DR Dual Action 15-Ton Gas User Manual

DR
SAFETY & OPERATING INSTRUCTIONS
®
DUAL-ACTION GAS LOG SPLITTER
DR Power Equipment
Serial No.
Order No.
Read and understand this manual and all instructions before operating the DR Dual-Action Gas Log Splitter.
Original Language
Toll-free phone: 1-800-DR-OWNER (376-9637) Fax: 1-802-877-1213 Website: www.DRpower.com
Table of Contents
Chapter 1: General Safety Rules ............................................................................................................................................................ 3
Chapter 2: Setting Up The DR DUAL-ACTION GAS LOG SPLITTER .................................................................................................. 7
Chapter 3: Operating The DR DUAL-ACTION GAS LOG SPLITTER ................................................................................................... 16
Chapter 4: Maintaining The DR DUAL-ACTION GAS LOG SPLITTER ................................................................................................ 19
Chapter 5: Troubleshooting .................................................................................................................................................................. 24
Chapter 6: DR DUAL-ACTION GAS LOG SPLITTER Road Towable Kit .............................................................................................. 26
Chapter 7: Parts Lists and Schematic Diagrams .................................................................................................................................. 30
Conventions used in this manual
This indicates a hazardous situation, which, if not avoided, could result in death or serious injury.
This indicates a hazardous situation, which, if not avoided, could result in minor or moderate injury.
This information is important in the proper use of your machine. Failure to follow this instruction could result in damage to your machine or property.
Serial Number and Order Number
A Serial Number is used to identify your machine and is located on the Serial Number Label on your machine. An Order Number is used to check and maintain your order history and is located on the upper left portion of your packing slip. For your convenience and ready reference, enter the Serial Number and Order Number in the space provided on the front cover of this manual.
Additional Information and Potential Changes
DR Power Equipment reserves the right to discontinue, change, and improve its products at any time without notice or obligation to the purchaser. The descriptions and specifications contained in this manual were in effect at printing. Equipment described within this manual may be optional. Some illustrations may not be applicable to your machine.
2 DR
®
DUAL-ACTION GAS LOG SPLITTER
Chapter 1: General Safety Rules
#
Read this safety & operating Instructions manual before you use the DR DUAL-ACTION GAS LOG SPLITTER. Become familiar with the operation and service recommendations to ensure the best performance from your machine. If you have any questions or need assistance, please contact us at www.DRpower.com or call toll-free 1-800-DR-OWNER (376-9637) and one of our Technical Support Representatives will be happy to help you.
Labels
Your DR DUAL-ACTION GAS LOG SPLITTER carries prominent labels as reminders for its proper and safe use. Shown below are copies of all the Safety and Information labels that appear on the equipment. Take a moment to study them and make a note of their location on your LOG SPLITTER as you set up and before you operate the unit. Replace damaged or missing safety and information labels immediately.
#13758
#18887
# 29395
29394
CONTACT US AT www.DRpower.com 3
Protecting Yourself and Those Around You
This is a high-powered machine, with moving parts operating with high energy. You must operate the machine safely. Unsafe operation can create a number of hazards for you, as well as anyone else in the nearby area. Always take the following precautions when using this machine:
Keep in mind that the operator or user is responsible for accidents or hazards occurring to other people, their property, and
themselves.
Always wear protective goggles or safety glasses with side shields while using the Log Splitter to protect your eyes from
possible thrown debris.
Avoid wearing loose clothing or jewelry, which can catch on moving parts. We recommend wearing gloves while using the Log Splitter. Be sure your gloves fit properly and do not have loose cuffs or
drawstrings.
Wear shoes with non-slip treads when using your Log Splitter. If you have safety shoes, we recommend wearing them. Do
not use the machine while barefoot or wearing open sandals.
Wear long pants while operating the Log Splitter. Use ear protectors or ear plugs rated for at least 20 dBA to protect your hearing. Keep bystanders at least 50 feet away from your work area at all times. Stop the engine when another person or pet
approaches.
