Bc1200xl Brush Chipper

Transcript

BC1200XL Brush Chipper 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: [email protected]; 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 Brush Chipper 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. BC1200XL Brush Chipper 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 BC1200XL Brush Chipper 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. BC1200XL Brush Chipper 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 BC1200XL Brush Chipper 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 BC1200XL Brush Chipper 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 BC1200XL Brush Chipper 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. BC1200XL Brush Chipper 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 BC1200XL Brush Chipper 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 BC1200XL Brush Chipper 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 BC1200XL Brush Chipper 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. BC1200XL Brush Chipper 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 BC1200XL Brush Chipper 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 BC1200XL Brush Chipper 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 BC1200XL Brush Chipper Drum Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61-7 Knife Sharpening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61-8 Knife Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61-9 Engine Fault Codes (110/120-HP Engine). . . . . 62-1 BC1200XL Brush Chipper 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. BC1200XL Brush Chipper 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 BC1200XL Brush Chipper 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. BC1200XL Brush Chipper 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 BC1200XL Brush Chipper 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. BC1200XL Brush Chipper 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 BC1200XL Brush Chipper (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. BC1200XL Brush Chipper Controls 20-3 IGNITION SWITCH (1) Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vertical position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . engine off 1st position clockwise . . . . . . . . . . . . . . . . . . . . . . preheat/engine on 1 2nd position clockwise . . . . . . . . . . . . . . . . . . . . . . . . . . engine start 110-HP ENGINE (OPTION) 1 120-HP ENGINE (OPTION) 20-4 Controls BC1200XL Brush Chipper 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) BC1200XL Brush Chipper 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 BC1200XL Brush Chipper 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. BC1200XL Brush Chipper 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 BC1200XL Brush Chipper 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 BC1200XL Brush Chipper 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 BC1200XL Brush Chipper (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 BC1200XL Brush Chipper 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 LEFT SIDE CONTROLS (OPTION) 20-12 Controls BC1200XL Brush Chipper 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) BC1200XL Brush Chipper 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 BC1200XL Brush Chipper 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 BC1200XL Brush Chipper 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 BC1200XL Brush Chipper (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. BC1200XL Brush Chipper 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 BC1200XL Brush Chipper (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. BC1200XL Brush Chipper 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 BC1200XL Brush Chipper 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 BC1200XL Brush Chipper 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 This page intentionally left blank. 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. BC1200XL Brush Chipper 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 BC1200XL Brush Chipper 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. BC1200XL Brush Chipper 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 BC1200XL Brush Chipper 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. BC1200XL Brush Chipper 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 BC1200XL Brush Chipper 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: [email protected]; 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. BC1200XL Brush Chipper 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 BC1200XL Brush Chipper 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. BC1200XL Brush Chipper Transporting the Brush Chipper 30-3 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 30-4 Transporting the Brush Chipper BC1200XL Brush Chipper 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. BC1200XL Brush Chipper Transporting the Brush Chipper 30-5 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 30-6 Transporting the Brush Chipper BC1200XL Brush Chipper 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 BC1200XL Brush Chipper 5 REAR JACK Transporting the Brush Chipper 30-7 BREAKAWAY ON HYDRAULIC SURGE BRAKE (OPTION) - RESET Step 1: Pry apart spring clips (1). Step 2: Return lever (2) to reset position. 2 1 30-8 Transporting the Brush Chipper BC1200XL Brush Chipper 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. BC1200XL Brush Chipper Transporting the Brush Chipper 30-9 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 30-10 Transporting the Brush Chipper BC1200XL Brush Chipper 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 LEFT SIDE CONTROLS (OPTION) BC1200XL Brush Chipper Transporting the Brush Chipper 30-11 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 30-12 Transporting the Brush Chipper BC1200XL Brush Chipper 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. BC1200XL Brush Chipper 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 BC1200XL Brush Chipper 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. BC1200XL Brush Chipper Preparing the Brush Chipper and Work Area 40-3 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. 