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BC1200XL Brush Chipper
BC1200XL_o2_00Serial No. 1001 -Order No. 105400BZ3Cabled Order No. 163698121
Operator’s Manual
BC1200XL Brush Chipper
e instructions thoroughly before operating or m damage. Consult your Vermeer dealer if you d
T information available at time of publication. Y anual.
V obligation.
O ith the machine. The tethered (cabled) m al storage box when not in use.
L vided with the machine. Refer to it for all l
A our dealer. Reorder numbers are listed on the f
C om your dealer.
S iones y Seguridad.
meer machine. Notify the Customer Data r.com; internet: www.vermeer.com or 0, Pella IA 50219 USA. Upon request, an
o nd Parts manuals.
Introduction
IntroductionThis manual explains the proper operation of your machine. Study and understand thes
aintaining the machine. Failure to do so could result in personal injury or equipment o not understand the instructions in this manual, or need additional information.
he instructions, illustrations, and specifications in this manual are based on the latestour machine may have product improvements and features not yet contained in this m
ermeer Corporation reserves the right to make changes at any time without notice or
peration instructions are included in the two Operator’s Manuals provided wanual must remain attached to the machine for ready reference. Store it in the manu
ubrication and maintenance procedures are in the Maintenance Manual proubrication and maintenance procedures.
dditional copies of the manuals, and Operations and Safety video, are available from yront covers of the manuals and on the video.
opies of this manual, and the Operations and Safety video, are available in Spanish fr
u distribuidor dispone de ejemplares en español de este manual y del vídeo de Operac
NOTICE TO OWNER
You are requested to notify Vermeer Corporation when you have purchased a used VerDepartment by telephone: 800-829-0051 or 641-628-3141; email: [email protected]; or, letter: Customer Data Dept., Vermeer Corporation, PO Box 20wner of a used Vermeer machine will receive one free set of Operator’s, Maintenance a
Introduction
ion of forward travel.
turing Company.
BC1200XL European
BC1200XL Brush Chipper
NOTE: Right and left sides of the machine are determined by facing in the direct
TRADEMARKS
VERMEER, VERMEER Logo and ECOIDLE are trademarks of Vermeer ManufacCUMMINS is a trademark of Cummins, Inc.FLEETGUARD is a trademark of Fleetguard, Inc.
BC1200XL
BC1200XL Brush Chipper
VERMEER NEW INDUSTRIAL EQUIPMENT LIMITED WARRANTY
RANTY PERIOD: 12 Months / 1000 Hoursermeer's manufacture to be free from defects
i nitial purchase/retail sale or 1000 operating h ines of Vermeer's manufacture, parts are
F VERMEER'S MANUFACTURE ARE W 'S WARRANTY AND SUBJECT TO T MANUFACTURER.
E
nship in any warranted item of Vermeer I tion without charge by any authorized
ermeer independent authorized dealer at the d abor in accordance with Vermeer's labor r nt parts as it deems appropriate.
R maintenance and periodic inspections of the th each new Industrial Equipment. The cost
aser. The retail purchaser is required to keep d
T ion if the above requirements are not
ly removed from service.
Introduction
(EFFECTIVE OCTOBER 1, 2008) WARVermeer Corporation (hereinafter “Vermeer”) warrants each new Industrial product of Vn material and workmanship, under normal use and service for one (1) full year after iours, whichever occurs first. This Limited Warranty shall apply only to complete mach
covered by a separate Limited Warranty. EQUIPMENT AND ACCESSORIES NOT OARRANTED ONLY TO THE EXTENT OF THE ORIGINAL MANUFACTURERHEIR ALLOWANCE TO VERMEER ONLY IF FOUND DEFECTIVE BY SUCH
XTENDED WARRANTY OPTIONS ARE AVAILABLE FOR PURCHASE.