Safety for Children and Pets
Tragic accidents can occur if the operator is not alert to the presence of children and pets. Children are often attracted to the machine and the splitting activity. precautions:
Never
assume that children will remain where you last saw them. Always follow these
Keep children and pets at least 50 feet from the working area and ensure they are under the watchful care of a responsible
adult.
Be alert and turn the machine off if children or pets enter the work area. Never allow children to operate the Log Splitter.
Hydraulic Safety
High fluid pressures are developed in hydraulic machines. Pressurized hydraulic fluid escaping through a pin hole opening can puncture skin and cause severe blood poisoning. Therefore, the following Instructions should be heeded at all times.
Do not operate the unit with frayed, kinked, cracked or damaged hoses, fittings, or tubing. Stop the engine, wait 5 minutes
and relieve hydraulic system pressure before changing or adjusting fittings, hoses, tubing, or other system components.
Do not change any Log Splitter relief valve settings. They are set at the factory for best Splitter performance and safety. Do not check for leaks with your hand. Leaks can be located by passing cardboard or wood over the suspected area: Look for
discoloration. If injured by escaping fluid, see a doctor at once. Serious infection or reaction can develop if proper medical treatment is not administered immediately.
Always wear safety glasses to protect your eyes from hydraulic fluid.
4 DR
®
DUAL-ACTION GAS LOG SPLITTER
Safety with Gasoline - Powered Machines
Gasoline is a highly flammable liquid. Gasoline also gives off flammable vapor that can be easily ignited and cause a fire or explosion. Never overlook the hazards of gasoline. Always follow these precautions:
Never run the engine in an enclosed area or without proper ventilation as the exhaust from the engine contains carbon
monoxide, which is an odorless, tasteless, and deadly poisonous gas.
Store all fuel and oil in containers specifically designed and approved for this purpose and keep away from heat and open
flame, and out of the reach of children.
Replace rubber fuel lines and grommets when worn or damaged and after 5 years of use. Fill the gasoline tank outdoors with the engine off and allow the engine to cool completely. Don't handle gasoline if you or
anyone nearby is smoking, or if you're near anything that could cause it to ignite or explode. Reinstall the fuel tank cap and fuel container cap securely.
If you spill gasoline, do not attempt to start the engine. Move the machine away from the area of the spill and avoid creating
any source of ignition until the gas vapors have dissipated. Wipe up any spilled fuel to prevent a fire hazard and properly dispose of the waste.
Allow the engine to cool completely before storing in any enclosure. Never store a machine that has gas in the tank, or a fuel
container, near an open flame or spark such as a water heater, space heater, clothes dryer or furnace.
Never make adjustments or repairs with the engine running. Shut down the engine, disconnect the spark plug wire, keeping it
away from the spark plug to prevent accidental starting, wait 5 minutes before making adjustments or repairs.
Never tamper with the engine’s governor setting. The governor controls the maximum safe operation speed and protects the
engine. Over-speeding the engine is dangerous and will cause damage to the engine and to the other moving parts of the machine. If required, see your authorized dealer for engine governor adjustments.
Keep combustible substances away from the engine when it is hot. Never cover the machine while the muffler is still hot. Do not operate the engine with the air cleaner or the carburetor air intake cover removed. Removal of such parts could create
a fire hazard. Do not use flammable solutions to clean the air filter.
The muffler and engine become very hot and can cause a severe burn; do not touch.
Towing (optional Road Tow Kit)
ALWAYS check before towing to make certain your splitter is correctly and securely attached to the towing vehicle. Be sure
that the ball hitch you are using is the proper size for the hitch coupler on the splitter. Be sure the safety chains are properly hooked to the vehicle leaving enough slack for turning.
ALWAYS raise the jack to the highest setting before transporting the splitter. ALWAYS use accessory lights and devices when transporting on a road or highway to warn operators of other vehicles. Check
your local government regulations for DOT information.
