the speed control to position „RUN“. Electronic starter: - Set ignition key to position "ON". After waiting 1-2 seconds, turn the ignition key to position “Start”. - Release ignition key as soon as the engine has started. - If the engine does not start within ten seconds, stop the starting process. - Wait at least 30 seconds, before attempting a new start. Recoil starter: - Pull the rope hard and fast. - Pull the rope all the way out. - Use two hands if necessary Possible reasons for starting difficulties: Cold weather – if necessary, use starter-spray in the intake nozzle. Low battery, low acidity level – contact a qualified person or, with appropriate experience, refill distilled water yourself. Low oil (refill oil) Air in fuel-pipeline.

13.3.2 Stop the engine

• Disconnect all electronic equipment from the generator before switching off the engine.

• Allow the device to continue running for approx. five minutes (5 min) after a long period of use. This helps the motor to cool down. Turning off procedure Set circuit breaker to position "OFF". Turn ignition key to the left into position "OFF". Close fuel tap.

13.3.3 Electrical consumers

When the generator is running on nominal speed, electrical consumers can be connected. (Only for ZI-STE7500DSH: Select whether 230V or 400V should be operated by means of selector switch) Activate circuit breaker (ON;I)) When operating several consumers, you should first connect the consumer with the higher inrush currents requirement! If no problem occurs, more consumers can be connected. If the generator shuts down, the required power was probably too high. NOTICE

If the voltage (see voltmeter) is too high or too low, adjust the speed level. If a problem occurs, stop the generator and take care of the problem. At the DC-module (12V), a maximum amount of 8.3 A current is possible. CAUTION

Pay attention to correct connecting: Red connection: + terminal Black connection: - terminal 14 MAINTENANCE The machine is low-maintenance. It contains only a few parts, which have to be maintained regularly by the operator. Malfunctions or defects that could impair the safety of the machine must be repaired immediately. 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 and wait until the machine has cooled down

14.1 Maintenance-chart

Please maintain the generator in specified months or hours whatever comes first.

Before any use After 1. month or after first 20 operating hours After 3 month or every 100 operating hours After 6 month or every 500 operating hours Check tank, refuel if necessary

Check for loss of fuel or oil

Check for loose or missing screws O O Changing of oil

Cleaning the air filter

Cleaning the fuel filter

Check battery 1 x every month

1. If used in dirty places, the generator should be maintained more regularly.

2. If the user does not have the right tool, or has too little knowledge, maintenance should be

performed by a qualified person.

14.1.1 Engine oil change

Engine oil is toxic and must not be released into the environment! Follow the instructions of the supplier and, if necessary, contact your local authorities for information on proper disposal. NOTICE

Changing the oil is easier when the engine is still warm.

• Drain the dirty oil into a suitable container.

• Fix the oil outlet screw again.

• Fill in new engine oil

• Check the engine oil level with the dipstick

• If the level is correct reinsert the dipstick

14.1.2 Transport / Storage

In order to avoid the generator leaking oil during transport or temporary storage, make sure to switch off the generator, keeping it at a standing pose under normal operations. After the engine is totally cooled, turn the ventilating pole of the fuel-filling lid to the “OFF” position thoroughly. When transporting the generator: Do not let the fuel spill out of the fuel tank. (The top of the fuel-filling tank should have no fuel.) When the generator is placed on a vehicle, do not run the engine. You should take the generator down from the car before operation. When you take the generator to the car, avoid exposing it to sunshine. If it is put in sealed carriage for a long time, the high temperature of the carriage may cause the fuel to boiling away, thus leads to burn. Before the generator is put into a long-time storage, you should: Make sure the storage area is clean and dry. NOTICE

Store the machine with closed inlet- and outlet valves. Therefore, pull on the rope of the starter until you fell resistance.

Do not dispose of the machine in residual waste. Contact your local authorities for information regarding the available disposal options. When you buy at your local dealer for a replacement unit, the latter is obliged to exchange your old. 15 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 any conversion, adjustment, cleaning or maintenance work and secure it against unintentional restarting and wait until the machine has cooled down If you find yourself unable to carry out necessary repairs properly and/or do not have the required training to do so, always consult a specialist to fix the problem. Trouble Reason Shooting Engine will not start

Fuel cock closed No fuel Too little oil in the tank Air in fuel pipeline Battery too weak Set fuel cock in position “ON” Refill fuel Refill oil Have the fuel pipeline blown through Charge the battery with appropriate charger Engine runs unevenly Wrong fuel Air in fuel pipeline Use correct fuel Have the fuel pipeline blown through Motor too little power

Clean the filter elements, possibly exchange Low output voltage under load

Too much load available

Reduce existing load Uneven Output voltage Unbalanced load available Disconnect all electrical consumers. Then apply again individually to determine which consumer causes the uneven loads. High noise level Loose screw connections Tighten all screwsUVOD (SL) ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 29

Engine-Generator Assembly

Output panel assembly

Buoy for oil level indication

Fuel filter connect cover

33 WARRANTY GUIDELINES (EN) 1.) Warranty: Company ZIPPER Maschinen GmbH grants for mechanical and electrical components a warranty period of 2 years for amateur use; and warranty period of 1 year for professional use, starting with the purchase of the final consumer. In case of defects during this period, which are not excluded by paragraph 3, ZIPPER will repair or replace the machine at its own discretion. 2.) Report: In order to check the legitimacy of warranty claims, the final consumer must contact his dealer. The dealer has to report in written form the occurred defect to ZIPPER. If the warranty claim is legitimate, ZIPPER will pick up the defective machine from the dealer. Returned shippings by dealers which have not been coordinated with ZIPPER, will not be accepted and refused. 3.) Regulations: a) Warranty claims will only be accepted, when a copy of the original invoice or cash voucher from the trading partner of ZIPPER is enclosed to the machine. The warranty claim expires if the accessories belonging to the machine are missing. b) The warranty does not include free checking, maintenance, inspection or service works on the machine. Defects due to incorrect usage of the final consumer or his dealer will not be accepted as warranty claims either. Some examples: usage of wrong fuel, frost damages in water tanks, leaving fuel in the tank during the winter, etc. c) Defects on wear parts are excluded, e.g. carbon brushes, collection bags, knives, cylinders, cutting blades, clutches, sealings, wheels, saw blades, splitting crosses, riving knives, riving knife extensions, hydraulic oils, oil/air/fuel filters, chains, spark plugs, sliding blocks, etc. d) Also excluded are damages on the machine caused by incorrect or inappropriate usage, if it was used for a purpose which the machine is not supposed to, ignoring the user manual, force majeure, repairs or technical manipulations by not authorized workshops or by the customer himself, usage of non-original ZIPPER spare parts or accessories. e) After inspection by our qualified personnel, resulted costs (like freight charges) and expenses for not legitimated warranty claims will be charged to the final customer or dealer. f) In case of defective machines outside the warranty period, we will only repair after advance payment or dealer’s invoice according to the cost estimate (incl. freight costs) of ZIPPER. g) Warranty claims can only be granted for customers of an authorized ZIPPER dealer who directly purchased the machine from ZIPPER. These claims are not transferable in case of multiple sales of the machine. 4.) Claims for compensation and other liabilities: The liability of company ZIPPER is limited to the value of goods in all cases. Claims for compensation because of poor performance, lacks, damages or loss of earnings due to defects during the warranty period will not be accepted. ZIPPER insists on its right to subsequent improvement of the machine.GARANCIJA (SL) ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 59