BC1200XL Brush Chipper

Transcription

Operator’s
Manual
BC1200XL_o2_00
Serial No. 1001 Order No. 105400BZ3
Cabled Order No. 163698121
Introduction
This manual explains the proper operation of your machine. Study and understand these instructions thoroughly before operating or
maintaining the machine. Failure to do so could result in personal injury or equipment damage. Consult your Vermeer dealer if you
do not understand the instructions in this manual, or need additional information.
The instructions, illustrations, and specifications in this manual are based on the latest information available at time of publication.
Your machine may have product improvements and features not yet contained in this manual.
Vermeer Corporation reserves the right to make changes at any time without notice or obligation.
Operation instructions are included in the two Operator’s Manuals provided with the machine. The tethered (cabled)
manual must remain attached to the machine for ready reference. Store it in the manual storage box when not in use.
Lubrication and maintenance procedures are in the Maintenance Manual provided with the machine. Refer to it for all
lubrication and maintenance procedures.
Additional copies of the manuals, and Operations and Safety video, are available from your dealer. Reorder numbers are listed on the
front covers of the manuals and on the video.
Copies of this manual, and the Operations and Safety video, are available in Spanish from your dealer.
Su distribuidor dispone de ejemplares en español de este manual y del vídeo de Operaciones y Seguridad.
NOTICE TO OWNER
You are requested to notify Vermeer Corporation when you have purchased a used Vermeer machine. Notify the Customer Data
Department by telephone: 800-829-0051 or 641-628-3141; email: customerdata@vermeer.com; internet: www.vermeer.com or
www.vermeerag.com; or, letter: Customer Data Dept., Vermeer Corporation, PO Box 200, Pella IA 50219 USA. Upon request, an
owner of a used Vermeer machine will receive one free set of Operator’s, Maintenance and Parts manuals.
Introduction
BC1200XL
BC1200XL European
NOTE: Right and left sides of the machine are determined by facing in the direction of forward travel.
TRADEMARKS
VERMEER, VERMEER Logo and ECOIDLE are trademarks of Vermeer Manufacturing Company.
CUMMINS is a trademark of Cummins, Inc.
FLEETGUARD is a trademark of Fleetguard, Inc.
Introduction
VERMEER NEW INDUSTRIAL EQUIPMENT LIMITED WARRANTY
(EFFECTIVE OCTOBER 1, 2008)
WARRANTY PERIOD: 12 Months / 1000 Hours
Vermeer Corporation (hereinafter “Vermeer”) warrants each new Industrial product of Vermeer's manufacture to be free from defects
in material and workmanship, under normal use and service for one (1) full year after initial purchase/retail sale or 1000 operating
hours, whichever occurs first. This Limited Warranty shall apply only to complete machines of Vermeer's manufacture, parts are
covered by a separate Limited Warranty. EQUIPMENT AND ACCESSORIES NOT OF VERMEER'S MANUFACTURE ARE
WARRANTED ONLY TO THE EXTENT OF THE ORIGINAL MANUFACTURER'S WARRANTY AND SUBJECT TO
THEIR ALLOWANCE TO VERMEER ONLY IF FOUND DEFECTIVE BY SUCH MANUFACTURER.
EXTENDED WARRANTY OPTIONS ARE AVAILABLE FOR PURCHASE.
WARRANTY TERMS
During the Limited Warranty period specified above, any defect in material or workmanship in any warranted item of Vermeer
Industrial Equipment not excluded below shall be repaired or replaced at Vermeer's option without charge by any authorized
independent Vermeer dealer. The warranty repair or replacement must be made by a Vermeer independent authorized dealer at the
dealer's location. Vermeer will pay for replacement parts and such authorized dealer's labor in accordance with Vermeer's labor
reimbursement policy. Vermeer reserves the right to supply remanufactured replacement parts as it deems appropriate.
RETAIL PURCHASER RESPONSIBILITY: This Limited Warranty requires proper maintenance and periodic inspections of the
Industrial Equipment as indicated in the Operator’s/Maintenance Manual furnished with each new Industrial Equipment. The cost
of routine or required maintenance and services is the responsibility of the retail purchaser. The retail purchaser is required to keep
documented evidence that these services were performed.
This Vermeer New Industrial Equipment Limited Warranty may be subject to cancellation if the above requirements are not
performed.
Vermeer Industrial Equipment with known failed or defective parts must be immediately removed from service.
Introduction
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 normal use and service of the Industrial
Equipment, or by any of the following; (i) accident (ii) misuse or negligence (iii) overloading (iv) lack of reasonable and
proper maintenance (v) improper repair or installation (vi) unsuitable storage (vii) non-Vermeer approved alteration or
modification (viii) natural calamities (ix) vandalism (x) parts or accessories installed on Industrial Equipment which were
not manufactured or installed by Vermeer authorized dealers (xi) the elements (xii) collision or other accident.
(2)
Any Industrial Equipment whose identification numbers or marks have been altered or removed or whose hourmeter has
been altered or tampered with.
(3)
Any Industrial Equipment which any of the required or recommended periodic inspection or services have been performed
using parts not manufactured or supplied by Vermeer or meeting Vermeer Specifications including, but without limitation,
engine tune-up parts, engine oil filters, air filters, hydraulic oil filters, and fuel filters.
(4)
New Industrial Equipment delivered to the retail purchaser in which the warranty registration has not been completed and
returned to Vermeer within ten (10) days from the date of purchase.
(5)
Any defect which was caused (in Vermeer’s sole judgment) by operation of the Industrial Equipment not abiding by standard
operating procedures outlined in the Operator’s Manual.
(6)
Engine, battery, and tire Limited Warranties and support are the responsibility of the respective product’s manufacturer.
(7)
Transportation costs, if any, of transporting to the Vermeer dealer. Freight costs, if any, of transporting replacement parts to
the Vermeer dealer.
(8)
The travel time of the Vermeer dealer’s service personnel to make a repair on the retail purchaser’s site or other location.
(9)
In no event shall Vermeer’s liability exceed the purchase price of the product,
(10) Vermeer shall not be liable to any person under any circumstances for any incidental or consequential damages (including
but not limited to, loss of profits, out of service time) occurring for any reason at any time.
(11) Diagnostic and overtime labor premiums are not covered under this Limited Warranty Policy. Oils and fluids are not covered
under this Limited Warranty.
Introduction
(12)
(13)
(14)
(15)
Depreciation damage caused by normal wear, lack of reasonable and proper maintenance, failure to follow operating
instructions, misuse, lack of proper protection during storage.
Accessory systems and electronics not of Vermeer’s manufacture are warranted only to the extent of such manufacturer’s
respective Limited Warranty if any.
Downhole toolage is not covered under this warranty.
Wear items which are listed by product group as follows:
ENVIRONMENTAL: Bearing Seals, Bearings, Belts, Brake Pads, Bolts/Torqued Parts, Chain, Clutches, Clutch Components,
Curtains, Cutter Wheels, Discharge Conveyor Belts, Fuel Filters, Hammers, Hoses, Infeed Conveyor Belts, Infeed Conveyor Chains,
Knives, Oil Filters, Pockets, Rods, Rollers, Rotor Plates, Screens, Service Items, Shear Bar/Bedknife, Sprockets, Teeth, Wear Blocks,
Wear Strips.
TRACK: Base Plates, Boom Wear Items, Buckets, Cable Fingers, Conveyor Belts, Clutches, Cups, Digging Chain, Digging Rims,
Drums, End Idler, Flashings, Pins and Bushings, Pivot Rings, Plastic Wear Strips, Rooter Bands, Scraper Knives, Sprockets, Teeth,
Track Chain, Track Rollers, Trench Cleaner (Crumber), Trip Cleaners, Truck Rollers, Wear Plates.
TRENCHLESS: Brushes, Clamping Vise Parts, Dies, Drive Chuck, Earth Stakes, Fan Belts, Jaws, Leaf Chain, Lights On Light
Kits, Packing Assemblies, Rod, Rod Loader Parts, Rollers, Tooling, Track Chain, Track Guides, Track Idlers, Track Pads, Track
Sprockets, Valve Seats, Wear Bars, Wear Blocks, Water Hoses, Water Swivels, Wear Bars.
UTILITY PRODUCTS: Augers, Belts, Bearings, Booms, Brake Pads, Bucket, Bushings, Chains, Clutches, Conveyor Belts, End
Rollers, Flashings, Pins, Pivot Rings, Plow Blades, Rubber Shielding, Sprockets, Teeth, Tires, Track Chain, Track Idlers, Track
Sprockets, Trench Cleaner (Crumber).
PARTS WARRANTY:
Parts replaced in the warranty period will receive the balance of the first year New Industrial Equipment Limited Warranty, during
the first (12) months or 1000 hours, whichever comes first. Replacement parts after the original machine warranty, are warranted to
be free from defects of material for ninety (90) days or the part will be repaired or replaced, without labor coverage for removal and
reinstallation.
Introduction
EXCLUSIONS OF WARRANTIES: EXCEPT FOR THE WARRANTIES EXPRESSLY AND SPECIFICALLY MADE
HEREIN, VERMEER MAKES NO OTHER WARRANTIES, AND ANY POSSIBLE LIABILITY OF VERMEER
HEREINUNDER IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS, IMPLIED, OR STATUTORY, INCLUDING, BUT
NOT LIMITED TO, ANY WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
VERMEER RESERVES THE RIGHT TO MODIFY, ALTER AND IMPROVE ANY PRODUCT WITHOUT INCURRING ANY
OBLIGATION TO REPLACE ANY PRODUCT PREVIOUSLY SOLD WITH SUCH MODIFICATION. NO PERSON IS
AUTHORIZED TO GIVE ANY OTHER WARRANTY, OR TO ASSUME ANY ADDITIONAL OBLIGATION ON VERMEER’S
BEHALF.
NO DEALER WARRANTY. The selling dealer makes no warranty of its own and the dealer has no authority to make any
representation or promise on behalf of Vermeer or to modify the terms or limitations of this warranty in any way.
