ZIPPER ZI-BR 160Y Vibrating Concrete Poker Compactor Instruction Manual

: September 15, 2024
: ZIPPER

ZIPPER MASCHINEN GmbH
Gewerbepark 8 | 4707 Schlüßlberg | AUSTRIA
Tel. +43 – 7248 / 61116-700 |
Fax. +43 / 7248 – 61116-720
info@zipper-maschinen.at, www.zipper- maschinen.at

Operation manual

ZI-BR 160Y

Read the operation manual carefully before first use.

Edition: 06.05.2014 – Revision 01 – EN

2 OPERATION MANUAL

Dear Customer!

This manual contains important information and advice for the correct and safe use and maintenance of the ZIPPER concrete compactor. The manual is part of the machine and may not be stored separately. Read it profoundly before 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!

Due to continuous development of our products illustrations, pictures might differ slightly.

Attention!
Technical changes reserved!

Copyright
© 2014
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 WELS, Austria.

Customer Support

Z.I.P.P.E.R MASCHINEN GmbH
Gewerbepark 8
A-4707 Schlüßlberg
Tel 0043 (0) 7248 61116 – 700
Fax 0043 (0) 7248 61116 – 720
info@zipper-maschinen.at

2.1 Components (Fig. A, B)

1	Main body of the machine
2	Vibration hose

2.2 Technical details

Engine type	1-cylinder 4-stroke OHV-engine G200F
Engine power	4,1 kW
Engine speed	3600 min-1
Starter	Recoil
Fuel type	Unleaded petrol
Fuel capacity	3,6 Litres
Cylinder diameter	Ø38 mm
Tube length	6 m
Packing size main body	530x420x470 mm
Packing size tube	800x680x70mm
Sound power level LWA	103 dB(A)
Weight	24 kg

Technical changes reserved.

2.3 Included in Delivery

Unpack the ZIPPER concrete compactor ZIBR160Y and check the machine for any transport damage and for completeness of delivery.

2.4 SAFETY INSTRUCTIONS

The ZIPPER concrete compactor shall be used only for the compaction from concrete subfloors. ZIPPER MASCHINEN cannot be held responsible for any injuries or damages if there was performed manipulation or adjustments to the machine.

Don’t operate the machine at insufficient lighting conditions.

Do not operate the machine when you are tired, when your concentration is impaired, and/or under the influence of drugs, medication or alcohol.

Always be focused when working, take care to maintain a safe posture at every time.

Do not use the compactor on a slope steeper than 10°.

Do not work on slippery ground.
The operation of the machine on icy or snowy ground is forbidden!

Slipping/ stumbling/ falling down are a frequent cause of severe injuries.

The machine shall be used only by trained persons.

Non authorized persons, especially children, shall be kept away from the work area.

Do not wear loose clothing, long hair openly or loose jewellery like necklaces etc. when operating the machine.

They might be catched by rotating parts and cause serious injuries.

During refuelling open light, fire, sparks or smoking is forbidden.

Don’t refuel when the engine’s running or some components are still hot.

Only refuel outdoors or in good ventilated rooms.

Always wipe off spilt fuel immediately.

Fuel is flammable easily!

Danger of Burning! During working hot exhaust gases escape and some parts like the engine are getting very hot.

Use proper safety clothing and devices when operating the machine (safety gloves, safety goggles, ear protectors, safety shoes …)!

The machine’s only allowed to be used outdoors or good ventilated rooms.

If there are some components still hot, the machine won’t be allowed to be stored.

2.4.1 Remaining risks

Even if you abide by all the safety regulations you’ll have to attend following remaining risks:

Danger of vibrations:
The operator should have breaks regularly and shirk a longer working period.
Through the vibrations the blood flow gets disturbed and the joints get very loaded.
Danger by the working area:
Take care of unprotected holes or other sources of danger.
Danger by sound
Working without ear protectors can damage the hearing.

2.5 Operation instructions

IMPORTANT

Do not operate the engine at maximum speed right from the start, as the engine itself as well as the gearing components need a running-in time. The engine itself reaches its maximum capacity after the first 10 hours of operation. Non-compliance with this instruction reduces your engine lifespan substantially.

2.5.1 Fitting the vibration tube (Fig. C, D)

Pull the cotter pin 3 out of the fitting 4. Put the tube 5 into the fitting and secure it with the cotter pin.

2.5.2 Starting (Fig. E, F, G)

Cold start:
- Turn the ignition 11 to the position ON.
- Turn the throttle control 6 to idling mixture (direction right).
- Open the petrol cock 8 (right position).
- Turn on the choker 7 (left position).
- Now pull at the cable control powerfully. If the machine doesn’t start you’ll have to accelerate a bit.
- When you have accelerated and the engine runs you have to set idling mixture again.
- Turn off the choker (right position).
- Let the engine run about 3 minutes before beginning to work.
- Set the required speed and begin to work.
Warm start:
- Let the choker turned off.
- You have to do the other steps like the steps of the cold start.

2.5.3 Stopping

Turn back the throttle control to idling mixture.
Switch off the ignition.
Turn off the petrol cock.
Wait till the machine stands still for depositing the tube.
Before storing you have to wait till the machine gets cold.

2.5.4 Placement of the machine (Fig. H)

Place the machine on a flat ground.
Pull the lock bolt 12 upwards.
Turn the machine a bit so that you can release the bolt without locking the machine again.
Before transporting the machine the next time, it must be locked again.

2.6 Maintenance

ATTENTION – DANGER!

No cleaning, upkeep, checks or maintenance when machine is running

Be safe: Shut off the machine, let it cool down, disconnect spark plug cap from spark plug.

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!

