ZIRD300 - Construction Equipment Zipper - Free user manual and instructions

USER MANUAL ZIRD300 Zipper

CE-Conformal! - This product complies with the EC-directives.

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 inju- ries and machine defects.

ATTENTION! Ignoring the safety signs and warnings applied on the machine as well as ignoring the security and operating instructions can cause serious inju- ries and even lead to death.

Stop before any break and engine maintenance!

Protective clothing!

It is forbidden to remove the protection devices and safety devices.

Gasoline and oil are highly flammable and explosive! Do not smoke or have open flames near the machine!

Burn hazard! Keep away from hot parts on the machine!

Solid Objects can be thrown away!

Keep your hands and feet clear from all rotating parts!

Only for working outside! The exhaust fumes are dangerous, containing car- bon monoxide.

Tipping hazard! Do not operate on slopes with angle over 15° or tip loading at an inclined position.

ATTENTION! For transport engine oil has been drained. Fill up with 4-stroke quality motor oil before first operation! Failure to do so will result in permanent engine damage and void guarantee.

HINWEIS Sollten sie sich bei notwendigen Reparaturen nicht in der Lage fühlen diese ord- nungsgemäß zu verrichten, oder besitzen sie die vorgeschriebene Ausbildung dafür nicht, ziehen sie immer eine Fachwerkstätte zum Beheben des Problems hinzu.PREFACE (EN) ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 26 ZI-RD300 10 PREFACE (EN) Dear Customer! This manual contains important information and advice for the correct and safe use and maintenance of the wheeled dumper ZI-RD300. Following the usual commercial name of the device (see cover) is substituted in this manual with the name "machine". The manual is part of the machine and may not be stored separately. Read it profoundly be- fore first use of the machine and keep it for later reference. When the machine is handed to other persons always put the manual to the machine. Please follow the security instructions! Please read the entire manual, to prevent misunderstandings, machine damage or even inju- ries! Due to continuous development of our products illustrations, pictures might differ slightly. If you however find errors in this manual, please inform us. Technical changes excepted! Copyright law © 2020 This manual is protected by copyright law – all rights reserved. Especially the reprinting as well as the translation and depiction of pictures will be prosecuted by law. Court of jurisdiction is the Landesgericht Linz or the competent court for 4707 Schlüsslberg, AUSTRIA.

The machine must only be used for its intended purpose! Any other use is deemed to be a case of misuse. To use the machine properly you must also observe and follow all safety regulations, the assem- bly instructions, operating and maintenance instructions lay down in this manual. All people who use and service the machine have to be acquainted with this manual and must be informed about the machine's potential hazards. It is also imperative to observe the accident prevention regulations in force in your area. The same applies for the general rules of occupational health and safety. The machine is used for: Small loading and transportation tasks in landscaping and agriculture. Any manipulation of the machine or its parts is a misuse, in this case ZIPPER-MASCHINEN and its sales partners cannot be made liable for ANY direct or indirect damage. Even when the machine is used as prescribed it is still impossible to eliminate certain residual risk factors.

Max. load 300kg Allowed tilt position in the direction of travel: 15° Allowed tilt position transverse to direction of travel: 10° It is forbidden to remove the protection devices and safety devices! Read also the separately packed operation manual of the engine manufacturer Ambient conditions The machine may be operated: humidity max. 70% temperature +5°С to +40°С (+41°F to +104°F) Prohibited use

• The operation of the machine outside the stated technical limits described in this manual is forbidden.

• Operation of the machine function without any protection devices is forbid- den.

• Any manipulation of the machine and parts is forbidden.

• The machine is not approved for transporting passengers

• The machine is not approved for public traffic!

• Etwaige Änderungen in der Konstruktion der Maschine sind unzulässig.

• The use of the machine for any purposes other than described in this user-man- ual is forbidden.