WARRANTY TERMS
During the Limited Warranty period specified above, any defect in material or workmandustrial Equipment not excluded below shall be repaired or replaced at Vermeer's op
independent Vermeer dealer. The warranty repair or replacement must be made by a Vealer's location. Vermeer will pay for replacement parts and such authorized dealer's leimbursement policy. Vermeer reserves the right to supply remanufactured replaceme
ETAIL PURCHASER RESPONSIBILITY: This Limited Warranty requires properIndustrial Equipment as indicated in the Operator’s/Maintenance Manual furnished wiof routine or required maintenance and services is the responsibility of the retail purch
ocumented evidence that these services were performed.
his Vermeer New Industrial Equipment Limited Warranty may be subject to cancellatperformed.
Vermeer Industrial Equipment with known failed or defective parts must be immediate
Introduction
normal use and service of the Industrial ce (iii) overloading (iv) lack of reasonable and orage (vii) non-Vermeer approved alteration or ies installed on Industrial Equipment which were ments (xii) collision or other accident.been altered or removed or whose hourmeter has
eriodic inspection or services have been performed er Specifications including, but without limitation, nd fuel filters. warranty registration has not been completed and
f the Industrial Equipment not abiding by standard
sibility of the respective product’s manufacturer.t costs, if any, of transporting replacement parts to
ir on the retail purchaser’s site or other location. duct, ny incidental or consequential damages (including ason at any time.ted Warranty Policy. Oils and fluids are not covered
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
Equipment, or by any of the following; (i) accident (ii) misuse or negligenproper maintenance (v) improper repair or installation (vi) unsuitable stmodification (viii) natural calamities (ix) vandalism (x) parts or accessornot manufactured or installed by Vermeer authorized dealers (xi) the ele
(2) Any Industrial Equipment whose identification numbers or marks have been altered or tampered with.
(3) Any Industrial Equipment which any of the required or recommended pusing parts not manufactured or supplied by Vermeer or meeting Vermeengine tune-up parts, engine oil filters, air filters, hydraulic oil filters, a
(4) New Industrial Equipment delivered to the retail purchaser in which thereturned to Vermeer within ten (10) days from the date of purchase.
(5) Any defect which was caused (in Vermeer’s sole judgment) by operation ooperating procedures outlined in the Operator’s Manual.
(6) Engine, battery, and tire Limited Warranties and support are the respon(7) Transportation costs, if any, of transporting to the Vermeer dealer. Freigh
the Vermeer dealer. (8) The travel time of the Vermeer dealer’s service personnel to make a repa(9) In no event shall Vermeer’s liability exceed the purchase price of the pro(10) Vermeer shall not be liable to any person under any circumstances for a
but not limited to, loss of profits, out of service time) occurring for any re(11) Diagnostic and overtime labor premiums are not covered under this Limi
under this Limited Warranty.
BC1200XL Brush Chipper
(12) Depreciation damage caused by normal wear, lack of reasonable and proper maintenance, failure to follow operating
only to the extent of such manufacturer’s
E , Chain, Clutches, Clutch Components, C ed Conveyor Belts, Infeed Conveyor Chains,
ar/Bedknife, Sprockets, Teeth, Wear Blocks,
hes, Cups, Digging Chain, Digging Rims, er Bands, Scraper Knives, Sprockets, Teeth, ear Plates.
Belts, Jaws, Leaf Chain, Lights On Light Guides, Track Idlers, Track Pads, Track rs.
s, Chains, Clutches, Conveyor Belts, End Tires, Track Chain, Track Idlers, Track
ustrial Equipment Limited Warranty, during t original machine warranty, are warranted to b ced, without labor coverage for removal and r
Introduction
instructions, misuse, lack of proper protection during storage.(13) Accessory systems and electronics not of Vermeer’s manufacture are warranted
respective Limited Warranty if any.(14) Downhole toolage is not covered under this warranty.(15) Wear items which are listed by product group as follows:
NVIRONMENTAL: Bearing Seals, Bearings, Belts, Brake Pads, Bolts/Torqued Partsurtains, Cutter Wheels, Discharge Conveyor Belts, Fuel Filters, Hammers, Hoses, Infe
Knives, Oil Filters, Pockets, Rods, Rollers, Rotor Plates, Screens, Service Items, Shear BWear Strips.
