OWNER
OPERATORS
MANUAL
6" and 8"
Chipper
Models
74824
8" 24 HP Chipper with
Hydraulic Feed
72620
6" 20 HP Chipper with
Hydraulic Feed
71620
6" 20 HP Chipper
Crary Company
A Division of TerraMarc Industries
237 12th St. NW P.O. Box 849
West Fargo, ND 58078-0849
(701)282-5520 FAX: (701)282-9522
www.bearcatproducts.com
www.terramarc.com
Manual P/N 13987-00
Rev. 02/03
Companion to 13988-00
Before you Begin
DEAR BEAR CAT CUSTOMER,
Thank you for purchasing a Crary Bear Cat product. The Bear Cat line is designed, tested, and
manufactured to give years of dependable performance. To keep your machine operating at
peak efficiency, it is necessary to adjust it correctly and make regular inspections. The following
pages will assist you in the operation and maintenance of your machine. Please read and
understand this manual before operating.
If you have any questions or comments about this manual, please call us toll-free at 1-800-247-
7335.
If you have any questions or problems with your machine, please call or write your local
factory-authorized Bear Cat dealer.
PLEASE SEND US YOUR WARRANTY CARD
A warranty card is included in your owner's kit packaged with your machine. Please take the
time to fill in the information requested on the card. When you send your completed card to us,
we will register your machine and start your coverage under our limited warranty.
How to Contact
Bear Cat
A
DDRESS
Crary Bear Cat
237 NW 12th Street
PO Box 849
West Fargo, ND 58078
P
HONE
800-247-7335
701-282-5520
Fax: 701-282-
9522
E
MAIL
opesales@crary.com
service@crary.com
H
OURS
EMISSION INFORMATION
WARNING
WARNING TO ALL CALIFORNIA
AND OTHER STATES OPERATING
OUTDOOR POWER EQUIPMENT
Under California Law and under the
laws of several other states you are
not permitted to operate an internal
combustion engine using hydrocarbon
fuels on any forest covered, brush
covered or grass covered land or on
land covered with grain hay or other
flammable agricultural crop, without an
engine spark arrester in continuous
effective working order.
The engine on your power equipment,
like most outdoor power equipment, is
an internal combustion engine that
burns gasoline, a hydrocarbon fuel.
Therefore, your power equipment must
be equipped with a spark arrester
muffler in continuous effective working
order. The spark arrester must be
attached to the engine exhaust system
in such a manner that flames or heat
from the system will not ignite
flammable material.
Failure of the owner/operator of the
equipment to comply with this
regulation is a misdemeanor under
California law, and may also be a
M-F, 8 a.m. to 5
p.m. Central Time
violation of other state and or federal
regulations, laws, ordinances, or
codes. Contact your local fire marshal
or forest service for specific information
about what regulations apply in your
area.
The standard muffler installed on the
engine is not equipped with a spark
arrester. One must be added before
use if this machine is intended to be
used in an area where a spark arrester
is required by law. Contact the local
authorities if these laws apply to you.
See your authorized engine dealer for
spark arrester options.
I
6" and 8" Bear Cat Chipper Operators Manual
Limited Warranty
Crary Bear Cat chippers are warranted for 1 year from date of sale for consumers , commercial, or rental
operations.
Within the above stated period, Crary Co. will replace any part(s) found to be defective in material and/or
workmanship, after the receipt of the part in our plant. Labor costs to replace these defective parts will be
paid at a Crary established labor rate and time allowed (flat rate) for repair. All transportation charges
incurred in shipping part(s) are the responsibility of the purchaser.
This warranty is void in the case of accidents, failure to perform normal maintenance, or failure to follow
those instructions listed in the service manual. This warranty is also in lieu of all other expressed warranties
and voids any implied warranty as to the merchantability or fitness of the product for a particular purpose
and of any other obligation on the part of Crary Co. Some states do not allow limitations on how long the
implied warranty lasts, so the above limitation may not apply to you.
This warranty applies only to parts or components that are defective, and does not cover necessary repair
due to normal wear, misuse, accidents, or lack of proper maintenance. This includes belts, pulleys, and
chipper blades. Regular routine maintenance of the unit to keep it in proper operating condition is the
responsibility of the owner.
All warranty repair reimbursable under the Crary Co. warranty must be performed by an authorized Bear
Cat service dealer using Bear Cat approved replacement parts. Repair or attempted repair by anyone other
than an authorized Bear Cat service dealer is not reimbursable under the Crary Co. warranty. In addition,
these unauthorized repair attempts may result in additional malfunction, the correction of which is not
covered by warranty.
Crary Co. is not liable for indirect, incidental, or consequential damages in connection with the use of this
product including any cost or expense or providing substitute equipment or service during periods of
malfunction or non-use.
Some states do not allow the exclusion of incidental or consequential damages, so the above exclusion
may not apply to you. This warranty gives you specific legal rights. You may also have other rights that
vary from state to state.
Be sure to note the serial number in any correspondence with Crary Co. or any authorized Bear Cat dealer.
Crary Company
A Division of TerraMarc Industries
237 12th St. NW P.O. Box 849
West Fargo, ND 58078-0849
(701)282-5520 FAX: (701)282-9522
www.bearcatproducts.com
www.terramarc.com
6" & 8" Bear Cat Chipper Operators Manual II
CONTENTS
SAFETY ..........................................................................................................................................................................1
1.1 THE SAFETY ALERT SYMBOL ................................................................................................................................1
1.2 BEFORE OPERATING .............................................................................................................................................. 1
1.3 BEFORE OPERATING .............................................................................................................................................. 2
1.4 OPERATION SAFETY ............................................................................................................................................... 2
1.5 MAINTENANCE AND STORAGE SAFETY ............................................................................................................... 3
1.6 TOWING SAFETY ..................................................................................................................................................... 3
1.7 BATTERY SAFETY ................................................................................................................................................... 3
ASSEMBLY .................................................................................................................................................................... 4
2.1 ASSEMBLING THE MACHINE .................................................................................................................................. 4
2.2 INSTALLING THE BATTERY ......................................................................................................................................5
CONTROLS ....................................................................................................................................................................6
3.1 MACHINE CONTROLS .............................................................................................................................................. 6
OPERATION ...................................................................................................................................................................7
4.1 STARTING THE MACHINE ........................................................................................................................................ 7
4.2 STOPPING THE ENGINE .......................................................................................................................................... 8
4.3 CHIPPING .................................................................................................................................................................8
4.4 ROTATING THE CHIPPER BASE .............................................................................................................................. 8
4.5 HYDRAULIC FEED OPERATION (MODELS 72620 & 74824) .................................................................................... 9
4.6 CONTROL ARM OPERATION (MODELS 72620 & 74824) ......................................................................................... 9
4.7 HYDRAULIC FEED COMPONENT LOCATIONS (MODELS 72620 & 74824) ............................................................ 9
SERVICE & MAINTENANCE ......................................................................................................................................... 10
5.1 SHARPENING CHIPPER BLADES ......................................................................................................................... 10
5.2 SETTING CHIPPER BLADE CLEARANCE .............................................................................................................. 11
5.3 ADJUSTING DRIVE BELTS ..................................................................................................................................... 11
5.4 REPLACING DRIVE BELTS .................................................................................................................................... 12
5.5 CLEARING PLUGGED ROTOR ............................................................................................................................... 12
5.6 REPAIRING OR REPLACING ROTOR BEARINGS .................................................................................................. 13
5.7 GREASEABLE BEARINGS AND PIVOTS .............................................................................................................. 13
5.8 OTHER SERVICE TIPS........................................................................................................................................... 13
5.9 TRAILER SERVICE TIPS ........................................................................................................................................ 13
5.10 HYDRAULIC FLUID (MODELS 72620 & 74824) ..................................................................................................... 14
5.11 PUMP COMPONENT LOCATIONS (MODELS 72620 & 74824) ............................................................................. 14
5.12 HYDROSTATIC PUMP START UP PROCEDURE (MODELS 72620 & 74824)........................................................ 14
5.13 HYDRAULIC FEED MAINTENANCE (MODELS 72620 & 74824) ........................................................................... 15
5.14 ADDING HYDRAULIC FLUID........................................................................ .................................................... 15
TROUBLESHOOTING .................................................................................................................................................. 16
6.1 GENERAL TROUBLESHOOTING ............................................................................................................................ 16
6.2 HYDROSTATIC PUMP TROUBLESHOOTING (MODELS 72620 & 74824) ............................................................... 17
SPECIFICATIONS ........................................................................................................................................................ 18
7.1 SPECIFICATIONS ................................................................................................................................................... 18
7.2 BOLT TORQUE ....................................................................................................................................................... 19
III
6" & 8" Chipper Bear Cat Operators Manual
1
Safety
Section
1.1 THE SAFETY ALERT SYMBOL
This is the safety alert symbol. It is used in this Owner / Operators Manual and on your machine
to alert you to potential hazards.
Whenever you see this symbol, read and obey the safety message that follows it. Failure to obey
the safety message could result in personal injury, death or property damage.
Indicates an imminently hazardous situation that, if not avoided, will result in
DANGER
death or serious injury.
WARNING
CAUTION
1.2 BEFORE OPERATING
1. Read this Owner / Operators
manual. Be completely familiar
with the controls and the proper
use of this equipment.
2. Before inspecting or servicing any
part of the machine, wait for all
parts to stop moving. Be aware that
rotating parts slow down gradually
after power is stopped.
Indicates a potentially hazardous situation that, if not avoided, could result in
death or serious injury.
Indicates a potentially hazardous situation that, if not avoided, may result in
minor or moderate injury.
4. Familiarize yourself with all of the
safety and operating decals on this
equipment and on any of its attachments or accessories.
5. Do not allow children or any person unfamiliar with the use of the
unit to use this machine.
6. Keep the area of operation clear of
all persons, particularly small children. Keep bystanders at least
50 feet (15 meters) away from the
area of operation.
7. Do not run this equipment in an
enclosed area. Do not operate this
equipment in or near buildings,
windows, or air conditioners.
8. If needed, always use an approved
fuel container. Keep open flames,
sparks, smoking materials, and
other sources of combustion away
from fuel.
9. Do not operate this machine if you
are under the influence of alcohol,
medications, or substances that
can affect your vision, balance, and
judgement. Do not operate if tired
or ill. You must be in good health
to operate this machine safely.
3. Keep safety decals clean and legible. Replace missing or illegible
safety decals.
Page 16" & 8" Bear Cat Chipper Operators Manual
Safety
1.3 BEFORE OPERATING
10. Wear safety glasses at all times
while operating this machine.
1.4 OPERATION SAFETY
WARNING
Material can kickup or shift suddenly
and cause serious injury or death.
Wear eye and hearing protection.
DANGER
Keep hands, feet and clothing out of
inlets and discharge openings while
machine is operating to avoid serious personal injury.
11. Use only in daylight or good artificial light.
12. Never use without proper guards
in place.
13. Avoid wearing loose fitting clothing. Never operate this machine
wearing clothing with drawstrings
that could wrap around or get
caught in the machine.