MANUFACTURED BY:
VERMEER CORPORATION
Pella, Iowa 50219 USA
Introduction
VERMEER EQUIPMENT EXTENDED LIMITED WARRANTY RIDER
BRUSH CHIPPER DRUM AND DRUM HOUSING
3,000 Hours / 3 Years*
(Parts only coverage during extended term)
VERMEER CORPORATION (hereinafter “Vermeer”) agrees to extend only the parts coverage of the applicable
Vermeer Industrial New Equipment Limited Warranty (the “Standard Limited Warranty”) for the Covered Components
of the Specified Models of New Vermeer Industrial Equipment for the Extended Term, provided that the Equipment is
operated and maintained in accordance with the directions and instructions set forth in the Operator’s and Maintenance
Manual(s). All conditions, exclusions, and limitations of the Standard Limited Warranty apply.
SPECIFIED MODEL:
BC1200XL, Serial Number 101 and above
COVERED COMPONENTS:
Drum housings, cutter drums, shafts, and ring fedder hubs (bearings
may be covered if required for drum replacement).
NON-COVERED COMPONENTS:
Bearings, knives, shear bar, and wear items (as specified on Vermeer
New Industrial Equipment Limited Warranty).
EXTENDED TERM*:
Three (3) full years from original retail sale date of the Equipment or
3,000 hours of machine operation, whichever occurs first. This warranty is
extended to the original purchaser and subsequent owners.
NOTE: Subject to future change Brush Chipper models introduced after August 1, 2006, will be covered as stated
in this warranty rider.
EXCEPT FOR THE STANDARD LIMITED WARRANTY AND THIS RIDER, VERMEER MAKES NO
OTHER WARRANTIES, AND ANY POSSIBLE LIABILITY OF VERMEER HEREUNDER IS IN LIEU OF
ALL OTHER WARRANTIES, EXPRESS, IMPLIED, OR STATUTORY, INCLUDING, BUT NOT LIMITED
TO, ANY WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
Introduction
Receiving and Delivery Report
DEALER 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 proper operation.
___
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.
Receiving and Delivery Report i
___
Check for loose hardware.
___
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.
ii Receiving and Delivery Report
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 Operation
Review and demonstrate with the customer the various aspects of brush chipper operation:
___
overall explanation of how the brush chipper works
___
brush chipper safety
___
preparing the brush chipper for operation
Receiving and Delivery Report iii
DEALER/CUSTOMER INFORMATION
dealer:
owner:
address:
address:
city:
city:
state / province:
state / province:
zip / postal code:
zip / postal code:
country:
country:
iv Receiving and Delivery Report
MACHINE IDENTIFICATION NUMBERS - RECORD
Machine Model Number_______________________
Machine Serial Number_______________________
MACHINE IDENTIFICATION DECAL
This decal provides easy identification of the model and 17-digit identification
number. The barcode contains the machine’s VIN number and can be scanned with
any barcode reading device.
Receiving and Delivery Report v
ENGINE IDENTIFICATION NUMBERS - RECORD
Engine Model Number________________________
Engine Serial Number________________________
Tier 3/Stage IIIA
Tier 4 Interim/Stage IIIB
vi Receiving and Delivery Report
Table of Contents
Receiving and Delivery Report . . . . . . . . . . . . . . . . . . . . .i
Dealer Prep . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Brush Chipper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Review of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Dealer/Customer Information. . . . . . . . . . . . . . . . . . . . . . . . . . . iv
Machine Identification Numbers - Record . . . . . . . . . . . . . . . . . v
Machine Identification Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . v
Engine Identification Numbers - Record . . . . . . . . . . . . . . . . . . vi
Safety Messages. . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Winch Controls - Left Side Controls Option
(BC1200XL Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-18
Jack Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20
Fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21
Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . 22-1
Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-1
Cold Weather Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-1
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-1
Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-2
Jump-Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-2
Battery Explosion - Avoid . . . . . . . . . . . . . . . . . . . . . . . . 22-2
Battery Burns - Avoid . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-3
Jump-Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . 22-3
Safety Symbol Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . 23-1
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1
Engine Monitors (Tier 3/Stage IIIA) . . . . . . . . . . . . . . . . . . . . 20-1
Engine Monitors (Tier 4 Interim/Stage IIIB) . . . . . . . . . . . . . . 20-2
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-4
Throttle/Cutter Engage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-5
Feed Roller Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-6
Droop Set Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-13
Park Brake (BC1200XL European Only) . . . . . . . . . . . . . . . 20-14
Wheel Chocks (BC1200XL European Only) . . . . . . . . . . . . 20-14
Discharge Chute Controls . . . . . . . . . . . . . . . . . . . . . . . . . . 20-15
Winch Controls (BC1200XL Only) . . . . . . . . . . . . . . . . . . . . 20-16
Stopping the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-1
Quick Stop Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 23-2
Transporting the Brush Chipper . . . . . . . . . . . . 30-1
Reporting Safety Defects . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1
Equipping the Towing Vehicle . . . . . . . . . . . . . . . . . . . . . . . . 30-1
Hitch Height - Adjust (BC1200XL Only) . . . . . . . . . . . . . . . . 30-2
Tongue Length - Adjust (BC1200XL Only) . . . . . . . . . . . . . . 30-3
Attach to Towing Vehicle (BC1200XL Only) . . . . . . . . . . . . . 30-4
Hitch - Pintle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-6
Attach to Towing Vehicle (BC1200XL European Only) . . . . . 30-7
Table of Contents vii
Breakaway on Hydraulic Surge Brake (Option) - Reset . . . . 30-8
Breakaway System - Reset Electric Brake . . . . . . . . . . . . . . 30-9
Machine - Clean Before Transporting. . . . . . . . . . . . . . . . . . 30-9
Prepare for Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10
Winch Line - Store (BC1200XL Only) . . . . . . . . . . . . . . . . . 30-11
Detach from Towing Vehicle. . . . . . . . . . . . . . . . . . . . . . . . 30-12
Preparing the Brush Chipper and Work Area . . 40-1
Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operator Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Personal Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sound Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Prepare the Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Prepare the Brush Chipper . . . . . . . . . . . . . . . . . . . . . . . . . .
Clean Flammable Materials from Machine . . . . . . . . . . .
Discharge Chute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Feed Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Feed Control Bars - Check . . . . . . . . . . . . . . . . . . . . . . .
40-1
40-1
40-2
40-3
40-3
40-4
40-5
40-6
40-9
40-9
Infeed System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10
Cutting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10
Chip Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-11
Feeding Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-11
Material Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-11
Plugs or Stalls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-12
Finishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-12
Operating the Optional Winch (BC1200XL Only). . . . . . . . .50-13
Winch Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-13
Line Pull and Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-13
Brush Chipper Preparation for Winching . . . . . . . . . . . 50-14
Winch Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-16
Winch Line and Choker - Repair/Replace . . . . . . . . . . . . . .50-23
Removing Plugs from the Brush Chipper . . . . . 51-1
Feed Roller - Unplug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51-3
Cutter Drum - Unplug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51-5
Discharge Chute - Clean Out . . . . . . . . . . . . . . . . . . . . . . . . .51-6
Operating the Brush Chipper . . . . . . . . . . . . . . . 50-1
Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . 60-1
Cutter Shaft - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-1
Cutter Drum - Engage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-1
Feed Roller Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-2
Upper Feed Control Bar . . . . . . . . . . . . . . . . . . . . . . . . . 50-3
Lower Feed Stop Bar and Side Feed Stop Bars . . . . . . . 50-3
Sensitivity Levels (BC1200XL Only) . . . . . . . . . . . . . . . . 50-4
Feed Roller - Engage . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-5
EcoIdle RPM Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7
Lower Feed Roller - Access Door . . . . . . . . . . . . . . . . . . 50-8
SmartFeed Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10
Safety Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-1
Maintenance Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-2
Hourmeter - Check for Maintenance Interval . . . . . . . . . . . . .60-2
Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-2
viii Table of Contents
Knife/Drum Maintenance . . . . . . . . . . . . . . . . . . 61-1
Knife Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61-2
Knife Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61-4
Bolt Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61-5
Knife Mount Surface Inspection . . . . . . . . . . . . . . . . . . . 61-6
Drum Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61-7
Knife Sharpening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61-8
Knife Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61-9
Engine Fault Codes (110/120-HP Engine). . . . . 62-1
Table of Contents ix
This page intentionally left blank.
Section 10: Safety Messages
General safety messages appear in this Safety Messages section. Specific safety messages are located in
appropriate sections of the manual where a potential hazard may occur if the instructions or procedures are not
followed.
A signal word “DANGER”, “WARNING”, or “CAUTION” is used with the safety alert symbol.
Safety signs with signal word “DANGER”, “WARNING”, or “CAUTION” are located near specific hazards.
DANGER
WARNING
CAUTION
Indicates a hazardous situation that, if not avoided, will result in death or serious injury.
Indicates a hazardous situation that, if not avoided, could result in death or serious injury.
Indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.
SAFETY SYMBOL EXPLANATION
This is the safety alert symbol. This symbol is used in combination with an exclamation mark or
other symbols to alert you to the potential for bodily injury or death.
WARNING: Read Operator’s Manual and safety signs, and watch the operations and safety
video, before operating machine.
Safety Messages 10-1
WARNING: Check machine before operating. Machine must be in good operating condition
and all safety equipment installed and functioning properly.
WARNING: Wear personal protective equipment. Wear close-fitting clothing and confine
long hair. Always wear a hard hat, safety glasses, and safety shoes. Refer to “Personal
Protection,” page 40-2.
WARNING: Keep spectators away.
WARNING: Engine exhaust can asphyxiate. Operate only outdoors.
10-2 Safety Messages
WARNING: Use Shutdown Procedure before servicing, cleaning, repairing or transporting
machine. Follow Shutdown Procedure, page 23-1.
WARNING: Pressurized fluid can penetrate body tissue and result in serious injury or death.
Leaks can be invisible. Keep away from any suspected leak. Relieve pressure in the hydraulic
system before searching for leaks, disconnecting hoses, or performing work on the system. If you
must pressurize the system to find a suspected leak, use an object such as a piece of wood or
cardboard rather than your hands. When loosening a fitting where some residual pressure may
exist, slowly loosen the fitting until oil begins to leak. Wait for leaking to stop before
disconnecting the fitting. Fluid injected under the skin must be removed immediately by a
surgeon familiar with this type of injury.
WARNING: Fuel and fumes can explode and burn.
Shut off engine before refueling. No flame. No smoking.
Safety Messages 10-3
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 those that follow within this manual, could
result in serious injury or death. This machine is to be used only for those purposes for which it was intended as
explained in this Operator’s Manual.
10-4 Safety Messages
Section 20: Controls
ENGINE MONITORS (TIER 3/STAGE IIIA)
(1)
(2)
Fuel Gauge
Gauge indicates how much fuel is in the tank.
Engine Display
B
A
1
Display can be set to show multiple items at once or one item.
Engine display shows the following machine parameters, with others parameters
available for display as customized by the operator:
Displayed
• Tachometer
• Engine Hours
• Battery Voltage
• Engine Oil Pressure
• Engine Coolant Temperature
(3)
Available
• Fuel Pressure
• Fuel Temperature
• Engine Boost
• Engine Intake Temperature
• Engine Coolant Level
2
3
110-HP (OPTION)
(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.
Wait-to-Start Light
White light turns off when ignition is “ON” and engine is ready to start.
Controls 20-1
ENGINE MONITORS (TIER 4 INTERIM/STAGE IIIB)
(1)
(2)
Fuel Gauge
Gauge indicates how much fuel is in the tank.
Engine Display
1
A
B
2
Display can be set to show multiple items at once or one item.
Engine display shows the following machine parameters, with others parameters
available for display as customized by the operator:
Displayed
• Tachometer
• Engine Hours
• Battery Voltage
• Engine Oil Pressure
• Engine Coolant Temperature
Available
• Fuel Pressure
• Fuel Temperature
• Engine Boost
• Engine Intake Temperature
• Engine Coolant Level
120-HP ENGINE (OPTION)
(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.
20-2 Controls
(3)
EcoIdle Switch
Push up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EcoIdle on
Engine speed drops from high RPM to 1400 rpm when there has been
no material chipped for 5 minutes.
3
Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EcoIdle off
Push down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EcoIdle on
Engine 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.
Controls 20-3
IGNITION SWITCH
(1)
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vertical position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . engine off
1st position clockwise . . . . . . . . . . . . . . . . . . . . . . preheat/engine on
1
2nd position clockwise . . . . . . . . . . . . . . . . . . . . . . . . . . engine start
1
20-4 Controls
THROTTLE/CUTTER ENGAGE
(1)
Throttle Lever/Clutch Engage
C
(A)
Down position . . . . . . . . . . . . . . . . . . . . . . . . . . disengaged, low RPM
(B)
Up, toward operator (chipping position) . . . . . . engaged, high RPM
B
A
(C)
Up, away from operator/toward machine . . . . . . engaged, low RPM
1
B
C
A
1
LEFT SIDE CONTROLS (OPTION)
Controls 20-5
FEED ROLLER CONTROLS
(1)
Upper Feed Control Bar
BC1200XL
Rear position . . . . . . . . . . . . . . . . . . . . feed roller emergency STOP
1
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.
20-6 Controls
BC1200XL
EUROPEAN
1
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.
Controls 20-7
(2) Lower Feed Stop Bar
Bar pressed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . feed roller stops
1
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).
2
BC1200XL
EUROPEAN
1
3
3
2
20-8 Controls
Feed roller will automatically restart when engine speed increases to a preset speed.
(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.
4
(5) Lower Feed Stop Bar Sensitivity Switch (BC1200XL)
Press top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Normal sensitivity
Feed roller stops when stop bar is pushed a shorter distance.
Press bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reduced sensitivity
Feed roller stops when stop bar is pushed a farther distance
NOTE: Each time engine key is turned OFF, the Lower Feed Stop Bar system
defaults to the “Normal Sensitivity” selection.
5
Controls 20-9
(6) Rear Warning Light - Center
BC1200XL Only:
Normal sensitivity setting selected . . . . . . . . . . . . . warning light off
Reduced sensitivity setting selected . . . . . . . . . . . . . warning light on
BC1200XL
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.
6
NOTE: When the Rear Warning Light flashes quickly, the Hold-toRun Button (4) must be pushed to reset stop system and stop
warning light from flashing.
BC1200XL
EUROPEAN
6
4
20-10 Controls
(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)
7
Feed Roller Down Pressure Knob
Clockwise . . . . . . . . . . . . . . . . . . increase feed roller down pressure
Counterclockwise . . . . . . . . . . . . decrease feed roller down pressure
8
Controls 20-11
(9)
Feed Roller Lock Bar
Fully 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.
9
Raise feed roller, remove bar, and store as shown (photo below)
before resuming operation.
A
20-12 Controls
Droop Set Switch
With SmartFeed control operation, the feed roller will stop and reverse feeding
material when the engine RPM drops below a preset speed, referred to as droop speed.
Feed roller will automatically restart when engine speed increases to a preset speed.
Droop speed can be adjusted to high, medium or low speed using Droop Set Switch (1).
Press bottom . . . . . . . . . . . . . . . . . . . . . . . . .low speed droop (brush)
Center . . . . . . . . . . . . . . . . . . . . . medium speed droop (small limbs)
1
Press top . . . . . . . . . . . . .high speed droop (large limbs and trunks)
Controls 20-13
PARK BRAKE (BC1200XL EUROPEAN ONLY)
(1)
Park Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Push back while facing forward . . . . . . . . . . . . . engage park brake
1
Pull forward to release lever . . . . . . . . . . . . . . disengage park brake
WHEEL CHOCKS (BC1200XL
EUROPEAN 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.
20-14 Controls
1
2
One on each side
DISCHARGE CHUTE CONTROLS
(1)
Chute Rotation Handles
Push handles clockwise
chute rotates left
Push handles counterclockwise . . . . . . . . . . . . . . . . . . . chute rotates right
(2)
Transport Lock Pin
Center lever and release lock pin so pin engages hole . . . . . . . . . . . . locked
Pull down and rotate lever to disengage lock pin from hole unlocked
(3)
Chute Deflector
Controls the distance chipped material is discharged.
1
2
Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .farther
Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .closer
(4)
Chute Deflector Lock - Standard
Loosen to change deflector position.
(5)
Chute Deflector Lock - Deluxe (Option)
Pull down and rotate to change deflector position.
3
4
5
Controls 20-15
WINCH CONTROLS (BC1200XL ONLY)
(1)
Winch/Upper Feed Control Bar
Bar in center STOP or FORWARD . . . . . required to operate winch
3
Feed rollers will not operate while winch is engaged unless the Holdto-Run button (A) has been pushed.
(2)
A
Winch Interlock Hook
Slide hook up:
(attach rope loop and pull with winch). . . . . . . . . . winch locked out
1
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.
20-16 Controls
2
(3)
Winch Engage/Disengage Lever
Rotate lever up . . . . . . . . . . . . . . . . . . . . . . . . . . . winch ENGAGED
3
Rotate lever down . . . . . . . . . . . . . . . . . . . . . . winch DISENGAGED
Allows winch line to be manually pulled off winch drum.
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
the 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 line
IMPORTANT: Maintain light tension on winch line when retracting,
to create smooth wrapping onto winch drum.
(5)
4
Rear Warning Light - Side
Amber lights are located on both sides of winch mounting frame.
Normal sensitivity setting selected . . . . . . . . . . . . warning light off
Reduced sensitivity setting selected. . . . . . . . . . . . warning light on
Light flashes quickly when feed rollers need to be restarted after pressing Lower
Feed Stop Bar, or pulling Upper Feed Control Bar.
5
NOTE: When the Rear Warning Light flashes quickly, the Hold-to-Run Button must
be pushed to reset stop system and stop warning light from flashing.
Controls 20-17
WINCH CONTROLS - LEFT SIDE CONTROLS OPTION (BC1200XL
ONLY)
(1)
1
Winch/Upper Feed Control Bar
Bar in center STOP or FORWARD . . . . . required to operate winch
3
Feed rollers will not operate while winch is engaged unless the
Hold-to-Run button (A) has been pushed.
(2)
A
Winch Interlock Hook
Slide 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.
20-18 Controls
2
(3)
Winch Engage/Disengage Lever
Rotate lever up . . . . . . . . . . . . . . . . . . . . . . . . . . . . winch ENGAGED
5
Rotate lever down . . . . . . . . . . . . . . . . . . . . . .winch DISENGAGED
Allows winch line to be manually pulled off winch drum.
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
the ENGAGED position, jog Retract/Extend Lever (4) until it does.
(4)
3
Winch Retract/Extend Lever - With winch engaged:
Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . retract winch line
Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . extend winch line
IMPORTANT: Maintain light tension on winch line when retracting,
to create smooth wrapping onto winch drum.
(5)
Rear Warning Light - Side
Amber lights are located on both sides of winch mounting frame.
Normal sensitivity setting selected. . . . . . . . . . . . . warning light off
Reduced sensitivity setting selected . . . . . . . . . . . . warning light on
4
Light flashes quickly when feed rollers need to be restarted after pressing Lower
Feed Stop Bar, or pulling Upper Feed Control Bar.
NOTE: When the Rear Warning Light flashes quickly, the Hold-to-Run Button must
be pushed to reset stop system and stop warning light from flashing.
Controls 20-19
JACK CONTROLS
(1)
Jack Handle
Clockwise. . . . . . . . . . . . . . . . . extend jack
Counterclockwise . . . . . . . . . . retract jack
(2)
Transport Storage Position
(3)
Lock Pin
Secure jack to tongue in either transport
position or when machine is not attached
to tow vehicle.
(4)
1
3
2
Rear Jack Transport Storage Position
(BC1200XL EURO Only)
4
20-20 Controls
FUSES
Fuses protect machine electrical circuits. Fuse box (1) is located in the engine
compartment, behind control panel. Fuse circuits are listed below and on the
decal on back side of control panel.
Relay
Forward Feed Solenoid
Reverse Feed Solenoid
Fuses
F1 - empty
F2 - 10A - Infeed
F3 - 10A - Feed Rollers
F4 - 5A - for future use
F5 - empty
F6 - empty
F7 - 30A - Engine Controller
F8 - 2A - Engine Diagnostics
F9 - 10A - SmartFeed Controller
F10 - empty
1
Controls 20-21
Section 22: Starting Procedure
STARTING THE ENGINE
Step 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) turns
off, turn key fully clockwise to start the engine. Release key once the engine
starts.
120-HP Engine (Option): After the wait to start turns off in display panel
(1), turn key fully clockwise to start the engine. Release key once the
engine starts.
1
110-HP Engine
1
IMPORTANT: Never run the starter motor for more than 30 seconds at a time. Allow
starter motor to cool 1 minute between attempts.
Step 5:
Allow engine to warm up for 3–5 minutes before engaging the cutter.
IMPORTANT: Do not idle engine for more than 10 minutes. The resulting low
temperatures in the combustion chamber will not allow fuel to burn completely and
can cause engine damage.
COLD WEATHER STARTING
120-HP Engine
Engine
Before operating in cold weather (below 32°F (0°C)), refer to the Engine Operation Manual for recommended
engine oil, fuel, and starting procedures.
Starting Procedure 22-1
Hydraulic Fluid
In cold weather, take more time to warm up the hydraulic fluid. After the engine is warm, let it run for a
minimum 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
WARNING: Battery fumes are flammable and can explode. Keep all burning materials away
from battery. Battery explosion can blind. Acid can blind and burn. Tools and cable clamps
can make sparks.
Do not smoke. Shield eyes and face. Read instructions.
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. Vehicles in contact have a
ground connection which allows a spark to occur at the battery when the positive jumper cable is connected or
removed. If equipped with battery caps, they must be in place and tight to reduce risk of battery explosion.
IMPORTANT: Use only a 12-volt system for jump-starting. Do not allow vehicles to touch.
22-2 Starting Procedure
Battery Burns - Avoid
Battery contains sulfuric acid which can cause severe burns. Avoid contact with eyes, skin, and clothing.
In case of acid contact:
External: Flush with plenty of water. If eyes have been exposed, flush with water for 15 minutes and get
prompt medical attention.
Internal: Drink large quantities of water or milk, follow with milk of magnesia, beaten egg, or vegetable oil.
Call a physician immediately.
Jump-Starting Procedure
Pb
WARNING: Battery post, terminals, and related accessories contain lead and lead
compounds, chemicals known to the state of California to cause cancer and reproductive
harm.
Wash hands after handling.
Starting Procedure 22-3
IMPORTANT: Review battery service safety
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:
TO ENGINE
STARTER
TO FRAME
MACHINE
BATTERY
CONNECT
TO FRAME
FOR GROUND
JUMPER
CABLES
a. Red to discharged battery POSITIVE (+)
terminal.
f. Red to booster battery POSITIVE (+)
terminal.
g. Black to booster battery NEGATIVE (-)
terminal.
BOOSTER
BATTERY
h. Black to frame of machine with the
discharged battery. Make connection away from battery, hydraulic lines, and moving parts.
NOTE: To avoid sparks near the battery, always disconnect black jumper cable from the booster battery before
making 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 positive cable clamp on the
battery.
22-4 Starting Procedure
Section 23: Shutdown Procedure
STOPPING THE MACHINE
IMPORTANT: For your safety and the safety of others, use the shutdown procedure before working on the
machine for any reason, including servicing, cleaning, unclogging, inspecting, or transporting the chipper.
A variation of this procedure may be used if so instructed within this manual, or if an emergency requires it.
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 position.
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) on left
side of cutter wheel housing.
IMPORTANT: The cutter drum will continue to turn for a short time after the engine
has stopped.
Step 7:
Remove ignition key.
Step 8:
Close and latch feed table.
1
Shutdown Procedure 23-1
Quick Stop 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.
23-2 Shutdown Procedure
To Stop Drum Quickly
Shut Off Engine With Clutch Engaged
Section 30: Transporting the Brush Chipper
REPORTING SAFETY DEFECTS
For Brush Chippers within the United States:
If you believe that your vehicle BC1200XL has a defect which could cause a crash or could cause injury or death,
you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to
notifying Vermeer Corporation.
If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in
a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in
individual problems between you, your dealer or Vermeer Corporation. To contact NHTSA, you may either call
the DOT Auto Safety Hotline toll-free at 1-888-DASH-2DOT (1-888-327-4236), or file a report on-line at:
www.nhtsa.dot.gov/hotline/, or write to: NHTSA, U.S. Department of Transportation, 400 - 7th St. SW,
Washington, D.C. 20590. You can also obtain other information about motor vehicle safety from the Hotline.
For Brush Chippers outside the United States:
Contact your local governmental road regulation authority or contact Product Safety Department, Vermeer
Corporation; Email: productsafety@vermeer.com; Telephone: 641.628.3141; Toll Free: 800.829.0051
EQUIPPING THE TOWING VEHICLE
IMPORTANT: (BC1200XL Only) The towing vehicle must be equipped with a brake controller that
automatically applies the towed machine's electric brakes.
(BC1200XL Only) Do not use a brake controller that is purely a manually operated controller. If your towing
vehicle is equipped with a manually operated controller, remove it and install one that can be applied both
automatically and manually.
It is recommended that the towing vehicle be equipped with mud flaps to reduce damage to the front of the
towed machine from road debris.
Transporting the Brush Chipper 30-1
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).
30-2 Transporting the Brush Chipper
1
TONGUE LENGTH - ADJUST (BC1200XL ONLY)
The tongue can be lengthened or shortened to fit the towing vehicle. There are two positions that allow a 16" (42
cm) total variation in tongue length.
NOTE: The wire harness is tied to the frame and the cable ties may need to be cut to allow tongue to be extended
to its longer length.
Use the following steps to adjust the tongue length.
WARNING: Overextending tongue will allow only one bolt to engage both inner and outer tubes. Damage to
tongue and separation of tongue possible. Maximum exposed inner tube length is 41" (104 cm).
NOTE: Tongue is adjusted most easily with hitch detached from towing vehicle.
Step 1:
Support machine with the jack.
Step 2:
Remove two tongue adjustment bolts (1). Second bolt is located beneath shielding
on inner side of frame.
Step 3:
Slide tongue to the new set of holes in tongue. Align holes in tongue with holes in
frame.
1
WARNING: A single tongue bolt could fail, allowing the chipper to separate from
the tow vehicle. Always install and secure both bolts after adjusting tongue length.
Step 4:
Insert both tongue adjustment bolts and secure with nuts, torque to specification.
ATTACH TO TOWING VEHICLE (BC1200XL ONLY)
WARNING: Safety towing chains may uncouple from towing vehicle if chain hook latches are damaged or
missing. Do not tow vehicle with damaged or missing hook latches.
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:
2
1
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.
3
To adjust chain length:
7
a. Remove bolt (4).
5
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 vehicle
bumper or frame.
Step 4:
If equipped with optional hydraulic surge brake chain/hook, connect to
towing vehicle.
IMPORTANT: The breakaway cable length should be adjusted so the breakaway
system applies the brakes only after both the hitch and the safety towing chains
have disconnected.
Step 5:
6
4
8
Attach electrical connector (8) to the towing vehicle. Check that highway
lights and electric brakes are functioning properly.
IMPORTANT: Inspect each safety chain slip hook latch
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:
SPRINGLOADED
LATCH
SLIP
HOOK
Fully raise jack (9), rotate 90° and secure to
tongue with attachment pin.
9
Hitch - Pintle
Step 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).
2
1
4
3
ATTACH TO TOWING VEHICLE (BC1200XL
EUROPEAN ONLY)
Step 1:
3
4
Attach to vehicle hitch.
a. Squeeze on bottom side of handle (1) and lift to unlock
the hitch.
2
1
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.
5
FRONT JACK
5
REAR JACK
BREAKAWAY ON HYDRAULIC SURGE BRAKE
(OPTION) - RESET
Step 1:
Pry apart spring clips (1).
Step 2:
Return lever (2) to reset position.
2
1
BREAKAWAY SYSTEM RESET ELECTRIC BRAKE
5
2
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
4
3
1
IMPORTANT: Machine controls and electrical/electronic devices are not rated to withstand high pressure water
and temperature power washers. Water intrusion will likely cause malfunction or damage to any devices hit
directly by the water spray. Keep pressure washer stream away from machine controls and electrical/electronic
devices. Compressed air can also push moisture through some connector and component seals. Do not point air
nozzle directly at seal areas.
Ensure feed table is empty. Clean machine to keep debris off road and from striking other vehicles during
transport.
PREPARE FOR TRANSPORT
Step 1:
Fold up feed table (1) and secure latch (2).
Step 2:
Rotate discharge chute (3) forward.
BC1200XL
3
2
1
BC1200XL
European
3
2
1
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) above the feed
table as shown.
Step 4:
Using the Winch Retract/Extend Lever, retract winch line until the hook slides
back and locks. Leave the line taut.
Step 5:
Follow Shutdown Procedure, page 23-1.
Step 6:
Place separate chain choker in machine toolbox.
1
2
NOTE: Winch line must be in stored position for transporting and to operate machine in
chipping mode.
2
DETACH FROM TOWING VEHICLE
Park 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.
1
NOTE: If operating the BC1200XL European while unhitched from tow
vehicle, both front and rear jacks must be used.
2
3
Section 40: Preparing the Brush Chipper and Work Area
INTENDED USE
The Vermeer BC1200XL and BC1200XL European Brush Chippers are designed solely for use in chipping
organic material such as wood, bark, limbs, brush, and undergrowth.
Always use the machine in accordance with the instructions contained in this Operator's Manual, safety signs
on the machine, and other material provided by Vermeer Corporation.
Proper maintenance and repair is essential for safety, and for efficient operation of the machine. Do not use the
machine if it is not in suitable operating condition.
OPERATOR QUALIFICATIONS
WARNING: Read Operator’s Manual and safety signs, and watch the operations and
safety video, before operating machine.
Allow only responsible, properly instructed individuals to operate machine.
Become familiar with the controls, operation and use of the machine under the supervision of a trained and
experienced operator.
The operator must be familiar with the workplace’s safety rules and regulations, and must be mentally and
physically capable of operating the machine safely.
Preparing the Brush Chipper and Work Area 40-1
PERSONAL PROTECTION
WARNING: Wear personal protective equipment. Wear close-fitting clothing and
confine long hair. Avoid jewelry, such as rings, wristwatches, necklaces, or bracelets.
Operating the machine will require you to wear protective equipment. You should always wear a hard hat,
safety shoes, loose-fitting gloves with narrow cuffs (gauntlet-type gloves with wide cuffs are not permitted),
hearing protectors, and eye protection. If working near traffic, wear reflective clothing.
Hearing protection is recommended when operating the machine. Hearing protection devices provide differing
levels of sound reduction. It is important to select a device that is adequate and appropriate for your specific
work environment. Actual sound levels may vary widely, depending on your working conditions. To determine
the level of hearing protection your work environment requires, enlist the help of your local environmental noise
specialist.
Eye protection must consist of wraparound safety glasses or goggles.
Other workers in immediate area must also wear the above listed required protective equipment.
Wear close-fitting clothing and confine long hair.
Avoid wearing jewelry, such as rings, wristwatches, necklaces, or bracelets.
40-2 Preparing the Brush Chipper and Work Area
SOUND LEVELS
The following sound levels are determined while chipping wood according to test procedures specified in
EN 13525.
Equivalent Continuous A-Weighted Sound Pressure Level
at Operator’s Ear (per ISO 11201) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 dB(A)
Guaranteed Sound Power Level (per 2000/14/EC, ISO 3744) . . . . . . . . . . . . . . . . . . . . . . . . . 124 dB(A)
NOTE: The stated sound levels are representative for a given operating condition. Operating conditions may
vary at each jobsite. The actual sound levels for your application and operating conditions may be different.
PREPARE THE AREA
WARNING: Keep all spectators and other workers away from the machine and work area
while in operation.
PREPARE THE BRUSH CHIPPER
WARNING: Check machine before operating. Machine must be in good operating condition
and all safety equipment installed and functioning properly.
•
Survey area around the machine for persons or obstacles before positioning machine on the jobsite.
•
Set up machine in an area free of obstructions that could interfere with the safe and efficient movement of
the 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) above ground when feeding
material.
•
During typical operation, the brush chipper must stay hitched to the towing vehicle.
•
•
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 pedestrian traffic. Use all necessary
signs, cones, and flag persons needed for the work situation.
Clean Flammable Materials from Machine
IMPORTANT: Machine controls and electrical/electronic devices are not rated to withstand high pressure water
and temperature power washers. Water intrusion will likely cause malfunction or damage to any devices hit
directly by the water spray. Keep pressure washer stream away from machine controls and electrical/electronic
devices. Compressed air can also push moisture through some connector and component seals. Do not point air
nozzle directly at seal areas.
Prevent fires by keeping engine compartment, battery, hydraulic lines, and fuel tank clean of accumulated
trash, grease, and debris.
Discharge Chute
WARNING: Thrown objects can blind you.
Keep everyone away from discharge area while cutter drum is turning. Direct discharge
chute away from people. Wear eye protection.
Step 1:
Pull down and rotate transport lock pin (3).
Step 2:
Rotate discharge chute (1) to the direction you want to deposit the chipped
material by moving the rotation handles (2) in that direction.
Step 3:
Engage lock pin (3).
1
2
3
NOTE: The discharge chute is equipped with a stop to prevent discharging material over
the feed table area. The discharge chute can be rotated 270° to direct the chips to the
desired position.
OPERATOR
AREA
WHEN
FEEDING BRUSH
CHIP
DISCHARGE
AREA
NOTE: If unable to reach the deflector or lock handle, position discharge chute over right
fender, and use step (4) on right front of frame.
4
Step 4:
•
To adjust discharge distance, raise or lower discharge chute deflector (5).
Standard deflector
Loosen locking handle (6). Adjust deflector height, tighten locking handle to
secure the adjusted deflector.
• Deluxe deflector (option)
Pull down on spring-loaded handle (7) to adjust deflector height.
5
6
7
Feed Table
BC1200XL
Unlatch 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.
2
Feed Control Bars - Check
The 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.
1
3
BC1200XL
European
2
1
4
3
Section 50: Operating the Brush Chipper
CUTTER SHAFT - CHECK
Start engine. Refer to Starting Procedure, page 22-1. Check cutter drum shaft end (1)
to see that the cutter drum does not turn while the Cutter Engage/Throttle Lever is in
the DISENGAGED/LOW RPM position. If rotation occurs, adjustment is necessary.
Refer to the Maintenance Manual, 50 Service Hours section for instructions.
1
CUTTER DRUM - ENGAGE
After engine has warmed up, grip Cutter Engage/
Throttle Lever (1) firmly and move it slowly to the
ENGAGED/HIGH RPM position.
1
1
Operating the Brush Chipper 50-1
FEED ROLLER OPERATION
DANGER: Limbs can snag clothing. Rollers or blades can grab and pull you in faster than you can let go
of limb. Cutting injury or death will result.
Feed material only from side of feed table.
Never climb onto feed table.
Feed base of limb or branch first.
Use wood object to push short material.
Wear gloves with narrow tight-fitting cuffs.
Keep away from rotating feed rollers and
blades.
WARNING: Feed roller may start unexpectedly with a small increase in engine speed. Place
Upper Feed Control Bar in Center Stop and stop engine before working on or near feed roller
for any reason including cleaning, servicing and unclogging feed intake area.
With SmartFeed control operation, the feed roller will stop feeding material when engine RPM drops below
preset speeds, and will automatically restart when engine speed increases.
50-2 Operating the Brush Chipper
Upper Feed Control Bar
The Upper Feed Control Bar (1) provides a means for the operator to quickly stop feed
rollers as well as selecting forward or reverse operation.
Lower Feed Stop Bar and Side Feed Stop Bars
1
The Lower Feed Stop Bar system (2) and Side Feed Stop Bars (3) (BC1200XL European
only) provides a means for the operator to quickly stop the feed rollers if snagged by a
branch and pulled toward the machine. This system is intended for your safety and must
be maintained in good operating condition. Do not operate the machine if the Lower Feed
Stop Bar or Side Feed Stop Bars are not functioning properly.
Stopping the feed rollers is accomplished by bumping the Lower Feed Stop Bar (2) or the
Side Feed Stop Bars (3). The Feed Stop Bars are strategically located to make it possible
for 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 bars, the
feed will not stop. It is therefore very important to follow all safety instructions for
feeding material into the chipper.
BC1200XL
2
IMPORTANT: Proper operation of the Upper Feed Control Bar, Lower Feed Stop Bar and
Side Feed Stop Bars (BC1200XL European) should be checked every 10 hours of
operation or daily. Refer to the Maintenance Manual for adjustment instructions.
3
2
BC1200XL European
Sensitivity Levels (BC1200XL ONLY)
The Lower Feed Stop Bar has two levels of sensitivity. When the NORMAL setting (top
of the Sensitivity Switch) is selected (3), the stop bar is depressed a shorter distance
before 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.
3
The amber warning lights located on the rear of the machine (5), and on the sides of
optional winch assembly (6), turn on when the REDUCED setting of the Sensitivity
Switch is selected.
Each time the engine key is turned OFF, the lower feed stop bar system defaults to the
NORMAL setting.
4
6
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 emergency.
Use NORMAL sensitivity setting whenever jobsite conditions permit. If the size and
shape of limbs cause branches to strike the bar, resulting in an unacceptable frequency
of feed stops, REDUCED sensitivity setting may be temporarily selected when these
difficult conditions have passed, select the NORMAL setting to continue chipping.
5
Feed Roller - Engage
Start 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 Stop Bar
and Side Feed Stop Bars to be ignored for one second.
Holding it causes feed rollers to operate for up to 30 seconds regardless of
position of Upper Feed Control Bar, Lower Feed Stop Bar and Side Feed Stop
Bars (European). After 30 seconds, feed rollers stop, and can be reset by
releasing the Hold-to-Run Button and pressing it again.
1
3
IMPORTANT: When Hold-to-Run Button is released:
•
Feed rollers stop if either bar is in the STOP position.
•
Feed rollers run if both bars are in the RUN position.
3
If material continues to strike the bar and stop the feed roller, trim or shorten material before
feeding it into the chipper.
NOTE: Each time the engine key is turned ON, the rear warning lights (3) flash quickly, and
Hold-to-Run Button (2) must be pushed to start feed rollers.
2
NOTE: Engine throttle must be set at HIGH RPM before feed rollers will start.
SHOWN
EcoIdle RPM Control
The 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.
1
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 Door
Bottom of lower feed roller is enclosed in a housing with a bottom access door (1) to allow
for cleaning and removing build-up around the feed roller. Refer to Feed Roller - Unplug,
page 51-3.
1
WARNING: Rotating feed roller above cover will cut off fingers and toes.
Stay away from rotating feed roller.
+
=
Stop feed roller, stop engine and remove key before approaching the feed roller.
Normal operation of the brush chipper is with bottom access door closed.
However, under certain conditions such as material covered with dirt, mud or
ice 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 carried
through the chipper. Shut machine down before opening or closing the bottom
access door. Follow Shutdown Procedure, page 23-1. Stay away from rotating
feed roller if bottom access door is open.
2
SMARTFEED OPERATION
SmartFeed monitors and automatically controls various machine functions to maintain optimum engine
performance. Its primary function is to control the infeed and cutting systems when they are heavily loaded.
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 Stop Bars and Upper Feed
Control Bar.
Infeed System
When the feed rollers are overloaded or stall, SmartFeed automatically starts a sequence that reverses the feed rollers for a short
time, then resumes forward feeding. The sequence occurs up to five times, or until material begins feeding. The length of time the
feed rollers are reversed starts at 1/2 second and increases slightly each time. If the material does not feed after five tries, the
whole 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 again
once engine speed recovers. This sequence may occur several times before the
material completely passes through the machine. The RPM setting depends on which
of three positions the Droop Set Switch (1) is set. Refer to Droop Set Switch, page 2013.
1
CHIP MATERIAL
WARNING: Check material being chipped. Avoid stones, wire, or other objects
which may damage the knives and become dangerous projectiles.
Feeding Tips
•
If feeding material by hand, always feed from the side of the infeed chute; never
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 curbside.
•
If feeding brushy material that frequently catches on Lower Feed Stop Bar and stops
the feed rollers, change sensitivity setting to REDUCED SENSITIVITY. (BC1200XL
only)
•
Sometimes during feeding, a limb will suddenly turn or move sideways and may strike
you. To reduce the possibility of being struck, release the limb immediately after it
begins 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 shorten the log to aid feeding it into the
chipper.
Plugs or Stalls
•
Discharge chute, cutter drum, or feed roller may become plugged during operation. Refer to Removing Plugs
from the Brush Chipper, page 51-1.
•
If the engine stalls while chipping, disengage cutter drum before restarting engine.
•
Start engine and, before engaging cutter drum, reverse feed rollers to remove the material that caused the
stall.
Finishing
•
Chipped material that accumulates in the infeed chute can be pulled into the machine by feeding in
a piece of brush, or by pushing it in with a long limb. Never push chipped material with hands,
feet, rake, shovel, or any other object.
•
Shut down machine when the chipping operation is complete. Follow Shutdown Procedure, page 231.
OPERATING THE OPTIONAL WINCH (BC1200XL ONLY)
Winch Capacity
2
The intended use of the winch is to assist the operator in pulling large tree limbs or
trunks to the brush chipper feed rollers without having to lift and carry. The winch can
handle material up to 12" (30 cm) in diameter.
The line assembly includes a 150 ft (46 m), 7/16" line double-braided Spectra® core
with a polyester jacket (1) and a separate chain choker (2). The recommended drum
storage capacity is 150 ft (46 m). This conforms to SAE J706 using a wireline
compensation factor, K = 0.8.
1
Line Pull and Speed
The line pull and speed of the winch vary based on the number of line layers on the drum, where one layer
equals one row of wraps covering the drum surface. The chart shows rated line pull and line speed, established
in 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
3
1609 lb/730 kg
4
1413 lb/641 kg
5
1217 lb/552 kg
WARNING: Never exceed the rated winch capacity of 2000 lb (900 kg). Winch line may break or suddenly
release while pulling. Serious injury or death may occur if struck. Do not use towing vehicle pulling power to
increase the pulling capacity of winch.
Brush Chipper Preparation for Winching
WARNING: Never operate winch with brush chipper detached from towing vehicle. Load may move brush
chipper or pull tongue off of support blocking.
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.
1
2
Step 6:
Unhook rope loop from interlock
hook (3) above feed table.
4
1
3
NOTE: When winch is enabled, the amber
rear warning lights (4) will flash quickly.
Step 7:
Remove chain choker from storage
box (5).
2
4
5
Winch Operation
Winching limbs to the brush chipper is possible with one operator but works best with two persons, one to
operate the winch controls, and one working the winch line and chain choker.
WARNING: Brush can snag winch line. Knives can grab and pull in line and anything
attached to it at high speed. Death or serious injury possible.
Do not allow winch line to be snagged and pulled into chipper knives.
WARNING: Chain choker struck by chipper knives will result in serious damage to machine and choker.
Metal can be ejected from infeed chute at high speed. Death or serious injury possible.
WARNING: Choker pulled in at high speed can kill.
Keep choker and winch line separate when pulling out line.
WARNING: Winch line pulled in at high speed can seriously injure you.
Never pull out winch line while material is feeding.
WARNING: Winch line can pull you into machine at high speed. Death or serious injury
possible.
Never put winch line loop over arm or hand.
WARNING: Limbs attached to winch line can be pulled in at high speed. Death or serious
injury possible.
Never attach winch line to installed choker if other limbs are feeding into machine.
Step 1:
Refer to Starting Procedure, page 22-1.
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.
1
1
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.
Step 4:
Securely attach choker chain to limb by passing end of chain around limb and through ring as shown
(2). Pull end of chain to tighten on limb, and then attach winch line loop (3) to end of chain.
IMPORTANT: Never attach the winch line to a choker that is connected to a limb while
material is feeding into the chipper.
3
2
NOTE: For larger limbs, attach chain near large end of limb.
WARNING: Winch line can break or release. Serious injury or
death is possible.
7000B-095
Stay clear when winching.
Step 5:
Push Winch Engage/Disengage Lever (1)
up to engage winch clutch.
1
4
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.
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.)
1
4
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.
WARNING: Unstable limb may fall off feed table. Serious injury may occur if struck. Stabilize limb on
feed table before repositioning chain.
Step 8:
Use Winch Retract/Extend Lever (4) to extend winch line to allow chain choker to slacken.
Step 9:
Remove winch line from choker and reposition choker farther back on limb. Further extend winch line
and re-attach loop to end of choker.
Step 10: Retract winch line to move limb forward
until it reaches feed rollers.
4
4
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).
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.
6
6
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.
7
5
7
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.
WINCH LINE AND CHOKER - REPAIR/REPLACE
1.
Always use a winch line approved by Vermeer Corporation for your brush
chipper winch.
2.
If winch line loop is repaired by a qualified rigger, original loop size of 10" (25
cm) must be maintained as shown (1).
3.
Always use a removable choker assembly approved by Vermeer Corporation.
Never permanently attach metal or heavy objects to loop end of winch line.
4.
If your original chain choker is worn, damaged, or lost, replace it immediately
from your authorized Vermeer dealer.
1
Section 51: Removing Plugs from the Brush Chipper
DANGER: Limbs can snag clothing. Rollers or blades can grab and pull you in faster than
you can let go of limb. Cutting injury or death will result.
Never climb onto feed table.
Use wood object to push short material.
Keep away from rotating feed rollers and blades.
Removing Plugs from the Brush Chipper 51-1
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.
51-2 Removing Plugs from the Brush Chipper
FEED ROLLER - UNPLUG
If the upper feed roller becomes plugged, reverse it using the Upper Feed Control Bar.
Inspect dislodged material, ensuring it is not too large or has branches that prevent it from
being fed into the machine. If reversing the feed roller does not dislodge the plug:
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 that cutter drum
rotation has stopped by looking to see if drum shaft end (1) has stopped.
Step 3:
1
Use Feed Roller Raise Lever to raise feed roller and install feed roller lock bar (2)
onto lift cylinder as shown.
WARNING: Raised feed roller can fall if not supported properly.
Crushing injury or death possible. Install feed roller lock bar
before working near raised feed roller.
Step 4:
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 storage tab.
Step 7:
Operate machine without chipping additional material to blow out chips
remaining in the chipper housing.
2
If the lower feed roller becomes plugged, reverse it using the Upper Feed Control Bar.
Follow Shutdown Procedure, page 23-1. Remove any dislodged material or contamination
that is preventing the lower feed roller from rotating.
WARNING: Rotating feed roller above cover will cut
off fingers and toes.
Stay away from rotating feed roller.
3
+
=
Stop feed roller, stop engine and remove key before
approaching the feed roller.
If required, access the bottom of the lower feed roller by opening the bottom access door (3) and remove any build-up
contamination. Refer to Lower Feed Roller - Access Door, page 50-8.
CUTTER DRUM - UNPLUG
2
1
4
3
IMPORTANT: Wear gloves when working near the cutter drum knives. Keep hands away from sharp knives.
Step 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 (2) and washers and open top cutter access door (3).
Step 4:
Manually reverse rotation of the cutter drum to dislodge chips by pushing on the outside surface (4) of
the drum. Stay well away from cutter knives.
Step 5:
If necessary to access bottom of drum, remove four bolts and lower shear bar access door located under
machine (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 remaining chips from chipper
housing.
DISCHARGE CHUTE - CLEAN OUT
WARNING: Thrown objects can blind you.
Keep everyone away from discharge area while cutter drum is
turning. Direct discharge chute away from people. Wear eye
protection.
1
Most plugs can be removed using the following procedure:
Step 1:
Step 2:
Check that cutter drum rotation has stopped by looking to see if drum shaft
end (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 (2)
to dislodge the plugged material.
2
Step 5:
If you are unable to dislodge the plugged material, unbolt discharge chute at
the rotation ring (3) and remove chute from machine to clean out the plugged
material.
Step 6:
Install cleaned discharge chute.
IMPORTANT: Use an appropriate lifting system when removing and installing the
discharge chute. Chute weighs approximately 79 lb (36 kg).
Step 7:
Operate machine, without chipping additional material, to blow out chips
that remain in the chipper housing and discharge chute.
3
Section 60: Maintenance Intervals
WARNING: Use Shutdown Procedure before servicing, cleaning, repairing, or transporting
machine. Follow Shutdown Procedure, page 23-1.
Visually inspect machine daily before starting the machine.
Make no modifications to your equipment unless specifically recommended or requested by Vermeer
Corporation.
SAFETY SIGNS
Safety signs located on your machine contain important and useful information. Refer to Controls, page 20-1. To
help you operate your equipment safely, refer to the Parts Manual for locations and for other information.
To assure that all signs remain in place and in good condition, follow instructions given below:
•
Keep signs clean. Use soap and water - not mineral spirits, abrasive cleaners, or other similar cleaners that
will damage the safety sign.
•
Replace any damaged or missing signs. When attaching signs, the temperature of the mounting surface
must be at least 40°F (5°C). The mounting surface must also be clean and dry.
•
When replacing a machine component with a sign attached, replace sign also.
•
Replacement signs can be purchased from your Vermeer equipment dealer.
Maintenance Intervals 60-1
MAINTENANCE MANUAL
Maintenance intervals are included for reference only. Before performing any maintenance, refer to the
Maintenance Manual for safety guidelines and correct procedures.
HOURMETER - CHECK FOR MAINTENANCE INTERVAL
The hourmeter on the power unit is used to determine maintenance intervals for the machine. The hourmeter
indicates the total number of hours the engine has been in operation.
Maintenance intervals are based on normal operating conditions. When operating under severe conditions, the
maintenance intervals should be shortened.
MAINTENANCE INTERVALS
Initial = Initial maintenance on new machine. Regular maintenance interval may be different.
= Regular maintenance interval.
Maintenance Interval - Service Hours
Service
5
10
50
100
250
500
1000
2000
As
Reqd.
Cutter 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
60-2 Maintenance Intervals
Service
5
10
50
100
250
500
1000
2000
As
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
5
10
50
100
250
500
1000
2000
As
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
5
10
50
100
250
500
1000
2000
As
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
5
10
50
100
250
500
1000
2000
As
Reqd.
Towing Chain - Replace
Storage
Section 61: Knife/Drum Maintenance
The recommended service interval to check the cutter knives is 10 service hours. However, the actual
service hours interval before knife maintenance is required may be more or less, depending upon the wood being
chipped and chipping conditions.
WARNING: Rotating knives under cover can cut off hand.
Thrown objects can strike you.
Stop engine, wait for drum to stop, then open access cover
Performing the following maintenance procedures will aid in reducing the possibility of the knives becoming
loose, failing, and being ejected from the machine.
Knife/Drum Maintenance 61-1
KNIFE REMOVAL
WARNING: Wear gloves when working with the cutter drum knives. Serious cutting injuries will result if
contact is made with the knives while removing or installing them.
IMPORTANT: Always remove and replace knives as sets. Chipper balance can be affected if matched knives are
not 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).
2
1
3
WARNING: Knives can cut off hand.
Lock drum before servicing knives.
61-2 Knife/Drum Maintenance
Step 4:
Lock cutter drum to prevent the drum from rotating while working on knives.
Align one of the two lock holes in the cutter drum and engage lock pin (4).
Step 5:
Remove four bolts (5) from first knife (6). To prevent damage, do not use
impact 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.
4
5
6
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 as per the instructions that follow.
Knife Inspection
•
1
Cracks — Thoroughly clean the knives and inspect both sides of each knife for
cracks. 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 models.
If cracked knives are reused, the cracks will extend across the knife and the knife can
separate from the cutter drum.
•
2
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 to
the mounting holes as shown.
3
Step 2:
Move straightedge slowly across the knife surface, and monitor for any light
that shows between the knife and straightedge. If any light appears between the knife surface and the
straightedge, this indicates that the knife is distorted, and the knife must be replaced.
Step 3:
Turn straightedge perpendicular to mounting holes and repeat Step 2.
Bolt Inspection
WARNING: Incorrect maintenance and torquing of the knife-mounting bolts can cause the knives to become detached
from the cutter drum. Death or serious injury is possible if the failed knives are ejected from the machine and strike
someone. Extensive and costly damage to the cutter drum and machine will probably occur if the knives become
detached.
WARNING: Knife-mounting bolts must be replaced each time knives are sharpened or replaced. Bolts may be reused
ONLY ONCE when rotating knife to its second cutting edge. Failure to replace bolts can cause knife/drum separation
resulting in death or serious injury, and machine damage.
WARNING: Overtightened bolts can cause knife distortion, allowing wood to pack under the knife. Distorted knives
can crack and fail resulting in death or serious injury, and machine damage. Use a straightedge and check all knives
for distortion; discard any that are distorted.
IMPORTANT: When installing a new or sharpened set of knives, discard the existing mounting bolts
and use new Vermeer-approved bolts. Repeated reuse of the bolts will decrease their clamping
capacity each time the bolts are torqued. Inadequate clamping of the knives will cause the knives to
loosen and fail.
1
Bolts —Inspect bolts (1) for damaged threads, corrosion, and distortion. If any are found, discard
the bolt and install a new one.
Knife Mount Surface Inspection
When a cutting knife is removed from the drum, the knife-mounting surfaces on the drum
must be cleaned and inspected.
IMPORTANT: Any debris left on the mounting surface can prevent the knife from lying
perfectly flat on its mating surface. Any dirty or damaged threads will affect the bolt
torque, and prevent the knives from being properly clamped. Either of these conditions can
lead to knife failure during operation.
1
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, distorted, or
damaged.
2
DRUM INSPECTION
2
2
1
3
4
2
The cutter drum must be free of any damage. Thoroughly clean and inspect the following:
•
Air Paddles — Inspect air paddles (1) and their gussets for cracking and deformation.
•
Edge Welds — Inspect entire drum for cracks in the welds (2) where the drum sides are joined to the
drum. Use a mirror to aid in this inspection.
•
Pockets — Closely inspect area in and around knife mount and pockets (3) for damage or cracks.
•
Cutter Drum Surface — Inspect drum surface (4) for cracks that may begin at the pockets and migrate
outward.
If any drum damage or cracks are found, contact an authorized independent Vermeer dealer.
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.
30°
2.00" (51 mm)
(Minimum)
IMPORTANT: The knives are double-edged and have a minimum usable size of 2.00" (51 mm)
measured from the centerline of the bolt holes to the knife edge. Do not use a side of a knife that
measures less than this.
2.00" (51 mm)
(Minimum)
30°
Knife Installation
Step 1:
Clean and inspect all cutter drum components as per the preceding instructions.
Step 2:
Lock cutter drum.
Step 3:
Install knife (1) with the bevel oriented as shown, and with thread bar (2) in place
inside drum.
1
3
IMPORTANT: On resharpened knives, measure the distance from the mounting holes to the
sharpened edges. Mount knives so edges with the same measurement are oriented the same way
at both locations.
Step 4:
Lubricate bolts (3) with light oil and install. Lightly tighten all four bolts to hold the
knife in place.
2
WARNING: Mounting bolts (3) must be replaced each time knives are sharpened or replaced. Bolts
may be reused ONLY ONCE when rotating knife to its second cutting edge. Failure to replace bolts
can cause knife/drum separation resulting in death or serious injury, and machine damage.
Also, to prevent bolt damage, do not use a power or impact tool to install knife/drum bolts.
Step 5:
Torque bolts with a torque wrench to 210 ft-lb (285 Nm) beginning with the center bolts. Torque in the
same sequence again after the last bolt is tightened.
WARNING: Overtightened bolts can cause knife distortion, allowing wood to pack under the knife.
Distorted knives can crack and fail resulting in death or serious injury, and machine damage. Use a
straightedge and check all knives for distortion; discard any that are distorted.
Step 6:
Unlock cutter drum and rotate 1/2 turn to the next cutter knife.
Step 7:
Lock cutter drum.
Step 8:
Repeat Steps 3–5 to install both knives.
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 released and stored.
Step 10: Adjust shear bar (refer to the Maintenance Manual, 50 Service Hours section, “Shear Bar - Check/
Adjust”).
IMPORTANT: The shear bar bolts must be checked weekly, even if you do not need to adjust or replace the shear
bar. Refer to the Maintenance Manual, 50 Service Hours section, “Shear Bar - Check/Adjust”.
Section 62: Engine Fault Codes (110/120-HP Engine)
Refer to the Engine Operation Manual for additional information on understanding and recording engine fault
codes displayed on engine multifunction display, and appropriate remedial actions. Always contact your
Vermeer dealer or engine service dealer for help in correcting diagnostic trouble codes which are displayed for
your engine.
NOTE: The first part of the code is a six-digit Suspect Parameter Number (SPN) which identifies the system or
component that failed, followed by a two-digit Failure Mode Identifier (FMI) code which identifies the type of
failure (example: high temperature). In order to determine the exact failure both parts of the code are needed.
Fault
Code
SPN
FMI
111
000629
12
Red
ECU Programming Error (Critical Internal Failure - Bad
Intelligent Device or Component)
Contact Servicing Dealer
115
000612
02
Red
System Diagnostic #2 (Engine Speed/Position Sensor Circuit
Lost Both Signals from Magnetic Pickup Sensor - Data Erratic,
Intermittent, or Incorrect)
Check Sensor and Wiring
122
000102
03
Amber
Boost Pressure (Intake Manifold Air Pressure Sensor Circuit Voltage Above Normal or Shorted to High Source)
123
000102
04
Amber
Boost Pressure (Intake Manifold Air Pressure Sensor Circuit Voltage Below Normal, or Shorted to Low Source)
124
000102
16
Amber
(110-hp only) Boost Pressure (Intake Manifold 1 Air Pressure Data Valid but Above Normal Operational Range - Moderately
Severe Level)
131
000091
03
Red
Throttle Position Sensor Circuit - Voltage Above Normal, or
Shorted to High Source
Check Switch and Wiring
Light
DESCRIPTION
CORRECTIVE ACTION
Engine Fault Codes (110/120-HP Engine) 62-1
Fault
Code
SPN
FMI
Light
DESCRIPTION
CORRECTIVE ACTION
132
00091
04
Red
Throttle Position Sensor Circuit - Voltage Below Normal, or
Shorted to Low Source
Check Switch and Wiring
133
000974
03
Red
Remote Throttle (Position Sensor Circuit - Voltage Above
Normal, or Shorted to High Source)
Non Engine Fault. Check Other
Shutdown Devices
134
000974
04
Red
Remote Throttle (Position Sensor Circuit - Voltage Below
Normal, or Shorted to Low Source)
Non Engine Fault. Check Other
Shutdown Devices
143
000100
18
Amber
Engine Oil Pressure Low - (Data Valid but Below Normal
Operational Range - Moderately Severe)
Check Oil Level
144
000110
03
Amber
Engine Coolant Temperature (Sensor Circuit - Voltage Above
145
000110
04
Amber
Engine Coolant Temperature (Sensor Circuit - Voltage Below
146
000110
16
Amber
Engine Coolant Temperature High (Data Valid but Above Normal
Operational Range - Moderately Severe)
Check Cooling System, Reduce
Power
151
000110
00
Red
Engine Coolant Temperature High (Data Valid but Above Normal
Operational Range - Most Severe Level - Engine will shut down
30 seconds after light stops flashing)
Check Cooling System, Reduce
Power
153
000105
03
Amber
Intake Manifold #1 Temperature (Sensor Circuit - Voltage Above
154
000105
04
Amber
Intake Manifold #1 Temperature (Sensor Circuit - Voltage Below
155
000105
00
Red
Intake Manifold #1 Temperature (Temperature High - Data Valid
but Above Normal Operational Range - Most Severe Level)
Check Air Cleaner, Aftercooler, or
Room Temperature
221
000108
03
Amber
Barometric Air Pressure (Sensor Circuit - Voltage Above
62-2 Engine Fault Codes (110/120-HP Engine)
Fault
Code
SPN
FMI
Light
DESCRIPTION
222
000108
04
Amber
Barometric Air Pressure (Sensor Circuit - Voltage Below Normal,
or Shorted to Low Source)
234
000190
00
Red
Engine Speed High (Data Valid but Above Normal Operational
Range - Most Severe Level)
Reduce Engine Speed
238
000611
04
Amber
System Diagnostic Code #1 (Sensor Supply Voltage #3 Circuit Voltage Below Normal, or Shorted to Low Source)
239
003511
03
Amber
System Diagnostic Code #2 (Sensor Supply Voltage #3 Circuit Voltage Above Normal, or Shorted to High Source)
271
001347
04
Amber
Fuel Pump Pressurizing Assembly #1 (High Fuel Pressure
Solenoid Valve Circuit - Voltage Below Normal, or Shorted to
Low Source)
Check Pump Wiring
272
001347
03
Amber
Fuel Pump Pressurizing Assembly #1 (High Fuel Pressure
Solenoid Valve Circuit - Voltage Above Normal, or Shorted to
High Source)
Check Pump Wiring
322
000651
05
Amber
Injector Solenoid Cylinder #1 Circuit (Current Below Normal, or
Open Circuit)
Check Injector Wiring or Injector
Solenoid
324
00653
05
Amber
Open Circuit
Solenoid
331
000652
05
Amber
Open Circuit)
Solenoid
332
000654
05
Amber
Open Circuit)
Solenoid
343
000629
12
Amber
Controller #1 (Engine Control Module Warning Internal
Hardware Failure - Bad Intelligent Device or Component)
CORRECTIVE ACTION
Fault
Code
SPN
FMI
Light
351
000629
12
Amber
Controller #1 (Injector Power Supply - Bad Intelligent Device or
Component)
352
001079
04
Amber
5 Volts DC Supply (Sensor Supply Voltage #1 Circuit - Voltage
Below Normal, or Shorted to Low Source)
Check Wiring
386
001079
03
Amber
5 Volts DC Supply (Sensor Supply Voltage #1 Circuit - Voltage
Above Normal, or Shorted to High Source)
Check Wiring
415
000100
01
Red
Engine Oil Pressure Low - (Data Valid but Below Normal
Operational Range - Most Severe Level)
Check Oil Level
428
000097
03
Amber
Water in Fuel Indicator (Water in Sensor Circuit - Voltage Above
429
000097
04
Amber
Water in Fuel Indicator (Water in Sensor Circuit - Voltage Below
431
000558
02
Amber
Accelerator Low Idle Switch (Validation Circuit Data Erratic,
432
000558
13
Red
Accelerator Low Idle Switch (Validation Circuit Out of
Calibration)
435
000100
02
Amber
Engine Oil Pressure (Oil Pressure Sensor Circuit - Data Erratic,
441
000168
18
Amber
Electrical Potential (Voltage) (Battery #1 Voltage Low - Data
Valid but Below Normal Operational Range - Moderately Severe
Level)
442
000168
16
Amber
Electrical Potential (Voltage) (Battery #1 Voltage High - Data
Valid but Above Normal Operational Range - Moderately Severe
Level)
DESCRIPTION
CORRECTIVE ACTION
Fault
Code
SPN
FMI
449
000157
00
Red
Injector Metering Rail #1 Pressure (Pressure Sensor Circuit Voltage Above Normal, or Shorted to High Source)
451
000157
03
Amber
Injector Metering Rail #1 Pressure (Pressure Sensor Circuit Voltage Below Normal, or Shorted to Low Source)
488
000105
16
Amber
Intake Manifold (Intake Manifold 1 Temperature - Data Valid but
Above Normal Operational Range - Moderately Severe Level)
Check Air Cleaner, Aftercooler, or
Room Temperature
528
00093
02
Amber
Switch - Data (Auxiliary Alternate Torque Validation Switch Data Erratic, Intermittent, or Incorrect)
553
000157
16
Amber
Injector Metering Rail #1 Pressure (Pressure High - Data Valid
but Above Normal Operational Range - Moderately Severe
Level)
559
000157
03
Amber
Injector Metering Rail #1 Pressure (Pressure Low - Data Valid
but Below Normal Operational Range - Moderately Severe
Level)
689
000190
02
Amber
Engine Speed (Primary Engine Speed Sensor Error - Data
Erratic, Intermittent, or Incorrect)
Reduce Engine Speed
Reduce Engine Speed
Light
DESCRIPTION
CORRECTIVE ACTION
731
000723
07
Amber
Engine Speed Sensor #2 (Engine Speed/Position #2
Mechanical Misalignment Between Camshaft and Crankshaft
Sensors - Mechanical System Not Responding Properly or Out
of Adjustment)
778
000723
2
Amber
Engine Speed Sensor #2 (Engine Speed Sensor (Camshaft)
Error - Data Erratic, Intermittent, or Incorrect)
Reduce Engine Speed
1117
000627
02
None
Power Supply (Power Lost With Ignition On - Data Erratic,
Fault
Code
SPN
FMI
Light
DESCRIPTION
1695
003513
03
Amber
Sensor Supply Voltage #5 (Voltage Above Normal or Shorted to
High Source. High Voltage Detect at Sensor Supply #5 in the
OEM Harness.)
1696
003513
04
Amber
Sensor Supply Voltage #5 (Voltage Below Normal or Shorted to
Low Source. High Voltage Detect at Sensor Supply #5 in the
OEM Harness.)
CORRECTIVE ACTION
Index
A
Attach to Towing Vehicle (BC1200XL European Only), 30-7
Attach to Towing Vehicle (BC1200XL Only), 30-4
B
Battery Burns - Avoid, 22-3
Battery Explosion - Avoid, 22-2
Bolt Inspection, 61-5
Breakaway on Hydraulic Surge Brake (Option) - Reset, 30-8
Breakaway System - Reset Electric Brake, 30-9
Brush Chipper Preparation for Winching , 50-14
Brush Chipper, iii
C
Chip Material, 50-11
Clean Flammable Materials from Machine, 40-5
Cold Weather Starting, 22-1
Controls, 20-1
Cutter Drum - Engage, 50-1
Cutter Drum - Unplug, 51-5
Cutter Shaft - Check, 50-1
Cutting System , 50-10
D
Dealer Prep, i
Dealer/Customer Information, iv
Delivery, iii
Detach from Towing Vehicle, 30-12
Discharge Chute - Clean Out, 51-6
Discharge Chute Controls, 20-15
Discharge Chute, 40-6
Droop Set Switch, 20-13
Drum Inspection, 61-7
E
EcoIdle RPM Control, 50-7
Engine Fault Codes (110/120-HP Engine), 62-1
Engine Identification Numbers - Record, vi
Engine Monitors (Tier 3/Stage IIIA), 20-1
Engine Monitors (Tier 4 Interim/Stage IIIB), 20-2
Engine, 22-1
Equipping the Towing Vehicle, 30-1
F
Feed Control Bars - Check, 40-9
Feed Roller - Engage, 50-5
Feed Roller - Unplug, 51-3
Feed Roller Controls, 20-6
Feed Roller Operation, 50-2
Feeding Tips, 50-11
Finishing, 50-12
Fuses, 20-21
G
H
Hitch - Pintle, 30-6
Hitch Height - Adjust (BC1200XL Only), 30-2
Hourmeter - Check for Maintenance Interval, 60-2
Hydraulic Fluid, 22-2
I
Ignition Switch, 20-4
Infeed System, 50-10
Intended Use, 40-1
M
Machine - Clean Before Transporting, 30-9
Machine Identification Decal, v
Machine Identification Numbers - Record, v
Maintenance Intervals, 60-1
Maintenance Intervals, 60-2
Maintenance Manual, 60-2
Material Size, 50-11
N
J
Jack Controls, 20-20
Jump-Starting Procedure, 22-3
Jump-Starting, 22-2
O
Operating the Brush Chipper, 50-1
Operating the Optional Winch (BC1200XL Only), 50-13
Operator Qualifications, 40-1
K
Knife Inspection, 61-4
Knife Installation, 61-9
Knife Mount Surface Inspection, 61-6
Knife Removal, 61-2
Knife Sharpening, 61-8
Knife/Drum Maintenance, 61-1
P
Park Brake (BC1200XL European Only), 20-14
Personal Protection, 40-2
Plugs or Stalls, 50-12
Prepare for Transport, 30-10
Prepare the Area, 40-3
Prepare the Brush Chipper, 40-4
Preparing the Brush Chipper and Work Area, 40-1
L
Line Pull and Speed, 50-13
Lower Feed Roller - Access Door, 50-8
Lower Feed Stop Bar and Side Feed Stop Bars, 50-3
Q
Quick Stop Procedure, 23-2
R
Removing Plugs from the Brush Chipper, 51-1
Reporting Safety Defects, 30-1
Review of Operation, iii
(BC1200XL Only), 20-18
Winch Controls (BC1200XL Only), 20-16
Winch Line - Store (BC1200XL Only), 30-11
Winch Line and Choker - Repair/Replace, 50-23
Winch Operation, 50-16
S
Safety Messages, 10-1
Safety Signs, 60-1
Safety Symbol Explanation, 10-1
Sensitivity Levels (BC1200XL Only), 50-4
Shutdown Procedure, 23-1
SmartFeed Operation, 50-10
Sound Levels, 40-3
Starting Procedure, 22-1
Starting the Engine, 22-1
Stopping the Machine, 23-1
T
Throttle/Cutter Engage, 20-5
Tongue Length - Adjust (BC1200XL Only), 30-3
Transporting the Brush Chipper, 30-1
U
Upper Feed Control Bar, 50-3
V
W
Wheel Chocks (BC1200XL European Only), 20-14
Winch Capacity, 50-13
Winch Controls - Left Side Controls Option
Revision History
Revision
Date
Page(s)
Description
o1_00
06/09
All
1st Edition Operator’s Manual released.
o1_01
08/09
R&D, v; TOC; Controls, 20-1,2,8,10,12–14; Starting, 21-1;
Shutdown, 22-1; Transport, 30-10; Prep, 40-6; Operating, 50-1,4,
5,11,14,16,17; Removing Plugs, 51-4; Maint. Int., 60-3; Index.
Added left side controls (option), 85-hp
engine (option), engine fault codes; misc.
updates.
o1_02
10/09
Intro.; Safety, p. 10-1; Preparing, p. 40-1; Maint. Intervals, p. 602,3.
Added maintenance items; updated Safety
message.
o1_03
03/10
Controls, Transporting, Preparing, Operating.
Added EU Side Feed Stop Bars, Safety
Updates.
o1_04
02/11
Introduction; TOC; Controls; Engine fault codes; Index
Model number, Typing errors
o1_05
10/11
Controls, Starting, Operating, Maintenance Interval
Control panel update, Updated maintenance
intervals
o2_00
01/12
All
TIER-4 enine update
WARNING
The Engine Exhaust from this product
contains chemicals known to the State
of California to cause cancer, birth
defects, or other reproductive harm.
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its
constituents are known to the State of
California to cause cancer, birth
defects, and other reproductive harm.
When operated in California, any off-road diesel vehicle may
be subject to the California Air Resources Board In-Use OffRoad Diesel Vehicle Regulation. It therefore could be subject
to retrofit or accelerated turnover requirements to reduce
emissions of air pollutants. For more information, please
visit the California Air Resources Board website at
http://www.arb.ca.gov/msprog/ordiesel/ordiesel.htm.
Copyright 2012. All rights reserved.
Vermeer Corporation
1210 Vermeer Road East, P.O. Box 200
Pella, Iowa 50219-0200

BC1200XL Brush Chipper

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