Safety, Operation, And Parts Manual Product

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PRODUCT REGISTRATION SAFETY, OPERATION, AND PARTS MANUAL PRODUCT REGISTRATION Single Disk Chipper Model No.______________ Serial No. ___________________________ (Serial Number Location: Stamped in Frame, Near the Engine) Engine Make: ____________________________________ Model No.: _________________ Serial No.: __________________ Clutch Make: _____________________________________ Model No.: _________________ Serial No.: __________________ C U S T O M E R I N F O R M AT I O N : Name: ______________________________________________________________________________ Address: ____________________________________________________________________________ City:_______________________________State:______Zip:________Phone No.:__________________ Signature/Title: _______________________________________________________________________ ❑ Yes, I have received my ❑ Chipper Manual, ❑ Knife Gage, ❑ Engine Manual, and ❑ Clutch Manual. ❑ Yes, I have been instructed on the operating and safety procedures of this machine. D E A L E R I N F O R M AT I O N : Dealer: ______________________________________________________________________________ Address: ____________________________________________________________________________ City:_______________________________State:______Zip:________Phone No.:__________________ Signature/Title: _________________________________________ Delivery Date:__________________ ❑ Yes, I have inspected and prepped this machine for delivery. Please Complete This Registration Form and Return It To Dosko. Dosko REV. 9/99 PAGE 1 D OS KO 20195 S. DIAMOND LAKE RD, STE 100 • ROGERS, MN 55374 • TOLL-FREE: 800.822.0295 • FAX: 763.428.4821 TABLE OF CONTENTS a. Opening Swing Away Feed Roll Assy ....... 26 b. Knives, Knife Care..................................... 27 Model 510 SD - Kubota PRODUCT REGISTRATION .............................. 1 For Your Records - 3 Part NCR Paper You Must Complete and Return Top White Copy To Dosko within 10 days for your warranty to be valid. c. d. e. f. g. h. i. j. k. l. m. n. o. p. q. r. TABLE OF CONTENTS....................................... 2 INTRODUCTION a. Message To Operator ................................... 3 b. Receiving Your Dosko Unit ......................... 4 c. Pre-Operating Check List ............................ 5 EQUIPMENT a. Component Identification ............................ 6 b. Dimensions .................................................. 7 c. Specifications ............................................ 8-9 SAFETY a. Definitions.................................................. 10 b. Sticker List ................................................. 11 c. Sticker Identification ............................. 12-13 d. Sticker Locations ....................................... 14 SAFETY & OPERATION a. Instructions To The Crew...................... 15-16 b. Safe Working Area ..................................... 17 c. Operation and Adjustments........................ 18 d. Towing Instructions............................... 19-21 Knife System.............................................. 28 Adjusting Bed Knife .................................. 29 Sharpen Feed Roller Blades ...................... 30 Changing Knife Holder/Fan Blade ............ 31 Closing Chipper Body ............................... 32 Adjust Chipper Belt Tension ..................... 33 Adjust Hydraulic Pump Belt Tension ........ 34 Belt and Sheave Care ................................. 35 Sheave Installation and Alignment ............ 36 Bolt Torque Chart ...................................... 37 Trailer Wiring Diagram.............................. 38 Hydraulics .................................................. 39 Trouble Shooting Hydraulics ................ 40-43 SMART FEED............................................... 44 SMART FEED (Wiring Diagram)................. 45 SMART FEED (Trouble Shooting) ............... 46 PARTS LIST AND ILLUSTRATIONS a. Hydraulic Components .............................. 47 b. Pump Mount .............................................. 48 c. Main Frame ........................................... 49-50 d. Chipper Assembly ...................................... 51 e. Rotating Chipper Assembly ....................... 52 f. Upper Feed Roll Assembly ........................ 53 g. In-Feed Hopper .......................................... 54 h. Discharge Assembly................................... 55 LIMITED WARRANTY POLICY..................... 56 OPERATION MAINTENANCE a. Fuel & Hydraulic Tanks............................. 22 b. Maintenance Schedule ............................... 23 c. Belt Inspection Cover ................................ 24 d. Lubrication ................................................. 25 MAINTENANCE REV. 9/99 (Engine Manual Are Separate Documents) PAGE 2 D OS KO 20195 S. DIAMOND LAKE RD, STE 100 • ROGERS, MN 55374 • TOLL-FREE: 800.822.0295 • FAX: 763.428.4821 INTRODUCTION M E S S AG E T O O P E R AT O R Upon receiving you new unit, it is always exciting to “get going” and see its performance! The “operator”, however, is the key to everything! Every operator should read this safety and operation manual to be sure of safety instructions and proper operating procedure. If the owner of this unit is different than the operator, his reading this manual will not protect the user. As with any mechanical equipment, this equipment is very safe if used with care and precaution--and very dangerous if used carelessly. Performance is relative to the operators knowledge of how to use the equipment! BE A GOOD OPERATOR... BE A SAFE OPERATOR! REV. 9/99 PAGE 3 DOSKOCIL POLICY Dosko, Inc., reserves the right to make changes in engineering, design, and specifi-cations; add improvements; or discontinue manufacture at any time without notice or obligation. Dosko, Inc., also reserves the right to change machine and part prices as needed without advance notice. D OS KO 20195 S. DIAMOND LAKE RD, STE 100 • ROGERS, MN 55374 • TOLL-FREE: 800.822.0295 • FAX: 763.428.4821 INTRODUCTION DOSKO RECEIVING YOUR SINGLE DISK CHIPPER UNIT Congratulations, You have just purchased the finest Chipper of it’s kind. Dosko wants to be sure that you have received it in good condition. Delivery By Dealer Your Doskocil unit should have been delivered completely inspected, tested, assembled, and ready to operate! Do Not take anything for granted! Read the “Pre-Operating Check List” on page 5 and verify that the unit has been properly “Prepped” before use. The dealer is responsible for delivering the manuals to you, If you have not received your manuals, DO NOT START the machine, but contact your dealer. Direct Shipment To Customer: Upon delivery, “and before the truck driver leaves your premises,” please check for any freight damages. If freight damages have occurred let the driver know immediately. Have the driver write up a claim form and contact this company’s claim adjustor to come out and assess the damages for payment to you. This is your responsibility to notify the truck company’s of freight damages. Freight damage is not covered under the Dosko warranty policy. Some assembly may be be required! If so, instructions are included as a separate written flyer. Please read these special assembly instructions carefully! Your Dosko Brush Chipper has been pre-run at the factory prior to shipping. Upon receiving your Dosko Chipper, read and understand the complete safety and operational instruction manual for your unit. Read the “pre-operating” check list on page 5 to properly “prep” your chipper before using. The owner’s manual is shipped next day registered air mail, to the customer when a chipper is shipped direct from the factory. If you should have any questions regarding the safety or operational procedures contact Dosko before using this chipper. Factory Pick Up or Delivery: In these cases, your unit has been completely assembled tested and pre-run. It should be ready for immediate usage. You will pick up the manuals with the machine. Read and study your manuals. REV. 9/99 PAGE 4 D OS KO 20195 S. DIAMOND LAKE RD, STE 100 • ROGERS, MN 55374 • TOLL-FREE: 800.822.0295 • FAX: 763.428.4821 INTRODUCTION P R E - O P E R AT I N G C H E C K L I S T This check list must be followed and verified before starting this new chipper. Read chipper, engine, and clutch manuals. ❑ With Kubota engine, centrifugal clutch will Start with checking the Machine: ❑ All safety sticker in place according to page 14. engage at 1,450 RPM. Listen for any foreign ❑ Check for safety chain metal to metal sounds. Identify all sounds!! ❑ Check all engine controls and function of gages. ❑ Check and set rear stabilizer stand and pin. ❑ Check function of jack stand and retainer. ❑ Check hitch and torque bolts. Kubota engine at 3,000 rpm check the following: ❑ Check function of all tail lights, running, license, ❑ Check feed control lever, pull to feed in, push to Stop, Right turn, Left turn lights. ❑ Check condition of plug and cable. stop, push farther to reverse feed. ❑ Check direction of feed roller rotation, when ❑ Check tires, lug nuts, pressure. ❑ Check fuel tank (min 1/4). control is pulled out, the feed should be in. ❑ Check function of speed control fast to slow, set ❑ Check hydraulic tank (oil on screen is full). ❑ Lube all left side bearings (chipper & feed at approximately 150 fpm. Lock control lever. ❑ Check Smart Feed function: rollers). ❑ Open belt guard hood, check drive belt tension. reduce engine rpm to 2800, feed roller will stop ❑ Open battery box, check terminals. turning. ❑ Lube all right side bearings (clutch, chipper, and Plan position of discharge before test run. Follow all safety rules, wear safety gear: feed rollers). Open Chipper Body: ❑ Feed brush into chipper for approximately one ❑ Check both knives / bed knife clearance. ❑ Check bolt torque, knifes, bed knife, fan blades, hour for break in period. ❑ Shut machine down; for complete inspection. disks. ❑ Close body, re-bolt, be sure all bolts/nuts are ❑ Check engine gages, check belt tension, and clutch engagement tension. Go through complete re-assembled and torqued. chipper and check for loose nuts and bolts and Before starting the engine, check the following: any possible hydraulic leaks. ❑ Check engine oil level. ❑ Check discharge clamp. ❑ Check deflector and control latch. 510 30 Kubota REV. 9/99 PAGE 5 D OS KO 20195 S. DIAMOND LAKE RD, STE 100 • ROGERS, MN 55374 • TOLL-FREE: 800.822.0295 • FAX: 763.428.4821 EQUIPMENT C O M P O N E N T I D E N T I F I C AT I O N Model 510 SD Discharge Tube RIGHT SIDE VIEW 360° Discharge Swivel Ring Deflector Deflector Angle Control Engine Hitch Jack Stand Rear Stabilizer Smart Feed Fuse In Feed Hopper LEFT SIDE VIEW Fuel Tank Hydraulic Oil Tank Feed Roll Motor Safety Feed Control Upper Feed Roll Arm SWING OPEN FOR SERVICE Knives Removable Fenders Tail Light Bed Knife REV. 9/99 PAGE 6 D OS KO 20195 S. DIAMOND LAKE RD, STE 100 • ROGERS, MN 55374 • TOLL-FREE: 800.822.0295 • FAX: 763.428.4821 EQUIPMENT DIMENSIONS MODEL 510 SD 65” 98” High Table Height 30” Fold Down 32” 21” Clearance 23” Hitch 124” WEIGHT 30 HP KUBOTA 2560 LBS 30” 10” 10” Throat 38” Hopper 71” Wide REV. 9/99 PAGE 7 D OS KO 20195 S. DIAMOND LAKE RD, STE 100 • ROGERS, MN 55374 • TOLL-FREE: 800.822.0295 • FAX: 763.428.4821 EQUIPMENT SPECIFICATIONS - MODEL 510 SD T R A I L E R & F R A M E Frame ...............................2” x 3” Rectangle Tube Sheet Decking ..................3/16” Steel Plate Jack Stand ........................2,000 lbs. Capacity Pad Jack Hitch.................................1 7/8 to 2” Adjustable Tongue..............................3” x 3” Rectangle Tube Safety Chains ...................3/8 Safety Chain Axle ..................................4,500 lbs. Capacity Lief Spring Suspension, 5 Bolt Hubs Tires .................................205/75 14” Load Range D Lights ...............................Protected Unitized 12 Volts Running, Stop, License, and Turning Brakes ..............................None Fenders .............................Removable 10 Gage Complete With Inner Wall Rear Stabilizer..................Adjustable Fuel Tank .........................12 Gallon Belt Guard ........................10 Gage Material Hinged For Easy Inspection Belts .................................2 belts B” Size Battery Box ......................Lockable Hinged Cover; Water Proofed Width ................................71” Outside Fenders Length ..............................124” With The Feed Table In The Closed Position Height...............................98” To The Top Of The Deflector Weight ..............................2,285 lbs, May Vary With Engine Options E N G I N E Size...................................25 to 35 hp, Determines Cutting Capacity From 6” to 9” Diameter Standard ...........................30 hp Kubota Optional............................Diesels D I S C H A R G E C H U T E Swivel Ring ......................360° Rotation, Collet Clamp, Lockable For Towing Discharge Tube ................Round 6” Diameter, 32” Bend Radius Discharge Deflector .........Adjustable From Straight to 45° Down Adjustment Handle ..........Easy Reach From Ground REV. 9/99 PAGE 8 D OS KO 20195 S. DIAMOND LAKE RD, STE 100 • ROGERS, MN 55374 • TOLL-FREE: 800.822.0295 • FAX: 763.428.4821 EQUIPMENT SPECIFICATIONS 510 SD (CONT’D) C H I P P E R H O U S I N G & F LY W H E E L A S S E M B LY Capacity ...........................10” Round Wood, Chipper Opening 10” High x 10” Wide Side Walls ........................3/8” Thick Lower Half Thru Bearing Support, 1/4” Top Half Belly Band .......................1/4” Thick Shaft .................................3” Diameter With Integral Bearing Stops and Hub Disk ..................................Machined 32” Diameter Disk, 1 1/2” Thick Knives ..............................Two 5/8 thick x 4” wide x 11” long threaded knives Fan Blades........................1/4” Thick With Cuff To Hold Cuttings Bearings, Shaft .................2 1/4” Flanged SCM Ball Bearings Bed Knife .........................4 Sided (3/4” Thick x 3” Wide) Thru Hardened CM Steel U P P E R F E E D R O L L Housing ............................Hinged To Swing Open For Service Of Knives, Bed Knife, Feed Roller Housing Wall....................1/4” Plate Housing Floor ..................3/8” Plate Feed Roller .......................12” Diameter x 10” Wide With 10 Sharpened Blades Bearings, Shaft .................1 1/2” Diameter Flanged SC Ball Bearings Ratchet Style ....................Feed Roller Assembly 3/8” Thick Mounted on Articulated Ball Bearings I N F E E D T A B L E & H O P P E R Hopper Material ...............10 Gage With Reinforced Bottom Corner Table Hinge ......................1” Diameter, .12 Wall Hinge Tube With .75 Diameter Hinge Pin Table Size .........................30” Deep