ZI-EWB150-100L - Electric wheelbarrow Zipper - Free user manual and instructions

USER MANUAL ZI-EWB150-100L Zipper

Green and black Zippers wheelbarrow with a small battery unit (no text or symbols visible on the vehicle itself)

ZI-EWB150-100L

EAN: 9120039234717

CE

YOUR

JOB.

OUR

TOOLS.

1 INHALT / INDEX

1 INHALT/INDEX....2

11.1 Intended use of the machine....19

11.1.1 Technical Restrictions....19

11.1.2 Prohibited applications / Dangerous misuse....19

11.2 User Requirements....19

11.3 General safety instructions....19

11.4 Special safety instructions for this machine....20

11.5 Hazard warnings....20

12 ASSEMBLY 21

12.1 Checking delivery content 21

12.2 Assembly-steps....21

13 OPERATION....23

13.1 Operation instructions....23

13.2 Operation....24

13.2.1 Start electrical support 24

13.2.2 Machine stopping / parking 24

13.3 Charger....24

14 CLEANING, MAINTENANCE, STORAGE, DISPOSAL....25

14.1 Cleaning....25

14.2 Maintenance....25

14.21 Maintenance plan 25

14.3 Storage 25

14.4 Disposal 25

15 TROUBLESHOOTING....25

16 ÚVODNÍ SLOVO (CZ) 26

17 BEZPEČNOST 27

29.1.1 Restrictions techniques....43

29.1.2 Applications interdites / Mauvaises applications dangereuses 43

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

EN Protect from rain, splashing!

EN Protective clothing!

EN Missing or non-readable security stickers have to be replaced immediately!

Close-up of a black plastic electronic device with a red indicator light and a yellow label pointing to it, labeled '1' (no readable text or symbols beyond the label)

1 2 3

This manual contains information and important notes for safe commissioning and handling of the ZIPPER electric wheelbarrow ZI-EWB150-100L, hereinafter referred to as “machine” in this document.

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 4707 Schlüsslberg is valid.

Customer service contact

This section contains information and important notes on the safe commissioning and handling of the machine.

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!

11.1 Intended use of the machine

The machine is designed exclusively for the following activities: Transportation of goods (sand, earth, wood, crushed stone, gravel or similar) within the maximum permissible load capacity.

NOTE

ZIPPER MASCHINEN GmbH 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 designed for the work under the following conditions:

Relative humidity:

max. 65 %

Temperature (for operation)

+5°C to +40°C

The machine, especially the battery; may not be exposed to a temperature of about 80 °C . Do not store in the blazing sun or a long time in the trunk of a car.

11.1.2 Prohibited applications / Dangerous misuse

• Operating the machine without adequate physical and mental fitness.
• Operating the machine without knowledge of the manual.
• Modifying the machine design.
• Operating the machine in wet and rainy conditions.
• Operating the machine outside the technical limits specified in this manual.
• Removing of the safety markings attached to the machine.
• Modifying, circumventing or disabling the safety devices of the machine.

The non-intended use or the disregard of the explanations and instructions described in this manual will result in the expiration of all warranty claims and compensation claims for damages against ZIPPER MASCHINEN GmbH.

11.2 User Requirements

The machine is designed for operation by one person. The prerequisites for operating the machine are physical and mental fitness as well as knowledge and understanding of the operating instructions. Persons who, due to their physical, sensory or mental capabilities, inexperience or lack of knowledge, are unable to operate the machine safely must not use the machine without supervision or instruction by a responsible person.

Basic knowledge of metalworking especially the correlation of material, tool, feed and speeds.

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 under the instruction and supervision of a qualified electrician.

11.3 General safety instructions

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

• Check the machine for completeness and function before starting. Only use the machine if the separating and other non-separating protective devices required for machining have are fitted.
• Ensure sufficient lighting conditions at the workplace to ensure safe handling of the machine.
• Remove tool keys and other setting tools before switching on the machine.
• Check the machine's connections for strength before each use.
• Never leave the running machine unattended. Switch off the machine before leaving the working area and secure it against unintentional or unauthorized restarting.
• The machine may only be operated, maintained or repaired by persons who are familiar and who have been informed about the dangers arising from this work.
• Ensure that unauthorized persons keep a safety distance from the machine and keep children away from the machine.
• Wear suitable work clothing and footwear.
  • Always work with care and the necessary caution and never use excessive force.
• Shut down the machine and disconnect it from the power supply, before adjustment, changeover, cleaning, maintenance or repair work, etc. Before starting work on the machine, wait until all tools or machine parts have come to a complete standstill and secure the machine against unintentional restart.
• Do not work on the machine if you are tired, not concentrated or under the influence of medication, alcohol or drugs!