TRACK: Base Plates, Boom Wear Items, Buckets, Cable Fingers, Conveyor Belts, ClutcDrums, End Idler, Flashings, Pins and Bushings, Pivot Rings, Plastic Wear Strips, RootTrack Chain, Track Rollers, Trench Cleaner (Crumber), Trip Cleaners, Truck Rollers, W
TRENCHLESS: Brushes, Clamping Vise Parts, Dies, Drive Chuck, Earth Stakes, Fan Kits, Packing Assemblies, Rod, Rod Loader Parts, Rollers, Tooling, Track Chain, Track Sprockets, Valve Seats, Wear Bars, Wear Blocks, Water Hoses, Water Swivels, Wear Ba
UTILITY PRODUCTS: Augers, Belts, Bearings, Booms, Brake Pads, Bucket, BushingRollers, Flashings, Pins, Pivot Rings, Plow Blades, Rubber Shielding, Sprockets, Teeth,Sprockets, Trench Cleaner (Crumber).
PARTS WARRANTY:
Parts replaced in the warranty period will receive the balance of the first year New Indhe first (12) months or 1000 hours, whichever comes first. Replacement parts after the e free from defects of material for ninety (90) days or the part will be repaired or replaeinstallation.
Introduction
RESSLY AND SPECIFICALLY MADE SIBLE LIABILITY OF VERMEER MPLIED, OR STATUTORY, INCLUDING, BUT NESS FOR A PARTICULAR PURPOSE. ANY PRODUCT WITHOUT INCURRING ANY SUCH MODIFICATION. NO PERSON IS ADDITIONAL OBLIGATION ON VERMEER’S
d the dealer has no authority to make any ions of this warranty in any way.
BC1200XL Brush Chipper
EXCLUSIONS OF WARRANTIES: EXCEPT FOR THE WARRANTIES EXPHEREIN, VERMEER MAKES NO OTHER WARRANTIES, AND ANY POSHEREINUNDER IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS, INOT LIMITED TO, ANY WARRANTIES OF MERCHANTABILITY OR FITVERMEER RESERVES THE RIGHT TO MODIFY, ALTER AND IMPROVEOBLIGATION TO REPLACE ANY PRODUCT PREVIOUSLY SOLD WITHAUTHORIZED TO GIVE ANY OTHER WARRANTY, OR TO ASSUME ANYBEHALF.
NO DEALER WARRANTY. The selling dealer makes no warranty of its own anrepresentation or promise on behalf of Vermeer or to modify the terms or limitat
MANUFACTURED BY:VERMEER CORPORATION
Pella, Iowa 50219 USA
BC1200XL Brush Chipper
WARRANTY RIDER HOUSING
term)
rts coverage of the applicable ranty”) for the Covered Components m, provided that the Equipment is in the Operator’s and Maintenance
anty apply.
ove
ring fedder hubs (bearings cement).
s (as specified on Vermeer nty).
le date of the Equipment or er occurs first. This warranty is bsequent owners.
06, will be covered as stated
ERMEER MAKES NO REUNDER IS IN LIEU OF
DING, BUT NOT LIMITED TICULAR PURPOSE.
Introduction
VERMEER EQUIPMENT EXTENDED LIMITED BRUSH CHIPPER DRUM AND DRUM
3,000 Hours / 3 Years*(Parts only coverage during extended
VERMEER CORPORATION (hereinafter “Vermeer”) agrees to extend only the paVermeer Industrial New Equipment Limited Warranty (the “Standard Limited Warof the Specified Models of New Vermeer Industrial Equipment for the Extended Teroperated and maintained in accordance with the directions and instructions set forthManual(s). All conditions, exclusions, and limitations of the Standard Limited Warr
SPECIFIED MODEL: BC1200XL, Serial Number 101 and ab
COVERED COMPONENTS: Drum housings, cutter drums, shafts, andmay be covered if required for drum repla
NON-COVERED COMPONENTS: Bearings, knives, shear bar, and wear itemNew Industrial Equipment Limited Warra
EXTENDED TERM*: Three (3) full years from original retail sa3,000 hours of machine operation, whichevextended to the original purchaser and su
NOTE: Subject to future change Brush Chipper models introduced after August 1, 20in this warranty rider.