40-4 Preparing the Brush Chipper and Work Area BC1200XL Brush Chipper 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. BC1200XL Brush Chipper Preparing the Brush Chipper and Work Area 40-5 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 40-6 Preparing the Brush Chipper and Work Area BC1200XL Brush Chipper 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 BC1200XL Brush Chipper Preparing the Brush Chipper and Work Area 40-7 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 40-8 Preparing the Brush Chipper and Work Area BC1200XL Brush Chipper 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 BC1200XL Brush Chipper Preparing the Brush Chipper and Work Area 40-9 This page intentionally left blank. 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 LEFT SIDE CONTROLS (OPTION) 1 BC1200XL Brush Chipper 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 BC1200XL 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 BC1200XL Brush Chipper Operating the Brush Chipper 50-3 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 50-4 Operating the Brush Chipper BC1200XL Brush Chipper 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. BC1200XL Brush Chipper 1 3 Operating the Brush Chipper 50-5 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. LEFT SIDE CONTROLS (OPTION) SHOWN 50-6 Operating the Brush Chipper BC1200XL Brush Chipper 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 BC1200XL Brush Chipper Operating the Brush Chipper 50-7 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. 50-8 Operating the Brush Chipper BC1200XL Brush Chipper 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. BC1200XL Brush Chipper 2 Operating the Brush Chipper 50-9 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 50-10 Operating the Brush Chipper BC1200XL Brush Chipper 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. BC1200XL Brush Chipper Operating the Brush Chipper 50-11 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. 50-12 Operating the Brush Chipper BC1200XL Brush Chipper 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 84 ft/min (26 m/min) 3 1609 lb/730 kg 96 ft/min (29 m/min) 4 1413 lb/641 kg 108 ft/min (33 m/min) 5 1217 lb/552 kg 119 ft/min (36 m/min) WARNING: Never exceed the rated winch capacity of 2000 lb (900 kg). 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. BC1200XL Brush Chipper Operating the Brush Chipper 50-13 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. 50-14 Operating the Brush Chipper 1 2 BC1200XL Brush Chipper 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 LEFT SIDE CONTROLS (OPTION) 4 5 BC1200XL Brush Chipper Operating the Brush Chipper 50-15 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. 50-16 Operating the Brush Chipper BC1200XL Brush Chipper 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. BC1200XL Brush Chipper Operating the Brush Chipper 50-17 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. LEFT SIDE CONTROLS (OPTION) 50-18 Operating the Brush Chipper BC1200XL Brush Chipper 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. BC1200XL Brush Chipper Operating the Brush Chipper 50-19 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. 50-20 Operating the Brush Chipper BC1200XL Brush Chipper 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. LEFT SIDE CONTROLS (OPTION) 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. BC1200XL Brush Chipper Operating the Brush Chipper 50-21 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. 50-22 Operating the Brush Chipper LEFT SIDE CONTROLS (OPTION) BC1200XL Brush Chipper 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. BC1200XL Brush Chipper 1 Operating the Brush Chipper 50-23 This page intentionally left blank. 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. BC1200XL Brush Chipper 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 BC1200XL 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: Follow Shutdown Procedure, page 23-1. 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. BC1200XL Brush Chipper 2 Removing Plugs from the Brush Chipper 51-3 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. 51-4 Removing Plugs from the Brush Chipper BC1200XL Brush Chipper 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: Follow 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 (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. BC1200XL Brush Chipper Removing Plugs from the Brush Chipper 51-5 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: Follow 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: 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. 51-6 Removing Plugs from the Brush Chipper 2 BC1200XL Brush Chipper 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. BC1200XL Brush Chipper 3 Removing Plugs from the Brush Chipper 51-7 This page intentionally left blank. 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. BC1200XL Brush Chipper 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 BC1200XL Brush Chipper Maintenance Interval - Service Hours 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 BC1200XL Brush Chipper Maintenance Intervals 60-3 Maintenance Interval - Service Hours 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 60-4 Maintenance Intervals BC1200XL Brush Chipper Maintenance Interval - Service Hours 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 BC1200XL Brush Chipper Maintenance Intervals 60-5 Maintenance Interval - Service Hours Service 5 10 50 100 250 500 1000 2000 As Reqd. Towing Chain - Replace Storage 60-6 Maintenance Intervals BC1200XL Brush Chipper 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. BC1200XL Brush Chipper 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 BC1200XL Brush Chipper 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. BC1200XL Brush Chipper Knife/Drum Maintenance 61-3 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. 