BGU SM 500 E User manual

USER’S MANUAL
Carefully read the entire manual before operating
the firewood maschine!
Südharzer Maschinenbau GmbH
Helmestraße 94 · 99734 Nordhausen/Harz
Receptionist: ℡+49(0)3631/6297-0 ·
7-111
Internet: www.bgu-maschinen.de
- Set-up
- Use
- Maintenance
- Accessories
HYDRAULIC
LOG SPLITTER
SM 500 E / SM 500 Z
We manufactu-
re in Germany

2
CONTENT
1. Introduction 3
1.1 About the manual 3
1.2 Delivery and transport claims 3
2. Product overview
5
3. Safety pictograms and warning labels 6
4. Safety 8
4.1 Mandatory application field 9
5. Operation 10
5.1 Splitter set-up ready for use 10
5.2 Extension table 10
5.3 PTO operation 10
5.4 Electric specs 11
5.5 Initial check-up 11
5.6 Start-up 12
5.7 Operating safety 12
5.8 Adjusting the ram travel 12
5.9 Hydraulic specs 13
5.10 Operation 13
5.11 Clearing logs jammed on the wedge 14
6. Handling and transportation 15
6.1 Short-distance handling 15
6.2 Handling on a three-point hitch (long distance) 15
6.3 Optional handle rod 15
7. Repairs and maintenance 16
7.1 Ordinary periodic maintenance 16
7.2 Hydraulic oil 16
7.3 Sliding pads in the log carriage 17
8. Dismountingand disposing/scrappingan obsolete machine 18
9. Technical data 19
9.1 Noise level and emissions 19
10. Electric diagram 20
11. Other area of possible danger 21
2.1 Mechanical dangers 21
2.2 Electrical dangers 21
12. Legal warranty 22
13. Extended warranty 22
14. EC Statement of compliance 23

3
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 perfor-mance.
Our range of hydraulic log splitters includes various different models
of different splitting force.
SM 500 E/ SM 500 Z
All log splitters are equipped with the safety 2-hands control.
1.1 About the manual
Please take time to read this manual and learn to how operate and
maintain the splitter safely. For your easier reading this manual is laid
out in several sections. The sections are progressively numbered 1th-
rough 14 and listed 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. Be-
cause of on-going product improvements and feature additions,infor-
mation in this document is subject to change without notice.
When you have checked all the possible causes listed and you are still
experiencing the problem,askyour Authorized Service Centre for help.
When you order parts maintenance 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 num-
bers that you have recorded on the product 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 al copies of the delivery bill.
Also have the truckdriver sign al copies of the delivery bill.Should your
shipper or the truckdriver refuse to accept your claim,fully reject de-
livery 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 delive-
ry. Therefore delivery must be collected and inspected within this term.
Later claims shall be disregarded.

4
In case of assumed but not visually clear transport damages make sure
to mark the following sentence on the delivery bill: „Reserved delive-
ry 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.

5
Casing
2. PRODUCT OVERVIEW
Splitter wedge
Extension
table
Handle rod Wheel
Log carriage
Hydraulic
ram (cylinder)
Push-block
Hand guard
Control
lever

6
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 acci-
dental start.“
This safety label reminds users of the general safety rules.
2. Machine safety label
„Read, understand, and follow all instructions in
this manual and on the splitter before starting!“
This safety label reminds the user about the importance of reading
and understanding the instructions of the manufacturer and getting
familiar with the machine before you first use it.
3. Operation safety label
„One-man operation only!“
Possible dangers can arise from moving parts on the machine.
The machine is to be strictly operated by one man at a time only.
4. Machine safety label “max pressure 235 bar“
Maximum operating pressure is 235 bars.
5. Operation safety label “Pinched hands danger!“
Keep your hands off all moving machine parts! Pinched hands danger.
6. Machine safety label „max 540 RPM“
This label shows the max admissible number of PTO shaft revolutions.
7. Operation safety label„Check motor revolutions!“
Avoid dangers and check motor revolutions upon starting when using
a 400V motor.
8. Machine safety label „Direction arrow“
The motor must be turning in the same direction as shown by this ar-
row.
3. SAFETY SIGNS AND WARNING LABELS

7
9. Operation safety label „Shift the wedge down“
The labels is used on the machine to identify the control lever position
when you wish to set the wedge down to a lower level.
10. Operation safety label „Shift the wedge up“
The labels is used on the machine to identify the control lever position
when you wish to raise the wedge up to a higher level.
11. „Product Identification label“
This label shows the company details of the manufacturer and the
main technical data of the machine.
12. „BGU-Maschinen” manufacturer’s logo
13. Operation safety label
“WARNING! Always wear safety boots“
14. Machine safety label
„Wear earplugs and googles “
15. Machine safety sign „Moving Parts Danger!“

8
Strictly perform installation, set-up, maintenance/repair, clea-
ning and transportation with the motor switched off and the
tool firmly secured against accidental operation.
Severe personal injury or machine damages can result from not com-
plying with the operation, assembly, maintenance and repair instruc-
tions contained in this manual. Allow only adults to operate/maintain
the log splitter after they have received sufficient training and have
made themselves familiar with the machine. Make sure that full com-
pliance is assured at all times with the general safety and health rules
on the workplace as well as the applicable local traffic rules.
No one under the age of 18 should be allowed to operate the log split-
ter. However, young people in age of 16 or slightly more may work on
the machine providing that they received adequate training, that they
carry all due personal protection safeties and that an adult supervisor
keeps standing nearby.
Machine instability can result in injury or severe damages. To ensu-
re stability during operation make sure to choose a flat, dry floor free
from any tall grass, brush or other interferences.
To avoid tripping, do not leave tools, logs, or other components laying
around in the work area. Avoid slippery floor conditions but do not
scatter saw dust or wood ash to improve the foundation floor.
Make sure that the equipment stands on a safe stable foundation.
Also assure that:
•Due and proper illumination of the working site is provided at all ti-
mes
•A wide but confined area is available around the machine to stop
access of unskilled personnel during operation and still assure maxi-
mum working freedom
•A skilled electrician is asked for any repair on the electric system
•All operators wear steel toe safety shoes and snug-fi t ting tear-resis-
tant work cloths
•No additional customised protections or tools are provided on board
of the machine, other than the ones designed and supplied by the
manufacturer
•the splitter is never left unattended with its motor on
Always assure compliance with safety, protection and accident pre-
vention rules as well as general road andtraffic rules in the country of
use.
4. SAFETY

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Operators should always wear personal protection cloths including
steel-toed safety shoes, snug-fi t ting tear-resistant work cloths, safety
gloves earplugs and safety goggles.
Site must be free of slippery surfaces and tripping obstacles. Make su-
re that all access ways are properly maintained so that wood can be
safely delivered, loaded and shipped.
4.1 Mandatory application field
Log splitters are one-man operation machines only. Never allow mo-
re than one person approach and work on the machine at the same
time.
The model “SM 500 E / SM 500 Z” is conceived for splitting logs for
fi r ewood preparation only. BEWARE: no cross-grain splitting is per-
mitted. Always split grain-wise.
When placing the log on the log splitter make sure that the chunk
rests entirely and safely on the log carriage.
Any other use or splitting method is considered by the manufactu-
rer as “misuse”. In case of misuse the manufacturer will not be liable
for any injuries or damages and the operator will be held entirely re-
sponsible.
Please make sure to comply with these set-up, operation and mainte-
nance/repair instructions in order to avoid happening of any injury or
dangerous condition.
BEWARE: this unit has a max log capacity of min 250 mm and max
300 mm diameter.

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5. OPERATION
As all PTO-driven units,this splitter are equipped with a three-point linka-
ge to fit on the one available on your tractor. The drive shaft is going to act
as linkage and driving element between the tractor and the processor and
should be therefore duly mounted and secured by the special pins available
on the machine.
Press the detent lockinward as you slide the machine shaft onto the-
tractor PTO stub shaft.Slide the machine shaft forward far enough to
make sure the detent lockhas snapped into the lockposition.Secure
the drive shaft with the special restraining chain to avoid dangerous
twisting.
Make sure that the machine is fully disconnected (switch the tractor
off) and all moving parts are secured before performing any mainte-
nance/repair work on the machine.
5.3 Connection and disconnection to PTO drive
Fig. 1
Fig. 2
5.1 Splitter set-up ready for use
For optimized transport dimensions and more effective handling, the
unit is shipped by the manufacturer with the ram fully retracted over
the log carriage. To set the unit ready for splitting you first need some
minor setup work. Bolt the cylinder flange firmly on the steel casing
(Figure 1). To do this, simply release both the nuts (SW19) and the
respectve U-rings from the special thread bolt and then push the ram
back to stop the flange against the casing.
Now secure the flange in place screwing both hex nuts (SW19)
tighly against the steel casing. Make sure that the ram keeps perfec-
ly straight and horizontal, as you tighten the screws. The push-plate
must advance smoothly and trouble-free all over the entire carriage,
as the ram slides back.
WARNING: a skewed, offset ram will cause the push plate to apply ex-
cessive strain on the piston rod ending up into leaks and even perma-
nent damage of the cylinder gaskets.
5.2 Extension table
The splitter comes with a special steel extension table.
The extension attaches to the carriage on the wedge side and is desi-
gned to collect the wood sticks as they come off the machine through
the wedge.
The extension attaches quickly and easily to the carriage without ha-
ving to use any special tool or equipment.
The retainer pin fits into the bracket of the handle rod (see Figure 2).
To remove the extension, just slightly tip it over to release it.

11
Before uncoupling the drive shaft, make sure to stop the trac-
tor and switch the engine off in order to avoid damaging the
splitter power drive.
Fig. 3
Fig. 4 1
5.4 Electric specifications
Connect the 400V motor using a 25 m long power cable in a minimum
section of 1.5 mm2.
Make sure to connect the neutral return wire of the conductor cord or
the machine won‘t start!
In case of splitters powered by a 400V motor, first check that the mo-
tor rotates in the direction shown by the arrow on the housing. To do
this, quickly switch the motor on and off. Should rotation be perfor-
med in the opposite direction than shown by the arrow-label on the
motor fan, immediately stop the motor and use a phase inverter (Fig.
3) to change the plugging polarity of the conductor cable.
Operating the splitter while the motor turns in the wrong di-
rection may cause major, even permanent damages of the
hydraulic pump!
5.5 Initial check-up
The log splitter is equipped with safety two-hands mechanical controls
(Fig. 4) designed for the operator to keep both hands free from dan-
ger and from infringing the moving ram zone during the entire split-
ting cycle.
It is strongly recommended to check the operation of the two-
hands control every time before a new use.
To do so, engage both hand levers (1) and hold them down at the sa-
me time to let the push-plate advance all the way to the wedge.
If your system is duly set, the push-plate stops upon releasing of just
one of the two levers while the ram stops its back/forth stroke at on-
ce.
On the other hand, the ram must recommence its backwards travel to
the initial start position as soon as the other lever is also released.
Make sure that the ram performs no travel when operating only one
single lever.
Check that both levers spring back into their normal position when the
hand pressure is released.

12
Abb. 5
5.6 Start-up
Before first use, make sure that the log splitter is in good conditions
and that there are no visual damages.
Check all hydraulic hoses, fittings and couplings and to detect and re-
pair eventual oil leaks.
Make sure that all safeties and protections are duly assembled on the
machine. Do not attempt to remove or by-pass these safeties!
Should any trouble or unusual behaviour be detected, do not
start splitting wood until these have been fixed.
2
5.7 Operating safety
Choose a flat, dry, and solid location to operate your splitter.
Make sure that the area is free of slippery surfaces and objects to trip
over. Slippery and icy floor conditions must be duly treated to ensure
solid standing conditions.
This unit is strictly one-man operation.
Never reach with your hands at pinch points where they can
get caught by the travelling push-plate!
5.8 Adjusting the ram travel
The ram travel is factory set to the maximum log capacity before
shipment. As you start the motor, the ram slides automatically
back to the maximum travel stroke.
Should your chunks be much shorter than the actual capacity adjus-
tment on the machine, it is possible to adjust it accordingly. Stepless
ram stroke adjustment is possible at all times.
Ram stroke adjustment procedure:
Let the ram slide forwards to the desired stroke length and shut the
motor off.
When you do this, make sure to keep engaging one of the control le-
vers in order to prevent the ram from returning back to its start po-
sition.
Now release the star-knob (Fig. 5 Pos. 2) on the adjustment rod loca-
ted underneath the log carriage and shift it to the new desired stop-
position. The ram travel is reduced by an equivalent stroke length as
the length of knob shift to the left hand side.
Once the desired ram stroke is obtained, tighten the star-knob back
to the original torque.

13
One can set the log capacity to 250mm, 330mm or 500mm by adjus-
ting the ram/push-plate stroke to the wedge and securing the new
position of the stop-plate using the special cotter pin.
The push-plate will then shift back as far as the new stop-plate positi-
on without ever reaching to maximum stroke.
Should you again require splitting to the maximum log capacity, re-
lease the star-knob and shift it to the right hand side.
Now the push-plate will perform travel back to the maxim ram exten-
sion stroke.
Tighten and secure the star-knob before getting back to work.
5.9 Hydraulic specifications
The splitter features an independant hydraulic plant with tank and
pump. The hydraulic tank is located on the chassis of the machine and
is always supplied by the manufacturer with a first hydraulic oil fill.
At cold temperatures the oil viscosity in the tank is relatively high.
For this reason you should refrain from cold start-up (and splitting) at
low ambient temperature in order to avoid damaging the hydraulic cir-
cuit and ancillary lines on the machine.
In order to assure top hydraulic performance of your processor even
at cold winter temperatures, make sure to first run the machine idle
for a few minutes so that it is fully cycled before start-up.
The splitter is hydraulically controlled by means a control valve
whose fine default-setting is performed by the manufacturer before
delivery. Do not alter these settings.
5.10 Operation
Start the gasoline motor and switch the splitter on.
Load a chunk centrally on the log-carriage.
Use wedge-lift levers to adjust the height of the splitting wedge de-
pendind on the size of your logs.
Now push both handles down at the same time to start the cycle and
engage the ram that will immediately start advancing to the wedge.
DO NOT RELEASE THE CONTROL HANDLES UNTIL THE CYCLE IS
COMPLETELY OVER AND THE LOG IS SPLIT.
Should any emergency arise and stopping be required,simply set both
control handles free from your grip. When doing this,the ram will im-
mediately travel all the way backto start position.
As soon as the log is completely split,release both control handles and
let the ram travel backto start position and be ready for a new cycle.
As soon as the log is completely split,release both control handles and
let the push-plate travel backto start position and be ready for a new
cycle after clearing the wood sticks from the extension table.

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Do not attempt to catch the split wood or remove wood sticks from
the extension table by hand until the cylinder rod stops at its maxi-
mum travel position.
Clear the table and remove chips and wood debris from the machine
before starting a new cycle.
When loading chunks, make sure that logs sits central and firmly on
the log carriage.
Do not split wood chunks with lots of branches, first clean it and re-
move all branches. DANGER : crooked trunk pieces with green/dry
branches may burst under wedge pressure!
Make sure to shut the motor off before leaving the area at work end.
5.11 Clearing logs sticking to the wedge
Depending on the type of wood being split, a log may not always
break into two pieces and clear off the wedge. If a log sticks to the
wedge, let the push-plate slide all the way back and switch the split-
ter off. Now carefully remove or hammer the log off the wedge.

15
3
4
Fig. 6
Fig. 7
6. HANDLING AND TRANSPORTATION
6.1 Short distance handling
This machine is conceived for very ergonomic easy handling thanks to
the special wheel arrangement in the rear bottom part of the machine.
Remove the extension table, grip the handle rod (Figure 6, Pos.
3) with one hand, pull the splitter up and start hauling it away
on its back wheels.
During hauling the ram must be fully retracted over the carriage while
the piston-rod guide must be firmly secured to the special safety catch
on both sides of the push-plate.
To retract the cylinder in trasport asset, first release both hex nuts
(SW 19) of the flange and then shift the ram all the way to the edge
on the opposite side of the splitter.
To set the splitter ready to work again, make sure to screw and secu-
re the cylinder back to the casing (see 5.1 "Splitter setup").
6.2 Handling on the three-point hitch
Like all PTO-powered machines, this unit is equipped with a 3-point
hitch for transportation on a tractor (or a similar vehicle). As you at-
tach your unit to a tractor or other equivalent self-propelled vehicle
make sure that the machine does not infringe the tractor profile nor
blinds tractor lights and signal lights (stop lights, tail lamps, etc...).
If so, you must provide for suitable additional travel lights on the split-
ter.
The same is applicable for all other tools or equipment infringing the
tractor profile by 1m in the back and 40cm on the side. In this latter
case, suitable clearance lamps must be provided in the front. Make
sure to apply suitable warning sings (white/red) as per DIN Standards
11300 to warn about protruding obstacles likely to endanger the ne-
arby traffic.
More details are obtainable from the StVO.
6.3 Optional handle rod
A special optional handle rod (Figure 7, Position 4) is available on re-
quest.
This rod attaches to the special socket purposely located underneath
the wedge assembly. Bolt the rod to this socket for efficient and more
comfortable handling.
Before pulling the splitter up, make sure to secure the wedge seating
with a safety pin. Now you are ready tosafely move and turn the split-
ter around.

16
Fig. 8
5
7. 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.
7.1 Regular maintenance
Make maintenance a regular part of daily operation. The daily mainte-
nance routine needs to include:
• Cleaning of the machine and clearing of all parts from residual wood
debris, chips, dust, bark pieces and eventual other waste
• Greasing of the sliding pads of the push-block
• Hydraulic oil check and (in case of leakage) hydraulic hose and fit-
tings check-up to detect eventual oil leaks. (To do so, you first need to
dismount the rear panel of the steel casing, see figure „Oil change“)
• Lubrication of all moving parts.
7.2 Hydraulic oil
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 splitter never runs without oil or with a low oil le-
vel. When this happens, air is likely to reach inside the hydraulic loop.
Failure to maintain due oil level may cause poor running and irregular
splitter operation (very rough, jerky motions) as well as major pump
damages.
Please schedule your first oil change after approximately 25-30 opera-
tion hours and later ones after each 50 operation hours or once a
year.
The oil drain plug is located on the bottom tank side while the filler
cap is on the rear side of the splitter (Figure 8, Position 5).
Recommended oil types:
DEA HD B 46, Shell Tellus 10-46, Esso Nuto H 46
When changing oil, never let used oil drop down on the ground,
rather collect whole of it in a sealed container for due disposal. Oil dis-
posal containers should be of at least 30 l capacity. If you are using
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 rules!
After refilling the tank with new oil, let the splitter cycle three or four
times and let the air blow out of the hydraulic loop before closing the
cap.

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7.3 Sliding pads inside the log carriage
Should irregular noisy knocks be heard while the ram is shifting back
and forth, grease the plastic sliding pads located inside the log carria-
ge. Preferably use commercial grease available in your country.
The noisy knocks should disappear after greasing.
Should you detect an unusually larger gap between the push-block
and and the sliding pads, sliding pads are likely to be worn out. If so
replace them with brand new ones.
To do so, first release both hex nuts (SW 19) on the cylinder flange
(see figure 9).
Now shift the cylinder half way through the log carriage, undo all 4
push-plate bolts and flip the flange off from one side (fi g ure 10).
Slightly raise the push-plate up, remove the old pads from underneath
the push-block and slip new ones in.
Now screw the pads back to the push-plate, shift the push-block back
against the steel casing and finally screw the cylinder flange to the
steel casing again.
Fig. 9
Fig. 10

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When the splitter 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 compo-
nents that belong to differentiated waste collection procedures appli-
cable 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 out machine parts for 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 be per-
formed by authorized service centres or trained skilled staff only!
• Lock and clamp all moving machine parts before pulling the machine
down into single components
• 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 the fire on the electric deployment system of the ma-
chine, use of an explosion-proof extinguish system is required (for ex-
ample powder fire extinguishers).
8. DISMOUNTING AND
SCRAPPING AN OBSOLETE MACHINE

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Technical data Unit
measure
SM 500 Z SM 500 /
400 V
Max log capacity (length) mm 1070 1070
Max log diameter mm 300 300
Splitting force t 9 9
Max operating pressure bar 235 235
Max PTO (shaft) speed RPM 540
under permanent load RPM 420
Motor power P1 kW 4,0
Rated current A 6,8
Motor speed RPM 2845
Rated voltage V 400
Domestic overload safety A 16 line prot. fuse
Out-to-out transport length mm 1870 1870
Length with extension table mm 3400 3400
Height mm 1200 1200
Width mm 700 700
Weight kg 310 330
Oil tank capacity l 30 30
* The actual splitting force may vary ± 10% of the nominal rating.
9. TECHNICAL DATA
9.1 Noise level & 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.
Noise levels were detected and measured 1600mm high above the
machine and 1000mm away in front of it. The detected noise level
was:
LpA = 80 dB(A)

20
10. ELECTRICAL DEPLOYMENT SYSTEM
BEWARE: only let expert skilled staff do electric repair/maintenance
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:
1. Box K900
2. Overload safety
switch 9.0A
3. KB-04 400V
4. Motor