EXCEPT FOR THE STANDARD LIMITED WARRANTY AND THIS RIDER, VOTHER WARRANTIES, AND ANY POSSIBLE LIABILITY OF VERMEER HEALL OTHER WARRANTIES, EXPRESS, IMPLIED, OR STATUTORY, INCLUTO, ANY WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PAR
Receiving and Delivery Report i
er operation.
BC1200XL Brush Chipper
Receiving and Delivery ReportDEALER PREP
Check or perform the following:
Engine___ Check oil level of the engine.
___ Check battery electrolyte level and charge.
___ Check condition of air cleaner.
___ Check coolant level and antifreeze concentration.
___ Check engine for proper operation.
Hydraulics___ Check hydraulic fluid level.
___ Check control levers for proper operation.
___ Check all hydraulic components for leaks or damage.
___ Check Lower Feed Stop Bar and Side Feed Stop Bar (European) for prop
___ Check Upper Feed Control Bar for proper operation.
General___ Check machine for shortage or damage in transit.
___ Check installation and condition of all shields.
___ Check machine for proper lubrication.
___ Check condition of all safety signs and operating decals.
___ Check all phases of operation.
BC1200XL Brush Chipper
___ Check for loose hardware.
ii Receiving and Delivery Report
___ Check wheel lug nuts torque: 90–120 ft-lb (122–163 Nm).
___ Check air pressure of tires: 80 psi (5.5 bar).
___ Check operation of the brakes.
___ Check operation of breakaway system.
___ Check operation of highway lights.
___ Check that towing hitch is properly attached to machine.
___ Check drive belts for proper tension.
___ Check Cutter Drum Clutch/Throttle Lever for proper function.
___ Check torque on cutter knife bolts: 210 ft-lb (285 Nm).
___ Check operation of SmartFeed system.
Receiving and Delivery Report iii
per operation:
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 OperationReview and demonstrate with the customer the various aspects of brush chip
___ overall explanation of how the brush chipper works
___ brush chipper safety
___ preparing the brush chipper for operation
BC1200XL Brush Chipper
iv Receiving and Delivery ReportDEALER/CUSTOMER INFORMATION
dealer: owner:
address: address:
city: city:
state / province: state / province:
zip / postal code: zip / postal code:
country: country:
Receiving and Delivery Report v
with
BC1200XL Brush Chipper
MACHINE IDENTIFICATION NUMBERS - RECORD
Machine Model Number_______________________
Machine Serial Number_______________________
MACHINE IDENTIFICATION DECALThis decal provides easy identification of the model and 17-digit identificationnumber. The barcode contains the machine’s VIN number and can be scannedany barcode reading device.
BC1200XL Brush Chipper
Tier 4 Interim/Stage IIIB
Tier 3/Stage IIIA
vi Receiving and Delivery Report
ENGINE IDENTIFICATION NUMBERS - RECORD
Engine Model Number________________________
Engine Serial Number________________________
Table of Contents vii
tstrols - Left Side Controls Option Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-18
ols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21
rocedure . . . . . . . . . . . . . . . . . . . . . . . 22-1 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-1er Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-1ic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-2ing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-2Explosion - Avoid . . . . . . . . . . . . . . . . . . . . . . . . 22-2Burns - Avoid . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-3tarting Procedure . . . . . . . . . . . . . . . . . . . . . . . . 22-3
Procedure . . . . . . . . . . . . . . . . . . . . . 23-1e Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-1top Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 23-2
ng the Brush Chipper . . . . . . . . . . . . 30-1afety Defects . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1he Towing Vehicle . . . . . . . . . . . . . . . . . . . . . . . . 30-1t - Adjust (BC1200XL Only) . . . . . . . . . . . . . . . . 30-2
ngth - Adjust (BC1200XL Only) . . . . . . . . . . . . . . 30-3owing Vehicle (BC1200XL Only) . . . . . . . . . . . . . 30-4intle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-6
owing Vehicle (BC1200XL European Only) . . . . . 30-7
BC1200XL Brush Chipper
Table of ContenReceiving and Delivery Report . . . . . . . . . . . . . . . . . . . . .i
Dealer Prep . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iEngine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iHydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iGeneral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iiiBrush Chipper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iiiReview of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Dealer/Customer Information. . . . . . . . . . . . . . . . . . . . . . . . . . . ivMachine Identification Numbers - Record . . . . . . . . . . . . . . . . . vMachine Identification Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . vEngine Identification Numbers - Record . . . . . . . . . . . . . . . . . . vi
Safety Messages. . . . . . . . . . . . . . . . . . . . . . . . . 10-1Safety Symbol Explanation . . . . . . . . . . . . . . . . . . . . . . . . . .10-1
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1Engine Monitors (Tier 3/Stage IIIA) . . . . . . . . . . . . . . . . . . . .20-1Engine Monitors (Tier 4 Interim/Stage IIIB) . . . . . . . . . . . . . .20-2Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-4Throttle/Cutter Engage . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-5Feed Roller Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-6
Droop Set Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-13Park Brake (BC1200XL European Only) . . . . . . . . . . . . . . .20-14Wheel Chocks (BC1200XL European Only) . . . . . . . . . . . .20-14Discharge Chute Controls . . . . . . . . . . . . . . . . . . . . . . . . . .20-15Winch Controls (BC1200XL Only) . . . . . . . . . . . . . . . . . . . .20-16
Winch Con(BC1200XLJack ContrFuses. . . .
Starting PStarting theCold Weath
Engine Hydraul
Jump-StartBattery Battery Jump-S
ShutdownStopping th
Quick S
TransportiReporting SEquipping tHitch HeighTongue LeAttach to T
Hitch - PAttach to T
BC1200XL Brush Chipper
Breakaway on Hydraulic Surge Brake (Option) - Reset . . . . 30-8 Infeed System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-12ional Winch (BC1200XL Only). . . . . . . . .50-13y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-13peed . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-13
Preparation for Winching . . . . . . . . . . . 50-14n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-16
hoker - Repair/Replace . . . . . . . . . . . . . .50-23
s from the Brush Chipper . . . . . 51-1lug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51-3lug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51-5 Clean Out . . . . . . . . . . . . . . . . . . . . . . . . .51-6
tervals . . . . . . . . . . . . . . . . . . . . . 60-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-1ual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-2k for Maintenance Interval . . . . . . . . . . . . .60-2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-2
ance . . . . . . . . . . . . . . . . . . 61-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61-4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61-5rface Inspection . . . . . . . . . . . . . . . . . . . 61-6
viii Table of Contents
Breakaway System - Reset Electric Brake . . . . . . . . . . . . . . 30-9Machine - Clean Before Transporting. . . . . . . . . . . . . . . . . . 30-9Prepare for Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10Winch Line - Store (BC1200XL Only) . . . . . . . . . . . . . . . . . 30-11Detach from Towing Vehicle. . . . . . . . . . . . . . . . . . . . . . . . 30-12
Preparing the Brush Chipper and Work Area . . 40-1Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1Operator Qualifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1Personal Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-2Sound Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-3Prepare the Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-3Prepare the Brush Chipper . . . . . . . . . . . . . . . . . . . . . . . . . . 40-4
Clean Flammable Materials from Machine . . . . . . . . . . . 40-5Discharge Chute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-6 Feed Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-9Feed Control Bars - Check . . . . . . . . . . . . . . . . . . . . . . . 40-9
Operating the Brush Chipper . . . . . . . . . . . . . . . 50-1Cutter Shaft - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-1Cutter Drum - Engage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-1Feed Roller Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-2
Upper Feed Control Bar . . . . . . . . . . . . . . . . . . . . . . . . . 50-3Lower Feed Stop Bar and Side Feed Stop Bars . . . . . . . 50-3Sensitivity Levels (BC1200XL Only) . . . . . . . . . . . . . . . . 50-4Feed Roller - Engage . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-5EcoIdle RPM Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7Lower Feed Roller - Access Door . . . . . . . . . . . . . . . . . . 50-8
SmartFeed Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10
Cutting SystemChip Material . . .
