Echo 75124 User Manual

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OWNER'S MANUAL

TOWABLE TRUCKLOADER

Manual PN 13991-00 Rev. 0504 Companion to 13992-00

MODEL

75124

Before you Begin

DEAR BEAR CAT CUSTOMER,

Thank you for purchasing a Crary Bear Cat product. The Bear Cat line is designed, tested, and manufactured to give years of dependable performance. To keep your machine operating at peak efficiency, it is necessary to adjust it correctly and make regular inspections. The following pages will assist you in the operation and maintenance of your machine. Please read and understand this manual before operating.

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

If you have any questions or problems with your machine, please call or write your local factory-authorized Bear Cat dealer.

PLEASE SEND US YOUR WARRANTY CARD

A warranty card is included in your owner's kit packaged with your machine. Please take the time to fill in the information requested on the card. When you send your completed card to us, we will register your machine and start your coverage under our limited warranty.

How to Contact

Bear Cat

ADDRESS

Crary Bear Cat

237 NW 12th Street

PO Box 849

West Fargo, ND 58078

PHONE

800-247-7335 701-282-5520

Fax: 701-282-9522

opesales@crary.com

service@crary.com

HOURS

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

Central Time

EMISSION INFORMATION

WARNING

WARNING TO ALL CALIFORNIA AND OTHER STATES OPERATING OUTDOOR POWER EQUIPMENT

Under California Law and under the laws of several other states you are not permitted to operate an internal combustion engine using hydrocarbon fuels on any forest covered, brush covered or grass covered land or on land covered with grain hay or other flammable agricultural crop, without

an engine spark arrester in continuous effective working order.

The engine on your power equipment, like most outdoor power equipment, is an internal combustion engine that burns gasoline, a hydrocarbon fuel. Therefore, your power equipment must be equipped wi th a sp ark arrester muffler in continuous effective working order. The spark arrester mu st be att ached to the engine exhaust system in such a manner that flames or heat from the system will not ignite flammable material.

Failure of the owner/operator of the equipment to comply with this regulation is a misdemeanor under Californ ia law, a nd may als o be a violation of other state and or federal regulations, laws, ordinances, or codes. Contact your local fire

marshal or forest service for specific information about what regulations apply in your area.

The standard muffler installed on the engine is not equipped with a spark arrester. One must be added before use if this machine is intended to be used in an area where a spark arrester is required by law. Contact the local authorities if these laws apply to you. See your authorized engine dealer for spark arrester options.

LIMITED WARRANTY

This warranty applies to Bear Cat, Crary, Load-N-Lift, Lockwood and Weed Roller brand products manufactured by Crary Company, a division of TerraMarc Industries, henceforth called Crary Company.

Crary Company warrants to the original owner each new Crary Company 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 Company. Replacement parts are warranted for (90) days from date of installation.

THE WARRANTY REGISTRATION MUST BE COMPLETED AND RETURNED TO CRARY COMPANY 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 Company dealer. Crary Company 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 Company 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 Company does not warrant replacement components not manufactured or sold by Crary Company.

This warranty applies only to parts or components that are defective in material or workmanship.

This warranty does not cover normal wear items including but not limited to bearings, belts, pulleys, filters

2. and chipper knives.

This warranty does not cover normal maintenance, service or adjustments.

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.

This warranty does not cover damage due to unauthorized modifications of the product.

Engines are warranted by the respective engine manufacturer and are not covered by this warranty.

Crary Company 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 Company 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 Company 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 Company or to modify the terms or limitations of this warranty in any way. Crary Company, at its discretion, may periodically offer limited, written enhancements to this warranty.

CRARY COMPANY RESERVES THE RIGHT TO CHANGE THE DESIGN AND/OR SPECIFICATIONS OF ITS PRODUCTS AT ANY TIME WITHOUT OBLIGATION TO PREVIOUS PURCHASERS OF ITS PRODUCTS.

CONTENTS

SECTION DESCRIPTION PAGE

1. SAFETY ...............................................................................................................1

1.1 THE SAFETY ALERT SYMBOL .......................................................................................................................... 1

1.2 BEFORE OPERATING ....................................................................................................................................... 1

1.3 OPERATION SAFETY ........................................................................................................................................ 2

1.4 MAINTENANCE AND STORAGE SAFETY ........................................................................................................ 3

1.5 TOWING SAFETY .............................................................................................................................................. 3

1.6 BATTERY SAFETY ............................................................................................................................................. 3

2. ASSEMBLY ..........................................................................................................4

2.1 ASSEMBLING THE MACHINE ........................................................................................................................... 4

2.2 ATTACHING THE HITCH .................................................................................................................................... 5

2.3 ATTACHING THE WHEELS ................................................................................................................................ 5

2.4 ATTACHING THE VACUUM HOSE TO THE HOSE SUPPORT ......................................................................... 5

2.5 ATTACHING THE BLOWER DISCHARGE TUBE .............................................................................................. 5

2.6 INSTALLING THE BATTERY. ............................................................................................................................. 6

3. OPERATION ........................................................................................................7

3.1 STARTING .......................................................................................................................................................... 7

3.2 VACUUMING ...................................................................................................................................................... 7

3.3 STOPPING ......................................................................................................................................................... 8

3.4 UNPLUGGING THE ROTOR .............................................................................................................................. 8

4. SERVICE & MAINTENANCE ...............................................................................9

4.1 SERVICE AND MAINTENANCE SCHEDULE .................................................................................................... 9

4.2 ADJUSTING THE DRIVE BELT .......................................................................................................................... 9

4.3 REPLACING THE DRIVE BELT ....................................................................................................................... 10

4.4 FLEX HOSE REPLACEMENT .......................................................................................................................... 10

4.5 ENGINE MAINTENANCE ................................................................................................................................. 10

4.6 OIL CHANGING INFORMATION ...................................................................................................................... 10

4.7 REFUELING INFORMATION ............................................................................................................................11

4.8 TRAILER SERVICE ...........................................................................................................................................11

4.9 GREASABLE BEARINGS ..................................................................................................................................11

5. TROUBLESHOOTING .......................................................................................12

5.1 GENERAL TROUBLESHOOTING .................................................................................................................... 12

6. SPECIFICATIONS ..............................................................................................13

6.1 TRUCK LOADER SPECIFICATIONS ............................................................................................................... 13

6.2 DIMENSION DIAGRAM .................................................................................................................................... 14

6.3 BOLT TORQUE ................................................................................................................................................. 15

Truck Loader Owner’s Manual

SERIAL NUMBER LOCATION

Always give your dealer the serial number of your Crary Bear Cat product 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. The serial number is located on the top chipper housing.

WARNING

To prevent personal injury or property damage: Disengage the source providing power to the machine and make sure that all moving parts have come to a complete stop, before obtaining serial number, servicing, adjusting or repairing.

Serial Number ___________________

Serial Number Decal

Serial Number Location

REPLACEMENT PARTS

Only genuine Bear Cat replacement parts should be used to repair the machine. Bear Cat replacement parts are available from your Bear Cat dealer. To obtain prompt, efficient service, remember to give the dealer the correct part description and serial number of the machine.

Please be sure to provide the following information:

1. The SERIAL NUMBER of your machine.

2. The PART NUMBER of the part.

3. The PART DESCRIPTION.

4. The QUANTITY needed.

Truck Loader Owner’s Manual

iii

NOTES

BearCat Owner’s Manual

Section

Safety

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.

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 and remove the spark plug wire. 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.

WARNING

Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury.

DANGER

Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury.

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.

Truck Loader Owner’s Manual

SAFETY

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 flames, sparks, smoking materials, and other sources of combustion away from fuel.

Do not operate this machine if you are under the influ-

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.

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.

Keep your body and clothing away from any moving

1. part of the machine.

Exclude pieces of metal, rocks, bottles, cans, and other

2. foreign objects from entering the machine.

Wear safety glasses at all times while operating this

10. machine.

Use only in daylight or good artificial light.

11.

Never use without proper guards in place.

12.

Avoid wearing loose fitting 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 8 hours of operation.

Keep all guards, deflectors, and shields in place and

15. in good working condition.

Do not transport or move machine while the machine

16. is running.

Shut off machine immediately if the cutting mechanism

3. strikes any foreign object or the machine starts making an unusual noise or vibrating. Allow the machine to stop completely. After machine stops:

Remove spark plug wire.

Inspect for damage.

Replace or repair any damaged parts.

Check for and tighten any loose parts.

Stand clear of the discharge area when operating this

5. machine.

Keep your face and body back from the feed open-

6. ing.

Do not climb on machine when operating. Keep proper

7. balance and footing at all times.

Keep the machine clear of debris and other accumula-

8. tions.

Set up your work site so you are not endangering traffic

9. and the public. Take great care to provide adequate warnings.

Ensure debris does not blow into traffic, parked cars,

10. or pedestrians.

Check the bolts for correct torque every 8 hours of

11. operation (see Section 6.3).

If the machine becomes clogged, shut off engine and

12. allow machine to stop completely before clearing debris.

Truck Loader Owner’s Manual

SAFETY

1.4 MAINTENANCE AND STORAGE SAFETY

NOTE

Always read and follow the engine owner's manual or contact the engine manufacturer for engine safety instructions and decals.

1. Disconnect the spark plug wire when this equipment is stopped for service, inspection, storage, or to change an accessory.

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.

4. Allow machine to cool before storing in an enclosure.

5. Drain the fuel and dispose of it in a safe manner for storage periods of three months or more.

1.6 BATTERY SAFETY

1. Improper use and care of the battery on electric start models can result in serious personal injury or property damage. Always observe the following safety precautions:

2. Danger / Poison - Causes Severe Burns. The battery contains sulfuric acid. Avoid contact with skin, eyes or clothing. Keep out of reach of children.

ANTIDOTE-External Contact: Flush immediately with

lots of water.

ANTIDOTE-Internal: Drink large quantities of water

or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Call a physician immediately.

ANTIDOTE-Eye Contact: Flush with water for 15 min-

utes. Get prompt medical attention.

1.5 TOWING SAFETY

1. Connect hitch safety chains. Tighten and secure trailer hitch bolts. Do not attempt to tow the trailer if vehicle is not equipped with the proper size hitch ball.

2. Do not exceed maximum towing speed, as indicated on the tire sidewall. Inflate tires to manufacturer's specification as stated on the sidewall.

3. Check wheel lug bolts periodically to ensure they are tight and secure.

4. Never allow passengers to ride on the chipper.

5. If applicable, shut off fuel supply when towing.

3. The battery produces explosive gases. Keep sparks, flame or cigarettes away. Ventilate area when charging battery. Always wear safety goggles when working near battery.

4. The battery contains toxic materials. Do not damage battery case. If case is broken or damaged, avoid contact with battery contents.

5. Neutralize acid spills with a baking soda and water solution. Properly dispose of a damaged or worn-out battery. Check with local authorities for proper disposal methods.

6. Do not short circuit battery. Severe fumes and fire can result.

7. Before working with electrical wires or components, disconnect the negative (-) cable first. Disconnect the positive (+) cable second. Reverse this order when reconnecting battery cables.

Truck Loader Owner’s Manual

HOSE ANCHOR

VACUUM HOSE

HITCH

TRAILER WHEELS

BLOWER DISCHARGE TUBE

BATTERY

Section

Assembly

Your truckloader arrives partially assembled. Perform the steps in this section to assemble your truckloader.

NOTE

REFER TO THE PARTS BOOK DURING ASSEMBLY

IMPORTANT

DO NOT ATTEMPT TO START THE ENGINE AT THIS TIME. Wait until you have read the complete Owner's Manual.

2.1 ASSEMBLING THE MACHINE

1. Remove the truckloader from the shipping crate.

2. Raise the truckloader using a hoist or jack.

3. Attach the Hitch (Section 2.2).

4. Attach the Wheels (Section 2.3).

5. Attaching the Vacuum Hose to the Hose Support (Section 2.4).

6. Installing the Battery (Section 2.6)

Figure 2.1 - Truckloader Assembly

Truck Loader Owner’s Manual

ASSEMBLY

2.2 ATTACHING THE HITCH

Determine which set of holes to use to achieve the

1. desired distance from the tow vehicle. The two sets of holes are 16" apart.

Thread the wiring harness through the hitch pole mak-

2. ing sure the correct end of the hitch pole is facing the trailer.

Slide the hitch pole into the hitch mount channel on

3. the truck loader frame. Attach the hitch to the frame using 1/2" x 4" bolts and centerlocknuts provided in the owner's kit. Tighten to the proper torque (Section

6.3).

2.3 ATTACHING THE WHEELS

Align the wheel lug holes on the wheel with the wheel

1. studs on the hub.

Thread the wheel studs into the lug holes and secure

2. with five 1/2" lug bolts. Follow a star pattern when tightening lug bolts. Torque to 80-95 Ft-lbs.

Repeat for the remaining wheel.

2.4 ATTACHING THE VACUUM HOSE TO THE HOSE SUPPORT

The vacuum hose and the vacuum hose support is shipped connected to the truck loader. However, the hose will have to be attached to the support with the provided chain.

2.5 ATTACHING THE BLOWER DISCHARGE TUBE

DANGER

Do not operate this unit without the discharge tube correctly installed. Flying debris can cause serious personal injury.

Attach the blower discharge tube to the mounting flange on the truck loader frame.

NOTE

Check torque after the first 10-15 miles. Re-torque to 80-95 Ft-lbs. if needed. Re-check for proper torque every 100 miles.

Truck Loader Owner’s Manual

ASSEMBLY

2.6 INSTALLING THE BATTERY.

NOTE

The battery that was shipped with the machine was shipped dry. The battery will need to be serviced before installation.

WARNING

To avoid sparks and a possible explosion or fire due to a short circuit:

1. Do not touch the positive (+) battery terminal and any surrounding metal with tools, jewelry or other metal objects.

2. When installing battery cables, connect positive (+) cable first and negative (-) cable last.

The machine may or many not have been shipped with a battery. If you did not receive a battery with your machine, you will need to purchase one. Use a battery that meets or exceeds the following specifications:

Install the negative (-) cable on the negative (-) battery

7. terminal using a 5/16" X 1" hex head bolt and 5/16" nylock nut. There is no insulating boot for this terminal

Secure battery box cover.

IMPORTANT

DO NOT ATTEMPT TO START THE ENGINE AT THIS TIME. Wait until you have read the complete starting instructions in the Operation Section of this Manual.

Battery, Category, Lawn and Garden BCI Group Size U1 200-250-CCA 7-3/4" x 5-3/16" x 7-5/16" Suggested Source: Exide Cutting Edge, Type GT-H

If you received a battery with your machine, follow the steps below:

Remove or destroy any sealing device which may have

1. been used to close or restrict the vent openings.

Remove battery vent caps and fill cells until baffle plate

2. is covered with 1.25" of electrolyte at 80° F. Battery and electrolyte must at a temperature above 60° F, but preferably not above 100° F.

After filling, battery should be charged to the specifi-

3. cations below and put into service immediately.

- Temperature over 60° F: 3 amperes for 4 Hours.

- Temperature under 60° F: 3 amperes for 6 Hours.

Place charged battery in battery box.

Remove key from engine ignition.

Install the positive (+) battery cable to the positive

6. (+) battery terminal using a 5/16" X 1" hex head bolt and 5/16" nylock nut. An insulating boot is loosely installed on this cable. Slide the insulating boot over the terminal, making sure that the terminal is completely covered.

Truck Loader Owner’s Manual

Operation

Section

3.1 STARTING 3.2 VACUUMING

CAUTION

Release the key if the engine fails to start within 10 seconds. Failure to release starter will overheat and possible damage the starter. Wait 60 seconds before trying again.

Check engine oil level before starting. Add oil if low,

but do not overfill.

Refer to Honda Engine Owners Manual for special

starting instructions.

Make sure the hose inlet is free from debris and the

discharge tube is pointed in a safe direction.

Ensure the engagement lever is in the START posi-

tion.

Move choke lever to the ON position.

Move the throttle to between half and full throttle.

Turn the key and release it when the engine starts,

allow the key to return to the ON position.

Release the key if the engine fails to start within 10

seconds. Allow a 60 second cool down period between starting attempts if the engine does not start. Failure to follow these guidelines can cause permanent damage to the starter.

Gradually move the choke lever to the OFF position

as the engine warms.

Engage the rotor by moving the engagement lever to

10.

the RUN position.

DANGER

The hose inlet vacuums debris as soon as the engine starts.

The towable truck loader is designed to suck in leaves and other debris then blow it into a trailer or truck.

Keep hands, or any part of body or clothing away from

1. the hose inlet, discharge chute, or any moving part.

Maintain proper balance and footing at all times.

Run unit at full operating speed before starting to

3. vacuum.

Be careful when vacuuming around gravel, gardens,

4. lawn ornaments, etc.

Adjust the discharge tube to the desired loading posi-

5. tion before starting.

Remove snapper pin to release hose inlet from hose

6. holder weldment.

Insert snapper pin into slot in hose holder for safe

7. keeping.

Pull the flex hose around to the back of the towable

8. truck loader using the aluminum handles.

Point the hose inlet towards the debris to remove;

9. use a sweeping motion to remove debris from a larger area.

Vacuuming radius is approximately nine (9) feet from

10. the end of the flex hose.

Gradually move the throttle to the full throttle posi-

11. tion.

Truck Loader Owner’s Manual

OPERATION

3.3 STOPPING

Move the throttle to between half and full throttle.

Turn the key to OFF.

3.4 UNPLUGGING THE ROTOR

WARNING

The rotor continues to turn after the engine is shut off. Make sure that all moving parts have come to a complete stop before servicing, adjusting or repairing.

The towable truck loader is designed to be used in fairly dry conditions. Wet material along with too much debris and large sticks can plug the rotor or hose. A plugged rotor bogs down the engine and can possibly stop the engine if the rotor is severely plugged.

Shut off engine and allow rotor to completely stop.

1. Remove spark plug wire.

Remove the access bolt.

Turn the access cover to fit the bolts through the

3. slots.

Remove the access cover to allow access to the ro-

4. tor.

Clear debris; verify the rotor is unplugged by turning it

5. by hand before replacing the access cover and bolt.

Truck Loader Owner’s Manual

Service & Maintenance

Section

4.1 SERVICE AND MAINTENANCE SCHEDULE

INSPECTION ITEMS

Check Nuts and Bolts

Engine Oil

Replace Spark Plug

Air Filter Element

Replace Fuel Filter

Check Drive Belt

Clean Machine

* Indicates first hours of use

** Service more frequently in dusty conditions

Check

Replace

Check

Clean

Replace

Before each use Every 25 Hrs Every 50 Hrs Every 100 Hrs Every 300 Hrs Once (1) a year

X X

X * X

4.2 ADJUSTING THE DRIVE BELT

WARNING

The rotor continues to turn after the engine is shut off. Make sure that all moving parts have come to a complete stop before servicing, adjusting or repairing.

INTERVAL

X **

Loosen the jam nut.

Tighten the push off bolt to move the engine away

from the rotor housing until the belt deflection is 3" when a 20 lb. load is placed against the belt (Figure 4.1).

Tighten the four carriage bolts securing the engine

plate to the trailer.

Check the condition of the drive belt annually or after every 25 hours of operation, whichever comes first. Replace a cracked, frayed, worn or stretched drive belt. To adjust the drive belt, proceed as follows:

Move the engagement lever to the start position.

Shut engine off.

Disconnect battery cables.

Remove the belt shield by removing the eight 3/8" x

3/4" bolts securing the belt shield to the rotor weldment.

Loosen the 5/16" bolt attaching the belt guide to the

engine.

To increase tension on the belt, do the following:

Loosen the four carriage bolts attaching the engine plate to the trailer.

Locate the engine plate push off bolt located above the gas tank. If needed, the gas tank can be re moved for better access to the push off bolt.

Truck Loader Owner’s Manual

Once the desired deflection is achieved, tighten

the jam nut to ensure the proper deflection is maintained.

Adjust the spring tension so there is 1/16" between

7. the coils when then the engagement lever is in the run position.

Replace the belt if the engine cannot be adjusted any

8. further and the idler arm comes in contact with the engagement lever rollers when in the run position (Section 4.3).

Move the engagement lever to the operate position.

Adjust the lower belt guide so there is 1/8" clearance

10. between the belt and the engine belt guide.

Ensure all bolts are torqued to the proper specifications

11. (Section 6.3).

Move the engagement lever to the start position.

12.

Reinstall the belt guard.

13.

SERVICE AND MAINTENANCE

Force 20lbs

7/16"Deflection

Span Length

Force 20 lbs.

Figure 4.1 - Belt Tension

3” Deflection

4.3 REPLACING THE DRIVE BELT

WARNING

The rotor continues to turn after the engine is shut off. Make sure that all moving parts have come to a complete stop before servicing, adjusting or repairing.

Move the engagement lever to the start position.

Shut engine off.

Disconnect battery cables.

Remove the belt shield by removing the eight 3/8" x

4. 3/4" bolts securing the belt shield to the rotor weldment.

4.4 FLEX HOSE REPLACEMENT

Check the condition of the flex hose frequently. Replace if split or damaged.

Shut off engine and allow rotor to completely stop.

Remove spark plug wire.

Remove the clamp attaching the hose inlet to the

3. flex hose.

Remove the hose inlet.

Remove two (2) bolts from the hose wraps to separate

5. the flex hose from the swivel boom.

Remove the remaining clamp securing the flex hose

6. to the hose adapter.

Install new hose on hose adapter.

Complete flex hose replacement by performing steps

8. 1-5 in reverse order.

4.5 ENGINE MAINTENANCE

Maintenance is essential in preserving engine life. The engine oil should be checked prior to each start-up. Regular oil service period is every season or 50 hrs. under regular use. The engine oil will have to be changed frequently upon first use. Service engine according to the maintenance schedule in your Honda engine owner's manual.

4.6 OIL CHANGING INFORMATION

Loosen and remove the idler pulley.

Loosen the two mounting bolts located at both ends

6. of the lower belt guide.

Loosen the 5/16" bolt attaching the belt guide to the

7. engine.

Loosen the four carriage bolts attaching the engine

8. plate to the trailer.

To release the tension on the belt, loosen the jam nut

9. and engine plate pushoff bolt located above the gas tank. If needed, the gas tank can be removed for better access to the jam nut and push off bolt.

Lift the engine belt guide away from the belt; remove

10. the old belt and install the new belt.

Reinstall the idler pulley.

11.

Adjust the drive belt (Section 4.2).

12.

Truck Loader Owner’s Manual

CAUTION

Place truck loader on a level surface prior to filling engine oil.

Shut off the engine. Disconnect the spark plug wire

1. and negative battery terminal.

Change oil while the engine is warm.

Empty the fuel tank before changing the oil.

Drain oil by removing drain plug. Refer to Honda en-

4. gine owners manual for location.

Refill with new SAE recommended oil. See Honda en-

5. gine owners manual for specific recommendations.

Check oil level. Oil should be at FULL mark or upper

6. limit line.

SERVICE AND MAINTENANCE

4.7 REFUELING INFORMATION

DANGER

Gasoline is highly flammable and explosive.

Allow engine to cool before refueling.

Refuel in a well-ventilated area.

Do not fill above the fuel level mark.

Clean around fuel fill before removing cap to refuel.

Remove cap.

Fill engine with clean, fresh gasoline.

Replace cap.

4.8 TRAILER SERVICE

Check wheel bolt torque every 8 hours of towing

1. use.

Check air pressure in tires every 8 hours. Fill to 60

2. PSI.

Check and repack wheel bearings with grease every

3. year.

Always connect the safety chains when towing. Check

4. to ensure trailer hitch bolts are tight and secure.

Check trailer lights.

4.9 GREASABLE BEARINGS

Mounted bearing are pre-lubricated at our factory and are ready for operation.

RELUBRICATION: Relubrication of bearings is determined by operating conditions and environment. Lubricate standard bearings with a LITHIUM based grease. Greasing intervals and quantities are shown on the next page using the following symbol:

Frequency (50 hours)

Quantity

GREASING INVTERVALS: Bearings in extreme environments will require more fre quent greasing invervals.

GREASE FILL AMOUNTS: It is preferred that experience dictate fill amounts due to wide variances in applications, greasing equipment and operating conditions. The quantities shown on the next page are recommended amounts. In most cases, it is best to lubricate in small amounts, under low pressure, until a thin bead of fresh greas is visible at the seal lip area.

Care should be taken when greasing bearings to avoid overfilling. Overfilling can lead to excessive heat and/or unseating of the seals. Grease should be introduced in small amounts and under light pressure. Whenever possible, the bearing should be rotated slowly while grease is added to ensure equal distribution throughout the raceways.

Recommended Qty. of grease.

The truckloader model described in this manual has one greaseable bearing that requires greasing. Refer to Figure

4.2 for greasing location, interval and quantity.

.18 OZ

5 GRAMS

Truck Loader Owner’s Manual

Grease Zerk

Figure 4.2 - Grease Zerk

Troubleshooting

Section

5.1 GENERAL TROUBLESHOOTING

PROBLEM PROBABLE CAUSE SUGGESTED REMEDY

Improper control settings Use proper settings.

Lack of fuel Fill fuel tank.

Engine will not start

Engine stalls or stops

Engine overheats

Excessive vibration while

running

Rotor will not turn

Excessive belt wear

Internal engine problems Contact dealer.

Spark plug disconnected Connect spark plug.

Dirty, stale or contaminated gas

Plugged rotor Clear rotor.

Vacuuming

material too fast

Cooling system plugged Clean Cooling fans and fins.

Improper oil level

Drive system vibration

Drive belt too loose or broken Adjust or replace.

Plugged rotor Clear rotor.

Not using correct belt

Pulley damaged or worn Replace pulley.

Pulley not in alignment Align pulley with straight edge.

Belt tension too loose Tighten belt or replace.

Refill gas tank with fresh, clean,

unleaded regular gasoline.

Slow vacuuming rate.

Fill engine to correct oil level. Refer to

Honda engine operator’s manual.

Check drive belts and pulleys

for bad or worn areas.

Contact authorized dealer

to order BearCat belts.

Trailer swings during towing Tire air pressure not correct

Engine speed too slow Increase engine speed.

Plugged discharge tube

Excessive belt noise Improper belt tension Adjust belt tension or replace.

Engine drives rotor

during startup.

Vacuuming too much material

into the machine

Engagement lever is

in the run position

Incorrect belt tension Adjust belt tension or replace.

Truck Loader Owner’s Manual

Check tire sidewall for inflation limits.

Vacuum debris at a slower rate.

Put the engagement lever

in the start position.

Specifications

Section

6.1 TRUCK LOADER SPECIFICATIONS

SPECIFICATIONS

Overall size 85" x 73" x 97"

Flex Hose Size 12" dia x 10'

Rotor Size 19.88" x 7"

Discharge Tube Size 8" dia.

Chute Rotation 360 degrees

Drive Type Belt

Belt Size 2B70

Weight (lbs.) 1022 lbs

Wheel Tread 62"

Tires 225/75/15

Fuel Tank Capacity 6.6 gallons

Engine Honda 24 HP gasoline

Specifications are subject to change due to design modifications.

Truck Loader Owner’s Manual

SPECIFICATIONS

12.00

83.69

18.61

112.54

72.53

32.98

144.63

6.2 DIMENSION DIAGRAM

Truck Loader Owner’s Manual

SPECIFICATIONS

SAE - 2

SAE - 5

SAE - 8

4.8

8.8

10.9

12.9

6.3 BOLT TORQUE

The tables shown below give correct torque values for various bolts and capscrews. Tighten all bolts to the torques specified in chart unless otherwise noted. Replace hardware with the same strength bolt.

ENGLISH TORQUE SPECIFICATIONS

BOLT TORQUE *

BOLT DIAMETER

1/4" 7.5 5.5 11 8 16 12

5/16" 15 11 23 17 34 25

3/8" 27 20 41 30 61 45

7/16" 41 30 68 50 95 70

1/2" 68 50 102 75 149 110

9/16" 97 70 149 110 203 150

5/8" 122 90 203 150 312 230

3/4" 217 160 353 260 515 380

7/8" 230 170 542 400 814 600

1" 298 220 786 580 1220 900

1-1/8" 407 300 1085 800 1736 1280

1-1/4" 570 420 2631 1940 2468 1820

SAE 2 SAE 5 SAE 8

N.m Ft-lb. N.m Ft-lb. N.m Ft-lb.

METRIC TORQUE SPECIFICATIONS

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

4.8 8.8 10.9 12.9

N.m Ft-lb. N.m Ft-lb. N.m Ft-lb. N.m Ft-lb.

BOLT TORQUE *

Torque figures indicated above are valid for non-greased or non-oiled threads and heads unless otherwise specified. Therefore, do not grease or oil

bolts or capscrews unless otherwise specified in this manual. When using locking elements, increase torque values by 5%.

* Torque value for bolts and capscrews are identified by their head markings.

Truck Loader Owner’s Manual

Manual Improvement Program

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