ZIWP400TN - Saw Zipper - Free user manual and instructions

USER MANUAL ZIWP400TN Zipper

READ THE MANUAL! Read the user and maintenance manual carefully and get familiar with the controls in order to use the machine correctly and to avoid injuries and machine defects.SICHERHEITSZEICHEN / SAFETY SIGNS / SYMBOLES DE SECURITE ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 4 ZI-WP400TN

Caution! Risk of injury! Failure to keep your hands away from the saw blade will result in serious personal injury.

It is forbidden to remove or tamper with the protection devices and safety devices!

sound pressure level L

• Sägeblatt tauschenPREFACE (EN) ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 24 ZI-WP400TN 11 PREFACE (EN) Dear Customer! This operating manual contains information and important notes for safe commissioning and handling of the Log Saw ZI-WP400TN, hereinafter referred to as "machine". The manual is an integral part of the machine and must not be removed. Keep it for later use in a suitable place, easily accessible to users (operators), protected from dust and moisture, and enclose it with the machine if it is passed on to third parties! Please pay special attention to the chapter Safety! Due to the constant further development of our products, illustrations and contents may differ slightly. If you notice any errors, please inform us. Technical changes reserved! Check the goods immediately after receipt and make a note of any complaints on the consignment note when the delivery person takes them over! Transport damage must be reported separately to us within 24 hours. Zipper cannot accept any liability for transport damage not noted.

Copyright © 2021 This documentation is protected by copyright. All rights reserved! In particular the reprint, the translation and the removal of photos and illustrations will be prosecuted.

Court of jurisdiction is the regional court Linz or the competent court for 4707 Schlüsslberg, Austria!

Customer service contact

Z.I.P.P.E.R MASCHINEN GmbH AT-4707 Schlüsslberg, Gewerbepark 8 Tel [phone] – 700 Fax [phone] – 720 [e-mail] ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 25 ZI-WP400TN 12 SAFETY This section contains information and important notes on safe start-up and handling of the 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 personal injury and damage to property. In addition, observe the symbols and pictograms used on the machine as well as the safety and hazard information!

12.1 Intended use of the machine

The machinery is intended exclusively for the following operations: For cutting round wood, logs and other woody materials. Information on the condition of the workpieces: - There must be no foreign objects, such as nails, in the workpiece! - Only one workpiece may be machined at a time, regardless of its dimensions! - It is not allowed to process several and also no bundles of cut material. - To prevent wedging and recoil of the cut material, bent cut material must always be placed in the log carriage so that the outer edge faces the machine. ZIPPER-MASCHINEN assumes no responsibility or warranty for any other use or use beyond this and for any resulting damage to property or injury.

12.1.1 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

12.1.2 Prohibited Use / Forseeable Misuse

- Operating the machine without adequate physical and mental aptitude - Operating the machine without knowledge of the operating instructions - Changes in the design of the machine - Remove the safety markings attached to the machine - Modify, circumvent or disable the safety devices of the machine - Operating the machine in a potentially explosive environment (Machine can generate ignition sparks during operation) - Operating the machine outside the technical limits specified in this manual - Machining of materials with dimensions outside the limits specified in these instructions. - Use of tools that do not comply with the safety requirements of the standard for machine tools for woodworking (EN847-1). - Use of saw blades made of HSS steel. - Use of saw blades with a lower max. speed than the machine. The improper use or disregard of the versions and instructions described in this manual will result in the voiding of all warranty and compensation claims against Zipper Maschinen GmbH.

12.2 User Requirements

The machine is designed for operation by one person. The physical and mental aptitude 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 supervision or instruction from 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!SAFETY ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 26 ZI-WP400TN 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 under the instruction and supervision of a qualified electrician.

12.3 General safety instructions

To avoid malfunctions, damage and health hazards when working with the machine, the following points must be observed in addition to the general rules for safe working:

• Before start-up, check the machine for completeness and function. Only use the machine if the guards and other non-parting guards required for machining have been fitted, are in good operating condition and have been properly maintained.

• Choose a level, vibration-free, non-slip surface for the installation location.

• Ensure sufficient space around the machine!

• Ensure sufficient lighting conditions at the workplace to avoid stroboscopic effects.

• Ensure a clean working environment.

• Only use perfect tools that are free of cracks and other defects (e.g. deformations).

• Remove tool keys and other adjustment tools before switching on the machine.

• Keep the area around the machine free of obstacles (e.g. dust, chips, cut parts, etc.).

• Check the strength of the machine connections before each use.

• Never leave the running machine unattended. Switch off the machine before leaving the working area and secure it against unintentional or unauthorised recommissioning.

• The machine may only be operated, serviced or repaired by persons who are familiar with it and who have been informed of the hazards arising from this work.