Feeding Tips . Material Size . Plugs or StallsFinishing . . . .
Operating the OptWinch CapacitLine Pull and SBrush ChipperWinch Operatio
Winch Line and C
Removing PlugFeed Roller - UnpCutter Drum - UnpDischarge Chute -
Maintenance InSafety Signs . . . . Maintenance ManHourmeter - ChecMaintenance Inter
Knife/Drum MaiKnife Removal . .
Knife InspectioBolt InspectionKnife Mount Su
vals
nten. . . . n . .
Table of Contents ix
BC1200XL Brush ChipperDrum Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61-7Knife Sharpening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61-8
Knife Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61-9
Engine Fault Codes (110/120-HP Engine). . . . . 62-1
.
This page intentionally left blankSafety Messages 10-1
ty messages are located in instructions or procedures are not
fety alert symbol.
located near specific hazards.
result in death or serious injury.
result in death or serious injury.
result in minor or moderate injury.
ion with an exclamation mark or ath.
and watch the operations and safety
BC1200XL Brush Chipper
Section 10: Safety MessagesGeneral safety messages appear in this Safety Messages section. Specific safeappropriate sections of the manual where a potential hazard may occur if the followed.
A signal word “DANGER”, “WARNING”, or “CAUTION” is used with the sa
Safety signs with signal word “DANGER”, “WARNING”, or “CAUTION” are
SAFETY SYMBOL EXPLANATION
DANGER Indicates a hazardous situation that, if not avoided, will
WARNING Indicates a hazardous situation that, if not avoided, could
CAUTION Indicates a hazardous situation that, if not avoided, could
This is the safety alert symbol. This symbol is used in combinatother symbols to alert you to the potential for bodily injury or de
WARNING: Read Operator’s Manual and safety signs,video, before operating machine.
BC1200XL Brush Chipper
be in good operating condition
-fitting clothing and confine hoes. Refer to “Personal
tdoors.
10-2 Safety Messages
WARNING: Check machine before operating. Machine must and all safety equipment installed and functioning properly.
WARNING: Wear personal protective equipment. Wear closelong hair. Always wear a hard hat, safety glasses, and safety sProtection,” page 40-2.
WARNING: Keep spectators away.
WARNING: Engine exhaust can asphyxiate. Operate only ou
Safety Messages 10-3
, cleaning, repairing or transporting
e and result in serious injury or death. eak. Relieve pressure in the hydraulic or performing work on the system. If you e an object such as a piece of wood or tting where some residual pressure may ait for leaking to stop before
must be removed immediately by a
.
BC1200XL Brush Chipper
WARNING: Use Shutdown Procedure before servicingmachine. Follow Shutdown Procedure, page 23-1.
WARNING: Pressurized fluid can penetrate body tissuLeaks can be invisible. Keep away from any suspected lsystem before searching for leaks, disconnecting hoses, must pressurize the system to find a suspected leak, uscardboard rather than your hands. When loosening a fiexist, slowly loosen the fitting until oil begins to leak. Wdisconnecting the fitting. Fluid injected under the skin surgeon familiar with this type of injury.
WARNING: Fuel and fumes can explode and burn.
Shut off engine before refueling. No flame. No smoking
BC1200XL Brush Chipper
that follow within this manual, could poses for which it was intended as
10-4 Safety Messages
WARNING: Hot fluid under pressure can scald.
Allow engine to cool before opening radiator cap.
WARNING: Moving parts can crush fingers.
Close all shields before starting.
WARNING: Failure to follow any of the preceding safety instructions or thoseresult in serious injury or death. This machine is to be used only for those purexplained in this Operator’s Manual.
Controls 20-1
rameters
, red
1
3
2
110-HP (OPTION)
AB
BC1200XL Brush Chipper
Section 20: Controls
ENGINE MONITORS (TIER 3/STAGE IIIA)(1) