bc1200xl brush chipper - abc equipment · pdf filedrums, end idler, flashings, pins and...

BC1200XL Brush Chipper

BC1200XL_o2_00Serial No. 1001 -Order No. 105400BZ3Cabled Order No. 163698121

Operator’s Manual


e instructions thoroughly before operating or m damage. Consult your Vermeer dealer if you d

T information available at time of publication. Y anual.

V obligation.

O ith the machine. The tethered (cabled) m al storage box when not in use.

L vided with the machine. Refer to it for all l

A our dealer. Reorder numbers are listed on the f

C om your dealer.

S iones y Seguridad.

meer machine. Notify the Customer Data r.com; internet: www.vermeer.com or 0, Pella IA 50219 USA. Upon request, an

o nd Parts manuals.

Introduction

IntroductionThis manual explains the proper operation of your machine. Study and understand thes

aintaining the machine. Failure to do so could result in personal injury or equipment o not understand the instructions in this manual, or need additional information.

he instructions, illustrations, and specifications in this manual are based on the latestour machine may have product improvements and features not yet contained in this m

ermeer Corporation reserves the right to make changes at any time without notice or

peration instructions are included in the two Operator’s Manuals provided wanual must remain attached to the machine for ready reference. Store it in the manu

ubrication and maintenance procedures are in the Maintenance Manual proubrication and maintenance procedures.

dditional copies of the manuals, and Operations and Safety video, are available from yront covers of the manuals and on the video.

opies of this manual, and the Operations and Safety video, are available in Spanish fr

u distribuidor dispone de ejemplares en español de este manual y del vídeo de Operac

NOTICE TO OWNER

You are requested to notify Vermeer Corporation when you have purchased a used VerDepartment by telephone: 800-829-0051 or 641-628-3141; email: [email protected]; or, letter: Customer Data Dept., Vermeer Corporation, PO Box 20wner of a used Vermeer machine will receive one free set of Operator’s, Maintenance a

Introduction

ion of forward travel.

turing Company.

BC1200XL European


NOTE: Right and left sides of the machine are determined by facing in the direct

TRADEMARKS

VERMEER, VERMEER Logo and ECOIDLE are trademarks of Vermeer ManufacCUMMINS is a trademark of Cummins, Inc.FLEETGUARD is a trademark of Fleetguard, Inc.

BC1200XL


VERMEER NEW INDUSTRIAL EQUIPMENT LIMITED WARRANTY

RANTY PERIOD: 12 Months / 1000 Hoursermeer's manufacture to be free from defects

i nitial purchase/retail sale or 1000 operating h ines of Vermeer's manufacture, parts are

F VERMEER'S MANUFACTURE ARE W 'S WARRANTY AND SUBJECT TO T MANUFACTURER.

E

nship in any warranted item of Vermeer I tion without charge by any authorized

ermeer independent authorized dealer at the d abor in accordance with Vermeer's labor r nt parts as it deems appropriate.

R maintenance and periodic inspections of the th each new Industrial Equipment. The cost

aser. The retail purchaser is required to keep d

T ion if the above requirements are not

ly removed from service.

Introduction

(EFFECTIVE OCTOBER 1, 2008) WARVermeer Corporation (hereinafter “Vermeer”) warrants each new Industrial product of Vn material and workmanship, under normal use and service for one (1) full year after iours, whichever occurs first. This Limited Warranty shall apply only to complete mach

covered by a separate Limited Warranty. EQUIPMENT AND ACCESSORIES NOT OARRANTED ONLY TO THE EXTENT OF THE ORIGINAL MANUFACTURERHEIR ALLOWANCE TO VERMEER ONLY IF FOUND DEFECTIVE BY SUCH

XTENDED WARRANTY OPTIONS ARE AVAILABLE FOR PURCHASE.

WARRANTY TERMS

During the Limited Warranty period specified above, any defect in material or workmandustrial Equipment not excluded below shall be repaired or replaced at Vermeer's op

independent Vermeer dealer. The warranty repair or replacement must be made by a Vealer's location. Vermeer will pay for replacement parts and such authorized dealer's leimbursement policy. Vermeer reserves the right to supply remanufactured replaceme

ETAIL PURCHASER RESPONSIBILITY: This Limited Warranty requires properIndustrial Equipment as indicated in the Operator’s/Maintenance Manual furnished wiof routine or required maintenance and services is the responsibility of the retail purch

ocumented evidence that these services were performed.

his Vermeer New Industrial Equipment Limited Warranty may be subject to cancellatperformed.

Vermeer Industrial Equipment with known failed or defective parts must be immediate

Introduction

normal use and service of the Industrial ce (iii) overloading (iv) lack of reasonable and orage (vii) non-Vermeer approved alteration or ies installed on Industrial Equipment which were ments (xii) collision or other accident.been altered or removed or whose hourmeter has

eriodic inspection or services have been performed er Specifications including, but without limitation, nd fuel filters. warranty registration has not been completed and

f the Industrial Equipment not abiding by standard

sibility of the respective product’s manufacturer.t costs, if any, of transporting replacement parts to

ir on the retail purchaser’s site or other location. duct, ny incidental or consequential damages (including ason at any time.ted Warranty Policy. Oils and fluids are not covered


EXCLUSIONS AND LIMITATIONS

The warranties contained herein shall NOT APPLY TO:(1) Any defect which was caused (in Vermeer’s sole judgment) by other than

Equipment, or by any of the following; (i) accident (ii) misuse or negligenproper maintenance (v) improper repair or installation (vi) unsuitable stmodification (viii) natural calamities (ix) vandalism (x) parts or accessornot manufactured or installed by Vermeer authorized dealers (xi) the ele

(2) Any Industrial Equipment whose identification numbers or marks have been altered or tampered with.

(3) Any Industrial Equipment which any of the required or recommended pusing parts not manufactured or supplied by Vermeer or meeting Vermeengine tune-up parts, engine oil filters, air filters, hydraulic oil filters, a

(4) New Industrial Equipment delivered to the retail purchaser in which thereturned to Vermeer within ten (10) days from the date of purchase.

(5) Any defect which was caused (in Vermeer’s sole judgment) by operation ooperating procedures outlined in the Operator’s Manual.

(6) Engine, battery, and tire Limited Warranties and support are the respon(7) Transportation costs, if any, of transporting to the Vermeer dealer. Freigh

the Vermeer dealer. (8) The travel time of the Vermeer dealer’s service personnel to make a repa(9) In no event shall Vermeer’s liability exceed the purchase price of the pro(10) Vermeer shall not be liable to any person under any circumstances for a

but not limited to, loss of profits, out of service time) occurring for any re(11) Diagnostic and overtime labor premiums are not covered under this Limi

under this Limited Warranty.


(12) Depreciation damage caused by normal wear, lack of reasonable and proper maintenance, failure to follow operating

only to the extent of such manufacturer’s

E , Chain, Clutches, Clutch Components, C ed Conveyor Belts, Infeed Conveyor Chains,

ar/Bedknife, Sprockets, Teeth, Wear Blocks,

hes, Cups, Digging Chain, Digging Rims, er Bands, Scraper Knives, Sprockets, Teeth, ear Plates.

Belts, Jaws, Leaf Chain, Lights On Light Guides, Track Idlers, Track Pads, Track rs.

s, Chains, Clutches, Conveyor Belts, End Tires, Track Chain, Track Idlers, Track

ustrial Equipment Limited Warranty, during t original machine warranty, are warranted to b ced, without labor coverage for removal and r

Introduction

instructions, misuse, lack of proper protection during storage.(13) Accessory systems and electronics not of Vermeer’s manufacture are warranted

respective Limited Warranty if any.(14) Downhole toolage is not covered under this warranty.(15) Wear items which are listed by product group as follows:

NVIRONMENTAL: Bearing Seals, Bearings, Belts, Brake Pads, Bolts/Torqued Partsurtains, Cutter Wheels, Discharge Conveyor Belts, Fuel Filters, Hammers, Hoses, Infe

Knives, Oil Filters, Pockets, Rods, Rollers, Rotor Plates, Screens, Service Items, Shear BWear Strips.

TRACK: Base Plates, Boom Wear Items, Buckets, Cable Fingers, Conveyor Belts, ClutcDrums, End Idler, Flashings, Pins and Bushings, Pivot Rings, Plastic Wear Strips, RootTrack Chain, Track Rollers, Trench Cleaner (Crumber), Trip Cleaners, Truck Rollers, W

TRENCHLESS: Brushes, Clamping Vise Parts, Dies, Drive Chuck, Earth Stakes, Fan Kits, Packing Assemblies, Rod, Rod Loader Parts, Rollers, Tooling, Track Chain, Track Sprockets, Valve Seats, Wear Bars, Wear Blocks, Water Hoses, Water Swivels, Wear Ba

UTILITY PRODUCTS: Augers, Belts, Bearings, Booms, Brake Pads, Bucket, BushingRollers, Flashings, Pins, Pivot Rings, Plow Blades, Rubber Shielding, Sprockets, Teeth,Sprockets, Trench Cleaner (Crumber).

PARTS WARRANTY:

Parts replaced in the warranty period will receive the balance of the first year New Indhe first (12) months or 1000 hours, whichever comes first. Replacement parts after the e free from defects of material for ninety (90) days or the part will be repaired or replaeinstallation.

Introduction

RESSLY AND SPECIFICALLY MADE SIBLE LIABILITY OF VERMEER MPLIED, OR STATUTORY, INCLUDING, BUT NESS FOR A PARTICULAR PURPOSE. ANY PRODUCT WITHOUT INCURRING ANY SUCH MODIFICATION. NO PERSON IS ADDITIONAL OBLIGATION ON VERMEER’S

d the dealer has no authority to make any ions of this warranty in any way.


EXCLUSIONS OF WARRANTIES: EXCEPT FOR THE WARRANTIES EXPHEREIN, VERMEER MAKES NO OTHER WARRANTIES, AND ANY POSHEREINUNDER IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS, INOT LIMITED TO, ANY WARRANTIES OF MERCHANTABILITY OR FITVERMEER RESERVES THE RIGHT TO MODIFY, ALTER AND IMPROVEOBLIGATION TO REPLACE ANY PRODUCT PREVIOUSLY SOLD WITHAUTHORIZED TO GIVE ANY OTHER WARRANTY, OR TO ASSUME ANYBEHALF.

NO DEALER WARRANTY. The selling dealer makes no warranty of its own anrepresentation or promise on behalf of Vermeer or to modify the terms or limitat

MANUFACTURED BY:VERMEER CORPORATION

Pella, Iowa 50219 USA


WARRANTY RIDER HOUSING

term)

rts coverage of the applicable ranty”) for the Covered Components m, provided that the Equipment is in the Operator’s and Maintenance

anty apply.

ove

ring fedder hubs (bearings cement).

s (as specified on Vermeer nty).

le date of the Equipment or er occurs first. This warranty is bsequent owners.

06, will be covered as stated

ERMEER MAKES NO REUNDER IS IN LIEU OF

DING, BUT NOT LIMITED TICULAR PURPOSE.

Introduction

VERMEER EQUIPMENT EXTENDED LIMITED BRUSH CHIPPER DRUM AND DRUM

3,000 Hours / 3 Years*(Parts only coverage during extended

VERMEER CORPORATION (hereinafter “Vermeer”) agrees to extend only the paVermeer Industrial New Equipment Limited Warranty (the “Standard Limited Warof the Specified Models of New Vermeer Industrial Equipment for the Extended Teroperated and maintained in accordance with the directions and instructions set forthManual(s). All conditions, exclusions, and limitations of the Standard Limited Warr

SPECIFIED MODEL: BC1200XL, Serial Number 101 and ab

COVERED COMPONENTS: Drum housings, cutter drums, shafts, andmay be covered if required for drum repla

NON-COVERED COMPONENTS: Bearings, knives, shear bar, and wear itemNew Industrial Equipment Limited Warra

EXTENDED TERM*: Three (3) full years from original retail sa3,000 hours of machine operation, whichevextended to the original purchaser and su

NOTE: Subject to future change Brush Chipper models introduced after August 1, 20in this warranty rider.

EXCEPT FOR THE STANDARD LIMITED WARRANTY AND THIS RIDER, VOTHER WARRANTIES, AND ANY POSSIBLE LIABILITY OF VERMEER HEALL OTHER WARRANTIES, EXPRESS, IMPLIED, OR STATUTORY, INCLUTO, ANY WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PAR

Receiving and Delivery Report i

er operation.


Receiving and Delivery ReportDEALER PREP

Check or perform the following:

Engine___ Check oil level of the engine.

___ Check battery electrolyte level and charge.

___ Check condition of air cleaner.

___ Check coolant level and antifreeze concentration.

___ Check engine for proper operation.

Hydraulics___ Check hydraulic fluid level.

___ Check control levers for proper operation.

___ Check all hydraulic components for leaks or damage.

___ Check Lower Feed Stop Bar and Side Feed Stop Bar (European) for prop

___ Check Upper Feed Control Bar for proper operation.

General___ Check machine for shortage or damage in transit.

___ Check installation and condition of all shields.

___ Check machine for proper lubrication.

___ Check condition of all safety signs and operating decals.

___ Check all phases of operation.


___ Check for loose hardware.

ii Receiving and Delivery Report

___ Check wheel lug nuts torque: 90–120 ft-lb (122–163 Nm).

___ Check air pressure of tires: 80 psi (5.5 bar).

___ Check operation of the brakes.

___ Check operation of breakaway system.

___ Check operation of highway lights.

___ Check that towing hitch is properly attached to machine.

___ Check drive belts for proper tension.

___ Check Cutter Drum Clutch/Throttle Lever for proper function.

___ Check torque on cutter knife bolts: 210 ft-lb (285 Nm).

___ Check operation of SmartFeed system.

Receiving and Delivery Report iii

per operation:


DELIVERY

Check and perform the following with the customer:

Brush Chipper___ Review all sections of the Operator’s Manual.

___ Grease or oil all lubrication points.

Review of OperationReview and demonstrate with the customer the various aspects of brush chip

___ overall explanation of how the brush chipper works

___ brush chipper safety

___ preparing the brush chipper for operation

iv Receiving and Delivery Report
DEALER/CUSTOMER INFORMATION

dealer: owner:

address: address:

city: city:

state / province: state / province:

zip / postal code: zip / postal code:

country: country:

Receiving and Delivery Report v

with


MACHINE IDENTIFICATION NUMBERS - RECORD

Machine Model Number_______________________

Machine Serial Number_______________________

MACHINE IDENTIFICATION DECALThis decal provides easy identification of the model and 17-digit identificationnumber. The barcode contains the machine’s VIN number and can be scannedany barcode reading device.


Tier 4 Interim/Stage IIIB

Tier 3/Stage IIIA

vi Receiving and Delivery Report

ENGINE IDENTIFICATION NUMBERS - RECORD

Engine Model Number________________________

Engine Serial Number________________________

Table of Contents vii

tstrols - Left Side Controls Option Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-18

ols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21

rocedure . . . . . . . . . . . . . . . . . . . . . . . 22-1 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-1er Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-1ic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-2ing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-2Explosion - Avoid . . . . . . . . . . . . . . . . . . . . . . . . 22-2Burns - Avoid . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-3tarting Procedure . . . . . . . . . . . . . . . . . . . . . . . . 22-3

Procedure . . . . . . . . . . . . . . . . . . . . . 23-1e Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-1top Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 23-2

ng the Brush Chipper . . . . . . . . . . . . 30-1afety Defects . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1he Towing Vehicle . . . . . . . . . . . . . . . . . . . . . . . . 30-1t - Adjust (BC1200XL Only) . . . . . . . . . . . . . . . . 30-2

ngth - Adjust (BC1200XL Only) . . . . . . . . . . . . . . 30-3owing Vehicle (BC1200XL Only) . . . . . . . . . . . . . 30-4intle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-6

owing Vehicle (BC1200XL European Only) . . . . . 30-7


Table of ContenReceiving and Delivery Report . . . . . . . . . . . . . . . . . . . . .i

Dealer Prep . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iEngine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iHydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iGeneral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i

Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iiiBrush Chipper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iiiReview of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

Dealer/Customer Information. . . . . . . . . . . . . . . . . . . . . . . . . . . ivMachine Identification Numbers - Record . . . . . . . . . . . . . . . . . vMachine Identification Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . vEngine Identification Numbers - Record . . . . . . . . . . . . . . . . . . vi

Safety Messages. . . . . . . . . . . . . . . . . . . . . . . . . 10-1Safety Symbol Explanation . . . . . . . . . . . . . . . . . . . . . . . . . .10-1

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1Engine Monitors (Tier 3/Stage IIIA) . . . . . . . . . . . . . . . . . . . .20-1Engine Monitors (Tier 4 Interim/Stage IIIB) . . . . . . . . . . . . . .20-2Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-4Throttle/Cutter Engage . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-5Feed Roller Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-6

Droop Set Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-13Park Brake (BC1200XL European Only) . . . . . . . . . . . . . . .20-14Wheel Chocks (BC1200XL European Only) . . . . . . . . . . . .20-14Discharge Chute Controls . . . . . . . . . . . . . . . . . . . . . . . . . .20-15Winch Controls (BC1200XL Only) . . . . . . . . . . . . . . . . . . . .20-16

Winch Con(BC1200XLJack ContrFuses. . . .

Starting PStarting theCold Weath

Engine Hydraul

Jump-StartBattery Battery Jump-S

ShutdownStopping th

Quick S

TransportiReporting SEquipping tHitch HeighTongue LeAttach to T

Hitch - PAttach to T


Breakaway on Hydraulic Surge Brake (Option) - Reset . . . . 30-8 Infeed System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-12ional Winch (BC1200XL Only). . . . . . . . .50-13y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-13peed . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-13

Preparation for Winching . . . . . . . . . . . 50-14n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-16

hoker - Repair/Replace . . . . . . . . . . . . . .50-23

s from the Brush Chipper . . . . . 51-1lug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51-3lug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51-5 Clean Out . . . . . . . . . . . . . . . . . . . . . . . . .51-6

tervals . . . . . . . . . . . . . . . . . . . . . 60-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-1ual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-2k for Maintenance Interval . . . . . . . . . . . . .60-2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-2

ance . . . . . . . . . . . . . . . . . . 61-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61-4

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61-5rface Inspection . . . . . . . . . . . . . . . . . . . 61-6

viii Table of Contents

Breakaway System - Reset Electric Brake . . . . . . . . . . . . . . 30-9Machine - Clean Before Transporting. . . . . . . . . . . . . . . . . . 30-9Prepare for Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10Winch Line - Store (BC1200XL Only) . . . . . . . . . . . . . . . . . 30-11Detach from Towing Vehicle. . . . . . . . . . . . . . . . . . . . . . . . 30-12

Preparing the Brush Chipper and Work Area . . 40-1Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1Operator Qualifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1Personal Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-2Sound Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-3Prepare the Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-3Prepare the Brush Chipper . . . . . . . . . . . . . . . . . . . . . . . . . . 40-4

Clean Flammable Materials from Machine . . . . . . . . . . . 40-5Discharge Chute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-6 Feed Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-9Feed Control Bars - Check . . . . . . . . . . . . . . . . . . . . . . . 40-9

Operating the Brush Chipper . . . . . . . . . . . . . . . 50-1Cutter Shaft - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-1Cutter Drum - Engage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-1Feed Roller Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-2

Upper Feed Control Bar . . . . . . . . . . . . . . . . . . . . . . . . . 50-3Lower Feed Stop Bar and Side Feed Stop Bars . . . . . . . 50-3Sensitivity Levels (BC1200XL Only) . . . . . . . . . . . . . . . . 50-4Feed Roller - Engage . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-5EcoIdle RPM Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7Lower Feed Roller - Access Door . . . . . . . . . . . . . . . . . . 50-8

SmartFeed Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10

Cutting SystemChip Material . . .

Feeding Tips . Material Size . Plugs or StallsFinishing . . . .

Operating the OptWinch CapacitLine Pull and SBrush ChipperWinch Operatio

Winch Line and C

Removing PlugFeed Roller - UnpCutter Drum - UnpDischarge Chute -

Maintenance InSafety Signs . . . . Maintenance ManHourmeter - ChecMaintenance Inter

Knife/Drum MaiKnife Removal . .

Knife InspectioBolt InspectionKnife Mount Su

vals

nten. . . . n . .

Table of Contents ix
Drum Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61-7Knife Sharpening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61-8

Knife Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61-9

Engine Fault Codes (110/120-HP Engine). . . . . 62-1

.
This page intentionally left blank

Safety Messages 10-1

ty messages are located in instructions or procedures are not

fety alert symbol.

located near specific hazards.

result in death or serious injury.

result in death or serious injury.

result in minor or moderate injury.

ion with an exclamation mark or ath.

and watch the operations and safety


Section 10: Safety MessagesGeneral safety messages appear in this Safety Messages section. Specific safeappropriate sections of the manual where a potential hazard may occur if the followed.

A signal word “DANGER”, “WARNING”, or “CAUTION” is used with the sa

Safety signs with signal word “DANGER”, “WARNING”, or “CAUTION” are

SAFETY SYMBOL EXPLANATION

DANGER Indicates a hazardous situation that, if not avoided, will

WARNING Indicates a hazardous situation that, if not avoided, could

CAUTION Indicates a hazardous situation that, if not avoided, could

This is the safety alert symbol. This symbol is used in combinatother symbols to alert you to the potential for bodily injury or de

WARNING: Read Operator’s Manual and safety signs,video, before operating machine.


be in good operating condition

-fitting clothing and confine hoes. Refer to “Personal

tdoors.

10-2 Safety Messages

WARNING: Check machine before operating. Machine must and all safety equipment installed and functioning properly.

WARNING: Wear personal protective equipment. Wear closelong hair. Always wear a hard hat, safety glasses, and safety sProtection,” page 40-2.

WARNING: Keep spectators away.

WARNING: Engine exhaust can asphyxiate. Operate only ou

Safety Messages 10-3

, cleaning, repairing or transporting

e and result in serious injury or death. eak. Relieve pressure in the hydraulic or performing work on the system. If you e an object such as a piece of wood or tting where some residual pressure may ait for leaking to stop before

must be removed immediately by a

.


WARNING: Use Shutdown Procedure before servicingmachine. Follow Shutdown Procedure, page 23-1.

WARNING: Pressurized fluid can penetrate body tissuLeaks can be invisible. Keep away from any suspected lsystem before searching for leaks, disconnecting hoses, must pressurize the system to find a suspected leak, uscardboard rather than your hands. When loosening a fiexist, slowly loosen the fitting until oil begins to leak. Wdisconnecting the fitting. Fluid injected under the skin surgeon familiar with this type of injury.

WARNING: Fuel and fumes can explode and burn.

Shut off engine before refueling. No flame. No smoking


that follow within this manual, could poses for which it was intended as

10-4 Safety Messages

WARNING: Hot fluid under pressure can scald.

Allow engine to cool before opening radiator cap.

WARNING: Moving parts can crush fingers.

Close all shields before starting.

WARNING: Failure to follow any of the preceding safety instructions or thoseresult in serious injury or death. This machine is to be used only for those purexplained in this Operator’s Manual.

Controls 20-1

rameters

, red

1

3

2

110-HP (OPTION)

AB


Section 20: Controls

ENGINE MONITORS (TIER 3/STAGE IIIA)(1) Fuel Gauge

Gauge indicates how much fuel is in the tank.(2) Engine Display

Display can be set to show multiple items at once or one item.

Engine display shows the following machine parameters, with others pa available for display as customized by the operator:

Displayed Available• Tachometer • Fuel Pressure• Engine Hours • Fuel Temperature• Battery Voltage • Engine Boost• Engine Oil Pressure • Engine Intake Temperature• Engine Coolant Temperature • Engine Coolant Level

(A) Engine Warning Light Amber indicator light signals the presence of an engine warning diagnostic code displayed on monitor.(B) Engine Shutdown Light When Ignition Switch is ON and engine shutdown fault is detected indicator light will show.

(3) Wait-to-Start LightWhite light turns off when ignition is “ON” and engine is ready to start.


ers

1 AB

2

120-HP ENGINE (OPTION)

20-2 Controls

ENGINE MONITORS (TIER 4 INTERIM/STAGE IIIB)(1) Fuel Gauge

Gauge indicates how much fuel is in the tank.(2) Engine Display

Display can be set to show multiple items at once or one item.

Engine display shows the following machine parameters, with others paramet available for display as customized by the operator:

Displayed Available• Tachometer • Fuel Pressure• Engine Hours • Fuel Temperature• Battery Voltage • Engine Boost• Engine Oil Pressure • Engine Intake Temperature• Engine Coolant Temperature • Engine Coolant Level

(A) Engine Warning Light Amber indicator light signals the presence of an engine warning diagnostic code displayed on monitor.(B) Engine Shutdown Light When Ignition Switch is ON and engine shutdown fault is detected red indicator light will show. (C) Wait-To-Start Display When “Wait To Start” in display turns off, engine is ready to start.

Controls 20-3

3


(3) EcoIdle Switch

Push up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EcoIdle onEngine speed drops from high RPM to 1400 rpm when there has been no material chipped for 5 minutes.

Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EcoIdle off

Push down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EcoIdle onEngine speed drops from high RPM to 1400 rpm when there has been no material chipped for 1 minute.

Refer to EcoIdle RPM Control, page 50-7.



1


1

20-4 Controls

IGNITION SWITCH(1) Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Vertical position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . engine off

1st position clockwise. . . . . . . . . . . . . . . . . . . . . . preheat/engine on

2nd position clockwise . . . . . . . . . . . . . . . . . . . . . . . . . . engine start

Controls 20-5

1

A

B

C

1

A

B

C

LEFT SIDE CONTROLS (OPTION)


THROTTLE/CUTTER ENGAGE

(1) Throttle Lever/Clutch Engage

(A) Down position . . . . . . . . . . . . . . . . . . . . . . . . . . disengaged, low RPM

(B) Up, toward operator (chipping position) . . . . . . engaged, high RPM

(C) Up, away from operator/toward machine . . . . . . engaged, low RPM


1

BC1200XLEUROPEAN

1

BC1200XL

20-6 Controls

FEED ROLLER CONTROLS

(1) Upper Feed Control Bar

Rear position . . . . . . . . . . . . . . . . . . . . feed roller emergency STOP

Second position from rear . . . . . . . . . . . . . . . feed roller FORWARD

Top/third position from rear . . . . . . . . . . . . . . . . . feed roller STOP

Forward position . . . . . . . . . . . . . . . . . . . . . . feed roller REVERSE

NOTE: Upper Feed Control Bar is spring-returned from REVERSE to STOP position and must be held to operate feed roller in REVERSE.

Controls 20-7
NOTE: Feed roller will not move unless:

• Cutter drum is engaged.

• Engine speed is at high RPM.

• Lower Feed Stop Bar and Side Feed Stop Bars (European) are reset (rear amber warning light not blinking).

• Upper Feed Control Bar is in FORWARD or REVERSE feeding position.

• Hold-to-Run Button is pressed.

NOTE: SmartFeed control is always ON, and is activated automatically.

Feed roller will move in REVERSE at any engine speed and when light blinks.


2

2

3

BC1200XLEUROPEAN

3

1

1

20-8 Controls

(2) Lower Feed Stop BarBar pressed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . feed roller stops

To reset: Briefly press Hold-to-Run Button (see (4) on next page).

(3) Side Feed Stop Bars (BC1200XL European Only)Bar pressed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . feed roller stops

To reset: Briefly press Hold-to-Run Button (see (4) on next page).

Controls 20-9

t speed.

4

5


Feed roller will automatically restart when engine speed increases to a prese

(4) Hold-to-Run Button (Located on both sides of feed table)Press briefly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . feed roller operates and Lower Feed Stop Bar and Side Feed Stop Bars are ignored for one second.

Press and hold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . feed roller operates for 30 sec. maximum regardless of position of Upper Feed Control Bar (1), Lower Feed Stop Bar (2), and Side Feed Stop Bars (3). After 30 seconds, feed roller stops.

(5) Lower Feed Stop Bar Sensitivity Switch (BC1200XL)

Press top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Normal sensitivityFeed roller stops when stop bar is pushed a shorter distance.

Press bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reduced sensitivityFeed roller stops when stop bar is pushed a farther distance

NOTE: Each time engine key is turned OFF, the Lower Feed Stop Bar systemdefaults to the “Normal Sensitivity” selection.


(6)

6

6

BC1200XLEUROPEAN

BC1200XL

20-10 Controls

Rear Warning Light - CenterBC1200XL Only:Normal sensitivity setting selected . . . . . . . . . . . . . warning light offReduced sensitivity setting selected. . . . . . . . . . . . . warning light on

BC1200XL and BC1200XL European:Light flashes quickly when feed roller needs to be restarted after pressing Lower Feed Stop Bar or Side Feed Stop Bars, or pulling Upper Feed Control Bar.

NOTE: When the Rear Warning Light flashes quickly, the Hold-to-Run Button (4) must be pushed to reset stop system and stop warning light from flashing.

4

Controls 20-11

7

8


(7) Feed Roller Raise/Float/Crush Boost Lever (located on both sides of feed table)Pull lever rearward . . . . . . . . . . . . . . . . . . . . . . . . . . raise feed roller

Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . feed roller floats

If not locked in raised position, feed roller will lower and remain in float position.Push lever forward. . . . . . . . . . . . . . engage feed roller Crush Boost

(8) Feed Roller Down Pressure KnobClockwise . . . . . . . . . . . . . . . . . . increase feed roller down pressure

Counterclockwise . . . . . . . . . . . . decrease feed roller down pressure


9

A

20-12 Controls

(9) Feed Roller Lock BarFully raise and hold feed roller up with control lever. Install red lock bar over cylinder rod as shown on controls side of machine and secure with pin (A) as shown.

Raise feed roller, remove bar, and store as shown (photo below) before resuming operation.


Controls 20-13

g p speed. speed.

itch (1).

1


Droop Set SwitchWith SmartFeed control operation, the feed roller will stop and reverse feedinmaterial when the engine RPM drops below a preset speed, referred to as drooFeed roller will automatically restart when engine speed increases to a preset

Droop speed can be adjusted to high, medium or low speed using Droop Set Sw

Press bottom . . . . . . . . . . . . . . . . . . . . . . . . .low speed droop (brush)

Center . . . . . . . . . . . . . . . . . . . . . medium speed droop (small limbs)

Press top . . . . . . . . . . . . .high speed droop (large limbs and trunks)


E

1

2

20-14 Controls

PARK BRAKE (BC1200XL EUROPEAN ONLY)

WHEEL CHOCKS (BC1200XL UROPEAN ONLY)Remove wheel chocks (1) from storage locations and place behind both rear wheels as shown (2) when machine is parked and handbrake is engaged.

The axle brakes have an automatic reverse function, even when handbrake is applied.

Be sure to use one chock behind each rear wheel; do not place them behind and ahead of the same wheel.

(1) Park Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Push back while facing forward . . . . . . . . . . . . . engage park brake

Pull forward to release lever. . . . . . . . . . . . . . disengage park brake

1

One on each side

Controls 20-15

r

2

1

43

5


DISCHARGE CHUTE CONTROLS(1) Chute Rotation Handles

Push handles clockwise chute rotates leftPush handles counterclockwise . . . . . . . . . . . . . . . . . . . chute rotates right

(2) Transport Lock PinCenter lever and release lock pin so pin engages hole . . . . . . . . . . . . locked Pull down and rotate lever to disengage lock pin from hole unlocked

(3) Chute DeflectorControls the distance chipped material is discharged.

Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .fartheDown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .closer

(4) Chute Deflector Lock - StandardLoosen to change deflector position.

(5) Chute Deflector Lock - Deluxe (Option)Pull down and rotate to change deflector position.


1

2

A

3

20-16 Controls

WINCH CONTROLS (BC1200XL ONLY)(1) Winch/Upper Feed Control Bar

Bar in center STOP or FORWARD . . . . . required to operate winch

Feed rollers will not operate while winch is engaged unless the Hold-to-Run button (A) has been pushed.

(2) Winch Interlock HookSlide hook up:(attach rope loop and pull with winch). . . . . . . . . . winch locked out

Feed rollers will operate if Control Bar (1) is in forward position and Hold-to-Run button (A) has been pushed.

Release and slide hook down: (rope unhooked and winch lever pulled out) . . . . . . winch unlocked

Winch Retract/Extend Lever (4) will move winch line if Winch Engage/Disengage Lever (3) is pushed in. Feed rollers are “OFF” when interlock hook is released.

Controls 20-17

GED ot lock into

Lower

tton must

4

3

5


(3) Winch Engage/Disengage LeverRotate lever up . . . . . . . . . . . . . . . . . . . . . . . . . . . winch ENGAGED

Rotate lever down . . . . . . . . . . . . . . . . . . . . . . winch DISENGAGEDAllows winch line to be manually pulled off winch drum.

IMPORTANT: Winch Engage/Disengage Lever must fully lock into ENGAposition in order to perform forward and reverse operation. If lever does nthe ENGAGED position, jog Retract/Extend Lever (4) until it does.

(4) Winch Retract/Extend Lever - With winch engaged:Right. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . retract winch line

Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . extend winch lineIMPORTANT: Maintain light tension on winch line when retracting, to create smooth wrapping onto winch drum.

(5) Rear Warning Light - SideAmber lights are located on both sides of winch mounting frame.Normal sensitivity setting selected . . . . . . . . . . . . warning light offReduced sensitivity setting selected. . . . . . . . . . . . warning light on

Light flashes quickly when feed rollers need to be restarted after pressingFeed Stop Bar, or pulling Upper Feed Control Bar.

NOTE: When the Rear Warning Light flashes quickly, the Hold-to-Run Bube pushed to reset stop system and stop warning light from flashing.


L 1

2

A3

20-18 Controls

WINCH CONTROLS - LEFT SIDE CONTROLS OPTION (BC1200XONLY)

(1) Winch/Upper Feed Control BarBar in center STOP or FORWARD . . . . . required to operate winch

Feed rollers will not operate while winch is engaged unless the Hold-to-Run button (A) has been pushed.

(2) Winch Interlock HookSlide hook up:(attach rope loop and pull with winch) . . . . . . . . . .winch locked out

Feed rollers will operate if Control Bar (1) is in forward position and Hold-to-Run button (A) has been pushed.

Release and slide hook down: (rope unhooked and winch lever pulled out) . . . . . . .winch unlocked

Winch Retract/Extend Lever (4) will move winch line if Winch Engage/Disengage Lever (3) is pushed in. Feed rollers are “OFF” when interlock hook is released.

Controls 20-19

GED ot lock into

g Lower

utton must

4

3

5


(3) Winch Engage/Disengage LeverRotate lever up . . . . . . . . . . . . . . . . . . . . . . . . . . . . winch ENGAGED

Rotate lever down . . . . . . . . . . . . . . . . . . . . . .winch DISENGAGEDAllows winch line to be manually pulled off winch drum.

IMPORTANT: Winch Engage/Disengage Lever must fully lock into ENGAposition in order to perform forward and reverse operation. If lever does nthe ENGAGED position, jog Retract/Extend Lever (4) until it does.

(4) Winch Retract/Extend Lever - With winch engaged:Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . retract winch line

Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . extend winch lineIMPORTANT: Maintain light tension on winch line when retracting, to create smooth wrapping onto winch drum.

(5) Rear Warning Light - SideAmber lights are located on both sides of winch mounting frame.Normal sensitivity setting selected. . . . . . . . . . . . . warning light offReduced sensitivity setting selected . . . . . . . . . . . . warning light on

Light flashes quickly when feed rollers need to be restarted after pressinFeed Stop Bar, or pulling Upper Feed Control Bar.

NOTE: When the Rear Warning Light flashes quickly, the Hold-to-Run Bbe pushed to reset stop system and stop warning light from flashing.


2

4

20-20 Controls

JACK CONTROLS(1) Jack Handle

Clockwise. . . . . . . . . . . . . . . . . extend jackCounterclockwise . . . . . . . . . . retract jack

(2) Transport Storage Position

(3) Lock PinSecure jack to tongue in either transport position or when machine is not attached to tow vehicle.

(4) Rear Jack Transport Storage Position (BC1200XL EURO Only)

3

1

Controls 20-21

1


FUSESFuses protect machine electrical circuits. Fuse box (1) is located in the enginecompartment, behind control panel. Fuse circuits are listed below and on the decal on back side of control panel.

Relay FusesForward Feed Solenoid F1 - emptyReverse Feed Solenoid F2 - 10A - Infeed

F3 - 10A - Feed RollersF4 - 5A - for future useF5 - emptyF6 - emptyF7 - 30A - Engine ControllerF8 - 2A - Engine DiagnosticsF9 - 10A - SmartFeed ControllerF10 - empty

This page intentionally left blank.

Starting Procedure 22-1

turns engine

y panel e

. Allow

r.

ly and

ation Manual for recommended

1

1

110-HP Engine

120-HP Engine


Section 22: Starting Procedure

STARTING THE ENGINEStep 1: Place Cutter Engage/Throttle Lever in DISENGAGED/LOW RPM.

Step 2: Place Upper Feed Control Bar in top STOP position.

Step 3: Turn keyswitch to preheat/ON position.

Step 4: 110-HP Engine (Option): After white Preheat Indicator Light (1) off, turn key fully clockwise to start the engine. Release key once thestarts.120-HP Engine (Option): After the wait to start turns off in displa(1), turn key fully clockwise to start the engine. Release key once thengine starts.

IMPORTANT: Never run the starter motor for more than 30 seconds at a timestarter motor to cool 1 minute between attempts.

Step 5: Allow engine to warm up for 3–5 minutes before engaging the cutte

IMPORTANT: Do not idle engine for more than 10 minutes. The resulting low temperatures in the combustion chamber will not allow fuel to burn completecan cause engine damage.

COLD WEATHER STARTING

EngineBefore operating in cold weather (below 32°F (0°C)), refer to the Engine Operengine oil, fuel, and starting procedures.


Hydraulic Fluidarm, let it run for a

ehicles in contact have a mper cable is connected or k of battery explosion.

ouch.

eep all burning materials away burn. Tools and cable clamps

22-2 Starting Procedure

In cold weather, take more time to warm up the hydraulic fluid. After the engine is wminimum of five more minutes at low RPM before operating any controls.

NOTE: Slow down engine if the hydraulic pump squeals due to insufficient oil.

JUMP-STARTING

Battery Explosion - Avoid

Do not jump-start or charge a battery that is frozen or low on electrolyte.

Avoid explosion hazard.

Do not allow vehicle used to jump-start to be in contact with the disabled machine. Vground connection which allows a spark to occur at the battery when the positive juremoved. If equipped with battery caps, they must be in place and tight to reduce ris

IMPORTANT: Use only a 12-volt system for jump-starting. Do not allow vehicles to t

WARNING: Battery fumes are flammable and can explode. Kfrom battery. Battery explosion can blind. Acid can blind and can make sparks.

Do not smoke. Shield eyes and face. Read instructions.

Starting Procedure 22-3

th eyes, skin, and clothing.

ater for 15 minutes and get

ia, beaten egg, or vegetable oil.

ries contain lead and lead cause cancer and reproductive


Battery Burns - AvoidBattery contains sulfuric acid which can cause severe burns. Avoid contact wi

In case of acid contact:

External: Flush with plenty of water. If eyes have been exposed, flush with wprompt medical attention.

Internal: Drink large quantities of water or milk, follow with milk of magnesCall a physician immediately.

Jump-Starting Procedure

WARNING: Battery post, terminals, and related accessocompounds, chemicals known to the state of California toharm.

Wash hands after handling.