• Ensure that unauthorised persons maintain a safe distance from the machine and keep children away from the machine.

• When working on the machine, never wear loose jewellery, loose clothing, ties or long, open hair.

• Hide long hair under hair protection.

• Wear close-fitting protective clothing and suitable protective equipment (eye protection, dust mask, ear protection; gloves only when handling tools).

• Hide long hair under hair protection.

• Always work with care and the necessary caution and never use excessive force.

• Do not overload the machine!

• Do not work on the machine if it is tired, not concentrated or under the influence of medication, alcohol or drugs!

• Do not use the machine in areas where vapours from paints, solvents or flammable liquids represent a potential danger (danger of fire or explosion!).

• Do not smoke in the immediate vicinity of the machine (fire hazard)!

• Shut down the machine and disconnect it from the power supply before carrying out any adjustment, conversion, cleaning, maintenance or repair work. Before starting any work on the machine, wait until all tools or machine parts have come to a complete standstill and secure the machine against unintentional restarting.

12.4 Electrical safety

• Improper use of extension cords may cause inefficient operation of the machine, resulting in overheating. Make sure that the extension cord is not longer than 10 m and its cross-section is not less than 2.5 mm² to allow sufficient current flow to the motor.

• Avoid using free and insufficiently insulated connections. Connections must be made with appropriate material suitable for outdoor use.

• A damaged or tangled cable increases the risk of electric shock. Handle the cable with care. Never use the cable to carry, pull or disconnect the power tool. Keep the cable away from heat, oil, sharp edges or moving parts.

• Proper plugs and sockets reduce the risk of electric shock.

• Water entry into machine increases the risk of electric shock. Do not expose machine to rain or moisture.

• The machine may only be used in humid environments if the power source is protected by a residual current circuit breaker.

• Do not use the power tool if it cannot be turned on and off with the ON-OFF-switch.SAFETY ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 27 ZI-WP400TN

12.5 Special safety instructions for this machine

• When using milling tools with a diameter of ≥ 16 mm and circular saw blades, these must comply with EN 847-1:2013 and EN 847-2:2013; tool carriers must comply with EN 847- 3:2013.

• 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.

• Replace cracked and deformed saw blades immediately, they cannot be repaired.

• Use saw blades that are clean and sharpened, they are less prone to failure and are easier to guide.

• Never attempt to cut logs that contain nails, wire or debris. Branches must be cut flush with the trunk.

• Always maintain a secure standing position and balance. Never stand on the machine. Serious injury can occur if the machine tips over or if the cutting tool is accidentally touched. Do not keep objects above or near the machine that someone could stand on to reach the machine.

• Do not attempt to load or unload logs until the machine has stopped.

• Do not remove residual pieces or other parts of the workpiece from the cutting area while the machine is running, unless you use a push stick.

• Keep your hands away from all moving parts.

• Do not grasp around the saw blade with both hands while the machine is running.

• Avoid awkward cutting operations and hand positions where a sudden slippage could cause your hand to get caught at the saw blade.

• Never deposit logs to be split in such a way that you have to reach over the machine.

• Operate the control handle with your hands only. Never use your foot, knee or any other extension tool.

• Never attempt to free a jammed saw blade without first turning off the machine.

12.6 Hazard warnings

Despite their intended use, certain residual risks remain. Due to the structure and construction of the machine, hazardous situations may occur when handling the machines: DANGER

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

Such a safety instruction indicates a potentially hazardous situation which, if not avoided, may result in serious injury or even death.

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

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!TRANSPORT ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 28 ZI-WP400TN 13 TRANSPORT For proper transport, follow the instructions and information on the transport packaging regarding centre of gravity, attachment points, weight, means of transport to be used and prescribed transport position, etc. Transport the machine in its packaging to the place of installation. When lifting, carrying and depositing the load, make sure that you are in the correct posture:

• Lifting, Depositing Ensure stability when lifting / setting down (legs hip width). Lift / lower load with bent knees and straight back (like weightlifter). Do not lift / lower the load jerkily.

• Carrying Carry load with both hands as close to body as possible. Carry load with straight back. 14 ASSEMBLY

14.1 Checking scope of delivery

Check the machine immediately after delivery for transport damage and missing parts.

Choose a suitable place for the machine. Pay attention to the safety requirements and the dimensions of the machine. The selected location must ensure a suitable connection to the electrical supply. Make sure that the machine is placed on a solid and level surface and that the ground can support the load of the machine. The machine must be levelled at all support points. It is also necessary to guarantee a distance of at least 0.8 m around the machine. The necessary distance for the feeding of long workpieces must be provided.