x 38” Wide Control Bar ......................1.0” Diameter Tube On Both Sides And Top, Directly Connected To Valve H Y D R A U L I C S Y S T E M Pump ................................5.7 GPM Driven By Engine, System Pressure 2,500 PSI Motor, Upper....................28 Cubic Inch At 11,269 In. Lbs. Torque Control Valve ...................Mounted At Top Of The Hopper With Forward - Neutral - Reverse Speed Control Valve ........Variable Speed From 0-150 fpm Feed Rate Oil Tank ...........................7 Gallon With Suction Strainer Filter .................................Cartridge Type REV. 9/99 PAGE 9 D OS KO 20195 S. DIAMOND LAKE RD, STE 100 • ROGERS, MN 55374 • TOLL-FREE: 800.822.0295 • FAX: 763.428.4821 SAFETY SAFETY DEFINITIONS This manual has been prepared to relate to the important information and procedures for the safe use of the Dosko Single Disk Chipper. The Dosko Single Disk Chipper has been designed and built with the utmost attention to safety in mind, but as with any piece of equipment safety must always be a constant thought while operating, maintaining, and/or storing this machine. Definition of Signal Words To Pay Attention To: SIGNAL WORDS LIKELIHOOD of OCCURRENCE DEGREE POTENTIAL WILL Occur If Ignored SEVERE CAN Occur If Ignored SEVERE COULD Occur If Ignored MINOR to SEVERE SAVE Save Time Save Money It is the responsibility of the owner or employer to insure that the operator is trained and practices safe operation while using and servicing the machine. It is also the owner’s responsibility to provide and follow a regularly scheduled preventative maintenance and repair program on the chipper using only factory approved replacement parts. Any unapproved parts, repairs, or modifications may not only damage the machine and its performance, but could result in severe personal injury. Consult the equipment manufacturer. REV. 9/99 PAGE 10 D OS KO 20195 S. DIAMOND LAKE RD, STE 100 • ROGERS, MN 55374 • TOLL-FREE: 800.822.0295 • FAX: 763.428.4821 SAFETY SAFETY STICKER LIST STICKER # PART NUMBER 1 2 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29500 30249 30248 29454 28455 29456 29457 29458 29459 29460 29461 29462 29463 29464 29465 29466 29467 29468 29469 29470 29471 29472 29473 29474 29475 29476 29477 29499 REV. 9/99 STICKER DESCRIPTION Complete 510 SD Chipper Decal Set Model 510 SD Chipper Dosko Logo Safe Working Area Warning - Before You Turn This Key Towing Instructions Danger No Smoking Area - Fuel Tank Caution - Before Chipping Discharge Chute Danger - Before Opening Belt Guard Attention - Before Removing Battery Cover Diesel Only Gas Only Hydraulic Oil Danger - High Speed Discharge Danger - Never Reach Inside Do Not Remove Stickers Never Engage Clutch Above Danger - Never Reach, Never Operate Caution - Hot Muffler Infeed Tray Must Be Closed Warning - Proper Safety Gear California Proposition 65 Warning Warning - Engine Exhaust Danger - Do Not Open When Turning Danger Keep Hands Away (Feed Roll Area) Before You Open This Hopper SMART FEED Kubota Starting Instructions PAGE 11 D OS KO 20195 S. DIAMOND LAKE RD, STE 100 • ROGERS, MN 55374 • TOLL-FREE: 800.822.0295 • FAX: 763.428.4821 SAFETY SAFETY STICKERS IDENTIFICATION If any of these stickers become unreadable replace immediately! 1 Brush Chipper 7 510 2 8 4 SAFE WORKING AREA 9 5 10 6 11 12 REV. 9/99 PAGE 12 D OS KO 20195 S. DIAMOND LAKE RD, STE 100 • ROGERS, MN 55374 • TOLL-FREE: 800.822.0295 • FAX: 763.428.4821 SAFETY SAFETY STICKERS IDENTIFICATION If any of these stickers become unreadable replace immediately! 21 13 14 15 22 16 23 17 24 Do Not Open When Chipper Disc Is Turning 18 25 26 27 SMART FEED 19 20 REV. 9/99 HYDRAULIC SYSTEM 28 INFEED TRAY MUST BE CLOSED & SECURED WHEN IN TRANSIT. PAGE 13 KUBOTA STARTING INSTRUCTIONS D OS KO 20195 S. DIAMOND LAKE RD, STE 100 • ROGERS, MN 55374 • TOLL-FREE: 800.822.0295 • FAX: 763.428.4821 SAFETY MODEL 510 SD S A F E T Y S T I C K E R L O C AT I O N S All stickers must be on machine during operation. If any sticker becomes worn or damaged, replace immediately. 14 2 16 12 7 13 5 6 4 21 25 21 8 25 9 28 10 24 24 4 25 18 24 18 20 26 2 27 1 REV. 9/99 PAGE 14 D OS KO 20195 S. DIAMOND LAKE RD, STE 100 • ROGERS, MN 55374 • TOLL-FREE: 800.822.0295 • FAX: 763.428.4821 SAFETY & OPERATION INSTRUCTIONS TO THE CREW Every Dosko machine is designed and manufactured with safety in mind. All Dosko machines are built with the highest grades of steel and component parts available. Equipped with lockable hood and belt guard, safety decals, and operating instructions on every machine provide minimum chance of an accident. No matter how hard a manufacturer tries to design a safe machine; accidents can still happen. Normally, accidents happen when people do not read the owner’s manual or ignore warning stickers. Don’t ever take the machine for granted, this is when accidents can happen. Listed are a safety procedure to keep in mind when operating a safe machine. Before starting the machine. Make sure the area has been secured to keep bystanders at a positioned into a safe and restricted area. Follow safe working area sticker as pictured on page 17. Check to see that all belt guards are in place and that the infeed hopper is clear of any foreign objects. Make sure to position the discharge chute into a safe and restricted area. Discharged chips are moving at a high rate of speed and can cause property damage and/or injuries to animals or pedestrians. When operating this type of machine, never wear loose fitting clothing or gloves that do not fit your hand snug. Loose fitting clothes can become entangled in the machine’s moving parts. Whenever feeding brush into chipper always stand to the curb side of the hopper infeed table. Never stand directly in hopper opening. Limbs and chips can be kicked back or thrown out of hopper. Never push short branches, twigs, and leaves into the Chipper. When you are feeding a longer branch simply toss the smaller pieces on top. The longer branch will pull them into the chipper automatically. “NEVER” reach into infeed hopper. If a feeding problem should occur shut the machine down and solve the problem. REV. 9/99 PAGE 15 D OS KO 20195 S. DIAMOND LAKE RD, STE 100 • ROGERS, MN 55374 • TOLL-FREE: 800.822.0295 • FAX: 763.428.4821 SAFETY & OPERATION INSTRUCTIONS TO THE CREW (CONT’D) Listed are a safety procedure to keep in mind when operating a safe machine. Whenever feeding limbs into chipper, feed butt end in first. This practice will decrease the problem of limbs wedging or jamming in hopper. Always keep chipper on level ground when unhooked from truck. Always block both tires, front and view. Make sure rear stabilizer tube is down and locked to keep chipper from tipping backwards. Chipper should always be sitting level from front to back when unhooked from truck. Replace all decals on the chipper that are missing or that may have become unreadable. Make sure decals are replaced in there original locations. Make sure to replace all nuts and bolts with the same grade and style used. Check all chipper bolts and nuts to maintain proper torques. All bolts and nuts should be checked every two weeks. Always tighten bolts to our recommended torque. After completing any type of maintenance on this machine, make sure you removed all tools and wrenches. Start engine and run chipper disk at a low RPM Listen for any type of metal against metal noise. If you should hear any foreign noise, disengage clutch immediately, stop engine and solve problem. Re-start and slowly bring engine to a full RPM this practice can prevent machine damage or worse, severe personal injury. 30 HP Kubota: Bring engine throttle to 3,000 RPM, in order to engage Smart Feed system. 510 30 Kubota REV. 9/99 PAGE 16 D OS KO 20195 S. DIAMOND LAKE RD, STE 100 • ROGERS, MN 55374 • TOLL-FREE: 800.822.0295 • FAX: 763.428.4821 SAFETY & OPERATION SAFE WORKING AREA In order to create a safe working area, each crew must consider: 1) 2) 3) 4) Placement of equipment and the brush pile. Keeping children, pets and onlookers at a safe distance. Guard chipper discharge. Minimize interference with auto traffic. Using these safety tools, layout a safe working area that best fits your project and/or situation. Barricade Signs Safety Cones Caution Tape The example below, is also a sticker on the side of your machine. Please Note: This is a proposed layout, your safe working area may vary. REV. 9/99 PAGE 17 D OS KO 20195 S. DIAMOND LAKE RD, STE 100 • ROGERS, MN 55374 • TOLL-FREE: 800.822.0295 • FAX: 763.428.4821 SAFETY & OPERATION OPERATION AND ADJUSTMENTS 1) Follow all Job Site, Equipment, and Operator Safety Precautions. 2) Start Engine (30 HPKubota) - Follow engine manual directions. Allow proper warm up period at idle speed, before bringing engine to full speed. 3) Clutch Engagement - With 30 HP Kubota Engines, bring engine throttle up slowly, clutch will automatically engage at approximately 1450 RPM. Listen every time for any sounds of possible foreign material (metal changing sounds) in chipper. 4) Set engine RPM to 5) Engage Safety Control (pictured on page 6) A push or pull will change the direction of the hydraulic powered feed roller. If a branch becomes stuck, reverse the control lever to free it. 6) Speed Control (a valve located next to the hydraulic tank) - Turn to the right to slow the infeed roller. Turn to the left to increase the infeed roller speed. Control valve is variable from 0 to 150 feet per minute. By adjusting roller speeds up you can increase or decrease the chip size. Be sure to retighten lock screw. 7) To Shut Down Engine: 1. Release locking nut on throttle. 2. Turn throttle slowly, clockwise until engine is down to 800 rpm. 3. Pull shut down knob to shut down engine. 4. Turn key to off position. 3000 on the 30 HP Kubota. Do not attempt to move or due any maintenance to the chipper until the disk has stopped turning completely. Be careful to step aside when feeding. 510 30 Kubota REV. 9/99 PAGE 18 D OS KO 20195 S. DIAMOND LAKE RD, STE 100 • ROGERS, MN 55374 • TOLL-FREE: 800.822.0295 • FAX: 763.428.4821 SAFETY & OPERATION T OW I N G I N S T RU C T I O N S In addition to common safety practices, there are certain legal road requirements for various states. It is the responsibility of the owner or user to be aware of these laws, and to abide by them. For example, there may be certain lighting or licensing requirements. Adjust Hitch To Proper Height Tighten Hitch/Tongue Bolts 5/8 size to 112 ft lbs X X Chipper Frame Must Set Level (Same Measurement Front and Back) Always Be Sure of Proper Size Ball and Coupler Connect Safety Chains in a Cross Pattern Right to Left, Left to Right Thread chain thru bracket as shown, thru central hole. Do not let chains drag on the pavement. REV. 9/99 PAGE 19 D OS KO 20195 S. DIAMOND LAKE RD, STE 100 • ROGERS, MN 55374 • TOLL-FREE: 800.822.0295 • FAX: 763.428.4821 SAFETY & OPERATION T OW I N G I N S T RU C T I O N S (C O N T ’ D ) Feed Chain Through Handle Always close and lock safety coupler. Oversight can cause loss of chipper or accident. 1) Raise the rear stabilizer stand. 2) Be sure that the Jack Stand is raised and removed before towing. Connect and check electric cable for working stop and turning lights, also check for brakes. Never attempt to transport chipper by lifting the tongue and moving the unit by lifting the tongue and moving it on two wheels. The chipper weighs 2560 lbs. The chipper may tip over or cause injury to you or others. REV. 9/99 PAGE 20 D OS KO 20195 S. DIAMOND LAKE RD, STE 100 • ROGERS, MN 55374 • TOLL-FREE: 800.822.0295 • FAX: 763.428.4821 SAFETY & OPERATION T OW I N G I N S T RU C T I O N S (C O N T ’ D ) Never tow with chipper engine running! NEVER USE CHIPPER TO CARRY OR TRANSPORT ITEMS. Be sure that the key is removed from the engine control panel. 55 Never exceed your local city, state, or federal highway speeds for towing! Doskocil Does Not recommend exceeding 55 mph when towing this chipper. ALWAYS BE CAUTIOUS WHEN BACKING. Before unhooking chipper from truck. 1. Block both sides of both tires. 2. Lower and pin rear stabilizer stand. REV. 9/99 PAGE 21 D OS KO 20195 S. DIAMOND LAKE RD, STE 100 • ROGERS, MN 55374 • TOLL-FREE: 800.822.0295 • FAX: 763.428.4821 OPERATION MAINTENANCE F U E L & H Y D R AU L I C T A N K S Fuel tank Hydraulic tank Fuel tank capacity 12 gallons Hydraulic tank capacity 7 gallons Use only designated type fuel. Wipe around filler cap before opening Follow all safe fueling rules. Use only recommended type oil See maintenance pages 39 No smoking while fueling. keep oil level 2 inches below top of tank Always Be Sure To Wipe Up Any Fuel Or Oil Spills REV. 9/99 PAGE 22 D OS KO 20195 S. DIAMOND LAKE RD, STE 100 • ROGERS, MN 55374 • TOLL-FREE: 800.822.0295 • FAX: 763.428.4821 OPERATION MAINTENANCE M A I N T E NA N C E S C H E D U L E MODEL 510 SD Make copies of this abbreviated check list DAILY 1) 2) 3) 4) Engine Oil Chipper Belt Tension Oil Pump Belt Tension Condition of Knives Checked Okay Serviced ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ 5) Air Cleaner 6) Fuel Level 7) Hydraulic Oil Level Serviced By__________________________________________ Checked Okay Serviced ❑ ❑ ❑ ❑ ❑ ❑ Date______________ WEEKLY 1) 2) 3) 4) Checked Okay Serviced Bed Knife Adjustment ❑ ❑ Check Tail Lights & Brakes ❑ ❑ Tires and Lug Nuts ❑ ❑ Check For Loose Nuts, Bolts ❑ ❑ Checked Okay Serviced DO NOT OVER GREASE. 6) Grease Chipper Bearing(2) ❑ 7) Grease Feed Roll Bearing(4) ❑ 8) Check Feed Roll Motor Couplings ❑ Serviced By__________________________________________ ❑ ❑ ❑ Date______________ MONTHLY 1) 2) 3) 4) Checked Okay Serviced Check Entire Hydraulic System for function & leaks ❑ ❑ Check Feed Roll Blades ❑ ❑ Check Discharge Deflector ❑ ❑ Check Swivel Clamp ❑ ❑ Checked Okay Serviced 5) Check Total hours for Engine Oil Change 6) Check Total Hours For Hydraulic Oil Filter Change 7) Grease Feed Roll Hinges Serviced By__________________________________________ REV. 9/99 PAGE 23 ❑ ❑ ❑ ❑ ❑ ❑ Date______________ D OS KO 20195 S. DIAMOND LAKE RD, STE 100 • ROGERS, MN 55374 • TOLL-FREE: 800.822.0295 • FAX: 763.428.4821 OPERATION MAINTENANCE H I N G E D B E LT C OV E R Always remove key from engine ignition and remove positive battery terminal from the battery. DRIVE BELTS Proper belt tension: 70 lbs deflection force, using belt tension gage. Simple test: Pull first belt mid span fairly hard, 1/2 deflection maximum. Adjust according to page 33 HYDRAULIC BELT: Proper belt tension: 7 lbs deflection force, using belt tension gage Simple test: Pull first belt mid span fairly hard, 3/8 deflection maximum. Adjust according to page 34 REV. 9/99 PAGE 24 D OS KO 20195 S. DIAMOND LAKE RD, STE 100 • ROGERS, MN 55374 • TOLL-FREE: 800.822.0295 • FAX: 763.428.4821 OPERATION MAINTENANCE L U B R I C AT I O N Front Bearing Engine Follow engine manufacturers guide line in manual. Chipper Main Bearings 2 each front and rear. Bearings should be greased weekly or every 10 hours of use. Note: Do not over grease. Too much grease will damage bearing seals. Use EP-2 lithium base grease for bearings. Open belt guard as per page 24 Feed Roll Bearings Two bearings on each side Rear Bearing Feed Role Bearings Bearing Bearing REV. 9/99 PAGE 25 D OS KO 20195 S. DIAMOND LAKE RD, STE 100 • ROGERS, MN 55374 • TOLL-FREE: 800.822.0295 • FAX: 763.428.4821 MAINTENANCE O P E N I N G S W I N G A WAY F E E D R O L L A S S Y Always remove key from engine ignition and remove positive battery terminal from the battery. 1) Remove (2) ea. 5/8” nuts holding feed roll assembly to the chipper body. 2) Remove one 3/4” bolt on feed roll chamber holding it to the frame. 3) Swing entire in-feed hopper to the left, being careful of hoses Nut/Washer Bolt Hinge Change Knives Adjust Bed Knife Sharpen Feed Roll Blades Upper Feed Roller Knives Bed Knife REV. 9/99 PAGE 26 D OS KO 20195 S. DIAMOND LAKE RD, STE 100 • ROGERS, MN 55374 • TOLL-FREE: 800.822.0295 • FAX: 763.428.4821 MAINTENANCE KNIVES How long can I go without changing the knives? The knives on your Dosko Chipper are made from the highest grade of Chipper Steel, which is heat treated and ground to a very sharp edge. Their life is simply relative to what they chip. They may dull the first day or they may last for months. The knife life naturally depends on the amount of dirt and rocks that enters the chipper. Sometimes trees will have nails or wire imbedded below the surface. Why must the knives be checked daily? Because... a) Dull knives cause excessive fuel consumption. b) Dull knives cause unnecessary stress and strain on the machine. c) Dull knives produce poor quality chips. d) Dull knives reduce production rate slowing the feed rate. e) Dull knives actually wear further and faster. Disk Knives See Page 28 Bolt Knife Bed Knife Adjustment See Page 29 .090 to .095 Bolt REV. 9/99 Bed Knife Dosko Model 510 SD PAGE 27 D OS KO 20195 S. DIAMOND LAKE RD, STE 100 • ROGERS, MN 55374 • TOLL-FREE: 800.822.0295 • FAX: 763.428.4821 MAINTENANCE CHANGING KNIVES TO TURN OR CHANGE KNIVES 1) Loosen bolts with 1 1/8” 12 point impact or socket wrench. 2) Remove knife. 3) Clean knife and knife pockets on disc. 4) Turn or replace knife. 5) Install all 5 knife bolts before tightening bolts to 130 ft. lbs. Note: Be sure to wear gloves while changing knives. REV. 9/99 PAGE 28 D OS KO 20195 S. DIAMOND LAKE RD, STE 100 • ROGERS, MN 55374 • TOLL-FREE: 800.822.0295 • FAX: 763.428.4821 MAINTENANCE ADJUST BED KNIFE Attention: Keep bed knife properly adjusted for efficient running chipper. Note: bed knife is thru hardened and will not be effected by regrinding. 1) Loosen bed knife, use 12 point socket wrench. 2) Adjust bed knife to proper gap of .090 to .095 inch. Since knives may vary from one to the other, check each knife gap with the Knife gage. Be sure to adjust to the closest knife. 3) Tighten bed knife bolts 4 each 5/8-11 12 point, 112 ft lbs torque. Double check each knife. Knife 3/4-16 Bolts 3/4 Lock Washer Bed Knife REV. 9/99 PAGE 29 D OS KO 20195 S. DIAMOND LAKE RD, STE 100 • ROGERS, MN 55374 • TOLL-FREE: 800.822.0295 • FAX: 763.428.4821 MAINTENANCE SHARPEN FEED ROLLER BLADES Open chipper body by swinging away feed roll as per page 26. Feed Roll As the feed roll blades become dull, they may be sharpened with a small hand grinder without being removed from the machine. 1) Remove hydraulic motor. 2) Place a 2x4 under feed roller to keep it from turning while sharpening blades. GRIND HERE 3) Grind the angled side of the blade only to a 45 degree angle, do not grind front face. 4) Turn feed roller to get all blades Always wear heavy duty gloves, long sleeve shirt, safety glasses, and face shield while sharpening blades. REV. 9/99 5) Inspect feed roll bolts for tightness by looking thru slots in roll body. 6) Reassemble Hydraulic motor. PAGE 30 D OS KO 20195 S. DIAMOND LAKE RD, STE 100 • ROGERS, MN 55374 • TOLL-FREE: 800.822.0295 • FAX: 763.428.4821 MAINTENANCE OPEN TOP CHIPPER HOOD TO CHANGE KEY KNIFE HOLDERS OR FAN BLADES Always remove key from engine ignition and remove positive battery terminal from the battery. 1) Open swing away feed roller assembly 2) Remove 4 top bolts on chipper body cover. Remove 2 Bolts Remove 2 Bolts 3) Discharge tube should face forward towards the tongue and be pinned so it will not rotate. 4) One man lifts the handle from the left side, a second man positioned on the right side of the machine catches the chipper hood and pulls it to its stop position, slowly. With two workers use extreme caution turning cutter wheel, it is very easy to injure the other guys fingers. If not careful. To close reverse this procedure. Re install 4 1/2 bolts to 60 ft lbs torque. REV. 9/99 PAGE 31 D OS KO 20195 S. DIAMOND LAKE RD, STE 100 • ROGERS, MN 55374 • TOLL-FREE: 800.822.0295 • FAX: 763.428.4821 MAINTENANCE C L O S I N G S W I N G A WAY F E E D R O L L A S S Y Note: Keep the feed roller housing hinges greased at all times with bearing grease. As Open Note: Keep the feed roller housing slide plate greased at all times with bearing grease 1) Swing Closed Do not pinch hoses. 2) Install and tighten 2 nuts/washers on the side of the feed roll. Torque 5/8-11 Nuts to 112 ft. lbs. 3) Install and tighten one 3/4” bolt on feed roll chamber support. Torque to 3/4-10 Bolt to 130 ft. lbs. 5/8 Nut/Washer 3/4 Bolt Closed Side View REV. 9/99 Do not attempt to operate chipper without re-installing these nuts and bolts and properly torquing them. PAGE 32 D OS KO 20195 S. DIAMOND LAKE RD, STE 100 • ROGERS, MN 55374 • TOLL-FREE: 800.822.0295 • FAX: 763.428.4821 MAINTENANCE A D J U S T C H I P P E R B E LT T E N S I O N Mount Bolt Always remove key from engine ignition and remove positive battery terminal from the battery. 1) Loosen all four (4) engine mount bolts Tension Bolt 2) Loosen jam nuts 3) Pull engine forward with tension nuts if Kubota engine Jam Nut Adjust both sides the same amount to avoid losing the proper alignment. 5) Always be sure to re-tighten engine hold down nuts & bolts, 1/2-13 to 80 ft lbs. torque. 6) Do not operate the machine without closing the belt guard. PROPER BELT TENSION: 70 LBS DEFLECTION FORCE, USING BELT TENSION GAGE Simple Test: Pull first belt mid span fairly hard, 1/2 inch deflection max. Check Daily Note: When installing a new set of belts, a breaking in period of 2 hours is recommended, with re-tensioning at that point. Caution: Never replace less than a full set of belts. Proper alignment is for the front and back of both sheaves (all 4 faces) to be in a straight line. Use a long straight edge to check. See page 35 for proper belt and sheave care. REV. 9/99 PAGE 33 D OS KO 20195 S. DIAMOND LAKE RD, STE 100 • ROGERS, MN 55374 • TOLL-FREE: 800.822.0295 • FAX: 763.428.4821 MAINTENANCE ADJUSTING HYDRAULIC PUMP BELT TENSION Always remove key from engine ignition key and remove positive battery terminal from the battery Tension Bolt 3 Nuts For Mounting Bolts The proper belt tension and sheave alignment is essential for trouble free performance and optimum production of your chipper. If the sheaves are not loosened or moved the belts can be tightened by simply sliding the pump bracket. 1) Loosen the 3 nuts. 2) Loosen jam nut on tension bolt. 3) Tighten tension bolt to tension the belt. Proper belt tension is 7 lbs deflection. Without a gage, pull the belt fairly hard with fore finger mid span. The belt should pull out approximately 3/8 inch. 4) Re-tighten 3/8-16 nuts to 23 ft. lbs. torque. 