Pb


IMPORTANT: Review battery service safety

, and moving parts.

the booster battery before

ve cable clamp on the

NGINETER

ERS

CONNECTTO FRAMEFOR GROUND

22-4 Starting Procedure

guidelines before jump-starting machine (refer to battery maintenance instructions in the “Maintenance - 500 Service Hours” section of the Maintenance Manual).

Step 1: Turn ignition switch to OFF.

Step 2: Connect jumper cables in the following order:

a. Red to discharged battery POSITIVE (+) terminal.

f. Red to booster battery POSITIVE (+) terminal.

g. Black to booster battery NEGATIVE (-) terminal.

h. Black to frame of machine with the discharged battery. Make connection away from battery, hydraulic lines

NOTE: To avoid sparks near the battery, always disconnect black jumper cable frommaking any adjustment to the red jumper cable.

Step 3: Start engine.

Step 4: Remove cables in REVERSE order and install the red cover over the positibattery.

MACHINEBATTERY

BOOSTERBATTERY

TO FRAMETO ESTAR

JUMPCABLE

Shutdown Procedure 23-1

dure before working on the or transporting the chipper.

, or if an emergency requires it.

osition.

on left

engine

1


Section 23: Shutdown Procedure

STOPPING THE MACHINEIMPORTANT: For your safety and the safety of others, use the shutdown procemachine for any reason, including servicing, cleaning, unclogging, inspecting,

A variation of this procedure may be used if so instructed within this manual

Step 1: Return Upper Feed Control Bar to top STOP position.

Step 2: Move Cutter Engage/Throttle Lever to ENGAGED/LOW RPM position.

IMPORTANT: Whenever practical and consistent with good safety practice, run engine without load for a few minutes before shutting it off. This allows engine temperatures to decrease and equalize, which will increase engine life.

Step 3: Wait for cutter drum to slow.

Step 4: Move Cutter Engage/Throttle Lever to DISENGAGED/LOW RPM p

Step 5: Turn ignition key to OFF position.

Step 6: Wait for cutter drum and belt to stop.

NOTE: Cutter drum rotation can be checked by looking at the end of shaft (1)side of cutter wheel housing.

IMPORTANT: The cutter drum will continue to turn for a short time after the has stopped.

Step 7: Remove ignition key.

Step 8: Close and latch feed table.


Quick Stop Procedure

.

To Stop Drum Quickly

Shut Off Engine With Clutch Engaged

23-2 Shutdown Procedure

Step 1: Turn ignition to OFF position while cutter drum clutch is still engaged.

Step 2: Wait for cutter drum and belt to stop.

Step 3: Move Cutter Engage/Throttle Lever to DISENGAGED/LOW RPM position

Step 4: Remove ignition key.

Transporting the Brush Chipper 30-1

Chipper

ash or could cause injury or death, tration (NHTSA) in addition to

finds that a safety defect exists in TSA cannot become involved in tact NHTSA, you may either call ), or file a report on-line at: rtation, 400 - 7th St. SW, ehicle safety from the Hotline.

Safety Department, Vermeer ll Free: 800.829.0051

a brake controller that

erated controller. If your towing one that can be applied both

ce damage to the front of the


Section 30: Transporting the Brush

REPORTING SAFETY DEFECTSFor Brush Chippers within the United States:

If you believe that your vehicle BC1200XL has a defect which could cause a cryou should immediately inform the National Highway Traffic Safety Adminisnotifying Vermeer Corporation.

If NHTSA receives similar complaints, it may open an investigation, and if it a group of vehicles, it may order a recall and remedy campaign. However, NHindividual problems between you, your dealer or Vermeer Corporation. To conthe DOT Auto Safety Hotline toll-free at 1-888-DASH-2DOT (1-888-327-4236www.nhtsa.dot.gov/hotline/, or write to: NHTSA, U.S. Department of TranspoWashington, D.C. 20590. You can also obtain other information about motor v

For Brush Chippers outside the United States:

Contact your local governmental road regulation authority or contact ProductCorporation; Email: [email protected]; Telephone: 641.628.3141; To

EQUIPPING THE TOWING VEHICLEIMPORTANT: (BC1200XL Only) The towing vehicle must be equipped with automatically applies the towed machine's electric brakes.

(BC1200XL Only) Do not use a brake controller that is purely a manually opvehicle is equipped with a manually operated controller, remove it and installautomatically and manually.

It is recommended that the towing vehicle be equipped with mud flaps to redutowed machine from road debris.


1

30-2 Transporting the Brush Chipper

HITCH HEIGHT - ADJUST (BC1200XL ONLY)Before attaching the machine to the towing vehicle, check the height of the hitch on the towing vehicle to the hitch on the machine. The height of the hitch needs to be approximately the same to keep the machine level during transport.

To adjust hitch:

Step 1: Remove two hitch bolts (1).

Step 2: Raise or lower hitch to match towing vehicle height.

Step 3: Replace the two hitch bolts and tighten. Torque to 210 ft-lb (285 Nm).


two positions that allow a 16" (42

cut to allow tongue to be extended

e.

ath shielding

with holes in

specification.

oth inner and outer tubes. Damage to e length is 41" (104 cm).

arate from gue length.

1


TONGUE LENGTH - ADJUST (BC1200XL ONLY)The tongue can be lengthened or shortened to fit the towing vehicle. There arecm) total variation in tongue length.

NOTE: The wire harness is tied to the frame and the cable ties may need to be to its longer length.

Use the following steps to adjust the tongue length.

NOTE: Tongue is adjusted most easily with hitch detached from towing vehicl

Step 1: Support machine with the jack.

Step 2: Remove two tongue adjustment bolts (1). Second bolt is located beneon inner side of frame.

Step 3: Slide tongue to the new set of holes in tongue. Align holes in tongueframe.

Step 4: Insert both tongue adjustment bolts and secure with nuts, torque to

WARNING: Overextending tongue will allow only one bolt to engage btongue and separation of tongue possible. Maximum exposed inner tub

WARNING: A single tongue bolt could fail, allowing the chipper to septhe tow vehicle. Always install and secure both bolts after adjusting ton


hook latches are damaged or

3

1

2


ATTACH TO TOWING VEHICLE (BC1200XL ONLY)

If chain hook latch is damaged, refer to “Maintenance As Required” section in the Maintenance Manual.

Step 1: Securely attach machine hitch to towing vehicle. Refer to instructions for specific hitch type.

Step 2: Cross safety chains (1) under the tongue and use one of the following methods to attach chains to the towing vehicle:

Secure each chain hook to an appropriate ring or loop (2) on towing vehicle hitch,

OR:

Loop each chain around towing vehicle frame or hitch cross member and clip the chain hook (3) back onto the chain. Ensure the spring-loaded latch snaps closed around the chain and rests snugly against the slip hook.

NOTE: Keep chains as short as possible, but leave enough slack to turn corners.

WARNING: Safety towing chains may uncouple from towing vehicle if chain missing. Do not tow vehicle with damaged or missing hook latches.


hicle

to

ay ins

hway

4

5

6

7

8


To adjust chain length:

a. Remove bolt (4).

b. Slide chain loops through slots (5) to increase or decrease chain lengths.

c. Install bolt (4) to lock chain loops in place.

Step 3: Route breakaway cable (6) through loop (7) and attach to towing vebumper or frame.

Step 4: If equipped with optional hydraulic surge brake chain/hook, connecttowing vehicle.

IMPORTANT: The breakaway cable length should be adjusted so the breakawsystem applies the brakes only after both the hitch and the safety towing chahave disconnected.

Step 5: Attach electrical connector (8) to the towing vehicle. Check that higlights and electric brakes are functioning properly.


IMPORTANT: Inspect each safety chain slip hook latch

9

K

4

1

3

2


system every time the machine is attached to a towing vehicle. If the latch is damaged, missing, or does not snap closed to the hook, the slip hook may not remain coupled. Refer to “Maintenance as Required” section for instructions on replacing damaged or missing safety towing chains and hooks.

Step 6: Fully raise jack (9), rotate 90° and secure to tongue with attachment pin.

Hitch - PintleStep 1: Open pintle (1).

Step 2: Back up towing vehicle until pintle is centered under pintle ring (2) of the hitch.

Step 3: Lower tongue until the pintle ring is seated in the pintle hook (3).

Step 4: Latch pintle and lock with cotter pin (4).

SPRING-LOADEDLATCH

SLIPHOO


2

4

3

5

REAR JACK


ATTACH TO TOWING VEHICLE (BC1200XL EUROPEAN ONLY)

Step 1: Attach to vehicle hitch.

a. Squeeze on bottom side of handle (1) and lift to unlock the hitch.

b. After hitch is placed over the ball on the towing vehicle, push down on the locking handle (1) until hitch locks into place.

Step 2: Attach breakaway cable (2) to towing vehicle bumper or frame.

IMPORTANT: Adjust cable length so the breakaway system is triggered only after the machine has disconnected from the hitch.

Step 3: Connect electrical connector (3) to receptacle on towing vehicle. Check that highway lights function correctly.

Step 4: Push Park Brake Lever (4) back towards the machine to activate brakes, pull forward to release.

Step 5: Fully raise front and rear jacks (5), rotate 90°, and secure to frame with attachment pin as shown.

1

5

FRONT JACK


(

12


BREAKAWAY ON HYDRAULIC SURGE BRAKE OPTION) - RESET

Step 1: Pry apart spring clips (1).

Step 2: Return lever (2) to reset position.


to withstand high pressure water n or damage to any devices hit controls and electrical/electronic

component seals. Do not point air

riking other vehicles during

34

5


BREAKAWAY SYSTEM - RESET ELECTRIC BRAKE

Route breakaway cable assembly (1) through loop (2) and insert plastic plug (3) back into body of switch (4). Ensure switch body (4) pivots freely on mounting bolts (5).

MACHINE - CLEAN BEFORE TRANSPORTING

IMPORTANT: Machine controls and electrical/electronic devices are not rated and temperature power washers. Water intrusion will likely cause malfunctiodirectly by the water spray. Keep pressure washer stream away from machinedevices. Compressed air can also push moisture through some connector and nozzle directly at seal areas.

Ensure feed table is empty. Clean machine to keep debris off road and from sttransport.

1

2


3

2

1

1

2

3

BC1200XL

EuropeanBC1200XL


PREPARE FOR TRANSPORTStep 1: Fold up feed table (1) and secure latch (2).

Step 2: Rotate discharge chute (3) forward.


the feed

ook slides

achine in

1

2


2


WINCH LINE - STORE (BC1200XL ONLY)Step 1: Refer to Starting Procedure, page 22-1.

Step 2: Engage winch.

IMPORTANT: Retracting winch line too tightly may damage line.

Step 3: Hook loop at the end of winch line (1) onto interlock hook (2) abovetable as shown.

Step 4: Using the Winch Retract/Extend Lever, retract winch line until the hback and locks. Leave the line taut.

Step 5: Follow Shutdown Procedure, page 23-1.

Step 6: Place separate chain choker in machine toolbox.

NOTE: Winch line must be in stored position for transporting and to operate mchipping mode.


2

3


DETACH FROM TOWING VEHICLEPark machine on level ground and chock wheels. Use jack to support tongue. Store electrical connector (1), breakaway cable, and safety chains (2) on end of tongue.

On BC1200XL European machines, engage Park Brake Lever and use blocks (3) provided to chock wheels.

NOTE: If operating the BC1200XL European while unhitched from tow vehicle, both front and rear jacks must be used.

1

Preparing the Brush Chipper and Work Area 40-1

hipper and Work Area

ed solely for use in chipping

Operator's Manual, safety signs

ion of the machine. Do not use the

e supervision of a trained and

ns, and must be mentally and

and watch the operations and


Section 40: Preparing the Brush C

INTENDED USEThe Vermeer BC1200XL and BC1200XL European Brush Chippers are designorganic material such as wood, bark, limbs, brush, and undergrowth.

Always use the machine in accordance with the instructions contained in thison the machine, and other material provided by Vermeer Corporation.

Proper maintenance and repair is essential for safety, and for efficient operatmachine if it is not in suitable operating condition.

OPERATOR QUALIFICATIONS

Allow only responsible, properly instructed individuals to operate machine.

Become familiar with the controls, operation and use of the machine under thexperienced operator.

The operator must be familiar with the workplace’s safety rules and regulatiophysically capable of operating the machine safely.

WARNING: Read Operator’s Manual and safety signs,safety video, before operating machine.


ways wear a hard hat, uffs are not permitted), ng.

n devices provide differing ropriate for your specific conditions. To determine r local environmental noise

e equipment.

fitting clothing and ecklaces, or bracelets.

40-2 Preparing the Brush Chipper and Work Area

PERSONAL PROTECTION

Operating the machine will require you to wear protective equipment. You should alsafety shoes, loose-fitting gloves with narrow cuffs (gauntlet-type gloves with wide chearing protectors, and eye protection. If working near traffic, wear reflective clothi

Hearing protection is recommended when operating the machine. Hearing protectiolevels of sound reduction. It is important to select a device that is adequate and appwork environment. Actual sound levels may vary widely, depending on your workingthe level of hearing protection your work environment requires, enlist the help of youspecialist.

Eye protection must consist of wraparound safety glasses or goggles.

Other workers in immediate area must also wear the above listed required protectiv

Wear close-fitting clothing and confine long hair.

Avoid wearing jewelry, such as rings, wristwatches, necklaces, or bracelets.

