Echo 77412 Owners Manual v.1
OWNER'S MANUAL
4.5" CHIPPERS
Manual PN 14783-00
Rev. 0304
Companion to 14784-00
MODELS
77412
77413
77412S
77413S
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.
How to Contact
Bear Cat
A
DDRESS
Crary Bear Cat
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.
EMISSION INFORMATION
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
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 with a spark arrester
muffler in continuous effective working
order. The spark arrester must be
attached 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
California law, and may also 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.
Page 1
4.5" BearCat Chipper Operator's Manual
LIMITED WARRANTY
Crary Bear Cat chippers are warranted one year from the date of sale to the original consumer purchaser and
one year from the date of sale to a commercial or rental operation. The engine is warranted by the original
manufacturer with the terms and limitations listed in the manufacturer's manual.
Within the above stated period, Crary Co. will replace any part(s) found to be defective in material and/or
workmanship, after the receipt of the part in our plant. Labor costs to replace these defective parts will be
paid at a Crary established labor rate and time allowed (flat rate) for repair. All transportation charges
incurred in shipping part(s) are the responsibility of the purchaser.
This warranty is void in the case of accidents, failure to perform normal maintenance, or failure to follow those
instructions listed in the service manual. This warranty is also in lieu of all other expressed warranties and
voids any implied warranty as to the merchantability or fitness of the product for a particular purpose and of
any other obligation on the part of Crary Co. Some states do not allow limitations on how long the implied
warranty lasts, so the above limitation may not apply to you.
This warranty applies only to parts or components which are defective, and does not cover necessary repair
due to normal wear, misuse, accidents, or lack of proper maintenance. This includes but is not limited to
belts, pulleys, bearings, and chipper blades. Regular routine maintenance of the unit to keep it in proper
operating condition is the responsibility of the owner.
All warranty repair reimbursable under the Crary Co. warranty must be performed by an authorized Bear Cat
service dealer using Bear Cat approved replacement parts. Repair or attempted repair by anyone other than
an authorized Bear Cat service dealer, or repairs using parts not approved by Bear Cat are 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. The serial number is located on the rotor assembly cover.
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
Page 2
4.5" BearCat Chipper Operator's Manual
CONTENTS
SECTION DESCRIPTION PAGE
SERIAL NUMBER LOCA TION ....................................................................................................................................3
REPLACEMENT PARTS ............................................................................................................................................ 3
1. SAFETY ................................................................................................................4
1.1 THE SAFETY ALERT SYMBOL ......................................................................................................................... 4
1.2 BEFORE OPERA TING .......................................................................................................................................4
1.3 OPERA TION SAFETY........................................................................................................................................5
1.4 MAINTENANCE AND STORAGE SAFETY ........................................................................................................6
1.5 TOWING SAFETY..............................................................................................................................................6
1.6 BA TTERY SAFETY ............................................................................................................................................6
2. ASSEMBLY...........................................................................................................................................7
2.1 ASSEMBLING THE MACHINE ........................................................................................................................... 7
2.2 ASSEMBLE THE HITCH, AXLE AND WHEELS. ................................................................................................. 8
2.2.1 MODELS 77412, 77412S...................................................................................................................8
2.2.2 MODELS 77413, 77413S...................................................................................................................9
2.3 ATTACH THE CHIPPER DEFLECTOR ............................................................................................................. 10
2.4 ATTACH THE OPTIONAL DISCHARGE TUBE.................................................................................................. 10
2.5 ATTACH THE CHIPPER CHUTE....................................................................................................................... 11
2.6 ATTACH THE CHIPPER CHUTE EXTENSION (S MODELS)............................................................................ 11
2.7 CONNECTING THE BATTERY ......................................................................................................................... 11
3. CONTROLS.......................................................................................................12
3.1 CONTROLS ...................................................................................................................................................... 12
4. OPERA TION......................................................................................................13
4.1 STARTING ELECTRIC MODELS (77412, 77412S) ........................................................................................... 13
4.2 STARTING RECOIL MODELS (77413, 77413S) ............................................................................................... 13
4.3 STOPPING ELECTRIC MODELS (77412, 77412S) .......................................................................................... 14
4.4 STOPPING RECOIL MODELS (77413, 77413S) .............................................................................................. 14
4.5 CHIPPING ........................................................................................................................................................ 14
4.6 HOOKING & UNHOOKING CHIPPER (MODEL 77413, 77413S)...................................................................... 15
5. SERVICE AND MAINTENANCE......................................................................16
5.1 INSTALLING THE DISK LOCK .................................................................................................................. .......16
5.2 SHARPENING CHIPPER BLADES .................................................................................................................. 16
5.3 REPLACING CHIPPING BLADES ....................................................................................................................17
5.4 SETTING CHIPPING BLADE CLEARANCE ..................................................................................................... 17
5.5 ADJUSTING THE DRIVE BELT......................................................................................................................... 17
5.6 REPLACING DRIVE BEL TS ............................................................................................................................. 18
5.7 CLEARING A PLUGGED DISK.........................................................................................................................18
5.8 REPLACING ROTOR BEARINGS. ................................................................................................................... 19
5.9 GREASEABLE BEARINGS.............................................................................................................................. 20
5.10 OTHER SERVICE AND MAINTENANCE TIPS..................................................................................................22
5.11 TRAILER SERVICE TIPS.................................................................................................................................. 22
6. TROUBLESHOOTING ......................................................................................23
6.1 GENERAL TROUBLESHOOTING..................................................................................................................... 23
7. SPECIFICA TIONS.............................................................................................25
7.1 SIZE SPECIFICA TIONS.................................................................................................................................... 25
7.2 BOL T TORQUE................................................................................................................................................. 26
Page 3
4.5" BearCat Chipper Operator'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 ___________________
YXXXXX
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.
Page 4
4.5" BearCat Chipper Operator's Manual
1
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
1. Read this Owner / Operator’s manual. Be completely
familiar with the controls and the proper use of this equipment.
2. Before inspecting or servicing any part of the machine,
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.
3. Keep safety decals clean and legible. Replace missing
or illegible safety decals.
4. Familiarize yourself with all of the safety and operating
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.
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, particu-
larly small children. Keep bystanders at least 50 feet
(15 meters) away from the area of operation.
7. Do not run this equipment in an enclosed area. Do not
Page 5
4.5" BearCat Chipper Operator's Manual
SAFETY
operate this equipment in or near buildings, windows, or
air conditioners.
8. If needed, always use an approved fuel container. Keep
open flames, sparks, smoking materials, and other
sources of combustion away from fuel.
9. 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.
10. Wear safety glasses at all times while operating this
machine.
11. Use only in daylight or good artificial light.
12. Never use without proper guards in place.
13. Avoid wearing loose fitting clothing. Never operate this
machine wearing clothing with drawstrings that could
wrap around or get caught in the machine.
14. Check that all screws, nuts, bolts, and other fasteners
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.
15. Keep all guards, deflectors, and shields in place and in
good working condition.
16. Do not transport or move machine while the machine is
running.
1.3 OPERATION SAFETY
WARNING
Material can kickup or shift suddenly and cause serious
injury or death. Wear eye and hearing protection.
DANGER
Keep hands, feet and clothing out of inlets and discharge
openings while machine is operating to avoid serious
personal injury.
1. Keep your body and clothing away from any moving
part of the machine.
2. Exclude pieces of metal, rocks, bottles, cans, and other
foreign objects from entering the machine.
3. 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:
A. Remove spark plug wire.
B. Inspect for damage.
C. Replace or repair any damaged parts.
D. Check for and tighten any loose parts.
4. Stand clear of the discharge area when operating this
machine.
5. Keep your face and body back from the feed opening.
6. Do not climb on machine when operating. Keep proper
balance and footing at all times.
7. Keep the machine clear of debris and other accumulations.
8. Set up your work site so you are not endangering traffic
and the public. Take great care to provide adequate warnings.
9. Ensure debris does not blow into traffic, parked cars, or
pedestrians.
10. Check the bolts for correct torque every 8 hours of operation (see Section 7.2).
11. If the machine becomes clogged, shut off engine and
allow machine to stop completely before clearing debris.