14. Check that all screws, nuts, bolts,
and other fasteners are properly se-
3. Shut off machine immediately if the
cutting mechanism strikes any foreign object or the machine starts
making an unusual noise or vibrating. Allow the machine to stop
completely. After machine stops:
A. Inspect for damage.
B. Replace or repair any
damaged parts.
C. Check for and tighten any
loose parts.
4. Stand clear of the discharge area
when operating this machine.
cured before starting the machine.
Check all screws, nuts, bolts, and
other fasteners for proper tightness
to ensure everything is in proper
working condition once every 10
hours of operation.
15. Keep all guards, deflectors, and
shields in place and in good working condition.
16. Do not transport or move machine
while the machine is running.
8. Set up your work site so you are
not endangering traffic and the public. Take great care to provide adequate warnings.
9. Ensure debris does not blow into
traffic, parked cars, or pedestrians.
10. Check the bolts for correct torque
every 10 hours of operation.
11. Shut off engine and allow machine
to stop completely before clearing
debris if the machine becomes
clogged.
1. Do not allow hands or any part of
body or clothing near any moving
part.
2. Exclude pieces of metal, rocks,
bottles, cans, and other foreign objects from entering the machine.
Page 2 6" & 8" Bear Cat Chipper Operators Manual
5. Keep your face and body back from
the feed opening.
6. Do not climb on machine when operating. Keep proper balance and
footing at all times.
7. Keep the machine clear of debris
and other accumulations.
1.5 MAINTENANCE AND STORAGE SAFETY
NOTE
If equipped, see engine owners
manual or contact the engine manufacturer for engine safety instructions and decals.
1. Replace any missing or unread-
able safety decals. Refer to the
parts manual for part numbers
when ordering safety decals from
an area Bear Cat dealer.
1.6 TOWING SAFETY
1. Rotate the discharge tube to face
the opposite direction of the towing vehicle before towing. This prevents the discharge tube from projecting over the trailer wheels and
striking foreign objects.
2. Connect hitch safety chains.
Tighten and secure trailer hitch
bolts. Do not attempt to tow the
trailer if vehicle is not equipped with
a 2 ball.
3. Do not exceed maximum towing
speed, indicated on tire sidewall.
Inflate tires to manufacturers specs
as stated on the tire sidewall.
4. Check wheel lug bolts periodically
to ensure they are tight and secure.
5. Make sure the jack stand on trailer
is in the UP position to clear the
ground during towing. Place the
jack stand on a level surface and
Safety
2. Store the machine out of reach of
children and where potential fuel
vapors will not reach an open flame
or spark.
3. Allow machine to cool before storing in an enclosure.
secure it in the DOWN position before use.
6. Never allow passengers to ride on
the chipper chute while the vehicle
is moving, whether the chipper is
running or not.
7. If applicable, shut off fuel supply
when towing.
1.7 BATTERY SAFETY
1. Improper use and care of the battery on electric start models can
result in serious personal injury or
property damage. Always observe
the following safety precautions:
2. Poison/Danger - Causes Severe
Burns. The battery contains sulfuric acid. Avoid contact with skin,
eyes or clothing. Keep out of
reach of children.
ANTIDOTE-External Contact:
Flush immediately with lots of water.
ANTIDOTE-Internal: Drink large
quantities of water or milk. Follow
with milk of magnesia, beaten egg
or vegetable oil. Call a physician
immediately.
ANTIDOTE-Eye Contact: Flush
with water for 15 minutes. Get
prompt medical attention.
3. The battery produces explosive
gases. Keep sparks, flame or
cigarettes away. Ventilate area
when charging battery. Always
wear safety goggles when working near battery.
4. The battery contains toxic materials. Do not damage battery case.
If case is broken or damaged,
avoid contact with battery contents.
DANGER / POISON
SHIELD EYES
EXPLOSIVE GASES
CAN CAUSE
BLINDNESS OR
INJURY
KEEP OUT OF THE REACH OF CHILDREN. DO NOT TIP. KEEP VENT CAPS TIGHT AND LEVEL.
NO
• SPARKS
• FLAMES
• SMOKING
Neutralize acid spills with a baking soda and water solution. Properly dispose of a damaged or wornout battery. Check with local authorities for proper disposal methods.
5. Do not short circuit battery. Severe fumes and fire can result.
6. Before working with electrical wires
or components: disconnect battery ground (negative) cable first.
Disconnect positive cable second.
Reverse this order when reconnecting battery cables.
FLUSH EYES
IMMEDIATELY
SULFURIC
ACID
CAN CAUSE
BLINDNESS OR
SEVERE BURNS
WITH WATER
GET
MEDICAL
HELP
FAST
Page 36" & 8" Bear Cat Chipper Operators Manual
2
Assembly
Section
2.1 ASSEMBLING THE MACHINE
1. Remove from shipping crate.
2. Support the frame on wood blocks or other support device.
3. Mount the two tires and rims to the axle assembly with
the lug nuts (supplied).
4. Mount the trailer hitch assembly to the frame using three
3/8 X 3-1/2 inch bolts and locknuts (supplied).
5. Fasten the chipper chute to the main frame mounting
bracket using eight 3/8 X 1 inch bolts and locknuts.
Use three bolts on each side and two on the bottom.
6. Attach the blower discharge tube to the mounting flange
on the chipper frame. Half of the mounting clamp is
already attached to the tube. Slide the tube into the
flange and tighten the bolts to secure it. Install the
second half of the clamp to the tube and flange. Rotate
the tube 360 degrees and lock it in place with the handle
to make sure it is mounted correctly.
7. Install battery. (See Section 2.2)
8. Fill the engine with oil (per instructions in supplied Honda
engine manual) and the gas tank with gasoline.
