ZIPPER MASCHINEN ZI-BES350Y Concrete Cutter User Manual

MASCHINEN ZI-BES350Y Concrete Cutter
User Manual ZI-BES350Y
EAN: 9120039231624

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ATTENTION: Check Oil!
Engine don’t start with low oil!!

SAFETY SIGNS

DEFINITION OF SYMBOLS

| CE-Conformal! – This product complies with the EC directives.
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| Follow the instructions!
| No open flame, fire, open-source ignition, and smoking are prohibited!
| The danger of Intoxication! Do not operate the unit in closed areas or in poorly ventilated rooms unless there is adequate ventilation through exhaust fans or hoses.!
| Hot Surface
| Wear personal protective equipment!
| ATTENTION: Check Oil! The engine doesn’t start with low oil!!

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

Components

Technical data

SAFETY

This section contains information and important notices for the safe commissioning and handling of machines.
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!

Intended use of the machine

The machine is intended exclusively for the following activities: Concrete, asphalt, and bitumen cutting
ZIPPER-MASCHINEN assumes no responsibility or warranty for any other use or use beyond this and for any resulting damage to property or injury.

Technical Restrictions
The machine is intended for use under the following ambient conditions:

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.
• Use of the machine for the transport of persons

The prohibited/hazardous use or disregard of the information and instructions presented in this manual will result in the voiding of all warranty and damage claims against  Zipper Maschinen GmbH.

User Qualification

A prerequisite for the use/operation of the machine is a corresponding physical and mental aptitude as well as knowledge and understanding of the instruction Manual.

Please note that local laws and regulations may determine the minimum age of the operator and restrict the use of this machine!
Put on your personal protective equipment before working on the machine.
Work on electrical components or equipment may only be carried out by a qualified electrician or carried out under the guidance and supervision of a qualified Electrician. Safety 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 that could be damaged by vibration.
• Remove the adjustment tool from the machine before operation.
• Never leave the running machine unattended (always stop the machine before leaving it).
• Ensure that unauthorized persons maintain a safe distance from the machine and keep children away from the machine.
• The machine may only be operated, serviced, or repaired by persons who are familiar with it and who have been informed of the dangers arising during this work.
• Always wear suitable personal protective equipment (ear protection, gloves, safety shoes, close-fitting protective clothing, etc.)!
• Do not work with the machine if you are tired, not concentrated, or under the influence of medication, alcohol, or drugs!
• Never operate the unit in the presence of flammable liquids or gases (danger of explosion!).
• Carry out maintenance, adjustment, and cleaning work only when the engine is switched off.
• Only use spare parts and accessories recommended by Zipper machines.

Special safety instructions for the operation of ZI-BES350Y

• The machine is designed to be operated by one person. Always operate the machine from behind. Never stand next to or in front of the machine when the engine is running.

• Keep a safe distance of 15m to other persons.

• Keep away from edges and trenches and avoid situations where the vibratory plate could tip over.

• Excessive noise can cause hearing damage and temporary or permanent hearing loss.
  Wear hearing protection certified to health and safety regulations to limit noise exposure.

• Do not increase the regulated idle speed of the engine above 3,500 rpm. This could result in damage to the machine or personal injury.

• DO NOT APPLY ANY PRESSURE TO THE SIDE OF THE ROTATING CUTTING BLADE! THIS RUINS THE DRIVE MECHANISM!

• DO NOT PERFORM TOO LONG CUTS IN A ROW

• THE MAX ALLOWED OPERATING TIME FOR CUTTING WITHOUT WATER COOLING IS 30 SECONDS.

• NEVER CUT DRY WITH CUTTING BLADES THAT ARE SUITABLE FOR WATER-COOLED WET CUTTING ONLY.

Safety instructions for machines with a 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 refueling 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 refueling.
• 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 vapors.
• Do not use fuel to clean machine parts, especially indoors. Vapors 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 refueling.
• 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.

Hazard warnings

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

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

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

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

NOTICE
A safety note designed in this way indicates a potentially dangerous situation that, 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!

OPERATION

Check the scope of delivery
After delivery, check the machine immediately for transport damage and missing parts.
Checklist before each use

NOTICE
The use of paint thinners, petrol, aggressive chemicals, or abrasives leads to material damage to the surfaces! Therefore use only mild detergents for cleaning!

• Clean the machine and remove dirt and dust if necessary.
• If the air filter is dirty, blow the filter cartridge from the inside by moving a jet of dry compressed air up and down. Continue until all dust has been removed. Replace the air filter with a new one if necessary.
• Check the carburetor for external dirt and dust and clean it with dry compressed air if necessary.
• Check the nuts and bolts for tightness. (Screws or bolts loosened by vibrations can lead to accidents!)

Checking the engine oil level

NOTICE
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.

| 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.
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| 3. Push the dipstick into the opening, but do not screw it in. (Make sure that the dipstick has really been pushed incompletely).
| 4. Pull out the oil dipstick again and read off the oil level. There are two markings for this – see the illustration on the left.
5. If the oil level is low, refill the recommended oil up to the upper edge (maximum filling volume:
approx. 0.5 liters).
6. Push in the oil dipstick again and tighten.

Checking the fuel tank level

NOTICE
Observe the safety regulations for fuel control. Filter the fuel during refueling 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. If necessary, top up with fuel with the appropriate octane number (RON 95).
3. Close the fuel filler cap tightly after refueling.

OPERATION

• Save the working environment before you start working.
• Only put the machine into operation after you have read and understood the safety instructions and carried out the necessary measures before initial commissioning.
• Proper preparation and consistency of the concrete are essential for good working.
• Transport of the machine onto the concrete to be processed: Mount the transport bar into the bar holder at the front side of the machine. A minimum of two persons lift the machine onto the concrete surface. Attention! The machine is heavy. Be sure to proper lifting techniques to avoid injuries.

Information on Initial Start-up

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

Test Run Initial Start-up

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

Notes on the first 20 operating hours
In order to optimize the life expectancy of your machine, the following points should be observed:

• Do not operate the engine for the first 20 operating hours @ maximum load (this also applies to used engines after extensive maintenance). This means lower speed and lower maximum working load than during normal operation.

• Change the engine oil after the first 20 hours of operation.
  Operating Instructions

• Never use the recoil starter while the engine is running. This will damage the engine.

• The pull mechanism for changing the engine speed is limited by an adjusting screw. This is a factory set. Never change this setting on your own, you could overload the motor.

• Do not operate the machine on slopes of more than 20°, as even with an optimum oil level the engine may not be supplied with sufficient lubrication.

• In the direction of the machine and within a range of one meter around the machine, nobody but the operator must stand.

• Bring the cutting blade to the uppermost position, hinge the cutting line marker (rod with red wheel) down, and bring the marker and blade into the cutting line.

• Adapt your cutting speed to the material.
  • If you see that the cutting blade does not hold the cutting depth but comes up, you push the machine too fast.
  • If you see that the saw blade is getting slower – you push the machine too fast

• Cuts with a cutting depth of more than 90mm should be performed in two consecutive working steps.

Starting the Machine

| 1. Turn the fuel valve to the “ON” position.
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| 2. Set the engine ON/OFF switch (ignition switch) also to the “On” position.
| Note: The closed position of the choke lever enriches the fuel mixture for starting a cold engine.  The open position provides the correct fuel mixture for normal operation after starting and for restarting a warm engine.
3. Turn the choke lever to the “Closed” position, only for a cold engine.
| 4. Set the throttle lever to “half throttle” (= middle position between “fast” and “slow”).
Note: Do not pull the starter rope through to the end and do not let it rewind after pulling, but only rewind it quickly.
5. Grab the starter handle and pull it out slowly. The resistance becomes strongest at a certain point. This point corresponds to the compression point. Let the rope roll back a little from this point and then pull it out powerfully.
6. Turn the choke lever to “Open when the engine is running.
7. Open the shut-off valve on the bottom of the water tank.
8. Crank the cutting blade slowly down, until it has reached the desired cutting depth in the material.

Stopping the Machine

Emergency Stop
In case of danger and/or in an emergency situation, you can quickly switch off the machine with the speed governor by pushing it completely into the STOP position.

Normal switch-off

1. Bring the cutting blade to the uppermost position
2. Set the upper throttle lever to “minimum” and let the engine run idle for approx. 3 minutes at low engine speed.
3. Then set the engine ON/OFF switch (ignition switch) to the OFF position.
4. Close the shut-off valve on the bottom of the water tank.
5. Close the fuel switch.
6. Wait until the engine has cooled down before storing the machine.

MAINTENANCE

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

Maintenance and Servicing PLan
Table of Measures

Checks and activities to be performed

Check fuel level| Always before operation
Loose or lost screws and nuts| Always before operation
Damage to any machine part| Always before operation
Check for fuel or oil patch/spot under the machine. Check fuel pipe, fuel tank, and fuel tank cap for leaks.| Always before operation
Check motor oil level/fill-up if necessary| Always before operation
Belt tension| Always before operation
Belt condition| Always before operation
Clean air filter| every 100 working hours/monthly
Check spark plug/ event. clean| every 50 working hour/weekly
CHANGE motor oil (SAE 10W40 or similar)| 20 working hours after 1st operation /every 200 working hours

The specified intervals refer to working under “normal” operating conditions. Depending on the load, a change/exchange may also be necessary at an earlier point in time.
Changing the engine oil

| NOTICE
Waste oils are toxic and must not be released into the environment! Contact your local authorities for information on proper disposal.
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1. Loosen the oil drain plug on the rear of the engine.
2. Open oil tank cap. Collect the draining oil in a collecting container and dispose of it properly!
3. Tighten the oil drain plug again after emptying.
4. Top up with fresh oil via the filling opening (K) (see section Checking the engine oil level).
   Only use high-quality engine oil, e.g. SAE30, 15W40, or similar!

Cleaning the air filter

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

• The engine power drops and the fuel consumption increases at the same time.
• the oil consumption increases
• the starting of the engine becomes more difficult

Cleaning the spark plug

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

TRANSPORT

WARNING
Never lift or transport the machine with the engine running!

Lifting and transporting with separate devices
NOTICE
There are two persons required to lift and park the machine on another transporting device. one person to operate the hoist and one person to keep the machine in balance.

Dismount the throttle on the handle. Drain fuel, engine oil, and transmission oil.
Then pack the machine into the packing box, lift it onto the transport trolley with forklift trucks, then fix it in place to avoid displacement and machine damage.

STORAGE

If the machine is not used for a longer period of time (>30 days):

1. Empty the oil tanks or fuel tanks.
2. Remove the spark plug and pour a few drops of engine oil into the cylinder. Using a rope starter, turn the engine a few times so that the oil is well distributed inside the cylinder. Clean the spark plug and replace it.
3. Cover the cooled machine and store it out of the reach of children and unauthorized persons in a well-ventilated, dry, and frost-free environment.

RECYCLING
Do not dispose of your machine in residual waste. Contact your local authorities for information on available disposal options. If you buy a new vibratory plate or equivalent from your dealer, he is obliged in certain countries to dispose of your old machine properly.

TROUBLESHOOTING

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

• Check the fuel cock if on
• Check for fuel, check the fuel pipe for leaks
• Cold start / warm start difference
• Spark plug
• Carburator or air filter polluted.
When the engine stops:| • Check fuel supply chain.
• Check motor oil level.
• Check the air filter.
When engine output drops:| • Check the air filter.
Diamond cutting disc vibrates| • Nut/flange not tightened/ set correctly à tighten
• Nut flange is dirty à clean and tighten
• Cutting disc not mounted correctly  à check
Diamond cutting disc does not cut| • Cutter disc is dull à renew
• Wrong cutter disc à choose the suitable one

SPARE PARTS

NOTE
The installation of parts other than original spare parts leads to the loss of the guarantee! Therefore, when replacing components/parts, only use original spare parts!
When ordering spare parts, please use the service form at the end of this manual. Always state machine type, spare part number, and designation. In order to avoid misunderstandings, we recommend enclosing a copy of the spare part drawing with the spare part order, on which the required spare parts are clearly marked.
You will find the ordering address under customer service addresses in the foreword to this documentation.

Exploded View

WARRANTY GUIDELINES

1. Warranty:
   Company ZIPPER Maschinen GmbH grants mechanical and electrical components a warranty period of 2 years for amateur use; and a 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 shipping 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 in 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 damage 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, resulting 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 them 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 the 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, lack, damages, or loss of earnings due to defects during the warranty period will not be accepted. ZIPPER insists on its right to the subsequent improvement of the machine.

PRODUCT MONITORING

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 FAX, E-Mail or post
My experiences:
name:
product:
purchase date:
purchased from:
Thank you for your cooperation!

KONTAKTADRESSE / CONTACT:
Z.I.P.P.E.R MASCHINEN GmbH
4707 Schlüsslberg, Gewerbepark 8
AUSTRIA
Tel :+43 7248 61116 700
Fax:+43 7248 61116 720
info@zipper-maschinen.at

SERVICE FORM

first name ——————-
street house number——————-
Zip code place——————-
mobile phone ——————-
Email ——————-
Fax——————-

Problem description
Please describe amongst others the problem: What has caused the problem/defect, and what was the last activity before you noticed the problem/defect? For electrical problems & Have you had checked your electric supply and the machine already by a certified electrician?

Additional information
INCOMPLETELY FILLED SERVICE FORMS CAN NOT BE PROCESSED! FOR GUARANTEE CLAIMS PLEASE ADD A COPY OF YOUR ORIGINAL. SALES I DELIVERY RECEIPT OTHERWISE IT CAN NOT BE ACCEPTED. FOR SPARE PART ORDERS PLEASE ADD TO THIS SERVICE FORM A COPY OF THE RESPECTIVE EXPLODED DRAWING WITH THE REQUIRED SPARE PARTS BEING MARKED CLEARLY AND UNMISTAKABLE. THIS HELPS US TO IDENTIFY THE REQUIRED SPARE PARTS FASTLY AND ACCEL-LERATES THE HANDLING OF YOUR INQUIRY.
THANK YOU FOR YOUR COOPERATION!

ZIPPER MASCHINEN GmbH
www.Zipper-Maschinen.at

References

• Your Job. Our Tools. - ZIPPER Maschinen GmbH

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