• It is not allowed to leave the immediate work area during the work is being performed.!SAFETY ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 28 ZI-RD300

11.2 Security instructions

Missing or non-readable security stickers have to be replaced immediately! To avoid malfunction, machine defects and injuries, read the following security instructions! The locally applicable laws and regulations may specify the minimum age of the operator and limit the use of this machine! Use the machine only in good enough light to allow a safe operation can be guaranteed. In tiredness, decreased concentration or under the influence of alcohol or drugs, the work on the machine is prohibited! Caution in slippery conditions - slip hazard - risk of injury. When working, robust and non- slip footwear. Slides / stumble / traps are a major cause of serious injury. Unauthorized persons, especially children and not trained personnel must be kept away from the running machine! The machine must be operated only by trained persons (knowledge and understanding of this manual), which have no limitations of motor skills compared with conventional workers. No other person, children or pets shall remain within 15m! If you pass the machine to third, these instructions must be attached to the machine. Before each use, the reliability of the machine is to be checked Do not climb into the dump box Never carry passengers!

Danger of burns! During the operation flow of hot exhaust gases and engine parts such as the muffler and engine become hot. Let the machine cool down before storage. After the operation, the machine must cool down. Otherwise there is an imminent risk of burns

WARNING: Gasoline is highly flammable!

Stop the engine before refuelling Smoking and open flames are prohibited during refuelling. Do not refuel when the engine and carburettor are still very hot Refuel only outdoors or in a well ventilated area. Avoid contact with skin and clothes (fire hazard). Check after refuelling tank cap and check for leaks. Spilled fuel is to wipe immediately. Keep the fuel in suitable containers only Make sure the fuel does not overflow. If the fuel overflows, the engine must not be started. Remove any dirt from the appliance and prevent any attempt at ignition until fuel fumes have evaporated. Damaged fuel tank or other tank cap must be replaced immediately

After the operation the fuel cock must be closed (if available) Work attentively, safety conscious and always be fully aware safe stand when working! Cau- tion on uneven work surfaces and work surfaces with a slope! Never operate the machine on slopes where the angle is over 15°! Avoid use in wet grass. Risk of slipping! Regular breaks reduce the security risk to loss of control due to fatigue. Walk! Never run with the machine Be especially careful when you turn the machine or move backwards! Never use the machine on soft ground. Risk of tipping!

Take especially care, if the ground contains many stones or roots. An unattended stalling of the drill might easily cause an accidentSAFETY ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 29 ZI-RD300 Use personal safety equipment: ear protectors, safety gloves in EN 388, class 3111, safety shoes S1, safety goggles or face protection when working with the machine! Never operate the machine without or with soft shoes! Do not operate in an enclosed or confined areas. Exhaust contains poisonous carbon monoxide. The exposure can cause unconsciousness and death. If the fuel tank has to be emptied it must be done outdoors. Keep the drained fuel in a spe- cially designated container or dispose of carefully Never leave the machine running unattended! Before leaving the working area switch the machine off and wait until the machine stops. Switch off the machine before maintenance or adjustment. Never remove the fuel tank cap when the engine is running or hot Switch of the engine and remove the ignition key (if is available): Before check, clean or work on the machine Before refueling

Always if you leave the machine

11.3 Remaining risk factors

It is important to ensure that each machine has remaining risks. In the execution of all work (even the simplest) greatest attention is required. A safe working depends on you! Even if the machine is used as required it is still impossible to eliminate certain residual risk factors totally. The following hazards may arise in connection with the machine´s construction and de- sign:

• Risk of noise: Working for a long time can damage your hearing if you do not use a very good hearing protection.

• Risks of working area: Keep attention for stones and other things that can be thrown around by the machine.

• Risk to the hands or fingers: Risk of crushing: Operate the machine firmly with both hands. When tilting the dump box keep extreme caution. Risk of burns: Access while it is working in the mowing apparatus. After the operation, the machine must cool down. Otherwise, there is an acute risk of scalding!

• Risk of fire and explosion: Gasoline is highly flammable and explosive under certain conditions. NEVER refuel fuel or engine oil while the machine is in operation or is hot. When refueling 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 refueling. 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 refueling 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-venti- lated rooms or outdoors in operation. Liquid fuels can cause serious damage on the skin and the environment.ASSEMBLY ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 30 ZI-RD300

• Vibration: The declared vibration emission value has been for a standardized test is measured and can be used to compare one tool with another electric are. The declared vibration emission value may also be used for a preliminary assessment of exposure.