WARNING: Wear personal protective equipment. Wear close-confine long hair. Avoid jewelry, such as rings, wristwatches, n


est procedures specified in

. . . . . . . . . . . 110 dB(A)

. . . . . . . . . . . 124 dB(A)

tion. Operating conditions may g conditions may be different.

y from the machine and work area


SOUND LEVELSThe following sound levels are determined while chipping wood according to tEN 13525.

Equivalent Continuous A-Weighted Sound Pressure Level at Operator’s Ear (per ISO 11201) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Guaranteed Sound Power Level (per 2000/14/EC, ISO 3744) . . . . . . . . . . . . . .

NOTE: The stated sound levels are representative for a given operating condivary at each jobsite. The actual sound levels for your application and operatin

PREPARE THE AREA

WARNING: Keep all spectators and other workers awawhile in operation.


hine on the jobsite.

and efficient movement of

bove ground when feeding

icle.

n traffic. Use all necessary

e in good operating condition


PREPARE THE BRUSH CHIPPER

• Survey area around the machine for persons or obstacles before positioning mac

• Set up machine in an area free of obstructions that could interfere with the safethe operator. Never set up beneath a tree being pruned or removed.

• Position machine so working surface of feed table is a minimum of 24" (61 cm) amaterial.

• During typical operation, the brush chipper must stay hitched to the towing veh

• The brush chipper may be operated while unattached to the towing vehicle if:

• Machine is parked on a level surface.• Tongue is supported by blocking.• Rear jack is supporting infeed end of machine (BC1200XL European Only).• Wheels are securely chocked.• Optional winch is not used.

• If operating along a road, properly warn and divert motor vehicle and pedestriasigns, cones, and flag persons needed for the work situation.

WARNING: Check machine before operating. Machine must band all safety equipment installed and functioning properly.


to withstand high pressure water n or damage to any devices hit controls and electrical/electronic

component seals. Do not point air

el tank clean of accumulated


Clean Flammable Materials from MachineIMPORTANT: Machine controls and electrical/electronic devices are not rated and temperature power washers. Water intrusion will likely cause malfunctiodirectly by the water spray. Keep pressure washer stream away from machinedevices. Compressed air can also push moisture through some connector and nozzle directly at seal areas.

Prevent fires by keeping engine compartment, battery, hydraulic lines, and futrash, grease, and debris.


Discharge Chute

turning. Direct discharge

1

3

2


Step 1: Pull down and rotate transport lock pin (3).

Step 2: Rotate discharge chute (1) to the direction you want to deposit the chippedmaterial by moving the rotation handles (2) in that direction.

Step 3: Engage lock pin (3).

WARNING: Thrown objects can blind you.

Keep everyone away from discharge area while cutter drum ischute away from people. Wear eye protection.


terial over s to the

e over right

CHIPDISCHARGE

AREA

OPERATORAREAWHEN

FEEDING BRUSH

4


NOTE: The discharge chute is equipped with a stop to prevent discharging mathe feed table area. The discharge chute can be rotated 270° to direct the chipdesired position.

NOTE: If unable to reach the deflector or lock handle, position discharge chutfender, and use step (4) on right front of frame.


Step 4: To adjust discharge distance, raise or lower discharge chute deflector (5).

o

65

7


• Standard deflector

Loosen locking handle (6). Adjust deflector height, tighten locking handle tsecure the adjusted deflector.

• Deluxe deflector (option)

Pull down on spring-loaded handle (7) to adjust deflector height.

aring the Brush Chipper and Work Area 40-9

1

3

2

1

3

4

2

BC1200XL

BC1200XLEuropean


Feed TableUnlatch feed table and lower to operating position. The feed table provides an important measure of safety by increasing the distance between the feed roller (1) (behind curtain) and the operator. Never operate brush chipper with the feed table removed.

Feed Control Bars - CheckThe brush chipper is equipped with an Upper Feed Control Bar (2) located across the top and sides of the feed table, and a Lower Feed Stop Bar (3) along the bottom of the feed table; also Side Feed Stop Bars along both sides (4) of the BC1200XL European. Do not operate brush chipper unless the control bars are installed and operating properly. Refer to Feed Roller Controls, page 20-6.

Prep

Operating the Brush Chipper 50-1

hipper

end (1) ver is in ssary.

1

1

1



Section 50: Operating the Brush C

CUTTER SHAFT - CHECKStart engine. Refer to Starting Procedure, page 22-1. Check cutter drum shaftto see that the cutter drum does not turn while the Cutter Engage/Throttle Lethe DISENGAGED/LOW RPM position. If rotation occurs, adjustment is neceRefer to the Maintenance Manual, 50 Service Hours section for instructions.

CUTTER DRUM - ENGAGEAfter engine has warmed up, grip Cutter Engage/Throttle Lever (1) firmly and move it slowly to the ENGAGED/HIGH RPM position.


gine RPM drops below

b and pull you in faster than you can let go

Never climb onto feed table.

Use wood object to push short material.

Keep away from rotating feed rollers and blades.

ncrease in engine speed. Place working on or near feed roller ed intake area.

50-2 Operating the Brush Chipper

FEED ROLLER OPERATION

With SmartFeed control operation, the feed roller will stop feeding material when enpreset speeds, and will automatically restart when engine speed increases.

DANGER: Limbs can snag clothing. Rollers or blades can graof limb. Cutting injury or death will result.

Feed material only from side of feed table.

Feed base of limb or branch first.

Wear gloves with narrow tight-fitting cuffs.

WARNING: Feed roller may start unexpectedly with a small iUpper Feed Control Bar in Center Stop and stop engine beforefor any reason including cleaning, servicing and unclogging fe


stop feed

European ged by a and must ower Feed

r (2) or the it possible

ars, the s for

p Bar and of s.

2

1

BC1200XL

BC1200XLEuropean

3

2


Upper Feed Control BarThe Upper Feed Control Bar (1) provides a means for the operator to quickly rollers as well as selecting forward or reverse operation.

Lower Feed Stop Bar and Side Feed Stop BarsThe Lower Feed Stop Bar system (2) and Side Feed Stop Bars (3) (BC1200XLonly) provides a means for the operator to quickly stop the feed rollers if snagbranch and pulled toward the machine. This system is intended for your safetybe maintained in good operating condition. Do not operate the machine if the LStop Bar or Side Feed Stop Bars are not functioning properly.

Stopping the feed rollers is accomplished by bumping the Lower Feed Stop BaSide Feed Stop Bars (3). The Feed Stop Bars are strategically located to makefor an operator to strike the bars and shut off the feed either intentionally or automatically in an emergency situation. If the operator does not strike the bfeed will not stop. It is therefore very important to follow all safety instructionfeeding material into the chipper.

IMPORTANT: Proper operation of the Upper Feed Control Bar, Lower Feed StoSide Feed Stop Bars (BC1200XL European) should be checked every 10 hoursoperation or daily. Refer to the Maintenance Manual for adjustment instruction


top

he

y. cy

4

3

5

6


Sensitivity Levels (BC1200XL ONLY)The Lower Feed Stop Bar has two levels of sensitivity. When the NORMAL setting (of the Sensitivity Switch) is selected (3), the stop bar is depressed a shorter distancebefore the feed rollers stop. When the REDUCED setting (bottom of the Sensitivity Switch) is selected (4), the stop bar is depressed farther before feed rollers stop.

The amber warning lights located on the rear of the machine (5), and on the sides ofoptional winch assembly (6), turn on when the REDUCED setting of the SensitivitySwitch is selected.

Each time the engine key is turned OFF, the lower feed stop bar system defaults to tNORMAL setting.

IMPORTANT: The NORMAL sensitivity setting provides the most protection for the operator since a leg is more likely to strike the bar and shut off feed in an emergencUse NORMAL sensitivity setting whenever jobsite conditions permit. If the size andshape of limbs cause branches to strike the bar, resulting in an unacceptable frequenof feed stops, REDUCED sensitivity setting may be temporarily selected when thesedifficult conditions have passed, select the NORMAL setting to continue chipping.


Stop Bar

ss of ed Stop by

3

1


Feed Roller - EngageStart feed roller:

• Pull Upper Feed Control Bar (1) to FORWARD feeding position.

• Press Hold-to-Run Button (2).

• Pressing it briefly causes feed rollers to operate and the Lower Feed and Side Feed Stop Bars to be ignored for one second.

• Holding it causes feed rollers to operate for up to 30 seconds regardleposition of Upper Feed Control Bar, Lower Feed Stop Bar and Side FeBars (European). After 30 seconds, feed rollers stop, and can be resetreleasing the Hold-to-Run Button and pressing it again.


IMPORTANT: When Hold-to-Run Button is released:

al before

ckly, and

2

3

LEFT SIDE CONTROLS (OPTION) SHOWN


• Feed rollers stop if either bar is in the STOP position.

• Feed rollers run if both bars are in the RUN position.

If material continues to strike the bar and stop the feed roller, trim or shorten materifeeding it into the chipper.

NOTE: Each time the engine key is turned ON, the rear warning lights (3) flash quiHold-to-Run Button (2) must be pushed to start feed rollers.

NOTE: Engine throttle must be set at HIGH RPM before feed rollers will start.


1


EcoIdle RPM ControlThe EcoIdle system is a fuel saving technology that drops the engine speed to 1500 rpm when the control system determines there has been no material chipped for 1 or 5 minutes depending on switch setting. The system is turned on by pushing EcoIdle switch (1) up or down. The machine must have EcoIdle selected, must be in high idle, and must have the clutch engaged.

• Push switch up: Engine speed drops from high RPM to 1500 rpm when there has been no material chipped for 5 minutes.

• Push switch down: Engine speed drops from high RPM to 1500 rpm when there has been no material chipped for 1 minute.

The system will exit EcoIdle mode whenever any of the following occur:

• Engine detects a load

• Operator adjusts engine speed

• Hold-to-Run button is selected

• EcoIdle is turned off

• Winch operation is selected

• Clutch is disengaged

• Switch is in center position


Lower Feed Roller - Access Doorallow lug,

cut off fingers and toes.

re approaching the feed roller.

1


Bottom of lower feed roller is enclosed in a housing with a bottom access door (1) to for cleaning and removing build-up around the feed roller. Refer to Feed Roller - Unppage 51-3.

WARNING: Rotating feed roller above cover will

Stay away from rotating feed roller.

Stop feed roller, stop engine and remove key befo+ =


2


Normal operation of the brush chipper is with bottom access door closed. However, under certain conditions such as material covered with dirt, mud orice build-up that cannot be easily removed, it is acceptable to operate the chipper with the access door (2) open. This will allow some of the material contamination to drop out the lower feed roller access door and not be carriedthrough the chipper. Shut machine down before opening or closing the bottomaccess door. Follow Shutdown Procedure, page 23-1. Stay away from rotating feed roller if bottom access door is open.


ain optimum engine they are heavily loaded.

Bars and Upper Feed

ence that reverses the feed rollers for a short aterial begins feeding. The length of time the material does not feed after five tries, the

-

1


SMARTFEED OPERATIONSmartFeed monitors and automatically controls various machine functions to maintperformance. Its primary function is to control the infeed and cutting systems when

The controller also does the following:

• controls the engine hourmeter

• controls engine low oil and high temperature shutdown system

• provides control and reset functions for the Lower Feed Stop Bar, Side Feed StopControl Bar.

Infeed SystemWhen the feed rollers are overloaded or stall, SmartFeed automatically starts a sequtime, then resumes forward feeding. The sequence occurs up to five times, or until mfeed rollers are reversed starts at 1/2 second and increases slightly each time. If thewhole process starts over.

Cutting System When engine speed drops below a selected RPM because of heavy chipping, SmartFeed momentarily reverses, then stops the feed rollers. Feed rollers start againonce engine speed recovers. This sequence may occur several times before the material completely passes through the machine. The RPM setting depends on whichof three positions the Droop Set Switch (1) is set. Refer to Droop Set Switch, page 2013.


; never

curbside.

r and stops (BC1200XL

d may strike ly after it

log to aid feeding it into the

tones, wire, or other objects us projectiles.


CHIP MATERIAL

Feeding Tips• If feeding material by hand, always feed from the side of the infeed chute

directly behind it.

• Feed large end of log or branch into chipper first.

• To stay out of traffic while operating along a road, feed material from the

• If feeding brushy material that frequently catches on Lower Feed Stop Bathe feed rollers, change sensitivity setting to REDUCED SENSITIVITY. only)

• Sometimes during feeding, a limb will suddenly turn or move sideways anyou. To reduce the possibility of being struck, release the limb immediatebegins feeding and then turn away.

Material Size• The brush chipper will chip logs approximately 12" (30 cm) in diameter.

• Sometimes a log, due to its size and shape, will not go in. Trim or shortenchipper.

WARNING: Check material being chipped. Avoid swhich may damage the knives and become dangero

the


Plugs or Stallson. Refer to Removing Plugs

ine.

e material that caused the

chine by feeding in rial with hands,

Procedure, page 23-


• Discharge chute, cutter drum, or feed roller may become plugged during operatifrom the Brush Chipper, page 51-1.

• If the engine stalls while chipping, disengage cutter drum before restarting eng

• Start engine and, before engaging cutter drum, reverse feed rollers to remove thstall.

Finishing• Chipped material that accumulates in the infeed chute can be pulled into the ma

a piece of brush, or by pushing it in with a long limb. Never push chipped matefeet, rake, shovel, or any other object.