ALWAYS allow for added length of the splitter when turning, parking, crossing intersections, and in all driving situations. ALWAYS be careful when backing up. You could jackknife your splitter if care is not taken. ALWAYS travel slowly over rough terrain, on hillsides, and around curves to prevent tipping. NEVER exceed 30 mph. when towing your splitter. Obey all state and local regulations when towing on state and local roads
and highways. Adjust your speed for terrain and conditions, as needed. Be extra cautious when towing over rough terrain, especially over a railroad crossing.
NEVER allow anyone to sit or ride on your splitter. NEVER carry any cargo on your splitter. NEVER tow the splitter near the edge of a ditch.
CONTACT US AT www.DRpower.com 5
General Safety
Operating this Log Splitter safely is necessary to prevent or minimize the risk of death or serious injury. Unsafe operation can create a number of hazards for you. Always take the following precautions when operating this Log Splitter:
Your Log Splitter is a powerful tool, not a plaything. Exercise extreme caution at all times. The machine is designed to split
logs. Do not use it for any other purpose.
Know how to stop the Log Splitter quickly; see “stopping the engine” in chapter 3. Never operate your unit on a slippery, wet, muddy, or icy surface. Exercise caution to avoid slipping or falling. See manufacturer’s instructions for proper operation and installation of accessories. Only use accessories approved by DR
Power Equipment.
Never use the machine without ensuring that all guards and shields are in place. Never, under any conditions, remove, bend, cut, fit, weld, or otherwise alter standard parts on the Log Splitter. This includes
all shields and guards. Modifications to your machine could cause personal injuries and property damage and will void your warranty.
Allow only one person to operate the Log Splitter at any time. If the machine should start making an unusual noise or vibration, shut down the engine, disconnect the spark plug wire,
keeping it away from the spark plug to prevent accidental starting, wait 5 minutes for machine to cool down, then inspect for damage. Vibration is generally a warning of trouble. Check for damaged parts and clean, repair and/or replace as necessary.
Never tamper with safety devices. Check their proper operation regularly. Before performing any maintenance or inspection procedure on the Log Splitter shut down the engine, disconnect the spark
plug wire keeping it away from the spark plug to prevent accidental starting, wait 5 minutes for machine to cool down.
Never allow people who are unfamiliar with these instructions to use the Log Splitter. Allow only responsible individuals who
are familiar with these rules of safe operation to use your machine.
Never overload or attempt to split logs beyond the manufacturer’s recommendation. Personal injury or damage to the
machine could result.
While using the Log Splitter, don't hurry or take things for granted. When in doubt about the equipment or your
surroundings, stop the machine and take the time to look things over.
Never operate the machine when under the influence of alcohol, drugs, or medication. Use the machine only in daylight. Stay alert for hidden hazards or traffic. Keep all nuts and bolts tight and keep the equipment in good operating condition.
A Note to All Users
Under California law, and the laws of some other states, you are not permitted to operate an internal combustion engine using hydrocarbon fuels without an engine spark arrester. This also applies to operation on US Forest Lands. All DR log splitters shipped to California, New Mexico and Washington State are provided with spark arresters. Failure of the owner or operator to maintain this equipment in compliance with state regulations is a misdemeanor under California law and may be in violation of other state and/or federal regulations. Contact your State Park Association or the appropriate state organization for specific information in your area.
No list of warnings and cautions can be all-inclusive. If situations occur that are not covered by this manual, the operator must apply common sense and operate this DR 1-800-DR-OWNER (376-9637) for assistance.
6 DR
®
DUAL-ACTION GAS LOG SPLITTER
®
Dual-action gas log splitter in a safe manner. Contact us at www.DRpower.com or call
®
Dual-action gas
Jack
r
Chapter 2: Setting Up The DR DUAL-ACTION GAS LOG SPLITTER
It may be helpful to familiarize yourself with the controls and features of your DR Dual-Action Gas Log Splitter as shown in Figure 1 before beginning these procedures. If you have any questions at all, please feel free to contact us at www.DRpower.com.