Emission level of vibration can be different from the specified value during the actual use of the electric tool, depending on the manner in which the power tool is used. When you feel uncomfort- able or notice discoloration of skin on your hands during the use of the machine, stop working im- mediately. Observe sufficient break times to rest. Failure to have sufficient break times may result in a hand-arm vibration syndrome. The extent of exposure depending on the type of work or machine use should be estimated and appropriate breaks taken. In this way, the extent of exposure can be considerably reduced over the entire work time. Minimize the risk caused by vibrations. Maintain this machine according to the instructions in the manual. These risk factors can be minimized through obeying all security and operation instructions, proper machine maintenance, proficient and appropriate operation by persons with technical knowledge and experience. In spite of all safety is and remains her healthy common sense and their corresponding technical qualification / training for use of the machines most important safety factor!! 12 ASSEMBLY 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 machine receipt and unpacking before putting the machine into operation. Please under- stand that later claims cannot be accepted anymore.

12.1 AssemblyOPERATION

ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 31 ZI-RD300 A Wheels: Mount the wheels and fasten them with nuts. B Handle frame: Mount the handle frame assembly to the chasis and secure it with M10X25 bolts, washers and nuts at the front and M10X45 bolts, washers and nuts at the rear. C Dump box: Install the dump box and fasten the front with two Ø4 R-clips.

13 OPERATION Device to be operated in a perfect state only. Inspect the device visually every time it is to be used. Check in particular the safety equipment, controls and screwed connection for damage and if tightened properly. Replace any damaged parts before operating the device.

13.1 Operation instructions

• Disengage clutch lever before starting the engine

• Always hold the unit with both hands when operating.

• Do not rapidly accelerate, turn sharply or stop.

• Do not overload the machine capacity

• Always make certain that the weight is evenly balanced

• Always move in directions parallel with the slope (up or down).

• Change the gears only when the machine stands still!

• To avoid danger, do not shift gears on slopes

• Attention: While tipping the centre of gravity will change suddenly!

• Do not tipping on soft ground

13.2 Functions of components

1 Engine switch: The engine switch must be in the ON position for the engine to run. Turning the engine switch to the OFF position stops the engine. 2 Throttle control: Controls engine speed. Put the throttle control on low speed(L)or high speed(H) 3 Right steering lever: Operate the lever to turn right 4 Clutch control lever: Squeeze the lever, clutch engaged. Release the lever, clutch disengaged 5 Left steering lever: Operate the lever to turn left 7 Gear selection lever: Controls forward (3x) or reverse (1x) movements of the machine. 8 Tipping handle: Controls the tipping of the dump box (manual!)OPERATION ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 32 ZI-RD300

1. Swing tipping handle A in the direction of

the arrow to release limiter B out of hook C. The dump box will be released.

1. After tipping the load, swing handle A

back to reset limiter B into hook C, which will lock the dump box. Before start operating, check the dump box to make sure it is locked (B, C)!

13.3.1 Checking the engine oil level

ATTENTION! For transport motor oil has been drained. Fill up with 4-stroke quality motor oil before first operation! Failure to do so will result in permanent motor dam- age and void guarantee!

NOTICE A too low oil level will cause damage to the engine and shorten the service life of the machine. Therefore, check the motor oil level before every start and if necessary fill up with oil.

1. To check the engine oil level, place the machine on a flat, level sur-

face. Switch off the motor and wait for ten minutes to allow the circulating oil to 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 back into the opening as far as possible, but do

not screw it in. (Make sure that the dipstick is really pushed in completely - occasionally it gets jammed).

Pull out the oil dipstick again and check the oil level. There are two markings for this - see illustration on the left.

5. If the oil level is low, fill up the recommended oil to the upper rim

at the maximum (maximum filling volume: see technical data: do not overfill!)

6. Insert the oil dipstick again and retighten it.

WARNING Use only unleaded fuel with min. 95 octane or higher Never use 2-stroke mixture of diesel! DAMAGE OF ENGINE

1. Refuelling only outdoors!

2. Before removing the filler cap, turn the engine off and let it

4. Remove the filler cap carefully

rim of the filler neck, so that the fuel has place for expansion.

Wipe any fuel residues and wait until it evaporates

Start the engine, if you have your wheeled dumper mounted correctly:

• Set the gear selection lever (7) to the neutral position.

• Move the choke lever on the machine to the full choke position.

• Turn engine switch to "ON".