• Shut down machine when the chipping operation is complete. Follow Shutdown 1.


bs or inch can

core drum

n the drum, where one layer e pull and line speed, established

. Winch line may break or suddenly ot use towing vehicle pulling power to

2

1


OPERATING THE OPTIONAL WINCH (BC1200XL ONLY)

Winch CapacityThe intended use of the winch is to assist the operator in pulling large tree limtrunks to the brush chipper feed rollers without having to lift and carry. The whandle material up to 12" (30 cm) in diameter.

The line assembly includes a 150 ft (46 m), 7/16" line double-braided Spectra®with a polyester jacket (1) and a separate chain choker (2). The recommendedstorage capacity is 150 ft (46 m). This conforms to SAE J706 using a wireline compensation factor, K = 0.8.

Line Pull and SpeedThe line pull and speed of the winch vary based on the number of line layers oequals one row of wraps covering the drum surface. The chart shows rated linin accordance with SAE J706.

Winch Line Layer Line Pull Line Speed

1 2000 lb/907 kg 73 ft/min (22 m/min)

2 1804 lb/818 kg 84 ft/min (26 m/min)

3 1609 lb/730 kg 96 ft/min (29 m/min)

4 1413 lb/641 kg 108 ft/min (33 m/min)

5 1217 lb/552 kg 119 ft/min (36 m/min)

WARNING: Never exceed the rated winch capacity of 2000 lb (900 kg)release while pulling. Serious injury or death may occur if struck. Do nincrease the pulling capacity of winch.


Brush Chipper Preparation for Winching

ehicle. Load may move brush

2


Step 1: Position brush chipper for best alignment of winch inlet, feed table, and load. Repeated side loading will shorten winch line life.

Step 2: Set transport vehicle park brake or chock vehicle wheels to prevent rolling when pulling a load with the winch.

Step 3: Open feed table.

Step 4: With engine running, push Retract/Extend Lever (1) for one second to slacken winch line.

Step 5: Pull Winch Engage/Disengage Lever (2) down to disable feed rollers, enable winch, and disengage winch clutch.

WARNING: Never operate winch with brush chipper detached from towing vchipper or pull tongue off of support blocking.

1


2

3


4

5


Step 6: Unhook rope loop from interlock hook (3) above feed table.

NOTE: When winch is enabled, the amber rear warning lights (4) will flash quickly.

Step 7: Remove chain choker from storage box (5).

1

4


Winch Operationth two persons, one to

pull in line and anything

knives.

age to machine and choker. possible.


Winching limbs to the brush chipper is possible with one operator but works best wioperate the winch controls, and one working the winch line and chain choker.

WARNING: Brush can snag winch line. Knives can grab and attached to it at high speed. Death or serious injury possible.

Do not allow winch line to be snagged and pulled into chipper

WARNING: Chain choker struck by chipper knives will result in serious damMetal can be ejected from infeed chute at high speed. Death or serious injury

WARNING: Choker pulled in at high speed can kill.

Keep choker and winch line separate when pulling out line.


iously injure you.

igh speed. Death or serious injury

at high speed. Death or serious

bs are feeding into machine.


WARNING: Winch line pulled in at high speed can ser

Never pull out winch line while material is feeding.

WARNING: Winch line can pull you into machine at hpossible.

Never put winch line loop over arm or hand.

WARNING: Limbs attached to winch line can be pulleinjury possible.

Never attach winch line to installed choker if other lim

d in


Step 1: Refer to Starting Procedure, page 22-1.1



Step 2: With winch disengaged (Engage/Disengage Lever (1) down), manually pull winch line out as far as needed. Take chain choker with you in other hand.

IMPORTANT:

• Keep chain choker and winch line separated when pulling out line.

• Never pull out winch line while brush or limbs are feeding into the chipper.

• Never put winch line loop over arm or hand.

Step 3: Inspect line and chain choker for damage or wear before each pull. See Maintenance Manual for procedures.

1


limb and through ring as shown loop (3) to end of chain.

mb while

jury or

3 2


Step 4: Securely attach choker chain to limb by passing end of chain around(2). Pull end of chain to tighten on limb, and then attach winch line

IMPORTANT: Never attach the winch line to a choker that is connected to a limaterial is feeding into the chipper.

NOTE: For larger limbs, attach chain near large end of limb.

WARNING: Winch line can break or release. Serious indeath is possible.

Stay clear when winching.

7000B-095


Step 5: Push Winch Engage/Disengage Lever (1) 4


up to engage winch clutch.

IMPORTANT: Winch Engage/Disengage Lever must fully lock into ENGAGED position in order to perform forward and reverse operation. If lever does not lock into ENGAGED position, jog Winch Retract/Extend Lever (4) slightly until it does.

IMPORTANT: Ground personnel must be visibly clear of load and winch line before pulling begins.

1


hain choker to slacken.

n limb. Further extend winch line

ccur if struck. Stabilize limb on

4



Step 6: Use Winch Retract/Extend Lever (4) to retract winch line and pull limb toward feed table. (Winch is designed to operate at full engine speed.)

IMPORTANT: Do not move Winch Engage/Disengage Lever (1) while winch line is under load. Limb on end of line may roll or fall back toward other workers.

Step 7: Continue pulling limb forward until front of limb rests on feed table.

Step 8: Use Winch Retract/Extend Lever (4) to extend winch line to allow c

Step 9: Remove winch line from choker and reposition choker farther back oand re-attach loop to end of choker.

WARNING: Unstable limb may fall off feed table. Serious injury may ofeed table before repositioning chain.

1


Step 10: Retract winch line to move limb forward 4

7

6

5



until it reaches feed rollers.

Step 11: Briefly press Hold-to-Run Button (5) to start limb into feed rollers.

Step 12: When limb is in the grip of the feed rollers, release Hold-to-Run Button (5).

Step 13: Detach choker from limb and remove winch line and choker from path of feeding materials.

Step 14: Hook winch line loop on interlock hook (6).

Step 15: Use Winch Retract/Extend Lever (4) to retract winch line until the interlock hook (6) slides back and locks.

Step 16: If necessary, place Upper Feed Control Bar (7) in FORWARD to feed remainder of limb into chipper. Press Hold-to-Run Button (5) to start feeding.

Step 17: To continue pulling limbs, repeat Steps 2–16.

Step 18: Store winch line and choker. Refer to Winch Line - Store (BC1200XL Only), page 30-11.

WARNING: Failure to detach chain choker from limb before continuing to feed will result in severe equipment damage and may result in injury or death.

4

7

6

5


h

" (25

tion. ne.

iately

1


WINCH LINE AND CHOKER - REPAIR/REPLACE1. Always use a winch line approved by Vermeer Corporation for your brus

chipper winch.

2. If winch line loop is repaired by a qualified rigger, original loop size of 10cm) must be maintained as shown (1).

3. Always use a removable choker assembly approved by Vermeer CorporaNever permanently attach metal or heavy objects to loop end of winch li

4. If your original chain choker is worn, damaged, or lost, replace it immedfrom your authorized Vermeer dealer.

Removing Plugs from the Brush Chipper 51-1

the Brush Chipper

an grab and pull you in faster than lt.


Section 51: Removing Plugs from

DANGER: Limbs can snag clothing. Rollers or blades cyou can let go of limb. Cutting injury or death will resu

Never climb onto feed table.

Use wood object to push short material.

Keep away from rotating feed rollers and blades.

51-2 Removing Plugs from the Brush Chipper
WARNING: Rotating knives behind cover can cut off hand.Thrown objects can strike you.

Stop engine, wait for drum to stop, then open access cover.


trol Bar. event it from lug:

cutter drum ped.

r lock bar (2)

storage tab.

d properly. ock bar

1

2


FEED ROLLER - UNPLUGIf the upper feed roller becomes plugged, reverse it using the Upper Feed ConInspect dislodged material, ensuring it is not too large or has branches that prbeing fed into the machine. If reversing the feed roller does not dislodge the p

Step 1: Reduce engine speed to idle and wait for cutter drum speed to slow.

Step 2: Disengage Clutch Lever and wait for cutter drum to stop. Check thatrotation has stopped by looking to see if drum shaft end (1) has stop

Step 3: Use Feed Roller Raise Lever to raise feed roller and install feed rolleonto lift cylinder as shown.


Step 5: Remove plug from the rear of the machine.

Step 6: Start engine, raise feed roller, and remove lock bar. Store lock bar on

Step 7: Operate machine without chipping additional material to blow out cremaining in the chipper housing.

WARNING: Raised feed roller can fall if not supporteCrushing injury or death possible. Install feed roller lbefore working near raised feed roller.

hips


If the lower feed roller becomes plugged, reverse it using the Upper Feed Control Bar. tion

oor (3) and remove any build-up

cut

re

3


Follow Shutdown Procedure, page 23-1. Remove any dislodged material or contaminathat is preventing the lower feed roller from rotating.

If required, access the bottom of the lower feed roller by opening the bottom access dcontamination. Refer to Lower Feed Roller - Access Door, page 50-8.

WARNING: Rotating feed roller above cover willoff fingers and toes.

Stay away from rotating feed roller.

Stop feed roller, stop engine and remove key befoapproaching the feed roller.

+ =


ands away from sharp knives.

m shaft end (1) has stopped.

).

shing on the outside surface (4) of

bar access door located under

aining chips from chipper

43


CUTTER DRUM - UNPLUG

IMPORTANT: Wear gloves when working near the cutter drum knives. Keep h


Step 2: Check that cutter drum rotation has stopped by looking to see if dru

Step 3: Remove six bolts (2) and washers and open top cutter access door (3

Step 4: Manually reverse rotation of the cutter drum to dislodge chips by puthe drum. Stay well away from cutter knives.

Step 5: If necessary to access bottom of drum, remove four bolts and lower shmachine (refer to the “Maintenance as Required” section).

Step 6: Remove chips.

Step 7: Close and bolt the access doors.

Step 8: Operate machine, without chipping additional material, to blow remhousing.

2

1

ear


t

)

1

2


DISCHARGE CHUTE - CLEAN OUT

Most plugs can be removed using the following procedure:


Step 2: Check that cutter drum rotation has stopped by looking to see if drum shafend (1) has stopped.

Step 3: Rotate discharge chute over left side of machine.

Step 4: Stand on the non-slip material in front of the fender and push a stick or wooden broom handle, if available, down the end of the discharge chute (2to dislodge the plugged material.

WARNING: Thrown objects can blind you.

Keep everyone away from discharge area while cutter drum isturning. Direct discharge chute away from people. Wear eye protection.

emoving Plugs from the Brush Chipper 51-7

chute at plugged

the

chips 3


Step 5: If you are unable to dislodge the plugged material, unbolt dischargethe rotation ring (3) and remove chute from machine to clean out thematerial.

Step 6: Install cleaned discharge chute.

IMPORTANT: Use an appropriate lifting system when removing and installingdischarge chute. Chute weighs approximately 79 lb (36 kg).

Step 7: Operate machine, without chipping additional material, to blow outthat remain in the chipper housing and discharge chute.

R

Maintenance Intervals 60-1

requested by Vermeer

n. Refer to Controls, page 20-1. To and for other information.

ions given below:

ers, or other similar cleaners that

rature of the mounting surface dry.

also.

r.

cleaning, repairing, or transporting


Section 60: Maintenance Intervals

Visually inspect machine daily before starting the machine.

Make no modifications to your equipment unless specifically recommended orCorporation.

SAFETY SIGNSSafety signs located on your machine contain important and useful informatiohelp you operate your equipment safely, refer to the Parts Manual for locations

To assure that all signs remain in place and in good condition, follow instruct

• Keep signs clean. Use soap and water - not mineral spirits, abrasive cleanwill damage the safety sign.

• Replace any damaged or missing signs. When attaching signs, the tempemust be at least 40°F (5°C). The mounting surface must also be clean and

• When replacing a machine component with a sign attached, replace sign

• Replacement signs can be purchased from your Vermeer equipment deale

WARNING: Use Shutdown Procedure before servicing,machine. Follow Shutdown Procedure, page 23-1.


tenance, refer to the

he machine. The hourmeter

under severe conditions, the

different.

terval - Service Hours

250 500 1000 2000As

Reqd.

60-2 Maintenance Intervals

MAINTENANCE MANUALMaintenance intervals are included for reference only. Before performing any mainMaintenance Manual for safety guidelines and correct procedures.

HOURMETER - CHECK FOR MAINTENANCE INTERVALThe hourmeter on the power unit is used to determine maintenance intervals for tindicates the total number of hours the engine has been in operation.

Maintenance intervals are based on normal operating conditions. When operating maintenance intervals should be shortened.

MAINTENANCE INTERVALSInitial = Initial maintenance on new machine. Regular maintenance interval may be

= Regular maintenance interval.

Service

Maintenance In

5 10 50 100Cutter Drum Bearings - Grease

Feed Roller Bearings - Grease

Engine Drive Belt -Inspect

Engine Systems - Check

Engine Cooling System - Check

Crankcase Breather Tube - Inspect

Engine Oil Level - Check

Air Cleaner Restriction Indicator - Check


nce Interval - Service Hours

100 250 500 1000 2000As

Reqd.


