Black Splitter S2 User manual

Black Splitter GmbH Zum Ritzenhagen 9 34508 Willingen, Germany Tel.: 05632 / 4594 Fax: 05632 / 966621
Original Operating
Instructions
Black Splitter
Type: S2
Keep next to the Black Splitter for future use!
Year of manufacture: 2012
Manufacturer: Black Splitter GmbH Zum Ritzenhagen 9a 34508 Willingen, Germany
Date of issue: 27.12.2011 Change index: 02

S. 1
Black-Splitter GmbH Zum Ritzenhagen 9 34508 Willingen, Germany Tel.: 05632 / 4594 Fax: 05632 / 966621
TABLE OF CONTENTS
PAGE
1.0 Safety
1.1General 3
1.2 Significance of symbols 4-5
1.3 Dangers of non-observance of safety information 6
1.4 Personal safety equipment 6
1.5 Safety information 7-8
• Safety regulations
• Precautionary measures
• General information and actions
• Machinery-specific regulations
1.6 Correct use of equipment 9-10
1.7 Hazards caused by accessories 10
1.8 Residual hazards 11
1.9 Workplace Black Splitter 12
1.10 Authorized persons 13
1.11 Confirmation of operatives 13
1.12 Operator 14
1.13 Safety precautions at the Black Splitter 15
1.14 Safety equipment 16
1.15Noiselevel 16
1.16 Checking safety equipment 17
1.17 Black Splitter safety equipment checklist 17
1.18 Unapproved modification and spare parts manufacture 18
1.19 Storage place for the operating instructions 18
2.0 Transport/installation
2.1 Layout diagram 19
2.2 Technical data 19
• Data Black Splitter
• Hydraulic motor
• Important connection information
2.3 Goods incoming check 19
2.4 Safety information for transport 20
2.5Transport/storage 21
2.6 Set up and connection 21
2.7 Welding the mounting plate with excavator attachment 22
2.8 Operating the Black Splitter for the first time 22
2.9 Removal the Black Splitter 23

S. 2
Black-Splitter GmbH Zum Ritzenhagen 9 34508 Willingen, Germany Tel.: 05632 / 4594 Fax: 05632 / 966621
TABLE OF CONTENTS
SEITE
3.0 Operation
3.1 Overview diagram 24
3.2 Safety information for operation 25
3.3 Before commissioning 26
3.4 Set up 27
3.4.1 Replacing the screw cone 27
3.5 Functional description 28
4.0 Faults
4.1 Safety instructions for troubleshooting 29
4.2 Troubleshooting 29
4.3 Malfunction checklist 30
4.4Faultlist 30
5.0 Care and maintenance (operative)
5.1 Maintenance schedule 31
6.0 Repair/maintenance (operative)
6.1 Safety information for repair and maintenance 32
6.2 Maintenance schedule 33
7.0 Repair/maintenance (maintenance list)
7.1 Maintenance record 34
8.0 Hydraulics
8.1 Safety instructions for the hydraulics 35
8.2 Hydraulics plan with parts list 36
9.0 Replacement and consumables list
9.1 Spare parts order and customer service 37
9.2 Spare part list and consumables list (part list) 38-39
10.0 Conformity declaration
10.1 Proof of conformity 40-41

S. 3
Black-Splitter GmbH Zum Ritzenhagen 9 34508 Willingen, Germany Tel.: 05632 / 4594 Fax: 05632 / 966621
1.0 Safety _______________________________________
1.1 General
This operating instruction manual contains basic instructions which must
be observed during installation, operation and maintenance. They must
therefore be read by operatives, specialist workshop and set up technicians
before commissioning.
The Black Splitter has undergone a safety and acceptance inspection.
Nevertheless when using it dangers can arise for the user or third parties,
respectively the Black Splitter and other material property can be damaged
in the following cases:
* use by untrained or uninstructed personnel
* incorrect use of equipment
* incorrect maintenance or repair
Improper operation or misuse poses a risk for
* the operative (danger of injury)
* the Black Splitter and other property of the operator
* the efficiency of the machine
Along with the general information listed in this "Safety" section,
the specific safety instructions included in other sections shall also be
observed.
.
The operating instruction manual must always be available at the
place of use of the machine.
All those involved with the installation, commissioning, operation
maintenance and repair of the machine shall
• follow this operating instruction manual exactly.
For your safety!

S. 4
Black-Splitter GmbH Zum Ritzenhagen 9 34508 Willingen, Germany Tel.: 05632 / 4594 Fax: 05632 / 966621
1.0 Safety ________________________________________
1.2 Significance of symbols
The safety instructions included in the
operating instruction manual which can
result in a risk to persons if ignored are
identified with the general hazard
symbol.
Caution: hot surface
Keep a sufficiently safe distance from the
swivel zone of the machine
Wear enclosed footwear
Wear protective gloves
Operating instruction manual

S. 5
Black-Splitter GmbH Zum Ritzenhagen 9 34508 Willingen, Germany Tel.: 05632 / 4594 Fax: 05632 / 966621
1.0 Safety ____________________________________
1.2 Significance of symbols
Caution
You will find this symbol on safety
instructions which, if ignored, can result in
risks for the machinery and its functions.
Note Represents advice or instructions which
will make work easier and ensure safe
operation
Figure 1: Black Splitter

S. 6
Black-Splitter GmbH Zum Ritzenhagen 9 34508 Willingen, Germany Tel.: 05632 / 4594 Fax: 05632 / 966621
1.0 Safety ____________________________________
1.3 Danger of non-compliance with safety notes
Non-compliance with safety information can invalidate any damage
compensation claims.
In individual cases non-compliance can, for instance, cause the following
dangers:
* failure of important machinery functions
* mechanical and electrical risk for personnel
1.4 Personal safety equipment
On the Black Splitter the setting up work, the commissioning and
the operating of the machine is only allowed to be carried out with
the stipulated protective gear.
Enclosed footwear must always be worn
when working with the Black Splitter.
Protective gloves must always be worn
when changing the screw tip.

S. 7
Black-Splitter GmbH Zum Ritzenhagen 9 34508 Willingen, Germany Tel.: 05632 / 4594 Fax: 05632 / 966621
1.0 Safety ____________________________________
1.5 Safety instructions
Safety regulations
1. Avoid damage to hydraulic lines.
2. Protect the hydraulic lines against sharp edges.
3. If the machine is not being used, interrupt the hydraulic supply.
4. Always disconnect the hydraulic supply to the machine if,
testing and maintenance tasks have to be carried out.
5. Do not remove the protective covers and screws.
Safety precautions
1. The Black Splitter is only allowed to be operated with the stipulated pressure.
2. All repair and maintenance work on the machine must be carried out by a
specialist workshop.
3. Set up work may only be carried out by a set up technician.
4. All operating and fitting personnel are only allowed
to commission the Black Splitter with closed footwear.

S. 8
Black-Splitter GmbH Zum Ritzenhagen 9 34508 Willingen, Germany Tel.: 05632 / 4594 Fax: 05632 / 966621
1.0 Safety ____________________________________
1.5 Safety instructions
General information and precautions
1. Use the Black Splitter exclusively for the purpose described in section
"1.6 Correct use of equipment".
2. Never work with a damaged Black Splitter.
Have the Black Splitter checked for faults immediately. All maintenance
and repairs must be carried out by a specialist workshop.
3. Store the Black Splitter only in a clean dry place.
Machine-specific regulations
1. The Black Splitter is only suitable for splitting and transporting logs.
2. The Black Splitter must only be operated with hydraulic oil.
3. Always observe safety instructions.
4. It is compulsory to read the operating instruction manual before assembling or
removal the Black Splitter.
5. The correct set-up of the Black Splitter is described in detail in the operating
instruction manual in section "3.0 Operation".
6. The care - and maintenance of the machine is described in detail
in the operating instruction manual in section
5.0 Care and maintenance (operator)
6.0 Maintenance/repair (operator)

S. 9
Black-Splitter GmbH Zum Ritzenhagen 9 34508 Willingen, Germany Tel.: 05632 / 4594 Fax: 05632 / 966621
1.0 Safety ____________________________________
1.6 Correct use of equipment
The Black Splitter is only suitable for splitting and transporting logs.
Figure 2: Splitting logs Figure 3: Transporting logs
Type max. pressure Length Width Height Volume Weight
S2 180-260 bar
180-230 bar
180-210 bar
180-380 bar
80 cm 23 cm 35 cm 518 cm3/rev
666 cm3/rev
801 cm3/rev
801 cm3/rev
ca. 109kg
The Black Splitter is connected with the carrier, e.g. forklift truck, tractor,
wheel loader, yard loader or excavator, by means of a mounting plate.
Caution When splitting, high forces must not be applied
by the carrier.
Any alternative or additional use is considered improper use of the Black
Splitter.
The operative/operator is responsible for any damage to the machine.
The same applies for unauthorised changes or manipulations of the Black
Splitter.

S. 10
Black-Splitter GmbH Zum Ritzenhagen 9 34508 Willingen, Germany Tel.: 05632 / 4594 Fax: 05632 / 966621
1.0 Safety ____________________________________
1.6 Correct use of equipment
Correct use of equipment also includes compliance with
instructions for
∗ safety
∗ operation
∗ maintenance, repair and troubleshooting
as described in this operating instruction manual.
Caution The Βlack Splitter must be repaired exclusively by a
specialist workshop.
The Black Splitter has undergone a safety inspection and a final inspection.
Unauthorised conversion or changing of the machine is prohibited on safety
grounds!
The conditions for use, maintenance and repairs in this operating instruction
manual shall be strictly adhered to.
1.7 Hazards caused by accessories
The addition of accessories must not disable any safety equipment on the Black
Splitter.
The safety equipment must always be in place.

S. 11
Black-Splitter GmbH Zum Ritzenhagen 9 34508 Willingen, Germany Tel.: 05632 / 4594 Fax: 05632 / 966621
1.0 Safety ____________________________________
1.8 Residual hazards
Despite compliance with all safety conditions, use of the Black Splitter
may still involve residual hazards.
Everyone who works on and with the machine must be aware of these
dangers, and must follow the instructions which prevent these residual
risks leading to accidents or damage.
Never remove protective covers or
disable them by modifying the Black
Splitter.
Caution: hot surface on the screw tip
Keep a sufficient distance from the
swivel zone of the machine.
Protective gloves must always be worn
when changing the screw tip.

S. 12
Black-Splitter GmbH Zum Ritzenhagen 9 34508 Willingen, Germany Tel.: 05632 / 4594 Fax: 05632 / 966621
1.0 Safety ____________________________________
1.9 Workplace Black Splitter
Zone 1: The operative is responsible that there are no persons within a sufficient
distance of the Black Splitter’s workplace.
Zone 1
Figure 4: Workplace Black Splitter
Keep a sufficiently safe distance from the
swivel zone of the machine.

S. 13
Black-Splitter GmbH Zum Ritzenhagen 9 34508 Willingen, Germany Tel.: 05632 / 4594 Fax: 05632 / 966621
1.0 Safety ____________________________________
1.10 Authorized persons
The minimum age for operatives is 18 years.
The responsibilities for different operations on the Black Splitter
shall be clearly defined and complied with.
Unclearly defined responsibilities are a safety risk.
Operatives may not start the Black Splitter unless they have read, understood
and signed the operating instruction manual.
Operatives => Persons who have read and understood
the operating instruction manual.
Maintenance personal => Operatives
Repair personnel => Persons from a specialist workshop
Any personnel under instruction of any kind must be under the constant
supervision of an experienced qualified staff member while working on
the machine!
1.11 Confirmation of the operators
The signature of the operator is confirmation of familiarity with the basic
occupational safety and accident prevention regulations and that instruction
has been received in the handling of the machinery and that s/he has read.
Date:__________ (Signature):___________
Date:__________ (Signature):___________
Date:__________ (Signature):___________
Date:__________ (Signature):___________
Date:__________ (Signature):___________

S. 14
Black-Splitter GmbH Zum Ritzenhagen 9 34508 Willingen, Germany Tel.: 05632 / 4594 Fax: 05632 / 966621
1.0 Safety ____________________________________
1.12 Operator
The operator is obliged to ensure that persons working on the Black Splitter
are familiar with the basic occupational safety and accident prevention
regulations and have received instruction in the handling of the machinery.
The operator shall additionally ensure that all maintenance and assembly
is carried out by maintenance personnel who have studied the operating
instructions carefully and are sufficiently well-informed.
The operator must
∗ ensure all operatives have constant access to the operating
instruction manual.
∗ make sure, and have this confirmed with a signature, that
the operating personnel have read the operating
instructions and understood them.
∗ instruct the operatives, the set up technicians the
maintenance personnel and the electrical engineers about
the Black Splitter and document this instruction.
∗ complete the faults list in section 4.4 and make this
available to Black-Splitter GmbH.
∗ provide personal safety equipment for use and
maintenance of the Black Splitter.
∗ provide additional instruction about residual hazards of the
Black Splitter.
∗ check at regular intervals that operatives are working
safely.
∗ at least every two years check that the Black Splitter safety
markings comply with regulations.

S. 15
Black-Splitter GmbH Zum Ritzenhagen 9 34508 Willingen, Germany Tel.: 05632 / 4594 Fax: 05632 / 966621
1.0 Safety ____________________________________
1.13 Safety precautions at the Black Splitter
The hydraulic lines connected to the Black Splitter must be attached to
the upper opening using the cable ties supplied.
Figure 5: Attachment of the hydraulic hoses
In addition, after the first splitting operation (after approx. 2 - 3 hours
of splitting operation), the bolts on the hydraulic motor and on the screw cone
have to be checked and retightened. In order to access the bolts on the hydraulic
motor, the protective cover on the side has to be disassembled.
Cable tie
Mounting bolts

S. 16
Black-Splitter GmbH Zum Ritzenhagen 9 34508 Willingen, Germany Tel.: 05632 / 4594 Fax: 05632 / 966621
1.0 Safety ____________________________________
1.14 Safety equipment
Safety equipment
* must not under any circumstances be altered, removed or
* circumvented by modifications to the Black Splitter.
Figure 6: Side protective cover on Black Splitter
1.15 Noise level
The noise measurement on the Black Splitter was measured for the workplace
at a distance of 1 m from the machine surface and 1.60 m above the ground.
The sound pressure level of the Black Splitter is below 80 dB(A).
During the working process a higher sound-pressure level is generated.
At a sound-pressure level of between 80 dB(A) and 85 dB(A)
the operator shall
∗ provide hearing protection information and instruction.
∗ provide the operative with ear protectors.
∗ at regular intervals carry out precautionary medical check-
ups to monitor the operator’s hearing.
Protective cover

S. 17
Black-Splitter GmbH Zum Ritzenhagen 9 34508 Willingen, Germany Tel.: 05632 / 4594 Fax: 05632 / 966621
1.0 Safety ____________________________________
1.16 Checking safety equipment
Use the checklist for regular inspections of the safety equipment:
1.17 Checklist for safety equipment
Before starting up the machine, check that all safety equipment is correctly
fitted and fully operable.
Safety equipment may only be removed
∗ after stopping the machine
∗ securing the machine against restarting
Caution The general inspection instructions and function
tests shall be carried out without production
material.
Ensure immediate remedy of any faults found on
lines and safety equipment!
Checking intervals
Caution ∗ at the start of each shift
∗ after any maintenance or repair
Check the following
Caution
∗ prescribed condition
∗ secure attachment
∗ prescribed function
1.17 Black Splitter safety equipment checklist
General checks
Side protective cover Fitted and screwed tight
Screw connection Fitted and screwed tight
Hydraulic lines Fitted and screwed tight
Cylinder Fitted and screwed tight
Check date:__________ Checked by (Signature):___________

S. 18
Black-Splitter GmbH Zum Ritzenhagen 9 34508 Willingen, Germany Tel.: 05632 / 4594 Fax: 05632 / 966621
1.0 Safety ____________________________________
1.18 Unapproved modification and spare parts manufacture
Refurbishment or changes to the Black Splitter are only admissible by
arrangement with the manufacturer. The manufacturer is Black-Splitter GmbH.
Original spare parts and manufacturer-authorised accessories contribute to safety.
There can be no liability accepted for the consequences of using other parts.
1.19 Storage place for the operating instructions
The operating instructions must be always kept
available next to the Black Splitter.

S. 19
Black-Splitter GmbH Zum Ritzenhagen 9 34508 Willingen, Germany Tel.: 05632 / 4594 Fax: 05632 / 966621
2.0 Transport/installation/dismantling _________________
2.1 Layout diagram
Figure 7: Black Splitter Figure 8: Black Splitter with excavator
attachment
2.2 Technical data
Data Black Splitter
Dimensions L 80 cm x B 23 cm x H 35 cm
Screw cone diameter 200 mm or 245 mm
Weight approx. 109 kg
Hydraulic motor
Hydraulic motor CPMV 500 Displacement 518cm3/rev 180-260 bar
Hydraulic motor CPMV 630 Displacement 660cm3/rev 180-230 bar
Hydraulic motor CPMV 800 Displacement 801cm3/rev 180-210 bar
Hydraulic motor EPMV 800 Displacement 801cm3/rev 180-380 bar
Important connection information
When connected to a depressurised line (leakage oil line), the max. pressure has
to be reduced by 30 bar. The screw tip can then only be turned in one direction.
2.3 Goods incoming check
Check the packaging for visible damage.
If the Black Splitter is supplied with visibly undamaged packaging but with
concealed damage, contact Black-Splitter GmbH immediately and document
the damage. (Pictures)