2.6.1 Upkeep and 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
Controlling the oil level| Regularly prior to each operation
Machine cleaning| Regularly after operation
Clean spark plug| Every 25 working hours
Clean air filter| Every 20-30 working hours

2.6.2 Refuelling

The machine is run by unleaded petrol. Ensure yourself that no particles get into the fuel tank when refuelling, so always use the filter that is under the tank cover 9. Use unleaded petrol because it is better for the environment than leaded ones.

2.6.3 Cleaning

Clean the machine from concrete, dust, etc … Clean the machine housing with a wet cloth and a mild cleaning solution.

IMPORTANT

The usage of solvents, aggressive chemicals or scouring agents damages the machine housing.

2.6.4 Cleaning the spark plug (Fig. I)

Take off the spark plug cap 14. Loosen and remove the spark plug 15. Clean it with a small brush from soot debris.
The contact distance shall account approx. 0, 5mm or ~ credit card thickness.

2.6.5 Controlling the oil level (Fig. H)

Open the oil screw 13 and control the oil level. If there’s too less oil you have to refill some oil before starting the machine again.

2.6.6 Cleaning the air filter (Fig. J, K, L)

A clogged air filter reduces the engines power output drastically and causes engine disfunction. Furthermore it reduces the engines lifespan!
Loosen the nut 16 and remove the air filter from the machine (Fig. K). Disassemble it in its components (Fig. L)
Clean the air filter with water. Wring it out strongly. Let it dry. Drip some drops of oil onto the filter. Mount the filter back.

2.6.7 Disposal

DO NOT dispose your ZIBR160Y in the residual waste! Contact your local authorities for information about best available disposal possibilities in your area. Drain fuel from the fuel tank completely before disposing the machine. Disaggregate the compactor into its components before disposing its components.

2.6.8 Storage

Before storing the machine must be cold and cleaned!
When you store the machine longer than 30 days:

Drain fuel from fuel tank.
Remove the spark plug, pour into the cylinder some drops of motor oil. Now pull the starter cable out slowly so that the engine revolutes several times in order to distribute the oil in the whole combustion chamber. Clean the spark plug and mount it back.
Cover the machine with a cloth sheet and store it at a dry place.

2.7 Spare part order

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

HINWEIS

The installation of non-original parts renders warranty null and void.
So only use original spare parts!
Send your spare part list inquiry to the reseller you acquired the machine from or to the ZIPPER Customer Service.

You find the order address in the preface of this operation manual.

2.8 Spare part lists and spare part drawings

Crankshaft case-assembly

Pos.

| Name| Pcs.
---|---|---
1| Drain plug| 2
2| Washer, drain plug| 2
3| Oil seal, crankshaft| 2
4| Crankshaft case| 1
5| Regulating sway bar| 1
6| Washer| 1
7| Split pin| 1
8| Regulating shaft| 1
9| Snap ring| 1
10| Driven gear assembly| 1
11| Dipstick with seal| 2
12| Case cover, crankshaft case| 1
13| Gasket, crankshaft case| 1
14| Bearing 6205| 2
15| Set pin Ø8×14| 2
16| Bolt M8x35| 6

Cylinder head and cylinder head cover-assembly

Pos.

| Name| Pcs.
---|---|---
1| Bolt M6x12| 6
2| Cylinder head cover| 1
3| Gasket, cylinder head cover| 1
4| Valve rocket assembly| 1 (2x)
5| Push guide| 1
6| Cap| 1
7| Exhaust spring seat| 1
8| Intake spring seat| 1
9| Valve spring| 2
10| Bolt M8x60| 4
11| Stud A M8x34| 2
12| Cylinder head assembly| 1
13| Cylinder head gasket| 1
14| Set pin| 2
15| Exhaust valve| 1
16| Intake valve| 1
17| Tappet| 2
18| Pusher| 2
19| Stud A M6x112| 2
20| Lead wind cover| 1

Crankshaft and camshaft assembly

Pos.

| Name| Pcs.
---|---|---
1| Piston ring set| 1
2| Piston pin circlip| 2
3| Piston| 1
4| Piston pin| 1
5| Connect rod assembly| 1
6| Crankshaft assembly| 1
7| Camshaft assembly| 1
8| Fly wheel| 1
9| Fly wheel fan| 1
10| Starting flange| 1
11| Nut M14x1,5| 1

Recoil starter and ignition coil assembly

Pos.

| Name| Pcs.
---|---|---
1| Engine switch| 1
2| Fan hood| 1
3| Bolt M6x12| 5
4| Bolt M6x8| 4
5| Recoil starter assembly| 1
6| Shroud comp.| 1
7| Diode| 1
8| Oil sensor| 1
9| Bolt M6x14| 2
10| Bolt M6x22| 2
11| Ignition coil assembly| 1
12| Spark plug F6RT CU| 1

Air filter assembly and muffler

Pos.

| Name| Pcs.
---|---|---
1| Air filter assembly| 1
2| Nut M6| 2
3| Bolt M6x22| 1
4| Air duck| 1
5| Exhaust muffler assembly| 1
6| Exhaust gasket| 1
7| Nut M8| 2

Fuel supply system

Pos.

| Name| Pcs.
---|---|---
1| Pipe clamp| 2
2| Fuel pipe Ø435×170| 1
3| Bolt M6x28| 1
4| Connection, fuel pipe| 1
5| Packing ring| 1
6| Nut M6| 2
7| Filter cap| 1
8| Fuel tank cup| 1
9| Fuel tank| 1
10| Inlet gasket| 1
11| Connection block| 1
12| Carburettor gasket| 1
13| Carburettor assembly| 1
14| Air filter gasket| 1
15| Regulating control assembly| 1
16| Back spring| 1
17| Regulating spring| 1
18| Pushing rod| 1
19| Lock bolt| 1
20| Regulating arm| 1
21| Bolt M6| 1