Echo CH5540HXE User Manual

Instructions
SUBJECT: SAFETY SWITCH
REPLACEMENT ON CE COMPLIANT CHIPPERS WITH HYDRAULIC FEED AND SAFETY KNEE BAR SYSTEM
WARNING
Before inspecting or servicing any part of this machine, shut off power source, disconnect spark plug wire from spark plug and make sure all moving parts have come to a complete stop.
SWITCH BOX INSTALLATION
MODELS:
CH5540HXE - KIT #77540-00
CH6730HXE - KIT #77542-00
CH611DHXE, CH6993HXE & CH6670HXE, CH8670HXE CH8993HXE, CH8720IHXE, CH911DHXE & CH922D­HXE, CH9540HXE - KIT # 77536-00
KIT #77542-00 FOR MODELS: CH6730HXE
SWITCH BOX REMOVAL
1. Remove control box cover (2) by removing four serrated
ange bolts (3).
2. Remove proximity sensors (4) by removing inside nut (5) closest to the control arm. Note from which position each sensor came from they will need to be installed in the same holes during installation of new control box.
TRI-COLOR LED
RED/YEL
RED/GRN
1. Mount new switch box (1) to switch box mount with two carriage bolts (10), washers, and nuts. Ensure switch box is all the to the front of the machine in the slot before tightening completely
2. Connect control arm to switch control bar using bolt (8), spacer, washer, and nut. Ensure spacer (9) is in the switch control bar before tightening.
2
3
COMPLETE CIRCUIT
WHT
7
6
4
10
5
1
9
8
3. Remove wires from the back of the reset switch (6) and Tri-Color LED (7). Remove Tri-Color LED from control box. (7)
4. Remove Bolt (8) connecting control arm to switch control bar.
5. Remove two carriage bolt (10) connecting switch box (1) to switch box mount.
3
CH6730HXE Chipper Chute
8
5
6
4
7
2
Rev. 032913
1
77541-00
3. Install Tri-Color LED into control box so that the silver terminal is located at the three o'clock position from the inside of the box.
4. Connect wires to the back of the reset switch (6) and Tri-Color LED (7). Ensure wires for the Tri-Color LED are connected as shown in diagram.
5. Install proximity sensors (4) into control box (1) using the nuts (5) previously removed. Ensure that sensors are put into the same hole that they came out of and that there is a 1/32” gap between the sensor and switch control bar. Ensure not to overtighten damage to sensor may occur.
6. Install control box cover (2) on control box (1) using four serrated ange bolts (3).
2
TRI-COLOR LED
RED/YEL
RED/GRN
6
3
WHT
COMPLETE CIRCUIT
7
4
10
5
1
9
8
CH6670HXE and CH6993HXE Chipper Chute
Instruction Sheet
3
7
8
5
6
4
1
2
COMPLETE CIRCUIT
WHT
RED/YEL
RED/GRN
TRI-COLOR LED
8
1
2
3
4
5
6
7
8
9
10
5
6
4
KNEE BAR SWITCH REMOVAL
1. Remove the two screws (2) and loosen the
nut (3) at the bottom of the knee bar switch cover (1) and remove it.
2. Remove plunger switch (4) from switch
bracket by removing plunger nut. Disconnect plunger switch from harness (7) by removing the two screws connecting them
3. Remove switch bracket (6) from extension
tray by removing two carriage bolts (8).
14624-00 CONNECTOR, 1/4 QD FEMALE 2
KIT, CONTROL SWITCHES (CH6730HXE)
PART# DESCRIPTION QTY
Part #77542-00
3
PLUNGER SWITCH INSTALLATION
1. Install new switch bracket (6) on to extension tray using two carriage bolts (8).
2. Install new plunger switch (4) into switch bracket using supplied plunger nut (5), washer, and plunger.
3. Cut off ring terminals from plunger end of harness (7) and replace with supplied female spade connectors. Connect harness to plunger switch (4).
4. Using two screws (2) mount the new switch cover (1) to switch bracket(6). While installing adjust the new switch cover so that it prevents the plunger switch from bottoming out when the knee bar is depressed.
