Bolens 522 User Manual

OWMEirSGUM

• ASSEMBLY • OPERATION • MAINTENANCE •

VERTICAL

LOG SPLITTER

Model 522

Important: Read Safety Rules

and Instructions Carefully

WARNING: This unit is equipped with an internal combustion engine and should not be used

on or near any unimproved forest-covered, brush-covered or grass-covered land unless the engine’s exhaust system is equipped with a spark arrester meeting applicable local or state laws (if any). If a spark arrester is used, it should be maintained in effective working order by the operator.

In the State of California the above is required by law (Section 4442 of the California Public

Made ^

Made in

AMERICA

Resources Code). Other states may have similar laws. Federal laws apply on federal lands. A spark arrester for the muffler is available through your nearest engine authorized service dealer or contact the service department, RO. Box 368022, Cleveland, Ohio 44136-9722.

IMPORTANT!

Record the exact Model No. and Serial No. which appear on the frame of your unit in the space below. You must have these numbers, along with the date of purchase, in order to receive warranty or service.

MEETS ANSI SAFETY STANDARDS

MODEL NO. SERIAL NO.

247G522G

FORM NO. 770-0365M

IMPORTANT INFORMiVTION FOR LOG SPLITTER USERS

ALWAYS:

Use clean fluid and check fluid level regularly Use Dexron II Automatic Transmission Fluid or

10W non-foaming hydraulic fluid. Use a filter (clean or replace regularly) Use a breather cap on fluid reservoir Keep end of reservoir return tube below fluid level Make certain pump is mounted and aligned f roperly Use a flexible “spider” type coupling between engine

and pump driveshafts Keep hoses clear and unblocked Bleed air out of hoses before operating Flush and clean hydraulic system before startup after

any malfunction or servicing Use “pipe dope” on all hydraulic fittings Allow time for warmup before splitting wood Prime the pump before initial startup by turni ig over

the engine with spark plug disconnected Split wood with the grain (lengthwise) only

NEVER:

Use fluid below 0° F., or above 150° F. Use a solid engine/pump coupling Force pump when mounting

Operate through relief valve for more than several

seconds

Attempt to adjust unloading or relief valve settings

without pressure gauges Operate with air in hydraulic system Use Teflon tape on hydraulic fittings Warm up engine apart from pump in cold weather Attempt to cut wood across the grain

CONDITIONS WHIC:H WILL VOID YOUR WARRANTY

Failure to maintain proper fluid level in rjservoir will void your warranty, causing permanent damage to pump

by allowing air to be drawn into pump. F luid will become foamy. Refer to “Initial Preparation” in the Operation section of this manual. Changing the relief valve setting or press ure adjustment of control valve without proper knowledge and instruc

tion from the factory will void your warranty. A very minor adjustment could destroy the structural and safety limits for which the unit was designed. The system will produce more power than the structure will withstand. Higher pressure could cause the hoses to burst, cylinder to rupture and intense fluid releases, which could result In serious personal injury. Disassembling the pump will void your \/arranty. If replacement is necessary, merely disconnect and replace.

3. Do not attempt to adjust pump settings, is they are adjusted by the manufacturer at the factory. Use of incorrect hydraulic fluid will void ;'Our warranty. Use only Dexron II automatic transmission fluid or 10W non-foaming hydraulic fluid.

The flexible pump coupler must be inspected regularly. Allowing the coupler to deteriorate will void your

warranty. Deterioration of spider insert !:nd prolonged use after deterioration will destroy pump bearings and engine bearings, along with total destruí tion of coupler hubs.

Improper beam lubrication will cause p emature wear and looseness. Lubricate the beam regularly. Lack of

lubrication will void your warranty. Improper adjustment of splitting wedgt will void your warranty. Become familiar with the proper tolerance

7. required for adjustment of the splitting wsdge as instructed in the Adjustment section of this manual.

a. If wedge is too loose, cylinder beam ind wedge wear will result. Allowing the wedge to loosen and be used

under operating stress will cause damage which will not be covered under warranty. b. If wedge is too tight, severe beam damage will result which will not be covered under warranty. Warranty card must be mailed or deli\ered directly to factory. Proper information must be completed and

mailed as per instructions. No warranty lecords on file may result in delay. Do not overheat the hydraulic system. EKcessive heat will destroy the hydraulic system with hardened 0-rings

9. and excessive friction.

Do not attempt to start in temperatures under 20° F. without pre-heating fluid in reservoir. Excessively cold fluid

cannot circulate and draw into pump. W.irranty will be void.