11.4 Special safety instructions for this machine

• 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 or death.
• Never use the machine when it is raining or in damp, wet areas.
  • Always use both hands to hold the machine when in use.
• Before start, after failure or shock, be sure to check the machine and make sure that it is in good condition.
  • Take special care when work near swimming pools or garden ponds.
• Unplug battery before all maintenance and settings!

CHARGER:

• The charger is designed exclusively to charge the battery of this machine. Charging other batteries is not permitted.
• Never use the charger in a damp or wet environment.
• Disconnect cable connections only by pulling the plug. Pulling on the cable could damage the cable and plug and electrical safety would no longer be guaranteed.
• Never use the charger if the cable, plug or the machine itself are damaged by external influences. Then take the charger to the nearest specialist workshop.
• Do not operate the machine in close proximity to heat sources.
• Do not use an extension cord to plug in the charging station's power supply.
• Do not place any metal objects in the area of the charging contacts of the charger.
• Do not open the charger. In case of failure, contact a specialist workshop.
• Only use the original charger to charge the battery. If other chargers are used, defects may occur or a fire might be caused.

BATTERY:

• Vapours may be emitted during improper use or when using damaged batteries. These vapours can irritate the respiratory tract. Inhale fresh air and consult a physician if you experience any discomfort.
• EXPLOSION HAZARD! Protect the battery from heat and fire.
• Only use the battery in an ambient temperature between 0^ and +45^ .
• HAZARD OF SHORT-CIRCUIT! For disposal, transport or storage, the battery must be packed (plastic bag, box) or the contacts must be taped.
• Never open the battery.

11.5 Hazard warnings

Due to the structure and construction of the machine, hazardous situations may occur which are identified in this manual as follows:

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.

NOTE

A safety note designed in this way indicates a potentially dangerous 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 factor in the error-free operation of the machine. Safe working depends on you!

12 ASSEMBLY

12.1 Checking delivery content

Check the delivery immediately for transport damage and missing parts. Report any damage or missing parts to your dealer or the shipping company immediately. Visible transport damage must also be noted immediately on the delivery note in accordance with the provisions of the warranty, otherwise the goods are deemed to have been properly accepted.

12.2 Assembly-steps

NOTE

Do not fully tighten all screws until assembly is complete.

Technical diagram of a vehicle suspension system with labeled components and parts

1. step

Place the base frame (1) with the wheel (2) facing upwards on a flat surface and fix the wheel. Remove the bolts, washers and nut (4) from the holder, push in the support wheels (3) and fix them with the removed bolts, washers and nuts.

Technical diagram of a bicycle frame with labeled parts and an inset detail view showing a component detail.

Technical diagram of a vehicle chassis with numbered components and labeled parts

Close-up of a mechanical component with a threaded bolt and attached wiring, shown in two views (no text or symbols visible)

Technical diagram of a mechanical device with labeled parts and close-ups of components, showing internal components and assembly.

Technical diagram of a vehicle tire assembly with labeled parts and close-up insets showing mechanical components

2. step

Turn the base frame (1) upside down.

Remove the screws, washers and nuts (2) from the holder.

Push in the handles (3) and fix them with the removed screws, washers and nuts.

3. step

Fix the battery box holder (1) to the mounting plates on the base frame using 4 screws, washers and spring washers (2).

4. step

Fit the cable for the tilt release (3) to the bracket as shown.

5. step

Slide the battery box (1) into the holder as shown and fix it to the top and bottom of the holder with 4 screws (2).

6. step

Secure the tilt frame (1) to the base frame with 2 bolts, washers, lock washers and nuts (2) as shown.

	7. stepPlace the tilting tray (1) on the fully assembled frame as shown.Fix to the tilting frame with screw (2), washer, spring washer and nut (4).Fix to the base frame with 4 screws (3), washer, spring washer and nut (4)..
	NOTEOptionally, an EWB150-100LTR tubular frame extension frame can be mounted next to the tray.
	8. Establishing the cable connectionsMotor control elementConnect the motor control unit cable to the one on the top of the battery box..MotorConnect the motor cable to the one on the underside of the battery box.Secure the cable to the frame with cable ties..
	9. Machine assembling completed

13 OPERATION

Only operate the machine when it is in a perfect condition. Before each operation, a visual inspection of the machine must be carried out. Safety devices and operating elements must be checked carefully. Check in particular the safety equipment, electrical controls, electric cables and screwed connection for damage and if tightened properly. Replace any damaged parts before operating the machine.

