OWNER
OPERATORS
MANUAL
For 6" Chipper
Models
74624 24HP Honda
74628 28HP Kubota
Crary Company
A Division of TerraMarc Industries
237 12th St. NW • P.O. Box 849
West Fargo, ND 58078-0849
(701)282-5520 • FAX: (701)282-9522
www.bearcatproducts.com
www.terramarc.com
Manual P/N 14295-00
Rev. 04/03
Companion to P/N 14294-00
Before you Begin
DEAR BEAR CAT CUSTOMER,
Thank you for purchasing a Crary Bear Cat 6 Inch Chipper. The 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 toll-free at 1-800-247-
7335.
If you have any questions or problems with your chipper, please call or write your local factoryauthorized 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: 701-282-9522
E
MAIL
opesales@crary.com
service@crary.com
H
OURS
M-F, 8 a.m. to 5
p.m. Central Time
SERIAL NUMBER LOCATION
Always give your authorized Bear Cat dealer the serial number of your Crary Bear Cat chipper when ordering parts, requesting service or any other information. Please record the serial number in the space provided below and on the warranty and
registration card.
WARNING
To prevent personal injury or property damage: Shut
YXXXXX
Fig. # 1 Serial number decal
Serial Number ________________________
off engine, disconnect spark plug wire (if applicable),
make sure that all moving parts have come to a complete
stop, before obtaining serial number, servicing, adjusting
or repairing.
Fig. #2, Serial number decal
6" Chipper Operator’s Manual
I
Section Description Page
SAFETY .................................................................................................................................... 1
1.1 THE SAFETY ALERT SYMBOL............................................................................................................. 1
1.2 BEFORE OPERATING .......................................................................................................................... 1
1.3 BEFORE OPERATING .......................................................................................................................... 2
1.4 OPERATION SAFETY ........................................................................................................................... 2
1.5 MAINTENANCE AND STORAGE SAFETY ............................................................................................ 3
1.6 FEED ROLLER SAFETY ....................................................................................................................... 3
1.7 MAINTENANCE AND STORAGE SAFETY ............................................................................................ 3
1.8 SAFETY DECAL LOCATIONS ............................................................................................................... 4
ASSEMBLY .................................................................................................................................... 5
2.1 ADDING MOTOR OIL TO ENGINE (ALL MODELS) ................................................................................ 5
2.2 ADDING HYDRAULIC FLUID ................................................................................................................. 5
2.3 ADDING COOLANT (DIESEL ONLY)...................................................................................................... 6
2.4 ASSEMBLY TORQUE CHART ............................................................................................................... 6
2.5 ATTACH THE TRAILER WHEELS.......................................................................................................... 7
2.6 ATTACHING THE DISCHARGE CHUTE ................................................................................................. 7
2.7 ATTACHING THE HITCH ........................................................................................................................ 7
2.8 INSTALLING THE REAR STABILIZER .................................................................................................... 8
2.9 ATTACHING THE BATTERY .................................................................................................................. 8
Contents
FEATURES AND CONTROLS ............................................................................................................................ 9
3.1 USE OF CONTROLS ........................................................................................................................... 10
OPERATION .................................................................................................................................. 11
4.1 FILLING THE TANK .............................................................................................................................. 12
4.2 STARTING THE GASOLINE CHIPPER ................................................................................................ 12
4.3 STARTING THE DIESEL CHIPPER ...................................................................................................... 13
4.4 HYD FEED CONTROL ......................................................................................................................... 13
4.5 CHIPPING .................................................................................................................................. 14
4.6 DIRECTING CHIPPER CHUTE ............................................................................................................. 15
4.7 FEED ROLLER BOTTLE JACK ............................................................................................................ 15
4.8 STOPPING INSTRUCTIONS ................................................................................................................ 15
SERVICE & MAINTENANCE ............................................................................................................................ 16
5.1 MAINTENANCE SCHEDULE ............................................................................................................... 16
5.2 REMOVING AND SHARPENING THE CHIPPER BLADES .................................................................. 17
5.3 REPLACING THE CHIPPER DRIVE BELT ........................................................................................... 18
5.4 REPLACING THE HYDRAULIC DRIVE BELT (HONDA ONLY) ............................................................. 19
5.5 GREASING .................................................................................................................................. 20
5.6 ADJUSTING CHIPPER ANVIL ............................................................................................................. 21
5.7 AIR FILTER (DIESEL SHOWN) ............................................................................................................ 21
5.8 CHECKING ANTIFREEZE (DIESEL) .................................................................................................... 21
5.9 HYD RESERVOIR FLUID .................................................................................................................... 22
5.10 HYD OIL FILTER ................................................................................................................................22
5.11 TRAILER SERVICE TIPS ................................................................................................................... 22
5.12 TROUBLESHOOTING ........................................................................................................................ 23
6" Chipper Operator’s ManualII
Chipper Limited Warranty
Crary Bear Cat Chippers are warranted for one year from date of sale for consumer and commercial or
rental operations.
Within the above stated period, Crary Co. will replace any part(s) found to be defective in material and/or
workmanship, after the receipt of the part in our plant. Labor costs to replace these defective parts will be
paid at a Crary established labor rate and time allowed (flat rate) for repair. All transportation charges
incurred in shipping part(s) are the responsibility of the purchaser.
This warranty is void in the case of accidents, failure to perform normal maintenance, or failure to follow
those instructions listed in the service manual. This warranty is also in lieu of all other expressed warranties
and voids any implied warranty as to the merchantability or fitness of the product for a particular purpose
and of any other obligation on the part of Crary Co. Some states do not allow limitations on how long the
implied warranty lasts, so the above limitation may not apply to you.
This warranty applies only to parts or components which are defective, and does not cover necessary
repair due to normal wear, misuse, accidents, or lack of proper maintenance. Components subject to wear
such as wheels, hoses, cables, chipper blades, chipper anvils, etc., are not included in the warranty.
Regular routine maintenance of the unit to keep it in proper operating condition is the
responsibility of the owner.
Engine warranty is not covered by Crary Co. Rather the warranty is covered by the engine manufacturer.
All warranty repair reimbursable under the Crary Co. warranty must be performed by an authorized Bear
Cat service dealer using Bear Cat approved replacement parts. Repair or attempted repair by anyone other
than an authorized Bear Cat service dealer is not reimbursable under the Crary Co. warranty. In addition,
these unauthorized repair attempts may result in additional malfunction, the correction of which is not
covered by warranty.
Crary Co. is not liable for indirect, incidental, or consequential damages in connection with the use of this
product including any cost or expense or providing substitute equipment or service during periods of
malfunction or non-use.
Some states do not allow the exclusion of incidental or consequential damages, so the above exclusion
may not apply to you. This warranty gives you specific legal rights. You may also have other rights which
vary from state to state.
Be sure to note the chipper serial number in any correspondence with Crary Co. or any authorized Bear
Cat dealer.
Crary Company
A Division of TerraMarc Industries
237 12th St. NW • P.O. Box 849
West Fargo, ND 58078-0849
(701)282-5520 • FAX: (701)282-9522
www.bearcatproducts.com
www.terramarc.com
6" Chipper Operator’s Manual
III
NOTES
1
Safety
Section
1.1 THE SAFETY ALERT SYMBOL
This is the safety alert symbol. It is used in this Owner / Operator’s Manual and on your machine
to alert you to potential hazards.
Whenever you see this symbol, read and obey the safety message that follows it. Failure to obey
the safety message could result in personal injury, death or property damage
DANGER
WARNING
CAUTION
1.2 BEFORE OPERATING
1. Read this Owner / Operator’s
manual carefully before operating
this equipment. Be completely
familiar with the controls and the
proper use of this equipment.
2. To prevent personal injury or death:
Stop chipper and engine.
Make sure that all moving parts
have come to a complete stop,
and disconnect quick couplers
from loader before servicing, adjusting or repairing.
Indicates an imminently hazardous situation that, if not avoided, will result in
death or serious injury.
Indicates a potentially hazardous situation that, if not avoided, could result in
death or serious injury.
Indicates a potentially hazardous situation that, if not avoided, may result in
minor or moderate injury.
4. Familiarize yourself with all of the
safety and operating decals on this
equipment and on any of its attachments or accessories.
5. Do not allow children or any person unfamiliar with the use of the
unit to use this machine.
6. Keep the area of operation clear of
all persons, particularly small children. Keep bystanders at least
50 feet (15 meters) away from the
area of operation.
7. Do not operate this machine if you
are under the influence of alcohol,
medications, or substances that
can affect your vision, balance, and
judgement. Do not operate if tired
or ill. You must be in good health
to operate this machine safely.
8. Use only in daylight or good artificial light.
9. Never use without proper guards
in place.
10. Wear safety glasses at all times
while operating this machine. One
pair of safety glasses is provided.
11. Wear hearing protection at all times
while operating this machine.
3. Keep safety decals clean and legible. Replace missing or illegible
safety decals.
Page 16” Chipper Pro Operator’s Manual
Safety
1.3 BEFORE OPERATING
12. Avoid wearing loose fitting clothing. Never operate this machine
wearing clothing with drawstrings
that could wrap around or get
caught in the machine.
1.4 OPERATION SAFETY
DANGER
Keep hands, feet and clothing out of
inlets and discharge openings while
machine is operating to avoid serious personal injury or death.
1. Do not allow hands, or any part of
body or clothing, inside the feeding
chamber, discharge chute, or near
any moving parts.
2. Check the cutting chamber to verify
it is empty before starting the machine.
3. Exclude pieces of metal, rocks,
bottles, cans, and other foreign objects when feeding chipable material into the machine.
4. Shut off machine immediately if the
cutting mechanism strikes any foreign object or the machine starts
making an unusual noise or vibrating. Allow the machine to stop completely. After machine stops:
13. Check that all screws, nuts, bolts,
and other fasteners are properly secured before starting the machine.
Check once in the first two hours
and every 10 hours thereafter.
14. Keep all guards, deflectors, and
shields in place and in good working condition.
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. Stand clear of the discharge area
when operating this machine.
7. Keep your face and body back from
the feed opening.
8. Do not climb onto chipper feed
chutes or frame when operating. Do
not overreach. Keep proper balance
and footing at all times.
15. Do not transport or move machine
while the machine is running.
WARNING
Material can kickup or shift suddenly
and cause serious injury or death.
• Wear eye and hearing protection.
• Stand to the side of the feed chute.
• Release material and stand to
side of the feed table and chute.
9. When feeding material into feed
roller:
A. Wear eye, face and hearing
protection.
B. Release material and stand to
side of feed table and chute.
WRONG
A. Shut off engine.
B. Remove ignition key.
C. Inspect for damage.
D. Replace or repair any
damaged parts.
E. Check for and tighten any
loose parts.
Page 2 6” Chipper Operator’s Manual
1.5 MAINTENANCE AND STORAGE SAFETY
WRONG
Safety
10. Setting up your chipping site so
you are not endangering the public is critical for safety.
WRONG
1.6 FEED ROLLER SAFETY
WARNING
To prevent personal injury or death:
Stop chipper and loader engine.
Make sure that all moving parts
have come to a complete stop, and
disconnect quick couplers from
loader before servicing, adjusting,
or repairing.
11. Rotate the discharge tube to face
the opposite direction of the towing vehicle before towing. This
prevents the discharge tube from
projecting over the trailer wheels
and striking foreign objects.
12. Flying debris can cause serious
injury or death and property damage.
13. Keep bystanders away from discharge chute.
2. Never climb onto chipper feed
chute or table when operating.
3. Do not over reach. Keep proper
balance and footing.
WRONG
14. Position discharge chute away
from bystanders and other property when opening.
15. Check the bolts torque on the
chipper every 10 hours of operation.
WARNING
Failure to maintain proper fastening torque on chipper blade bolts
may result in severe damage to the
chipper and / or personal injury.
4. No riders allowed, keep off the at-
tachment.
1. Feed roller and rotating chipper
can cause serious injury or death.
Keep hands, feet and clothing
away from feed roller chipper
blades.
1.7 MAINTENANCE AND STORAGE SAFETY
1. Shut off machine, remove key, and
disconnect the spark plug wire when
this equipment is stopped for service, inspection, or storage.
2. Replace any missing or unreadable
safety decals. Refer to the parts
manual for part numbers when ordering safety decals from an area
Bear Cat dealer.
3. Store the machine out of reach of
children and where fuel vapors will
not reach an open flame or spark.
Drain the fuel and dispose of it in a
safe manner for storage periods of
three months or more.
4. Allow machine to cool before storing in an enclosure.
5. Never store this machine with fuel
in the fuel tank inside a building
where fumes may reach an open
flame or spark, or where ignition
sources are present such as furnaces, clothes dryers, stoves, electric motors, hot water and space
heaters, etc.
NOTE
See engine owners manual or contact the engine manufacturer for
engine safety instructions and decals.
Page 36” Chipper Pro Operator’s Manual
Safety
1.8 SAFETY DECAL LOCATIONS
Familiarize yourself with all of the safety and operational decals on the machine and the associated hazards. Make certain
that all safety decals and operational decals on this equipment are kept clean and in good condition. If you need a
replacement decal, please refer to the parts catalog. Decals that need replacement must be applied to their original
locations.
Fig. #3, Safety decal locations
Fig. #4, Safety decal locations
Page 4 6” Chipper Operator’s Manual
2
Assembly
Section
Your Chipper may arrive totally or partially assembled. If your machine arrives partially assembled, you may need to perform
the steps in this section.
2.1 ADDING MOTOR OIL TO ENGINE (ALL MODELS)
IMPORTANT
Motor oil should be
checked before the chipper is started. Add if
necessary.
1. The machine was shipped with oil
in the engine, as it was tested at
the factory.
2. To determine which type of oil to use,
refer to the engine owners manual
included in the owners kit of the
chipper.
2.2 ADDING HYDRAULIC FLUID
Hydraulic fluid is used to drive the feed
roller. The hydraulic pump is attached
to the motor (diesel models) or
connected to the motor with a belt
(gasoline models).
Premium hydraulic fluids containing
high quality rust, oxidation, and foam
inhibitors are required. These include
premium turbine oils, API CD engine
oils per SAE J183, M2C33F or G
automatic transmission fluids meeting
Allison C-3 or Caterpillar TO-2, and
certain specialty agricultural tractor
fluids.
If system has no oil, follow this startup
procedure:
1. Before starting the hydraulic pump,
make sure all system components
(reservoir, fittings, etc.) are clean.
2. Fill the reservoir with recommended
hydraulic fluid, which should be filtered before entering the reservoir.
3. The inlet line leading from the reservoir to the pump must be filled before start-up. Loosen the fitting at
the pump on this inlet line until oil
bleeds out.
4. Start the engine and run at the lowest possible RPM.
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.
7. Run the feed roller in both directions
for several minutes until any remaining air is purged from the unit. Refill
the reservoir as necessary.
3. Remove the oil fill plug.
4. Checking as necessary, add oil to
the motor until the dipstick shows
the correct reading.
Fig. #5, Hydraulic reservoir
8. Shut down the engine, check for and
correct any fluid leaks, and check
the reservoir level. Add fluid if necessary. The hydraulic gear pump is
now ready for operation.
Page 56” Chipper Pro Operator’s Manual
Assembly
2.3 ADDING COOLANT (DIESEL ONLY)
You may need to add coolant before
you start the diesel engine. While
operating, make sure the fluid is
between the full and the low marks,
add if necessary.
To fill:
1. Remove the top cover.
2. Add a 50/50 mix of water and antifreeze until it reads slightly below
the full line. (The antifreeze should
drain from the tank into the radiator).
3. Wait 10 minutes and check level
again. Refill if necessary.
4. After running the machine, recheck
the level of antifreeze, and fill is necessary.
Fig. #6, Coolant level
2.4 ASSEMBLY TORQUE CHART
UNIFIED INCH BOLT TORQUE VALUES (COARSE THREAD)
(unless otherwise specified in the manual)
Bolt
Diameter
"A"
1/4" 7.5 5.5 12 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
1-3/8” 950 700 2150 1550 3400 2550
1-1/2” 1250 930 2850 2100 4550 3350
SAE 2
(N.m) (ft - lb) (N.m) (ft - lb) (N.m) (ft - lb)
Bolt Torque *
SAE 5 SAE 8
Page 6 6” Chipper Operator’s Manual
Assembly
2.5 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 in
the back of the manual for tightening torque of bolts and screws.
2. Raise the trailer several inches from
the ground with a hoist or jack. Support the chipper securely.
3. Lift one wheel to a hub and align the
wheel lug holes with the hub lug
bolts. Thread the lug nuts (found in
the parts kit) into the holes and
tighten the lug nuts to 75 ft. lbs. Follow a star pattern when tightening
the lug nuts . Repeat this step for
the remaining wheel.
2.6 ATTACHING THE
DISCHARGE CHUTE
1. The chute rotator is connected to
the chipper frame first with two 3/8
bolts from the owners kit. Install but
do not tighten. Remove the top cover
from the chute rotator to expose the
rotator drive sprocket.
2. Attach the discharge chute to the
mounting flange on the chipper
frame. The square discharge chute
will fit over the round section of the
chipper frame.
3. Place the discharge ring, and discharge retainer around the base of
the mounting flange on the chipper
frame.
4. Attach the discharge ring and retainer to the flange with the provided
3/8” x 1-1/4” bolts and nuts. Tighten
to proper torque.
2.7 ATTACHING THE
HITCH
1. Attach the ball coupler to the hitch
weldment using the provided 1/2” x
4” bolts and 1/2” washers and 1/2”
nuts. Tighten to proper torque.
2. Slide the hitch weldment into the
hole in the frame, back to the 1/2”
mounting holes.
3. Connect the hitch weldment to the
frame using the two 1/2” x 4-1/2”
bolts, 1/2” washers and 1/2” nuts.
Tighten to proper torque.
4. Check to make sure the tongue jack
and safety chains are installed correctly.
Fig. #7, Trailer wheels
5. Install the chain around the discharge ring and sprocket on the inside of the chute rotator. Connect
chain with the connector link.
6. Reassemble the top cover and
tighten the 4 bolts.
7. Slide the chute rotator assembly
back to remove chain slack and
tighten the two attachment bolts.
8. Torque all fasteners to proper values.
Fig. #9, Trailer hitch
Fig. #8, Discharge chute
Page 76” Chipper Pro Operator’s Manual
Assembly
2.8 INSTALLING THE
REAR STABILIZER
The rear stabilizer is installed by sliding
the stabilizer into the corresponding
slot on the rear of the chipper frame.
The stabilizer is secured and adjusted
with the provided snap pin.
Fig. #10, Rear stabilizer
2.9 ATTACHING THE
BATTERY
The chipper is shipped with a battery.
The battery is connected to the battery
cables using the two 1/4” bolts and
nuts found in the parts kit. To connect:
1. Route the battery cables to the
proper battery terminals, hooking
positive to positive, and negative to
negative.
2. Connect cables with 1/4” bolt and
nuts. Tighten nuts to proper torque.
3. Check battery for proper fluid level
and fill if necessary.
4. If necessary, charge battery.
Page 8 6” Chipper Operator’s Manual
3
Features and Controls
Section
FEATURES AND CONTROLS IDENTIFICATION
Learn the location of the features and controls on your machine before operating.
DESCRIPTION OF OPERATION
Fig. #11, features and controls
Fig. #12, features and controls
The chipper pulls in wood with the feed roller, chips the wood, and blows the chips out through the adjustable discharge
chute.
Page 96” Chipper Pro Operator’s Manual
Features & Controls
3.1 USE OF CONTROLS
WARNING
To prevent personal injury or property damage: Shut off engine, disconnect spark plug wire, and make
sure that all moving parts have come
to a complete stop, before servicing, adjusting or repairing.
1. Key: The key is located on the
control panel on both the diesel
and gas engines. Turn the key to
the right to activate the electric
start. On diesel models turning the
key to the left activates the glow
plug. DO NOT START THE MACHINE WITH THE CHIPPER ENGAGED.
2. Throttle: This controls the speed
of the engine. On diesel models
the throttle is adjusted by twisting, or by pushing the button and
pushing or pulling.
chipper from tipping from heavy
loads when disconnected from the
towing vehicle.
9. Bottle Jack: Used to lift feed roller
for unplugging.
10. Tongue Jack: Used to adjust the
height of the hitch.
11. Fuel Gauge: Shows remaining
fuel.
12. Murphy Switch: See starting instructions for diesel engines. The
murphy switch will not let the engine run if the oil pressure is to
low, or the engine temperature too
high. To start the engine, this
switch must be held until oil pressure is present on the gauge.
Fig. #15, Engagement instructions
3. Choke: Use this to start the gaso-
line engine when cold. Move
switch to original position as engine warms.
4. Chipper Engagement: To acti-
vate slowly push the handle toward
the ground. To disengage the machine move the handle back up to
the original position (See Fig. #15).
5. Feed Roller Engagement: To engage the feed roller move the control arm. The cycle of the control
arm, forward to back, is R, F, N,
R.
6. Chute Rotor: Directs the discharge of chipped material horizontally.
7. Discharge cap rotor: Directs the
discharge of material vertically.
8. Rear Stabilizer: Prevents the
Fig. #13, Diesel controls
Fig. #14, Gasoline controls
Page 10 6” Chipper Operator’s Manual
4
Operation
Section
WARNING
Before operating your machine, be
sure you read and understand all
safety, controls and operation instructions in this Owner/Operators
manual and on your machine.
Failure to follow these instructions
can result in serious injury or property damage.
As with any other piece of outdoor
power equipment, getting the “feel” for
how your machine operates and getting
to know the best techniques for
particular jobs are important to overall
good performance.
Read this section thoroughly before you
start the engine. The instructions given
here will help you become familiar with
your machine and have you operating
efficiently in a short time.
This section covers:
• Filling the tank (Gas and diesel instructions)
• Starting the gasoline chipper
• Starting the diesel chipper
• Hydraulic feed
• Chipping
• Directing the chipper chute
• Feed roller bottle jack
• Stopping Instructions
Fig. #16, Chipping
Page 116” Chipper Pro Operator’s Manual
Operation
4.1 FILLING THE TANK
DANGER
Gasoline is highly flammable
and its vapors are explosive. To
prevent personal injury or property damage:
Store gasoline only in approved
containers, in well ventilated, unoccupied buildings, away from sparks
or flames. Do not fill the fuel tank
while the engine is hot or running,
since spilled fuel could ignite if it
comes in contact with hot parts or
sparks from ignition. Do not start
the engine near spilled fuel. Never
use gasoline as a cleaning agent.
FILLING THE FUEL TANK
Gasoline Type:
For best results use only clean, fresh,
unleaded gasoline with a pump sticker
octane rating of 87 or higher. In countries using the Research method, it
should be 90 octane minimum.
Gasoline Alcohol blends
Gasohol (up to 10% ethyl alcohol, 90%
unleaded gasoline by volume) is approved as a fuel for Honda engines.
Other gasoline/alcohol blends are not
approved.
Gasoline Ether blends
Methyl Tertiary Butyl Ether (MTBE) and
unleaded gasoline blends (up to a maximum of 15% MTBE by volume) are
approved as a fuel for Honda engines.
Other gasoline/ether blends are not
approved.
Diesel Fuel:
For best results use only clean, fresh,
#2 diesel. An additive for cold weather
can be used to prevent the fuel from
turning into a gel.
To Add Fuel:
1. Stop engine, wait for all parts to stop
moving, then disconnect the spark
plug wire. Allow the engine and muffler to cool for at least three minutes.
2. Clean area around fuel fill cap and
remove cap.
3. Using a clean funnel, fill fuel tank to
1/2” below bottom of filler neck to
provide space for fuel expansion.
Install fuel fill cap securely and wipe
up any spilled diesel.
4.2 STARTING THE
GASOLINE CHIPPER
WARNING
Handle fuel with care. It is highly
flammable. Always use an
approved container and fill tank
outdoors.
CAUTION
Move machine to a clear level
area. Do not operate in the vicinity
of bystanders.
Make sure the chamber is empty before
starting.
1. Reference the Honda Owners
Manual.
2. Check engine oil level before starting. Do not overfill or underfill oil. The
Honda engine is equipped with an
oil level sensor and will not allow the
engine to start in either condition.
3. Make sure the chipper engagement
is in the start position.
4. Engage the choke if necessary.
5. Adjust throttle to start/idle position.
6. Turn the key to the right to engage
the starter.
7. Release the key after the engine
starts.
8. For a Cold Engine — Gradually
return the choke from the choke
position to the run position as the
engine warms up.
Page 12 6” Chipper Operator’s Manual
Operation
4.3 STARTING THE DIESEL CHIPPER
WARNING
Allow the machine to come to complete stop before inspection or servicing.
WARNING
Handle fuel with care. It is highly
flammable. Always use an
approved container and fill tank
outdoors.
CAUTION
Move machine to a clear, level
area. Do not operate in the vicinity
of bystanders.
6. Push in and hold the Murphy switch
push-button. Continue to hold
Murphy switch in when cranking
engine until engine is running.
7. Activate the starter. Release the
switch as soon as the engine starts.
Do not crank over for more than 10
seconds. After engine is running;
hold murphy switch until engine has
oil pressure.
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.
4.4 HYD FEED CON-
TROL
The controller functions are further
detailed below:
1. The first function is that the controller operates is the feed roller. The
controller monitors the RPMs of the
chipper rotor and if it drops below
the preset range the feed roller
stops. When the RPMs are back
up to an acceptable level the feed
roller will reengage.
2. The controller also has a “try again”
feature. The controller monitors the
hydraulic pressure of the feed roller.
If it senses the level is too high (the
feed roller becomes obstructed) the
controller will reverse the feed roller
, removing the material trying to be
chipped. The controller will then
engage the roller into the forward
position and try to feed the material
again. If this cycle continues the
obstruction will have to be removed
manually, or material to be chipped
should be removed, trimmed, and/
or repositioned.
1. Reference the Kubota Owners
Manual. Also, make sure cutting
chamber is empty before starting.
2. Before starting, fill engine with oil to
the correct level. See engine manual
for additional starting, operation and
maintenance instructions. Some oil
usage is normal. Check level before
each use.
3. Before starting, fill fuel tank with
fresh and clean diesel fuel. For instructions on bleeding the fuel system on initial start up or if fuel runs
out, see engine manual.
4. Turn key switch to preheat position
(to the left). Hold in preheat position
for several seconds until glow plug
indicator light switches off.
5. Place throttle control in the idle position.
6. Make sure the chipper engagement
lever is disengaged.
Fig. #17, Controller
The Bear Cat chipper is equipped with
a pre-programmed hydraulic feed
control. The controller serves a variety
of functions including monitoring
chipper rotor RPM, controlling the feed
roller, and providing routine
maintenance alerts. The controller has
an on/off feature located below the
control panel. If the controller becomes
damaged, the chipper will still run with
the controller shut off, however all of
the controller functions will be disabled.
The feed roller will have to be controlled
with the control arm. The controller is
located under the control panel.
To disable the try again feature disconnect the 2 pin connector going
to the pressure switch. It is located
above the feed roller motor on the
SA-1987 assembly.
3. The controller will also flash service
alerts when it is started. Every 15
hours it will flash (error light blinks
5 times) for the chipper blades to
be sharpened. Every 100 hours it
will flash (error light blinks 10 times)
for the engine oil to be changed.
NOTE: The RPM sensor on the rotor
must be flashing or the controller won’t
work. Clearance between the sensor
and the bolt must be between 1/32”
and 3/32”.
To reprogram the hydraulic feed
control, software must be purchased.
Contact your distributor or the Bear
Cat factory for more information.
Page 136” Chipper Pro Operator’s Manual
Operation
4.5 CHIPPING
WARNING
6. Never push brush into the chute with
your feet.
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.
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. Adjust engine speed with the
throttle. On diesel models the
throttle can be locked.
2. Select limbs that are up to 6 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.
7. Engage the hydraulic feed by moving the control arm. Pull the arm
toward you to engage the hydraulic
feed. The speed of the feed roller
can be adjusted by turning the speed
control knob on the chipper valve assembly.
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.
9. If the feed roller slips downward pressure on the roller can be increased
by moving the eyebolt that connects
the spring to the feed roller.
10. 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."
3. Feed brush from the side of the
chute, rather than from the front.
Step aside to avoid being hit by the
brush moving into the chipper.
4. Never lean over the 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 and cause major damage. In addition, metal pieces can come back
like shrapnel to injure or kill.
Page 14 6” Chipper Operator’s Manual
Operation
4.6 DIRECTING CHIPPER CHUTE
Fig. #18, Directing the chute
The chipper chute can be locked in 53
different positions using the chute rotor.
The discharge cap can be directed to
adjust how high and how far the chipped
material is blown.
4.7 FEED ROLLER
BOTTLE JACK
Fig. #19, Bottle jack
The feed roller bottle jack is used to
raise the feed roller if chipping material
becomes wedged in the feed roller. The
jack will raise the feed roller and remove
the tension on the chipped material.
Turning the check valve clockwise will
engage the pump of the jack. Once the
jack is engaged pumping the handle
will raise the jack. Turning the check
valve counterclockwise will disengage
the pump and lower the jack.
4.8 STOPPING INSTRUCTIONS
WARNING
Allow the machine to come to
complete stop before inspection
or servicing.
1. Move throttle to slowest position.
2. Move chipper engagement to the
engine start position.
3. Let machine idle for a few seconds.
4. Turn key to off position.
5. Allow machine to come to a complete stop.
To adjust the chute rotor lift up the rotor
lock. Turn the chute rotor until the
chute faces the desired position. Let
go of the rotor lock and fine tune the
position of the rotor until the lock snaps
in place.
The discharge cap is adjusted by
turning the discharge crank cap either
clockwise or counterclockwise. Turning
the handle clockwise will raise the
position of the discharge cap. Turning
the handle counterclockwise will lower
the position of the discharge cap.
Page 156” Chipper Pro Operator’s Manual
5
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Service & Maintenance
Section
WARNING
To prevent personal injury or property damage: Shut
off engine, disconnect spark plug wire and make sure
that all moving parts have come to a complete stop
before, servicing, adjusting or repairing.
See engine owners manual for further maintenance and
troubleshooting information.
5.1 MAINTENANCE SCHEDULE
The following items listed in the service and maintenance
schedule are to be checked and if necessary, corrective
action should be taken. This schedule is designed for units
operating under normal conditions. If the unit is operating in
adverse or severe usage conditions it may be necessary for
the items to be checked and serviced more frequently.
SERVICE AND MAINTENANCE SCHEDULE
FREQUENCY
COMPONENT
AIR CLEANER CHECK AND CLEAN (1)
AIR INTAKE CLEAN (1)
ENGINE OIL CHANGE (1)
FUEL FILTER REPLACE
SPARK PLUG
ENGINE OIL CHECK
FUEL TANK FILL
CHIPPER ANVIL
CHIPPER BLADES
ALL INTERNAL AND
EXTERNAL NUTS AND
BOLTS
BELT CONDITION CHECK
BELT TENSION CHECK
GREASE ZERKS LUBE
ENTIRE MACHINE CLEAN
HYD. OIL FILTER REPLACE
WHEEL BEARINGS CHECK AND REPACK
(1) PERFORM MORE FREQUENTLY UNDER EXTREMELY DUSTY CONDITIONS.
(2) PERFORM MORE FREQUENTLY WHEN CHIPPING DRY OR DIRTY WOOD.
As the Chipper Limited Warranty states, failure by the Owner to perform normal maintenance will void the machine's
warrant
NORMAL MAINTENANCE. S
INTERNAL AND EXTERNAL NUTS AND BOLTS is the sole res
cause for Crar
. The aggressive, high-speed nature of chipping REQUIRES THE OWNER TO PERFORM THE ABOVE LISTED
BearCat to deny warranty.
MAINTENANCE
REQUIRED
CHECK CONDITION AND
GAP
CHECK 1/16" TO 1/8"
CLEARANCE AND RETORQUE TO 75 FT. LBS. (2)
CHECK SHARPNESS AND
RETORQUE TO 75 FT. LBS.
(2)
RE-TORQUE PER
ASSEMBLY TORQUE CHART
ecial consideration to maintain and re-torque the CHIPPER ANVIL, CHIPPER BLADES, AND ALL
Refer to Engine
Operator manual
•
onsibility of the Owner. Failure by the Owner to do so shall be
EVERY 8
HOURS
•
•
•
EVERY
25
HOURS
EVERY
50
HOURS
EVERY
200
HOURS
EVERY
YEAR
Page 16 6” Chipper Operator’s Manual
Service & Maintenance
5.2 REMOVING AND SHARPENING
THE CHIPPER BLADES
WARNING
To prevent personal injury or property damage: Shut
off engine, remove ignition key and make sure that all
moving parts have come to a complete stop, before,
servicing, adjusting or repairing.
WARNING
The chipping blades are sharp!! Use care when working
on the machine to avoid injury.
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. The chipper
will not operate when the cover is open. Rotate the rotor
so that the bolts holding the blades are most accessible.
To remove the inner blade the access cover will need to
be removed from the top of the feed roller.
Sharpening the chipper blades:
Depending on the type of wood fed into the chipper, the
blades will eventually dull, making if difficult to feed material
and produce chips. It is recommended that the blades be
checked for sharpness every 8 hours.
Regrind the angled edge of the chipping blades to 45 degrees. (refer to figure below) The blades can be ground on a
bench grinder or by a professional. Make sure some type of
fixture is used to correctly hold the blade at the proper angle.
Be careful when grinding so that the blade does not become
overheated and change color (This will remove the heattreated properties). Use short grinding times and cool with
water or some type of liquid coolant. Try to remove an equal
amount off of each blade to maintain rotor balance.
Never sharpen or back grind the flat side of the chipping
blade. This will cause the edge to roll and the chipper blade
will be damaged, resulting in poor chipping performance.
Small imperfections such as nicks, burrs, etc. on the flat
side of the blade will not affect the chipping performance of
the machine.
When completed, replace the chipping blades and tighten
the bolts to 75 ft. lbs. Install all safety screens and guards
and resume chipping.
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 one side has not been used, remove
and reverse the chipping blades. Tighten bolts to proper
torque and secure access cover.
Fig. # 20, Exposing the chipper blades
SHARPENED
SURFACE
.38
45°
MOUNTING SURFACE
Fig. # 21, Sharpening the chipper blades
DO NOT GRIND
MOUNTING SURFACE
DO NOT GRIND
SHARPENED
SURFACE
Page 176” Chipper Pro Operator’s Manual
Service & Maintenance
5.3 REPLACING THE CHIPPER DRIVE BELT
Fig. # 22, Idler pulley
The condition of the drive belt should be checked annually,
or after every 25 hours of operation. If the belt is cracked,
worn, frayed, or stretched, replace it. Only replace it with
the original banded belt type, do not use singe belt types.
To replace the belt:
1. Remove idler pulley. The pulley is removed by loosening
the 1/2” mounting hardware.
2. Lift belt idler pulley off of the idler arm weldment.
3. Remove the drive belt from the pulleys and take the old
belt out of the machine.
4. Install new belt on pulleys and lower belt idler. Check
alignment of pulleys and adjust if needed.
5. Reinstall the belt idler pulley to the idler arm weldment
using the 1/2” hardware. Tighten bolt to proper torque.
Fig. # 23, Removing the belt
5. Check belt tension before start-up. If necessary adjust
spring tension
Page 18 6” Chipper Operator’s Manual
Service & Maintenance
5.4 REPLACING THE HYDRAULIC DRIVE BELT (HONDA ONLY)
Fig. # 24, Hydraulic pump
The condition of the hydraulic drive belt should be checked
annually, or after every 25 hours of operation. Replace the
belt if it is cracked, worn, frayed, or stretched.
To replace:
1. Loosen the mounting bolts shown in Fig. #20.
2. Loosen the nut (not shown) on the back side of the adjusting bolt to relieve tension on the belt. Make sure that
the pump mounting bracket moves and relieves the belt
tension.
3. Remove drive belt according to instructions on prior page.
4. Remove the loosened hydraulic belt from the chipper.
5. Install the new hydraulic belt in the same manner as the
old belt was removed.
6. Replace the drive belt, according to directions on prior
page.
7. Install the hydraulic drive belt onto the two pulleys.
8. Tighten the nuts on the adjusting bolt to move the pump
mounting bracket. Stop when the belt is at the desired
tension.
9. Tighten the mounting bolts on the pump mounting bracket
to the proper torque.
10. Check pulleys for proper alignment and adjust if neces-
sary.
Page 196” Chipper Pro Operator’s Manual
Service & Maintenance
5.5 GREASING
Grease zerks on the Bear Cat 6” Chipper should be greased
every 25 hours, depending upon conditions.
Fig. # 25, Greasing
Fig. # 27, Greasing
Fig. # 28, Greasing
Fig. # 26, Greasing
Page 20 6” Chipper Operator’s Manual
Service & Maintenance
5.6 ADJUSTING CHIPPER ANVIL
5.7 AIR FILTER (DIESEL SHOWN)
Fig. # 30, Diesel Air Filter
Both the Kubota diesel and the Honda gas engines used on
the 6” chipper have air filters. Refer to the Kubota and Honda
engine manuals, included with your machine, for specific
instructions on replacing and cleaning these filters.
Fig. # 29, Chipper anvil
The four chipping blades should clear the chipper anvil by 1/
16 inch to 1/8 inch. The chipper anvil is adjustable and
reversible. All four sides of the anvil can be used for chipping.
To adjust:
1. Lift rotor access cover and expose rotor.
2. Loosen the three 1/2 inch bolts that hold the chipper anvil
to the frame.
3. Measure the amount of clearance between chipping blade
and chipper anvil from inside of housing.
4. Adjust inward or outward to the desired measurement,
using the adjustment nuts provided.
5. Tighten bolts on chipping block to 75 ft. lbs. and resume
operation.
5.8 CHECKING COOLANT (DIESEL)
Fig. # 31, Diesel coolant level
The diesel Kubota is tested before shipping. In order to test
the equipment the fluid levels are filled. However, before
starting the machine, and every time the engine is started
thereafter, be sure to check the coolant level. If the level is
low add fluid.
To add fluid follow the procedure below:
1. Make sure the coolant isn’t hot.
If chipper anvil edge is damaged or worn unevenly, remove
the three bolts holding the anvil and use one of the other
three edges. Replace as necessary
2. Open the radiator cap pictured in Fig #28.
3. Check level and add if necessary. Use a 50/50 mixture of
antifreeze and water.
Page 216” Chipper Pro Operator’s Manual
Service & Maintenance
5.9 HYD RESERVOIR FLUID
Fig. # 32, Hydraulic reservoir
The chippers are tested before shipping. In order to test the
equipment the fluid levels are filled. However, check the fluid
levels before initial operation and add if necessary (see the
assembly section). Always check levels before each use.
To check levels look at the side of the hydraulic oil container
and make sure the fluid level falls between the marks. If
necessary add oil.
On the Kubota models the hydraulic tank is located next to
the fuel tank. A cutout exists to check the fluid level.
Premium hydraulic fluids containing high quality rust,
oxidation and foam inhibitors are required. These include
premium turbine oils, API CD engine oils per SAE J183,
M2C33F or G automatic transmission fluids meeting Allison
C-3 or Caterpillar TO-2, and certain specialty agricultural
tractor fluids.
5.10 HYD OIL FILTER
Fig. # 33, Hyd oil filter
It is recommended that this filter be changed after the first
50 hours and every 200 hours thereafter. To change:
1. Using an oil filter wrench turn the filter counterclockwise.
2. Once the filter becomes loose, turn it out the rest of the
way with your hand.
3. Properly discard old filter.
4. Lube the rubber seal on the new filter (P/N 16588) with
clean hydraulic oil.
5. Install the filter onto the threaded pipe. Turn with your
hand until the filter is finger tight.
6. Turn, by hand, another 1/2 turn.
7. Check hydraulic oil level and fill if necessary.
5.11 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.
Page 22 6” Chipper Operator’s Manual
Service & Maintenance
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5.12 TROUBLESHOOTING
Before performing any of the correction in this troubleshooting chart, refer to the appropriate information contained in this
manual for the correct safety precautions and operating or maintenance procedures. Contact your nearest dealer or the
factory for service problems with the machine.
PROBLEM POSSIBLE CAUSE CORRECTION
Dull chipping blades. Sharpen or replace.
Chipper does not chip. Poor
performance.
Unusual vibration or noise.
Engine runs poorly.
Engine won't start or is hard to start.
Drive belts loose or worn. Re
Too lar
Solid ob
Broken or missin
Solid ob
Chipper blade loose or damaged. Tighten or replace.
En
Loose or missin
Chi
Bad s
Incorrect choke settin
Dirty air filter. Clean or replace.
Stale
Dirt or water in fuel tank. Contact en
Gas tank is em
S
S
Gas line is obstructed. Remove gas line at carburetor and check for
Dirt
Flooded engine. Put throttle control in run position and crank
Dirty or plugged air cleaner. Clean air cleaner and replace.
e of branch. Limit branch size.
ect jammed in the unit. Check and remove.
chipper blade. Replace blade.
ect jammed in the unit. Check and remove obstruction.
ine crankshaft is bent or damaged. See Engine Service Dealer.
bolts on unit. Tighten or replace bolts.
ed or broken chipper blades. Replace chipped or broken blades.
ark plug.Ins
.Chan
asoline. Drain gasoline and add fresh fuel.
. Fill gas tank.
ark plug wire is disconnected. Connect loose wire to spark plug.
ark plug is defective. Replace spark plug.
, stale, water-contaminated gas. Drain tank and fill with fresh gasoline.
lace drive belts, or increase spring tension
ect spark plug and replace if necessary.
e choke setting.
ine service dealer.
obstruction. Drain gas tank and refill with fresh,
asoline.
clean
en
ine several times to clear out excess gas.
Page 236” Chipper Pro Operator’s Manual
Manual Improvement Program
If you have a suggestion on how to improve this manual, send it to us. Participants whose ideas are
implemented will receive a free pair of Crary genuine leather gloves.
Send your suggestions to:
Crary Company
C/O Technical Writer
237 NW 12th St. Box 849
West Fargo, ND 78078
Suggestions:
Name:
Address:
Phone Number:
Email (if applicable):
Product purchased:
Manual part number:
Page 24 6” Chipper Operator’s Manual
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 OTHER
PETROLEUM PRODUCTS AND THEIR VAPORS, 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 CONTAINS
CHEMICALS KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER, BIRTH DEFECTS, OR
OTHER REPRODUCTIVE HARM.
Crary Company
A Division of TerraMarc Industries
237 12th St. NW • P.O. Box 849
West Fargo, ND 58078-0849
(701)282-5520 • FAX: (701)282-9522
www.bearcatproducts.com
www.terramarc.com
Manufactured in the
United States of America
by Crary Company
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