11. Repair any leaks in hydraulic system immediately. Unattended leaks will cause air to enter system and/or decrease fluid level in reservoir, caus ng damage to the hydraulic system which will not be covered by

warranty.

IMPORTANT

RULES FOR SAFE OPERATION

THIS SYMBOL POINTS OUT IMPORTANT SAFETY INSTRUCTIONS WHICH, IF NOT FOLLOWED. COULD ENDANGER THE PERSONAL

k SAFETY AND/OR PROPERTY OF YOURSELF AND OTHERS. READ AND FOLLOW ALL INSTRUCTIONS IN THIS MANUAL BEFORE

m ATTEMPTING TO OPERATE YOUR LOG SPLITTER. FAILURE TO COMPLY WITH THESE INSTRUCTIONS MAY RESULT IN PERSONAL

INJURY. WHEN YOU SEE THIS SYMBOL-^ HEED ITS WARNING.

Your log splitter was built to be operated according to the rules for safe operation in this manual. As with any type of power equipment, carelessness or error on the part of the operator can result in serious injury. It you violate any of these rules, you may cause serious injury to yourself or others.

TRAINING

i 1. Before operating this splitter, read and understand this manual

completely. Become familiar with it for your own safety. To fail to do so may cause serious injury. Do not allow anyone to oper ate your splitter who has not read this manual. Keep this man ual in a safe place for future and regular reference and for ordering replacement parts.

2. Never use your splitter for any other purpose than splitting wood. It is designed for this use and any other use may cause an injury. Your log splitter is a precision piece of power equip ment, not a toy. Therefore, exercise extreme caution at all times.

3. Never allow children to operate your log splitter. Do not allow adults to operate it without proper instruction. Only persons well acquainted with these rules of safe operation should be

allowed to use your log splitter.

4. Only the operator is to be near your log splitter during use. Keep all others, including pets and children, a minimum of 20 feet away from your work zone. Flying wood can be hazardous. If a helper is assisting in loading logs, never activate the control until the helper is clear of the area. More accidents occur when more than one person operates the log splitter than at any other

time.

5. No one should operate this unit while intoxicated or while taking medication that impairs the senses or reactions. A clear mind is

essential for safety. Never allow a person who is tired or otherwise not alert to use your splitter.

DANGER

8. Only operate your splitter on level ground and not on the side of a hill. It could tip, or rolling logs or poor footing could cause an accident. Operating the splitter on level ground also prevents the spillage of gasoline from the fuel tank.

9. Never attempt to move the log splitter over hilly or uneven terrain without a tow vehicle or adequate help.

10. Always block the wheels to prevent movement of log splitter while in operation.

11. Check the fuel before starting the engine. Gasoline is an extremely flammable fuel. Do not fill the gasoline tank indoors, when the engine is running, or while the engine is still hot. Replace gasoline cap securely and wipe off any spilled gasoline before starting the engine as it may cause a fire or explosion.

12. Both ends of each log must be cut as square as possible to help prevent the log from riding out of the splitter during operation.

OPERATION

^ 1. Vertical Operating Position: Stand in front

Horizontal Operating Position: Stand behind the reservoir tank. See illustrations.

the log splitter.

PREPARATION

I 1. Never wear loose clothing or jewelry that can be caught by

moving parts of your log splitter and pull you into it. Keep cloth

ing away from all moving parts of your log splitter.

2. Wear proper head gear to keep hair away from moving parts. Always wear protective hearing devices as needed.

3. Always wear safety shoes. A dropped log can seriously injure your foot.

4. Always wear safety glasses or goggles while operating your splitter. A piece of splitting log could fly off and hit your eyes.

5. Wear leather work gloves. Be sure they are tight fitting without loose cuffs or draw strings.

6. Use your log splitter in daylight, or under good artificial light.

7. Never operate your splitter on slippery, wet, muddy or icy sur faces. Safe footing is essential in preventing accidents. Never operate your splitter while attached to a towing vehicle.

2. Know how to stop the unit and disengage the controi

3. Never piace hands or feet between log and splitting wedge or

between log and end plate during forward or reverse stroke. To do so may result in crushed or amputated fingers or toes, or

worse, you may lose an arm or foot.

4. Do not straddle the splitter when using it. A siip in any position

could result in a serious injury.

5. Do not step over your log splitter when the engine s running.

You may trip or accidentaiiy activate the spiitting wfdge if you step over, if you need to get to the other side, waik ai ound.

6. Never try to spiit two logs on top of each other. One i nay fly out

and injure you.

7. When loading the iog splitter, piace your hands on he side of

the log, not at the ends. Never attempt to load your sf litter whiie the spiitting wedge is in motion. You may get caught by the wedge and injured.

8. Oniy use your hand to operate the splitting wedge or controi

iever. Never use your foot or a rope or any other extension device. This couid resuit in your inability to stop your spiitter quickiy enough to avoid injury.

9. Always keep fingers away from any cracks that oper in the log

during splitting operation. They can quickly close ard pinch or amputate your fingers.

10. Never attempt to spiit woods across the grain. Some types of wood may burst or fly out of your splitter and resuit n injury to you or a bystander.

11. For iogs that are not cut square, the iongest portior of the iog should be rotated down and the most square end pla ;ed against the spiitting wedge.

12. Keep your work area ciean. Immediateiy remove spiit wood around your splitter so that you do not stumble ov;r it. Clean chips and dirt off end plate (wood platform) after lach log is spiit, or whenever necessary to maintain fiat contaft between wood and end plate (platform).

13. Never move the log splitter while the engine is running.

14. Never ieave your iog splitter unattended with he engine

running. Shut off the engine if you are ieaving your s liitter, even for a short period of time. Someone couid accidenh ily activate the spiitting wedge and be injured.

15. Do not run engine in an enciosed area. Exhaust ga ;es contain carbon monoxide. This odorless gas can be deadly when

inhaled.

16. Be careful not to touch the muffler after the engini has been

running. It will be FIOT!

17. If the equipment should start to vibrate abnormally, stop the engine and check immediately for the cause, \ibration is

generaiiy a warning of trouble.

18. When cleaning, repairing or inspecting, make certair aii moving

parts have stopped. Disconnect the spark plug wira and keep

the wire away from the piug to prevent accidentai st; rting.

3. Replace all damaged or worn parts such as hydraulic hoses and fittings immediately with manufacturer approved replacement parts.

4. Do not change the engine governor settings or overspeed the engine. This increases the hazard of personai injury. The maximum engine speed is preset by the manufacturer and is within safety limits.

5. Do not alter your splitter in any manner such as attaching a rope or extension to the controi lever or adding to the width or height of the wedge. Such alterations may cause your spiitter to be

unsafe.

6. Perform all recommended maintenance procedures before you use your splitter.

7. Do not service or repair your iog spiitter without disconnecting the spark piug wire and moving it away from the spark plug.

8. Never store the equipment with gasoiine in the tank inside of a buiiding where ignition sources are present, such as hot water and space heaters, clothes dryers and the like. Aiiow the engine to cool before storing in any enciosure.

9. Always store gasoline in an approved, tightiy seaied container.

Store the container in a cool, dry place. Do not store in a buiiding where ignition sources are present.

10. To reduce fire hazard, keep engine free of grass, ieaves, wood chips, and excessive grease and oii.

11. The hydraulic system of your log splitter requires careful

inspection, aiong with the mechanical parts. Be sure to replace

frayed, kinked, or otherwise damaged hydrauiic components.

12. Fiuid escaping from a very smail hole can be almost invisible.

Do not check for leaks with your hand. Escaping fiuid under pressure can have sufficient force to penetrate skin, causing

serious personal injury. Leaks can be iocated by passing a piece

of cardboard or wood over the suspected leak and looking for discoloration.

13. Should it become necessary to ioosen or remove any hydraulic fitting or line, be sure to relieve ail pressure by shutting off the

engine and moving the controi handie back and forth severai

times.

14. Do not remove the cap from the hydrauiic tank or reservoir

while your log splitter is running. Hot oil under pressure could cause injury.

15. The pressure reiief vaive on your spiitter is preset at the factory.

Do not adjust the vaive. Only a qualified service technician shouid perform this adjustment.

16. Compieteiy drain fuei tank prior to storage. This guards against

accumulation of fuei fumes which couid resuit in a fire hazard.

17. Never store log splitter outside without a waterproof cover. Rain

will cause rust on the inside of the cyiinder.

CUSTOMER RESPONSIBILITIES

Do not operate your spiitter in poor mechanical condition or

when in need of repair. Periodicaiiy check that aii nuts, bolts, screws, hose :lamps and

hydraulic fittings are tight to be sure equipment is ir safe work ing condition. Where appropriate, check all safety guards and

shields to be sure they are in the proper position. Never operate your splitter with safety guards, shields or other pntective fea tures removed. These safety devices are for your protection.

TOWING

I 1. This unit shouid not be towed on any street, highway or public

road without checking the existing federal, local or state vehicle

requirements. Any iicensing or modifications such as taillights, etc., needed to comply with the existing federai, iocai or state vehicle requirements is the soie responsibility of the purchaser.

2. Before towing, be certain the iog spiitter is correctly and securely attached to the towing vehicle, and the safety chains are in piace. Leave slack in chains for turning allowance.

3. Do not allow anyone to sit or ride on your splitter. They can easily fall off and be seriously injured.

ASSEMBLY INSTRUCTIONS

Tools Required for Assembly

(1) Crowbar or Large Screwdriver (1) Soft Hammer or Mallet (2) 9/16" Wrenches* (2) 1/2" Wrenches* (1) 7/16" Wrench* (1) 13/16" Wrench* (1) 7/8" Wrench* (1) Wrench* (1) Screwdriver (1) Pliers (1) Knife (1) Cutters *Adjustable Wrenches may be used.

Other Materials Required for Assembly:

Engine Oil Unleaded Gasoline Approximately 4 Gallons of Dexron II Automatic

Transmission Fluid or 10W Non-Foaming Hydraulic Fluid

Reservoir

Engine and Tank Assembly

’ump Assembly

Beam Support/

Latch Bracket

IMPORTANT: This unit has been shipped without gasoline or oil in the engine. Be certain to service engine with gasoline and oil before operating your

log splitter. Refer to the separate engine manual.

UNPACKING

WARNING: Exercise extreme caution as parts are very heavy. Mechanical handling

Most of the hardware for the assembly of the log

splitter has been placed in position on the various

parts.

equipment should be used, or sufficient people to prevent injury.

Pry the top, sides and ends off crate using a crowbar or large screwdriver. Set panels aside to avoid tire punctures.

Remove and discard plastic bag that covers unit. Remove wheels and small box from crate.

Cut and remove straps which secure parts to bottom of crate. Unbolt parts which are bolted to the bottom of the crate.

Assembly

FIGURE 1.

Hitch

Parts in Crate (See figure 1)

Reservoir Tank Assembly Engine and Pump Assembly (Bolted to bottom of

carton)—Connected to Wedge, Beam and

Cylinder Assembly by Pressure Hose

Wedge, Beam and Cylinder Assembly Tongue Assembly Wheels

Small box which contains:

Hitch Assembly Beam Support/Latch Bracket

Two (2) Hub Caps

Tongue Assembly

INSTALLATION OF WHEELS

Attach the wheels to the reservoir tank assembly as

follows. See figure 2.

1. Block up the reservoir tank assembly about 8 inches.

2. Remove and discard plastic shipping caps on the

outside of the wheels.

3. Remove the cotter pin, hex slotted nut and flat

washer from each axle. Place one wheel on each axle, hub side toward the log splitter (valve stem facing outward).

FIGURE 3.

FIGURE 4.

4. Place one flat washer just removed on each axle. Secure with hex slotted nut. Tighten siotted nut until snug, then back off approximately 1/3 turn or until one of the slots on the slotted nut lines up

with the hole in the axle.

5. Insert cotter pins through slots in nuts and holes in

axle. Secure by bending the ends of the cotter

pins in opposite directions, using pliers and a screwdriver.

6. Check the assembly of the wheels. There should be no side to side play, and the wheels should

spin freely.

7. Place hub caps in position on wheels, and tap on with a soft hammer or mallet. (It may be neces sary to use a screwdriver to tap on the raised rib of the hub cap.)

8. Check tires for correct air pressure. Correct tire pressure is between 12-15 lbs.

AHACHING TONGUE TO RESERVOIR TANK

1. The tongue is shipped with the jack stand already attached to the tongue. The jack stand is in the transport position. Remove the spring pin and clevis pin. Pivot the jack stand to the operating position (90°), and secure with the clevis pin and spring pin. See figure 3.

2. Remove the two hex bolts, lock washers and hex nuts on the front of the reservoir tank. Two 9/16" wrenches are required. Place the tongue in position with jack stand facing down, and secure with hardware just removed. Remove the assem bly from the blocks. See figure 4.

ATTACHING THE BEAM SUPPORT/

LATCH BRACKET

1. Remove the two hex bolts, lock washers and hex nuts from the tongue, using two 9/16" wrenches.

2. Place the beam support/latch bracket on the tongue as shown in figure 5. Secure with hex bolts, lock washers and hex nuts just removed. Tighten securely.

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