13.1 Operation instructions

WARNING

Unplug battery before all maintenance and settings!

NOTE

• Never remove the battery while the machine is running.
  • In case of longer standstill, press the shut-down button.
• Use the electric motor only with sufficient battery charge.

13.2 Operation

13.2.1 Start electrical support

1 2 3

1. Turn ON-Off-Switch (1) to Position „I“

2. Turn switch (1) on the handle to "0" BAS activated/EBS deactivated. BAS = Brake assistance if no electronic support is requested EBS = Electronic Brake: Machine is braked and braking effect is maintained as long as

- until battery empty

- until EBS is deactivated again

1. Turn the right-hand control handle (2) to adjust the strength of the electrical support, the further the handle is turned counter clockwise (+) the stronger the support.

Note: no activation on electrical support means BAS active (braking effect noticeable)

Note: If EBS is set to "I", no electric drive assistance in forward or reverse direction.

13.2.2 Machine stopping / parking

Close-up of a transparent plastic enclosure with a red indicator light and a yellow arrow pointing to it, labeled '1' (no readable text or symbols on the device itself)

1 2 3

1. Turn ON-Off-Switch (1) to Position "I"

2. Switch (1) on the handle set to "0" BAS activated. The machine must be braked by manually by manpower when used on slopes.

3. Switch (1) on the handle set to "I" EBS activated The machine brakes until it comes to a complete stand still and the braking effect remains active as long as the switch is set to position "I". Also holds the machine in position on slops up to 20%. If the machine is to remain in position for a longer period of time, first bring it onto level ground and secure it against rolling away (chock under the wheels).

Note: Braking function EBS requires battery energy, designed for short times only (max. 15 minutes)

13.3 Charger

Charging the battery:

2 1 3

1. remove battery from battery box

2. connect the charger to the power supply (socket) 230 V / 50 Hz and the charging socket (1)..

3. battery charging

4. When the battery is fully charged (display on the charger), disconnect the charger again.

5. charging status is indicated by pressing button (2) on the display (3).

Voltage display on battery box system indicates the status of the battery:

Voltage display shows 42 V

Voltage display shows 35 V

Voltage display shows < 30 V

Battery capacity 100%

Battery capacity \~50%

Please charge the battery (too less capacity left)

Note:

• Avoid overheating when charging the battery. Ensure sufficient air supply so that no heat can accumulate.
• Only charge the battery in an ambient temperature between 0^ and +40^ .
• Allow the battery to cool down after intensive use before recharging it.
  • Always charge the battery in a well-ventilated area.

• FIRE HAZARD! Never charge batteries near acids and flammable materials.

• Do not smoke when charging the battery. Keep the battery away from open flames and sparks.

• Allow the battery to cool down immediately after charging.

14 CLEANING, MAINTENANCE, STORAGE, DISPOSAL

14.1 Cleaning

NOTE

The usage of certain solutions containing ingredients damaging metal surfaces as well as the use of scrubbing agents will damage the machine surface!

Clean the machine surface with a wet cloth soaked in a mild solution Never use running water or a high pressure cleaner to clean the machine.

• Clean the outer parts with a damp sponge.
• Never clean the electronic parts with water!
• Check the machine and remove the deposits and / or residues with a brush.

14.2 Maintenance

CAUTION

Unplug battery before all maintenance and settings! Serious injury due to unintentional or automatic activation of the machine!

The machine does not require extensive maintenance. If malfunctions and defects occur, let it be serviced by trained persons only.

NOTE

Clean your machine regularly after every usage – it prolongs the machines lifespan and is a pre-requisite for a safe working environment.

Repair jobs shall be performed by respectively trained professionals only!

• Check regularly the condition of the security stickers. Replace them if required.
• Check regularly the condition of the machine.
• Store the machine in a closed, dry location.

14.2.1 Maintenance plan

After each workshift:

- Check the cables (tight fit, damage)

Monthly:

- Charge the battery (for longer period of storage): Monthly check of the charge level.