Engine Oil Level - Check

Fuel/Water Separator - Drain

Crankcase Breather Tube - Check

Hydraulic Fluid Level - Check

Engine Cooling System - Check

Fuel Tank - Fill

Brake System - Check

Drum and Knives - Maintain

Fluid Level in Optional Hydraulic Surge Brake - Check

Feed Roller Controls - Check

Wheel Lug Nut Torque - Check Initial

Cutter Drum Drive Belt Tension - Check/Adjust Initial

Pintle Hitch - Check

Lower Feed Stop Bar Switch - Check

Function of Optional Hydraulic Surge Brakes - Check

Electric Brakes - Test

Machine - Grease

Engine Oil and Filters - Change and Replace Initial

Hydraulic Fluid Filter - Initial Replacement Initial

Feed Roller Arm Pivot Pins - Grease

Feed Roller Lift Arms - Grease

Feed Roller Lift Cylinders - Grease

Belt Drive U-Joints - Grease

Belt Drive Pivots - Grease

Service

Maintena

5 10 50


erval - Service Hours

250 500 1000 2000As

Reqd.


Cutter Drum Drive Belt Tension - Check/Adjust

Machine Components - Inspect

Cutter Shaft - Check

Shear Bar Mounting Hardware - Check

Winch (Option) Line - Clean

Hydraulic System - Check

Overall Machine - Check

Safety Sign Maintenance

Upper Feed Control Bar Force - Check/Adjust

Lower Feed Stop Bar Switch - Check/Adjust

Tires and Rims - Check

Winch (Option) Line - Check

Winch (Option) Line and Choker - Repair/Replace

Winch (Option) Interlock - Check

Engine Oil and Filter - Change and Replace

Cutter Drum Drive Belt Wear - Check

Air Intake System - Check

Corrosion Inhibitors - Add to Coolant

Radiator Hose - Check

Hydraulic Fluid Filter - Replace

Jack - Lubricate

Automatic Brake Controller - Check

Air Cleaner Element(s) - Inspect/Replace (if indicated)

Brakes - Adjust

Winch (Option) Bearings - Grease

Service

Maintenance Int

5 10 50 100


ce Interval - Service Hours

100 250 500 1000 2000As

Reqd.


Cooling System - Check

Injection Pump - Vent

Fuel Filter - Change

Fuel Supply Lines - Vent

Hydraulic Fluid - Change

Battery Electrolyte Level and Terminals - Check

Cutter Drum Drive Belt - Replace

Feed Table Curtains - Replace

Wheel Bearings - Check/Repack

Ball Coupler - Lubricate and Inspect

Engine Drive Belt Tension/Tensioner - Check

Cooling System - Drain and Clean

Air Cleaner Secondary Element - Replace

Surge Brake Actuator (European)

Park Brake Lever (European) - Grease

Battery - Replace

Valve Lash - Adjustment

Crankcase Breather Element - Replace

Cooling System - Check

Air Cleaner - Inspect

Highway Lights - Replace

SmartFeed System Fuse - Replace

Shear Bar - Check/Adjust/Replace

Knife-Mounting Surface - Check

Slip Hook - Replace

Service

Maintenan

5 10 50


erval - Service Hours

250 500 1000 2000As

Reqd.


Towing Chain - Replace

Storage

Service

Maintenance Int

5 10 50 100

Knife/Drum Maintenance 61-1

cervice hours. However, the actual s, depending upon the wood being

sibility of the knives becoming

nd.

er


Section 61: Knife/Drum MaintenanThe recommended service interval to check the cutter knives is 10 seservice hours interval before knife maintenance is required may be more or leschipped and chipping conditions.

Performing the following maintenance procedures will aid in reducing the posloose, failing, and being ejected from the machine.

WARNING: Rotating knives under cover can cut off haThrown objects can strike you.

Stop engine, wait for drum to stop, then open access cov


cted if matched knives are

cutting injuries will result if

2

3

61-2 Knife/Drum Maintenance

KNIFE REMOVAL

IMPORTANT: Always remove and replace knives as sets. Chipper balance can be affenot kept together.

To remove knives:

Step 1: Refer to Shutdown Procedure, page 23-1.

Step 2: Check that cutter drum rotation has stopped by looking to see if drum shaft end (1) has stopped.

Step 3: Remove six bolts and washers (2), and open cutter drum access door (3).

WARNING: Wear gloves when working with the cutter drum knives. Seriouscontact is made with the knives while removing or installing them.

WARNING: Knives can cut off hand.

Lock drum before servicing knives.

1


on knives. in (4).

t use

s per the instructions that follow.

4

5

6


Step 4: Lock cutter drum to prevent the drum from rotating while working Align one of the two lock holes in the cutter drum and engage lock p

Step 5: Remove four bolts (5) from first knife (6). To prevent damage, do noimpact tool to remove bolts.

Step 6: Lift off knife from drum.

Step 7: Unlock cutter drum and rotate 1/2 turn to the next cutter knife.

NOTE: Rotate by pushing on the outside surface of the drum.

Step 8: Lock cutter drum.

Step 9: Repeat Steps 3–6 to remove both knives.

Step 10: Clean and inspect the drum, mounting surfaces, knives, and bolts a


Knife Inspection

s.

n

o

t n the knife surface and the be replaced.

1

2

3


• Cracks — Thoroughly clean the knives and inspect both sides of each knife forcracks. If any are found, discard the knife and install a new one.

Cracks (1) that start at the mounting hole and progress outward result from the mounting bolts being improperly torqued.

NOTE: Knife sizes and number of mounting holes may vary between machine model

If cracked knives are reused, the cracks will extend across the knife and the knife caseparate from the cutter drum.

• Distortion — Check the mounting side of the knife for distortion. Bolting a distorted knife to the cutter drum will add stresses in the knife and possibly cause knife cracking and failure.

Step 1: Place a straightedge (2) on the mounting side of the knife (3) and parallel tthe mounting holes as shown.

Step 2: Move straightedge slowly across the knife surface, and monitor for any lighthat shows between the knife and straightedge. If any light appears betweestraightedge, this indicates that the knife is distorted, and the knife must

Step 3: Turn straightedge perpendicular to mounting holes and repeat Step 2.


xisting mounting bolts e their clamping ill cause the knives to

y are found, discard

bolts can cause the knives to become detached nives are ejected from the machine and strike will probably occur if the knives become

re sharpened or replaced. Bolts may be reused replace bolts can cause knife/drum separation

ood to pack under the knife. Distorted knives age. Use a straightedge and check all knives

1


Bolt Inspection

IMPORTANT: When installing a new or sharpened set of knives, discard the eand use new Vermeer-approved bolts. Repeated reuse of the bolts will decreascapacity each time the bolts are torqued. Inadequate clamping of the knives wloosen and fail.

Bolts —Inspect bolts (1) for damaged threads, corrosion, and distortion. If anthe bolt and install a new one.

WARNING: Incorrect maintenance and torquing of the knife-mountingfrom the cutter drum. Death or serious injury is possible if the failed ksomeone. Extensive and costly damage to the cutter drum and machinedetached.

WARNING: Knife-mounting bolts must be replaced each time knives aONLY ONCE when rotating knife to its second cutting edge. Failure toresulting in death or serious injury, and machine damage.

WARNING: Overtightened bolts can cause knife distortion, allowing wcan crack and fail resulting in death or serious injury, and machine damfor distortion; discard any that are distorted.


Knife Mount Surface Inspection drum

ng t ns can

d, or

2

1


When a cutting knife is removed from the drum, the knife-mounting surfaces on themust be cleaned and inspected.

IMPORTANT: Any debris left on the mounting surface can prevent the knife from lyiperfectly flat on its mating surface. Any dirty or damaged threads will affect the boltorque, and prevent the knives from being properly clamped. Either of these conditiolead to knife failure during operation.

Thoroughly clean and inspect the following:

• Knife Mount Surface — Remove all wood chips and other material from the mounting pocket area (1).

• Replaceable Thread Bars (2) — Replace when threads become worn, distortedamaged.


e following:

d deformation.

drum sides are joined to the

(3) for damage or cracks.

begin at the pockets and migrate

ermeer dealer.

43


DRUM INSPECTION

The cutter drum must be free of any damage. Thoroughly clean and inspect th

• Air Paddles — Inspect air paddles (1) and their gussets for cracking an

• Edge Welds — Inspect entire drum for cracks in the welds (2) where thedrum. Use a mirror to aid in this inspection.

• Pockets — Closely inspect area in and around knife mount and pockets

• Cutter Drum Surface — Inspect drum surface (4) for cracks that may outward.

If any drum damage or cracks are found, contact an authorized independent V

2

2

21


(51 mm) a knife that

(Minimum)

30°

2.00" (51 mm)

(Minimum)2.00" (51 mm)

30°


KNIFE SHARPENING• Sharpen knives at a 30° angle.

• Use a soft “J” grade grinding wheel with 36 to 46 grit.

• Use adequate coolant while grinding.

• Hone knives between sharpenings with an oil honing stone.

IMPORTANT: The knives are double-edged and have a minimum usable size of 2.00"measured from the centerline of the bolt holes to the knife edge. Do not use a side ofmeasures less than this.


instructions.

bar (2) in place

g holes to the nted the same way

bolts to hold the

he center bolts. Torque in the

harpened or replaced. Bolts dge. Failure to replace bolts d machine damage.

ife/drum bolts.

ood to pack under the knife. and machine damage. Use a istorted.

31

2


Knife InstallationStep 1: Clean and inspect all cutter drum components as per the preceding


Step 3: Install knife (1) with the bevel oriented as shown, and with thread inside drum.

IMPORTANT: On resharpened knives, measure the distance from the mountinsharpened edges. Mount knives so edges with the same measurement are orieat both locations.

Step 4: Lubricate bolts (3) with light oil and install. Lightly tighten all fourknife in place.

Step 5: Torque bolts with a torque wrench to 210 ft-lb (285 Nm) beginning wsame sequence again after the last bolt is tightened.

Step 6: Unlock cutter drum and rotate 1/2 turn to the next cutter knife.


WARNING: Mounting bolts (3) must be replaced each time knives are smay be reused ONLY ONCE when rotating knife to its second cutting ecan cause knife/drum separation resulting in death or serious injury, anAlso, to prevent bolt damage, do not use a power or impact tool to insta

WARNING: Overtightened bolts can cause knife distortion, allowing wDistorted knives can crack and fail resulting in death or serious injury, straightedge and check all knives for distortion; discard any that are d

ith t

ll kn


Step 8: Repeat Steps 3–5 to install both knives.

eased and stored.

n, “Shear Bar - Check/

adjust or replace the shear djust”.


Step 9: Release drum lock, close and secure cutter drum access door.

NOTE: The cutter drum access door will not fully close until the drum lock pin is rel

Step 10: Adjust shear bar (refer to the Maintenance Manual, 50 Service Hours sectioAdjust”).

IMPORTANT: The shear bar bolts must be checked weekly, even if you do not need tobar. Refer to the Maintenance Manual, 50 Service Hours section, “Shear Bar - Check/A

Engine Fault Codes (110/120-HP Engine) 62-1

10/120-HP Engine)tanding and recording engine fault

actions. Always contact your uble codes which are displayed for

SPN) which identifies the system or ) code which identifies the type of both parts of the code are needed.

CORRECTIVE ACTION

re - Bad Contact Servicing Dealer

Sensor Circuit or - Data Erratic, Check Sensor and Wiring

Sensor Circuit - rce)

Contact Servicing Dealer

Sensor Circuit - rce)


1 Air Pressure - ge - Moderately Contact Servicing Dealer

e Normal, or Check Switch and Wiring


Section 62: Engine Fault Codes (1Refer to the Engine Operation Manual for additional information on underscodes displayed on engine multifunction display, and appropriate remedial Vermeer dealer or engine service dealer for help in correcting diagnostic troyour engine.

NOTE: The first part of the code is a six-digit Suspect Parameter Number (component that failed, followed by a two-digit Failure Mode Identifier (FMIfailure (example: high temperature). In order to determine the exact failure

Fault Code

SPN FMI Light DESCRIPTION

111 000629 12 RedECU Programming Error (Critical Internal FailuIntelligent Device or Component)

115 000612 02 RedSystem Diagnostic #2 (Engine Speed/PositionLost Both Signals from Magnetic Pickup SensIntermittent, or Incorrect)

122 000102 03 AmberBoost Pressure (Intake Manifold Air Pressure Voltage Above Normal or Shorted to High Sou

123 000102 04 AmberBoost Pressure (Intake Manifold Air Pressure Voltage Below Normal, or Shorted to Low Sou

124 000102 16 Amber(110-hp only) Boost Pressure (Intake ManifoldData Valid but Above Normal Operational RanSevere Level)

131 000091 03 RedThrottle Position Sensor Circuit - Voltage AbovShorted to High Source


l, or Check Switch and Wiring

ve Non Engine Fault. Check Other Shutdown Devices

w Non Engine Fault. Check Other Shutdown Devices

al Check Oil Level

Above Check Sensor and Wiring

Below Check Sensor and Wiring

Normal Check Cooling System, Reduce Power

Normal ut down

Check Cooling System, Reduce Power

e Above Check Sensor and Wiring

e Below Check Sensor and Wiring

ata Valid Check Air Cleaner, Aftercooler, or Room Temperature


CORRECTIVE ACTION

62-2 Engine Fault Codes (110/120-HP Engine)

132 00091 04 RedThrottle Position Sensor Circuit - Voltage Below NormaShorted to Low Source

133 000974 03 RedRemote Throttle (Position Sensor Circuit - Voltage AboNormal, or Shorted to High Source)

134 000974 04 RedRemote Throttle (Position Sensor Circuit - Voltage BeloNormal, or Shorted to Low Source)

143 000100 18 AmberEngine Oil Pressure Low - (Data Valid but Below NormOperational Range - Moderately Severe)

144 000110 03 AmberEngine Coolant Temperature (Sensor Circuit - Voltage Normal, or Shorted to High Source)

145 000110 04 AmberEngine Coolant Temperature (Sensor Circuit - Voltage Normal, or Shorted to Low Source)

146 000110 16 AmberEngine Coolant Temperature High (Data Valid but AboveOperational Range - Moderately Severe)

151 000110 00 RedEngine Coolant Temperature High (Data Valid but AboveOperational Range - Most Severe Level - Engine will sh30 seconds after light stops flashing)

153 000105 03 AmberIntake Manifold #1 Temperature (Sensor Circuit - VoltagNormal, or Shorted to High Source)

154 000105 04 AmberIntake Manifold #1 Temperature (Sensor Circuit - VoltagNormal, or Shorted to Low Source)

155 000105 00 RedIntake Manifold #1 Temperature (Temperature High - Dbut Above Normal Operational Range - Most Severe Le

221 000108 03 AmberBarometric Air Pressure (Sensor Circuit - Voltage AbovNormal, or Shorted to High Source)

Fault Code


vel)

e

Engine Fault Codes (110/120-HP Engine) 62-3

Below Normal, Contact Servicing Dealer

al Operational Reduce Engine Speed

age #3 Circuit - e)

Check Sensor and Wiring

age #3 Circuit - e)

Check Sensor and Wiring

l Pressure r Shorted to Check Pump Wiring

l Pressure r Shorted to Check Pump Wiring

low Normal, or Check Injector Wiring or Injector Solenoid

ormal, or Check Injector Wiring or Injector Solenoid

ormal, or Check Injector Wiring or Injector Solenoid

low Normal, or Check Injector Wiring or Injector Solenoid

nternal ponent)


CORRECTIVE ACTION


222 000108 04 AmberBarometric Air Pressure (Sensor Circuit - Voltageor Shorted to Low Source)

234 000190 00 RedEngine Speed High (Data Valid but Above NormRange - Most Severe Level)

238 000611 04 AmberSystem Diagnostic Code #1 (Sensor Supply VoltVoltage Below Normal, or Shorted to Low Sourc

239 003511 03 AmberSystem Diagnostic Code #2 (Sensor Supply VoltVoltage Above Normal, or Shorted to High Sourc

271 001347 04 AmberFuel Pump Pressurizing Assembly #1 (High FueSolenoid Valve Circuit - Voltage Below Normal, oLow Source)

272 001347 03 AmberFuel Pump Pressurizing Assembly #1 (High FueSolenoid Valve Circuit - Voltage Above Normal, oHigh Source)

322 000651 05 AmberInjector Solenoid Cylinder #1 Circuit (Current BeOpen Circuit)

324 00653 05 AmberInjector Solenoid Cylinder #3 Circuit (Current BeOpen Circuit



343 000629 12 AmberController #1 (Engine Control Module Warning IHardware Failure - Bad Intelligent Device or Com

Fault Code


low N

low N


evice or Contact Servicing Dealer

Voltage Check Wiring

Voltage Check Wiring

al Check Oil Level

e Above Check Sensor and Wiring

e Below Check Sensor and Wiring

atic, Contact Servicing Dealer


Erratic, Check Sensor and Wiring

Data y Severe Contact Servicing Dealer

Data ere Contact Servicing Dealer

CORRECTIVE ACTION


351 000629 12 AmberController #1 (Injector Power Supply - Bad Intelligent DComponent)

352 001079 04 Amber5 Volts DC Supply (Sensor Supply Voltage #1 Circuit - Below Normal, or Shorted to Low Source)

386 001079 03 Amber5 Volts DC Supply (Sensor Supply Voltage #1 Circuit - Above Normal, or Shorted to High Source)

415 000100 01 RedEngine Oil Pressure Low - (Data Valid but Below NormOperational Range - Most Severe Level)

428 000097 03 AmberWater in Fuel Indicator (Water in Sensor Circuit - VoltagNormal, or Shorted to High Source)

429 000097 04 AmberWater in Fuel Indicator (Water in Sensor Circuit - VoltagNormal, or Shorted to Low Source)

431 000558 02 AmberAccelerator Low Idle Switch (Validation Circuit Data ErrIntermittent, or Incorrect)

432 000558 13 RedAccelerator Low Idle Switch (Validation Circuit Out of Calibration)

435 000100 02 AmberEngine Oil Pressure (Oil Pressure Sensor Circuit - DataIntermittent, or Incorrect)

441 000168 18 AmberElectrical Potential (Voltage) (Battery #1 Voltage Low - Valid but Below Normal Operational Range - ModeratelLevel)

442 000168 16 AmberElectrical Potential (Voltage) (Battery #1 Voltage High -Valid but Above Normal Operational Range - ModeratelLevel)

Fault Code


y Sev

ngine Fault Codes (110/120-HP Engine) 62-5

nsor Circuit - ce)


nsor Circuit - e)


- Data Valid but Severe Level)

Check Air Cleaner, Aftercooler, or Room Temperature

tion Switch - Check Sensor and Wiring

gh - Data Valid tely Severe Contact Servicing Dealer

w - Data Valid ely Severe Contact Servicing Dealer

rror - Data Reduce Engine Speed

n #2 d Crankshaft

Properly or Out Reduce Engine Speed

r (Camshaft) Reduce Engine Speed

ta Erratic, Contact Servicing Dealer

CORRECTIVE ACTION


449 000157 00 RedInjector Metering Rail #1 Pressure (Pressure SeVoltage Above Normal, or Shorted to High Sour

451 000157 03 AmberInjector Metering Rail #1 Pressure (Pressure SeVoltage Below Normal, or Shorted to Low Sourc

488 000105 16 AmberIntake Manifold (Intake Manifold 1 Temperature Above Normal Operational Range - Moderately

528 00093 02 AmberSwitch - Data (Auxiliary Alternate Torque ValidaData Erratic, Intermittent, or Incorrect)

553 000157 16 AmberInjector Metering Rail #1 Pressure (Pressure Hibut Above Normal Operational Range - ModeraLevel)

559 000157 03 AmberInjector Metering Rail #1 Pressure (Pressure Lobut Below Normal Operational Range - ModeratLevel)

689 000190 02 AmberEngine Speed (Primary Engine Speed Sensor EErratic, Intermittent, or Incorrect)

731 000723 07 Amber

Engine Speed Sensor #2 (Engine Speed/PositioMechanical Misalignment Between Camshaft anSensors - Mechanical System Not Responding of Adjustment)

778 000723 2 AmberEngine Speed Sensor #2 (Engine Speed SensoError - Data Erratic, Intermittent, or Incorrect)

1117 000627 02 NonePower Supply (Power Lost With Ignition On - DaIntermittent, or Incorrect)

Fault Code


E


orted to in the Contact Servicing Dealer

orted to in the Contact Servicing Dealer

CORRECTIVE ACTION


1695 003513 03 AmberSensor Supply Voltage #5 (Voltage Above Normal or ShHigh Source. High Voltage Detect at Sensor Supply #5OEM Harness.)

1696 003513 04 AmberSensor Supply Voltage #5 (Voltage Below Normal or ShLow Source. High Voltage Detect at Sensor Supply #5 OEM Harness.)

Fault Code


ute - Clean Out, 51-6ute Controls, 20-15ute, 40-6itch, 20-13ion, 61-7

Control, 50-7Codes (110/120-HP Engine), 62-1fication Numbers - Record, viors (Tier 3/Stage IIIA), 20-1ors (Tier 4 Interim/Stage IIIB), 20-2

Towing Vehicle, 30-1

Bars - Check, 40-9 Engage, 50-5 Unplug, 51-3ontrols, 20-6peration, 50-2

, 50-1112


IndexAAttach to Towing Vehicle (BC1200XL European Only), 30-7Attach to Towing Vehicle (BC1200XL Only), 30-4

BBattery Burns - Avoid, 22-3Battery Explosion - Avoid, 22-2Bolt Inspection, 61-5Breakaway on Hydraulic Surge Brake (Option) - Reset, 30-8Breakaway System - Reset Electric Brake, 30-9Brush Chipper Preparation for Winching , 50-14Brush Chipper, iii

CChip Material, 50-11Clean Flammable Materials from Machine, 40-5Cold Weather Starting, 22-1Controls, 20-1Cutter Drum - Engage, 50-1Cutter Drum - Unplug, 51-5Cutter Shaft - Check, 50-1Cutting System , 50-10

DDealer Prep, iDealer/Customer Information, ivDelivery, iiiDetach from Towing Vehicle, 30-12

Discharge ChDischarge ChDischarge ChDroop Set SwDrum Inspect

EEcoIdle RPMEngine Fault Engine IdentiEngine MonitEngine MonitEngine, 22-1Equipping the

FFeed ControlFeed Roller -Feed Roller -Feed Roller CFeed Roller OFeeding TipsFinishing, 50-Fuses, 20-21

G


H Mfore Transporting, 30-9n Decal, vn Numbers - Record, vls, 60-1ls, 60-2l, 60-2

Chipper, 50-1al Winch (BC1200XL Only), 50-13ns, 40-1

XL European Only), 20-14 40-22rt, 30-10-3hipper, 40-4 Chipper and Work Area, 40-1

-2

Hitch - Pintle, 30-6Hitch Height - Adjust (BC1200XL Only), 30-2Hourmeter - Check for Maintenance Interval, 60-2Hydraulic Fluid, 22-2

IIgnition Switch, 20-4Infeed System, 50-10Intended Use, 40-1

JJack Controls, 20-20Jump-Starting Procedure, 22-3Jump-Starting, 22-2

KKnife Inspection, 61-4Knife Installation, 61-9Knife Mount Surface Inspection, 61-6Knife Removal, 61-2Knife Sharpening, 61-8Knife/Drum Maintenance, 61-1

LLine Pull and Speed, 50-13Lower Feed Roller - Access Door, 50-8Lower Feed Stop Bar and Side Feed Stop Bars, 50-3

Machine - Clean BeMachine IdentificatioMachine IdentificatioMaintenance IntervaMaintenance IntervaMaintenance ManuaMaterial Size, 50-11

N

OOperating the BrushOperating the OptionOperator Qualificatio

PPark Brake (BC1200Personal Protection,Plugs or Stalls, 50-1Prepare for TranspoPrepare the Area, 40Prepare the Brush CPreparing the Brush

QQuick Stop Procedu
re, 23


R (BC1200XL Only), 20-181200XL Only), 20-16BC1200XL Only), 30-11ker - Repair/Replace, 50-23-16

Removing Plugs from the Brush Chipper, 51-1Reporting Safety Defects, 30-1Review of Operation, iii

SSafety Messages, 10-1Safety Signs, 60-1Safety Symbol Explanation, 10-1Sensitivity Levels (BC1200XL Only), 50-4Shutdown Procedure, 23-1SmartFeed Operation, 50-10Sound Levels, 40-3Starting Procedure, 22-1Starting the Engine, 22-1Stopping the Machine, 23-1

TThrottle/Cutter Engage, 20-5Tongue Length - Adjust (BC1200XL Only), 30-3Transporting the Brush Chipper, 30-1

UUpper Feed Control Bar, 50-3

V

WWheel Chocks (BC1200XL European Only), 20-14Winch Capacity, 50-13Winch Controls - Left Side Controls Option

Winch Controls (BCWinch Line - Store (Winch Line and ChoWinch Operation, 50

Description

1st Edition Operator’s Manual released.

1,4, .

Added left side controls (option), 85-hp engine (option), engine fault codes; misc. updates.

0- Added maintenance items; updated Safety message.

Added EU Side Feed Stop Bars, Safety Updates.

Model number, Typing errors

Control panel update, Updated maintenance intervals

TIER-4 enine update


Revision HistoryRevision Date Page(s)

o1_00 06/09 All

o1_01 08/09R&D, v; TOC; Controls, 20-1,2,8,10,12–14; Starting, 21-1; Shutdown, 22-1; Transport, 30-10; Prep, 40-6; Operating, 50-5,11,14,16,17; Removing Plugs, 51-4; Maint. Int., 60-3; Index

o1_02 10/09Intro.; Safety, p. 10-1; Preparing, p. 40-1; Maint. Intervals, p. 62,3.

o1_03 03/10 Controls, Transporting, Preparing, Operating.

o1_04 02/11 Introduction; TOC; Controls; Engine fault codes; Index

o1_05 10/11 Controls, Starting, Operating, Maintenance Interval

o2_00 01/12 All

ALIFORNIAsition 65 Warning

e exhaust and some of its are known to the State of cause cancer, birth other reproductive harm.

vehicle may In-Use Off-

d be subject to reduce n, please at

.htm.

WARNINGThe Engine Exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

CPropo

Diesel enginconstituentsCalifornia todefects, and

Copyright 2012. All rights reserved.Vermeer Corporation

1210 Vermeer Road East, P.O. Box 200Pella, Iowa 50219-0200

When operated in California, any off-road diesel be subject to the California Air Resources BoardRoad Diesel Vehicle Regulation. It therefore coulto retrofit or accelerated turnover requirements emissions of air pollutants. For more informatiovisit the California Air Resources Board websitehttp://www.arb.ca.gov/msprog/ordiesel/ordiesel

bc1200xl brush chipper - abc equipment · pdf filedrums, end idler, flashings, pins and...

Documents