DR DUAL-ACTION GAS LOG SPLITTER Controls and Features
Splitting Wedge
Log Tray
Dipstick/Hydraulic Fluid Fill
Pneumatic Tires
Operator Lever
Tow Hitch
Oil Fill
Maintenance Meter (option)
Fuel Shut-off
Gas Fill
Key Switch
Choke Lever
Starter Cord
Throttle Leve
Figure 1
CONTACT US AT www.DRpower.com 7
Specifications
g
g
Engine
Bed height Wedge
Log Trays Force/Tonnage
Log Length Log Diameter* Cycle Time Wheels & Tires
Weight Dimensions Cylinder Size Hydraulic Tank Pump Control Valve Hydraulic Fluid
Manual Start Electric Start
Refer to Engine Manufacturers User Manual for Engine Specifications
24" (610mm) 24" (610mm)
6.61" (168mm) h, .75" (19mm) w h carbon steel.
hi
27.45in (697mm) L x 11.45in (290mm) W 27.45in (697mm) L x 11.45in (290mm) W
15 ton 15 ton 20 inches 20 inches 30 inches 30 inches Approx. 11 seconds Approx. 11 seconds Dot Approved, 4.8/4-8, Steel Wheel With
Taper Roller Bearings
328 lbs (150kg) 336 lbs (153kg) 64"L X 40.5"W X 38.5"H 64"L X 40.5"W X 38.5"H 3" (76mm) Bore, 18.51" (470mm) Stroke 3" (76mm) Bore, 18.51" (470mm) Stroke 6 Quarts 6 Quarts Single Stage, 2.84Gal/min (10 L/minute) Single Stage, 2.84Gal/min (10 L/minute) Integrated Pressure Relief Integrated Pressure Relief See Table-1 on page 10 See Table-1 on page 10
Refer to Engine Manufacturers User Manual for Engine Specifications
6.61" (168mm) h, .75" (19mm) w hi
h carbon steel.
Dot Approved, 4.8/4-8, Steel Wheel With Taper Roller Bearings
*The diameter listed is indicative of the maximum suggested size - a small log can be difficult to split when it contains knots or a particularly tough fiber. On the other hand, it may not be difficult to split logs with regular fibers even if its diameter exceeds the maximum indicated above.
Assembling the DR DUAL-ACTION GAS LOG SPLITTER
Tools and Supplies Needed:
Two 3/4" Wrenches 1-1/2" Wrench Pliers Soft Face Hammer Two 1/2" Wrenches 7/8" Wrench
17mm Wrench Two 7/16" Wrenches Jack Stands Utility Knife Wire Cutters Safety Glasses
8 DR
®
DUAL-ACTION GAS LOG SPLITTER
1. Open the Parts Box and lay them out on a clean flat area (Figure 2).
A
A
A
s
9 10 11 12 13 14
17 18 19 20 21
Note: For assembly location, the part numbers in the following list can be
referenced to the Parts List and illustrations in Chapter 6.
Parts Box (Figure 2):
Item #
Part # Description Qty
1 ............. 13443 .............. Bolt, HCS, 5/16-18 X 1-1/2, Gr5, ZP .............. 4
2 ............. 11238 .............. Washer, Flat, 1/4" USS .................................. 12*
3 ............. 11076 .............. Nut, Nylon Lock, 5/16-18, ZP ........................ 4
4 ............. 29054 .............. Mount, Tow Hitch, Rear ................................. 1
5 ............. 29367 .............. Dipstick ........................................................... 1
6 ............. 27610 .............. Abrasion Resistant Sheathing, 15.5in ............ 1
7 ............. 11214 .............. Cable Tie, 7-1/2 Long ..................................... 2
8 ............. 25616 .............. Hyd Adapter jcm08-obm08-90 ....................... 1
9** ......... 24230 .............. Strap, Battery .................................................. 1
10** ....... 29365 .............. Mount, Battery ................................................ 1
11** ....... 11149 .............. Bolt, HCS, 1/4-20 X 1.00, GR5, ZP ................ 2
12** ....... 11073 .............. Nut, Nylon Lock, 1/4-20, ZP .......................... 2
13** ....... 13447 .............. Battery, 12V, 9AH ........................................... 1
14 ........... 15192 .............. Pin, Hitch Clip, 5/16" - 3/8" ........................... 4
15 ........... 25311 .............. Pin, Cotter, 3/16" X 2.5" ................................. 2
16 ........... 25310 .............. Nut, Slotted, 1-14, ZP ..................................... 2
17 ........... 25318 .............. Cap, Dust ........................................................ 2
18 ........... 11075 .............. Nut, Nylon Lock, 3/8-16, ZP .......................... 4
19 ........... 11241 .............. Washer, Flat, 5/16 USS, ZP ........................... 4
20 ........... 29377 .............. Clamp, 2 inch, Jack ......................................... 2
21 ........... 29378 .............. U-bolt, 3/8-16 X 2 X 4, ZP .............................. 2
1
2
16
15
Figure 2
4
3
7
6
2
5
8
* Quantity of 8 for manual start Engine.
** Electric Start only.
Compare the contents of the Parts Box, Product Pack and Shipping Box with the “Parts Supplied” list above. If you have any questions please contact us at www.DRpower.com or call 1-800-DR-OWNER (376-9637) for assistance.
Assembly
We recommend two people when handling assemblies during the following procedures. The assemblies involved are heavy and could cause injury when lifting or if dropped.
1. Position the Beam at the center of the pallet and lay it on its side to remove
the four sets of Bolts, Flat Washers and Locknuts where the Axle assembly attaches (Figure 3).
2. Set the Beam assembly onto the Axle assembly and align the holes (Figure
4).
3. Insert the four Bolts, Flat Washers (outside of main Beam) and Locknuts
and tighten with two 3/4" Wrenches.
Bolts, Washers and Locknuts
Figure 3
Beam
ssembly
Bolts, Flat Washers and Locknut
xle ssembly
Figure 4
CONTACT US AT www.DRpower.com 9
A
Jack
Figure 5
Figure 6
Taper Bearing
Cotter Pin
Castle Nut
4. Place Jack Stands under the Axle assembly to allow room to install the
Wheels.
5. Place a Wheel onto the Axle with the Valve Stem facing out and the loose
Tapered Bearing on the outside (Figure 5).
Note: Make sure the rollers of the Tapered Bearing are facing in. The Hub and Bearing were greased at the factory. Do not remove the grease.
6. Install the Castle Nut onto the Axle Threads with a 1-1/2" Wrench until the
Tapered Bearing is just pushing against the inside of the Wheel Hub but not too tight (Figure 6). There should be minimal amount of drag on the Wheel when rotated by hand.
7. Turn the Castle Nut back only as far as needed to align the closest slot in the
Nut with the Hole in the Axle. Insert the Cotter Pin and bend the ends around with Pliers to secure the Nut. Check that the wheel will rotate freely and does not wobble on the axle.
8. Install the Dust Cap with a soft face Hammer (Figure 7).
9. Repeat steps 5 thru 8 for the second Wheel.
10. Use a Jack Stand to raise the front of the Splitter allowing room for installing
the Tow Hitch and Jack.
11. Remove the six sets of hardware (three per side) that are installed at the
front of the Beam assembly (Figure 8).
Dust Cap
Figure 7
Bolts, Washers and Locknuts (both sides)
Figure 8
Leave These Out
Tow Hitch
ssembly
12. Position the Tow Hitch and secure the right side with three sets of the Bolts,
Lock Washers and Locknuts and one set on the left side using two 3/4" Wrenches (Figure 9).
13. Install the Jack, Spacers and U-Bolts with the lower Clamp and U-Bolt
located between the two positioning rings of the Jack Housing (Figure 10).
Note: The Jack must be installed at a 45° angle for Handle clearance. Temporarily install a Tray as a guide for checking Handle clearance.
14. Secure the U-Bolts with Flat Washers and Locknuts using a 9/16" Wrench.
15. Remove the Jack Stand and roll the Splitter from the Pallet.
Tray
U-Bolt
Clamp
Hitch Pin
Position Rings
Figure 9
10 DR
Figure 10
®
DUAL-ACTION GAS LOG SPLITTER
Note: The Slots of the Engine Mount are for Gas Engine mounting and the round
J
holes are for Electric Motor mounting.
16. Position the Engine onto the Bracket and align the Engine Base holes with
the slots of the Bracket (Figure 11).
17. Electric Start only: Route the Harness down to the front left corner of the
Engine and connect the green wire ground Terminal of the Harness to the Engine mounting flange with a Bolt, Flat Washers (top and bottom) and Locknut using two 1/2" Wrenches (Figure 12).
18. Install the four sets of Bolts, Flat Washers (top and bottom) and Locknuts
using two 1/2" Wrenches to secure the Engine to the Mount (remaining three sets for electric start).
Note: Remove protective Caps as needed for the following Hydraulic Hose
connections.
19. Install the Elbow Hydraulic Fitting into the Tank assembly by hand until it
cannot be turned any more with your hand. If needed, turn the Elbow back to align it parallel with the ground and facing out (Figure 13).
20. Tighten the Elbow Jam Nut against the Tank with a 7/8" Wrench.
21. Use Wire Cutters to cut the Cable Ties holding the Hydraulic Hoses
together.
22. Install the Fluid Suction Hose onto the Pump and Tank fittings using a 7/8"
Wrench.4
23. Slide the Sheathing over one of the Pressure Hoses and secure it to the
Hose with a Cable Tie near each end (Figure 14).
Figure 11
Hole
Figure 12
Engine Mount
am Nut
Engine Hardware
Wire Harness
Ground Terminal
Elbow
Note: When installing the following Hose fittings they should be tight, but try not
to over tighten. Start with a snug fit and if leaking is detected then tighten a bit more until no leaks are detected.
24. Install the Hose with Sheathing to the Control Valve (long elbow end) and
Pump using a 7/8" Wrench.
25. Install the Fluid Return Hose (long elbow end) at the Control Valve and the
top of the Tank using a 7/8" Wrench (Figure 15).
Long Elbow
Figure 15
Fluid Return Hose
Tank
Figure 13
Control Valve
Figure 14
Pump
Suction Hose
Long Elbow
Cable Tie
Pressure Hose
Sheathing
Cable Tie
Pump
CONTACT US AT www.DRpower.com 11
Hydraulic
s
J
s
l
Cap/Dipstick
Figure 16
Flat Washer
Figure 17
Receiving Tube
Trays
Control Lever
am Nut
26. Install Hydraulic Cap/Dipstick into the hole on top of the Tank (Figure 16).
27. Remove the Nut and Flat Washer from the Control Lever threads and
reinstall the Nut all the way onto the threads (Figure 17).
28. Place the Washer onto the threads and screw the Control Lever into the top
of the Control Valve as far as it will go. Turn it back to the desired position depending of your preference to split on the right or left side of the splitter. Tighten the Jam Nut against the Valve to secure the Lever using a 17mm Wrench.
29. Install the Trays onto the sides of the Beam assembly by aligning the legs
with the receiving tubes and secure with the Hitch Clips (Figure 18).
30. Remove the two left side Bolts, Flat Washers and Locknuts from the Tank
and Axle using two 3/4" Wrenches. Position the Tow Bracket and secure with the hardware you just removed (Figure 19).
31. Raise the Jack so the Wood Splitter is parallel with the ground.
32. The following steps are for Electric Start only: Position the Battery Mount
and Hold down under the Engine and install a Bolt, Washer (each side) and Locknut closest to the axle by hand (Figure 20).
33. Place the battery into the Hold Down with the Terminals facing to the rear of
the Splitter.
34. Rotate the Mount and Battery into position and install the second mounting
Bolt, Washer (each side) and Locknut. Tighten both sets of Hardware using two 7/16" Wrenches (Figure 21).
35. Install the red positive Terminal to the Battery. Do not install the Negative
Terminal at this time.
Figure 18
Figure 19
12 DR
Tow
Bolts, Washers and Locknuts
®
DUAL-ACTION GAS LOG SPLITTER
Bracket
Battery Hold Down
Figure 20
Positive Termina
Battery Mount
Figure 21
Hardware
Battery Mount
Hold Down
Bolts and Locknut
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