Echo 72928 Owners Manual v.2

Chipper
and Hydraulic Feed

I

nstruction & Owners Manual

Chipper Models:

72928 (28 HP Diesel)
72942 (42 HP Ford)

Crary Company

Box 849
West Fargo, ND 58078
[phone] [phone]
FAX: [phone]

Manufactured in the

United States of America

by Crary Company

Cat. No. 16783

Manual No. 1196

B

EARCAT

Dear Bear Cat Customer,

Thank you for purchasing a Crary Bear Cat Chipper. The Bear Cat Chipper is
designed, tested, and manufactured to give years of dependable performance.
To keep your chipper 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 the chipper.

If you have any questions or comments about this manual, please call us toll­free at 1-800-247-7335.

If you have any questions or problems with your chipper, 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 chipper.
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: [phone]

H

OURS

M-F, 8 a.m. to 5 p.m.

Central Time

Owner's Record

Please take a moment to record the following
information about your chipper. If you need to
call for assistance, please be ready to provide
your model and serial numbers. This
information will allow us (or your dealer) to
help you more quickly when you call.

Model Number

Serial Number

This safety alert symbol identifies important safety messages in this manual.
When you see this symbol, be alert to the possibility of personal injury and
carefully read the message that follows.

Serial Number Decal Location

Serial Number Decal

Be alert! Your Safety is Involved.

W

ARRANTY

Chipper and Hydraulic Feed Limited Warranty

Crary Bearcat Chipper models 72928 and 72942 are warranted for one year from date of sale.
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 which 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 Bearcat
service dealer using Bearcat approved replacement parts. Repair or attempted repair by anyone other than an
authorized Bearcat 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 which vary
from state to state.

Be sure to note the Chipper serial number in any correspondence with Crary Co. or any authorized Bearcat
dealer. The serial number is located on the rotor assembly cover.

Warranty

Contents

Section 1: Safety Instructions................................... 2

1.2 Safety Decals....................................................................................4

Section 2: Assembly, Controls, and Operation ....... 5

2.1 Assembly ..........................................................................................5

2.1.1 Attach the Trailer Wheels ............................................................ 5

2.1.2 Attach the Pintle Hitch.................................................................. 5

2.1.3 Attach the Chipper Chute............................................................. 6

2.1.4 Attach the Chute Extension Tray ................................................. 6

2.1.5 Attach the Blower Discharge Tube .............................................. 6

2.1.6 Connect the Control Cable........................................................... 6

2.1.7 Adjusting the Hydrostatic Control Cable ...................................... 7

2.1.8 Before Using ................................................................................ 8

2.1.9 Hydraulic Fluids ........................................................................... 8

2.1.10 Prepare Hydraulic System ......................................................... 8

2.2 Identification......................................................................................9

2.3 Operation........................................................................................ 10

2.3.1 Starting: 28 HP Kubota Model ................................................... 10

2.3.3 Starting: 42 HP Ford Model ....................................................... 11

2.4 Chipping ......................................................................................... 12

2.5 Stopping Instructions ......................................................................12

2.6 Automatic Feed Sensor ..............................................................13,14

C

ONTENTS

Section 3: Service and Maintenance ...................... 15

3.1 Sharpening Chipper Blades ............................................................ 16

3.1.1 Chipping Blade Sharpening Tips .............................................. 16

3.1.2 Setting Chipping Blade Clearance ............................................. 17

3.1.3 Adjusting Drive Belt.................................................................... 17

3.1.4 Replacing Drive Belt .................................................................. 17

3.1.5 Clearing Plugged Rotor.............................................................. 18

3.1.6 Repairing or Replacing Rotor Bearings ..................................... 18

3.1.7 Greaseable Bearings ................................................................. 19

3.1.8 Trailer Service Tips .................................................................... 1 9

3.2 Hydraulic Feed Maintenance .......................................................... 19

3.3 Hydrostatic Pump Troubleshooting .................................................19

Troubleshooting ........................................................ 20

Specifications............................................................ 21

Warranty

1

S

ECTION

1

Safety Instructions

This chipper is designed and tested to offer
reasonably safe service. However, failure to
operate it in accordance with the following

safety instructions MAY RESULT IN PERSONAL

INJURY!

Before Operating

1. Become familiar with the owner's manual before
attempting to operate this equipment. See engine
owner's manual for additional safety information.

2. Do not allow children to operate this equipment.

3. Do not operate this equipment in the vicinity of
bystanders.

4. Carbon monoxide can be extremely dangerous in
enclosed areas; do not run the machine in an
enclosed area. The exhaust from the engine contains
carbon monoxide, which is colorless, odorless, and
tasteless.

5. Do not allow hands, or any part of body or clothing,
inside the feeding chamber, discharge chute, or near
any moving part.

6. Before inspecting or servicing any part of the
machine, shut off the engine, and make sure all
moving parts have come to a complete stop.

Preparation

1. Obtain and wear safety glasses at all times while
operating the machine. One pair of safety glasses is
provided with each chipper.

2. Avoid wearing loose-fitting clothing. Never operate
this machine wearing loose clothing particularly if
it has drawstrings which could wrap around or get
caught in the machine.

3. Operate the machine only on a level surface. Do
not operate the machine on a paved, concrete, or
hard gravel surface. Operating on a hard surface
may cause discharged material to rebound and
kickback. It will also cause increased machine
vibration. Increased vibration may cause the ma­chine to move and will promote premature wear of
parts or loosening of fasteners.

4. Before starting the machine, visually check that all
screws, nuts, bolts, and other fasteners are properly

secured. Once every 10 hours of operation, all
screws, nuts, bolts, and other fasteners should be
checked for proper tightness to insure everything is
in proper working condition.

Operation

One of the critical moments in job safety, as well as
chipper safety, is setting up your chipping site so you
are not endangered by traffic and the public is not
endangered by your work. Great care must be taken to
provide adequate warning by way of singage and
coning, if it is necessary to divert vehicle or pedestrian
traffic.

A well-prepared traffic plan should include parking off
the highway whenever possible. The work area should
be coned off as soon as the chipper vehicle is stopped.
Avoid sudden traffic stoppage or lane devirsion. Do not
allow pedestrians to walk through the work area. Make
sure chips or dust do not blow into traffic, parked cars,
or pedestrians.

1. Before starting the machine, make certain that the
cutting chamber is empty .

2. When feeding chipable material into the machine,
be extremely careful to exclude pieces of metal,
rocks, bottles, cans, and other foreign objects.

3. If the cutting mechanism strikes any foreign object
or if the machine should start making an unusual
noise or vibration, immediately shut off the engine,
and allow the machine to come to a complete stop.
After machine stops:

a) Inspect for damage.
b) Replace or repair any damaged parts.
c) Check for and tighten any loose parts.

4. Every 10 hours of operation, check the bolts on the
following for correct torque (75 ft. lbs.):

• Hydraulic feed roller bearing

• Hydraulic motor mounting

• Chipper rotor bearing

• Chipper blades

• Rotor paddles

2

S

ECTION

1

• Chipper anvil
Failure to maintain proper fastening torque (75 ft.

lbs.) on bolts for the components listed above may
result in severe damage to the chipper and/or
personal injury!

5. Do not allow processed material to build up in the
discharge area; this may prevent proper discharge
and can result in kickback of material through the
feed opening.

6. Do not attempt to operate the chipper with any of
the guards, deflectors, or shrouds removed. Keep
away from moving parts.

7. Keep all guards, deflectors, and shrouds in good
working condition.

8. Always stand clear of the discharge area when
operating this machine.

9. Keep your face and body back from the feed opening.

10. Do not overreach. Keep proper balance and footing
at all times.

it. This will prevent the discharge tube from
projecting over the trailer wheels and striking
foreign objects.

2. Always connect hitch safety chains. Make sure

trailer hitch bolts are tight and secure. Do not
attempt to attach the pintle hitch to a ball type
vehicle hitch.

3. Maximum towing speed should not exceed 55
M.P.H. Inflate tires to manufactures specs. as stated
on the tire sidewall. Check wheel lug bolts periodi­cally to be sure they are tight and secure.

4. Make sure that 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 secure it in the
DOWN position before use.

5. Never allow passengers to ride on the infeed chute
while the vehicle is moving, whether the chipper is
running or not.

Maintenance and Storage

11. Do not transport or move machine while the ma­chine is running.

12. If the machine becomes clogged, shut off engine.
Allow machine to come to a complete stop before
clearing debris.

Additional Safety Rules for Towing

1. Before towing, rotate the discharge tube to face in
the opposite direction of the vehicle that is towing

The Standard muffler installed on the

chipper engine does not include a spark
arrestor. If this machine is to be used in an
area where a spark arrestor is required by
law, one will have to be added before use.
Contact the local authorities to see if these
laws apply to you. See your authorized
engine dealer for spark arrestor options.

1. When this equipment is stopped for servicing,
inspection, storage, or to change an accessory, make
sure that the key is removed from key switch.
Disconnect battery.

2. Store the machine out of the reach of children and
where fuel vapors will not reach an open flame or
spark. For storage periods of three months or more,
drain the fuel and dispose of it in a safe manner.
Always allow the machine to cool before storing.

3

S

ECTION

1

PN 17423

PN 16085

Safety Decals
Safety and instruction decals are located on the chipper frame and engine. Replace any
decal that is damaged or unreadable.
Call dealer for information on decals in Spanish, French, or other languages. For location
of safety decals on the chipper frame, see parts drawings and lists in section 4.
NOTE: For engine safety and instruction decals, see engine owner's manual or contact the
engine manufacturer.

PN 16558

PN 17846

PN 16551

PN 12010

4

Assembly

S

ECTION

2

Your chipper may arrive totally or partially assembled.
If your chipper arrives partially assembled, you may
need to perform the steps in this section.

2.1.1 Attach the Trailer Wheels

1. Remove the chipper from its shipping crate. Place
the unit on a level surface before attempting to
assemble it. See the Torque Chart at the bottom of
this page for minimum tightening torque of bolts
and screws.

2. Raise the trailer several inches from the ground
with a hoist or jack. Make sure that the chipper is
supported securely.

3. Hold one wheel up to a hub and align the wheel lug
holes with the hub lug holes (see figure 2.1). Thread
the lug bolts into the holes and tighten the lug bolts
to 75 ft lbs. Follow a star pattern when tightening
the lug bolts. Repeat this step for the remaining
wheel.

2.1.2 Attach the Pintle Hitch

1. Insert the adjustable hitch into the hitch opening in
the chipper trailer. Insert a 3/8" x 2" bolt through
the bolt hole in the adjustable hitch as shown in
figure 2.1. Place the end link in the safety chain
welded to the chipper trailer over the 3/8" bolt end.
Secure the chain with a washer and nut.

2. Attach the pintle hitch eye to the adjustable hitch
with 5/8" x 2" bolts, washers, and nuts. Torque the
bolts to 90 ft. lbs.

3. Connect the safety chains to the adjustable hitch
weldment as shown in figure 2.1. Use a 3/8" x
2-1/2" bolt, washers, and nut to attach the two
safety chains with hooks as shown.

4. Push the top link pin through the holes in the hitch
and trailer. Secure the top link pin with a lynch pin.

Adjust the hitch to make the chipper trailer as level as
possible when connected to the towing vehicle.

Top Link Pin

Lynch Pin

Figure 2.1

Adjustable

Hitch

Weldment

Pintle Eye

3/8" x 2"

Bolt

3/8" x 2-1/2"

Bolt

Torque Chart

Standard minimum tightening
torque for normal assembly
applications.

Bolts (SAE GR5)

Size Ft. Lbs.

5/16" 20
3/8" 35
1/2" 75
5/8" 90

Screws

Size Ft. Lbs.

5/16" Set 15

5

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ECTION

2

2.1.3 Attach the Chipper Chute

Do not operate this unit without the chipper chute
correctly installed. Rotating cutting blades can

cause serious personal injury.
Mount the chipper chute to the hydraulic feed using

eight 3/8" x 1" bolts and locknuts. To insert the top
bolts, you may need to temporarily lift the grab roller
with a pry bar. Use three bolts on each side and two on
the bottom (see figure 2.2).

2.1.4 Attach the Chute Extension Tray

1. After mounting the chute to the hydraulic feed, slide
the chute extension tray over the chipper chute as
shown in figure 2.3. Make sure that you position

the lip on the extension tray behind the lip on the
chipper chute. Align the five bolt holes in the chute

extension tray with the bolt holes in the hinge.

2. Insert five 3/8" x 1" carriage bolts (included in
owner's kit packaged with the chipper) through the
tray and the extension hinge. Secure the bolts with
washers and nuts. Secure with hairpin clips.

2.1.5 Attach the Blower Discharge

Tube

Attach the blower discharge tube to the mounting flange
on the chipper frame (see figure 2.4). 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.

Hairpin

Clip

Extension Tray

Hydraulic

Feed

Chipper
Chute

Figure 2.2

Position this lip

▲▲

▲

▲▲

behind the lip on
the chipper chute
shown below.
Hold the extension
tray directly above
the chipper chute
and slide it
downward.

2.1.6 Connect the Control Cable

1. Remove the clevis assembly from the hydrostatic
control cable end (see figure 2.5). Remove one nut
on the cable end. Insert the cable end into the hole
in the cable anchor weldment. Replace the nut and
the clevis assembly.

2. Attach the clevis assembly to the center hole on the
feed control lever.

3. Adjust the cable detent ball to hold the control arm
is in the forward position or neutral position
detents.

6

Feed

Control

Lever

▲

▲▲

▲▲

Extension
Hinge

Chipper
Chute

Figure 2.3

▲▲

▲

▲▲

2.1.7 Adjusting the Hydraulic
Feed Control Cable

S

ECTION

2

Blower Discharge Tube

Mounting Clamp

Mounting Flange

Figure 2.6 shows the hydraulic feed control cable
assembly and the detent position slots. The cable
is attached and adjusted from the factory, but it
should be checked and adjusted as needed before
use. The hydraulic feed control lever has three
positions:

Forward (lever moved toward the operator)
Neutral (lever in center position)
Reverse (lever moved away from operator;

reverse has no detent position)
When the operator moves the control lever to the

neutral position, the detent ball should be
positioned in the rear detent slot (see figure 2.6).
The feed roller should come to a complete stop
when the control lever is in the neutral position. If
it does not stop, adjust the clevis assembly on the
control cable as follows:

1. If the control lever is in neutral and the roller
creeps forward, the cable is too short; adjust it
to a longer length.

Insert cable
through hole

Figure 2.4

Clevis
AssemblyNut

Detent
Ball

Feed
Control
Lever

Cable
Anchor
Weldment

Hydrostat
Control
Cable

2. If the roller creeps in a reverse direction, the
cable is too long; adjust it to a shorter length.

3. Adjust the cable as needed to
compensate for cable stretch.

Clevis Assembly

▲

Neutral
Detent

▲

Adjust cable here as needed.

Chipper Chute

Forward
Detent

Figure 2.5

Figure 2.6

7

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ECTION

2

2.1.8 Before Using

1. Install battery (not included: use group 22F 300
CCA min), connect positive and ground battery
cables, and check battery condition. Charge if
needed. Note:If needed, a larger group UB72
battery may be used.

Use caution when connecting battery cables near
fuel. A spark could ignite the fuel and cause a fire.

2. Fill the engine with oil (per instructions in supplied
engine manual) and fill the fuel tank with fuel.

Important! See instructions below, for hydrostatic
pump start-up procedure.

2.1.9 Hydraulic Fluids

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.

Warning! Do not start engine unless pump is in
neutral or detent position on the cable.

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 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 feed roller in both directions for several
minutes until any remaining air is purged from the
unit. Refill the reservoir as necessary.

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.

Hydrostatic pressure controlled by the crossover relief
valve is factory set at 1750 PSI. A 2000 PSI shim kit is
available for extreme conditions.

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.

2.1.10 Prepare Hydraulic System

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.

The flow from the reservoir to the hydrostatic pump and
the flow returning from the hydrostatic pump are always
the same. Hydraulic fluid can flow either direction
between the hydrostatic pump, crossover relief valve,
and motor. Refer to page 21 for the hydraulic Schematic.

1. Before starting the hydrostatic pump, make sure all
system components (reserv oir, fittings, etc.) are clean.

2. Fill the reservoir with recommended hydraulic
fluid, which should be filtered before entering the
reservoir.

Figure 2.7 Pump-Component Locations

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 this inlet line until oil
bleeds out.

8

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ECTION

2

2.2 Identification

1. Extension T ray: Assists in f eeding chipping

material. Folds for towing.

2. Feed Control Lever: Move the arm forward to

increase the feed rate. Push back to reverse the feed.

3. Chipper Chute: Feeds materials to the chipper

blades for chipping.

4. Discharge Tube: Chipped material exits through

this tube. Tube is adjustable 360 degrees.

5. Drive Belt Shield: Never remove shields when in

use.

6. Control Panel: Contains the key switch, throttle

control, Murphy switch, gauges, and choke control
(gas engine models only).

7. Fuel Tank: Fuel level indicator is located on top.

8. Pintle Hitch: Always use safety chains when

towing chipper.

9. Pivoting Tongue Jack: Always have in UP posi-

tion and clear from ground when moving. When in
use, place in DOWN position on a level surface.
Turn handle to raise or lower wheel.

10. Battery: (Not included.) Use group 22F 300 CCA

min.

11. Clutch Foot Pedal: Used to engage rotor assembly

drive belt.

4

NOTE: Your chipper
may be different

3

2

because of design
modifications at the
time of production.

1

5

7

8

11

6

10

9

9

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ECTION

2

2.3 Operation

2.3.1 Starting: 28 HP Kubota Model

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.

1. Before starting, fill engine with oil to the correct

level. See engine manual for additional starting,
operation, and maintenance instructions.

NOTE: Some oil usage is normal. Check level with
each use.

WARNING: Handle fuel with care. It is highly
flammable. Always use an approved container

and fill tank outdoors.

2. Before starting, fill fuel tank with fresh, clean diesel

fuel. For instructions on bleeding the fuel system on
initial start up or if fuel runs out, see engine manual.

drive belt and the rotor will turn. If the engine kills
when engaging the drive belt, release foot clutch
pedal more slowly.

10. When clutch is engaged, the foot pedal may vibrate
or shake until the engine and rotor have increased to
full running RPM (3000 RPM).

Do not move chipper during operation.
CAUTION: Obtain and wear safety glasses at all

times when operating the machine. Do not wear

loose fitting clothing. Use common sense and
practice safety to protect yourself from branches, sharp
objects and other harmful objects.

WARNING: Do not leave machine unattended or
attempt any inspection or service unless the engine
is stopped and the key switch is in OFF position.

CAUTION: See operation/start-up decal by foot
clutch pedal on machine before starting.

3. Turn key switch to preheat position. Hold in preheat
position for several seconds until glow plug indica­tor light switches off.

4. Push throttle control in until it stops.

5. Depress foot clutch pedal, this will disengage drive belt
and enable engine to start.

6. Push in and hold Murphy switch push-button.
Continue to hold Murphy switch in when cranking
engine until engine is running.

7. Activate the starter switch. Release the switch as
soon as the engine starts. Do not crank over for
more than 10 seconds. Release Murphy switch after
engine is running; hold murphy switch in longer if
engine immediately kills after releasing.

Note: The Murphy switch system will shut the engine
off if the oil pressure is too low or if the engine
temperature is too high. If the engine will not run or
shuts of for these reasons, consult your local dealer.

Throttle

Murphy

Glow Plug

Indicator

No Charge

Indicator

Switch

Hour Meter
(Optional)

Temperature
Gauge

Pressure
Gauge

Key Switch

8. Push center throttle control button in. Increase
throttle control to full throttle. Turn throttle control
knob clockwise to achieve maximum RPM.

9. Slowly let foot clutch pedal up. This will engage

10

28 HP Kubota Chipper Control Panel

S

ECTION

2

2.3.3 Starting: 42 HP Ford Models

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.

1. Before starting, fill engine with oil to the correct

level. See engine manual for additional starting,
operation, and maintenance instructions.

NOTE: Some oil usage is normal. Check level with

each use.

WARNING: Handle gasoline with care. It is
highly flammable. Always use an approved container
and fill tank outdoors.

2. Before starting, fill fuel tank with fresh, clean

unleaded regular gasoline.

CAUTION: See operation/start-up decal by foot
clutch pedal on machine before starting.

3. Pull choke control out until it stops.

9. Push choke control in after engine is running
smoothly. After a short shutdown, full choke may
not be necessary. If engine fails to start, use partial
choke.

9. Slowly let foot clutch pedal up. This will engage
drive belt and the rotor will turn. If the engine kills
when engaging the drive belt, release foot clutch
pedal more slowly.

10. When clutch is engaged, the foot pedal may vibrate

or shake until the engine and rotor have increased
to full running RPM (3000 RPM).

Do not move chipper during operation.
CAUTION: Wear safety glasses at all times

when operating the machine. Do not wear loose fitting
clothing. Practice safety to protect yourself from

branches, sharp objects and other harmful objects.
WARNING: Do not leave machine unattended or

attempt any inspection or service unless the engine is
stopped and the key switch is in OFF position.

4. Push center throttle control button in. Position the
throttle control 1/3 of the distance between no
throttle and full throttle.

5. Depress foot clutch pedal, this will disengage drive
belt and enable engine to start.

6. Push in and hold Murphy switch push-button.
Continue to hold Murphy switch in when cranking
engine until engine is running.

Note: The Murphy switch system will shut the engine
off if the oil pressure is too low or if the engine
temperature is too high. If the engine will not run or
shuts off for these reasons, consult your local dealer.

7. Activate the starter switch. Release the switch as
soon as the engine starts. Do not operate the starter
for periods longer than 10 seconds at a time. If unit
does not stay running, repeat steps 5, 6, and 7 until
the engine is running smoothly. Release the Murphy
switch after engine is running; hold murphy switch
in longer if engine immediately kills after releasing.

8. Push center throttle control button in. Increase
throttle control to full throttle. Turn throttle control
knob clockwise to achieve maximum operating
RPM (3000 RPM). If needed, the collar on the cable
can be rotated to lock the cable in position.

Choke

Hour Meter
(Optional)

No Charge
Indicator

Temperature
Gauge

Throttle

Murphy

Switch

Pressure
Gauge

Key Switch

Ford Engine Chipper Control Panel

11

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2

2.4 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.

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!

1. Be sure the unit is at full operating speed before you

start to chip material.

2. Select limbs that are up to 9 inches in diameter.

Trim side branches that cannot be bent enough to
feed into the chipper chute. Small diameter
branches can be held together in a bundle and fed in
simultaneously.

3. Feed brush from the side of the infeed chute, rather

than from the front. Then, step aside to avoid being
hit by the brush moving into the chipper.

4. Never lean over the infeed chute to push objects

into the cutting device. Use a push stick or brush
paddle.

5. Never use shovels or forks to push brush. They can

go through the chipper, are expensive to replace and
cause major damage. In addition, metal pieces can
come back like shrapnel to injure or kill.

6. Never push brush into the infeed chute with your

feet.

to full speed.

9. 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.

Alternately insert and retract the limb or insert
continuously at a rate that will not kill the engine.

Chipping dead, dry material will create heat and
dull the chipping blades quickly. Alternate greener
material with dry material to lubricate the chipping
blades for longer life and better performance. When
the chipping blades become dull, they will require
periodic sharpening. Refer to Service and Mainte­nance, "Sharpening Chipper Blades."

Stopping Instructions:

1. Move throttle to slowest position.

2. Depress foot clutch pedal.

3. Turn key switch to off position.

4. Allow machine to come to a complete stop. 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. You can tell that the rotor has
stopped when no noise or machine vibration is present.

WARNING: Do not leave machine unattended, or
attempt any inspection or service unless the engine is
stopped and the key is removed from key switch.

7. Engage the hydraulic feed by moving the control
arm. Pull the arm toward you to engage the hydrau­lic feed (see figure 2.9). In the forward direction,
the feed rate increases as the arm is moved.

8. Place limb, butt end first, into the chipper chute
until it contacts the hydraulic feed roller and is
drawn into the chipper blades. The actual feed rate
of the limb into the chipper will depend on the type
of material fed, and sharpness of the cutting blades.

If the engine slows to where it may stall, push the
control lever inwards to slow or stop the material
feeding and allow the engine to recover. Pull the
lever out to restart feeding when the engine is back

12

Reverse

▲▲

▲▲

▲

Neutral

Figure 2.9

▲

▲▲

▲▲

Forward

Feed Control
Lever

Electronic Feed Sensor:Installation Instructions for

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ECTION

2

Models 928 & 942

1. Remove belt guard.
*If serial number is equal to or greater to 19317 skip

to step 9.

2. Losen hydraulic pump mount and remove pump

drive belt.

3. Remove chipper drive belt.

4. Remove the pump and chipper-driven pulley from

the rotor shaft.

5. Replace collar, shown below, with

the sprocket and collar
weldment supplied with the
valve kit.

6. Replace the chipper-driven

pulley and

10. Mount the speed switch bracket to the center bolt
in the chipper base.(Ref #6)

11. Replace the crossover relief valve with the new
valve suppled with the valve kit. (Serial number
less than 19317 only)(Ref #3)

12. Remove outer and inner plugs
from the relief valve. Install
the soliniod cartridge valve and

coil so that the wires lead

down.(Metal side of

valve coil towards relief
valve).

13. Connect the solenoid
valve and sensor to the
speed switch and attach
the ground wires to the
frame. Route positive to
engine. (See wiring
diagram)(Ref #4)

pump pulley.

Note: To maintain the chipper rotor
position, push the chipper pulley bushing
tight against the collar and the collar tight
against the rotor bearing before tightening.

7. Replace the chipper drive belt.

8. Replace the pump drive belt, position the
pump to tension the belt, and tighten the
pump mount.

9. Attach the sensor and bracket under one of
the rotor bearing bolts so that it lines up with
the sprocket teeth.(Pickup should be approxi­mately .020" from the teeth of the sprocket.
See Figure 1.)

14. Mount speed switch
and route wires according
to wiring diagram.

15. Attach cover over
speed switch with two
self tapping screws.

16. Replace the belt
guard.

17. Attach the chipper to
the tow vehicle.

13

S

ECTION

2

and attach the ground wires to the frame. Route positive

to engine. (See wiring diagram)(Ref #4)

14. Mount speed switch and route wires according to
wiring diagram.

15. Attach cover over speed switch with two self
tapping screws.

16. Replace the belt guard.

17. Attach the chipper to the tow vehicle.

18. Operate the chipper per manual instructions.

NOTE: When approaching the end of a log, it might be necessary
to manually override the automatic feed sensor. Be sure to pay
attention to the engine speed and feeding of the material.

Operation of the Electronic Feed
Control

When the speed switch senses that the chipper rotor
has slowed to a certain preset level, the speed switch
will open the crossover valve and allow the oil to
return to the tank.

Operate the chipper as instructed in the chipper
manual. The feed control will start and stop the feed
roller automatically. To maximize performance, there
are two adjustments on the Speed Switch to tailor the
unit to your specific engine and needs..

1.The Setpoint screw is used to determine the engine

RPM that the switch opens and halts the feed.

The setpoint screw is used to adjust the RPM that
the feed roller turns off. Turning the screw clock­wise will increase the speed setting.(This is a very

Figure 1

fine adjustment. it is not recommended to go over
1/2 a turn each adjustment.)

It is recommended to have this set so that the roller
shuts off when the engine speed is slightly higher than
the maximum torque speed of the engine.

2. The Hysteresis is used to determine the amount of
recovery time the engine is allowed. This is directly
related to the Setpoint setting.

Turning the screw clockwise will increase the
speed between when the roller stops and when it
turns on.

It is recommended to have this set at the minimum by
turning the screw counter clockwise approximately 10
turns.(It you don't seem to be getting any adjustment,
you have turned adjustment to end of its range.)

14

Service and Maintenance

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ECTION

3

Inspection Items

Check Nuts & Bolts

Engine Oil Level

Change Engine Oil

Replace Oil Filter Cartridge

Check Hydraulic Fluid Level

(3 Gallons)

Replace Air Filter Element

Replace Fuel Filter

Before

Each Use

Every

10

Hours

Every

25

Hours

Every

50

Hours

Interval

Every

100

Hours

Every

200

Hours

Every

400

Hours

Every

800

Hours

Every

1

years

Check Sharpness of Chipper Blades

Grease Bearings and Pivots

Check Bolts: Chipper Blade, Feed Roller,

Chipper Anvil, Rotor Paddles

Check Drive Belt

Hydraulic Control Cable

(Feed Roller)

Check Water Level

Clean Machine

Indicates first hours of use.

15

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ECTION

3

Service and Maintenance

WARNING: Before inspecting or servicing any

part of the machine, shut off the engine, 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.

WARNING: The rotor assembly has a lock

mechanism. When working on the rotor assembly,
use the lock mechanism at all times. Remove the plastic
bearing cover beside the chipper chute. There is a hole
in the rotor 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.

Check the engine oil, and change the oil and filter as
recommended in the manual. Service and replace the air
cleaner as recommended.

3.1 Sharpening Chipper
Blades

The chipper blades will eventually become dull, making
chipping difficult. It is recommended that the chipper
blades are sharpened every 5-15 hours of chipper
operation. To remove the chipping blades for
sharpening:

1. Remove the two 3/8 inch retaining bolts holding

access cover to main frame assembly.

2. Tilt access cover over to allow rotor access. Rotate

the rotor so that the bolts holding a chipping blade
are most accessible.

and cool with water. Try to remove an equal amount off
each blade to maintain balance. Replace the chipping
blades and tighten bolts to 75 ft. lbs. Close cover and
replace bolts.

3.1.1 Chipping Blade Sharpening
Tips

Poor chipping performance is usually a result of dull
chipping blades. If your chipper's performance has
decreased, check for the following symptoms:

• Severe vibration when feeding material into the
chipper.

• Small diameter branches do not self-feed.

• Chips discharge unevenly or have stringy tails–
especially when chipping green branches.

Before you sharpen the chipping blades, check for
permanent damage. Replace the blade if:

• The blade is cracked (especially around the bolt
holes) or the edges are too deeply chipped to be

Sharpening

Edges

⋅⋅

45

⋅

▼▼

▼

▼▼
▲▲

▲

▲▲

0.38

▼▼

▼

▼▼

Figure 3.1

⋅⋅

▼▼

▼

▼▼

3. Remove the two allen 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. If both
sides have not been used, remove and reverse the
chipping blades. Reinstall chipping blades and
proceed with chipping.