5) Re-tighten tension nut. 6) If sheaves are removed, follow directions on page 36 for sheave installation. REV. 9/99 PAGE 34 D OS KO 20195 S. DIAMOND LAKE RD, STE 100 • ROGERS, MN 55374 • TOLL-FREE: 800.822.0295 • FAX: 763.428.4821 MAINTENANCE BELT AND SHEAVE CARE No matter how many times you hear it; proper belt tension and sheave alignment is vital to every brush chipper success. Here are just a few problems that can occur when belts and sheave are not properly maintained or cared for. Loose Belt - a loose belt will slip and then glaze over. Once this happens the belt will not transmit power to the flywheel which can cause the chipper to clog. Loose belts once glazed over, can cause excess sheave wear. Over Tightened Belt - to much belt tension can cause premature bearing wear. If the belts are over tightened you can break the crank shaft of the engine or ruin the clutch from to much side load. When the belts are worn out from over tightening they will only cause the sheaves to wear. Misaligned Sheaves - when sheaves are not aligned properly the belts will glaze very quickly and a slipping will occur. Misaligned sheaves will cause belt to bounce or vibrate causing damage to bearings, clutch and metal stress on machine. REV. 9/99 PAGE 35 Good Sheave Top View Top View Worn Sheave Chipper Body Chipper Body D OS KO 20195 S. DIAMOND LAKE RD, STE 100 • ROGERS, MN 55374 • TOLL-FREE: 800.822.0295 • FAX: 763.428.4821 MAINTENANCE SHEAVE INSTALLATION & ALIGNMENT Always remove key from engine ignition key and remove positive battery terminal from the battery Top View 1) Before installing sheaves, make sure the chipper shaft and engine shaft are clean and square or parallel to each other. This can be done by using two large contractor’s squares. Square to Sidewall Chipper Body 2) Assemble bushings into sheaves leaving them loose then slide them on the shafts and finally install key, be sure to consider belt guard and cover clearance. Tighten set screws evenly to the proper torque. Bushing No. 1610 2012 2517 3030 Screws 3/8” Set Screws 7/16” Set Screws 1/2” Set Screws 5/8” Set Screws Torque ft lbs 15 23 36 67 3) Place and slide the sheaves onto the shaft, and make sure they are in line. Then using a long straight edge, align them with each other. Tighten all bolts evenly; chipper and engine sheave bushings should be torqued according to chart above. Top View Chipper Body 4) Tighten belts keeping sheaves properly aligned. REV. 9/99 PAGE 36 D OS KO 20195 S. DIAMOND LAKE RD, STE 100 • ROGERS, MN 55374 • TOLL-FREE: 800.822.0295 • FAX: 763.428.4821 MAINTENANCE BOLT TORQUE CHART (These Values Are Based On Clean Dry Threads) BOLT SIZE LOCATION BOLT GRADE TORQUE, FT LBS. 3/4-10 NC Swing Open Feed Roller 5 130 3/4-16 NF Knife Bolts 8 130 5/8-11 NC Adjust Hitch to Tongue 8 112 5/8-11 NC Feed Roll Shaft Bearings 5 112 5/8-11 12 Point Bed Knife 4 ea. 8 112 1/2-20 NF Wheel Lug Nuts 8 80 1/2-13 NC Engine Hold Down Disks, Fan Blades 8 80 1/2-13 NC Covers 5 60 3/8-16 NC Oil Pump Mount Fenders 5 23 5/16-18 NC Flanges, Covers 5 20 5/8 Set Screw Taper Bushing 67 1/2 Set Screw Taper Bushing 36 7/16 Set Screw Taper Bushing 23 3/8 Set Screw Taper Bushing 15 REV. 9/99 PAGE 37 D OS KO 20195 S. DIAMOND LAKE RD, STE 100 • ROGERS, MN 55374 • TOLL-FREE: 800.822.0295 • FAX: 763.428.4821 ELECTRICAL MAINTENANCE T R A I L E R W I R I N G D I AG R A M WIRE COLOR CODE Bk . . . . . . . . . . . .Black Bl. . . . . . . . . . . . . .Blue R . . . . . . . . . . . . . . Red G . . . . . . . . . . . . Green W. . . . . . . . . . . . White Or . . . . . . . . . . Orange Y . . . . . . . . . . . . Yellow 12 Gage Wire Shown here with optional electric brakes REV. 9/99 PAGE 38 D OS KO 20195 S. DIAMOND LAKE RD, STE 100 • ROGERS, MN 55374 • TOLL-FREE: 800.822.0295 • FAX: 763.428.4821 MAINTENANCE H Y D R AU L I C S MODEL 510 SD Wipe top of tank clean before opening filler cap 1) Keep hydraulic oil level in tank within 2 inches of the top. Do not over fill. 2) Use a good grade anti-wear hydraulic fluid equivalent to ISO-32. Check with supplier for severe hot or severe cold oil recommendation. 3) The spin-on type hydraulic filter must be changed after the first ten hours of use, this allows for the initial system cleanout. Then the filter should be changed after every 250 hours of use. 4) The hydraulic pump is belt driven directly from the engine so that the system is continuously under pressure when the engine is running. Keep the belt tight, see page 34. 5) The system pressure is set for 2500 psi. Do not raise the pressure relief beyond 2500 psi. This would damage the motors. (Note: Pressure relief valve is preset at the factory. DO NOT ADJUST or alter the factory setting.) 6) The safety control bar is connected to the direction control valve causing the feed roll to turn forward, neutral or reverse. 7) The speed control valve is located next to the hydraulic tank. 8) Keep your hydraulic system clean. Replace oil yearly, thoroughly clean tank. Clean filter screen. Replace oil immediately if it becomes contaminated. 9) See SMART FEED section on pages 44-46. REV. 9/99 PAGE 39 D OS KO 20195 S. DIAMOND LAKE RD, STE 100 • ROGERS, MN 55374 • TOLL-FREE: 800.822.0295 • FAX: 763.428.4821 MAINTENANCE TROUBLE SHOOTING HYDRAULICS PROBLEM POSSIBLE CAUSE SOLUTION Hydraulic oil hot or system runs slow 1) 2) 3) 4) 5) 6) 7) - Fill - Replace - Open swing away feed roll & clean - Replace - See page 41 Clean and adjust - See page 42 Test & replace - Clean and replace Feed Roller turns slow or not at all 8) Plugged suction line screen 9) Pump belt slipping 10) Feed control valve worn or not shifting properly 11) Plugged cartridge valve 12) SMART FEED stopping feed roller Test Tools Low oil level Dirty oil filter Feed roll jammed Damaged hose Pressure relief valve stuck open Worn pump Wrong hydraulic oil - Clean - Tighten or replace - Repair or replace - See page 43 clean - See pages 44 and 46 Pressure Test Tool #29000 JIC Tee JIC Nipple Flow Meter Tool #29001 REV. 9/99 PAGE 40 D OS KO 20195 S. DIAMOND LAKE RD, STE 100 • ROGERS, MN 55374 • TOLL-FREE: 800.822.0295 • FAX: 763.428.4821 MAINTENANCE TROUBLE SHOOTING HYDRAULICS (CONT’D) 5) Suspect plugged pressure relief valve PARTS LIST Item Part# DIRECTION CONTROL VALVE Name 4 82515 Slot Set Screw 5 A-6033 Relief Spring 15 82531 Ball 11/32 dia. 16 82527 Boss plug 28 A-6154 Valve Seat 15 28 4 5 16 PRESSURE RELIEF A) Follow standard safety procedures: Always remove key from engine ignition and remove positive battery terminal from the battery. B) Remove Boss Plug #16. C) Notice the exact position of the adjusting Screw Slot. D) Count the exact number of turns required to remove the Screw and record. E) Remove Spring, Ball, and Seat. F) Clean and flush out. G) Re-assemble using same number of turns and position for Screw slot of approximate pressure adjustment. If position is lost, turn screw all the way in, then back off 1 1/2 turns. H) Re-install Boss Plug #16. I) For exact pressure relief setting, the system must be tested under pressure with the chipper turning and the engine running at full RPM 1) install pressure gage and Tee fitting (DOSKO PN# 29000) at the speed control discharge position A, see page 47. 2) Run chipper engine and feed roller in forward direction. 3) Adjust the pressure relief valve to 2500 psi. REV. 9/99 PAGE 41 D OS KO 20195 S. DIAMOND LAKE RD, STE 100 • ROGERS, MN 55374 • TOLL-FREE: 800.822.0295 • FAX: 763.428.4821 MAINTENANCE TROUBLE SHOOTING HYDRAULICS (CONT’D) 6) 1) Suspect worn pump. Use flow meter to prove pump’s performance. Pump Hose to Tank Dosko PN#29001 2) Disconnect hose #6 from cartridge valve. See page 47, this is test point B. 3) Connect flow meter as shown, use hose to flow back to tank. 4) Adjust engine to 3000 RPM, flow should be 5.7 GPM (use auxiliary tach). 2500 RPM, flow should be 4.75 GPM 2000 RPM, flow should be 3.8 GPM 1500 RPM, flow should be 2.85 GPM 1000 RPM, flow should be 1.9 GPM 5) If pump does not meet the standards listed above, replace. REV. 9/99 PAGE 42 D OS KO 20195 S. DIAMOND LAKE RD, STE 100 • ROGERS, MN 55374 • TOLL-FREE: 800.822.0295 • FAX: 763.428.4821 MAINTENANCE TROUBLE SHOOTING HYDRAULICS (CONT’D) 11) Suspect plugged cartridge valve. SOLENOID CARTRIDGE VALVE CARTRIDGE A) Follow standard safety procedures: Always remove key from engine ignition and remove positive battery terminal from the battery. B) Remove Solenoid. C) Remove Cartridge D) Check for debris and wash Cartridge with solvent (brake cleaner). E) Re-assemble. REV. 9/99 PAGE 43 D OS KO 20195 S. DIAMOND LAKE RD, STE 100 • ROGERS, MN 55374 • TOLL-FREE: 800.822.0295 • FAX: 763.428.4821 MAINTENANCE SMART FEED The SMART FEED system monitors the chipper shaft speed and automatically stops the feed roller before clogging occurs. SMART FEED will increase bearing, belt, and clutch life while reducing engine stress. Normal Operation 1) 30 HP Kubota: Bring the engine speed up slowly to operating speed of 3000 RPM. The feed roller will not turn until the engine exceeds 2800 RPM, the feed roller will start automatically. 2) SMART FEED is always on, and in operation. The feed rollers will not turn if the chipper is not turning at proper speed. 3) SMART FEED may be by-passed by removing its fuse. By removing the fuse you can by-pass the SMART FEED if a failure occurs. Chipping can continue; However the operator must monitor the material in take by using the forward, neutral, reverse bar located at the back of the hopper. Sensor MAGNETS Controller Cartridge Valve Factory set not to be adjusted Keep this area free of grease 510 30 KUBOTA REV. 9/99 PAGE 44 D OS KO 20195 S. DIAMOND LAKE RD, STE 100 • ROGERS, MN 55374 • TOLL-FREE: 800.822.0295 • FAX: 763.428.4821 MAINTENANCE SMART FEED WIRING DIAGRAM Controller PN 29251 PN 29253 Factory Set DO NOT ADJUST PN 29252 Coil PN 29250 REV. 9/99 PAGE 45 D OS KO 20195 S. DIAMOND LAKE RD, STE 100 • ROGERS, MN 55374 • TOLL-FREE: 800.822.0295 • FAX: 763.428.4821 MAINTENANCE TROUBLE SHOOTING SMART FEED PROBLEM POSSIBLE CAUSE SOLUTION Feed Rollers will not turn 1) No power to SMART FEED box. Check for lose wiring connections or blown fuse. 2) Chipper not running at full speed. Set engine at 3000 RPM. (Use separate tach to check RPM) 3) Forward/Reverse feed control valve in neutral position 4) Sensor dirty. Stop chipper, open belt guard, clean sensor and magnets. Set sensor 1/8 to 1/2 in. from magnet. 5) Sensor out of adjustment. SMART FEED will not operate, Set in forward direction. (pull out) 6) Two magnets not in place. (a missing magnet) Replace magnet collar. 1) Fuse blown. Replace fuse. 2) Check for power to SMART FEED. Measure 12 volts. 3) Coil on cartridge valve not operating. Check for 12 volts at coil at full RPM. if power is present, then replace coil. Must have 9 volts to the magnetic sensor feed rollers keep turning 4) Check that the wiring is not damaged. 5) Check output of the magnetic sensor. Use inductive tach (Like Fluke MD 88 meter). 30 HP Kubota High Low 95.00 Hz - 80.00 Hz Please Note: To properly trouble shoot this SMART FEED System you must use a “multimeter” like the Fluke brand MD 88 meter, or one that is similar. This multi meter must be able to read RPM & Hz to properly trouble shoot this system. Do not use any other electrical component parts on this SMART FEED system other than what is recommended by the factory. 510 30 KUBOTA REV. 9/99 PAGE 46 D OS KO 20195 S. DIAMOND LAKE RD, STE 100 • ROGERS, MN 55374 • TOLL-FREE: 800.822.0295 • FAX: 763.428.4821 PARTS LIST & ILLUSTRATIONS MODEL 510 SD Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Qty 1 3 3 1 1 1 3 1 1 1 1 1 1 1 1 1 REV. 9/99 Part # 30251 30266 30701 30260 30267 30261 30268 29248 29249 29250 30269 30270 30271 29204 30263 29202 HYDRAULIC COMPONENTS Part Name Hydraulic Pump 5.7GPM Fitting 8 MJ x 12 MP Fitting 10 MB x 8 MJ Hose 33” Fitting 8 MB x 8 MJ Hose 32” Fitting 8 MJ x 8 MP Cartridge Valve Assembly Cartridge Only Coil Only Nipple 8 Mp x 8 MB Elbow 8 MP x 8 FP90 Fitting 12 MB x 12 MJ90 Speed Control Valve Hose 87” Direction Control Valve Item 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 PAGE 47 Qty 1 2 1 1 2 1 1 1 1 1 1 1 1 1 1 Part # 30262 29207 30264 30265 30272 30258 30259 30273 29208 29209 30155 29210 29211 29223 29225 30702 Part Name Hose 55” Hydraulic Motor 28 CU Hose 56” Hose 79” Fitting (T) MJ FJ x MJT8 Hose 19” Hose 24” Fitting 8 MJ x 8 MP90 Filter Assembly Filter Cartridge Tank Filler Cap Screen Fitting 12 MJ x 16 MP Plug Fitting 8 MB x 8 MJ90 D OS KO 20195 S. DIAMOND LAKE RD, STE 100 • ROGERS, MN 55374 • TOLL-FREE: 800.822.0295 • FAX: 763.428.4821 PARTS LIST & ILLUSTRATIONS MODEL 510 SD Item 1 2 3 4 5 6 Qty 1 1 1 1 1 1 REV. 9/99 Part # 30251 50856 30213 30214 30212 50415 PUMP MOUNT Part Name Item Hydraulic Pump 5.7 GPM 7 Key 8 Bushing 9 Belt 10 Pulley 11 Bolt 3/8-16 x 2 1/2 Full Thread PAGE 48 Qty 1 5 3 1 2 Part # 50021 50022 50110 30014 50403 Part Name Nut Plain 3/8-16 Lock Nut 3/8-16 Washer USS 3/8 Pump Mount Weldment Bolt 3/8-16 x 1 1/4 D OS KO 20195 S. DIAMOND LAKE RD, STE 100 • ROGERS, MN 55374 • TOLL-FREE: 800.822.0295 • FAX: 763.428.4821 PARTS LIST & ILLUSTRATIONS MODEL 510 SD Item Qty Part # 1 1 30012 2 1 28255 3 1 28257 4 1 28258 5 1 28259 6 1 30218 7 1 30158-G 7 1 30158-D 8 2 29210 9 1 30155 10 1 30219 11 2 30171 12 2 30222 13 2 30223 14 1 30224 15 2 30222 16 2 50961 17 2 30234 18 4 30235 19 2 30236 20 2 30237 21 2 30225 22 2 30226 23 1 29113 24 1 29249 25 1 30190 26 1 50962 27 1 50963 28 1 50803 29 1 29114 30 1 29250 31 1 28265 32 1 30220 33 1 30221 34 1 30192 35 1 30164 36 1 30189 37 1 29253 38 1 29251 39 1 29252 40 1 30375 REV. 9/99 M A I N F R A M E A S S E M B LY Part Name Main Frame Weldment Tongue Jack With Pad Jack Keeper Pin Safety Chain Electrical Plug Electrical Harness Fuel Tank - Gas Fuel Tank - Diesel Filler Cap Hydraulic Tank Fuel Line Bolt on Fender Wheel Tire Axle Assy (Plain) Dust Cap Cotter Pin Castle Nut Bearing Hub Dust Seal Lief Spring Hanger Light Guard LH Modular Lamp LH Rear Support Stand Lock Pin Safety Pin Bolt 3/4-10 x 1 1/2 Light Guard RH Modular Lamp RH Battery Positive Lead Negative Lead Belt Guard Filler Belt Guard SMART FEED Cover SMART FEED Fuse SMART FEED Controller SMART FEED Sensor 30 HP Kubota Engine 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 PAGE 49 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 2 4 4 8 3 1 1 1 1 1 1 1 1 30376 30377 30378 30379 30208 30381 50866 30307 30308 30309 30310 30380 50887 30311 30312 30382 30383 30384 30385 30386 30387 30388 30389 30390 30391 30392 30393 30394 30403 30402 30401 30400 30399 30398 30397 30395 30396 Oil Filter Fuel Filter Shroud, Flywheel Stub Shaft Pulley Engine Hyd. Pump Belt B-39 Keyway 3/8 x 3/8 x 1/2 5/32 Long Shaft Spacer Clutch Rotor Spring Assy. Clutch Housing Only Complete Clutch Belts 5VX-600 