DK2 Power OPC525 User manual

CUSTOMER SERVICE 1 [phone] | WWW.DK2.COM
DK2 USA WEST
3311 MEADE AVENUE STE
E DOCK 13, LAS VEGAS, NEVADA
89102 USA
DK2 USA EAST
3750 SOUTH AVENUE
NORTH UNIT, TOLEDO, OHIO
43615 USA
DK2 CORPORATE HEAD OFFICE
5330 MAINWAY
BURLINGTON, ONTARIO
L7L6A4 CANADA
OPC525
5INCH KINETIC CHIPPER
POWERED BY KOHLER®
USER MANUAL

2 | OPC525(D) man.
WARRANTY
PLEASE DO NOT RETURN TO THE STORE
YOU HAVE A 1-YEAR WARRANTY AND DK2 WILL REPLACE A DEFECTIVE PART FOR FREE. CALL US AT 1 (888)
277-6960 FOR FAST WARRANTY PARTS AND QUESTIONS.
WHAT IS COVERED – 3-YEAR ENGINE AND 1-YEAR DK2 LIMITED WARRANTY INCLUDED
DK2 warrants to the original purchaser that product will be free and clear of manufacturing defects in workmanship
and materials under normal use and service for a period of one (1) year from the date of the original purchase. If
within one (1) year from the original date of purchase this product fails due to defect in material or workmanship,
DK2 will repair, replace, or supply any covered defective part at our option. DK2 POWER is 1-year parts only warranty
no labor. KOHLER® 3-year warranty is PARTS and LABOR.
Upon expiry of one (1) year, DK2 will have no further liability related to the product. DK2 does not authorize any
party, including its authorized distributors or dealers, to oer any other warranty on behalf of DK2.
SERIAL NUMBERS MUST BE REGISTERED ONLINE AT WWW.DK2.COM, WARRANTY NON-TRANSFERABLE.
KOHLER® ENGINES –KOHLER® CH SERIES ENGINES 3 YR PARTS AND LABOR WARRANTY
KOHLER® ENGINES –KOHLER® SH SERIES ENGINES RESIDENTIAL 2 YR PARTS AND LABOR WARRANTY
See your KOHLER® manual for specific warranty.
DK2 – 1-year parts only, no labor. 3-year KOHLER® warranty.
THIS WARRANTY DOES NOT COVER OR APPLY TO:
(a) Damage to the product due to misuse, mishandling and abuse
(b) Improper installation, maintenance and storage
(c) Expendable parts such as nuts and bolts, pins and springs, wiring and switch components, hydraulic hoses and
fittings, cutting teeth, cutting chains, cutting blades, throttles, belts and tires.
(d) Normal wear and tear
(e) Consequential damage & incidental damages such as damage to persons or property
PROCEDURE FOR OUTDOOR POWER EQUIPMENT WARRANTY
Within the one (1) year warranty period, the purchaser of the product can CALL 1 [phone] or contact us
on www.DK2.com. Notify us of the claimed defect and provide proof of original purchase. At this time the validity
of the claim will be determined, and if approved replacement parts will be issued. No returned product will be
accepted under warranty unless accompanied by an RGA# issued by DK2.
DAMAGED FREIGHT
Damage to your product caused by freight mishandling is NOT covered under warranty. If your freight arrives
damaged, REFUSE it. Inspect your product when it arrives, otherwise if you accept it, you will be responsible for
filing any freight claims with the delivery company. DK2 warranty excludes damage to product.
RETURNS BEFORE GAS AND OIL
Follow the return policy from the retailer you purchased the equipment from.
RESOLUTION FOR A DEFECTIVE PRODUCT AFTER GAS AND OIL HAS BEEN ADDED.
Call us at 1 [phone] between 8am-4pm Monday to Friday EST.
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ONLINE RESOURCES
LEARN MORE ABOUT YOUR PRODUCT
Visit your product’s web page by visiting www.detailk2.com/
opc525-info where you can find all sorts of information specific
to your product, from description, to photos/videos, specifications,
and support. You can also visit this page on your mobile device by
scanning the PRODUCT PAGE QR Code on the left.
PURCHASING REPLACEMENT PARTS
In need of replacement parts? You can visit www.detailk2.com/
shop-power-equipment-parts where you can purchase anything
from small to large items. You can also shop on your mobile device
by scanning the PARTS STORE QR Code on the left and you’ll be
directed to our online store.