7
2
1
14625-00 CONNECTOR, 1/4 QD MALE 2
15176 SCW,11/32*7/8 HWH AB THREAD ZP 2
15349 BOLT,CARR 5/16*7/8" GR5 NC ZP 2
15904-00 NUT, 5/16-18 NYLOCK-FLANGE 2
32375-00
77527-00 ASSEMBLY, SWITCH BOX 1
77532-12 BRACKET, SWITCH 1
77535-12 SHIELD, SAFETYBAR SWITCH 1
SWITCH, MOMENTARY IP67 NOR­MALLY ON
Instruction Sheet
5. Adjust plunger switch (4) by loosening the two carriage bolts (8) and setting it so that it is activated when the knee bar is depressed.
1
COMPLETE
10
KIT #77536-00 FOR MODELS: CH611DHXE, CH6993HXE & CH6670HXE
CH8993HXE,CH8720IHXE, CH8670HXE, CH911DHXE, CH922DHXE
SWITCH BOX REMOVAL
1. Remove control box cover (2) by removing four serrated ange bolts (3).
2. Remove proximity sensors (4) by removing inside nut (5) closest to the control arm. Note from which position each sensor came from they will need to be installed in the same holes during installation of new control box.
3. Remove wires from the back of the reset switch (6) and Tri-Color LED (7). Remove Tri-Color LED from control box. (7)
4. Remove Bolt (8) connecting control arm to switch control bar.
5. Remove two carriage bolt (10) connecting switch box (1) to chipper chute.
TRI-COLOR LED
RED/YEL
RED/GRN
WHT
CIRCUIT
5
1
9
7
6
2
4
8
3
8
CH611DHXE Chipper Chute
5
6
4
3
7
2
1
SWITCH BOX INSTALLATION
1. Mount new switch box (1) to top of chipper
chute with two carriage bolts (10), washers, and nuts. Ensure switch box is all the to the front of the machine in the slot before tightening completely
2. Connect control arm to switch control bar
using bolt (8), spacer, washer, and nut. Ensure spacer (9) is in the switch control bar before tightening.
3. Install Tri-Color LED into control box so that
the silver terminal is located at the three o'clock position from the inside of the box.
4. Connect wires to the back of the reset switch
(6) and Tri-Color LED (7). Ensure wires for the Tri-Color LED are connected as shown in diagram.
TRI-COLOR LED
RED/YEL
WHT
COMPLETE CIRCUIT
5. Install proximity sensors (4) into control box (1) using the nuts (5) previously removed. Ensure that sensors are put into the same hole that they came out of and that there is a 1/32” gap between the sensor and switch control bar. Ensure not to overtighten damage to sensor may occur.
6. Install control box cover (2) on control box (1)
using four serrated ange bolts (3).
2
3
10
5
RED/GRN
1
9
7
6
8
4
8
5
6
4
3
CH8720iHXE, CH8993HXE, CH911DHXE, CH922DHXE & CH9540H Chipper Chute
Instruction Sheet
7
2
1
COMPLETE CIRCUIT
WHT
RED/YEL
RED/GRN
TRI-COLOR LED
8
1
2
3
4
5
6
7
8
9
10
5
6
4
KNEE BAR SWITCH REMOVAL
1. Remove the two screws (2) and loosen the nut (3) at the bottom of the knee bar switch cover (1) and remove it.
2. Remove plunger switch (4) from switch bracket by removing plunger nut. Disconnect plunger switch from harness (7) by removing the two screws connecting them
3. Remove switch bracket (6) from extension tray by removing two carriage bolts (8).
KIT, CONTROL SWITCHES, Part #77536-00
PART# DESCRIPTION QTY
14624-00 CONNECTOR, 1/4 QD FEMALE 2
3
PLUNGER SWITCH INSTALLATION
1. Install new switch bracket (6) on to extension tray using two carriage bolts (8).
2. Install new plunger switch (4) into switch bracket using supplied plunger nut (5), washer, and plunger.
3. Cut off ring terminals from plunger end of harness (7) and replace with supplied female spade connectors. Connect harness to plunger switch (4).
4. Using two screws (2) mount the new switch cover (1) to switch bracket(6). While installing adjust the new switch cover so that it prevents the plunger switch from bottoming out when the knee bar is depressed.
