Echo 74554 Owners Manual v.3

Page 1
5 INCH CHIPPER
MADE WITH PRIDE IN THE...
CH5540H (74554) - 540 PTO HYDRAULIC FEED
OWNER'S MANUAL
PN: 12666 R092107
Companion to 12665
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MANUFACTURED BY CRARY INDUSTRIES
MANUFACTURED IN U.S.A.
XXXXXX
WEST FARGO, NORTH DAKOTA 58078 U.S.A. SERIAL NUMBER
DEAR ECHO BEAR CAT CUSTOMER
Thank you for purchasing a ECHO Bear Cat product. The ECHO Bear Cat line is designed, tested, and manufactured
to give years of dependable performance. To keep your machine operating at peak efciency, 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 your machine.
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 authorized ECHO Bear Cat Dealer. This document is based on information available at the time of its publication. ECHO Bear Cat is continually making improvements and developing new equipment. In doing so, we reserve the right to make changes or add improvements to our product without obligation for equipment previously sold.
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 ll 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.
PARTS ORDERING INFORMATION
For service assistance or parts, contact your nearest authorized ECHO Bear Cat dealer or the factory. Your nearest authorized dealer will need to know the serial
number of your machine to provide the most efcient
service. See below for information on how to identify and record the serial number for your machine.
If you need engine service or parts:
For engine service or parts, contact your nearest authorized engine dealer. An authorized engine dealer can handle all parts, repairs, and warranty service concerning the engine.
SERIAL NUMBER LOCATION
Please record the serial number in the space provided and on the warranty and registration card.
REPLACEMENT PARTS
Only genuine ECHO Bear Cat replacement parts should be used to repair the machine. Replacement parts manufactured by others could present safety hazards,
even though they may t on this machine. Replacement
parts are available from your ECHO Bear Cat dealer.
Provide the following when ordering parts:
The SERIAL NUMBER of your machine. The PART NUMBER of the part. The PART DESCRIPTION. The QUANTITY needed.
SERIAL NUMBER
HOW TO CONTACT ECHO BEAR CAT
ADDRESS PHONE E-MAIL HOURS
237 NW 12th Street
P.O. Box 849
West Fargo, ND 58078
*Original Instructions
© 2006, CRARY INDUSTRIES, ALL RIGHTS RESERVED. PRODUCED AND PRINTED IN THE U.S.A.
800-247-7335 701-282-5520
FAX: 701-282-9522
sales@bearcatproducts.com
service@bearcatproducts.com
Monday - Friday,
8 am to 5 pm
Central Time
Page 3
LIMITED WARRANTY
This warranty applies to all AG and Outdoor Power Equipment manufactured by Crary Industries.
Crary Industries warrants to the original owner each new Crary Industries product to be free from defects in material and workmanship, under normal use and service. The warranty shall extend 1 year from date of delivery for income producing (commercial) applications and 2 years from date of delivery for non-income producing (consumer) use of the product. The product is warranted to the original owner as evidenced by a completed warranty registration on file at Crary Industries. Replacement parts are warranted for (90) days from date of installation.
THE WARRANTY REGISTRATION MUST BE COMPLETED AND RETURNED TO CRARY INDUSTRIES WITHIN 10 DAYS OF DELIVERY OF THE PRODUCT TO THE ORIGINAL OWNER OR THE WARRANTY WILL BE VOID.
In the event of a failure, return the product, at your cost, along with proof of purchase to the selling Crary Industries dealer. Crary Industries will, at its option, repair or replace any parts found to be defective in material or workmanship. Warranty on any repairs will not extend beyond the product warranty. Repair or attempted repair by anyone other than a Crary Industries dealer as well as subsequent failure or damage that may occur as a result of that work will not be paid under this warranty. Crary Industries does not warrant replacement components not manufactured or sold by Crary Industries.
This warranty applies only to parts or components that are defective in material or workmanship. 1.
This warranty does not cover normal wear items including but not limited to bearings, belts, pulleys, lters 2. and chipper knives.
This warranty does not cover normal maintenance, service or adjustments.3.
This warranty does not cover depreciation or damage due to misuse, negligence, accident or improper 4. maintenance.
This warranty does not cover damage due to improper setup, installation or adjustment.5.
This warranty does not cover damage due to unauthorized modications of the product. 6.
Engines are warranted by the respective engine manufacturer and are not covered by this warranty.7.
Crary Industries is not liable for any property damage, personal injury or death resulting from the unauthorized
modification or alteration of a Crary product or from the owner’s failure to assemble, install, maintain or operate the product in accordance with the provisions of the Owner’s manual.
Crary Industries is not liable for indirect, incidental or consequential damages or injuries including but not
limited to loss of crops, loss of profits, rental of substitute equipment or other commercial loss.
This warranty gives you specific legal rights. You may have other rights that may vary from area to area.
Crary Industries makes no warranties, representations or promises, expressed or implied as to the performance of its products other than those set forth in this warranty. Neither the dealer nor any other person has any authority to make any representations, warranties or promises on behalf of Crary Industries or to modify the terms or limitations of this warranty in any way. Crary Industries, at its discretion, may periodically offer limited, written enhancements to this warranty.
CRARY INDUSTRIES RESERVES THE RIGHT TO CHANGE THE DESIGN AND/OR SPECIFICATIONS OF ITS PRODUCTS AT ANY TIME WITHOUT OBLIGATION TO PREVIOUS PURCHASERS OF ITS PRODUCTS.
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Contents
DESCRIPTION PAGE
SAFETY ...........................................................................................1
1.1 SAFETY ALERT SYMBOL ...................................................................... 1
1.2 BEFORE OPERATING ............................................................................1
1.3 OPERATION SAFETY ............................................................................. 2
1.4 PTO SAFETY ........................................................................................... 2
1.5 FEED ROLLER SAFETY ........................................................................ 3
1.6 MAINTENANCE AND STORAGE ............................................................ 3
1.7 SAFETY DECAL LOCATIONS ................................................................. 4
1.8 SAFETY DECALS ................................................................................... 5
ASSEMBLY ......................................................................................6
2.1 ATTACH CHUTE AND SUPPORT ...........................................................6
2.2 ATTACH DISCHARGE TUBE DEFLECTOR ............................................ 6
2.3 ATTACH DISCHARGE TUBE .................................................................. 7
2.4 CONNECT PTO DRIVELINE ................................................................... 7
FEATURES AND CONTROLS .........................................................8
OPERATION ....................................................................................9
4.1 STARTING AND OPERATING CHIPPER ................................................ 9
4.2 STOPPING THE CHIPPER ..................................................................... 9
4.3 CHIPPING GUIDELINES ......................................................................... 9
SERVICE & MAINTENANCE .........................................................10
5.1 SERVICE AND MAINTENANCE SCHEDULE ....................................... 10
5.2 WHEN TO SHARPEN BLADES ............................................................. 10
5.3 REMOVING CHIPPER BLADES ........................................................... 11
5.4 SHARPENING CHIPPER BLADES ....................................................... 11
5.5 SETTING BLADE CLEARANCE ............................................................ 11
5.6 CLEARING A PLUGGED ROTOR ......................................................... 12
5.7 REPLACING THE DRIVE BELT ............................................................ 12
5.8 GREASING ............................................................................................ 12
5.9 REMOVING THE ROTOR ..................................................................... 13
5.10 FILLING HYDRAULIC FLUID .............................................................. 14
5.11 CHANGING HYDRAULIC OIL FILTER ................................................ 14
5.12 PROGRAMMING THE OPTIONAL HYDRAULIC
FEED SENSOR (LOFA) ......................................................................... 15
5.13 TROUBLESHOOTING .......................................................................... 16
SPECIFICATIONS ..........................................................................17
6.1 BOLT TORQUE ...................................................................................... 18
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1
SECTION

SAFETY

1.1 SAFETY ALERT SYMBOL

The Owner/Operator's manual uses this symbol to alert you of 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.
DANGER
Indicates an imminently hazardous situation that, if not
avoided, will result in death or serious injury.
WARNING
Indicates a potentially hazardous situation that, if not
avoided, could result in death or serious injury.
CAUTION
Indicates a potentially hazardous situation that, if not
avoided, may result in minor or moderate injury.

1.2 BEFORE OPERATING

Read this Owner / Operator’s manual. Be completely 1. familiar with the controls and the proper use of this equipment.
Before inspecting or servicing any part of the machine, 2. wait for all parts to stop moving. Be aware that rotating parts slow down gradually after power is stopped.
Keep safety decals clean and legible. Replace missing 3. or illegible safety decals.
Familiarize yourself with all of the safety and operating 4. decals on this equipment and on any of it’s attachments or accessories.
Do not allow children or any person unfamiliar with the 5. use of the unit to use this machine.
Keep the area of operation clear of all persons, particu-6. larly small children. Keep bystanders at least 50 feet (15 meters) away from the area of operation.
Do not run this equipment in an enclosed area. Do not 7. operate this equipment in or near buildings, windows, or air conditioners.
If needed, always use an approved fuel container. 8.
Keep open ames, sparks, smoking materials, and
other sources of combustion away from fuel.
Do not operate this machine if you are under the inu-9. ence 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.
Use only in daylight or good articial light.10.
Wear safety glasses at all times while operating this 11. machine.
Never use without proper guards in place.12.
Avoid wearing loose tting clothing. Never operate this 13. machine wearing clothing with drawstrings that could wrap around or get caught in the machine.
Check that all screws, nuts, bolts, and other fasten-14. ers are properly secured 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.
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SAFETY
Keep all guards, deectors, and shields in place and 15. in good working condition.
Do not transport or move machine while the machine 16. is running.

1.3 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.
Always stand clear of discharge area when operating 1. this machine. Keep face and body away from feed and discharge openings.
Keep hands and feet out of feed and discharge open-2. ings while machine is operating to avoid serious
personal injury. Stop and allow machine to come to a
complete stop before clearing obstructions.
Set up your work site so you are not endangering traffic 3. and the public. Take great care to provide adequate warnings.
Do not climb on machine when operating. Keep proper 4. balance and footing at all times.
Check cutting chamber to verify it is empty before 5. starting the machine.
The disk will continue to rotate when belt is disen-6. gaged.
Do not insert branches larger than 5 inches in diameter 7. into chipper or machine damage may occur.
When feeding material into machine, do not allow 8. metal, rocks, bottles, cans or any other foreign material to be fed into the machine.
Ensure debris does not blow into traffic, parked cars, 9. or pedestrians.
Keep the machine clear of debris and other accumula-10. tions.
Do not allow processed material to build up in the 11. discharge area. This may prevent proper discharge and can result in kickback of material through the feed opening.
Shut off machine immediately if the machine becomes 12. clogged, the cutting mechanism strikes any foreign
object, or the machine starts vibrating or making an
unusual noise. Shut off the machine, disconnect the battery, remove the ignition key and make sure all moving parts have come to a complete stop. After machine stops:
Inspect for damage.
Replace or repair any damaged parts.
Check for and tighten any loose parts.
Check blade bolts for proper torque after every 8 hours 13. of operation. Check blades and rotate or resharpen daily or as required to keep blades sharp. Failure to do so may cause poor performance, damage or personal
injury and will void the machine warranty.

1.4 PTO SAFETY

1. Read and follow instructions on PTO safety decals.
2. Stay alert and pay attention when PTO is operating.
3. Keep bystanders, especially children, away from PTO driveline.
4. Check the driveline to ensure it is attached securely to the power supply.
5. Keep guards and shields in place at all times while operating. Disengage PTO and shut off engine before removing guards or shields.
6. Clothing worn by operator must be fairly tight. Never wear loose tting jackets, shirts, or pants when work­ing around the PTO. Tie long hair back or put under a cap.
7. Keep hydraulic hoses, electric cords, chains, and other items from contacting the driveline.
8. Do not exceed the recommended 540 RPM PTO op­erating speed.
9. When this equipment is stopped for servicing, inspec­tion, or storage make sure to disengage PTO.
10. Keep hands, feet, and clothing away from all PTO drive parts.
11. Do not clean, lubricate, or adjust the PTO driveline
when it is running.
2
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SAFETY

1.5 FEED ROLLER SAFETY

The feed roller can cause serious injury or death. 1. Keep hands, feet and clothing away from the feed roller and chipper disk blades.
Never climb onto the feed chute when the unit is op-2. erating or running.
Do not overreach. Keep proper balance and footing 3. at all times.
Never allow passengers to ride on the feed chute.4.
When feeding material into the feed roller:5.
Wear eye, face and hearing protection.A.
Release material and stand to side of feed B.
chute.
When inspecting or servicing the feed roller, secure 6. the feed roller in the raised position using the snap pin located on the roller slide.

1.6 MAINTENANCE AND STORAGE

Replace any missing or unreadable safety decals. Re-1. fer to the parts manual for part numbers when ordering safety decals from an area dealer.
Allow machine to cool before storing in an enclosure.2.
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SAFETY

1.7 SAFETY DECAL LOCATIONS

See Section 1.8 for decal descriptions. Familiarize yourself with all of the safety and operating decals on the machine and the associated hazards. See the engine owners manual for engine safety instructions and decals. Make certain that all safety and operational decals on this machine are kept clean and in good condition. Refer to the parts catalog if you need a replacement decal. Decals that need replacement must be applied to their original locations.
4
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SAFETY

1.8 SAFETY DECALS

See Section 1.7 for decal locations. Familiarize yourself with all of the safety and operating decals on the machine and the associated hazards. See the engine owners manual for engine safety instructions and decals. Make certain that all safety and operational decals on this machine are kept clean and in good condition. Refer to the parts catalog if you need a replacement decal. Decals that need replacement must be applied to their original locations.
1
KEEP HANDS, FEET AND BODY AWAY FROM DRIVELINE WHILE MACHINE IS OPERATING TO AVOID ENTANGLEMENT. OPERATE MACHINE AT 540 RPM.
2
KEEP HANDS AND FEET OUT OF INLET AND DISCHARGE OPENINGS WHILE MACHINE IS OPERATING TO AVOID SERIOUS PERSONAL INJURY. ALLOW MACHINE TO COME TO A COMPLETE STOP BEFORE CLEARING OBSTRUCTIONS.
3
READ AND UNDERSTAND THIS OWNER/OPERATORS MANUAL. BE COMPLETELY FAMILIAR WITH THE CONTROLS AND THE PROPER USE OF THIS EQUIPMENT. OBTAIN AND WEAR SAFETY GLASSES AND USE HEARING PROTECTION AT ALL TIMES WHEN OPERATING THIS MACHINE. BEFORE INSPECTING OR SERVICING ANY PART OF THIS MACHINE, SHUT OFF POWER SOURCE, DISCONNECT SPARK PLUG WIRE FROM SPARK PLUG AND MAKE SURE ALL MOVING PARTS HAVE COME TO A COMPLETE STOP.
4
PN 12168
PN 12169
PN 12172
PN 12173
5
DO NOT OPERATE MACHINE WITHOUT SHIELDS IN PLACE. FAILURE TO DO SO MAY CAUSE SERIOUS INJURY OR DEATH.
6
KEEP HANDS AND FEET OUT OF INLET AND DISCHARGE OPENINGS WHILE MACHINE IS OPERATING TO AVOID SERIOUS PERSONAL INJURY. ALLOW MACHINE TO COME TO A COMPLETE STOP BEFORE CLEARING OBSTRUCTIONS.
7
CHECK BLADE BOLTS FOR PROPER TORQUE AFTER EVERY 8 HOURS OF OPERATION. CHECK BLADES AND ROTATE OR RESHARPEN DAILY OR AS REQUIRED TO KEEP BLADES SHARP. REFER TO OWNERS MANUAL FOR INSTRUCTIONS. FAILURE TO DO SO MAY CAUSE POOR PERFORMANCE, DAMAGE OR PERSONAL INJURY AND WILL VOID THE MACHINE WARRANTY.
8
READ AND UNDERSTAND THIS OWNER/OPERATORS MANUAL. BE COMPLETELY FAMILIAR WITH THE CONTROLS AND THE PROPER USE OF THIS EQUIPMENT.
PN 12174
PN 12175
PN 12250
PN 13711-00
DO NOT OPERATE THIS EQUIPMENT IN THE VICINITY OF BYSTANDERS. DO NOT ALLOW CHILDREN TO OPERATE THIS EQUIPMENT. ALWAYS STAND CLEAR OF DISCHARGE AREA WHEN OPERATING THIS MACHINE. KEEP FACE AND BODY AWAY FROM DISCHARGE AREAS.
9
5 INCH CHIpper
PN 14942-00
5
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2
FEED CHUTE EXTENSION
FEED CHUTE
SUPPORT BRACKET
FEED CHUTE EXTENSION
FEED CHUTE
CHUTE SUPPORT
5/16 x 1” BOLT
5/16 x 1-3/4” BOLT
5/16” NYLOCK NUT
DEFLECTOR KNOB
SECTION

ASSEMBLY

2.1 ATTACH CHUTE AND SUPPORT

Mount the feed chute to the chipper housing using six 1. (6) 3/8 x 1-1/4" carriage bolts, 3/8" washers, and 3/8" nylock nuts (see Figure 2.1).
Secure the chute support to the chipper leg stand with 2.
one (1) 3/8 x 2-3/4" bolt, one 3/8" washer, and one 3/8" nylock nut as shown in Fig. 2.1.
Secure the other end of the chute support by removing 3. the middle bolt holding the feed chute to the hinge (shown in Fig 2.1 insert). Put the support bracket end between the washer and the hinge, and then retighten the bolt and nut.
Figure 2.1 Attach the chipper chute and chute support

2.2 ATTACH DISCHARGE TUBE DEFLECTOR

Attach the deector to the discharge tube with (2) 1-3/4" bolts, (2) 1" bolts, (2) deector knobs, (4) 5/16" nylock
nuts, and (8) 5/16" washers as shown in Figure 2.2.
6
Figure 2.2 Attach the discharge tube deector
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ASSEMBLY
5/16 x 1” BOLT
5/16 x 1-3/4” BOLT
5/16” NYLOCK NUT
DEFLECTOR KNOB
3/8 X 1-1/4” HEX BOLT
3/8” NYLOCK NUT

2.3 ATTACH DISCHARGE TUBE

1. Slide the blower discharge tube onto the mounting
ange on the chipper frame (see Figure 2.3). Half of
the mounting clamp is already attached to the tube.
2. Tighten the bolts to secure it.
3. Install the second half of the clamp to the tube and
ange. Secure it with (3) 1-1/4" bolts and nylock nuts.
4. Grease the chute grease zerk to allow free rotation. Rotate the tube 360 degrees and lock it in place with the handle to make sure it is mounted correctly.
2.4.1 CHECK LENGTH OF PTO DRIVELINE
Attach chipper to tractor with three-point hitch. 1.
You must make sure that the PTO driveline supplied 2. with your machine is the appropriate length for your
tractor. Adjust the chipper up and down and measure
the shortest and longest distance between the chipper rotor shaft and tractor PTO.
The PTO driveline has a 3. maximum extension of
24.49" with a 6.43" overlap. If your longest distance is greater than 24.49", contact your dealer to obtain a longer PTO driveline.
The PTO driveline has a 4. minimum compression of
18.1". If your shortest distance is less than this, cut the driveline to fit as explained in section 2.4.2.
2.4.2 SHORTENING A PTO DRIVELINE
Pull the driveline into two pieces. Connect one end to 1. the tractor PTO and the other end to the chipper rotor shaft. Line up the two halves parallel to each other.
Measure the distance from the end of one driveline 2. tube to the bottom of the end shield of the other drive­line half (dimension A in Fig. 2.4). Measure and mark the driveline tube 1-9/16” inward from dimension A.
Figure 2.3 Attach discharge tube

2.4 CONNECT PTO DRIVELINE

IMPORTANT
The tractor must have a standard 540 RPM PTO shaft.
If the tractor has an electric PTO clutch, consult your dealer for correct operating procedures.
2.4.3 CONNECTING THE PTO DRIVELINE
5 INCH CHIpper
Figure 2.4 Shorten the driveline if it is too long
Cut the shield tube in the marked position.3.
Using the cut piece of shield tube as your measure-4. ment, place the cut piece against the end of the shaft. Mark and cut the shaft.
Using the cut piece of shield tube as your measure-5. ment, mark and cut the tube on the other half of the driveline, and then the shaft.
File both shaft ends, and slide the two halves back 6. together.
When you have confirmed that the driveline is the 1. correct length for your tractor, connect the driveline to the chipper rotor shaft using key stock and two set screws in the owner’s kit.
Connect the opposite end of the PTO shaft to the 2. tractor.
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3
SAFETY BAR (WHERE AVAILABLE)
DISCHARGE CHUTE
DISCHARGE LOCK
THREE-POINT HITCH
HYDRAULIC FEED CONTROL
LEG STANDS
HYDRAULIC RESERVOIR
FLOW CONTROL KNOB
FEED ROLLER JACK
BELT GUARD
FEED CHUTE EXTENSION
SECTION
FEATURES AND CONTROLS
Belt Guard: Remove to grease rotor and jack shafts and
to check or replace belt.
Discharge Lock: Used to pivot and lock the discharge chute.
Feed Roller Jack: Use the feed roller jack to raise the feed roller to remove jammed materials.
Flow Control Knob: To adjust feed rate, rst loosen the inner jam nut, then turn the knob clockwise to increase
feed roller speed or counterclockwise to decrease speed.
When desired speed is reached, tighten jam nut.
Hydraulic Feed Control: Engages and disengages the feed roller.
Hydraulic Reservoir: Hold the hydraulic uid. Check uid level periodically.
Leg Stands: Adjustable to allow proper driveline angle. Do
not move machine unless the legs clear the ground.
Safety Bar: Push in the safety bar to stop forward feed. To restart forward feed, push the reset/override button (not available on all models).
Three-Point Hitch Connections: Mount chipper to tractor. Connect direct for categories 0 & 1. A bushing kit must be installed on three point connections for category 2 hitches.
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4
SECTION

OPERATION

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!

4.1 STARTING AND OPERATING CHIPPER

Read and understand all safety warnings and chipping 1. guidelines contained in this manual before proceeding.
Connect PTO driveline to tractor as described in Sec. 2.
2.4.
Adjust three-point top link so the chipper sits level.3.
Start tractor engine and engage PTO (refer to trac-4. tor owners manual). Increase engine speed to rated PTO RPM.
Engage the hydraulic feed by moving the hydraulic 5. feed control arm. The control arm has four positions: Reverse, Forward, Stop, and Reverse.
Feed branches up to ve inches in diameter into the 6. chipper.
Reverse the feed by moving the control arm to reverse 7.
position if the chipper jams. Remove the branch and
rotate it before reinserting it into the chute.
Adjust the speed of the feed roller, if necessary, with 8. the ow control knob.
DANGER
Do not inspect or work on PTO drive area without rst
disengaging PTO and shutting off tractor engine.

4.2 STOPPING THE CHIPPER

1. Move tractor throttle to SLOW position.
2. Disengage PTO lever and shut off tractor engine.
3. Allow machine to come to a complete stop.
NOTE
The heavy rotor will continue to turn for some time after the engine or tractor 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.

4.3 CHIPPING GUIDELINES

WARNING
Due to the aggressiveness of the machines chipping capacity, do not attempt to hold on to material intended for chipping once it has been placed in the chute.
This chipper is designed to chip a variety of materials into a more readily decomposing or handled condition. The following guidelines will help you get started.
Be sure the unit is at full operating speed before you 1. start to chip material.
Select limbs that are up to 5 inches in diameter. Trim 2. 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.
Feed brush from the side of the chute, rather than 3. from the front. Then, step aside to avoid being hit by the brush moving into the chipper.
Never lean over the chute to push objects into the 4. cutting device. Use a push stick or brush paddle.
Never use shovels or forks to push brush. They can 5. go through the chipper, are expensive to replace, and
cause major damage. In addition, metal pieces can be shot back like shrapnel to injure or kill the operator
or bystanders.
Never push brush into the feed chute with your feet.6.
Engage the hydraulic feed by moving the control 7. arm.
Place limb, butt end first, into the chipper chute until 8. 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 the sharpness of the cutting blades.
If the chipper jams, reverse the feed by moving the 9. 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 10. 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 sharpening. Re­fer to the Service and Maintenance section for more information.
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5

SERVICE & MAINTENANCE

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

5.1 SERVICE AND MAINTENANCE SCHEDULE

FREQUENCY
COMPONENT
NUTS AND BOLTS CHECK
CHIPPER BLADES
CHIPPER ANVIL
2-BOLT FLANGE BEARINGS GREASE
BELT TENSIONER PIVOT GREASE
PTO CROSS JOURNALS GREASE
PTO INNER TUBES GREASE
PTO SHIELD BEARINGS GREASE
BELT CONDITION CHECK
BELT TENSION CHECK
DISCHARGE TUBE FLANGE GREASE
ENTIRE MACHINE CLEAN
1
WHEN MATERIAL STOPS SELF FEEDING, IT IS A SIGN THAT YOUR CHIPPER BLADES NEED SHARPENING.
MAINTENANCE
REQUIRED
CHECK, SHARPEN IF NEEDED, TORQUE TO 20 FT-LBS.
CHECK BLADE CLEARANCE, TORQUE TO 75 FT-LBS.
1
BEFORE
EACH
USE
EVERY 8
HOURS
EVERY
25
HOURS
EVERY
50
HOURS
EVERY
100
HOURS
As the Chipper Limited Warranty states, failure by the Owner to perform normal maintenance will void the machine's warranty. The aggressive, high-speed nature of chipping REQUIRES THE OWNER TO PERFORM THE ABOVE LISTED NORMAL MAINTENANCE. Special consideration to maintain and re-torque the CHIPPER ANVIL, CHIPPER BLADES, AND ALL INTERNAL AND EXTERNAL NUTS AND BOLTS is the sole responsibility of the Owner. Failure by the Owner to do so shall be cause for denial of warranty.

5.2 WHEN TO SHARPEN BLADES

Poor chipping performance is usually a result of dull chipping blades. It is recommended the blades be sharpened every 5-15 hours of chipper operation. If your chipper's performance has decreased, the following symptoms indicate the blades must be sharpened:
10
5 INCH CHIpper
1. Severe vibration when feeding material into the chipper.
2. Small diameter branches do not self-feed.
3. Chips discharge unevenly or have stringy tails–espe­cially when chipping green branches.
Page 15

5.3 REMOVING CHIPPER BLADES

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.
To remove the chipping blades for sharpening:
Remove the one 3/8 inch retaining bolt holding the ac-1. cess cover to main frame assembly (see Fig. 5.1).
SERVICE AND MAINTENANCE
Figure 5.2 Sharpening the blades

5.5 SETTING BLADE CLEARANCE

The chipping blades should clear the chipper anvil (located directly under the chipper chute) by 1/16 inch to 1/8 inch.
To adjust the blade clearance, proceed as follows:
Figure 5.1 Access bolt
Tilt access cover over to allow rotor access. Rotate 2. the rotor so that the bolts holding a chipping blade are most accessible.
Remove the two hex bolts holding the chipper blade. 3.
Repeat for all four chipper blades. 4.

5.4 SHARPENING CHIPPER BLADES

The four chipping blades have two edges per blade and can be reversed one time each before sharpening (see Figure 5.2). Remove and reverse the chipping blades if both sides have not been used. Reinstall chipping blades and proceed with chipping.
Before you sharpen the chipping blades, check for permanent damage. Replace the blade if:
1. The blade is cracked (especially around the bolt holes) or the edges are too deeply chipped to be ground smooth.
2. The base of the cutting edge is worn or has been re-sharp­ened so that it is too close to the rotor chipping slot.
1. Lift rotor access cover and expose rotor. Loosen the two 1/2 inch bolts that hold the chipper anvil to the frame.
2. Measure the amount of clearance between chipping blade and chipper anvil from inside of housing. The gap should be 1/16" to 1/8".
3. Adjust inward or outward to desired measurement. Use the nuts on the adjustment bolt (See Fig. 5.3).
4. Tighten bolts on chipping block to 75 ft. lbs. and resume operation.
Remove the two bolts holding the anvil and use one of the other three edges if the chipper anvil edge is damaged or
worn unevenly. Adjust for correct measurement.
If blades need sharpening, grind the angled edge of the chipping blade to 45 degrees. 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 and cool with water. Try to remove an equal amount off each blade to maintain balance. Reinstall.
5 INCH CHIpper
Figure 5.3 Chipper blade and anvil clearance
11
Page 16
SERVICE AND MAINTENANCE
IDLER PULLEY
JACK SHAFT

5.6 CLEARING A PLUGGED ROTOR

The feed roller lift jack is used to raise the feed roller if chip­ping material becomes wedged in or behind the feed roller.
To raise the feed roller:
Disengage PTO and shut off tractor engine. Wait for 1. all moving parts to come to a complete stop.
Remove lock pin from storage position (see Fig. 5.4)2.
Turn check valve clockwise to engage jack pump.3.
Once the jack is engaged, pump the handle to raise 4.
the feed roller until the lock pin position aligns with one of the support bracket holes.
Secure the position by putting the lock pin through the 5. support bracket and lock pin position.
Clear materials out from underneath the feed roller.6.
Remove the lock pin.7.
Turn the check valve counterclockwise to disengage 8.
the pump and lower the jack.
Replace lock pin in storage position.9. LEAVING THE LOCK PIN IN ANY OTHER POSITION MAY INTER­FERE WITH FEED ROLLER OPERATION.
Put idler pulley back in place and replace bolt. 5.
Replace belt guard.6.
Figure 5.5 Belt and pulleys with belt shield removed

5.8 GREASING

The chipper has grease zerks that must be greased every 50 hours. For their locations, see below:
Two zerks on the jack shaft (remove belt cover 1. to access). Two zerks on the rotor shaft (remove belt cover 2. to access). Two zerks on the feed roller shaft.3. Two universal joints on the PTO driveline.4. One grease zerk on the discharge chute.5.
Figure 5.4 Feed roller jack and lock pin

5.7 REPLACING THE DRIVE BELT

Check the condition of the drive belt annually or after every
25 hours of operation, whichever comes rst. Replace a
cracked, frayed, worn, or stretched drive belt. Only replace drive belt with original banded type belt, do not use single
type belts. To adjust the drive belt, proceed as follows:
Remove large belt guard by removing ve (5) 5/16" 1.
bolts and washers.
Remove the idler pulley by removing the 4" bolt in the 2. center of the pulley (see Fig. 5.5).
Remove drive belt from pulleys.3.
Install new belt on pulleys.4.
12
5 INCH CHIpper
Figure 5.6 Grease zerk on jack shaft
Figure 5.7 Grease zerk on rotor shaft
Page 17
GREASE
Figure 5.8 Grease zerks on discharge chute, other side of rotor
shaft, and other side of jack shaft
Figure 5.9 Grease zerk on left side of feed roller
Figure 5.10 Grease zerk on right side of feed roller
SERVICE AND MAINTENANCE
Figure 5.11 Grease zerk on driveline

5.9 REMOVING THE ROTOR

1. Remove the one 3/8 inch retaining bolt holding access cover to main frame assembly. Tilt access cover over to allow rotor access.
2. Remove large belt guard.
3. Remove belt idler pulley and remove drive belt from pulleys.
4. Remove the bushing and pulley from the rotor shaft using the push bolts from the bushing.
5. Remove the two 1/2 inch bolts on each rotor bearing.
6. Pound 1/4" roll pin out of the rotor shaft on front bear­ing.
7. Lift the rotor assembly completely out of the frame with an overhead hoist or lifting device. The complete rotor assembly is 140 lbs.
8. Remove both bearings with a puller when the rotor assembly is out of the frame and place new bearings on rotor shaft.
9. Replace roll pin with a new 1/2" x 2" pin, P/N 15137.
10. Return the complete rotor assembly to the chipper frame with an overhead hoist or lifting device.
11. Slide rotor back until front roll pin is tight against the front bearing.
12. 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.
13. Check and adjust chipper anvil if needed. Lock rear
bearing.
14. Slide bushing onto shaft with ange against bearing
and lock bushing to shaft.
15. Attach large pulley to bushing.
16. Replace drive belt on pulleys and lower belt idler.
Check alignment of pulleys and adjust engine if
needed.
17. Close cover and replace bolts.
18. Replace belt guard and resume operation.
5 INCH CHIpper
13
Page 18
SERVICE AND MAINTENANCE
HYDRAULIC FILTER

5.10 FILLING HYDRAULIC FLUID

CAUTION
Handle pressurized hydraulic uid carefully. Escaping pressurized hydraulic uid can have sufcient force to penetrate your skin causing serious injury. This uid
may also be hot enough to burn. Serious infection or reactions can develop if proper medical treatment is not administered immediately.
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 uid odor
(excessive heat). The hydraulic pump normally does not
require regular uid changes.
Premium hydraulic uids 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 uids.
System pressure is controlled by the hydraulic control valve, which is set at 2500 PSI.

5.11 CHANGING HYDRAULIC OIL FILTER

The hydraulic oil lter should be changed after the rst
50 hours and every 200 hours thereafter or at annual
intervals. The uid and lter should be changed and system cleaned if the uid becomes contaminated with foreign matter (water, dirt, grease, etc.) or if the uid has been subjected to temperature levels greater than the
maximum recommended.
The lter is located underneath the hydraulic reservoir.
To change the hydraulic oil lter:
Using an oil filter wrench, unscrew the filter.1.
Once the filter becomes loose, turn it out the rest of 2. the way with your hand.
Properly discard old filter.3.
Lube the rubber seal on the new filter (PN 16588) with 4. clean hydraulic oil.
Install the filter onto the threaded pipe. Turn with your 5. hand until the filter is finger tight.
Turn, by hand, another 1/2 turn.6.
Check hydraulic oil level and fill if necessary.7.
In the unlikely event the the oil is completely drained from the hydraulic system, oil must be added and any air bubbles must be purged from the system. To do this:
1. Make sure all system components (reservoir, ttings,
etc.) are clean before starting the hydrostatic pump.
2. Fill the reservoir with recommended hydraulic uid. Filter uid before lling the reservoir.
3. Fill the inlet line leading from the reservoir to the hy-
draulic pump before start-up. Loosen the tting on the
pump inlet line until oil bleeds out.
4. Start the engine and run at the lowest possible RPM.
5. The oil level in the reservoir drops and bubbles may
appear in the uid as air is purged from the unit. Rell
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. Rell the reservoir as neces­sary.
7. Check to ensure the feed roller stops when the control arm is in the neutral position.
CAUTION
Hydraulic systems contain uid under high pressure. Never check for leaks with your hands. Relieve pressure before disconnecting any hydraulic lines.
8. Shut down the engine or disengage PTO, check for
and correct any uid leaks, and check the reservoir level. Add uid if necessary.
14
5 INCH CHIpper
Page 19
SERVICE AND MAINTENANCE

5.12 PROGRAMMING THE OPTIONAL HYDRAULIC FEED SENSOR (LOFA)

Some models may have the optional Lofa hydraulic feed sensor installed. To reset the Lofa program, refer to the instructions below.
The following settings are recommended:
LOW = 1400 RPM NORMAL = 1675 RPM HIGH = 0 RETURN = 1425 RPM
POLES = 1
STEP 1. INITIATE PROGRAM MODE
Hold down the "S" button while turning the engine key to
the "on" position until "L" starts to ash on the LCD.
STEP 2. ENTER LOW RPM (L=LOW)
The low setting is the RPM speed where the feed roller stops. The "up" arrow increases the RPM setting, while the "down" arrow decreases the RPM setting. Setting the speed lower causes the engine to lug down more before the feed roller stops.
1. Hold the appropriate (either up or down) arrow until
1400 RPM is displayed.
2. Push the "S" button once to save.
NOTE: Do not choose a setting equal to or below zero.
1. Hold the appropriate (either up or down) arrow until 1425 RPM is displayed.
2. Push the "S" button once to save.
STEP 6. ENTER NUMBER OF POLES (IPU = NUMBER OF POLES)
The number of poles indicates the number of speed pickup devices.
1. Hold the appropriate (either up or down) arrow until one (1) is displayed.
2. Push the "S" button to save.
RESETTING DAILY HOUR METER (OPTIONAL)
The feed sensor is equipped with an hour meter to track hour usage. The hours will continue to accumulate until reset by the operator.
To reset the hour meter:
Stop the engine and make sure the chipper blades and 1. all moving parts are completely stopped.
Turn key switch to "ON" to energize the feed sensor.2.
Push the "S" button until Day ashes on the LCD 3. display.
Depress the "S" button for ve seconds and release.4.
Push and hold down the "S" button for an additional 13 5. seconds until daily hours are reset to zero.
STEP 3. ENTER NORMAL RPM (N=NORMAL)
The normal setting is the RPM at which the chipper rotor usually turns.
1. Hold the appropriate (either up or down) arrow until 1675 RPM is displayed.
2. Push the "S" button once to save.
STEP 4. ENTER HIGH RPM (H=HIGH)
The high setting is not needed with this application.
1. Set to zero to deactivate.
2. Push the "S" button once with zero displayed to save.
STEP 5. ENTER RETURN RPM (RET = RETURN)
The return setting is the RPM speed where the feed roller restarts. The feed roller should restart before the rotor
reaches "normal" RPM to maximize chipper efciency.
Setting the speed higher allows the engine to recover more before the feed roller restarts.
5 INCH CHIpper
15
Page 20
SERVICE AND MAINTENANCE

5.13 TROUBLESHOOTING

PROBLEM POSSIBLE CAUSE CORRECTION
Hard to feed chipper
requires excessive
power
Improper blade clearance Adjust clearance
Dull chipper blades Sharpen blades
Obstructed discharge Use branch or similar object to clear discharge
Material from chipper
wraps around the
rotor shaft
Excessive vibration
while running
Rotor will not turn
Stringy, green material bypasses
chipper blades
Improper blade clearance Adjust clearance
Chipper blades to anvil clearance
is incorrect
Dull chipper blades Sharpen or replace blades
Drive system vibration
Rotor out of balance
Chipper blade to anvil clearance is incorrect
Drive belt too loose or broken Adjust or replace
Obstructed discharge Use branch or similar object to clear discharge
Rotate branch or material when feeding
to cut completely
Set chipper blade to anvil clearance to recommended distance (1/16” to 1/8”)
Check drive belts and pulleys for bad or worn areas.
Check PTO driveline for wear.
Inspect rotor for broken or missing chipper blades.
Repair if needed. Check rotor to see if rotor is
assembled correctly.
Set chipper blade to anvil clearance to recommended distance (1/16” to 1/8”)
Excessive belt wear
Plugged discharge tube
16
Plugged rotor Clear rotor
Not using correct belt Contact authorized dealer to order belts
Pulley damaged or worn Replace pulley
Pulley not in alignment Align pulley with straight edge
Belt tension too loose Tighten belt or replace
Engine speed too slow Increase engine speed
Feeding material too
fast into chipper
5 INCH CHIpper
Slow feed rate
Page 21
6
SECTION

SPECIFICATIONS

Overall Size 150” x 73” x 90”
Max. Chipper Capacity
(Dia.)
Chipper Blade Qty. 4 Reversible Tool Steel
Rotor Size 20” Dia. X .125
Rotor Weight 140 lbs.
Rotor Shaft Diameter 1.75”
5”
Hydraulic Tank Capacity 3 gal.
5 INCH CHIpper
Discharge Size 6”
Drive Type Belt
Belt Size 4L350
Weight (lbs.) 980 lbs.
17
Page 22
SPECIFICIATIONS

6.1 BOLT TORQUE

The tables below are for reference purposes only and their use by anyone is entirely voluntary, unless otherwise noted. Reliance on their content for any purpose is at the sole risk of that person and any loss or damage resulting from the use of this information is the responsibility of that person.
ENGLISH
BOLT TORQUE *
BOLT DIAMETER
1/4” 7.5 5.5 9.5 9 17 12.5
5/16” 15 11 25 18 35 26
3/8” 27 20 44 33 63 46
7/16” 44 32 70 52 100 75
1/2” 67 50 110 80 150 115
9/16” 95 70 155 115 225 160
5/8” 135 100 215 160 300 225
3/4” 240 175 375 280 550 400
7/8” 240 175 625 450 875 650
1” 360 270 925 675 1300 975
1-1/8” 510 375 1150 850 1850 1350
1-1/4” 725 530 1650 1200 2600 1950
SAE 2 SAE 5 SAE 8
(N.m.) (Ft-lbs.) (N.m.) (Ft-lbs.) (N.m.) (Ft-lbs.)
* Torque value for bolts and capscrews are identified by their head markings.
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%.
BOLT DIAMETER
M3 0.5 0.4 - - - - - -
M4 3 2.2 - - - - - -
M5 5 4 - - - - - -
M6 6 4.5 11 8.5 17 12 19 14.5
M8 15 11 28 20 40 30 47 35
M10 29 21 55 40 80 60 95 70
M12 50 37 95 70 140 105 165 120
M14 80 60 150 110 225 165 260 190
M16 125 92 240 175 350 255 400 300
M18 175 125 330 250 475 350 560 410
M20 240 180 475 350 675 500 800 580
M22 330 250 650 475 925 675 1075 800
M24 425 310 825 600 1150 850 1350 1000
M27 625 450 1200 875 1700 1250 2000 1500
18
METRIC
BOLT TORQUE *
4.8 8.8 10.9 12.9
5 INCH CHIpper
Page 23
Declaration of Conformity
The undersigned manufacturer:
Crary Industries, Inc.
237 NW 12
P.O. Box 849
West Fargo, ND 58078-0849
Declares that hereunder specified unit:
CHIPPER
Brand: ECHO Type: PTO driven Chipper Model Number: 74554E
Complies with the requirements of:
Machinery Directive 2006/42/EC
EN 13525:2005-Forestry Machinery-Wood Chippers -Safety
EN ISO 12,100, Part 1-Safety of Machinery-Basic Conce pt s, General Principles for Design
EN 982 – Safety of Machinery–Requirements for Fluid Power Systems & their Components-Hydraulics
Noise Emissions Directive 2000/14/EC
-Conformity Assessment Procedure: Annex V (Use of harmonized standard EN ISO 3744:2010)
Sound Power Level: 86 dB L Guaranteed Sound Power Level: 103 dB LWA
74554E Serial number 705411 and up
West Fargo, ND 58078-0849 June 29, 2011 CRARY INDUSTRIES, INC. The authorized representative in Europe who is authorized to compile the technical file: Company: Atlantic Bridge Limited Address: Atlantic House, PO Box 4800 Earley, Reading RG5 4GB, United Kingdom ______________________________
Arlan Mathias Mr. Phillip Wicks Senior Project Engineer
PA
th
Street
Data contained in this document pertains only to machines sold in areas that require CE compliance standards. To identify if your machine is CE compliant, it will have the following CE mark decal:
Page 24
Declaration of Conformity
The undersigned manufacturer:
Crary Industries, Inc.
237 NW 12
P.O. Box 849
West Fargo, ND 58078-0849
Declares that hereunder specified unit:
CHIPPER
Brand: ECHO Bear Cat Type: PTO driven Chipper Model Number: 74554
Complies with the requirements of:
Machinery Directive 2006/42/EC
EN 13525:2005-Forestry Machinery-Wood Chippers -Safety
EN ISO 12,100, Part 1-Safety of Machinery-Basic Conce pt s, General Principles for Design
EN 982 – Safety of Machinery–Requirements for Fluid Power Systems & their Components-Hydraulics
Noise Emissions Directive 2000/14/EC
-Conformity Assessment Procedure: Annex V (Use of harmonized standard EN ISO 3744:2010)
Sound Power Level: 86 dB L Guaranteed Sound Power Level: 103 dB LWA
74554 Serial number X00731 thru 709993
West Fargo, ND 58078-0849 June 29, 2011 CRARY INDUSTRIES, INC. The authorized representative in Europe who is authorized to compile the technical file: Company: Atlantic Bridge Limited Address: Atlantic House, PO Box 4800 Earley, Reading RG5 4GB, United Kingdom ______________________________
Arlan Mathias Mr. Phillip Wicks Senior Project Engineer
PA
th
Street
Data contained in this document pertains only to machines sold in areas that require CE compliance standards. To identify if your machine is CE compliant, it will have the following CE mark decal:
Page 25
Declaration of Conformity
The undersigned manufacturer:
Crary Industries, Inc.
237 NW 12
P.O. Box 849
West Fargo, ND 58078-0849
Declares that hereunder specified unit:
CHIPPER
Brand: ECHO Bear Cat Type: PTO driven Chipper Model Number: CH5540H & CH5540HXE
Complies with the requirements of:
Machinery Directive 2006/42/EC
EN 13525:2005-Forestry Machinery-Wood Chippers -Safety
EN ISO 12,100, Part 1-Safety of Machinery-Basic Conce pt s, General Principles for Design
EN 982 – Safety of Machinery–Requirements for Fluid Power Systems & their Components-Hydraulics
Noise Emissions Directive 2000/14/EC
-Conformity Assessment Procedure: Annex V (Use of harmonized standard EN ISO 3744:2010)
Sound Power Level: 86 dB L Guaranteed Sound Power Level: 103 dB LWA
CH5540H Serial number 705899 and up CH5540HXE Serial number 800791 and up
West Fargo, ND 58078-0849 June 29, 2011 CRARY INDUSTRIES, INC. The authorized representative in Europe who is authorized to compile the technical file: Company: Atlantic Bridge Limited Address: Atlantic House, PO Box 4800 Earley, Reading RG5 4GB, United Kingdom ______________________________
Arlan Mathias Mr. Phillip Wicks Senior Project Engineer
PA
th
Street
Data contained in this document pertains only to machines sold in areas that require CE compliance standards. To identify if your machine is CE compliant, it will have the following CE mark decal:
Page 26
ECHO BEAR CAT
237 NW 12th Street, West Fargo, ND 58078-0849
Phone: 701.282.5520 • Toll Free: 800.247.7335
Fax: 701.282.9522
E-mail: service@crary.com • opesales@crary.com
www.BearCatProducts.com
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