BGU ZA 160/2 User manual

USER’S MANUAL
Carefully read these instructions before starting
and using your machine!
Südharzer Maschinenbau GmbH
Helmestraße 94 ∙ 99734 Nordhausen/Harz
Zentrale: 03631/6297-0 ∙ -111
Internet: www.bgu-maschinen.de
e-mail: [email protected]
- Set-up & installation
- Use
- Maintenance
- Accessories
KINDLING WOOD PROCESSOR
ZA 160/2

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CONTENT
1. INTRODUCTION 3
1.1 About the manual 3
1.2 Delivery and transport claims 3
2. PRODUCT OVERVIEW 5
3. SAFETY SIGNS AND WARNING LABELS 6
4. SAFETY 8
4.1 Mandatory application field 9
5. OPERATING INSTRUCTIONS 10
5.1 About use of the electric version 10
5.2 About the hydraulic plant 10
5.3 Getting started 11
5.4 Operation method 11
5.5 Initial set-up 11
5.6 Switching the motor on 12
5.6.1 Start-up procedure 12
5.6.2 End of work 12
5.6.3 Removing the protection grid 13
5.6.4 Emergency stopping during splitting 13
5.6.5 Control display 13
5.6.6 Adjusting the forward stroke 14
6. HANDLING AND TRANSPORTATION 15
6.1 Short-distance handling on own wheels 15
7. TROUBLE-SHOOTING 15
8. REPAIRS AND 17
MAINTENANCE 17
8.1 Ordinary maintenance 17
8.2 Hydraulic oil specifications 17
9. DISPOSING OF AN OBSOLETE MACHINE 18
10. TECHNICAL DAtA 19
10.1 Noise level and emissions 19
11. WIRING DIAGRAM 20
12. OTHER AREAS OF POSSIBLE DANGERS 21
12.1 Mechanical dangers 21
12.2 Electric dangers 21
13. LEGAL WARRANTY 22
14. EXTENDED WARRANTY 22
15. EC – STATEMENT OF COMPLIANCE 23

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1. INTRODUCTION
Dear customer, thank you very much for your trust and preference in
choosing our equipment and joining the number of our best custo-mers
in the world. We are confident that our equipment will be up to all your
expectations and assure you a long lasting quality and performance.
1.1 About the manual
Please take time to read this manual and learn to how operate and
maintain the processor safely. For your easier reading this manual is laid
out in several sections. The sections are progressively numbered and lis-
ted on the “content” page. The information, pictures and technical data in
this document reflect current or planned product features, functions, and
characteristics as of the publication date. Because of on-going product im-
provements and feature additions, information in this document is subject
to change without notice. If you are experiencing a problem or a functio-
nal trouble on your machine, please read the “trouble-shooting” section to
identify possible causes and remedies. If the problem or functional trou-
ble is not listed in the trouble-shooting chart contained in this manual, ask
your Authorized Service Centre for service. When you have checked all
the possible causes listed and you are still experiencing the problem, ask
your Authorized Service Centre for help. When you order parts mainte-
nance or repair services, your Authorized Service Centre, your dealer or
eventually the manufacturer need your machine serial number and engine
serial number. These are the numbers that you have recorded on the pro-
duct identification label of the manufacturer on the machine.
1.2 Delivery and transport claims
Upon delivery of the machine please check for visual machine dama-
ges such as damaged packing or scratched buckled parts. If so, make
a remark on all copies of the delivery bill before signing for accep-
tance. Also have the truck driver sign all copies of the delivery bill.

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Also have the truck driver sign al copies of the delivery bill.
Should your shipper or the truck driver refuse to accept your claim,
fully reject delivery and make sure to inform us (the manufacturer)
immediately. No claims shall be taken into account by the shipper or
by the insurance company, if a reservation note is not made on the
delivery bill.
All transport damages must be notified within latest 2 days from de-
livery. Therefore delivery must be collected and inspected within this
term. Later claims shall be disregarded. In case of assumed but not
visually clear transport damages, make sure to mark the following
sentence on the delivery bill: „Reserved delivery due to assumed
transportation damages.“
Insurance and shipping companies act with extreme caution in case
of transport damages and sometimes refuse to accept responsibility.
Please make sure to provide clear and exhaustive evidence (photos)
of the claimed damages.
Thank you in advance for your help and attention to this matter.

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Wheels arrangement
2. PRODUCT OVERVIEW
start/stop
button
Combination
plug switch with
emergency
stop button
Flap closure
safety hood
Bagging
framework
Cylinder
Infeed chute
Steel stand
Tank

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1. Machine safety label
„Before setting-up, servicing, maintaining and
cleaning the machine, disengage power and stop
the engine. Lock the tool and secure it against ac-
cidental start.“
This safety label reminds users of a pinched hands danger.
2. Machine safety label
„Read, understand, and follow all instructions in
this manual and on the splitter before starting!“
Keep at safe distance from machine moving parts!
3. Operation safety label „Warning: lubrication
nipple“
This label shows the location of the various nipples on the machine
that need lubrication several times a day.
4. Operation safety label “Pinched hands danger!“
Keep your hands off all moving machine parts! Pinched
hands danger.
8. „BGU-Maschinen” manufacturer’s logo
9. „Product Identification label“
This label shows the company details of the manufacturer
and the main technical data of the machine.
10. Personal protecion sign
“Wear suitable protective gloves!”
This label shows that you must wear safety gloves when
working with the saw.
11. Personal protection sign “Wear suitable protec-
tive boots!”
This label shows that you must wear safety boots when
working with the saw.
3. SAFETY SIGNS AND WARNING LABELS

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12. Machine safety label
„Wear earplugs and googles “
13. Safety-alert symbol
„Danger: beware in this area!“
14. Personal protection sign
Mind these instructions for safe operation!
15. Maintenance label „Lubricate every 10 h“
This decal is used to remind the operator of the
right lubrication point (every 10 operation hours)
of the processor.
16. Machine safety sign
„Check direction of motor revolutions“
17. Machine safety sign
„Moving Parts Danger!“

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Strictly perform installation, set-up, maintenance, cleaning
and transportation with the motor switched off and the machi-
ne firmly secured against accidental operation.
The user shall strictly comply with these operation, set-up, mainte-
nance, repair and trouble-shooting instructions in order to assure safe
operation and no damages to the equipment. Moreover we recom-
mend to let the machine be run only and strictly by trained and skilled
staff who must be familiar with the applicable occupational safety and
health administration rules as well as applicable transportation rules.
Incorrect use of the saw can cause serious injury or death.
No person under school leaving age should operate a log splitting ma-
chine. Those who have reached school leaving age but are below the
age of 18 may operate a circular saw if supervised by a competent
person of 18 years or over. The machine shall be installed and kept in
a suitable location selected by the customer for safest operation.
Make sure that the equipment stands on a safe stable foundation.
The working area around the machine must be kept as clear as pos-
sible from surrounding obstacles and slippery foundation floors should
be duly treated (do not use saw dust or wood ash for this purpose).
● Due and proper illumination of the working site must be provided at all times.
● Ensure that a wide but confined area is available around the mach
ne and assure maximum working freedom.
● A skilled licensed electrician must be asked for any repair of the
electric system.
● Operators must wear steel toe safety shoes and snug-fitting tear-re
sistant work cloths.
● No additional customised protections or tools should be provided on
board of the machine, other than the ones designed and supplied by
the manufacturer.
● NEVER leave the machine unattended with the running motor.
Operator‘s hearing protection, safety glasses, safety shoes and
gloves, close fitting cloths and other adequate protection means are
strongly recommended. Make sure that all access ways are properly
maintained so that wood can be safely delivered, loaded and shipped.
4. SAFETY

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4.1 Mandatory application field
This machine is one-man operation only. Do not ever let more than
one person work on the machine at the same time.
This machine can handle firewood splitting along the wood fibres.
When splitting your logs, be sure that the log is safely laid down in
the special infeed chute.
The manufacturer will consider any other use or application as “misu-
se”, in which case the manufacturer will not be responsible for custo-
mers’ claims or resulting damages.
Strictly feed firewood into this machine starting from a minimum dia-
meter of 100 up to the maximum diameter of 210 mm. This machine
can handle logs in a maximum length of 160 mm.
Customers are to operate the machine in strict accordance with these
installation, operation, maintenance and repair instructions. Lack of
compliance with these instructions may lead to dangerous risks and
situations.

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Three-phase, 400V motor versions should be powered using a 25 m long
power cord with at least 1.5 sq. mm. section.
Ensure bonding of the machine neutral wire to ground. Failure to provide
proper insulation will prevent your machine to start and operate.
Power supply is performed by means of a control push-button switch combination
with built-in outlet and safety electrically connected between a power source (plug)
and the drive motor.
THe socket for electric drife of machine must be equipped with a Residual
current circuit braker (sensitivity 30 mA).
Before starting to work, quickly switch the motor on and off to check
that revolutions occur in the direction shown by the arrow on the motor
casing. Should rotation be performed in the opposite direction, immedia-
tely stop the motor and use a phase inverter (Fig. 1) to switch the polari-
ty in the plug of main power cord using a phase changer.
Operating the processor while the motor turns in the wrong di-
rection may cause major, even permanent damages of the hy-
draulic pump!
5.1 About use of the electric version
5. OPERATING INSTRUCTIONS
5.2 About the hydraulic plant
This kindling wood processor has own inbuilt hydraulic system with pump
and oil reservoire purposely integrated in the steel stand. The machine
comes from the factory with a first oil fill. (see page 17).
Hydraulic oil in the lines may become quite viscous at very low
ambient temperature. In this case, sudden start-up may dama-
ge the hydraulic system of your machine.
In order to protect the system, rather let the processor run idle (with
no load and no operation) for a while (approx. 15 min) till the oil in
the lines warms up.
The processor is hydraulically controlled by means a control valve
whose fine default-settings are performed by the manufacturer before
delivery. Do not alter these settings.
Fig. 1

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5.3 Getting started
Before starting, inspect the machine for evident, visible damages and unusual conditions.
Check the state of all hydraulic hoses, fittings and connectors and seal eventu-
al leaks, if required. Do not check for leaks with your hand. Leaks can be lo-
cated by passing a piece of cardboard or wood around the suspected leak and
looking for discoloration. High-pressure fluid escaping from a very small hole
can be almost invisible. Escaping fluid under pressure can have sufficient force
to penetrate skin, causing serious injury or even death.
Altering the equipment, or using the equipment in such a way as to circum-
vent its safeties, could result in serious or fatal injury. NEVER operate your
processor when it’s in need of repair or in poor mechanical conditions.
5.4 Operation method
Max. 16 cm long logs can be stacked on the infeed chute one after the other.
A number of different indexing bits provides for smooth and even ad-
vancing of the round logs to the splitting knife, nomatter what size.
The indexing unit is the heart of the machine. The size of the kindling
sticks is adjustable by means of an adjustment screw to obtain thicker
or thinner kindling depending on your requirements.
Make sure to perform adjustments strictly after the machine has been
disconnected from power and has come to a complete stop.
The splitting blade is conceived for non-stop back-and-forth operati-
on to process round logs in 10-21 cm diameter and split it into smal-
ler kindling. The final performance is an homogeneous production of
high-quality, uniform kindling (dry logs is a must) for quick, effortless
lighting of wood fire.
The bagging system is consisting of a set of 2 sliding trays and sup-
port rails suitable for two bags so that non-stop filling can continue in
one bag while the other one is being replaced.
5.5 Initial set-up
Install the bagging facility on the machine before starting to operate.
Insert the special bolts (1) in the respective recess on the machine
before you install the bagging frame on the machine.
(see figure 2).
Fig. 2
1

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Fig. 3
4
Fig. 5
5
86
After having securely installed the bagging framework, fi t the upper
fl ap closure between the two side fl anks making sure that the closure
hangs perfectly straight and does not hit against the front panel.
Not fi t the safety pins (2) through the side fl anks and through the top
of the fl ap closure (fi gure 2).
Finally secure the two pins using a cotter (3) as shown on fi gure 3.
Fig. 4
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Install the infeed chute on the processor using the two hex nuts (4)
supplied with the machine by the manufacturer (see fi gure 4).
5.6 Switching the motor on
Close the safety grid and push the greem button of the electric motor
switch to start the motor. Check the direction of motor revolutions.
Motor revolutions should occur in the same direction as shown by the
arrow label on motor casing.
5.6.1 Start-up procedure
• Perform power connection and wait for approximately 10
seconds before starting to operate the processor.
• Press the green Start/Stop button on the electrical box (5) to
trigger the control valve assembly and start the splitting cycle (see
fi gure 5). As the control valve is switched on, the cylinder slides
outwards while the infeed chute moves back.
• As the cylinder reaches its front end position, the control valve is
switched over and the cylinder starts sliding back making logs
advance on the infeed chute.
• As the cylinder reaches its front end position, the control valve is
switched over and a new cycle is started.
5.6.2 End of work
• Press the green Start/Stop button on the electrical board (5) to stop
the actual splitting cycle.
• If you press the button (5) as the cylinder is completing its forward
stroke, the splitting cycle will immediately stop and the cylinder will
automatically move back to its initial position.

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Fig. 6
9
Fig. 7
• If you press the button as the cylinder is completing its
backward stroke, it will simply slide back to its intial position and
stop as it gets there.
5.6.3 Removing the protection grid
The control valve (9) automatically switches over in its neutral position
and the cylinder is stopped, if the protection grid is removed or ope-
ned while the machine is operated (see figure 6).
Close the grid back into place and press the green Start-Stop button
(5) to make the push-block slide back to start position and then start
the machine again (see figure 5).
As soon as the push block reaches again in its start-position, a new
kindling cycles can be started again.
5.6.4 Emergency stopping during splitting
Both the electric motor and the control unit will be immediately dis-
connected, if the stop button (8) or the emergency stop (7) are enga-
ged during a splitting cycle.
In order to restart the machine again, release the emergency stop (7),
press the green start-button (6) and then the on/off switch (5) to re-
start.
The ram will slide 2 cm forth and back and the splitting cycle will have
to be repeated, if you keep on holding the on/off switch (5) down for a
little longer time. (see Fig.5)
5.6.5 Control display
The control display (see figure 7) shows the following operating times:
1.splitting height
2. operation hours
3. operation minutes
4. operation seconds

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Fig. 8
10
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5.6.6 Adjusting the forward stroke
To change the rate of logs advancing into the processor:
Release the locknut (10) of the adjustment rod and optimize the po-
sition of the stop bushing (11) by turning the threaded portion (see
figure 8).
The forward stroke increases as closer as you move the stop bushing
to the splitting knife.
After optimizing the new stroke, tighten the locknut to the stop bu-
shing again.

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Before handling, moving or transporting the machine make su-
re to disconnect the machine from the power network.
The processor can be conveniently transported by dismounting both
the infeed chute and the bagging framework so to reduce the overall
transport dimensions. For size and dimensions please see the follo-
wing section „Technical Data“.
6.1 Short-distance handling on own wheels
This processor can be easily moved on short-distance by one person
only by means of own wheel arrangement and two ergonomic, practi-
cal grip-handles. Simply grasp the grip-handles and pull the unit up
and lean it back on the wheels to push it to a new placement.
6. HANDLING AND TRANSPORTATION
7. TROUBLE-SHOOTING
If advancing of the logs suddendly and unexpectedly stops:
• Make sure you did not run out of logs in the infeed chute
• Make sure that no log was too short and got stuck across the chute
• Make sure that there are no banches on a log getting tagles and
preventing further advancing
• Make sure that the logs on the chute do not exceed the maximum
admissible length of 16 cm and that their diameter is between 10
and 21 cm.
If you feeding logs of different diameters into the processor, make su-
re to comply with the following instruction:
Logs must enter the processor by a decreasing-size sequence. This
means you should first load the largest logs on the chute so that they
are fed first to the knife followed by decreasingly smaller logs (smaller
diameter).
Feeding smaller logs first (that is to say the opposite way around) may
cause larger logs to roll over the smaller ones and jamming the ma-
chine inlet.

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Never use hands to clear or push logs into the machine!
In case of jamming, be cautious and make sure to first switch
the machine off, clear eventual obstructions and then start
again.
If the processor comes to a sudden stop due but not limited to a jam-
med piece of wood, move the wedge adjustment lever in the off-posi-
tion and wait for the ram to slide back in its initial position.
If the processor becomes suddendly inoperable, check the machine
for the any of the following possible causes:
• Eventual jammed logs
• There may be a damaged hydraulic hose
• Poor, unsufficient operating pressure
• Faulty or badly set control valve
• Defective switch
• Power disconnection
If the processor operates too slowly, check the machine for the any of
the following possible causes:
• Unsufficient oil in the hydraulic system
• Poor, insufficient operating pressure
• Defective control valve (or wrong settings)
• Jammed logs

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8. REPAIRS AND
MAINTENANCE
Make sure that the machine is fully disconnected and all mo-
ving parts are secured before performing any maintenance/re-
pair work on the machine. In the event of any malfunctioning,
switch the machine off before trouble-shooting.
8.1 Ordinary maintenance
The following tasks belong to ordinary maintenance works:
● Cleaning of the machine from eventual residual wood, chips or dirt
● Repeading lubrication of the knife sliding surface (use a brush) over
a working day time
● Checking the level of hydraulic oil and tightness of the system
(hoses and couplings)
• Grease and lubricate all moving parts when required
8.2 Hydraulic oil specifications
Periodically check the oil level inside the hydraulic oil tank. When do-
ing so, accurately avoid contaminating the tank with dirt, wood chips,
sow dust etc... Make sure that the machine never runs without oil or
with a low oil level. When this happens, air is likely to reach inside the
hydraulic loop. Failure to maintain due oil level may cause poor run-
ning and irregular processor operation (very rough, jerky motions) as
well as major pump damages.
Please schedule your first oil change after approximately 50 operation
hours and later ones after each 250 operation hours or once a year.
Recommended oil types:
DEA HD B 46, Shell Tellus 10-46, Esso Nuto H 46
When changing the oil, never let used oil drop down on the ground,
rather collect whole of it in a sealedcontainer for due disposal. Oil
disposal containers should be of at least 80 l capacity. If you are us-
ing smaller containers, make sure to drain the tank in more than one
round to avoid spilling old oil out on the ground.
Used oil is very polluting and should be disposed in accordance with
local regulations!
After refilling the tank with new oil, let the processor cycle three or
four times and let the air blow out of the hydraulic loop before closing
the cap. All hose connections must be always tight and sealed.

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When the processor is fully obsolete and cannot be of any longer use,
it should be duly dismounted ahead of discarding. Certain components
need deactivation and dismantling in order to assure that no further
use is made by other parties and that no worn out parts are recycled
for other applications.
During dismantle be alert for possible recyclable materials and com-
ponents that belong to differentiated waste collection procedures ap-
plicable in your country.
The manufacturer is not liable and undertakes no responsibility for
personal injuries or damages that may result from the recycling of
worn outmachine parts and eventual re-use in other applications diffe-
rent than originally stated in this manual.
Dismantling procedure:
Take good note please: each and every dismantling task must beper-
formed by authorized service centres or trained skilled staff only!
● Pull the machine down into single components
● Lock and clamp all moving machine parts
● Deliver each single component only to authorized waste manage
ment facilities
● Drain oil and fuel out of respective tanks and lines before disposal of
the machine
● Remove rubber and plastic parts from the machine that must be se
parately disposed of.
Deactivated, clamped moving/driving parts and components are of no
further risk and danger.
Electric components must be separately disposed to avoid substantial
environmental threat. In the event of fire on the electric deployment
system of the machine, use of an explosion-proof extinguish system is
required (for example powder fire extinguishers).
9. DISPOSING OF AN OBSOLETE MACHINE

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10. TECHNICAL DATA
* please account for ± 10% splitting power rates.
10.1 Noise level and emissions
Noise emissions were measured in accordance with the European di-
rectives for the measurement of noise emissions on the workplace.
The measurement was performed by external authorized certification
bodies in compliance with the applicable standards based on applica-
ble rules for agricultural and forestry equipment.
The detected noise level was:
LpA = 80 dB(A) and 90 dba at max loading conditions
Technical data Unit of
measure-
ment
min. logs diameter mm 100
max. logs diameter mm 210
admissible logs length mm 160
max. final output cbm/Std. 2,4
max. operating pressure bar 90
motor power P1 KW 5,5
number of motor rev. U/min 1435
height without infeed chute mm 1500
height with infeed chute mm 2000
width without infeed chute and bagging
framework
mm 1000
width with infeed chute and bagging fra-
mework
mm 2200
machine length mm 1250
weight kg approx. 450

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11. WIRING DIAGRAM
BEWARE: only let expert skilled staff do electric repair/mainte-
nance works!
As for all electric tools and equipment we strongly recommend use a
portable residual current device (PRCD), unless you already have a
residual current device (RCD) in your house assuring safety and pro-
tection up to max 0.03A nominal fault current.
Components list:
1. Metal housing K3000
2. KB-S 30 Ucc400V
3. Overload safety switch 9.0A
4. Emergency stop
5. Disc brakes 408306
6. Stop switch (opener) 40722016
7. Motor