Echo 76854 User Manual

540 PTO CHIPPER

CH8540 - GRAVITY FEED

CH9540H - HYDRAULIC FEED

CHF9540H - HYDRAULIC FEED, FINE CHIP

ENGLISH ESPAÑOL FRANÇAIS PORTUGUES

Manual P/N: 16812

Rev. 010111

Companion to P/N 12141

SN Range: B00001 - C09929

OWNER'S MANUAL

Before You Begin

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.

FOR MACHINE SERVICE OR PARTS:

For service assistance, contact your nearest authorized
ECHO Bear Cat dealer or the factory. For parts, contact
your authorized dealer. The parts manual for your
machine is available at http://bearcatproducts.com/
main/support/index_html. Your 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.

FOR ENGINE SERVICE OR PARTS:

For engine service or parts, contact your nearest
authorized engine dealer. ECHO Bear Cat does not
handle any parts, repairs or warranties for engines.

SERIAL NUMBER LOCATION

Please record the serial number in the space provided
and on the warranty and registration card.

MANUFACTURED BY CRARY INDUSTRIES

WEST FARGO, NORTH DAKOTA 58078 U.S.A.
SERIAL NUMBER

MANUFACTURED IN U.S.A.

XXXXXX

ORDERING 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

© 2012, CRARY INDUSTRIES, ALL RIGHTS RESERVED. PRODUCED AND PRINTED IN THE U.S.A.

800.247.7335

701.282.5520

FAX: [phone]

[e-mail]

[e-mail]

Monday - Friday,

8 am to 5 pm

Central Time

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.

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

2. This warranty does not cover normal wear items including but not limited to bearings, belts, pulleys, filters
and chipper knives.

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

4. This warranty does not cover depreciation or damage due to misuse, negligence, accident or improper
maintenance.

ENGLISH

5. This warranty does not cover damage due to improper setup, installation or adjustment.

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

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

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.

TABLE OF CONTENTS

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

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

1.2 EMISSION INFORMATION ....................................................................................1

1.3 BEFORE OPERATING ...........................................................................................2

1.4 OPERATION SAFETY ...........................................................................................2

1.5 FEED ROLLER SAFETY .......................................................................................3

1.6 MAINTENANCE/STORAGE SAFETY ....................................................................3

1.7 PTO SAFETY .........................................................................................................3

1.8 SAFETY DECAL LOCATIONS ...............................................................................4

1.9 SAFETY DECALS ..................................................................................................5

ASSEMBLY ........................................................................................................... 6

2.1 ATTACH CHUTE - CH8540 ....................................................................................6

2.2 ATTACH CHUTE - HYDRAULIC FEED MODELS WITH SAFETY BAR ................6

2.3 ATTACH CHUTE - HYDRAULIC FEED MODELS WITHOUT SAFETY BAR ........7

2.4 ATTACH DISCHARGE TUBE - MODELS CH8540 AND CH9540H .......................8

2.5 ATTACH DISCHARGE TUBE - MODEL CHF9540H ..............................................8

2.6 CONNECT TO PTO DRIVELINE ...........................................................................9

2.7 CONNECT CONTROL BOX WIRES TO TRACTOR ..............................................9

FEATURES & CONTROLS ................................................................................. 10

OPERATION ....................................................................................................... 12

4.1 STARTING THE CHIPPER ..................................................................................12

4.2 STOPPING THE CHIPPER ..................................................................................12

4.3 OPERATING THE CHIPPER ...............................................................................12

4.4 RAISE EXTENSION TRAY BEFORE TOWING ...................................................13

4.5 FEED ROLLER CONTROL BAR .........................................................................13

4.6 CHIPPER CONTROLLER ....................................................................................14

4.7 FEED ROLLER SPEED CONTROL .....................................................................14

SERVICE & MAINTENANCE ..............................................................................15

5.1 INSTALLING DISK LOCK ....................................................................................16

5.2 CHIPPER BLADE MAINTENANCE .....................................................................16

5.3 CHANGING THE BLADES ...................................................................................16

5.4 SHARPENING THE BLADES ..............................................................................17

5.5 ADJUSTING THE CHIPPER ANVIL .....................................................................17

5.6 LUBRICATION .....................................................................................................18

5.7 PTO DRIVELINE LUBRICATION .........................................................................19

5.8 CLEARING A PLUGGED ROTOR .......................................................................19

5.9 ADJUSTING/REPLACING DRIVE BELT ..............................................................20

5.10 REPLACING BEARINGS ...................................................................................20

5.11 CHANGING HYDRAULIC OIL FILTER ...............................................................21

5.12 FILLING HYDRAULIC FLUID.............................................................................21

TROUBLESHOOTING ........................................................................................ 22

6.1 FLASH CODE GUIDE FOR THE CONTROLLER ................................................22

6.2 TROUBLESHOOTING GUIDE .............................................................................23

SPECIFICATIONS ............................................................................................... 25

BOLT TORQUE ...........................................................................................................26

OPTIONS ............................................................................................................ 27

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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.

CAUTION

Indicates a potentially hazardous situation that, if not

avoided, may result in minor or moderate injury.

1.2 EMISSION INFORMATION

Under California
Law and 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 ammable agricultural

crops, 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 or diesel fuel (hydrocarbons). Therefore,
your power equipment must be equipped with a spark

arrester mufer in continuous effective working order. The

spark arrester must be attached to the engine exhaust

system in such a manner that ames or heat from the
system will not ignite ammable material.

ENGLISH

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.

Failure of the owner/operator of the equipment to comply
with this regulation is a misdemeanor under California law
and may also be a violation of other state and/or federal
regulations, laws, ordinances, or codes. Contact your

local re marshal or forest service for specic information

about which regulations apply in your area.

The standard mufer installed on the engine is not equipped

with a spark arrester. One must be added before using
this machine 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.

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1

SAFETY

1.3 BEFORE OPERATING

1. Read and understand this owner’s manual. Be
completely familiar with the controls and the proper
use of this equipment.

2. Familiarize yourself with all of the safety and operating
decals on this equipment and on any of its attachments
or accessories.

3. Keep safety decals clean and legible. Replace missing
or illegible safety decals.

4. Obtain and wear safety glasses and
use hearing protection at all times
when operating this machine.

5. Avoid wearing loose fitted clothing.
Never operate this machine while
wearing clothing with drawstrings
that could wrap around or get caught in the machine.

6. Do not operate this machine if you are under the
influence of alcohol, medications, or substances that

can affect your vision, balance or judgement. Do not

operate if tired or ill. You must be in good health to
operate this machine safely.

7. Do not operate this equipment in the vicinity of
bystanders. Keep the area of operation clear of all
persons, particularly small children. It is recommended
that bystanders keep at least 50 feet (15 meters) away
from the area of operation.

8. Do not allow children to operate this equipment.

9. Use only in daylight or good artificial light.

10. Do not run this equipment in an enclosed area. Engine
exhaust contains carbon monoxide gas, a deadly
poison that is odorless, colorless and tasteless. Do not
operate this equipment in or near buildings, windows
or air conditioners.

11. Always use an approved fuel container. Do not remove
gas cap or add fuel when engine is running. Add fuel
to a cool engine only.

12. Do not fill fuel tank indoors. Keep open flames, sparks,
smoking materials and other sources of combustion
away from fuel.

13. Do not operate machine without shields in place.

Failure to do so may cause serious injury or death.

14. Keep all guards, deflectors, and shields in good
working condition.

15. Before inspecting or servicing any part of this machine,
shut off the machine and make sure all moving parts
have come to a complete stop. Disconnect the battery
and remove the ignition key where applicable.

16. Check that all screws, nuts, bolts, and other fasteners
are secured, tightened and in proper working condition
before starting the machine.

17. Do not transport or move machine while it is operating
or running.

1.4 OPERATION SAFETY

1. Always stand clear of discharge area when operating
this machine. Keep face and body away from feed
and discharge openings.

2. Keep hands and feet out of feed
and discharge openings while
machine is operating to avoid

serious personal injury. Stop

and allow machine to come to
a complete stop before clearing
obstructions.

3. Set up your work site so you are not endangering traffic
and the public. Take great care to provide adequate
warnings.

4. Do not climb on machine when operating. Keep proper
balance and footing at all times.

5. Check cutting chamber to verify it is empty before
starting the machine.

6. The disk will continue to rotate after being disengaged.
Shut off the machine and make sure all moving parts
have come to a complete stop before inspecting or
servicing any part of the machine. Disconnect the
battery and remove the ignition key if applicable.

7. Do not insert branches with a diameter larger than
the max chipper capacity into machine or machine
damage may occur.

8. When feeding material into machine, do not allow
metal, rocks, bottles, cans or any other foreign material
to be fed into the machine.

9. Ensure debris does not blow into traffic, parked cars,
or pedestrians.

10. Keep the machine clear of debris and other
accumulations.

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SAFETY

11. 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.

12. If the machine becomes clogged, the cutting mechanism

strikes any foreign object, or the machine starts

vibrating or making an unusual noise, shut off machine
immediately and make sure all moving parts have come
to a complete stop. Disconnect the battery and remove
the ignition key if applicable. After the machine stops: A)
Inspect for damage, B) Replace or repair any damaged
parts, and C) Check for and tighten any loose parts.

13. On electric start models, disconnect cables from battery
before doing any inspection or service. Remove key.

14. 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. Failure to do
so may cause poor performance, damage or personal

injury and will void the machine warranty.

1.5 FEED ROLLER SAFETY

1. The feed roller can cause serious injury or death. Keep
hands, feet and clothing away from the feed roller and
chipper disk blades.

2. Never climb onto the feed chute
when the unit is operating or
running.

WRONG

1.6 MAINTENANCE/STORAGE SAFETY

1. Before inspecting, servicing, storing, or changing
an accessory, shut off the machine and make sure
all moving parts have come to a complete stop.
Disconnect the battery and remove the ignition key
where applicable.

2. Replace any missing or unreadable safety decals.
Refer to the safety decal section for part numbers.

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

4. Store the machine out of reach of children and where
fuel vapors will not reach an open flame or spark.

5. Never store this machine with fuel in the fuel tank
inside a building where fumes may be ignited by an
open flame or spark. Ignition sources can be hot water
and space heaters, furnaces, clothes dryers, stoves,
electric motors, etc.

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

1.7 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.

ENGLISH

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

4. Never allow anyone to sit on the
feed chute.

5. When feeding material into the
feed roller wear eye, face and
hearing protection.

6. Stand to side of feed chute when feeding material and
release material quickly.

7. When inspecting or servicing the feed roller, secure
the feed roller in the raised position using the lock pin,
if applicable.

WRONG

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, shut off power source, and
make sure all moving parts have come to a complete
stop before removing guards or shields.

6. Clothing worn by operator must be fairly tight. Never

wear loose fitted 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. Proper recommended PTO operating speed is 540
+/- 10 RPM.

9. Before inspecting or servicing the PTO drive area,
disengage the driveline, shut off power source, remove
ignition key, and make sure all moving parts have come
to a complete stop.

10. Keep hands, feet, and clothing away from all PTO
drive parts.

11. Do not clean, lubricate or adjust the PTO shaft when
it is running.

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3

SAFETY

PN 12174

1.8 SAFETY DECALS

See Section 1.9 for decal locations. Familiarize yourself with all of the safety and operating decals on the machine
and the associated hazards. See the engine owner’s manual or contact the engine manufacturer for engine safety
instructions and decals. Make certain that all safety and operational decals on this machine are kept clean and in good
condition. Decals that need replacement must be applied to their original locations.

PN 12168

1

CONTACT WITH ROTATING DRIVELINE
CAN CAUSE DEATH. DO NOT OPERATE
WITHOUT ALL DRIVELINE, TRACTOR
AND EQUIPMENT SHIELDS IN PLACE.
ENSURE THE DRIVELINE IS SECURELY
ATTACHED AT BOTH ENDS AND
DRIVELINE SHIELDS THAT TURN FREELY ON THE DRIVELINE
ARE IN PLACE.

2

PN 12169

KEEP HANDS AND FEET OUT OF INLET AND
DISCHARGE OPENINGS WHILE MACHINE IS
OPERATING TO AVOID SERIOUS PERSONAL
INJURY. STOP AND ALLOW MACHINE TO COME
TO A COMPLETE STOP BEFORE CLEARING
OBSTRUCTIONS.

6

PN 12175

KEEP HANDS AND FEET OUT OF INLET
AND DISCHARGE OPENINGS WHILE
MACHINE IS OPERATING TO AVOID
SERIOUS PERSONAL INJURY. STOP
AND ALLOW MACHINE TO COME
TO A COMPLETE STOP BEFORE
CLEARING OBSTRUCTIONS.

PN 12250

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.

PN 12172

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, REMOVE
THE KEY, DISCONNECT SPARK PLUG
WIRE FROM SPARK PLUG AND MAKE
SURE ALL MOVING PARTS HAVE COME
TO A COMPLETE STOP.

PN 12173

4

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.

PN 12174

5

DO NOT OPERATE MACHINE WITHOUT
SHIELDS IN PLACE. FAILURE TO DO SO MAY
CAUSE SERIOUS INJURY OR DEATH.

PN 14942-00

8

CAREFULLY READ THE USER MANUAL BEFORE 'ACTIVATION. IF
THE USER MANUAL WAS NOT INCLUDED WITH ANY QUESTIONS
OR CALL [phone].

PN 18983-00

9

FEED ROLLER SUPPORT MUST BE
SECURED IN THE UP POSITION
PRIOR TO SERVICING CHIPPER
FEED AREA. THE FEED ROLLER
CAN FALL AND CAUSE SEVERE
BODILY HARM. CONSULT OWNERS
MANUAL FOR PROPER METHOD OF SECURING FEED ROLLER
SUPPORT. LOWER FEED ROLLER BEFORE OPERATING
CHIPPER.

10

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. ROTATE THE
DISCHARGE TUBE OVER THE
HITCH BEFORE TOWING AND LOCK
SECURELY IN PLACE.

PN 32109-00

(MODELS CH9540H AND
CHF9540H ONLY)

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SAFETY

1.9 SAFETY DECAL LOCATIONS

The numbers below correspond to the decals in Section 1.8 Familiarize yourself with all of the safety and operational
decals on the machine and the associated hazards. See the engine owner’s manual or contact the engine manufacturer
for engine safety instructions and decals. Make certain that all safety and operating decals on this machine are kept
clean and in good condition. Decals that need replacement must be applied to their original locations.

4

3

7

2

ENGLISH

Model CHF9540H

discharge chute

1

5

*

9

*DECAL LOCATED BENEATH SHIELD

10

6

4

8

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5

2

ASSEMBLY

Section

2.1 ATTACH CHUTE - CH8540

1. Remove chipper from shipping crate. Place unit on a level surface before assembling. See the Torque Chart in
Section 7 for the recommended torque for tightening bolts and screws.

2. Mount the chipper chute to the frame mounting bracket using eight 3/8 x 1-1/2" bolts and locknuts. Use three bolts
on each side and two on the bottom.

3. For models with extension trays: Attach the extension tray to the chute with five 3/8 x 1" bolts and nuts.

Figure 2.1. Figure 2.2.

2.2 ATTACH CHUTE - HYDRAULIC FEED MODELS WITH SAFETY BAR

1. Remove chipper from shipping
crate. Place unit on a level
surface before assembling.
See the Torque Chart in
Section 7 for the recommended
torque for tightening bolts and
screws.

2. Attach the chute support to the
front side of the chipper base
with one 3/8 x 1" hex bolt,
washer and nut.

3. Attach the chipper chute to
the feed roller with eight 3/8 x
1-1/2" carriage bolts, washers,
and nuts. Thread the bolts from
inside the chute.

4. Attach the chute support to the chute through the
middle hole on the extension tray hinge using
existing hardware.

5. Connect the three wires coming from the feed chute
to the connectors that are located underneath the
feed roller, matching ziptie colors.

6. Plug the safety bar wire harness into the matching
color plugs on the chipper frame.

Figure 2.3

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