Anchoring on level ground Use four bolts to secure your machine to the ground. Due to the different ground conditions, these are not included in the delivery content. Select the correct bolt type for your soil conditions.ASSEMBLY ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 29 ZI-WP400TN

The machine was disassembled for transport and must be assembled as shown below. Before commissioning, check all screw connections for tightness and tighten them if necessary.

1. Assembly saw blade guard 1

Place the back plate 1 against the outside of the connection part on the log carriage and align its two holes with the upper two holes of the connection part as shown in Fig. A, Pic. 1.

Fix the back plate 1 to the table by using one M8×12 screw, a washer and a nut as shown in Fig. A, Pic. 2. Place the saw blade guard 1 against the inner side of the same connecting part, align the holes and connect the saw blade guard 1, the connecting part and the back plate 1 by using three M8×20 screws, washers and nuts.

Repeat the same assembly steps on the other side for back plate 2 and saw blade guard 2, as shown in Fig. A, Pic. 3 & 4.ASSEMBLY ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 30 ZI-WP400TN

Attach the handle to the back of the log carriage. Fix it with two M8×25 screws and locknuts as shown in Fig. B. Screw the M5×20 wing screw into the hole at the upper right corner.

Fix the ON- OFF switch to the motor plate with M4×55 screws as shown in Fig. C.

Fix one end of the guide pipe with return spring to the left leg using M8×55 bolts, washers and locknut as shown in Fig. D.ASSEMBLY ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 31 ZI-WP400TN

5. Connecting pivoting log carriage and base

frame Place the pivoting log carriage on the ground with the legs inside the base frame and put one end of the cross brace to the outside as shown in Fig. E. Secure them using M8×40 bolts, washers and lock nuts on both sides. Fix the other end of the cross brace from the inner side of the base frame using M8×70 bolts, washers and lock nuts on both sides.

6. Assembly inner saw blade cover

Slide the shaft through the centre hole of the inner saw blade cover and a lign the other holes with those on the motor plate as shown in Fig. F. Secure the shaft with three M8×20 screws, washers and locknuts on the upper side and one M8×45 screw, washer and locknut on the lower side.ASSEMBLY ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 32 ZI-WP400TN

7. Assembly saw blade

Slide the rear saw blade flange onto the motor shaft. Place the saw blade together with the front clamping flange on the rear flange and secure it with the nut M20×1.5 as shown in Fig. G, Pic. 1. Tighten the nut with the saw blade wrench by holding the f ront clamping flange with the face wrench in order to stop back as shown in Fig. G, Pic. 2 & 3. NOTICE

Please note! Always keep the two special keys properly.

When handling circular saw blades when changing tools, please use safety gloves to avoid risk of injury. CAUTION Make sure that the saw blade is inserted in the correct position. The arrow on the saw blade must point in the direction of the operating side!

8. Assembly outer saw blade cover

Fix the outer saw blade cover to the inner cover using four M5×10 cross-head screws and washers as shown in Fig. H.ASSEMBLY ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 33 ZI-WP400TN

9. Fixing return spring and Chain

Take the cotter pin and washer out of the guiding pipe with spring as in Fig. I, step 1. Move the log carriage to the base frame until the open end of the gu iding pipe is inserted into the angle part at the base frame, as Fig. I, step 2.

Secure the pipe by using a washer and cotter pin as shown in Fig. I, step 3. Fix the open end of the chain to the base frame at the left side by using a M8×50 screw, two washers and a nut as shown in Fig. I, step 4. Guard plate of the inner saw blade cover Install the guard plate of the inner saw blade cover on the saw blade guard by using a M5 nut and two washers as shown in Fig. I, step 5.

Install the limit plate and fasten it with two M5×10 screws and washers as shown in Fig. JASSEMBLY ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 34 ZI-WP400TN

Install the top guard with four M5×10 screws and lock nuts as shown in Fig. K.

Loosen the M5×20 wing screw on the rear side of the log carriage until the log carriage extension can be inserted into the opening. Slide the log carriage extension into the channel and align it correctly. Then fix it with the wing screw.OPERATION ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 35 ZI-WP400TN

14.4 Electrical connection

• Connect the machine to a standard 230V±10% (50Hz±1Hz) power supply equipped with protections for undervoltage, overvoltage, overcurrent and a residual current device (RCD) with a maximum residual current of 0.03A.

• The plug of the machine must fit into the socket. The plug must not be modified in any way. Do not use adapter plugs together with protectively earthed machines. Unmodified plugs and matching sockets reduce the risk of electric shock.

• Only use extension cords that are also suitable for outdoor use. Using an extension cord suitable for outdoor use reduces the risk of electric shock. 15 OPERATION

15.1 Work before start-up

• Make sure that the saw blade is firmly secured, in perfect condition, sharpened and guaranteed to run smoothly.