DON’T SEE YOUR PRODUCT’S PARTS ONLINE?
Not a problem, visit www.detailk2.com/shop-power-equipment-
parts and fill out the form prompted by the button on the top of
the page. Our team will acknowledge your request and proceed
to upload your part(s) to the store as soon as possible. You can
also get to this form on your mobile device by scanning the PARTS
STORE QR Code on the left.
VIEW THIS USER MANUAL ON YOUR PHONE
Scan the USER MANUAL QR Code on the left to view this product’s
user manual on your mobile device. You may save the manual to
your phone or keep it open in your phone’s internet browser for
future use.
PARTS STORE
USER MANUAL
PRODUCT PAGE
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4 | OPC525(D) man.
TABLE OF CONTENTS
WARRANTY..........................................................................2
ONLINE RESOURCES .................................................................3
TABLE OF CONTENTS ................................................................4
TECHNICAL SPECIFICATIONS..........................................................5
SECTION I  SAFETY ..............................................................6
SAFETY CONVENTIONS ..............................................................7
IMPORTANT SAFETY INFORMATION....................................................7
SAFETY DECALS .....................................................................8
OPERATOR ZONE ....................................................................9
GENERAL SAFETY INFORMATION ......................................................9
SECTION II  ASSEMBLY ..........................................................14
STEP 1: CHECK THE PACKING.........................................................15
STEP 2: WHEELS ....................................................................16
STEP 3: EXPULSION CHUTE ..........................................................16
STEP 4: FEED CHUTE ................................................................ 17
STEP 5: TOW BAR AND STAND ASSEMBLY .............................................18
STEP 6: AXLE ASSEMBLY.............................................................19
STEP 7: EXPULSION CHUTE DEFLECTOR ..............................................20
STEP 8: CHUTE GUIDE ...............................................................21
STEP 9: TOOL BOX ..................................................................22
ENGINE CHECKLIST .................................................................23
REVERSING THE BLADES ............................................................24
SECTION III  OPERATION.........................................................25
OPERATING INSTRUCTIONS ..........................................................26
STARTING YOUR EQUIPMENT ........................................................26
STOPPING YOUR EQUIPMENT ........................................................27
MAINTENANCE .....................................................................27
TROUBLESHOOTING ................................................................28
SECTION IV  PARTS & SCHEMATICS ...............................................29
PARTS LIST .........................................................................30
SCHEMATICS .......................................................................31
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TECHNICAL SPECIFICATIONS
MODEL NUMBER OPC525
ENGINE KOHLER® CH395 9.5 HP 277cc
LOG CAPACITY Ø5” (Ø12.7cm)
CHIPPER Auto-adjusts up to Ø5” (Ø12.7cm) trees and brush
CUTTING BLADES Double-edge, reversible
EXPULSION CHUTE Tool-free, swing open and 180° adjustable
ASSEMBLED
DIMENSIONS
91” (L) x 46” (W) x 30” (H)
231.1cm (L) x 116.8cm (W) x 76.2cm (H)
ASSEMBLED WEIGHT 308lb (140kg)
SHIPPING DIMENSIONS 35.8” (L) x 22” (W) x 37.8” (H)
91cm (L) x 56cm (W) x 96cm (H)
SHIPPING WEIGHT 352.7lb (160kg)
WHEELS 145/70-6 ATV
COUPLER 1-7/8” (4.76cm) ball with safety chains
WARRANTY 3-year KOHLER® warranty
1-year DK2 limited chassis warranty
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SECTION I • SAFETY

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SAFETY CONVENTIONS
DANGER! This indicates a hazardous situation, which, if not avoided, will result in death or
serious injury.
WARNING! This indicates a hazardous situation, which, if not avoided, could result in death
or serious injury.
CAUTION! This indicates a hazardous situation, which, if not avoided, may cause minor or
moderate injury.
ADDITIONAL INFORMATION AND POTENTIAL CHANGES
We reserve the right to discontinue, change, and improve our products at any time without notice
or obligation to the purchaser. The descriptions and specifications contained in this manual were
in eect at printing. Equipment described within this manual may be optional. Some illustrations
may not be applicable to your machine.
IMPORTANT SAFETY INFORMATION
WARNING! Read and understand the complete User Manual before assembling
or using this product. Failure to comprehend and comply with warnings,
cautions and instructions for assembly and operation could result in serious
injury or death.
WARNING! Do not permit children to operate this equipment at any time. Do not permit
others that have not read and understood the complete User Manual to operate this
equipment. Operation of power equipment can be dangerous. It is the sole responsibility
of the operator to understand the assembly and safe operation of this product.
DANGER! INTENDED USE: Do not use this machine for any purpose other than chipping
wood, for which it was designed. Any other use is unauthorized and may result in serious
injury or death.
DANGER! PERSONAL PROTECTIVE EQUIPMENT: When operating
this machine, it is essential that you wear safety gear including goggles
or safety glasses, steel-toed shoes and tight-fitting gloves (no loose
cus or draw strings). Always wear ear plugs or sound-deafening
headphones to protect against hearing loss when operating this
wood chipper.
CAUTION! Do not wear loose clothing or jewelry that can be caught
by moving parts of the machine. Keep clothing and hair away from all moving parts of the
machine.
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8 | OPC525(D) man.
SAFETY DECALS
Make sure all safety warning decals are attached and in readable condition.
Please call DK2 at 1 [phone] if you need help replacing missing or defaced safety decals.
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OPERATOR ZONE
Operate the machine from within the operation zone as shown in the diagrams below. The
operator has the safest and most ecient access to the controls in these locations.
DANGER! FAILURE TO OPERATE THE MACHINE IN HIGHLIGHTED GREEN POSITION
BELOW CAN RESULT IN SERIOUS INJURY OR DEATH.
ITEM # DESCRIPTION
1 Operator zone
2 Feeding zone
3 Engine
4 Foot plate
GENERAL SAFETY INFORMATION
DANGER! GENERAL SAFETY: Failure to follow warnings, cautions, assembly and operation
instructions in the User Manual may result in serious injury or death.
DANGER! READ THE USER MANUAL BEFORE OPERATION
• Do not permit children to operate this equipment at any time. Do not permit
others that have not read and understood the complete User Manual to
operate this equipment.
• Keep all people and pets a minimum of 12 feet (3.7m) away from the work
area when operating this machine. Only the operator is to be near the
machine during use.
• Do not operate the machine when under the influence of alcohol, drugs,
1
1
2
3
4
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10 | OPC525(D) man.
or medication.
• Do not allow a person who is tired or otherwise impaired or not completely alert to
operate this machine.
DANGER! WORK AREA
• Do not operate the machine on icy, wet, muddy or otherwise slippery ground. ONLY
operate your machine on level ground. Operating on a slope could cause the machine
to roll over, which could result in injury.
• Do not operate the machine in an enclosed area. Exhaust fumes from
the engine contain carbon monoxide which can be harmful or deadly
when inhaled.
• Do not move the machine over hilly or uneven terrain without a tow
vehicle or adequate help.
• Use a tire chock or block on wheels to prevent movement of the machine while in
operation.
• Operate the machine in daylight or under good artificial light.
• Keep the work area free of clutter. Remove chipped wood from around the machine
frequently to avoid potential tripping.
DANGER!
• Make sure the operator knows how to stop and disengage the controls
before operating.
• Do not place hands or feet inside the machine during operation.
Serious injury or death could result.
• Do not straddle or step over the machine during operation.
• Do not move the machine while the engine is running
• Never leave the equipment unattended while the engine is running.
Shut o the engine even if you are leaving the machine for a short period
of time.
• Avoid contact with the muer and other hot areas of the engine during
operation or after running to prevent burns.
WARNING! REPAIR AND MAINTENANCE
• Do not operate the machine when it is in poor mechanical condition or in need of
repair. Frequently check that all nuts, bolts, and screws are tight.
• Do not alter the machine in any manner. Any alteration will void the warranty and could
cause the machine to be unsafe to operate. Perform all recommended maintenance
procedures before using the machine. Replace all damaged or worn parts immediately.
• Do not tamper with the engine to run it at excessive speeds. The maximum engine
speed is preset by the manufacturer and is within safety limits. See KOHLER® Engine
manual for more information.
• Remove the spark plug wire before performing any service or repair on the machine.
• Replacement parts must meet manufacturer’s specifications.
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CAUTION! FIRE PREVENTION
• Do not operate the machine near an open flame or spark. Gasoline is
highly flammable and can explode.
• Do not fill the gas tank while the engine is hot or running. Allow the
engine to cool before refueling.
• Do not smoke while operating or refueling the machine. Gas fumes can
easily explode.
• Refuel the machine in a clear area with no gas fumes or spilled gas.
Use an approved fuel container. Replace the gas cap securely. If gas
has spilled, move the machine away from the area of the spill and avoid
creating any source of ignition until the spilled gas has evaporated.
• Keep a Class B fire extinguisher on hand when operating this machine
in dry areas as a precautionary measure against possible flying sparks.
• Drain the fuel tank prior to storage to avoid the potential fire hazard. Store
gasoline in an approved, tightly sealed container. Store the container in
a cool, dry place.
• Turn the fuel shut o valve on the engine to the “OFF” position before towing the
machine. Failure to do so may result in flooding the engine.
CAUTION! IMPORTANT NOTE: 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 arrester
meeting applicable local or state laws (if any). If a spark arrester is used, it should be
maintained in eective working order by the operator. In the state of California a spark
arrester is required by law. Other states have similar laws. Federal laws apply on federal
lands. A spark arrester muer is available as an accessory at your nearest engine dealer.
Always check legal requirements in your area.
CAUTION! TOWING SAFETY
• Check all local and state regulations regarding towing, licensing, and lights before
towing your machine.
• Check before towing to make sure that the machine is correctly and securely attached
to the towing vehicle and that the safety chains are secured to the hitch or bumper of
the vehicle with enoughs lack to allow turning. Always use a Class I, 2” ball with this
machine.
• Do not carry any cargo or wood on the machine.
• Do not allow anyone to sit or ride on the machine.
• Disconnect the machine from the towing vehicle before operating it.
• Use care when backing up with the machine in tow to avoid jack-knifing. Allow for
added length of the machine when turning, parking, crossing intersections and in all
driving situations.
• Do not exceed 15mph (24km/h) when towing your machine. Towing the machine
at speeds higher than 15mph (24km/h) could result in loss of control, damage to the
equipment, serious injury or death. Adjust towing speed for terrain and conditions. Be
extra cautious when towing over rough terrain.
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12 | OPC525(D) man.
WARNING! PROPER MAINTENANCE AND STORAGE
• Keep machine, attachments, and accessories in safe working condition.
• Check engine mounting bolts and other hardware before each use for proper tightness.
Never operate your equipment in poor mechanical condition or when in need of repair.
Be sure all safety guards and shields are in proper position. These safety devices are
for your protection.
• Never store the equipment with fuel in the fuel tank inside a building where ignition
sources are present, such as hot water and space heaters, clothes dryers and the like.
Allow the engine to cool before storing in any enclosure.
• If the fuel tank is to be drained, do this outdoors.
• If it is necessary for any reason to unclog the feed chute or discharge openings or to
inspect or repair the equipment where a moving part can come in contact with your
body or clothing, shut the machine o, allow all moving parts to come to a complete
stop, disconnect the spark plug wire(s) and allow the engine to cool before attempting
to unclog, inspect, or repair.
• Check the blade mounting screws before each use for proper tightness. Also visually
inspect the blade for wear and damage. Replace the blade with parts that meet original
equipment specifications.
• Blades should be checked for sharpness and the bolts attaching them to the flywheel
for tightness before each operation.
• Replace the nylock nuts securing the blade every time you replace the blade.
• Check the gap between the blade and the wear plate every time you replace the blade.
• Never tamper with safety devices. Check their proper operation regularly.
• Inspect the belt each time you use the equipment. Look for damage, worn areas or
tears. Do not use the unit if this condition exists.
CALIFORNIA PROPOSITION 65 WARNING: Engine exhaust, some of its constituents and
certain product components contain or emit chemicals known to the State of California to
cause cancer and birth defects or other reproductive harm.
WARNING! OPERATION
• Never place your hands, feet, or any part of your body in the chipper
chute, discharge opening, or near or under any moving part while the
engine is running. Keep clear of the discharge opening at all times. If it
becomes necessary to push material into the chipper chute, use a small
diameter stick, NOT YOUR HANDS.
• Keep your face and body back from the chipper chute to avoid accidental
bounce back of any material.
• If the cutting mechanism strikes a foreign object or if your machine should
start making an unusual noise or vibration, immediately stop the engine.
After the machine has come to a complete stop proceed as follows:
• Remove the spark plug wire(s) and wait for all moving parts to come to a complete stop.
• Inspect for any damage.
• Repair or replace any damaged parts before restarting and operating the machine.
• Exercise caution to avoid slipping or falling.
• If the machine should start to vibrate abnormally, immediately stop the engine, and wait
for all moving parts to come to a complete stop and inspect for the cause. Vibration is
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v.220704 | 13
generally a warning sign of trouble.
• Stop the engine when leaving the operating position, and when making any repairs,
adjustments and inspections. STAY CLEAR OF THE CHIP CHUTE AT ALL TIMES.
• Take all possible precautions as recommended in this manual when leaving the machine
unattended.
• Before cleaning, repairing, or inspecting, shut o the engine and make certain the
flywheel and all moving parts have come to a complete stop. Disconnect the spark
plug wire(s) and keep the wire away from the spark plug to prevent accidental starting.
• Keep all guards and safety devices in place and operating properly. Do not operate the
machine if all safety guards are not in place.
• Do not use the unit with the chipper hopper removed.
• Do not overload or attempt to chip material beyond 5 inches.
• Only use accessories approved for this machine by the manufacturer. Read, understand,
and follow all instructions provided with the approved accessory.
• Only operate the equipment in good daylight. Do not operate this equipment at night
or in dark areas where your vision may be impaired.
• Use extreme caution when reversing or pulling the machine towards you. NEVER move
the machine while it is running.
• Do not tamper with the engine’s governor setting. The governor controls the maximum
safe operation speed and protects the engine. Over-speeding the engine is dangerous
and will cause damage to the engine and to the other moving parts of
the machine.
• Start the engine according to the manufacturer’s instructions. Keep
hands and feet away from the inlet and discharge areas.
• Do not operate while under the use of alcohol, drugs, or medication. A
clear mind is essential for safety.
• When feeding material into this equipment, be extremely careful that pieces of metal,
rocks, or other foreign objects are not included. Personal injury or damage to the
equipment could result.
• Do not allow an accumulation of processed material to build up in the
discharge area as this will prevent proper discharge and can result in
kick-back from the chipper chute.
• Do not allow any part of the engine, especially around the cooling fins
and muer, to become clogged with processed material, leaves, oil,
grease or any other combustible material.
• Do not operate the engine if air cleaner or cover over carburetor air-intake is removed,
except for adjustment. Non-removal of such parts could create a fire hazard.
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SECTION II • ASSEMBLY

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STEP 1: CHECK THE PACKING
Open and unpack all items, leave lots of working space, and inspect all parts.
Upon inspection of parts, if you find any missing or damaged parts please call DK2 POWER at 1
[phone] or contact us via our website at www.dk2.com.
Please do not return to the store.
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16 | OPC525(D) man.
STEP 2: WHEELS
1. Remove all hardware from the axle.
2. Install the wheel with the stem facing outward, then place the washer, then the nut.
STEP 3: EXPULSION CHUTE
1. Tip the unit back and balance it with a helper.
2. Place the chip chute on the chipper.
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STEP 4: FEED CHUTE
1. Install the feed chute on the two hinges. To seat the hinge pins for the first time, use a rubber
mallet to tap the pins into the hinges. These are tight fitting to reduce vibration noise during
operation.
2. Close the chute and latch it.
3. Plug the safety shut-o wire connectors together.
4. You can now use the chute by the handles to tip the unit back so you can perform the next
step and install the hitch.
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18 | OPC525(D) man.
STEP 5: TOW BAR AND STAND ASSEMBLY
1. Grab the feed chute and tip the unit back, raising the front up.
2. Install the tow bar hitch using provided bolts.
3. Assembled tow stand and insert the hitch pin.
4. Lower the unit back to level and rest on the drop stand.
5. Insert the tow bar and secure with tow bar screw lock.
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STEP 6: AXLE ASSEMBLY
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20 | OPC525(D) man.
STEP 7: EXPULSION CHUTE DEFLECTOR
Install the expulsion chute deflector and tighten the locking handles.
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