Keyway 3/8 x 4 3/4 Endcap Shaft Bolt Control Panel RPM Gauge Wire Harness Engine Shut Down Cable Glow Lamp Light Throttle Control Key Switch Lamp Timer Jam Nut Engine Adjustment Bolt Bolt 1/2-13 x 2 Lock Nuts 1/2-13 Washers 1/2 USS Clamp Hose Hose Air Cleaner Air Cleaner Hood Air Cleaner Pre Cleaner Cap Mount Bracket - Air Cleaner Rubber Gasket - Air Cleaner Air Filter Air Cleaner Hood - End Cap Remote Air Cleaner Complete - Kubota D OS KO 20195 S. DIAMOND LAKE RD, STE 100 • ROGERS, MN 55374 • TOLL-FREE: 800.822.0295 • FAX: 763.428.4821 PARTS LIST & ILLUSTRATIONS MODEL 510 SD M A I N F R A M E A S S E M B LY 30 HP KUBOTA & DRIVE REV. 9/99 PAGE 50 D OS KO 20195 S. DIAMOND LAKE RD, STE 100 • ROGERS, MN 55374 • TOLL-FREE: 800.822.0295 • FAX: 763.428.4821 PARTS LIST & ILLUSTRATIONS MODEL 510 SD Item 1 2 3 4 5 6 7 8 Qty 1 1 1 4 4 4 2 4 REV. 9/99 Part # 30018 30019 30050 50119 50121 50701 50604 50116 C H I P P E R A S S E M B LY Part Name Hood Assy Weldment Body Weldment Bed Knife Washer 5/8 USS Washer 5/8 Lock Bolt 5/8-11 x 1 1/4 Bolt 1/2-13 x 1 1/2 Washer 1/2 USS Item 9 10 11 12 13 14 15 16 PAGE 51 Qty 2 1 1 2 2 2 2 1 Part # 50052 50711 50602 50119 50062 50052 50116 30052 Part Name Flex Lock Nut 1/2-13 Bolt 5/8-11 x 7 1/2 Flex Lock Nut 5/8-11 Washer 5/8 USS Flex Lock Nut 5/8-11 Flex Lock Nut 1/2-13 Flat Washer 1/2 USS Stud Bar D OS KO 20195 S. DIAMOND LAKE RD, STE 100 • ROGERS, MN 55374 • TOLL-FREE: 800.822.0295 • FAX: 763.428.4821 PARTS LIST & ILLUSTRATIONS MODEL 510 SD Item 1 2 3 4 5 6 7 10 11 12 Qty 1 1 14 14 10 10 2 2 2 Part # 30010 30035 50607 50052 30009 30008 30011 30094 30036 30201 R OTAT I N G C H I P P E R A S S E M B LY Part Name Disk 1 1/2 Shaft Bolt 1/2-13 x 2 1/4 Flex Lock Nut 1/2 -13 Bolt 3/4-16 x 1 3/4 GR#8 Lock Washer 3/4 Knives 5/8 x 4 x 11 Fan Blade Assy Shims 1/32, 1/16, 1/8, 3/16 Bearing 2 1/4 SCM Item 13 14 15 16 17 18 20 21 22 23 Qty 1 1 3 1 1 1 8 1 1 1 Part # 30152 30151 30217 30202 30204 50809 50062 30346 29252 29251 Part Name SMART FEED Bracket SMART FEED Magnet Collar Magnet Sheave Bushing 2 1/4 Key 1/2 Sq x 3 Flex Lock Nut 5/8-11 Bearing Protector Smart Feed Sensor Smart Feed Controller See Pages 44-46 REV. 9/99 PAGE 52 D OS KO 20195 S. DIAMOND LAKE RD, STE 100 • ROGERS, MN 55374 • TOLL-FREE: 800.822.0295 • FAX: 763.428.4821 PARTS LIST & ILLUSTRATION MODEL 510 SD Item 1 2 3 4 5 6 7 8 Qty 1 1 1 1 1 2 2 1 REV. 9/99 Part # 30020 30097 30375 29267 50881 50719 50064 30021 U PPER F EED R OLL A SSEMBLY Part Name Feed Roll Weldment Feed Roller Shaft Coupling Key 1/4 Woodruff Bolt 5/8-11 GR 8 x 3 Stover Lock Nut 5/8-11 Arm Assembly Item 9 10 11 12 13 14 16 17 PAGE 53 Qty 4 8 8 1 1 8 16 16 Part # 29269 50604 50052 29207 50856 50117 50114 50042 Part Name Bearing 1 1/2 SC (Square) Bolt 1/2 - 13 x 1 1/2 Flex Lock Nut 1/2 -13 Hydraulic Motor 28 cu inch Key 1/4 sq. Washer 1/2 SAE Washer 7/16 SAE Flex Lock Nut 7/16 -14 D OS KO 20195 S. DIAMOND LAKE RD, STE 100 • ROGERS, MN 55374 • TOLL-FREE: 800.822.0295 • FAX: 763.428.4821 PARTS LIST & ILLUSTRATIONS MODEL 510 SD Item 1 2 3 4 5 6 7 Qty 1 1 1 1 1 4 1 REV. 9/99 Part # 30022 30023 30078 30071 30073 50112 29202 IN-FEED HOPPER Part Name In-Feed Hopper Assy. Tray Assembly Hinge Pin Tray Feed Control Arm Hinge Pin Feed Control Lock Washer 3/8 Valve Item 8 9 10 11 12 13 PAGE 54 Qty 4 2 3 3 1 1 Part # 50401 29075 50203 50012 29260 50902 Part Name Bolt3/8-16 x 3/4 Control Lever Bolt 1/4-20 x 1 1/4 Flex Lock Nut 1/4-20 Latch - Hopper Spring D OS KO 20195 S. DIAMOND LAKE RD, STE 100 • ROGERS, MN 55374 • TOLL-FREE: 800.822.0295 • FAX: 763.428.4821 PARTS LIST & ILLUSTRATIONS MODEL 510 SD Item 1 2 3 4 5 6 7 8 9 10 11 Qty 1 1 1 1 1 1 1 1 2 2 2 REV. 9/99 Part # 30017 30039 30091 29165 29168 50901 50116 50952 50601 50117 50042 D I S C H A R G E A S S E M B LY Part Name Item Complete 6” Discharge Assy 12 Discharge Tube Weldment 13 Deflector Weldment 14 Control Arm Weldment 15 Lock Handle 16 Spring 17 Washer 1/2 USS 18 Keeper Spring Pin 19 Bolt 1/2-13 x 3/4 20 Washer 1/2 SAE 21 Flex Lock Nut 7/16-14 22 PAGE 55 Qty 2 1 1 1 1 1 1 1 1 1 1 Part # 50114 50546 30034 30035 29172 50123 50702 50062 30016 29171 50956 Part Name Washer 7/16 SAE All Thread Shaft 7/16-14 x 9 1/2 Clamp Half Single Ear Clamp Half Double Ear Clamp Handle Bolt Washer 3/4 SAE Bolt 5/8-11 x 1 1/2 Lock Nut 5/8-11 Complete Clamp Assy Pin Assy, Flange Lock Keeper Spring Pin D OS KO 20195 S. DIAMOND LAKE RD, STE 100 • ROGERS, MN 55374 • TOLL-FREE: 800.822.0295 • FAX: 763.428.4821 D E D I C AT E D T O B U I L D I N G Q U A L I T Y P R O D U C T S W O R L D W I D E 1324 RIALTO AVENUE • SAN BERNARDINO • CALIFORNIA • 92410 • (909) 885-0988 • FAX (909) 381-4743 Limited Warranty Policy Dosko, Inc. warrants each Dosko chipper to be free from defect in factory materials and workmanship for a period of one year subsequent to the first retail purchase. During the first 90 days period of this warranty your authorized Dosko dealer will repair or replace free of any charge for parts or labor, that are found to be defective. Labor is covered only on the first 90 days of this warranty policy. This warranty will not apply to any Dosko chipper which has been modified, repaired, or altered in such a manner as to effect its stability, performance or operation, and which has been subjected to misuse, abuse, negligence or accident. The following examples would void warranty: 1) The chipper has been abused or neglected proper maintenance. 2) Repairs made without prior written authorization. 3) Repairs made due to normal wear. 4) The machine is involved in or damaged by an accident. 5) Chipper damaged from foreign materials such as steel, rocks, nails, etc. The owner is responsible for all regular maintenance as explained in the operators manual. Neglect in regular maintenance or failure to replace normal wear items such as knives, bed knife, lubrication oils, filters, belts, bearings, etc. may void warranty. THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING ANY IMPLIED WARRANTY OR MERCHANTABILITY OF FITNESS FOR A PARTICULAR PURPOSE AND OF ANY NON-CONTRACTUAL LIABILITIES INCLUDING PRODUCT LIABILITIES, BASED UPON NEGLIGENCE OR STRICT LIABILITY. DOSKO, INC. WILL NOT BE LIABLE FOR CONSEQUENTIAL DAMAGES RESULTING FROM BREACH OF WARRANTY. In order to validate this warranty on your new Dosko chipper fill out and return to Dosko the enclosed product registration form with in 10 days of purchase. (Page 1) Purchased component parts (i.e. tires, batteries, engines, belts bearing, etc. are not warranted by Dosko. Many of these component parts are warranted by the manufacture of that component part. Any machines used for lease or rental - warranty is limited to 90 days from first day of initial service. It is the owner’s responsibility to report the claims promptly to Dosko or one of our authorized dealer from whom the equipment was purchased. 1. Dealer from whom purchased 2. Date purchased & delivered 3. Model number, serial of unit 4. Engine make and serial number 5. Number of hours in use 6. Date failure occurred 7. Nature of failure. REV. 9/99 - CHIPPER PAGE 56 D OS KO 20195 S. DIAMOND LAKE RD, STE 100 • ROGERS, MN 55374 • TOLL-FREE: 800.822.0295 • FAX: 763.428.4821 r e p p i h C o k s o D r u o Y y o Enj 20195 S . D I A M O N D L A K E R D S U I T E 100 R O G E R S , M N 55374 800- 822- 0295 Safety, Operation, And Parts Manual Model 510 SD Brush Chipper 20195 S. D I A M O N D L A K E R D S U I T E 100 R O G E R S , M N 55374 800- 822- 0295