61-4 Knife/Drum Maintenance BC1200XL Brush Chipper 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. BC1200XL Brush Chipper Knife/Drum Maintenance 61-5 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. 61-6 Knife/Drum Maintenance 2 BC1200XL Brush Chipper 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. BC1200XL Brush Chipper Knife/Drum Maintenance 61-7 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° 61-8 Knife/Drum Maintenance BC1200XL Brush Chipper 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. BC1200XL Brush Chipper Knife/Drum Maintenance 61-9 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”. 61-10 Knife/Drum Maintenance BC1200XL Brush Chipper 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) Contact Servicing Dealer 123 000102 04 Amber Boost Pressure (Intake Manifold Air Pressure Sensor Circuit Voltage Below Normal, or Shorted to Low Source) Contact Servicing Dealer 124 000102 16 Amber (110-hp only) Boost Pressure (Intake Manifold 1 Air Pressure Data Valid but Above Normal Operational Range - Moderately Severe Level) Contact Servicing Dealer 131 000091 03 Red Throttle Position Sensor Circuit - Voltage Above Normal, or Shorted to High Source Check Switch and Wiring Light BC1200XL Brush Chipper 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 Normal, or Shorted to High Source) Check Sensor and Wiring 145 000110 04 Amber Engine Coolant Temperature (Sensor Circuit - Voltage Below Normal, or Shorted to Low Source) Check Sensor and Wiring 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 Normal, or Shorted to High Source) Check Sensor and Wiring 154 000105 04 Amber Intake Manifold #1 Temperature (Sensor Circuit - Voltage Below Normal, or Shorted to Low Source) Check Sensor and Wiring 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 Normal, or Shorted to High Source) Contact Servicing Dealer 62-2 Engine Fault Codes (110/120-HP Engine) BC1200XL Brush Chipper Fault Code SPN FMI Light DESCRIPTION 222 000108 04 Amber Barometric Air Pressure (Sensor Circuit - Voltage Below Normal, or Shorted to Low Source) Contact Servicing Dealer 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) Check Sensor and Wiring 239 003511 03 Amber System Diagnostic Code #2 (Sensor Supply Voltage #3 Circuit Voltage Above Normal, or Shorted to High Source) Check Sensor and Wiring 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 Injector Solenoid Cylinder #3 Circuit (Current Below Normal, or Open Circuit Check Injector Wiring or Injector Solenoid 331 000652 05 Amber Injector Solenoid Cylinder #2 Circuit (Current Below Normal, or Open Circuit) Check Injector Wiring or Injector Solenoid 332 000654 05 Amber Injector Solenoid Cylinder #4 Circuit (Current Below Normal, or Open Circuit) Check Injector Wiring or Injector Solenoid 343 000629 12 Amber Controller #1 (Engine Control Module Warning Internal Hardware Failure - Bad Intelligent Device or Component) Contact Servicing Dealer BC1200XL Brush Chipper CORRECTIVE ACTION Engine Fault Codes (110/120-HP Engine) 62-3 Fault Code SPN FMI Light 351 000629 12 Amber Controller #1 (Injector Power Supply - Bad Intelligent Device or Component) Contact Servicing Dealer 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 Normal, or Shorted to High Source) Check Sensor and Wiring 429 000097 04 Amber Water in Fuel Indicator (Water in Sensor Circuit - Voltage Below Normal, or Shorted to Low Source) Check Sensor and Wiring 431 000558 02 Amber Accelerator Low Idle Switch (Validation Circuit Data Erratic, Intermittent, or Incorrect) Contact Servicing Dealer 432 000558 13 Red Accelerator Low Idle Switch (Validation Circuit Out of Calibration) Contact Servicing Dealer 435 000100 02 Amber Engine Oil Pressure (Oil Pressure Sensor Circuit - Data Erratic, Intermittent, or Incorrect) Check Sensor and Wiring 441 000168 18 Amber Electrical Potential (Voltage) (Battery #1 Voltage Low - Data Valid but Below Normal Operational Range - Moderately Severe Level) Contact Servicing Dealer 442 000168 16 Amber Electrical Potential (Voltage) (Battery #1 Voltage High - Data Valid but Above Normal Operational Range - Moderately Severe Level) Contact Servicing Dealer DESCRIPTION 62-4 Engine Fault Codes (110/120-HP Engine) CORRECTIVE ACTION BC1200XL Brush Chipper Fault Code SPN FMI 449 000157 00 Red Injector Metering Rail #1 Pressure (Pressure Sensor Circuit Voltage Above Normal, or Shorted to High Source) Contact Servicing Dealer 451 000157 03 Amber Injector Metering Rail #1 Pressure (Pressure Sensor Circuit Voltage Below Normal, or Shorted to Low Source) Contact Servicing Dealer 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) Check Sensor and Wiring 553 000157 16 Amber Injector Metering Rail #1 Pressure (Pressure High - Data Valid but Above Normal Operational Range - Moderately Severe Level) Contact Servicing Dealer 559 000157 03 Amber Injector Metering Rail #1 Pressure (Pressure Low - Data Valid but Below Normal Operational Range - Moderately Severe Level) Contact Servicing Dealer 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, Intermittent, or Incorrect) Contact Servicing Dealer BC1200XL Brush Chipper Engine Fault Codes (110/120-HP Engine) 62-5 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.) Contact Servicing Dealer 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.) Contact Servicing Dealer 62-6 Engine Fault Codes (110/120-HP Engine) CORRECTIVE ACTION BC1200XL Brush Chipper 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 BC1200XL Brush Chipper 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 BC1200XL Brush Chipper 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 BC1200XL Brush Chipper This page intentionally left blank. 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 BC1200XL Brush Chipper 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