• Make sure that the rocker unit with the log carriage is fully extended before each use. Otherwise there is an increased risk of recoil.

• When cutting material, pay attention to foreign objects such as wires, nails, etc. as well as irregularities in the material, such as knots.

• Check that the moving parts are working properly and are not jammed.

• Ensure that the machine is securely anchored to the ground.

• Ensure that the correct power supply and cable are used. Insert the plug into the socket.

1. Switch on the machine.

2. Open the top guard.

3. Position the cut material into the log carriage on the completely extended rocker unit.

4. Close the top guard again.

5. Grasp the handle on the left side of the carriage and slide it towards the saw blade cover.

6. Continue pressing with even force until the cut material has been cut.

7. After the cut, move the log carriage all the way back again.

8. If necessary, reposition the cut material and repeat steps 4 to 7 until the work is finished.

9. Switch off the machine after work.

10. Wait until the machine stops.

11. Disconnect the power plug and clean the unit if necessary.

Free blocked log If the saw blade is blocked, proceed as follows:

1. Switch off the machine immediately!

2. Wait until the machine comes to a standstill

3. Pull out power plug.

4. Carefully remove the blocked log from the machine.MAINTENANCE

Danger due to electrical voltage! Handling the machine with the power supply up can lead to serious injuries or even death. Always disconnect the machine from the power supply before servicing or maintenance work and secure it against unintentional or unauthorised reconnection! The machine is low-maintenance and only a few parts have to be serviced. Nevertheless, malfunctions or defects which could impair the safety of the user must be rectified immediately! Repair work may only be carried out by qualified personnel! To prolong the lifespan of the machine, oil the rotating parts once a month. Do not oil the motor.

16.1 Sharpening the saw blade

The saw blade can be sharpened several times without being removed from the machine. Use a fine-cut square-blade file of 8–12’’ for sharpening. Pay attention to the following points when sharpening:

• During manual sharpening only file the front rake of the tooth over a distance of about 5–7 mm.

• Always keep the original shape of the tooth.

• Do not make sharp notches at the root of the tooth with the file.

• Always clean the blade-clamps carefully.

16.2 Changing the saw blade

1. Dismantle the limit plate by loosening the

M5×10 screws, spring washers and washers.

2. Remove the M5 nut and flat washers from the

guard plate. CAUTION

3. Pull the cotter pin and washer out of the return

4. Remove the M8×50 screw, washers and the

5. Lower the log carriage slowly towards the

6. Remove the four M5×10 screws and washers

from the saw blade guard and also from the outer saw blade cover.MAINTENANCE ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 38 ZI-WP400TN

7. Dismantle the M20×1.5 nut and the front

clamping flange. Remove the old saw blade.

NOTICE The use of paint thinners, petrol, aggressive chemicals or scouring agents will damage the plastic surfaces! Therefore, only use mild cleaning agents for cleaning! Make sure that no water seeps into the machine! Clean the machine after each use. Wipe it with a clean, damp cloth or blow off dust and material residues with compressed air at low pressure. Keep all safety devices, ventilation openings and the motor housing as free as possible from dirt and dust. Make sure that no water can enter the machine. The entry of water into a power tool increases the risk of electric shock.

• Disconnect the power plug

• Store unused machines in a dry, locked place out of the reach of children. To extend the service lifespan of the machine and ensure smooth operation, carry out the following before storing it for a longer period of time:

• Clean the machine thoroughly.

• Treat all moving parts with an environmentally friendly oil. Never use grease! Do not oil the engine!

Observe the national waste disposal regulations. Never dispose of the machine, machine components or equipment in residual waste. If necessary, contact your local authorities for information on the disposal options available. If you buy a new machine or an equivalent device from your specialist dealer, he is obliged in certain countries to dispose of your old machine properly.TROUBLESHOOTING ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 39 ZI-WP400TN 17 TROUBLESHOOTING WARNIUNG

Danger due to electrical voltage! Handling the machine with the power supply up can lead to serious injuries or even death. Always disconnect the machine from the power supply before servicing or maintenance work and secure it against unintentional or unauthorised reconnection! Problem Possible cause Fault eleimination Saw blade gets loose after turning off the motor

• Fastening nut tightened insufficiently

• Tighten fastening nut (right-hand thread) Motor does not start

• 3. Connections of the motor or switch defect

• 4. Motor or connections defect

• 3. Have it checked by an electrician

• 4. Have it checked by an electrician Wrong direction of motor rotation

• Capacitor defect • Have it checked by an electrician. Motor unable to run – the fuse is tripped

• Cross section of the extension cable insufficient

Overload by dull saw blade

• See the wiring diagram in the manual

Exchange saw blade Burns on the cutting surface

• Insert sharpened saw blade

19.1.1 Restrictions techniques