9. Fill the hydraulic reservoir. See Section 5.13 for specific
instructions.
10. Your chipper should be ready to use.
Page 4 6" & 8" Bear Cat Chipper Operators Manual
Fig. #1
2.2 INSTALLING THE BATTERY
Assembly
1. The machine may or may not have been shipped with a
battery depending on your area. If you did not receive a
battery with your machine, you will need to purchase
one.
2. Use a battery that meets or exceeds the following specifications:
Battery, Category, Lawn and Garden
BCI Group Size U1
200-250 CCA
7-3/4 X 5-3/16 X 7-5/16
Suggested Source: Exide Cutting Edge, Type GT-H
3. If you received a battery with your machine, proceed to
the next step.
NOTE
The battery that was shipped with the machine was
shipped dry. The battery will need to be serviced
before installation.
4. Remove or destroy any sealing device which may have
been used to close or restrict the vent openings.
º 5. Remove battery vent caps and fill cells until baffle
plate is covered with 1.25 of electrolyte at 80° F. Battery and electrolyte must be at a temperature above
60° F, but should not exceed 100° F.
6. After filling, battery should be charged to the specifications below and put into service immediately.
Temperature over 60° F
3 amperes for 4 Hours.
Temperature under 60° F
3 amperes for 6 Hours.
7. Place charged battery in battery box on chipper shredder.
8. Remove key from engine ignition.
9. Install the positive (+) battery cable to the positive (+)
battery terminal using a 5/16 X 1 hex head bolt and 5/
16 nylock nut. An insulating boot is loosely installed
on this cable. Slide the insulating boot over the terminal, making sure that the terminal is completely covered.
10. Install the negative (-) cable on the negative (-) battery
terminal using a 5/16 X 1 hex head bolt and 5/16 nylock
nut. There is no insulating boot for this terminal.
IMPORTANT
DO NOT ATTEMPT TO START THE ENGINE AT THIS
TIME. Wait until you have read the complete starting
instructions in the Operation Section of this Manual.
WARNING
To avoid sparks and a possible explosion or fire due
to a short circuit:
1. Do not touch the positive (+) battery terminal and
any surrounding metal with tools, jewelry or other
metal objects.
2. When installing battery cables, connect positive
(+) cable first and negative (-) cable last.
11. Secure battery box cover.
Page 56" & 8" Bear Cat Chipper Operators Manual
3
Controls
Section
3.1 MACHINE CONTROLS
For engine controls and maintenance please refer to the
Honda engine owners manual included with the machine.
1. Engine Fuel Tank: Use unleaded fueldo not mix with
oil.
2. Trailer Hitch: Always use 2 inch ball and safety chains.
3. Jack Stand: Always have in UP position and clearfrom
ground when moving. When is use, place in DOWN
position on a level surface.
4. Engine Drive Belts and Shield: Never remove shields
when in use.
5. Chipper Chute: Feed materials to be chipped through
the chute.
6. Rotor Access Cover: Used to remove chipper blades.
7. Engine Battery: Shipped without battery.
8. Clutch Foot Pedal: Used to engage rotor assembly drive
belt.
9. Adjustable Chipping Anvil.
CAUTION
The chipper rotor may continue to rotate even with the
engine stopped. Do not attempt any repair or
adjustments until the entire machine has come to a
complete stop and spark plug wire is removed. Never
operate this machine without all safety shields in place.
Page 6 6" & 8" Bear Cat Chipper Operators Manual
Fig. #2
4
Operation
Section
4.1 STARTING THE MACHINE
CAUTION
Move machine to a clear, level area outdoors before
starting. Do not operate machine on a paved, concrete,
or gravel surface. Do not operate in the vicinity of
bystanders. Make sure cutting chamber is empty
before starting.
CAUTION
Obtain and wear safety glasses at all times when
operating the machine. Do not wear loose fitting
clothing. The operator should always wear heavy
boots, gloves, pants, and shirt. Use common sense
and practice safety to protect yourself from branches,
sharp objects, and other harmful objects.
1. Before starting, fill engine with oil to the correct level.
See engine manual for operation and maintenance instructions.
3. Depress foot clutch pedal down, this will disengage drive
belts and enable engine to start.
4. Refer to Honda engine owners manual for engine staring.
5. Once engine is running and no choke is needed, slowly
let foot clutch pedal up. This will engage drive belt and
the rotor will turn.
6. If engine kills when engaging foot clutch pedal, either
use more choke or increase engine RPM.
7. When clutch is engaged, the foot pedal may vibrate or
shake until the engine and rotor have increased to full
running RPM.
8. The chipper frame assembly can turn 360 degrees clockwise or counterclockwise. Press down on the foot pedal
located underneath the frame near the tow hitch and
the frame will pivot on the trailer to your desired location. Let up on the foot pedal and the frame will lock
into place for use. The discharge tube can also turn 360
degrees to your desired location.
NOTE
Some oil usage is normal. Check level with each use.
2. Before starting, fill fuel tank with fresh, clean unleaded
regular gasoline. DO NOT MIX OIL WITH GASOLINE.
WARNING
Handle fuel (gasoline) with care. It is highly flammable.
Always use an approved container and fill tank
outdoors. Never add fuel to a running or hot engine.
Page 76" & 8" Bear Cat Chipper Operators Manual
Operation
4.2 STOPPING THE ENGINE
CAUTION
Obtain and wear safety glasses at all times when
operating the machine. Avoid wearing loose fitting
clothing. Always wear heavy boots, gloves, pants, and
shirt. Use common sense and practice safety to protect
yourself from branches, sharp objects, and other
harmful objects.
1. Move throttle to SLOW position.
2. Depress foot clutch pedal.
4.3 CHIPPING
The Bear Cat chipper is designed to chip a variety of materials
into a more readily decomposing or handled condition. The
following guidelines can be used to help you get started.
WARNING
Keep face and body away from the feed opening. Do not
overreach. Keep proper balance and footing at all times.
1. Trim side branches that cannot be bent enough to feed
into the chipper chute. Hold small diameter branches
together in a bundle and feed in simultaneously.
3. Refer to Honda owners manual for stopping procedures.
4. Allow machine to come to a complete stop. You may
release the foot clutch pedal to help slow the rotor once
the engine has stopped running.
NOTE
The heavy rotor will continue to turn for some time
after the engine has been shut off. You can tell that
the rotor has stopped when no noise or machine
vibration is present. Inserting a branch into the
chipper chute to contact the blades will slow the rotor
and shorten stopping time.
2. Place limb, butt end first, into the chipper chute until it
contacts the feed roller. The actual feed rate of the limb
into the chipper depends on the type of material fed and
sharpness of the cutting blades. Operate feed roller at a
rate that will not kill the engine.
3. Rotate the branch to improve cutting action.
4. The chipping blades dull with use and require periodic
sharpening. Refer to Service and Maintenance, "Sharpening Chipper Blades" for instructions.
4.4 ROTATING THE CHIPPER BASE
Fig. #3
Page 8 6" & 8" Bear Cat Chipper Operators Manual
1. Disengage the Chipper Lift Arm from the Chipper Base
and then realese it by pressing it down.
2. Rotate the Chipper Base to desired position.
3. Once the Chipper Base has been positioned, lift up the
Chipper Arm and lock it in place.
WARNING
The Chipper Base must always be locked in place.
Failure to do so my result in machine vibration, serious
bodily injury or death.
4.5 HYDRAULIC FEED OPERATION MODELS 72620 & 74824
Operation
1. Start the chipper engine. Bring the chipper up to operating speed. See "Operation" section for starting, operation, and stopping instructions.
2. Engage the hydraulic feed by moving the control arm as
shown below. The feed rate increases as the arm is
moved.
3. If the chipper jams, reverse the feed by moving the control arm in the reverse direction. Remove the branch
and rotate it before reinserting it into the chute again.
WARNING
Please read and follow all safety instructions in this
manual. Failure to operate the chipper in accordance with
the safety instructions MAY RESULT IN PERSONAL INJURY!
4.6 CONTROL ARM OPERATION MODELS 72620 & 74824
Fig. #4
4.7 HYDRAULIC FEED COMPONENT LOCATIONS MODELS 72620 & 74824
Roller Assembly
Reservoir
Hydrostatic
Pump
Fig. #5
Hydraulic
Motor
Chipper
Chute
Crossover
Relief
Valve
Page 96" & 8" Bear Cat Chipper Operators Manual
5
Service & Maintenance
Section
5.1 SHARPENING CHIPPER BLADES
When the Chipper Blades dull, chipping becomes difficult.
It is recommended that the chipper blades are sharpened
every 5-15 hours of chipper operation.
The Chipper Blades are two edged. When the first edge
dulls, flip the blade to use the sharp second edge. After
both edges are dull, sharpen the chipper blades.
Follow the procedure below to remove the chipping blades
for sharpening:
WARNING
The rotor assembly has a lock mechanism. When
working on the rotor assembly, use the lock
mechanism at all times. Remove plastic bearing cover
under chipper chute. There is a hole in the rotor jack
shaft and a matching hole in the bracket mounted to
the rotor bearing front side. Install a punch through the
rotor shaft and bracket to lock the rotor in place.
rotor so that the bolts holding the chipper blades are
most accessible (See Fig. #6).
WARNING
Before inspecting or servicing any part of the machine,
shut off the power source, disconnect the spark plug
wire from the spark plug, and make sure all moving
parts have come to a complete stop. The chipping
blades are sharp! Use care when working on machine
to avoid injury.
1. Remove the two 3/8 inch retaining bolts holding the access cover to main frame assembly.
2. Tilt access cover over to allow rotor access. Rotate the
3. Remove the two hex head bolts holding the blade itself.
Repeat for all four blades. The four chipping blades have
two edges per blade and can be reversed one time each
before sharpening. Reinstall chipping blades and proceed with chipping.
4. If already reversed, the chipping blades will have to be
ground to a 45 degree angle. Be careful when grinding
so that the blade material does not get too hot and
change colorthis will remove the blade's special heat
treated properties. Use short grinding times and cool
with water. Try to remove an equal amount off each blade
to maintain balance.
5. Replace the chipping blades and tighten bolts to 75 ft.
lbs.
Fig. #6
Page 10 6" & 8" Bear Cat Chipper Operators Manual
Service and Maintenance
5.3 SETTING CHIPPER BLADE
CLEARANCE
The four edged chipping blades should clear the chipping
anvil located directly under the chipper chute by 1/16 inch
to 1/8 inch. The chipping anvil is adjustable and
reversible.
1. Lift rotor access cover and expose rotor (See Fig. #7).
Loosen the three 1/2 inch bolts that hold the chipper
anvil to the frame.
2. Measure the amount of clearance between chipping
blade and chipping anvil from inside of housing.
3. Adjust inward or outward to desired measurement.
4. Tighten bolts on chipping anvil to 75 ft. lbs. and resume
operation.
If chipping anvil edge is damaged or worn unevenly,
remove the three bolts holding the anvil and use one of the
other three edges. Adjust for correct measurement.
5.3 ADJUSTING DRIVE BELTS
Check the condition of the drive belt annually or after every
30 hours of operation, whichever comes first. If the belt is
cracked, frayed, worn, or stretched, replace it. Only
replace belt with original branded type belt, do not use
single type belts. To adjust the belt, proceed as follows:
1. Depress foot clutch pedal. Shut engine off and disconnect battery cables.
2. Remove large belt guard (three 5/16 inch bolts).
3. Adjust the eyebolt that anchors the idler spring to adjust belt tension. Tighten the eyebolt until the belt deflection at the center of the belt is 7/16" when a 20 lb.
load is placed against the belt (See Fig. # 9).
4. Replace belt guard.
5. Start engine and test belt for looseness.
Fig. #7
Page 116" & 8" Bear Cat Chipper Operators Manual
Service and Maintenance
5.4 REPLACING DRIVE BELTS 5.5 CLEARING PLUGGED ROTOR
1. Remove large belt guard (three 5/16" bolts).
2. Loosen bolts on hydraulic pump and remove belt, if
equipped.
3. Lift belt idler pulley off drive belt and remove drive belt
from pulleys.
4. Install new belt on pulleys and lower belt idler. Check
alignment of pulleys and adjust if needed.
5. Adjust the eyebolt that anchors the idler spring to adjust belt tension. Tighten the eyebolt until the belt deflection at the center of the belt is 7/16" when a 20 lb
load is place against the belt (See Fig. #9).
6. Replace hydraulic pump belt, if equipped. Readjust hydraulic pump belt tension by sliding the hydraulic pump
in the mounting slots. Tighten bolts.
7. Replace belt guard.
8. Depress foot clutch pedal, start engine, release foot
clutch pedal to engage belt, and test unit. Readjust
pulleys and belt tension if needed.
WARNING
If the machine becomes plugged, depress the foot
clutch pedal, shut off the engine, disconnect the spark
plug wire, and allow the machine to come to a complete
stop before clearing debris. Do not operate the machine
without proper guards and screens in place.
CAUTION
Remember to use rotor shaft lock when working on rotor.
Feeding too large or too much chipable material at once
may plug the chipper. To clear plugged rotor, proceed as
follows:
1. Depress foot clutch pedal and stop engine. Release
foot clutch pedal when engine is stopped.
2. Remove the two 3/8" retaining bolts holding the access
cover to the main frame assembly.
3. Lift up rotor access cover.
Fig.#8
4. Clean the debris out the chipper rotor. Turn the rotor by
hand to be sure it is free to rotate.
7/16" Deflection
5. Close rotor access cover and replace bolts.
6. Depress foot clutch pedal, and start engine. Release
foot clutch pedal when engine is running to engage drive
belt. Resume operation.
Page 12 6" & 8" Bear Cat Chipper Operators Manual
Service and Maintenance
5.6 REPAIRING OR REPLACING ROTOR BEARINGS
1. Remove the two 3/8 inch retaining bolts holding access
cover to main frame assembly. Tilt access cover over to
allow rotor access.
2. Remove large belt guard (three 5/16 inch bolts).
3. Lift belt idler pulley off drive belt and remove belt from
pulleys. Using the push bolts from the bushing, remove
the bushing and pulley from the rotor shaft.
WARNING
The rotor assembly has a lock mechanism. When working on the rotor assembly, use the lock mechanism at all
times. To use, remove plastic bearing cover under the
chipper chute. There is a hole in the rotor jack shaft and a
matching hole in the bracket mounted to the rotor bearing
front side. Install a punch through the rotor shaft and
bracket to lock the rotor in place.
11. Close cover and replace bolts.
12. Replace belt guard and resume operation.
13. Depress foot clutch pedal, start engine, release foot
clutch pedal to engage belt, and test unit. Readjust
pulleys and belt tension if needed.
14. On hydraulic units remove hydraulic pump and belts
prior to step 3 and replace prior to step 12.
5.7 GREASEABLE BEARINGS AND
PIVOTS
The models have five greaseable bearings and pivots that
require grease every 50 hours:
1. Two bearings on the rotor shaft.
2. One greaseable bushing on the foot clutch pedal pivot.
3. One grease zerk on idler pivot.
4. If a rotor bearing needs repair, it is best to remove the
complete rotor assembly from chipper frame.
5. Using an overhead hoist or lifting device, remove the
four 1/2 inch bolts on each rotor bearing and lift the rotor
assembly completely out of the frame. The complete
rotor assembly weighs 275 lbs.
6. Once the rotor assembly is out of the frame, both bearings can be removed by a puller and replaced on the
shaft.
7. Use the overhead hoist or lifting device to return the
complete rotor assembly to the chipper frame.
8. Install the four 1/2 inch bolts on each bearing to secure
them to the frame. Tighten bolts to 75 ft. lbs.
9. Replace drive belt on pulleys and lower belt idler. Check
alignment of pulleys and adjust engine if needed.
10. Check belt tension before start-up. Adjust the eyebolt
that anchors the idler spring to adjust the belt tension.
Tighten the eyebolt until the belt deflection at the center
of the belt is 7/16" when a 20 lb. load is placed against
the belt (See Fig. #8).
4. One grease zerk on discharge chute.
5.8 OTHER SERVICE TIPS
1. Service engine according to the Honda engine manual.
Change engine oil and filter as recommended in manual.
2. Every 10 hours of operation, all bolts and other fasteners should be checked for correct torque.
5.9 TRAILER SERVICE TIPS
1. Check wheel bolt torque every 10 hours of towing use.
2. Check air pressure in tires every 10 hours of towing.
Inflate to pressure marked on sidewall of tire.
3. Check and repack wheel bearings with grease every 12
months.
4. When towing, use a 2 inch trailer ball, and always connect the safety chains. Make sure trailer hitch bolts are
tight and secure.
Page 136" & 8" Bear Cat Chipper Operators Manual
Service and Maintenance
5.10 HYDRAULIC FLUID (MODELS
72620 & 74824)
Handle pressurized hydraulic fluid carefully. Escaping
pressurized hydraulic fluid can have sufficient force to
penetrate your skin causing serious injury. This fluid may
also be hot enough to burn. Serious infection or reactions
can develop if proper medical treatment is not
administered immediately.
Premium hydraulic fluids containing high quality rust,
oxidation, and foam inhibitors are required. These include
premium turbine oils, API CD engine oils per SAE J183,
M2C33F or G automatic transmission fluids meeting
Allison C-3 or Caterpillar TO-2, and certain specialty
agricultural tractor fluids.
5.11 PUMP COMPONENT LOCATIONS (MODELS 72620 & 74824)
5.12 HYDROSTATIC PUMP START UP
PROCEDURE (MODELS 72620 &
74824)
Follow this start-up procedure when starting a new
installation or when restarting an installation in which the
hydrostatic pump has been removed from the system.
1. Before starting the hydrostatic pump, make sure all
system components (reservoir, fittings, etc.) are clean.
2. Fill the reservoir with recommended hydraulic fluid, which
should be filtered before entering the reservoir.
3. The inlet line leading from the reservoir to the charge
pump must be filled before start-up. Loosen the fitting
on this inlet line until oil bleeds out.
WARNING
Do not start engine unless pump is in neutral position on
the cable.
Fig. #9
4. Start the engine and run at the lowest possible RPM.
5. As air is purged from the unit, the oil level in the reservoir will drop and bubbles may appear in the fluid. Refill
the reservoir as necessary.
6. Run the unit and move the control arm in both directions for several minutes until any remaining air is purged
from the unit. Refill the reservoir as necessary.
7. Check to ensure feed roller stops when control arm is in
the neutral position. Adjust the cable clevis or anchor if
the feed roller doesn't stop.
NOTE
A motor fitting may have to be loosened and oil bled to
remove air from the system (use same procedures as
steps 3-5).
8. Shut down the engine, check for and correct any fluid
leaks, and check the reservoir level. Add fluid if necessary. The hydrostatic pump is now ready for operation.
Page 14 6" & 8" Bear Cat Chipper Operators Manual
NOTE
Hydrostatic pressure controlled by the crossover relief
valve is factory set at 1750 PSI.
Service and Maintenance
5.13 HYDRAULIC FEED MAINTENANCE (72620 & 74824)
CAUTION
Before servicing or repairing any of the hydrostatic feed
components (pump, motor, and/or relief valve), contact
your dealer or factory service department. Warranty on
these items may be void without prior authorization.
CAUTION
Hydraulic systems contain fluid under high pressure.
Never check for leaks with your hands. Relieve pressure before disconnecting any hydraulic lines.
The hydrostatic pump normally does not require regular
fluid changes. The system filter should be changed at 250
hour or annual intervals. The fluid and filter should be
changed and system cleaned if the fluid becomes
contaminated with foreign matter (water, dirt, grease, etc.)
or if the fluid has been subjected to temperature levels
greater than the maximum recommended.
2. Fill the reservoir with recommended hydraulic fluid.
(Note: The hydraulic fluid must be filtered before before
entering the reservoir)
3. The inlet line leading from the reservoir to the charge
pump must be filled before start-up. Loosen the fitting
at the pump on the inlet line until oil bleeds out.
4. Start the engine and run at the lowest possible RPM.
5. Loosen the motor fittings until oil bleeds out to remove
air from the system. Retighten fittings.
6. As air is expelled from the unit, the oil level in the reser-
voir drops down and bubbles may appear in the fluid.
Refill the reservoir as necessary.
7. Run the feed roller in both directions for several minutes
until any remaining air is completely expelled from the
unit. Refill the reservoir as necessary.
8. Shut down the engine, check and correct any fluid leaks.
check. Check the reservoir level and add fluid if necessary. The hydrostatic pump is now ready for operation.
There is a greaseable bearing on each side of the main
jack shaft on the main hydraulic feed housing. Grease
periodically.
5.14 ADDING HYDRAULIC FLUID
Hydraulic fluid is used to drive the feed roller. The
hydraulic pump is attached to the motor (diesel models)
or connected to the motor with a belt (gasoline models).
Premium hydraulic fluids containing high quality rust,
oxidation, and foam inhibitors are required. These include
premium turbine oils, API CD engine oils per SAE J183,
M2C33F or G automatic transmission fluids meeting
Allison C-3 or Caterpillar TO-2, and certain specialty
agricultural tractor fluids.
Below are the necessary startup procedures:
1. Before starting the hydrostatic pump, make sure all system components (reservoir, fittings, etc.) are clean.
Page 156" & 8" Bear Cat Chipper Operators Manual
6
Troubleshooting
Section
6.1 GENERAL TROUBLESHOOTING
Problem Probable Cause Suggested Remedies
Rotor does not turn
Hard to feed chipper or
excessive power needed
to chip
Chipper requires
excessive power or stalls
Drive belts squealing or
smoking
Obstructed discharge
Plugged rotor Clear rotor
Obstructed discharge
Dull chipper blades Sharpen blades
Improper blade clearance Adjust clearance
Obstructed discharge
Plugged rotor
Green material will not
discharge
Plugged rotor Clear rotor
Loose or worn belts
Use branch or similar object
to clear discharge
Use branch or similar object
to clear discharge
Use branch or similar object
to clear discharge
Clear rotor, feed material into
shredder more evenly
Alternately feed dry material,
or allow material to dry
Adjust belt tension or replace
belts if needed
Drivehead vibration
Vibration while running
Rotor out of balance
Engine dies or runs
poorly
Page 16 6" & 8" Bear Cat Chipper Operators Manual
Engine problems Contact local Honda dealer
Check drive belts and pulleys
for bad or worn spots
Inspect rotor for broken or
missing chipper blades and
paddles. Repair if needed.
Check rotor to see if it
wobbles. Check to see if the
rotor is assembled correctly
Troubleshooting
6.2 HYDROSTATIC PUMP TROUBLESHOOTING MODELS 72620 & 74824
Symptom Probable Cause Suggested Remedy
Will not attain normal feed rate
Will not feed when control arm
is moved
Engine not operating at correct
speed.
Control linkage damaged or
binding.
Bypass valve stuck partially
open. (Problem in one direction
only.)
Control linkage damaged or not
connected
Drive between engine and
pump damaged
Pump low on fluid.
Loose belt between engine and
pump.
Repair engine governor
Repair control linkage.
Repair bypass valve. Remove
foreign material from valve.
Repair or reconnect control
linkage
Repair drive (replace broken
belt, repair sheared key, repair
splined coupling, etc.
Refill reservoir. Purge air from
transmission.
Tension drive belt (replace if
necessary).
Feed rate is sluggish under
load
Hydraulic feed will not pull in
logs over 4" in diameter, or
continuously stalls or stops
Pump low on fluid.
Large amount of water in
hydraulic fluid (evaporates
when hot resulting in low fluid
level).
Hydraulic system overloading
and causing system to go over
relief.
Refill reservoir. Purge air from
transmission.
Drain fluid from reservoir and
unit, replace filter element, and
refill with new fluid.
Check relief pressure in
system with a pressure gauge
rated to 2500 psi. (System set
by factory at 1750 psi.)
Page 176" & 8" Bear Cat Chipper Operators Manual
7
g
y
Specifications
Section
7.1 SPECIFICATIONS
Specifications
Overall size
(LxWxH)
Max. Chipper
Capacity
Chipper Blade
Qty.
Rotor Speed 1500 RPM 1500 RPM 1500 RPM
Rotor Size
Rotor Weight 275 lbs. 275 lbs. 275 lbs.
Rotor Shaft
Diameter
Dischar
Drive T
Wheel Base 66" 66" 66"
e Size 8" 8" 8"
pe Belt Belt Belt
Belt Size 3B83 3D83 3B83
Weight 1445 1865 1870
Model
71620
76x80x90" 93x80x90" 93x80x90"
6" 6" 8"
4
Reversible
Tool Steel
30" Dia. X
1.25"
1.75 1.75 1.75"
Model
72620
4
Reversible
Tool Steel
30" Dia.x
1.25"
Model
72824
4
Reversible
Tool Steel
30" Dia. X
1.25"
Tire Size 5.31-12 5.31-12 5.31-12
Fuel Tank Cap.
(Gal.)
Engine
Specifications are subject to change because of design
modifications.
Page 18 6" & 8" Bear Cat Chipper Operators Manual
666
Honda 20 HPHonda 20 HPHonda 24
HP
Specifications
7.2 BOLT TORQUE
CHECKING BOLT TORQUE:
The tables shown below give correct torque values for various bolts and capscrews. Tighten all bolts to the torques specified
in chart unless otherwise noted. Replace hardware with the same strength bolt.
SAE - 8SAE - 2ASAE - 5
ENGLISH TORQUE
Bolt
Diameter
1/4
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
1-1/8
1-1/4
METRIC TORQUE SPECIFICATIONS
Bolt
Diameter
SAE 2
7.5
15
27
44
67
95
135
240
240
360
510
725
A
Bolt Torque*
4.8
Bolt Torque*
5.5
11
20
32
50
70
100
175
175
270
375
530
9.5
25
44
70
110
155
215
375
625
925
1150
1650
SAE 5
8.8
9
18
33
52
80
115
160
280
450
675
850
1200
17
35
63
100
150
225
300
550
875
1300
1850
2600
SAE 8
10.9
12.5
26
46
75
115
160
225
400
650
975
1350
1950
12.9
M3
M4
M5
M6
M8
M10
M12
M14
M16
M18
M20
M22
M24
M27
Torque figures indicated above are valid for non-greased or non-oiled threads and heads unless otherwise specified. Therefore, do not grease or
oil bolts or capscrews unless otherwise specified in this manual. When using locking elements, increase torque values by 5%.
* Torque value for bolts and capscrews are identified by their head markings.
.5
3
5
6
15
29
50
80
125
175
240
330
425
625
.4
2.2
4
4.5
11
21
37
60
92
125
180
250
310
450
-
-
11
28
55
95
150
240
330
475
650
825
1200
-
-
-
8.5
20
40
70
110
175
250
350
475
600
875
-
-
17
40
80
140
225
350
475
675
925
1150
1700
-
-
12
30
60
105
165
255
350
500
675
850
1250
-
-
19
47
95
165
260
400
560
800
1075
1350
2000
-
-
-
14.5
35
70
120
190
300
410
580
800
1000
1500
Page 196" & 8" Bear Cat Chipper Operators Manual
Crary Company
A Division of TerraMarc Industries
237 12th St. NW P.O. Box 849
West Fargo, ND 58078-0849
(701)282-5520 FAX: (701)282-9522
www.bearcatproducts.com
www.terramarc.com
Manufactured in the
United States of America
by Crary Company
Gardening Suppl
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