• Pull the starter rope several times so that the carburettor is filled with gasoline.

• Pull the starter handle, pull-out until resistance is felt. Let the rope rewind slowly across and then move expeditiously.

• Run the pull-starter handle slowly to the rope guide back as soon as the engine starts.

• Set the choke lever after a few seconds of engine run position ˝OPEN˝ To start the engine is warm the choke lever is not to be operated.

• When the engine is warmed up, place the gear lever (7) (forward / reverse) in the desired position. If the desired gear can not load, press the clutch lever short and repeat the pro- cess. After inserting the gear lever Push the clutch lever and the mini transporter begins to drive. Drag to adjust the throttle lever to the speed accordingly.

• With the steering arm on the handles and can be easily controlled. To drive in the desired direction each use the right or left steering lever.

Throttle lever to the "SLOW" (SLOWLY) take to protect the motor if no work is done. Downshifting the engine to idle prolongs the life of engine reduces fuel consumption and the noise level of the machine.

13.4.3 Stop the engine

To stop the engine, release the clutch lever and turn the switch on the motor to the "OFF" po- sition. Under normal conditions, proceed as follows. a. Move the throttle lever to the SLOW position. b. Allow engine to idle for 1-2 minutes. c. Turn engine switch to OFF "OFF". d. Turn the fuel valve lever to OFF.MAINTENANCE ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 34 ZI-RD300 ATTENTION: Not move the choke lever to stop the engine to CHOKE. Risk of reignition or da- mage to the engine! NOTES The steering characteristics change proportional to the speed driven and the laden weight. The lightly loaded machine can be steered with lighter lever operation. With greater loading of the steering lever to control with higher pressure. The highest loadings of mini handling is according to the floor on which the machine is used to adjust. It is therefore recommended to drive on difficult tracks in a low gear and with caution. In such situations, the machine to be driven over the entire range in a low gear. Avoid sharp turns and frequent changes of direction when driving on the road, especially on rough, tough terrain, which has many sharp, uneven areas, causing high friction. Although the unit has 4-wheel traction, please remember, to be careful when working under adverse weather conditions (ice, rain and snow) or on soils where the mini-dumper could be un- stable. When the clutch lever is released, the machine is automatically braked and stops. If the machine is stopped on steep slopes, one of the wheels must be secured with a wedge. 14 MAINTENANCE

ATTENTION No cleaning, upkeep, checks or maintenance when machine is running Shut off the machine and let it cool down before start servicing!

The machine does not require intense maintenance. However, to ensure a long lifespan, we strongly recommend following the upkeep and maintenance plan. Repairs must be carried out by specialists! Use original ZIPPER parts only! NOTICE Only a properly maintained equipment may be a satisfactory tool. Care and maintenance deficiencies can cause unpredictable accidents and injuries. Repairs should be performed only by authorized service centers. Improper operation may damage the equipment or endanger your safety.

14.1 Maintenance plan

Controls for the maintenance of the machine Loose or lost screws, nuts, bolts Regularly prior to each operation Damage of any part of the machine Regularly prior to each operation Fuel tank of tightness Regularly prior to each operation Tires checking Regularly prior to each operation Machine cleaning Regularly after operation Cleaning spark plug Every 25 working hours Cleaning air filter Every 20-30 working hours Oil level checking Every 50 working hoursMAINTENANCE ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 35 ZI-RD300

Clean the machine and the working attachment from soil, dust, grass, chips, and small twigs, etc. NOTICE The use of solvents, harsh chemicals or abrasive cleaners leads to damage to the machine! Therefore: When cleaning, use only mild detergent The use of high pressure cleaners is not recommended. It shortens the service life and reduces the operational integrity. (Water can get into the gear!) Impregnate bare surfaces of the machine against corrosion (e.g., anti-rust WD40)

Information about engine maintenance you can find in operation manual of the engine manufac- turer!

14.3.1 Engine oil exchange

The engine oil change would be explicitly mentioned here in order to be included in the machine operating manual. Oil change interval after the first 20h or 1 month after commissioning and then every 100h or 1x per year.

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

1. Remove the oil drain plug (1) from the engine.

2. Open the oil tank cap (2). Collect the draining oil in a col-

lection container and dispose of it properly.

3. Retighten the oil drain plug after draining.

4. Fill in fresh oil through the filling opening (3) (see sec-

tion Checking the engine oil level).

5. Use only high quality engine oil, e.g: SAE30, 15W40 or

Drain the used oil when the engine is warm. Warm oil drains quickly and completely.

As clutch wears out, the same lever could have a wider opening, being so uneasy to use. To enable proper operation, the clutch cable must be adjusted:

1. Loosen the jam nut (1) by turning it counter clockwise with 10

2. The clutch lever is set to the original position with the adjusting

If you have difficulty steering the unit, you will need to adjust the steering levers with the special ad- justers.

1. Loosen the jam nut (3) by turning it counter clockwise with 10

2. Unscrew the adjust nut (4) to eliminate the play in the cable,

which can occur after initial use or normal wear. Be very careful not to unscrew the adjust nut too much because this can create another problem: the loss of traction.

3. Then retighten the lock nut (3).

If the above adjustment does not create enough cable tension, follow the steps below:

1. Loosen the jam nut (5) by turning it counter clockwise with 10

2. Unscrew the adjustment nut (6) to eliminate the play in the ca-

ble. (do not to unscrew the adjust nut too much because this can create another problem: the loss of traction).

Check the pressure of tires periodically to make sure they are properly inflated. Recommended pressure is: 2,1 bar (0,21Mpa)

14.7.1 Check gearbox oil

The gearbox is pre-lubricated and sealed at the factory. Unless there is evidence of leakage or ser- vice has been performed on the gearbox, no additional lubricate should be required until 50 hours of use. For future use, check the oil level after every 50 hours of use.

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

If you remove the oil level plug and no oil flows out, please add oil and then screw the oil level plug. NOTICE: recommended motor oil: GL-5, GL-6, SAE80W-90. Do not use synthetic oil! If you want to replace oil, place the machine on a level ground. The machine must be stopped and still warm. Unscrew the filter cap and the drain plug. When the oil is drained, replace the drain plug, fill up with fresh oil and then replace the filter cap.

If the machine is stored for longer than 30 days:

• Let the machine cool down

• Clean the machine and dry

• Empty Tank and carburetor completely, avoid fuel spillage

• Store in a dry, out of reach of children place, well packagedTROUBLE SHOOTING ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 37 ZI-RD300

Do not dispose the machine, machine components fuel and oil 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 TROUBLE SHOOTING Trouble Possible cause Trouble Engine will not start

• Incorrect starting sequence • Observe the correct starting sequence

• Dirty air filter • Clean/replace air filter

• No fuel supply • Refuel

• Fault in the fuel line • Check the fuel line for kinks or damages

• Engine flooded. • Screw off, clean and dry the spark plug. Then pull the cranking rope several times and reinstall the spark plug

• Spark plug connector not placed on.

• Place on the spark plug con- nector

• No ignition spark • Clean/replace spark plug

• Check ignition cable Engine starts and is stalled immedi- ately

• Incorrect idle adjustment • Contact customer service Machine works with interruptions

• Check spark plug connector Machine does not work with full per- formance

• Machine overloaded • Too much pressure

• Dirty air filter • Clean/replace air filter

• Carburetor incorrectly adjusted • Contact customer service Machine does not run while the engine is running

• Gear is not engaged properly

The installation of other than original spare parts voids the warranty! So you always have to use original spare parts Order the spare parts directly on our homepage – category SPARE PARTS or contact our customer service

No. Description Qty No. Description Qty

Expansion brake cover

Mounting Base for Engine

Cable connection plate weldment

Joint bush composite bushing

Output shaft composite bushing

Cable stopper (short)

Small Connecting Plate

Wheel Axle Press Board

• oder nutzen Sie das Online Reklamations- bzw. Ersatzteilbestellformular, zur Verfügung gestellt auf unserer Homepage – Kategorie SERVICE/NEWS.WARRANTY GUIDELINES (EN) ZIPPER MASCHINEN GmbH www.Zipper-Maschinen.at 110 ZI-RD300 49 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 acces- sories 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 pay- ment 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. SERVICE After Guarantee and warranty expiration specialist repair shops can perform maintenance and repair jobs. But we are still at your service as well with spare parts and/or product service. Place your spare part/repair service cost inquiry by