7
2
1
14625-00 CONNECTOR, 1/4 QD MALE 2
15176 SCW,11/32*7/8 HWH AB THREAD ZP 2
15349 BOLT,CARR 5/16*7/8" GR5 NC ZP 2
15904-00 NUT, 5/16-18 NYLOCK-FLANGE 2
32375-00
77527-00 ASSEMBLY, SWITCH BOX 1
77532-12 BRACKET, SWITCH 1
SWITCH, MOMENTARY IP67 NOR­MALLY ON
Instruction Sheet
5. Adjust plunger switch (4) by loosening the two carriage bolts (8) and setting it so that it is activated when the knee bar is depressed.
1
KIT # 77540-00 FOR MODEL: CH5540HXE
2
TRI-COLOR LED
RED/YEL
RED/GRN
WHT
COMPLETE CIRCUIT
4
6
7
10
3
5
1
9
8
SWITCH BOX INSTALLATION
1. Mount new switch box (1) to top of chipper chute with two hex bolts (10), washers, and nuts. Ensure switch box is all the to the front of the machine in the slot before tightening completely
2. Connect control arm to switch control bar using bolt (8), spacer, washer, and nut. Ensure spacer (9) is in the switch control bar before tightening.
3. Install Tri-Color LED into control box so that the silver terminal is located at the three o'clock position from the inside of the box.
SWITCH BOX REMOVAL
1. Remove control box cover (2) by removing
serrated ange bolts (3).
2. Remove mechanical switches (4) by removing inside nut (5) closest to the control arm. Note from which position each switch came from they will need to be installed in the same holes during installation of new control box.
3. Remove wires from the back of the reset switch (7) and Tri-Color LED (6).
4. Remove Bolt (8) connecting control arm to switch control bar.
5. Remove two hex bolt (10) connecting switch box (1) to chipper chute.
Instruction Sheet
6. Connect wires to the back of the reset switch (7) and Tri-Color LED (6). Ensure wires for the Tri-Color LED are connected as shown in diagram.
7. Install mechanical switches (4) into control box (1) using the nuts (5) previously removed. Ensure that switches are put into the same hole that they came out of. Ensure not to overtighten damage to switch may occur.
8. Install control box cover (2) on control box (1)
using serrated ange bolts (3).
COMPLETE CIRCUIT
WHT
RED/YEL
RED/GRN
TRI-COLOR LED
8
1
2
3
4
5
6
7
8
9
10
5
6
4
KNEE BAR SWITCH REMOVAL
1. Remove the two screws (2) and loosen the nut (3) at the bottom of the knee bar switch cover (1) and remove it.
2. Remove plunger switch (4) from switch bracket by removing plunger nut. Disconnect plunger switch from harness (7) by removing the two screws connecting them
3. Remove switch bracket (6) from extension tray by removing two carriage bolts (8).
PART# DESCRIPTION QTY
14624-00 CONNECTOR, 1/4 QD FEMALE 2
14625-00 CONNECTOR, 1/4 QD MALE 2
15176 SCW,11/32*7/8 HWH AB THREAD ZP 2
15349 BOLT,CARR 5/16*7/8" GR5 NC ZP 2
15904-00 NUT, 5/16-18 NYLOCK-FLANGE 2
32375-00
KIT, CONTROL SWITCHES (5 INCH)
Part #77540-00
SWITCH, MOMENTARY IP67 NOR­MALLY ON
3
1
PLUNGER SWITCH INSTALLATION
1. Install new switch bracket (6) on to extension tray using two carriage bolts (8).
2. Install new plunger switch (4) into switch bracket using supplied plunger nut (5), washer, and plunger.
3. Cut off ring terminals from plunger end of harness (7) and replace with supplied female spade connectors. Connect harness to plunger switch (4).
4. Using two screws (2) mount switch cover (1) to switch bracket(6). While installing adjust the switch cover so that it is prevents plunger switch from bottoming out when the knee bar is depressed.
5. Adjust plunger switch (4) by loosening the two carriage bolts (8) and setting it so that it is activated when the knee bar is depressed.
1
7
2
77530-00 ASSEMBLY, SWITCH BOX 1
77532-12 BRACKET, SWITCH 1
77534-12 SHIELD, SAFETY BAR SWITCH 1
ECHO BEAR CAT
Phone: 701.282.5520 • Toll Free: 800.247.7335 • Fax: 701.282.9522
E-mail: service@bearcatproducts.com • sales@bearcatproducts.com
237 NW 12th Street, West Fargo, ND 58078-0849
www.bearcatproducts.com
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