Page 6
4.5" BearCat Chipper Operator's Manual
DANGER / POISON
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.
1.5 TOWING SAFETY
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
minutes. Get prompt medical attention.
FLUSH EYES
IMMEDIATELY
SHIELD EYES
EXPLOSIVE GASES
CAN CAUSE
BLINDNESS OR
INJURY
KEEP OUT OF THE REACH OF CHILDREN. DO NOT TIP. KEEP VENT CAPS TIGHT AND LEVEL.
NO
• SPARKS
• FLAMES
• SMOKING
SULFURIC
ACID
CAN CAUSE
BLINDNESS OR
SEVERE BURNS
WITH WATER
GET
MEDICAL
HELP
FAST
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.
Page 7
4.5" BearCat Chipper Operator's Manual
2
Section
Assembly
Your chipper may arrive totally or partially assembled.
Perform the steps in this section if your chipper arrives
partially assembled.
NOTE
REFER TO THE PARTS BOOK DURING ASSEMBLY
2.1 ASSEMBLING THE MACHINE
1. Remove the chipper from the shipping crate.
2. Place the unit on a firm, level surface before attempting
to assemble it.
3. Assemble and attach the Hitch, Axle and Wheels (Section 2.2).
4. Attach the Chipper Deflector (Section 2.3) or Optional
Discharge Tube (Section 2.4). The Optional Discharge
Tube is purchased separately.
5. Attach the Chipper Chute (Section 2.5).
6. Attach the Chipper Chute Extension Chute (S Models)
(Section 2.6).
7. Connect the Battery (Models 77412, 77412S) (Section
2.7).
8. Check engine oil (see engine owner's manual) and fill the
gas tank with fresh gasoline.
IMPORTANT
DO NOT ATTEMPT TO START THE ENGINE AT THIS
TIME. Wait until you have read the complete Owner's
Manual.
Fuel Tank
Engine
Hitch
Drive Belts and
Belt Guard
Chipper Engagement Lever
Wheels
Battery
Axle
Figure 2.1 - Chipper Assembly
Chipper Chute
Extension Chute
(S Models only)
Chipper Chute
Chipping Anvil
Disk Cover
Chipper Deflector
Trailer
Page 8
4.5" BearCat Chipper Operator's Manual
ASSEMBLY
2.2 ASSEMBLE THE HITCH, AXLE AND WHEELS.
NOTE
REFER TO THE PARTS BOOK DURING ASSEMBLY
2.2.1 MODELS 77412, 77412S
1. When assembling the axles, the wheel base can be
adjusted from 36" to 46". Attach both axles to the hitch
pole using U-Bolts, 1/4" washers and 1/4" locknuts.
2. Slide a wheel onto the axle and secure with a 5/8" washer
and cotter pin. Repeat for the remaining wheel.
3. Position the trailer onto the axle using a hoist or jack:
3a. Standard Configuration (Figures 2.2 & 2.3): The
axle and wheels should be positioned at the end
furthest away from the engine. Secure the trailer
to the hitch pole using two 3/8" x 1" carriage bolts,
3/8" washers and 3/8" nuts. The axle mounting
brackets located on each side of the trailer are already mounted in the correct spot. Attach the axles to the axle brackets using U-bolts, 1/4" washers and 1/4" locknuts.
3b. Optional Configuration (Figure 2.4): Move the
axle mounting brackets on the side of the trailer to
the holes closest to the engine. The axle and wheels
should be positioned at the end closest to the engine. Secure the trailer to the hitch pole using two
3/8" x 1" carriage bolts, 3/8" washers and 3/8" nuts.
Attach the axles to the axle brackets using U-bolts,
1/4" washers and 1/4" locknuts.
5. Attach the hitch pole plate to the hitch pole using two
3/8" x 1" bolts, 3/8" washers and 3/8" nuts.
Figure 2.3 - Standard Trailer Configuration
(Models 77412, 77412S)
Figure 2.4 - Optional Trailer Configuration
(Models 77412, 77412S)
Figure 2.2 - Standard Trailer/Hitch Assembly
(Models 77412, 77412S)
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