540 PTO CHIPPER
CH8540 - GRAVITY FEED
CH9540H - HYDRAULIC FEED
CHF9540H - HYDRAULIC FEED, FINE CHIP
ENGLISH ESPAÑOL FRANÇAIS
Manual P/N: 16812
Rev. 040809
Companion to P/N 12141
SN/VIN Range: 902153 - A03337
OWNER'S MANUAL
Before You Begin
MANUFACTURED BY CRARY INDUSTRIES
MANUFACTURED IN U.S.A.
XXXXXX
WEST FARGO, NORTH DAKOTA 58078 U.S.A.
SERIAL NUMBER
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 efciency, 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 efcient 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.
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
© 2009, CRARY INDUSTRIES, ALL RIGHTS RESERVED. PRODUCED AND PRINTED IN THE U.S.A.
800-247-7335
701-282-5520
FAX: 701-282-9522
sales@bearcatproducts.com
service@bearcatproducts.com
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.
This warranty applies only to parts or components that are defective in material or workmanship. 1.
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.3.
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.5.
This warranty does not cover damage due to unauthorized modifications of the product. 6.
Engines are warranted by the respective engine manufacturer and are not covered by this warranty.7.
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
DESCRIPTION PAGE
SAFETY ................................................................................................................1
1.1 SAFETY ALERT SYMBOL ....................................................................................1
1.2 EMISSION INFORMATION ...................................................................................1
1.3 BEFORE OPERATING ..........................................................................................1
1.4 OPERATION SAFETY ..........................................................................................2
1.5 FEED ROLLER SAFETY ......................................................................................2
1.6 MAINTENANCE/STORAGE SAFETY ...................................................................3
1.7 TOWING SAFETY .................................................................................................3
1.8 PTO SAFETY ........................................................................................................3
1.9 SAFETY DECAL LOCATIONS .............................................................................4
1.10 SAFETY DECALS ...............................................................................................5
ASSEMBLY ........................................................................................................... 6
2.1 ATTACH CHUTE SUPPORT (HYDRAULIC FEED MODELS ONLY) ...................6
2.2 ATTACH CHIPPER CHUTE ..................................................................................6
2.3 ATTACH EXTENSION TRAY .................................................................................7
2.4 SAFETY BAR .........................................................................................................7
2.5 ATTACH DISCHARGE TUBE ................................................................................7
2.6 ATTACH DISCHARGE TUBE ................................................................................8
2.7 CONNECT PTO DRIVELINE ................................................................................8
2.8 CONNECT CONTROL BOX WIRES TO TRACTOR .............................................8
FEATURES & CONTROLS ................................................................................... 9
OPERATION .......................................................................................................10
4.1 STARTING THE CHIPPER ..................................................................................10
4.2 STOPPING THE CHIPPER ..................................................................................10
4.3 OPERATING THE CHIPPER ..............................................................................10
4.4 RAISE EXTENSION TRAY BEFORE TOWING ...................................................11
4.5 FEED ROLLER CONTROL BAR ........................................................................11
4.6 CHIPPER CONTROLLER ...................................................................................12
4.7 FEED ROLLER SPEED CONTROL ....................................................................12
SERVICE & MAINTENANCE .............................................................................. 13
5.1 INSTALLING THE DISK LOCK ...........................................................................14
5.2 CHIPPER BLADE MAINTENANCE ....................................................................14
5.3 REMOVING THE BLADES .................................................................................14
5.4 SHARPENING THE BLADES .............................................................................15
5.5 ADJUSTING THE CHIPPER ANVIL ....................................................................15
5.6 LUBRICATION ....................................................................................................16
5.7 PTO DRIVELINE LUBRICATION ........................................................................17
5.8 CLEARING A PLUGGED ROTOR .......................................................................17
5.9 ADJUSTING/REPLACING DRIVE BELT ..............................................................18
5.10 REPLACING BEARINGS ..................................................................................18
5.11 CHANGING HYDRAULIC OIL FILTER ..............................................................19
5.12 FILLING HYDRAULIC FLUID............................................................................19
TROUBLESHOOTING ........................................................................................ 20
SPECIFICATIONS ............................................................................................... 21
7.1 CHIPPER SPECIFICATIONS ...............................................................................21
7.2 BOLT TORQUE ....................................................................................................22
7.3 FLASH CODES FOR THE CONTROL LIGHT .....................................................23
PTO CHIPPERSiv
1
SAFETY
Section
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.
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 mufer 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.
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 specic information
about which regulations apply in your area.
The standard mufer 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.
1.3 BEFORE OPERATING
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.
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.
Read and understand this owner ’s manual. Be 1.
completely familiar with the controls and the proper
use of this equipment.
Familiarize yourself with all of the safety and operating 2.
decals on this equipment and on any of its attachments
or accessories.
Keep safety decals clean and legible. Replace missing 3.
or illegible safety decals.
Obta i n and w e ar sa f ety 4.
glass es and use heari ng
protection at all times when
operating this machine.
Avoid wearing loose fitted 5.
clothing. N eve r operate
this machine while wearing
clothing with drawstrings that
could wrap around or get caught in the machine.
Do not operate this machine if you are under the 6.
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.
PTO CHIPPERS
1
SAFETY
WRONG
WRONG
Do not operate this equipment in the vicinity of 7.
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.
Do not allow children to operate this equipment.8.
Use only in daylight or good artificial light.9.
Do not run this equipment in an enclosed area. Engine 10.
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.
Always use an approved fuel container. Do not remove 11.
gas cap or add fuel when engine is running. Add fuel
to a cool engine only.
Do not fill fuel tank indoors. Keep open flames, sparks, 12.
smoking materials and other sources of combustion
away from fuel.
Do not operate machine without shields in place. 13.
Failure to do so may cause serious injury or death.
Keep all guards, deflectors, and shields in good 14.
working condition.
Before inspecting or servicing any part of this machine, 15.
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.
Check that all screws, nuts, bolts, and other fasteners 16.
are secured, tightened and in proper working condition
before starting the machine.
Do not transport or move machine while it is operating 17.
or running.
1.4 OPERATION SAFETY
Always stand clear of discharge 1.
area when op era ting this
machine. Keep face and body
away from feed and discharge
openings.
Keep hands and feet out of 2.
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.
Set up your work site so you are not endangering traffic 3.
and the public. Take great care to provide adequate
warnings.
Do not climb on machine when operating. Keep proper 4.
balance and footing at all times.
Check cutting chamber to verify it is empty before 5.
starting the machine.
The disk will continue to rotate after being disengaged. 6.
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.
Do not insert branches with a diameter larger than 7.
the max chipper capacity into machine or machine
damage may occur.
When feeding material into machine, do not allow 8.
metal, rocks, bottles, cans or any other foreign material
to be fed into the machine.
Ensure debris does not blow into traffic, parked cars, 9.
or pedestrians.
Kee p the machi ne clear of debris and other 10.
accumulations.
Do not allow processed material to build up in the 11.
discharge area. This may prevent proper discharge
and can result in kickback of material through the feed
opening.
If the machine becomes clogged, the cutting mechanism 12.
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.
On electric start models, disconnect cables from battery 13.
before doing any inspection or service. Remove key.
Check blade bolts for proper torque after every 8 hours 14.
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
The feed roller can cause serious injury or death. Keep 1.
hands, feet and clothing away from the feed roller and
chipper disk blades.
Never climb onto the feed chute when the unit is 2.
operating or running.
Do not overreach. Keep proper 3.
balance and footing at all times.
Never allow anyone to sit on the 4.
feed chute.
When feeding material into the 5.
feed roller wear eye, face and
hearing protection.
Stand to side of feed chute when 6.
feeding material and release
material quickly.
When inspecting or servicing the 7.
feed roller, secure the feed roller in the raised position
using the lock pin, if applicable.
PTO CHIPPERS2
SAFETY
1.6 MAINTENANCE/STORAGE SAFETY
Before inspecting, servicing, storing, or changing 1.
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.
Replace any missing or unreadable safety decals. 2.
Refer to the safety decal section for part numbers.
Allow machine to cool before storing in an enclosure.3.
Store the machine out of reach of children and where 4.
fuel vapors will not reach an open flame or spark.
Never store this machine with fuel in the fuel tank 5.
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.
Drain the fuel and dispose of it in a safe manner for 6.
storage periods of three months or more.
1.7 TOWING SAFETY
Rotate the discharge tube to face the opposite direction 1.
of the towing vehicle before towing.
Insert transport safety pin and clip, and set brake handle 2.
to locked position, if applicable.
Connect hitch safety chains. Tighten trailer hitch bolts. 3.
Do not attempt to tow the trailer if the vehicle is not
equipped with a 2” (50 mm) ball.
Do not exceed the maximum towing speed indicated 4.
on tire sidewall. Inflate tires to manufacturer’s
specifications as stated on the tire sidewall.
Optimum towing performance can be achieved by 5.
maintaining a horizontal trailer hitch.
Check wheel lug bolts periodically to ensure they are 6.
tight and secure.
Make sure the jack stand and the rear stabilizer (where 7.
applicable) on the trailer are in the UP position during
towing. Place the jack stand on a level surface and
secure it in the DOWN position before using.
Never allow passengers to ride on the machine.8.
If applicable, shut off fuel supply when towing.9.
Towing laws may vary in different countries/regions/10.
states. It is recommended that you contact your local
motor vehicle department for any special regulations
that pertain to towing and know the laws of any country/
region/state you travel through.
1.8 PTO SAFETY
Read and follow instructions on PTO safety decals.1.
Stay alert and pay attention when PTO is operating.2.
Keep bystanders, especially children, away from PTO 3.
driveline.
Check the driveline to ensure it is attached securely to 4.
the power supply.
Keep guards and shields in place at all times while 5.
operating. Disengage PTO, shut off power source, and
make sure all moving parts have come to a complete
stop before removing guards or shields.
Clothing worn by operator must be fairly tight. Never 6.
wear loose fitted jackets, shirts, or pants when working
around the PTO. Tie long hair back or put under a
cap.
Keep hydraulic hoses, electric cords, chains and other 7.
items from contacting the driveline.
Proper recommended PTO operating speed is 540 8.
+/- 10 RPM.
Before inspecting or servicing the PTO drive area, 9.
disengage the driveline, shut off power source, remove
ignition key, and make sure all moving parts have come
to a complete stop.
Keep hands, feet, and clothing away from all PTO 10.
drive parts.
Do not clean, lubricate or adjust the PTO shaft when 11.
it is running.
ENGLISH
PTO CHIPPERS
3
SAFETY
7
4
3
2
4
1
5
4
8
6
9
1.9 SAFETY DECAL LOCATIONS
The numbers below correspond to the decals in Section 1.10 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.
Figure 1.1 Rotor access cover decals
Figure 1.2 Model CHF9540H (76854) discharge chute
Figure 1.3 Chipper decal locations
PTO CHIPPERS4
SAFETY
1.10 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.
DO NOT OPERATE MACHINE
WITHOUT SHIELDS IN PLACE.
FAILURE TO DO SO MAY CAUSE
SERIOUS INJURY OR DEATH.
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.
5
6
7
PN 12174
PN 12175
PN 12250
ENGLISH
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.
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 14942-00
8
PN 18983-00
9
FEED ROLLER SUPPORT
MUST BE SECURED IN THE
UP POS ITI ON PRI OR TO
SERVICING CHIPPER FEED
AREA. THE FEED ROLLER
C A N FALL A N D C A U S E
SEVERE BODILY HARM. CONSULT OWNERS MANUAL FOR
PROPER METHOD OF SECURING FEED ROLLER SUPPORT.
LOWER FEED ROLLER BEFORE OPERATING CHIPPER.
(MODELS CH9540H AND
CHF9540H ONLY)
PTO CHIPPERS
5
CHIPPER CHUTE BASE
CONNECTED TO
MAIN ASSEMBLY
3/8” x 1-1/2” BOLT
3/8” WASHER
3/8” NUT
3/8" NUT
3/8" WASHER
3/8" X 1"
BOLT
CHUTE SUPPORT
2
CHIPPER CHUTE
CHUTE
SUPPORT
DETAIL OF CHUTE
SUPPORT MOUNTING
ON CHUTE
ASSEMBLY
Section
WARNING
If any bolts or nuts are dropped in the machine, be
sure to remove them before starting the machine.
2.1 ATTACH CHUTE SUPPORT (HYDRAULIC FEED MODELS ONLY)
WARNING
Do not operate this unit without the chipper chute correctly installed. Rotating cutting blades can cause se-
rious personal injury.
Remove chipper from shipping crate. Place unit on a 1.
level surface before attempting to assemble. See the
Torque Chart in Section 7 for the minimum tightening
torque of bolts and screws.
Attach the chute support to the front side of the chipper 2.
base with one 3/8" x 1" bolt, washer and nut. Refer to
Figure 2.1.
Figure 2.2. Attaching the chipper chute (gravity feed models)
Figure 2.1. Chute support positioning
2.2 ATTACH CHIPPER CHUTE
For gravity feed models, mount the chipper chute to the
frame mounting bracket using eight 3/8" x 1" bolts and
locknuts (see Figure 2.2). Use three bolts on each side
and two on the bottom.
For hydraulic feed models, mount the chipper chute directly
to the feed roller as shown in Figure 2.3.
For hydraulic feed models, connect the three wires coming
from the feed chute to the connectors that are located
underneath the feed roller.
Figure 2.3. Attaching the chipper chute (hydraulic models)
PTO CHIPPERS6
ASSEMBLY
2.3 ATTACH EXTENSION TRAY
(Not available on all models. Model CH8540 shown here.)
Slide the chute extension tray over the chipper chute. 1.
Make sure that you position the lip on the extension
tray behind the lip on the chipper chute. Align the
bolt holes in the chute extension tray with the bolt
holes in the hinge.
Insert 3/8" x 1" carriage bolts (included in owner's kit) 2.
through the four outside holes on the extension tray
and hinge. Secure the bolts with washers and nuts.
Insert one 3/8" x 1-1/2" carriage bolt through the end 3.
of the chute support and middle hole of the extension
hinge and tray. Secure the bolts with washer and nuts.
Secure with hairpin clips.
2.5 ATTACH DISCHARGE TUBE
(Models CH8540 and CH9540H)
Slide the tube onto the mounting flange on the chipper 1.
frame (Figure 2.5). The discharge clamp should slide
underneath the lip of the flange. Tighten the bolts to
secure it.
Install the second half of the spacer and clamp to the 2.
discharge tube. Rotate the tube 360 degrees and lock
it in place with the lock pin to make sure it is mounted
correctly.
Attach the discharge deflector to the discharge tube. 3.
Connect the cap with 3/8" x 2" bolts through the bottom
hole in the discharge tube. Run these bolts through
the inside of the tube, the cap, washer, knob, and
then nut. Finish bolting the cap to the tube with 3/8"
x 1" bolts through the end hole in the discharge tube
(Figure 2.6).
ENGLISH
Figure 2.4. Attaching the extension tray
2.4 SAFETY BAR
(Not available on all models.)
Plug safety bar wire harness into the loose wire 1.
harness on the chipper frame.
Fig. 2.5. Attach spacer and clamp underneath tube base
Fig. 2.6. Attach discharge deector
PTO CHIPPERS
7
ASSEMBLY
2.6 ATTACH DISCHARGE TUBE
(Model CHF9540H)
Bolt the discharge tube onto the mounting flange with the
eight 3/8" x 7/8" bolts, nuts and washers provided. Put the
bolts through every other hole.
to fit as explained in section 2.4.2.
2.4.2 SHORTENING A PTO DRIVELINE
Pull the driveline into two pieces. Connect one end to 5.
the tractor PTO and the other end to the chipper rotor
shaft. Line up the two halves parallel to each other.
Measure the distance from the end of one driveline tube 6.
to the bottom of the end shield of the other driveline
half (dimension A in Fig. 2.4). Measure and mark the
driveline tube 1-9/16” inward from dimension A.
Cut the shield tube in the marked position.7.
Using the cut piece of shield tube as your measurement, 8.
place the cut piece against the end of the shaft. Mark
and cut the shaft.
Using the cut piece of shield tube as your measurement, 9.
mark and cut the tube on the other half of the driveline,
and then the shaft.
File both shaft ends, and slide the two halves back 10.
together.
2.4.3 CONNECTING THE PTO DRIVELINE
When you have confirmed that the driveline is the 11.
correct length for your tractor, connect the driveline
to the chipper rotor shaft using key stock and two set
screws in the owner’s kit.
Figure 2.7. Attach the discharge tube
2.7 CONNECT PTO DRIVELINE
IMPORTANT
The tractor must have a standard 540 RPM PTO
shaft.
If the tractor has an electric PTO clutch, consult your
dealer for correct operating procedures.
2.4.1 CHECK LENGTH OF PTO DRIVELINE
Attach chipper to tractor with three-point hitch. 1.
You must make sure that the PTO driveline supplied 2.
with your machine is the appropriate length for your
tractor. Adjust the chipper up and down and measure
the shortest and longest distance between the chipper
rotor shaft and tractor PTO.
The PTO driveline has a maximum extension of 3.
24.49” with a 6.43” overlap. This driveline will fit most
models. However, if your longest distance is greater
than 24.49”, you will need to purchase a longer PTO
driveline.
The PTO driveline has a minimum compression of 4.
18.1”. If your shortest distance is less than this, cut it
Figure 2.8
2.8 CONNECT CONTROL BOX WIRES TO TRACTOR
There are two electrical wires (red and white) that come
wrapped around the three-point PTO connector.
Connect the red wire to a 12-volt power source, such •
as the alternator or the battery.
Ground the white wire (connect to negative post on •
the battery or another point).
PTO CHIPPERS8
3
4
17
2
3
16
7
15
1
6
6
5
14
8
9
11
12
13
10
FEATURES & CONTROLS
Section
Understanding how your machine works will help you achieve the best results when using your machine. The following
descriptions dene the features and controls of your machine.
ENGLISH
Discharge tube1. : Chipped materials will exit through
this tube. It is adjustable 360 degrees. The discharge
tube for the fine chip model is not adjustable. It is
designed to blow materials onto the ground.
Rotor shaft bearing cover2. : Covers rotor shaft and
front bearing.
Manual Holder: 3. Conveniently stores your owner's and
parts manuals.
Leg stands4. : Never move machine unless the threepoint is lifted and legs clear the ground.
Chipper chute5. : Feed materials into the chipper
chute.
Safety bar: 6. (Not available on all models.) Push
the safety bar to stop the feed roller in event of an
emergency.
Reset/Override button: 7. (Not available on all models.)
When the safety bar has been activated, the red light
will go on and the feed roller will stop. Push the reset/
override button to resume forward feed. Upon start-up,
the safety bar light will be on and will need to be reset
before the feed roller will operate.
Rotor access cover8. : Tilts up to provide access to
blades.
Feed roller lift jack: 9. Use the jack to lift the feed roller
to inspect or service the machine. Secure feed roller
in the raised position with the snap pin.
Hydraulic fluid tank:10. Inspect level of fluid each time
the machine is operated.
Drive belt shield11. : Remove shield to inspect drive
belt.
Three-point connection: 12. Mounts chipper to tractor
three-point hitch.
PTO driveline13. : Connects chipper to tractor PTO
shaft.
Controller Light14. : When the light is flashing green
increase RPM. The feed roller can be shifted into
Forward when the controller light is steady green. See
Section 7.3 for more information.
Disk Lock and Pin15. : Use the disk lock to hold the
chipper disk in place when doing any maintenance
work on it. See Sec. 5.2.
Feed Roller Control Bar16. : Move the feed roller control
bar to begin feeding materials into the chipper.
Feed Roller Speed Control17. : Turn clockwise to
increase feed roller speed and counterclockwise to
decrease.
PTO CHIPPERS
9
4
Section
OPERATION
As with any other piece of outdoor equipment, getting the
feel for how your machine operates and getting to know
the best techniques for particular jobs are important to
overall good performance.
CHIPPING OPERATION
The chipping operation takes place on the front of the
machine, where hardened steel chipper blades are
mounted on a rotating disk assembly. Material fed into the
chipper chute is sliced into small chips and propelled out
through a discharge tube.
WARNING
Move machine to a clear, level area outdoors before
starting. Do not operate in the vicinity of bystanders.
Make sure cutting chamber is empty before starting.
WARNING
Before operating your machine, be sure you read
and understand all safety, controls and operating
instructions in this owner’s manual and on your
machine. Failure to follow these instructions can result
in serious injury or property damage.
4.2 STOPPING THE CHIPPER
Move tractor throttle to slowest position.1.
Disengage PTO lever and shut off tractor engine.2.
Allow machine to come to a complete stop.3.
4.3 OPERATING THE CHIPPER
WARNING
Read and follow all safety instructions in this manual.
Failure to operate the machine in accordance with
the safety instructions MAY RESULT IN PERSONAL
INJURY!
CAUTION
Obtain and wear safety glasses at all times when
operating the machine.
Do not wear loose fitting clothing.
4.1 STARTING THE CHIPPER
Connect PTO driveline to tractor as described in Sec. 1.
2.8.
Adjust three-point top link so the chipper sits level.2.
Start tractor engine and engage PTO (refer to tractor 3.
owner’s manual). Increase engine speed to rated PTO
RPM.
Make sure the feed roller control bar is in the Stop 4.
position. The controller will flash red until the bar is in
Stop. See Sec 7.3 for a table of all flash codes for the
controller light.
NOTE
If forward and reverse feed positions are reversed
when you power up the machine, you may have
plugged the connectors into the wrong plug.
WARNING
Do not inspect or work on PTO drive area without rst
disengaging PTO and shutting off tractor. Allow all
moving parts to come to a complete stop.
The operator should always wear heavy boots, gloves,
pants, and a long-sleeved shirt.
Use common sense and practice safety to protect
yourself from branches, sharp objects, and other
harmful objects.
WARNING
Never lean over the chipper chute to push objects
into the cutting device. Use a push stick or brush
paddle.
Never use shovels or forks to feed brush. They can
cause extensive damage if they contact the blades.
In addition, metal pieces can be ejected from the
chipper chute and cause serious injury or death.
Never feed brush into the chute with your feet.
Never use hands or feet to clear materials that build up
in the chute.
PTO CHIPPERS10
OPERATION
R
REVERSE
R
F
FORWARD
STOP
REVERSE
RESET/OVERRIDE
BUTTON (WHERE
AVAILABLE)
CONTROLLER
LIGHT
FEED ROLLER
CONTROL BAR
SAFETY BAR
(WHERE
AVAILABLE)
The machine chips a variety of materials into a more
readily decomposed or handled condition. The following
guidelines will help you get started.
Run unit at full operating speed1. before starting to
chip material.
Limbs fed in to the chipper chute must be 8 inches 2.
(20 cm) in diameter or less. Trim side branches that
cannot be bent enough to feed into the chipper chute.
Hold small diameter branches together in a bundle and
feed in simultaneously.
Exclude pieces of metal, rocks, bottles, cans, and 3.
other foreign objects when feeding material into the
machine.
Feed brush from the side of the chipper chute,4. rather
than from the front. Step aside to avoid being hit by the
brush moving into the chipper.
Place limb, butt end first, into the chipper chute 5.
until it contacts the chipper blades. The actual feed
rate of the limb into the chipper will depend on the type
of material fed and sharpness of the cutting blades.
If the engine slows to where it may stall,6. stop feeding
material and allow the engine to recover. Feed material
more evenly.
If the chipper jams,7. remove the branch and rotate it
before reinserting it into the chute. Alternately insert
and retract the limb or insert continuously at a rate that
will not kill the engine.
Do not use the clutch to clear a plugged rotor.8. This
may cause belt damage. Refer to the instructions for
clearing a plugged rotor in the Service and Maintenance
section.
Alternate greener material with dry material9. to
lubricate the chipping blades for longer life and better
performance. Chipping dead, dry material will create
heat and dull the chipping blades quickly.
Sharpen the chipping blades periodically.10. Check
the sharpness of the blades every 5-15 hours. Refer
to the Service and Maintenance section for sharpening
instructions.
To prevent personal injury or property damage: shut
off engine and make sure that all moving parts have
come to a complete stop before servicing, adjusting,
or repairing machine. Disconnect the battery and
remove ignition key where applicable.
WARNING
4.4 RAISE EXTENSION TRAY BEFORE TOWING
Raise the extension tray to an upright position before
towing the machine. Secure with the fastener located near
the top of the chute.
If your model is equipped with a safety bar, once the
extension tray is in an upright position, push the safety bar
down to lock the bar. To unlock, lower the extension tray
and push in the safety bar.
4.5 FEED ROLLER CONTROL BAR
The Feed Roller Control Bar is used to manually control
the direction of the feed roller rotation.
Move the feed roller control bar to FORWARD (F) when
you want the materials to feed into the chipper. The
controller light must be steady green.
Move the feed roller bar to REVERSE (R) when you want
the chipper push materials back out of the feed chute.
Move the feed roller bar to STOP to halt the rotation of the
feed roller.
EUROPEAN MODELS ONLY
Push the Safety Bar in the event of an emergency and
forward feed will stop. Push the reset/override button to
resume forward feed after returning the safety bar to its
normal operating position.
Upon start-up, the controller light will glow a steady red.
Push the reset/override button to reset.
If false trips occur, the reset button can be held in for 5
ENGLISH
PTO CHIPPERS
11
OPERATION
4.6 CHIPPER CONTROLLER
This machine is equipped with a Plus 1 Controller. The
controller monitors the chipper disk RPM and regulates
the feed roller.
When chipper disk RPM drops too low, the feed roller
is stopped automatically to allow the chipper disk to
process material.
When the chipper disk returns to chipping RPM, the
feed roller will automatically reengage.
Try Again Feature: If the feed roller becomes obstructed,
the controller will reverse the feed roller momentarily
to clear the obstruction. The controller will then engage
the feed roller and feed the material again.
If this cycle continues, remove or reposition the material
manually.
Remember to sharpen blades frequently so material
will feed smoothly.
The controller light will flash the following codes (See
Sec. 6 for more information):
Normal Operating RPM:• Stead y green li ght
indicates engine has reached full RPM.
Feed Bar Not in STOP:• Flashing red light indicates
operator must put feed bar in STOP position.
Service Code• : Flashing amber light is a reminder
to check blade sharpness.
RPM Too Low• : Flashing green light indicates
operator must increase engine RPM before
starting to chip.
Safety Bar Activated:• Steady red light (European
models only).
4.7 FEED ROLLER SPEED CONTROL
With the feed roller speed control the operator can adjust
the speed of the feed roller, allowing the operator to have
better control of how material is fed into the chipper.
It is recommended that the feed roller operate at a faster
rate for smaller branches and at a slower rate for larger
branches.
NOTE
The disk sensor and feed roller control bar sensors must
NOTE
The RPM sensor on the rotor must be ashing as the
rotor turns or the controller won’t work. Clearance
between the sensor and the bolt must be between
1/32” (0.8 mm) and 3/32” (2.4 mm). There are also two
sensors in the feed roller control box. These sensors
must have a clearance of 5/64” (2 mm).
PTO CHIPPERS12
5
Section
SERVICE & MAINTENANCE
The items listed in this service and maintenance schedule
are to be checked, and if necessary, corrective action taken.
This schedule is designed for units operating under normal
conditions. If the unit is operating in adverse or severe
conditions, it may be necessary for the items to be checked
and serviced more frequently.
SEE ENGINE OWNER’S MANUAL FOR FURTHER
To prevent personal injury or property damage: shut
off engine and make sure that all moving parts have
come to a complete stop before servicing, adjusting,
or repairing machine. Disconnect the battery and
remove ignition key where applicable.
WARNING
ENGINE MAINTENANCE AND TROUBLESHOOTING
INFORMATION.
SERVICE AND MAINTENANCE SCHEDULE
FREQUENCY
REFER TO
COMPONENT
AIR CLEANER CHECK AND CLEAN (1)
AIR INTAKE CLEAN (1)
HYDRAULIC OIL CHECK/FILL
ALL INTERNAL AND
EXTERNAL NUTS AND
BOLTS
CHIPPER ANVIL
CHIPPER BLADES
ENTIRE MACHINE CLEAN
PTO CROSS JOURNALS LUBE
PTO INNER TUBES LUBE
PTO SHIELD RETAINING
BEARING
DRIVE BELT CHECK
HYDRAULIC DRIVE BELT CHECK
BELT TENSION CHECK
BELT/PULLEY ALIGNMENT CHECK
GREASE ZERKS LUBE
HYDRAULIC OIL FILTER REPLACE
WHEEL BEARINGS CHECK AND REPACK
(1) PERFORM MORE FREQUENTLY UNDER EXTREMELY DUSTY CONDITIONS.
(2) PERFORM MORE FREQUENTLY WHEN CHIPPING DRY OR DIRTY WOOD.
As the Limited Warranty states, failure by the Owner to perform normal maintenance will void the machine’s warranty.
The aggressive, high-speed nature of chipping REQUIRES THE OWNER TO PERFORM THE ABOVE LISTED NORMAL
MAINTENANCE. Special consideration to maintain and re-torque the CHIPPER ANVIL, CHIPPER BLADES, AND ALL
INTERNAL AND EXTERNAL NUTS AND BOLTS is the sole responsibility of the Owner. Failure by the Owner to do so
shall be cause for denial of warranty.
MAINTENANCE
REQUIRED
CHECK TIGHTNESS
CHECK CLEARANCE AND
RE-TORQUE TO 75 FTLBS. (2)
CHECK SHARPNESS AND
RE-T O RQU E M ODE L S
CH854 0 AN D CH9 54 0H
TO 120 FT-LBS. TORQUE
MOD EL CHF9540H TO 25
FT-LBS. (2)
LUBE
ENGINE
OPERATOR’S
MANUAL
BEFORE
EACH
USE
EVERY
8
HOURS
EVERY
25
HOURS
EVERY
50
HOURS
EVERY
200
HOURS
EVERY
YEAR
ENGLISH
PTO CHIPPERS
13
SERVICE & MAINTENANCE
NICK GREATER
THAN 1/8”
CRACK
GREATER
THAN 1/8”
BROKEN
CORNER
NEW
BLADE
CHIPPER
DISC
CHIPPING
SLOT
CHIPPER
DISC
BLADE IS
TOO SHORT,
MUST BE
REPLACED
CHIPPING
SLOT
BEFORE INSPECTING OR SERVICING ANY PART OF THIS MACHINE, SHUT OFF POWER SOURCE,
AND MAKE SURE ALL MOVING PARTS HAVE COME TO A COMPLETE STOP.
WARNING
5.1 INSTALLING THE DISK LOCK
When working on the chipper disk, use the disk lock to
hold the disk in place. Follow these steps:
Tilt the rotor access cover open to expose the chipper 1.
disk.
Remove the pin from its storage position and put it into 2.
the hole in the shaft cap.
Rotate the chipper disk until the pin slides all the way 3.
in through the shaft cap.
After maintenance is done, remove the pin and place 4.
it back in its storage position.
Before you sharpen the chipping blades, check for
permanent damage. Replace the blade if:
• There are cracks, broken corners or nicks greater than
1/8" (see below).
• The base of the cutting edge is worn or has been re-
sharpened so that it no longer extends past the chipping
slot (see below).
5.2 CHIPPER BLADE MAINTENANCE
The chipper blades will eventually become dull, making
chipping difcult and adding extra strain on the machine.
CHECK THE SHARPNESS OF THE BLADES EVERY
5 - 15 HOURS OF OPERATION AND SHARPEN AS
NEEDED.
The controller light will ash an amber code every 15
hours as a reminder to check the chipper blades. To reset
the controller, see Sec. 7.3.
Your blades need to be sharpened if:
• Machine vibrates severely when material is fed into the
chipper.
• Small diameter branches do not self-feed.
• Chips discharge unevenly or have stringy tails,
especially when chipping green branches.
5.3 REMOVING THE BLADES
WARNING
Chipping blades are sharp! Use caution when working
on machine to avoid injury.
Remove the two 3/8" bolts on the rotor access cover.1.
Tilt access cover open to allow access to rotor. Rotate 2.
the rotor so that the bolts holding the blades are best
accessible.
Secure the rotor in place by installing the disk lock. 3.
Remove the two bolts that hold the blade to the disk. 4.
The hardware can be reused. Repeat for remaining
blade.
The blades have two edges and can be reversed one 5.
time before sharpening.
PTO CHIPPERS14
SERVICE & MAINTENANCE
45˚
SHARPENED
SURFACE
MOUNTING SURFACE
(DO NOT GRIND)
.38
SHARPENED
SURFACE
MOUNTING SURFACE
(DO NOT GRIND)
WARNING
BEFORE INSPECTING OR SERVICING ANY PART OF THIS MACHINE, SHUT OFF POWER SOURCE,
AND MAKE SURE ALL MOVING PARTS HAVE COME TO A COMPLETE STOP.
5.4 SHARPENING THE BLADES
The blades can be ground on a bench grinder or by a
professional.
1. Never sharpen or grind the mounting surfaces of the
blades. This will cause the edge to roll and the blade will
be damaged, resulting in poor chipping performance.
2. Regrind the angled edge of the chipping blades to 45
degrees (see below). Make sure some type of fixture is
used to correctly hold the blade at the proper angle.
3. Be careful when grinding so that the blade does not
become overheated and change color. This will remove
the heat-treated properties.
5.5 ADJUSTING THE CHIPPER ANVIL
The chipping blades should clear the anvil by 1/16 inch to
1/8 inch. Check the clearance every 8 hours of operation
and adjust if needed. The chipping anvil is reversible. All
four sides of the anvil can be used for chipping.
To adjust the anvil:
Remove the two 3/8" bolts on the rotor access cover.1.
Lift rotor access cover and expose rotor. 2.
Measure the amount of clearance between chipping 3.
blade and chipping anvil from inside the housing.
Loosen the three 1/2 inch bolts that hold the chipper 4.
anvil to the frame. The bolts are accessed underneath
the feed roller (see picture below).
ENGLISH
4. Use short grinding times and cool with water or some
type of liquid coolant.
5. Remove an equal amount off each blade to maintain
rotor balance.
6. Small imperfections such as nicks and burrs on
the flat side of the blade will not affect the chipping
performance of the machine.
7. For blades that have been repeatedly sharpened,
ensure that the sharpened surface extends past the
chipping slot opening. If it does not extend past the
opening, the blades should be replaced.
Arrow points to chipper anvil
Adjust anvil inward or outward to the correct clearance. 5.
Check how all blades clear the anvil.
Tighten bolts on chipping anvil to 75 ft. lbs. and bolt 6.
rotor access cover closed.
If the chipping anvil edge is damaged or worn unevenly,
remove the three bolts holding the anvil and use one of the
other three edges. Adjust for correct measurement.
PTO CHIPPERS
15
SERVICE & MAINTENANCE
BEFORE INSPECTING OR SERVICING ANY PART OF THIS MACHINE, SHUT OFF POWER SOURCE,
AND MAKE SURE ALL MOVING PARTS HAVE COME TO A COMPLETE STOP.
WARNING
5.6 LUBRICATION
Lubricate the machine periodically with a lithium-based
grease. Extreme working conditions will require more
frequent greasing.
Grease the following points every 50-100 hours of
operating time:
Two bearings on the rotor shaft. •
Two bearing on the bottom jack shaft.•
One zerk on the feed roller assembly.•
One zerk on discharge chute.•
Discharge chute
IMPORTANT
Polyurea and lithium-based greases are not compatible.
Mixing the two grease types may lead to premature
failure.
NOTE
Do not over grease bearings. Overlling can lead to
excessive heat and/or unseating of the seals. Add
grease slowly and under light pressure. Whenever
possible, rotate bearing slowly while lubricating.
Feed roller assembly
Rotor shaft (other side of machine)
Rotor shaft
Jack shaft (other side
of machine)
Jack shaft
PTO CHIPPERS16
BEFORE INSPECTING OR SERVICING ANY PART OF THIS MACHINE, SHUT OFF POWER SOURCE,
8
h
8
h
8
h
8
h
8
h
AND MAKE SURE ALL MOVING PARTS HAVE COME TO A COMPLETE STOP.
5.7 PTO DRIVELINE LUBRICATION
Every 8 hours, lubricate PTO cross journals. Make sure 1.
grease purges through all four bearings.
Every 8 hours, lubricate PTO inner tubes. Telescoping 2.
members must have lubrication to operate successfully.
Telescoping members without fittings should be pulled
apart and grease should be added manually with a
brush.
Every 8 hours, lubricate the PTO shield retaining 3.
bearing. Molded nipples on the guard near each guard
bearing are intended as grease fittings and should be
lubricated every 8 hours of operation.
5.8 CLEARING A PLUGGED ROTOR
SERVICE & MAINTENANCE
WARNING
ENGLISH
If the machine becomes plugged, shut off the engine,
disconnect the spark plug wire and allow the machine to
come to a complete stop before clearing debris. Do not
operate the machine without proper guards and shields
in place.
Feeding too large or too much material at once may plug
the chipper. To clear a plugged disk, proceed as follows:
Disengage PTO and shut off tractor engine.1.
Allow all moving parts to come to a complete stop.2.
Remove the two 3/8” retaining bolts holding the access 3.
cover to the chipper frame and lift up access cover.
Remove the lock pin from storage position (see 4.
illustration on right).
Turn check valve clockwise to engage the jack pump.5.
Pump the handle to raise the feed roller until the lock pin 6.
position aligns with one of the support bracket holes.
Secure the position by putting the lock pin through the 7.
support bracket and lock pin position.
Clean the debris away from the chipper disk. Turn the 8.
disk by hand to be sure it is free to rotate. Be careful
to avoid the chipper blades when cleaning out the
debris.
Remove the lock pin and put it back in storage 9.
position. LEAVING THE LOCK PIN IN ANY OTHER
POSITION MAY INTERFERE WITH FEED ROLLER
OPERATION.
Turn the check valve counterclockwise to disengage 10.
the pump and lower the jack.
Close access cover and replace bolts.11.
WARNING
LOCK PIN IN
STORAGE
POSITION
SUPPORT
BRACKET
LOCK PIN
POSITION
FEED
ROLLER
JACK
CHECK
VALVE
PTO CHIPPERS
17
SERVICE & MAINTENANCE
BEFORE INSPECTING OR SERVICING ANY PART OF THIS MACHINE, SHUT OFF POWER SOURCE,
AND MAKE SURE ALL MOVING PARTS HAVE COME TO A COMPLETE STOP.
5.9 ADJUSTING/REPLACING DRIVE BELT
WARNING
Check the condition of the drive belt annually or after every
25 hours of operation, whichever comes first. If the belt is
cracked, worn, frayed, or stretched, replace it.
To replace the belt:
Disengage PTO and shut off tractor engine.1.
Remove PTO shaft from tractor; disconnect machine 2.
from 3 pt. hitch.
5.10 REPLACING BEARINGS
Rotate discharge to the right side of the machine. 1.
Remove the two 3/8 inch retaining bolts holding the
access cover to the main frame assembly. Tilt the
access cover open to allow access to the rotor.
Remove upper and lower belt guards (10-5/16 bolts).2.
FRONT BEARING REMOVAL
Remove the Hitch Support. 3.
Loosen the bolts holding the hydraulic pump bracket to 4.
the 3-point, slide the bracket up and remove hydraulic
pump belt.
Remove the idler tensioning springs, and remove the 5.
1/2 bolt holding the idler pulley in place.
Remove the drive belt.6.
Taking the bolts out of the pulley and reinserting them 7.
into the empty holes, slowly tighten each bolt in a
rotating clockwise direction to remove the bushing and
sheave from the rotor shaft.
Loosen the set screw holding the spacer in place and 8.
remove. If rear bearing does not need to be removed
go to step 14.
REAR BEARING REMOVAL
Lift up the feed roller and insert the retaining pin to 9.
hold in place.
Remove the protective cap. 10.
Remove the 3/8 bolt holding the retaining spacer and 11.
remove the spacer.
Remove round shield connected to belt guard that 3.
covers PTO shaft by removing two 5/16" nuts.
Remove belt guard covering pulleys and belts.4.
Remove spring loaded idler pulley off belts and remove 5.
belt.
Remove Hitch Support.6.
Install new belt and reverse above instructions to 7.
complete belt replacement.
180 inch-lbs (20 Nm). Reinstall front collar and tighten
the cap screw. Make sure the speed sensor is aligned
and gapped properly.
Reinstall the rear rotor protective cap. Slide the bushing 16.
on and tighten set screw, then slide the sheave on.
Insert bolts into the sheave and tighten in a clockwise
direction. Torque to 108 inch-lbs (12 Nm).
Check the alignment of pulleys with a straight edge 17.
and adjust if needed.
Replace the drive belt. 18.
Replace the idler and tighten. Reinstall tensioning 19.
springs.
Bolt the hitch support back in its original position.20.
Close cover and replace bolts. 21.
Replace the hydraulic pump belt. Readjust hydraulic 22.
pump belt tension by sliding the hydraulic pump in the
mounting slots. Tighten bolts.
Replace belt guard and resume operation.23.
Start tractor engine and engage PTO drive clutch (see 24.
tractor owner’s manual). Increase engine speed to rated
PTO RPM position. Test unit; readjust pulleys and belt
tension if needed.
Remove the four 1/2 inch bolts on each rotor bearing 12.
and loosen the two set screws on each bearing. (Note:
You may have to clean the shaft with emery cloth.)
Remove and replace with new bearings. 13.
Put the bolts back in the bearings and slide into place. 14.
Tighten bolts to 75 ft-lbs (102 Nm). Slide rear collar
back into place and insert 3/8 bolt.
Taking a rubber mallet, tap the rotor shaft until the rear 15.
collar is tight against the rear bearing. Tighten the bolt
and lock the set screws on both bearings. Torque to
PTO CHIPPERS18
SERVICE & MAINTENANCE
WARNING
BEFORE INSPECTING OR SERVICING ANY PART OF THIS MACHINE, SHUT OFF POWER SOURCE,
AND MAKE SURE ALL MOVING PARTS HAVE COME TO A COMPLETE STOP.
5.11 CHANGING HYDRAULIC OIL FILTER
Change the hydraulic oil filter after the first 50 hours of
operation and every 200 hours thereafter.
To change the hydraulic oil filter:
U s i n g a n oi l f i l t e r wr e n c h , t u r n t h e f i l t e r 1.
counterclockwise.
Once the filter becomes loose, turn it out the rest of the 2.
way with your hand.
Properly discard old filter.3.
Lube the rubber seal on the new filter (PN 16922) with 4.
clean hydraulic oil.
Install the filter onto the threaded pipe. Turn with your 5.
hand until the filter is finger tight.
Using an oil filter wrench, tighten the filter another ½ 6.
turn.
Check hydraulic oil level and fill if necessary.7.
5.12 FILLING HYDRAULIC FLUID
Hydraulic uid drives the feed roller. Check the uid
level daily and ll as needed. The uid and lter should
be changed and system cleaned if the uid becomes
contaminated with foreign matter (water, dirt, grease, etc.)
or if the uid has been subjected to temperatures greater
than the maximum recommended.
The hydraulic pump requires premium hydraulic uids
containing high quality rust, oxidation, and foam inhibitors.
These include premium turbine oils, API CD engine oils
per SAE J183, M2C33F or G automatic transmission
uids meeting Allison C-3 or Caterpillar TO-2, and certain
specialty agricultural tractor uids.
In the unlikely event that the oil is completely drained
from the hydraulic system, oil must be added and any air
bubbles must be purged from the system. To do this:
Clean all system components (reservoir, fittings, 1.
etc.).
Fill the hydraulic reservoir.2.
Fill the inlet line leading from the reservoir to the pump 3.
before start-up. Loosen the fitting at the pump on this
inlet line until oil bleeds out.
Start the engine and run at the lowest possible RPM.4.
As you purge air from the unit, the oil level in the 5.
reservoir will drop and bubbles may appear in the fluid.
Refill the reservoir as necessary.
Run the feed roller in both directions for several minutes 6.
until any remaining air purges from the unit. Refill the
reservoir as necessary.
Shut down the engine, check for and correct any 7.
fluid leaks, and check the reservoir level. Add fluid
if necessary. The hydraulic pump is now ready for
operation.
ENGLISH
PTO CHIPPERS
19
6
TROUBLESHOOTING
Section
Before performing any of the corrections in this troubleshooting chart, refer to the appropriate information contained in
this manual for the correct safety precautions and operating or maintenance procedures. Contact your dealer or the
factory for service problems with the machine.
PROBLEM POSSIBLE CAUSES REMEDY
Obstructed discharge. Use branch or similar object to clear discharge.
Rotor stalls or stops.
Chipper does not chip.
Hard to feed chipper;
requires excessive
power to chip.
Shredder requires
excessive power or
stalls.
Belt squeals when
engaging clutch.
Material from chipper
wraps around rotor
shaft
Excessive vibration
while running.
Rotor will not turn.
Cannot engage clutch.
Excessive belt wear.
Trailer sways during
towing.
Plugged rotor. Clear rotor. Feed material more evenly.
Feeding material that is too
large.
Dull chipper blades. Rotate or sharpen blades.
Drive belts loose or worn. Inspect drive belts, adjust or replace if needed.
Attempting to feed branches
that are too large.
Broken or missing chipper
blades
Dull chipper blades. Reverse or sharpen blades.
Obstructed discharge. Use branch or similar object to clear discharge.
Improper blade clearance. Adjust clearance between chipper anvil and chipper blades.
Obstructed discharge. Use branch or similar object to clear discharge.
Plugged rotor. Clear rotor, feed material into shredder more evenly.
Wet or green material will not
discharge.
Engaging clutch too fast. Engage clutch more slowly.
Plugged rotor. Clear rotor. Feed material more evenly.
Belt tension too loose. Replace belt or spring.
Stringy, green material
bypasses chipper blades.
Dull chipper blades. Sharpen blades.
Improper blade clearance. Adjust clearance between anvil and chipper blades.
Drive system vibration.
Rotor out of balance.
Chipper blade to anvil
clearance is incorrect.
Drive belt too loose or broken. Replace belt or spring.
Obstructed discharge. Use branch or similar object to clear discharge.
Plugged rotor. Clear rotor. Feed material more evenly.
Improper belt installation; belt
not under belt guide.
Improper belt tension. Adjust belt tension. Replace belt or spring if needed.
Not using correct belt.
Pulley(s) damaged or worn. Replace pulley(s).
Pulley(s) not in alignment. Align pulley(s) with straight edge.
Belt(s) tension too loose. Replace belt or spring.
Tire air pressure not correct Check tire sidewall for inflation limits.
Reduce size of material.
Limit branch size to x inches in diameter.
Replace blade.
Alternately feed dry material or install larger discharge screen.
Rotate branch or material when feeding to cut completely.
Check drive belts and pulleys for bad or worn areas. Check for dull
chipper blades or shredder knives.
Inspect rotor for broken or missing chipper blades and shredder
knives; replace if needed. Check rotor to see if it wobbles. Check to
see if rotor is assembled correctly.
Set chipper blade/anvil clearance to recommended distance (1/16” to
1/8”).
Install belt properly; install belt under belt guide.
Contact your nearest authorized dealer to order the correct belt for
your chipper/shredder.
PTO CHIPPERS20
7
Section
SPECIFICATIONS
7.1 CHIPPER SPECIFICATIONS
CH8540 SELF FEED
DESCRIPTION English Metric
OVERALL SIZE 45" x 47" x 90" 114 x 119 x 229 cm
OVERALL WEIGHT 885 LBS. 402 kg
MAX CHIPPER CAPACITY 8" 20 cm
CHIPPER BLADES 4 4
CHIPPING ANVIL 9.25" X 3.5"' X .63"23.5 X 8.9 X 1.6 CM
DISC SPEED 1500 RPM 1500 RPM
DISC SIZE 30" Dia. x 1.25" 76 cm x 3.2 cm
DISC WEIGHT 247 lbs. 112 kg
DISCHARGE TUBE SIZE 32" x 36" 81 cm x 91 cm
DISCHARGE TUBE HEIGHT 95" 2.41 m
DRIVE TYPE Belt Belt
BELT SIZE 3RBP90 3RBP90
HYDRAULIC FEED RATE 0-150 ft/min 0-46 m/min
HYDRAULIC OIL TANK
CAPACITY
SPLINE SIZE
3 POINT HITCH Category 1 Category 1
PTO 540 +/- 10 RPM 540 +/- 10 RPM
3 gal. 11.3 L
1.375" diameter
(6 SPLINE)
3.49 cm diameter
(6 SPLINE)
CHF9540H HYDRAULIC FEED (FINE CHIP)
DESCRIPTION English Metric
OVERALL SIZE 45" x 47" x 90" 114 x 119 x 229 cm
OVERALL WEIGHT 885 LBS. 402 kg
MAX CHIPPER CAPACITY 9" 23 cm
CHIPPER BLADES 16 16
CHIPPING ANVIL 9.25" X 3.5"' X .63" 23.5 X 8.9 X 1.6 CM
DISC SPEED 1500 RPM 1500 RPM
DISC SIZE 30" Dia. x 1.25" 76 cm x 3.2 cm
DISC WEIGHT 275 lbs. 125 kg
DISCHARGE TUBE SIZE 32" x 36" 81 cm x 91 cm
DISCHARGE TUBE HEIGHT 95" 2.41 m
DRIVE TYPE Belt Belt
BELT SIZE 3RBP90 3RBP90
HYDRAULIC FEED RATE 0-150 ft/min 0-46 m/min
HYDRAULIC OIL TANK
CAPACITY
SPLINE SIZE
3 POINT HITCH Category 1 Category 1
PTO 540 +/- 10 RPM 540 +/- 10 RPM
3 gal. 11.3 L
1.375" diameter
(6 SPLINE)
3.49 cm diameter
(6 SPLINE)
ENGLISH
CH9540H HYDRAULIC FEED
DESCRIPTION English Metric
OVERALL SIZE 45" x 47" x 90" 114 x 119 x 229 cm
OVERALL WEIGHT 885 LBS. 402 kg
MAX CHIPPER CAPACITY 9" 23 cm
CHIPPER BLADES 4 4
CHIPPING ANVIL 9.25" X 3.5"' X .63" 23.5 X 8.9 X 1.6 CM
DISC SPEED 1500 RPM 1500 RPM
DISC SIZE 30" Dia. x 1.25" 76 cm x 3.2 cm
DISC WEIGHT 247 lbs. 112 kg
DISCHARGE TUBE SIZE 32" x 36" 81 cm x 91 cm
DISCHARGE TUBE HEIGHT 95" 2.41 m
DRIVE TYPE Belt Belt
BELT SIZE 3RBP90 3RBP90
HYDRAULIC FEED RATE 0-150 ft/min 0-46 m/min
HYDRAULIC OIL TANK
CAPACITY
SPLINE SIZE
3 POINT HITCH Category 1 Category 1
PTO 540 +/- 10 RPM 540 +/- 10 RPM
3 gal. 11.3 L
1.375" diameter
(6 SPLINE)
3.49 cm diameter
(6 SPLINE)
PTO CHIPPERS
21
SPECIFICATIONS
SAE - 8
SAE - 2
A
SAE - 5
SAE
Grade
and
Head
Markings
BOLT DIAMETER
10.9
4.8
A
8.8
METRIC
Grade
and
Head
Markings
BOLT DIAMETER
12.9
4.8
8.8 10.9
12.9
7.2 BOLT TORQUE
The tables below are for reference purposes only and their use by anyone is entirely voluntary, unless otherwise noted.
Reliance on their content for any purpose is at the sole risk of that person and any loss or damage resulting from the
use of this information is the responsibility of that person.
ENGLISH
BOLT DIAMETER (A)
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.
BOLT TORQUE *
* To rq ue v alue for bolts and
capscrews are identified by their
head markings.
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.
Wh en u si ng loc ki ng e le me nt s,
increase torque values by 5%.
METRIC
BOLT DIAMETER
(A)
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 *
PTO CHIPPERS22
SPECIFICATIONS
7.3 FLASH CODES FOR THE CONTROL LIGHT
CONTROLLER FLASH CODES GUIDE
SIGNAL FREQUENCY CAUSE ACTION TO TAKE
Green Solid Forward feed available. Begin feeding materials into the chute.
Green One flash per second
Red One flash per second
Red Solid
Amber
Long and short flashes at
initial startup
RPM not high enough to chip
upon initial startup.
RPM dropped suddenly while
chipping due to an obstruction.
Feed bar is not in STOP (upon
initial startup or when RPM has
dropped).
(CE compliant models only).
Light is solid red upon startup.
(CE compliant models only).
Safety bar was activated.
(NON-CE compliant models
only). Jumper harness plug
was damaged.
When the controller is started
up, it will flash an amber
code to show total hours of
operation. Each long flash
equals 10 hours of operation,
each short flash equals 1 hour
of operation.
Increase RPM until the green light stops
flashing.
No action necessary, the feed roller will
automatically reverse to clear the obstruction.
Put feed bar in STOP position.
Push reset/override button to reset.
Check connections to jumper harness plug.
Replace if plug necessary (PN 36391-00)
No action necessary. The hours of operation
code can be interrupted by engaging the feed
roller.
ENGLISH
Amber
Amber
Amber
Amber
Two flashes followed by
a 1.5 second pause and
then two flashes followed
by a long pause
Three flashes followed by
a 1.5 second pause and
then three flashes followed
by a long pause
Two flashes followed by
a 1.5 second pause and
then five flashes followed
by a long pause
Two flashes followed by
a 1.5 second pause and
then six flashes followed
by a long pause
Chipper blades should be
checked and sharpened if
necessary.
Engine oil should be changed.
Forward feed has a short or
open circuit.
Reverse feed has a short or
open circuit.
Check sharpness of chipper blades. Check
sharpness of chipper blades. Reset the
controller by setting the feed bar in the STOP
position.
turn the key to the ON position. With the key
remaining in the ON position, shift the feed
bar from one of the REVERSE positions to the
other REVERSE position and back, three times
within eight seconds.
Change oil. Reset the controller by setting
the feed bar in the STOP position. Without
starting the machine, turn the key to the ON
position and WAIT 10 SECONDS. With the
key remaining in the ON position, shift the feed
bar from one of the REVERSE positions to the
other REVERSE position and back, three times
within eight seconds.
Check connections to the forward coil on the
feed hydraulic valve. Replace coil if necessary.
Check connections to the reverse coil on the
feed hydraulic valve. Replace coil if necessary.
Without starting the machine,
PTO CHIPPERS
23
Declaration of Conformity
The undersigned manufacturer:
Crary Industries, Inc.
237 NW 12
P.O. Box 849
West Fargo, ND 58078-0849
Declares that hereunder specified:
CHIPPER
Brand: ECHO Bear Cat
Type: PTO driven Chipper
Model Number: CH9540H & CH9540HXE
Complies with the requirements of:
Machinery Directive 2006/42/EC
EN 13525:2005-Forestry Machinery-Wood Chippers -Safety
EN ISO 12,100-Safety of Machinery-Basic Concepts, General Principles for Design
EN 982 – Safety of Machinery–Requirements for Fluid Power Systems & their Components-Hydraulics
Noise Emissions Directive 2000/14/EC
-Conformity Assessment Procedure: Annex V
(Use of harmonized standard EN ISO 3744:2010)
Sound Power Level: 95 dB L
Guaranteed Sound Power Level: 112 dB LWA
CH9540H Serial number 708370 and up
CH9540HXE Serial number 709895 and up
West Fargo, ND 58078-0849
June 29, 2011
CRARY INDUSTRIES, INC. The authorized representative in Europe who is authorized to
compile the technical file:
Company: Atlantic Bridge Limited
Address: Atlantic House, PO Box 4800
Earley, Reading RG5 4GB, United Kingdom
______________________________
Arlan Mathias Mr. Phillip Wicks
Senior Project Engineer
PA
th
Street
Data contained in this document pertains only to machines sold in areas that require CE compliance
standards. To identify if your machine is CE compliant, it will have the following CE mark decal:
Declaration of Conformity
The undersigned manufacturer:
Crary Industries, Inc.
237 NW 12
P.O. Box 849
West Fargo, ND 58078-0849
Declares that hereunder specified:
CHIPPER
Brand: ECHO Bear Cat
Type: PTO driven Chipper
Model Number: CH8540 & CH8540XE
Complies with the requirements of:
Machinery Directive 2006/42/EC
EN 13525:2005-Forestry Machinery-Wood Chippers -Safety
EN ISO 12,100-Safety of Machinery-Basic Concepts, General Principles for Design
Noise Emissions Directive 2000/14/EC
-Conformity Assessment Procedure: Annex V
(Use of harmonized standard EN ISO 3744:2010)
Sound Power Level: 95 dB L
Guaranteed Sound Power Level: 112 dB LWA
CH8540 Serial number 706072 and up
CH8540XE Serial number B01580 and up
West Fargo, ND 58078-0849
June 29, 2011
CRARY INDUSTRIES, INC. The authorized representative in Europe who is authorized to
compile the technical file:
Company: Atlantic Bridge Limited
Address: Atlantic House, PO Box 4800
Earley, Reading RG5 4GB, United Kingdom
______________________________
Arlan Mathias Mr. Phillip Wicks
Senior Project Engineer
PA
th
Street
Data contained in this document pertains only to machines sold in areas that require CE compliance
standards. To identify if your machine is CE compliant, it will have the following CE mark decal:
Declaration of Conformity
The undersigned manufacturer:
Crary Industries, Inc.
237 NW 12
P.O. Box 849
West Fargo, ND 58078-0849
Declares that hereunder specified:
CHIPPER
Brand: ECHO Bear Cat
Type: PTO driven Chipper
Model Number: CHF9540H & CHF9540HXE
Complies with the requirements of:
Machinery Directive 2006/42/EC
EN 13525:2005-Forestry Machinery-Wood Chippers -Safety
EN ISO 12,100-Safety of Machinery-Basic Concepts, General Principles for Design
EN 982 – Safety of Machinery–Requirements for Fluid Power Systems & their Components-Hydraulics
Noise Emissions Directive 2000/14/EC
-Conformity Assessment Procedure: Annex V
(Use of harmonized standard EN ISO 3744:2010)
Sound Power Level: 95 dB L
Guaranteed Sound Power Level: 112 dB LWA
CHF9540H Serial number 710723 and up
CHF9540HXE Serial number B04092 and up
West Fargo, ND 58078-0849
June 29, 2011
CRARY INDUSTRIES, INC. The authorized representative in Europe who is authorized to
compile the technical file:
Company: Atlantic Bridge Limited
Address: Atlantic House, PO Box 4800
Earley, Reading RG5 4GB, United Kingdom
______________________________
Arlan Mathias Mr. Phillip Wicks
Senior Project Engineer
PA
th
Street
Data contained in this document pertains only to machines sold in areas that require CE compliance
standards. To identify if your machine is CE compliant, it will have the following CE mark decal:
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