To grind the angled edge of the chipping blade to 45
degrees (see figure 3.1): Grind the blades on a slow­speed wet grinder if possible, or have them sharpened
by a professional. If you use a bench grinder, be careful
when grinding so that the blade material does not get
too hot and change color–this will remove the blade's
special heat treated properties. Use short grinding times

16

Figure 3.2

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ECTION

3

ground smooth.

• The base of the cutting edge is worn or has been re-

sharpened so that it is too close to the rotor chipping
slot.

3.1.2 Setting Chipping Blade
Clearance

The four chipping blades should clear the chipper anvil
located directly under the chipper chute by 1/16 inch to
1/8 inch. The chipper anvil is adjustable and reversible.

To adjust:

1. Lift rotor access cover and expose rotor (see figure

3.2). Loosen the three 1/2 inch bolts that hold the
chipper anvil to the frame (see figure 3.3).

2. Measure the amount of clearance between chipping

blade and chipper anvil from inside of housing.

3. Adjust inward or outward to desired measurement.

4. Tighten bolts on chipping block to 75 ft. lbs. and

resume operation.

If chipper 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.

3.1.3 Adjusting Drive Belt

Check the condition of the drive belt annually or after
every 25 hours of operation, whichever comes first. If
the belt is cracked, frayed, worn, or stretched, replace it.
Only replace belt with original banded 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 the belt tension. Tighten the eyebolt until the
belt deflection at the center of the belt is 7/16"
when a 20 l b . load is placed against the belt (see
figure 3.4).

4. Replace belt guard.

5. Start engine and test belt for looseness. Replace the
belt if no adjustment is left.

3.1.4 Replacing Drive Belt

1. Remove large belt guard (three 5/16" bolts).

2. Loosen bolts on hydraulic pump and remove belt.

Chipper Anvil

Rotor Housing

Spacer

Figure 3.3

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. 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

7/16" Deflection

(20 lbs.)

Figure 3.4

17

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ECTION

3

20 lb. load is placed against the belt (see figure 3.4).

6. Replace hydraulic pump belt. 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.

3.1.5 Clearing Plugged Rotor

WARNING: If the machine becomes plugged,

depress foot clutch pedal, shut off the engine, 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.

Feeding 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.

4. Clean the debris out of the chipper rotor. Turn the

rotor by hand to be sure it is free to rotate.

DANGER: Blades are sharp; avoid contact with
chipper blades.

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.

remove the bushing and pulley from the rotor shaft.

WARNING: The rotor assembly has a lock mecha-

nism. When working on the rotor assembly, use the
lock mechanism at all times. 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.

5. Remove the four 1/2 inch bolts on each rotor

bearing and remove the punch used to lock the
rotor.

6. Using an overhead hoist or lifting device, lift the

rotor assembly completely out of the frame. The
complete rotor assembly is 275 lbs.

7. Once the rotor assembly is out of the frame, remove

3/8" bolts and collar from front. Remove both
bearings with a puller and place new bearings on
rotor shaft. Replace collar.

8. Use the overhead hoist or lifting device to return the

complete rotor assembly to the chipper frame.

9. Slide rotor back until front collar is tight against

the front bearing. Lock the front bearing and install
the four 1/2 inch bolts on each bearing to secure
them to the frame. Tighten bolts to 75 ft. lbs. Check
and adjust chipper anvil if needed. Lock rear
bearing.

10. Slide rear collar on shaft against rear bearing. Slide

bushing onto shaft with flange against collar and
lock bushing to shaft. Attach large pulley to bush­ing. Replace drive belt on pulleys and lower belt
idler. Check alignment of pulleys and adjust engine
if needed.

3.1.6 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. Loosen bolts on hydraulic pump and remove
hydraulic pump belt. Using the push bolts from the
bushing, remove the bushing and pulley from the
rotor shaft.

4. Lift belt idler pulley off drive belt and remove belt
from pulleys. Using the push bolts from the bushing,

18

11. 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 figure 3.4,
page 15).

12. Close cover and replace bolts.

13. Replace hydraulic pump bushing and pulley.
Replace hydraulic pump belt. Readjust hydraulic
pump belt tension by sliding the hydraulic pump in
the mounting slots. Tighten bolts.

14. Replace belt guard and resume operation.

S

ECTION

3

15. Depress foot clutch pedal, start engine, release foot
clutch pedal to engage belt, and test unit. Readjust
pulleys and belt tension if needed.

3.1.7 Greaseable Bearings and

Pivots

The chipper has five greaseable bearings and pivots that
require grease every 50 hours:

• Two bearings on the rotor shaft.

• One greaseable bushing on the foot pedal pivot.

• One grease zerk on idler pivot.

• One grease zerk on discharge chute.
Service engine according to engine manual. Change

engine oil and filter as recommended in manual.

3.1.8 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.

3. Check and repack wheel bearings with grease every
12 months.

4. When towing, always connect the safety chains.
Make sure trailer hitch bolts are tight and secure.

5. Check trailer lights.

3.2 Hydraulic Feed

Maintenance

NOTE: Check the reservoir daily for proper fluid level,
the presence of water (noted by a cloudy to milky
appearance, or free water in bottom of reservoir), and
rancid fluid odor (excessive heat).

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.

There is a greaseable bearing on each side of the shaft
on the hydraulic feed housing. Grease periodically.

3.3 Hydrostatic Pump Troubleshooting

Symptom

Will not attain normal feed
rate.

Will not feed when control arm
is moved.

Feed rate is sluggish under
load.

Hydraulic Feed will not pull in
logs over 4" in diameter, or
continuously stalls or stops.

Probable Cause

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 drive belt between
engine and pump.
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.

Suggested Remedy

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).
Refill reservoir. Purge air from
transmission if necessary.
Drain fluid from reservoir and
unit, replace filter element,
and refill with new fluid.
Check relief pressure in sys­tem with a pressure guage
rated to 2500 psi. (System set
by factory at 1750 psi.)

Caution: Hydraulic systems contain
fluid under high pressure. Never check
for leaks with your hands. Relieve
pressure before disconnecting any
hydraulic lines.

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.

19

T

ROUBLESHOOTING

Troubleshooting

Problem

1. Rotor does not turn

2. Hard to feed
chipper or
excessive power
needed to chip

3. Chipper requires
excessive power or
stalls

Probable Cause

a) Obstructed

discharge

b) Plugged rotor

a) Obstructed

discharge
b) Dull chipper blades
c) Improper blade

clearance

a) Obstructed

discharge
b) Plugged rotor
c) Green material will

not discharge

Suggested
Remedies

a) Use branch or

similar object to
clear discharge

b) Clear rotor
a) Use branch or

similar object to

clear discharge
b) Sharpen blades
c) Adjust clearance

a) Use branch or

similar object to

clear discharge
b) Clear rotor, feed

material into

shredder more

slowly
c) Alternately feed dry

material, or allow

material to dry

Reference

Service and Maintenance

Service and Maintenance

Service and Maintenance

4. Drive belts
squealing or
smoking

6. Vibration while
running

7. Engine dies or runs
poorly

a) Plugged rotor
b) Loose or worn belts

a) Drivehead vibration
b) Rotor out of

balance

a) Engine problems

a) Clear rotor
b) Adjust belt tension

or replace belts if
needed

a) Check drive belts

and pulleys for bad
or worn spots.

b) Inspect rotor for

broken or missing
chipper blades and
paddles. Repair if
needed.

c) Check rotor to see if

it wobbles

d) Check to see if rotor

is assembled
correctly

a) Contact local

engine service
center

Service and Maintenance

Service and Maintenance

Service and Maintenance

Engine Manual

20

Specifications

S

PECIFICATIONS

Overall Size (LxWxH)
Max. Chipper Cap. (dia.)
Chipper Blade Qty.
Rotor Speed

Rotor Size
Rotor Weight
Rotor Shaft Diameter
Discharge Size
Drive Type
Belt Size

Weight (Lbs.)

Model 72928

119" x 79" x 89"
9"
4 Reversible Tool Steel
1500 RPM

30" Dia. x 1.25"
275 lbs.

1.75"
8"
Belt
3B83

2486

Model 72942

119" x 79" x 89"
9"
4 Reversible Tool Steel
1500 RPM

30" Dia. x 1.25"
275 lbs.

1.75"
8"
Belt
3B85

2540

Wheel Base
Tire Size
Fuel Tank Cap. (Gal.)

Engine

68"
P215/75R15
18
Kubota 28hp Diesel

68"
P215/75R15
18
Ford 42hp Gasoline

Specifications are subject to change because of design modifications.

21

S

ECTION

3

Replacement & Maintenance Chart

Note: When ordering replacement parts, be sure to identify the
Model and Serial number of the machine.

Replacement Parts Ordered

Date Part Ordered

Date Part Replaced

Replaced By

Checked By

22

HEALTH WARNING

GASOLINE, DIESEL, AND

OTHER PETROLEUM PRODUCTS

Harmful or fatal if swallowed.
Long-term exposure to vapors has caused cancer in
laboratory animals.

• Avoid prolonged breathing of vapors.

• Keep face away from nozzle and gas tank/container
opening.

• Never siphon by mouth.

Failure to use caution may cause serious injury or illness.

WARNING

CHEMICALS KNOWN TO THE STATE OF CALIFOR­NIA TO CAUSE CANCER, BIRTH DEFECTS, OR
OTHER REPRODUCTIVE HARM ARE FOUND IN
GASOLINE, DIESEL, CRUDE OIL, AND MANY O THER
PETROLEUM PRODUCTS AND THEIR V APORS , OR
RESULT FROM THEIR USE.

READ AND FOLLOW LABEL DIRECTIONS AND USE
CARE WHEN HANDLING OR USING ALL PETRO­LEUM PRODUCTS.

ENGINE EXHAUST FROM THIS PRODUCT CON­T AINS CHEMICALS KNO WN T O THE ST ATE OF CALI­FORNIA TO CAUSE CANCER, BIRTH DEFECTS, OR
OTHER REPRODUCTIVE HARM.

Box 849
West Fargo, ND 58078
[phone] [phone]
FAX: [phone]