14.3 Storage

• Clean thoroughly all components before storage.
• Store all components separately in a dry area at not less than 0^ .

Important notes on storing the battery to avoid possible damage:

If the machine will not be used for a longer period of time, the battery should be disconnected and disassembled from the machine. Before storage, the battery should be charged again. An exception to this rule are batteries permanently installed in the machine, which should not be disassembled and simply charged with the charger supplied. Batteries should be stored at room temperature (approx. 20^ C) in a dry and frost-proof place. Avoid large temperature fluctuations (e.g. do not expose battery to direct sunlight or store near heating systems). Higher temperatures can lead to accelerated ageing and premature loss of function of the battery. If the battery is not used for a longer period of time, check the charge level regularly (monthly, max. every 3 months). If necessary, recharge the battery.

14.4 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.

15 TROUBLESHOOTING

BEFORE YOU START WORKING FOR THE ELIMINATION OF DEFECTS, UNPLUG THE BATTERY.

Trouble	Possible cause	Solution
No electrical support	Battery is not charged	Recharge battery
	Motor stucks	Check motor
	Power switch is damaged	Check switch
	Broken or loose cables	Check cables
No charging of battery	Loosen cable	Check cable connection

16 ÚVODNÍ SLOVO (CZ)

Vážený zákazníku!

Technical diagram of a vehicle suspension system with labeled components and parts

Technical diagram of a mechanical assembly with numbered components and highlighted detail view

1. krok

Labeled diagram of a vehicle chassis with parts numbered 1, 2, and 3, showing structural components and a magnified inset of two bolts.

Close-up of a mechanical component with a threaded bolt and connector, showing a magnified view (no text or symbols visible)

Close-up of a mechanical device with labeled parts and close-ups of a car's wheel (no visible text or symbols)

Technical diagram of a bicycle steering wheel assembly with labeled parts and close-up details

H ZIPPER 2 3 4

3. krok

Diagram showing a device connected to an electronic charger with labeled parts and wiring connections

Technical diagram of a vehicle's front and side views with numbered components labeled 1, 2, 3, and 4.

Technical diagram of a bicycle frame with labeled parts and an inset detail view showing a bracket detail.

1. Krok

Diagram of a device with labeled parts including a control box, connector, and cable assembly

Diagram showing a power supply unit connected to an electronic device with labeled parts and wiring.

29.1.1 Restrictions techniques

Technical diagram of a bicycle suspension system with labeled components and parts

1. étape

Close-up of a black electronic device casing with two red indicator lights and a yellow arrow pointing to the top-right corner (no visible text or symbols)

1 2 3

Diagram showing a device connected to an electronic circuit board with labeled components and wiring connections

(EN) With original ZIPPER spare parts you use parts that are attuned to each other shorten the installation time and elongate your products lifespan.

NOTE

The installation of parts other than original spare parts leads to the loss of the guarantee! Therefore: When replacing components/parts, only use spare parts recommended by the manufacturer.

Order the spare parts directly on our homepage – category SPARE PARTS or contact our customer service

• via our Homepage – category SERVICE/NEWS - SPARE PARTS REQUEST,
• by e-mail to [e-mail].

Always state the machine type, spare part number and designation. To prevent misunderstandings, we recommend that you add a copy of the spare parts drawing with the spare parts order, on which the required spare parts are clearly marked, especially when not using the online-spare-part catalogue.

Pos	Parts name Qty
1	tray 1
2	upper dump frame 2
3	upper main frame 1
4	motor control lever	1
5	left handle cap 1
6	battery box (with motor controller)	1
7	battery box support	1
8	universal wheel	2
9	dump frame lock	1

Pos	Parts name Qty
10	below main frame 1
11	Wheel & motor assy 1
11a	Tyre	1
12a	left below dump frame	1
12b	right below dump frame	1
12c	reinforce rib for below dump frame	1
14	battery 1
15	charger	1

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.

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

• Mail to [e-mail].
• Or use the online complaint order formula provided on our homepage – category service/news.

38 PROHLÁŠENÍ O ZÁRUCE (CZ)

(EN) We monitor the quality of our delivered products in the frame of a Quality Management policy.

Your opinion is essential for further product development and product choice. Please let us know about your:

• Impressions and suggestions for improvement.
• Experiences that may be useful for other users and for product design
• Experiences with malfunctions that occur in specific operation modes

We would like to ask you to note down your experiences and observations and send them to us via E-Mail or by post: