Safe Operation Practices Set-Up Operation Service Troubleshooting Warranty. Log Splitter


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1 Safe Operation Practices Set-Up Operation Service Troubleshooting Warranty Operator s Manual Log Splitter WARNING READ AND FOLLOW ALL SAFETY RULES AND INSTRUCTIONS IN THIS MANUAL BEFORE ATTEMPTING TO OPERATE THIS MACHINE. FAILURE TO COMPLY WITH THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. NOTE: This Operator s Manual covers several models. Features may vary by model. Not all features in this manual are applicable to all models and the model depicted may differ from yours. TROY-BILT LLC, P.O. BOX CLEVELAND, OHIO QR Code for manufacturing purposes only. Form No (June 27, 2016)

2 To The Owner 1 Thank You Thank you for purchasing this product. It was carefully engineered to provide excellent performance when properly operated and maintained. Please read this entire manual prior to operating the equipment. It instructs you how to safely and easily set up, operate and maintain your machine. Please be sure that you, and any other persons who will operate the machine, carefully follow the recommended safety practices at all times. Failure to do so could result in personal injury or property damage. All information in this manual is relative to the most recent product information available at the time of printing. Review this manual frequently to familiarize yourself with the machine, its features and operation. Please be aware that this Operator s Manual may cover a range of product specifications for various models. Characteristics and features discussed and/or illustrated in this manual may not be applicable to all models. We reserve the right to change product specifications, designs and equipment without notice and without incurring obligation. If applicable, the power testing information used to establish the power rating of the engine equipped on this machine can be found at www. opei.org or the engine manufacturer s web site. If you have any problems or questions concerning the machine, phone an authorized service dealer or contact us directly. Customer Support telephone numbers, website address and mailing address can be found on this page. We want to ensure your complete satisfaction at all times. Throughout this manual, all references to right and left side of the machine are observed from the operating position The engine manufacturer is responsible for all engine-related issues with regards to performance, power-rating, specifications, warranty and service. Please refer to the engine manufacturer s Owner s/operator s Manual, packed separately with your machine, for more information. Table of Contents Safe Operation Practices... 3 Assembly & Set-Up... 5 Controls & Operation... 7 Service... 9 Troubleshooting...11 Replacement Parts...13 Warranty...14 Spanish... Record Product Information Before setting up and operating your new equipment, please locate the model plate on the equipment and record the information in the provided area to the right. You can locate the model plate by standing at the operator s position and looking down at the top of the reservoir tank behind the engine. This information will be necessary, should you seek technical support via our web site, Customer Support Department, or with a local authorized service dealer. Model Number Serial Number Customer Support Please do NOT return the machine to the retailer or dealer without first contacting the Customer Support Department. If you have difficulty assembling this product or have any questions regarding the controls, operation, or maintenance of this machine, you can seek help from the experts. Choose from the options below: Web: Phone: (800) or (330) Mail: Troy-Bilt LLC P.O. Box Cleveland, OH

3 Important Safe Operation Practices 2 WARNING! This symbol points out important safety instructions which, if not followed, could endanger the personal safety and/or property of yourself and others. Read and follow all instructions in this manual before attempting to operate this machine. Failure to comply with these instructions may result in personal injury. When you see this symbol. HEED ITS WARNING! CALIFORNIA PROPOSITION 65 WARNING! Engine Exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known to State of California to cause cancer and birth defects or other reproductive harm. DANGER! This machine was built to be operated according to the safe operation practices in this manual. As with any type of power equipment, carelessness or error on the part of the operator can result in serious injury. This machine is capable of amputating hands and feet and throwing debris. Failure to observe the following safety instructions could result in serious injury or death. Training 1. Read, understand, and follow all instructions on the machine and in the manual(s) before attempting to assemble and operate. Keep this manual in a safe place for future and regular reference and for ordering replacement parts. 2. Be familiar with all controls and their proper operation. Know how to stop the machine and disengage them quickly. 3. Never allow children under 16 years of age to operate this machine. Children 16 and over should read and understand the instructions and safe operation practices in this manual and on the machine and be trained and supervised by an adult. 4. Never allow adults to operate this machine without proper instruction. 5. Many accidents occur when more than one person operates the machine. If a helper is assisting in stacking logs, never activate the control until the helper is a minimum of 10 feet from the machine. 6. Keep bystanders, pets, and children at least 10 feet from the machine while it is in operation. 7. Never allow anyone to ride on this machine. 8. Never transport cargo on this machine. 9. Hydraulic log splitters develop high fluid pressures during operation. Fluid escaping through a pin hole opening can penetrate your skin and cause blood poisoning, gangrene, or death. Give attention to the following instructions at all times: a. Do not check for leaks with your hand. b. Do not operate machine with frayed, kinked, cracked, or damaged hoses, fittings, or tubing. c. Stop the engine and relieve hydraulic system pressure by cycling the valve control lever from forward to reverse several times while engine is not running; returning to neutral before repairing or adjusting fittings, hoses, tubing, or other system components. d. Do not adjust the pressure settings of the pump or valve. 10. Leaks can be detected by passing cardboard or wood, while wearing protective gloves and safety glasses, over the suspected area. Look for discoloration of cardboard or wood. 11. If injured by escaping fluid, see a doctor immediately. Serious infection or reaction can develop if proper medical treatment is not administered immediately. 12. Keep the operator zone and adjacent area clear for safe, secure footing. 13. If your machine is equipped with an internal combustion engine and is intended for use near any unimproved forest, brush, or grass covered land, the engine exhaust should be equipped with a spark arrestor. Make sure you comply with applicable local, state, and federal codes. Take appropriate firefighting equipment with you. 14. This machine should be used for splitting wood only, do not use it for any other purpose. 15. Follow the instructions in the manual(s) provided with any attachment(s) for this machine. Preparation 1. Always wear safety shoes or heavy boots. 2. Always wear safety glasses or safety goggles when operating this machine. 3. Never wear jewelry or loose clothing that might become entangled in moving or rotating parts of the machine. 4. Make sure machine is on a flat, dry, solid ground before operating. 5. Always block wheels to prevent unintended movement, and lock beam in either the horizontal or vertical position. 6. Always operate this machine from the operator zone(s) specified in the manual. See Figure 2-1. Vertical Figure 2-1 Horizontal 7. Logs should be cut with square ends prior to splitting. 8. Use log splitter in daylight or under good artificial light. Safe Handling of Gasoline To avoid personal injury or property damage use extreme care in handling gasoline. Gasoline is extremely flammable and the vapors are explosive. Serious personal injury can occur when gasoline is spilled on yourself or your clothes which can ignite. Wash your skin and change clothes immediately. a. Use only an approved gasoline container. b. Extinguish all cigarettes, cigars, pipes, and other sources of ignition. c. Never fuel machine indoors. d. Never remove gas cap or add fuel while the engine is hot or running. e. Allow engine to cool at least two minutes before refueling. f. Never overfill the fuel tank. Fill tank to no more than 1 2-inch below bottom of filler neck to provide space for fuel expansion. g. Replace gasoline cap and tighten securely. h. If gasoline is spilled, wipe it off the engine and equipment and move machine to another area. Wait five (5) minutes before starting the engine. i. Never store the machine or fuel container inside where there is an open flame, spark or pilot light as on a water heater, space heater, furnace, clothes dryer or other gas appliances. j. Allow machine to cool at least five (5) minutes before storing. Operation 1. Before starting this machine, review the Safe Operation Practices. Failure to follow these rules may result in serious injury to the operator or bystanders. 2. Never leave this machine unattended with the engine running. 3. Do not operate machine while under the influence of alcohol, drugs, or medication. 4. Never allow anyone to operate this machine without proper instruction. 5. Always operate this machine with all safety equipment in place and working. Make sure all controls are operating properly for safe operation. 6. Operator Zone a. Horizontal Operating Position: Stand on the control lever side of the log splitter and stabilize log as shown, if needed. See Figure 2-1. b. Vertical Operating Position: Stand in front of the log splitter and stabilize log as shown, if needed. See Figure 2-1. WARNING! When stabilizing log with left hand, remove your hand when the wedge just contacts the log or serious injury may occur. 7. When loading a log, always place your hands on the side of the log, not on the ends, and never use your foot to help stabilize a log. Failure to do so, may result in crushed or amputated fingers, toes, hand, or foot. 8. Use only your right hand to operate the controls. 9. Never attempt to split more than one log at a time. 10. For logs which are not cut square, the least square end of the log should be placed toward the beam and wedge, and the square end placed toward the end plate. 11. When splitting in the vertical position, stabilize the log before moving the control handle. Split as follows: a. Place log on the end plate and turn until it leans against the beam and is stable. 3

4 b. When splitting extra large or uneven logs, the log must be stabilized with wooden shims or split wood placed between the log and end plate or ground. 12. Always keep fingers away from any cracks that open in the log while splitting. They can quickly close and pinch or amputate your fingers. 13. Keep your work area clean. Immediately remove split wood around the machine so you do not stumble over it. 14. Do not change the engine governor settings or overspeed the engine. The governor controls the maximum safe operating speed of the engine. 15. Never move this machine while the engine is running. 16. This machine should not be towed on any street, highway or public road without checking the existing federal, state, or local vehicle requirements. Any licensing or modifications such as taillights, etc., needed to comply, is the sole responsibility of the purchaser. If a Statement of Origin is required in your state, see your local dealer. 17. Do not tow machine over 45 mph. 18. See Transporting the Log Splitter section in this manual for proper towing instructions once all federal, local, or state requirements are met. Maintenance and Storage 1. Stop the engine, disconnect the spark plug and ground it against the engine before cleaning, or inspecting the machine. 2. Stop the engine and relieve hydraulic system pressure by cycling the valve control lever from forward to reverse several times while engine is not running; returning to neutral before repairing or adjusting fittings, hoses, tubing, or other system components. 3. To prevent fires, clean debris and chaff from the engine and muffler areas. If the engine is equipped with a spark arrestor muffler, clean and inspect it regularly according to manufacturers instructions. Replace if damaged. 4. Periodically check that all nuts and bolts, hose clamps, and hydraulic fittings are tight to be sure equipment is in safe working condition. 5. Check all safety guards and shields to be sure they are in the proper position. Never operate with safety guards, shields, or other protective features removed. 6. The pressure relief valve is preset at the factory. Do not adjust the valve. 7. Never attempt to move this machine over hilly or uneven terrain without a tow vehicle or adequate help. 8. For your safety, replace all damaged or worn parts immediately with original equipment manufacturer s (O.E.M.) parts only. Use of parts which do not meet the original equipment specifications may lead to improper performance and compromise safety! 9. Do not alter this machine in any manner, alterations such as attaching a rope or extension to the control handle, or adding to the width or height of the wedge may result in personal injury. 10. According to the Consumer Products Safety Commission (CPSC) and the U.S. Environmental Protection Agency (EPA), this product has an Average Useful Life of seven (7) years, or 130 hours of operation. At the end of the Average Useful Life have the machine inspected annually by an authorized service dealer to ensure that all mechanical and safety systems are working properly and not worn excessively. Failure to do so can result in accidents, injuries or death. Spark Arrestor WARNING! This machine 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 arrestor meeting applicable local or state laws (if any). If a spark arrestor 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 Resources Code). Other states may have similar laws. Federal laws apply on federal lands. A spark arrestor for the muffler is available through your nearest engine authorized service dealer or contact the service department, P.O. Box Cleveland, Ohio Safety Symbols This page depicts and describes safety symbols that may appear on this product. Read, understand, and follow all instructions on the machine before attempting to assemble and operate. Symbol Description READ THE OPERATOR S MANUAL(S) Read, understand, and follow all instructions in the manual(s) before attempting to assemble and operate WARNING CRUSHING HAZARD Keep hands away from wedge, end plate, partially split wood and moving parts. BYSTANDERS Keep bystanders, helpers and children at least 10 feet away. tsingle OPERATOR Only one person should operate the machine at a time. The adult who loads and stabilizes the log must be the person who operates control handle. WARNING PRESSURIZED FLUID Never check for hose leaks with your hands. High pressure fluid can escape through a pin hole leak and cause serious injury by puncturing the skin and causing blood poisoning. EYE PROTECTION Always wear safety glasses or safety goggles when operating this machine. WARNING MOVING WEDGE Keep hands away from wedge and moving parts. WARNING GASOLINE IS FLAMMABLE Allow the engine to cool at least two minutes before refueling. WARNING CARBON MONOXIDE Never run an engine indoors or in a poorly ventilated area. Engine exhaust contains carbon monoxide, an odorless and deadly gas. WARNING HOT SURFACE Engine parts, especially the muffler, become extremely hot during operation. Allow engine and muffler to cool before touching. WARNING! Your Responsibility Restrict the use of this power machine to persons who read, understand and follow the warnings and instructions in this manual and on the machine. SAVE THESE INSTRUCTIONS! 4 Section 2 Important Safe Operation Practices

5 Assembly & Set-Up 3 Contents of Carton Log Splitter (1) Operator s Manual (1) Engine Operator s Manual (1) NOTE: This Operator s Manual covers several models. Features may vary by model. Not all features in this manual are applicable to all models and the model depicted may differ from yours. IMPORTANT: A minimum of two people are recommended to assemble this unit. WARNING! Do not remove the beam support or attempt to remove the machine from the crate until after you have completed all assembly steps. See Figure 3-1. WARNING! Do NOT remove any supports or cut any straps securing the log splitter to the crate at this time. Only remove straps and/or supports when instructed to do so. 4. Inspect the bottom of the crate for any protruding staples or wood splinters and remove. 5. Remove and set aside any loose parts included with the log splitter. Repositioning the Tongue Tube For shipping purposes, the tongue tube is secured to the log splitter frame near its center. To reposition it, refer to Figure 3-2 and Figure 3-3 and proceed as follows: NOTE: To assist in aligning the holes in the tongue tube with the holes in the beam bracket, a hole punch can be used. 5. Fasten the tongue tube to the frame by reinstalling the two hex screws removed in Step 1 and tightly securing with the two flange lock nuts. See D in Figure 3-3. Positioning the Jack Stand CAUTION: Do not attempt to move the log splitter off of the crate base until after the jack stand has been positioned downward. The jack stand is shipped in the transport position. It must be repositioned prior to fully removing the log splitter from the crate. 1. Remove the spring clip and clevis pin and pivot the jack stand toward the ground into the operating position. 2. Secure the jack stand in position with the clevis pin and the spring clip. See Figure 3-4. Spring Clip Figure 3-1 WARNING! Use extreme caution when unpacking this machine. It is very heavy and may require additional people to assist in removing the log splitter from the crate. NOTE: All references in this manual to the left or right side of the log splitter are from the operating position only. Exceptions, if any, will be specified. Unpacking & Assembling the Log Splitter Tools Required Safety Glasses Two 9/16 Wrenches (or Adjustable Wrenches) Leather Safety Gloves Wire Cutters, Tin Snips or Utility Knife Pry Bar and/or Claw Hammer Hole Punch Crate Disassembly 1. Use a pry bar or claw hammer to loosen and remove the top of the crate. 2. Use a pry bar or claw hammer to remove the four sides of the crate, beginning with the short sides (or front and back side of the log splitter) and then the long sides (or left and rides side of the log splitter. Set the sides of the crate aside to avoid injury. 3. Remove the large plastic cover, if present, and discard. Figure Cut the straps securing the tongue tube to the beam support. 2. Remove the pair of hex screws and flange nuts securing the tongue tube to the log splitter frame. See A in Figure Carefully slide the tongue tube toward the front of the machine. See B in Figure Pull the beam lock outward, line it up with the hole in the beam bracket and release the beam lock. See C in Figure 3-3. Clevis Pin Figure Carefully pry the small block of wood from the base of the crate and position it beneath the jack stand. See Figure 3-5. Figure 3-5 Figure 3-3 5

6 Removing the Supports CAUTION: Do not attempt to move the log splitter off of the crate base until after the crate supports and nylon straps have been removed. 1. Cut the two nylon straps securing the log splitter to the crate, one on each side of the reservoir tank, near each fender. There are also two supports found on the log splitter crate, one beneath the engine and one beneath the beam. Carefully cut and discard each tie-strap and remove and discard each support. See Figure 3-6. Figure 3-6 NOTE: The jack stand will support the weight of the log splitter with the supports removed. WARNING! The next step requires two people to safely remove the log splitter from the base of the crate. 2. Carefully move the log splitter off of the crate by lifting up on the tongue tube, near the hitch coupling, and slowly pushing the machine backwards over the two rear wheel chucks and off the back of the crate base. See Figure 3-7. Figure 3-7 Repositioning the Control Handle The control handle is shipped hanging from the valve on the handle link. 1. Remove the clevis pin and bow-tie cotter pin from the control handle. See Figure 3-8. Bow-Tie Cotter Pin Figure 3-8 Control Handle Clevis Pin 2. Rotate the control handle into the operating position and secure with the clevis pin and bow-tie cotter pin removed in step 1. See Figure 3-8. Set-Up Gas and Oil Fill-Up Service the engine with gasoline and oil as instructed in the Engine Operator s Manual. Read the instructions carefully. WARNING! Use extreme care when handling gasoline. Gasoline is extremely flammable and the vapors are explosive. Never fuel the machine indoors or while the engine is hot or running. NOTE: Your log splitter is shipped with motor oil in the engine. You MUST check the oil level before operating. Be careful not to overfill. Gasoline can be added to the engine when the log splitter is in either the horizontal or vertical position. However, it may be easier when the log splitter is in the vertical position. Preparing the Log Splitter 1. Lubricate the beam area (where the splitting wedge will slide) with engine oil. Do not use grease. 2. Use a wrench to remove the vented dipstick, which is located in front of the engine on top of the reservoir tank. See Figure 3-9. NOTE: The log splitter is filled to the proper operating level from the manufacturer with Shell Tellus S2 M 32 Hydraulic Fluid. However, you MUST check the fluid level before operating. If not filled, proceed with the following steps: Caution: Much of the original fluid has been drawn into the cylinder and hoses. Make certain to refill the reservoir to prevent damage to the hydraulic pump. 3. Check the fluid level using the dipstick. See Figure 3-9. Do not overfill. NOTE: Approved fluids include Shell Tellus S2 M 32 Hydraulic Fluid, Dexron III/Mercon Automatic Transmission Fluid, Pro-Select AW-32 Hydraulic Oil or 10WAW-ISO Viscosity Grade 32 Hydraulic Oil. It is not recommended that fluids be mixed. To top off the reservoir tank during initial set-up, use Shell Tellus S2 M 32 Hydraulic Fluid only. 4. Replace the dipstick securely, tightening it until the top of the threads are flush with the top of the pipe. 5. Disconnect the spark plug and prime the pump by slowly pulling the recoil starter as far as it will go. Repeat approximately 10 times. NOTE: Close the fuel shut-off valve (if equipped) before performing Step 5. Remove and set aside any loose parts included with the log splitter. to avoid engine flooding. 6. Reconnect the spark plug wire and start the engine following instructions in the Engine Operator s Manual. 7. Use the control handle to engage the wedge to the farthest extended position. Then retract the wedge. 8. Refill the tank as specified on the dipstick if necessary. NOTE: Failure to refill the tank will void the log splitter s warranty. 9. Extend and retract the wedge 12 complete cycles to remove any trapped air in the system (the system is self-bleeding ). 10. Refill the reservoir within the range marked on the dipstick if necessary. NOTE: Some fluid may overflow from the vent plug as the system builds heat and the fluid expands and seeks a balanced level. Tire Pressure The max recommended operating pressure is 30 psi. Do not under any circumstances exceed the manufacturer s recommended psi. Maintain equal pressure in both tires. WARNING! Excessive pressure when seating beads may cause tire/rim assembly to burst with force sufficient to cause serious injury. Figure Section 3 Assembly & Set-Up

7 Controls & Operation 4 Operating Positions Hitch Coupling Log Dislodger Control Handle 1. Place the log splitter on flat, dry, solid ground. 2. Block the front and back of both wheels. See Figure 4-1. Vertical Safety Chain Log Tray Jack Stand Horizontal Beam Lock Dipstick Vertical Beam Lock Horizontal Figure Place the beam in either the horizontal or vertical position and lock into place. NOTE: This Operator s Manual covers several models. Features may vary by model. Not all features in this manual are applicable to all models and the model depicted may differ from yours. Engine Controls See the Engine Operator s Manual for the location and function of the controls on the engine. Beam Locks The beam locks are used to secure the beam in either the horizontal position or the vertical position. The vertical beam lock is located next to the engine. The horizontal beam lock is located on the beam support latch bracket. Control Handle Use the control handle to move the log splitter wedge forward and backward along the beam. It has three positions; FORWARD, NEUTRAL and REVERSE. See the Operation section for instructions. Vented Dipstick Use the vented dipstick to check the hydraulic fluid level. Log Dislodger The log dislodger is designed to remove any partially split wood from the wedge while it is retracting. This may occur while splitting large diameter wood or freshly cut wood. Log Tray The log tray is designed to stabilize the log after it is split. Hitch Coupling Use the hitch coupling to attach the log splitter to a towing vehicle for transportation. Jack Stand The jack stand supports the log splitter while in the operating position. Figure 4-10 Safety Chain The safety chains are hooked to the towing vehicle for transportation. NOTE: This Operator s Manual covers several models. Features may vary by model. Not all features in this manual are applicable to all models and the model depicted may differ from yours. Pre-Start Checklist 1. Remove the vented dipstick and check hydraulic fluid level. Refill if necessary. Approved fluids include Shell Tellus S2 M 32 Hydraulic Fluid, Dexron III/Mercon Automatic Transmission Fluid, Pro-Select AW-32 Hydraulic Oil or 10WAW-ISO Viscosity Grade 32 Hydraulic Oil. Check the engine oil level. Refill if necessary. 2. Check the engine oil level. Refill if necessary. 3. Fill up with gasoline if necessary. 4. Lubricate the beam area where the splitting wedge will slide with engine oil using a clean rag. Do not use grease to lubricate. Make sure to lubricate both the front and the back of the beam face. 5. Attach the spark plug wire to the spark plug. Starting the Engine Refer to the Engine Operator s Manual for detailed starting instructions. WARNING! Read, understand and follow all the instructions and warnings on the machine and in included in the Operator s Manuals before operating. Using the Log Splitter WARNING! Wear work gloves, safety shoes, ear protection and safety glasses when operating the log splitter. Ensure safe footing. WARNING! Take extra care when raising and lowering the beam as it is heavy. Having a second person assist with raising or lowering the beam is recommended. Be sure to keep hands away from any possible pinch points. 4. To place the beam in the vertical position, proceed as follows: 1 WARNING! Always use the log splitter in the vertical position when splitting heavy logs. a. Pull the horizontal beam lock out to release the beam and pivot the beam to the vertical position. b. To lock the beam in the vertical position, pull out on the vertical beam lock and rotate it to secure the beam. See Figure Vertical Beam Lock Figure To place the beam in the horizontal position proceed as follows: a. Pull the vertical beam lock out and rotate it down. Pivot the beam to the horizontal position. 7

8 b. The horizontal beam lock is selflocking. The spring loaded lock will snap into place when the beam is lowered into position. See Figure Horizontal Beam Lock Figure 4-3 Using the Control Handle The control handle has three positions. See Figure REVERSE FORWARD Figure 4-4 NEUTRAL To Return Wedge To Stop Wedge To Split Wood FORWARD Move the control handle to the FORWARD position to move wedge toward the log to split. NOTE: The control handle will return to the NEUTRAL position as soon as the handle is released (FORWARD position only). NEUTRAL Release the control handle or move the lever to the NEUTRAL position to stop the wedge movement. REVERSE Move the control handle to the REVERSE position to return the wedge toward the cylinder. The control handle stays in the REVERSE position and returns to the NEUTRAL position automatically when fully retracted. Do not hold the handle in the REVERSE position when fully retracted. NOTE: The REVERSE position may also be moved back to the NEUTRAL position manually, if necessary. WARNING! If the control handle on your log splitter is not functioning properly, STOP USE IMMEDIATELY and contact an authorized service dealer. WARNING! Do not attempt to service, repair or replace control valve. Contact an authorized service dealer. WARNING! Do not attempt to adjust or modify the control valve or the hydraulic system from its original settings or manufacture in any way. Splitting the Wood 1. Start the engine as instructed in the Engine Operator s Manual. 2. Place the log against the end plate and only split the wood in the direction of the grain. 3. To stabilize the log, place your left hand on the side of the log opposite the beam as shown in Figure 4-1. WARNING! Never place a hand on the ends of the log, between the log or end plate and the splitting wedge. WARNING! Only one operator permitted. The operator who loads and stabilizes the log, must be the adult who operates the control handle. 4. Move the control handle to the FORWARD position to split the wood. 5. Remove left hand from the side of the log once wedge just contacts the log. Continue moving control handle forward to split the log. 6. Release the control handle to stop the wedge movement. 7. Move the control handle to the REVERSE position to return the wedge. 8. To remove partially split wood from wedge, move the control handle to the REVERSE position until the wedge is fully retracted to allow split wood portion to contact the log dislodger. WARNING! Never remove partially split wood from the wedge with your hands. Fingers may become trapped between the split wood. 9. Once removed from the wedge with the log dislodger, split the wood from the opposite end or in another location. Transporting the Log Splitter WARNING! Do not tow faster than 45 mph and check the local, state and federal requirements before towing on any public road. Always check the tire condition before towing. 1. Lower the beam to its horizontal position. Make certain the beam is locked securely with the horizontal beam lock. 2. Remove the spring clip and clevis pin from the jack stand. 3. Support the tongue and pivot the jack stand up against the tongue. See Figure 4-5. Clevis Pin Spring Clip 4. Secure with the spring clip and clevis pin previously removed in Step 2. See Figure Attach the coupler hitch to a class I or higher 2 ball on the towing vehicle; latch securely. a. If the coupler hitch does not fit on the ball, turn the adjustment nut one turn counter-clockwise. b. If the coupler hitch is too loose on the ball, turn the adjustment nut one turn clockwise. Then recheck and adjust accordingly. 6. Connect the safety chains to the towing vehicle. 7. Plug in the lights (if equipped) to the tail light connector on the tow vehicle. 8. Move fuel shut-off valve to OFF position. NOTE: Use caution when backing up, a spotter outside the vehicle is recommended. Operating Tips Always: 1. Use clean fluid and check the fluid level regularly. 2. Use an approved hydraulic fluid. Approved fluids include Shell Tellus S2 M 32 Hydraulic Fluid, Dexron III/Mercon Automatic Transmission Fluid, Pro-Select AW-32 Hydraulic Oil or 10WAW-ISO Viscosity Grade 32 Hydraulic Oil. Check the engine oil level. Refill if necessary. 3. Use a filter (clean or replace regularly). 4. Use a breather cap on the fluid reservoir. 5. Make sure the pump is mounted and aligned properly. 6. Use a flexible spider type coupling between the engine and pump drive shafts. 7. Keep the hoses clear and unblocked. 8. Bleed the air out of hoses before operating. 9. Flush and clean the hydraulic system before restarting after servicing. 10. Use liquid thread sealant on all hydraulic fittings. 11. Allow time for the engine to warm-up before splitting wood. 12. Prime the pump before initial start-up by cranking the engine with the spark plug disconnected. 13. Split wood along the grain (lengthwise) only. Never: 1. Use when fluid is below 20 F or above 150 F. 2. Use a solid engine/pump coupling. 3. Operate through the relief valve for more than five (5) seconds. 4. Attempt to adjust unloading or relief valve settings. 5. Operate with air in hydraulic system. 6. Use Teflon tape on hydraulic fittings. 7. Attempt to cut the wood across the grain. 8. Attempt to remove partially split wood from the wedge with your hands. Fully retract the wedge to dislodge wood with the log dislodger. 8 Section 4 Controls & Operation Figure 4-5

9 Service 5 NOTE: This Operator s Manual covers several models. Features may vary by model. Not all features in this manual are applicable to all models and the model depicted may differ from yours. WARNING! Do not at any time make any adjustments without first stopping engine, disconnecting spark plug and grounding it against the engine. Always wear safety glasses during operation or while performing any adjustments or repairs. Maintenance Engine Refer to the Engine Operator s Manual for all engine maintenance instructions. Tire Pressure See the sidewall of the tire for recommended pressure. Do not, under any circumstances, exceed manufacturer s recommended psi. Maintain equal pressure on all tires. WARNING! Excessive pressure when seating beads may cause tire/rim assembly to burst with force sufficient to cause serious injury. Refer to the sidewall of tire for recommended pressure. Hydraulic Fluid & Inlet Filter Check the hydraulic fluid level in the log splitter reservoir tank before each use. Maintain the fluid level within the range specified on the dipstick at all times. Change the hydraulic fluid in the reservoir every 100 hours of operation. Follow the steps below: 1. Place a suitable oil collection container under the tank. 2. If your engine has a horizontal engine setup shown in Figure 5-1, see Figure 5-1 for changing the hydraulic fluid. If your engine has a vertical set-up shown in Figure 5-2, see Figure 5-2 for changing the hydraulic fluid. Suction Hose Inlet Filter Figure 5-1 Suction Hose Figure 5-2 Inlet Filter 3. Disconnect the suction hose from the bottom of the reservoir tank. See Figure 5-1 for horizontal engines or Figure 5-2 for vertical engines. 4. Carefully un-thread the inlet filter and clean it with penetrating oil. See Figure 5-3. Inlet Filter Figure Allow the fluid to drain into a suitable container. NOTE: The reservoir tank of the 27/28 ton units has a capacity of 3 gallons and the entire hydraulic system has a capacity of approximately 4.7 gallons. The reservoir tank of the 33 ton units has a capacity of 5 gallons and the entire hydraulic system has a capacity of approximately 7 gallons. 6. Reinstall the filter inlet screen and suction hose. Tighten the hose clamp. 7. Check the fluid level using the dipstick. Do not overfill. NOTE: Approved fluids include Shell Tellus S2 M 32 Hydraulic Fluid, Dexron III/Mercon automatic transmission fluid, Pro-Select AW- 32 Hydraulic Oil or 10WAW-ISO viscosity grade 32 hydraulic oil. It is recommended that fluids not be mixed. 8. Replace the vented dipstick securely, tightening it until the top of the threads are flush with top of the pipe. 9. Disconnect the spark plug and prime the pump by pulling the recoil starter as far as it will go. Repeat approximately 10 times. 10. Reconnect the spark plug wire and start the engine following the instructions in the Engine Operator s Manual. 11. Use the control handle to engage the wedge to the farthest extended position. Then retract the wedge. 12. Refill the reservoir within range marked on the dipstick. See Figure 5-4. Dipstick MAX MIN Hydraulic Fluid Only Figure Extend and retract the wedge 12 complete cycles to remove trapped air in the system (the system is self-bleeding ). WARNING! Much of the original fluid has been drawn into the cylinder and hoses. Make certain to refill the reservoir to prevent damage to the hydraulic pump. Failure to refill the tank will void the log splitter s warranty. NOTE: Some fluid may overflow from the vent plug as the system builds heat and the fluid expands and seeks a balanced level. Do not operate the log splitter without the proper amount of transmission fluid in the reservoir tank. 14. Maintain the fluid level within the range specified on the dipstick at all times. When checking the fluid, always make sure to tighten the dipstick until the top of the threads are flush with the top of the pipe. NOTE: Always dispose of any used hydraulic fluid and engine oil at approved recycling centers only. 15. Contaminants in the fluid may damage the hydraulic components. Flushing the reservoir tank and hoses with kerosene whenever service is performed on the tank, hydraulic pump or valve is recommended. Contact an authorized service dealer. 9

10 Hose Clamps Check the clamps on the return hose before each use and check the clamps on the suction hose once a season. Hydraulic Filter Change the hydraulic filter every 50 hours of operation. Use a 10 micron hydraulic filter only. Order part number Beam & Splitting Wedge Lubricate the top, sides and bottom of the beam and where it comes into contact with the splitting wedge with engine oil before each use. Off-Season Storage If the log splitter will not be used for more than 30 days, prepare for storage as follows: WARNING! Never store the machine with fuel in the fuel tank inside of building where fumes may reach an open flame or spark, or where ignition sources are present such as hot water and space heaters, furnaces, clothes dryers, stoves, electric motors, etc. 1. Refer to the Engine Operator s Manual packed with your log splitter for information on the off-season storage of the engine. 2. Clean the log splitter thoroughly. NOTE: The use of pressure washers or a garden hose to clean the splitter is not recommended. They may cause damage to the bearings or the engine. The use of water to clean the log splitter will result in a shortened life and reduce serviceability. 3. Wipe the machine with an oiled rag to prevent rust, especially on the wedge, beam and horizontal bracket. 4. Store the log splitter in a clean, dry area. Do not store it next to corrosive materials, such as fertilizer. NOTE: If storing in an unventilated or metal storage shed, be certain to rustproof the equipment by coating it with a light oil or silicone.flexible Pump Coupler The flexible pump coupler is a nylon spider insert, located between the pump and the engine shaft. Over time, the coupler will harden and deteriorate. Replace the coupler if you detect vibration or noise coming from the area between the engine and the pump. If the coupler fails completely, you will experience a loss of power. NOTE: Never hit the engine shaft in any manner, as a blow will cause permanent damage to the engine. 1. Disconnect the spark plug wire and ground it against the engine. 2. Remove the three flange lock nuts and hex screws that secure the pump to the coupling shield. Two flange lock nuts and hex screws are at the bottom corners and one is in the top center. See Figure 5-5. Hex Screw Set Screw Flange Lock Nuts 3. Remove the pump. Figure Loosen the set screw on the pump coupling half and remove the coupling half Rotate the engine by slowly pulling the starter handle until the engine coupling half set screw is at the bottom. Loosen the set screw using an allen wrench and slide the coupling half off the engine shaft. 6. Slide the new engine coupling half onto the engine shaft until the end of the shaft is flush with the inner portion of the coupling half. (There must be space between the end of the engine support bracket and the coupling half). Tighten the set screw. 7. Install the nylon spider onto the engine coupling half. 8. Install the pump coupling half and key on the pump shaft. Rotate the coupling half until the set screw faces down. Do not tighten the set screw. 9. Align the pump coupling half with the nylon spider by rotating the engine using the starter handle. Slide the coupling half into place while guiding the three hex screws through the holes in the pump support bracket. 10. Secure with the nuts removed in Step 2 of this section. 11. Set.020 to.090 of a clearance/gap between the nylon spider and the engine coupling half by sliding a feeler gauge between the nylon spider and the engine coupling half and moving the pump coupling half as needed. Install the set screw and torque to 78 in-lbs to secure the pump coupling half. See Figure 5-5. NOTE: Make certain the proper clearance/gap is obtained before tightening the set screw. 12. Reconnect the spark plug. 10 Section 5 Service

11 Troubleshooting 6 Problem Cause Remedy Engine fails to start Engine running erratically/ inconsistent RPM (hunting or surging) Engine Overheats Cylinder rod will not move 1. Spark plug wire disconnected. 2. Fuel tank empty or stale fuel. 3. Choke, if equipped, not in CHOKE position. 4. Faulty spark plug. 5. Blocked fuel line. 6. Engine not primed properly (if equipped). 7. Throttle control lever not in correct starting position. 1. Log splitter running with CHOKE applied (if equipped). 2. Spark plug wire loose. 3. Blocked fuel line or stale fuel. 4. Water or dirt in fuel system. 5. Dirty air cleaner. 6. Carburetor not adjusted properly. 1. Engine oil level low. 2. Dirty air cleaner. 3. Carburetor not adjusted properly. 1. Broken drive shaft. 2. Set screws in coupling not adjusted properly. 3. Loose shaft coupling. 4. Gear sections damaged. 5. Damaged relief valve. 6. Hydraulic lines blocked. 7. Incorrect oil level. 8. Damaged directional valve. 9. Blocked directional valve. 1. Connect wire to spark plug. 2. Fill tank with clean, fresh fuel. 3. Move choke to CHOKE position. 4. Clean, adjust gap, or replace spark plug. 5. Clean fuel line. 6. Prime engine. 7. Move throttle lever to FAST position. 1. Move choke lever to RUN position. 2. Connect and tighten spark plug wire. 3. Clean fuel line; fill tank with clean, fresh (less than 30 days old) fuel. 4. Drain fuel tank. Refill with fresh fuel. 5. Clean or replace air cleaner. 6. See authorized service dealer. 1. Fill crankcase with proper oil. 2. Clean or replace air cleaner. 3. See authorized service dealer. 1. See authorized service dealer. 2. See authorized service dealer. 3. Correct engine/pump alignment as necessary. 4. See authorized service dealer. 5. See authorized service dealer. 6. Flush and clean hydraulic system. 7. Check oil level and fill as required. 8. See authorized service dealer. 9. Flush and clean hydraulic system. 11

12 Problem Cause Remedy Slow cylinder shaft speed while extending and retracting. Leaking Cylinder Engine runs but wood will not split or wood splits too slowly Engine stalls during splitting Engine will not turn or stalls under low load conditions Leaking pump shaft seal 1. Gear sections damaged. 2. Excessive pump inlet vacuum. 3. Slow engine speed. 4. Damaged relief valve. 5. Incorrect oil level. 6. Contaminated oil. 7. Directional valve leaking internally. 8. Internally damaged cylinder. 1. Broken seals. 2. Scored cylinder. 1. Small gear section damaged. 2. Pump check valve leaking. 3. Excessive pump inlet vacuum. 4. Incorrect oil level. 5. Contaminated oil. 6. Directional valve leaking internally. 7. Overloaded cylinder. 8. Internally damaged cylinder. 1. Low horsepower/weak engine. 2. Overloaded cylinder. 1. Engine/pump misalignment. 2. Frozen or seized pump. 3. Low horsepower/weak engine. 4. Hydraulic lines blocked. 5. Blocked directional valve. 1. Broken drive shaft. 2. Engine/pump misalignment. 3. Gear sections damaged. 4. Poorly positioned shaft seal. 5. Plugged oil breather. 1. See authorized service dealer. 2. Make certain pump inlet hoses are clear and unblocked-use short, large diameter inlet hoses. 3. See authorized service dealer. 4. See authorized service dealer. 5. Check oil level. 6. Drain oil, clean reservoir, and refill. 7. See authorized service dealer. 8. See authorized service dealer. 1. See authorized service dealer. 2. See authorized service dealer. 1. See authorized service dealer. 2. See authorized service dealer. 3. Make certain pump inlet hoses are clear and unblocked. 4. Check oil level. 5. Drain oil, clean reservoir, and refill. 6. See authorized service dealer. 7. Do not attempt to split wood against the grain. 8. See authorized service dealer. 1. See authorized service dealer. 2. Do not attempt to split wood against the grain or see authorized service dealer. 1. Correct alignment as necessary. 2. See authorized service dealer. 3. See authorized service dealer. 4. Flush and clean hydraulic system. 5. Flush and clean hydraulic system. 1. See authorized service dealer. 2. Correct alignment as necessary. 3. See authorized service dealer. 4. See authorized service dealer. 5. Make certain reservoir is properly vented. 12 Section 6 Troubleshooting

13 Replacement Parts 7 Component Part Number and Description A Vented Dipstick Spider Bushing Engine Coupling Half,.875 (33 Ton, 28/27 Ton w/honda Engine) Engine Coupling Half,.750 (27 Ton w/ Troy-Bilt Engine Pump Coupling Half, A Set Screw Hydraulic Oil Filter Inlet Filter Inlet Hose (33 Ton) Inlet Hose (28/27 Ton w/ Honda Engine) Inlet Hose (28 Ton w/ Troy-Bilt Engine) Hydro Hose Return Hose Hydro Hose Hose Clamp Wheel Assembly, 16.0 x 4.8 x Phone (800) to order replacement parts or a complete Parts Manual (have your full model number and serial number ready). Parts Manual downloads are also available free of charge at

14 MANUFACTURER S LIMITED WARRANTY FOR The limited warranty set forth below is given by Troy-Bilt LLC with respect to merchandise purchased and used in the United States and/ or its territories and possessions ( Troy-Bilt ). This warranty is in addition to any applicable emissions warranty provided with your product. Troy-Bilt warrants this product (excluding its Normal Wear Parts and Attachments as described below) against defects in material and workmanship for a period of two (2) years commencing on the date of original purchase by the first purchaser of such product and will, at its option, repair or replace, free of charge, any part found to be defective in materials or workmanship ( Warranty Period ). This limited warranty shall only apply if this product has been used for non-commercial purposes and has been operated and maintained in accordance with the Operator s Manual furnished with the product, and has not been subject to misuse, abuse, commercial use, neglect, accident, improper maintenance, alteration, vandalism, theft, fire, water, or damage because of other peril or natural disaster. Damage resulting from the installation or use of any part, accessory or attachment not approved by Troy-Bilt for use with the product(s) covered by this manual will void your warranty as to any resulting damage. Normal Wear Parts are warranted to be free from defects in material and workmanship for a period of thirty (30) days from the original date of purchase. Normal wear parts include, but are not limited to items such as: batteries, belts, blades, blade adapters, tines, grass bags, wheels, rider deck wheels, seats, snow thrower skid shoes, friction wheels, shave plates, auger spiral rubber and tires. Attachments Troy-Bilt warrants attachments for this product against defects in material and workmanship for a period of one (1) year, commencing on the date of the attachment s original purchase or lease. Attachments include, but are not limited to items such as: grass collectors and mulch kits. HOW TO OBTAIN SERVICE: Warranty service is available, WITH PROOF OF PURCHASE, through your local authorized service dealer. Registering your product is not a requirement to obtain warranty service. To locate the dealer in your area, check your Yellow Pages, or contact Troy-Bilt LLC at P.O. Box , Cleveland, Ohio , or call , or log on to our Web site at www. troybilt.com. This limited warranty does not provide coverage in the following cases: a. Log splitter pumps, valves, and cylinders have a separate oneyear warranty. Routine maintenance items such as lubricants, filters, blade sharpening, tune-ups, brake adjustments, clutch adjustments, deck adjustments, and normal deterioration of the exterior finish due to use or exposure. b. Service completed by someone other than an authorized service dealer. c. Troy-Bilt does not extend any warranty for products sold or exported outside of the United States and its respective possessions and territories, except those sold through Troy- Bilt s authorized channels of export distribution. d. Replacement parts that are not genuine Troy-Bilt parts. e. Transportation charges and service calls. f. Troy-Bilt does not warrant this product for commercial use. No implied warranty, including any implied warranty of merchantability or fitness for a particular purpose, applies after the applicable period of express written warranty above as to the parts as identified. No other express warranty, whether written or oral, except as mentioned above, given by any person or entity, including a dealer or retailer, with respect to any product, shall bind Troy-Bilt. During the period of the warranty, the exclusive remedy is repair or replacement of the product as set forth above. The provisions as set forth in this warranty provide the sole and exclusive remedy arising from the sale. Troy-Bilt shall not be liable for incidental or consequential loss or damage including, without limitation, expenses incurred for substitute or replacement lawn care services or for rental expenses to temporarily replace a warranted product. Some states do not allow the exclusion or limitation of incidental or consequential damages, or limitations on how long an implied warranty lasts, so the above exclusions or limitations may not apply to you. In no event shall recovery of any kind be greater than the amount of the purchase price of the product sold. Alteration of safety features of the product shall void this warranty. You assume the risk and liability for loss, damage, or injury to you and your property and/or to others and their property arising out of the misuse or inability to use the product. This limited warranty extends to the original purchaser (i.e, the first purchaser of a new product) and to a succeeding owner of the product for non-commercial use for the duration of the warranty beginning from the original date of purchase by the first purchaser of such product. In the event that the original date of purchase by the first purchaser of the product is indeterminable, the Warranty Period shall be established as twenty-eight (28) months from the product s date of manufacture, as determined by Troy-Bilt. In no event shall a product s warranty extend beyond the established Warranty Period. HOW STATE LAW RELATES TO THIS WARRANTY: This limited warranty gives you specific legal rights, and you may also have other rights which vary from state to state. GDOC REV. A Troy-Bilt LLC, P.O. BOX CLEVELAND, OHIO ; Phone: ,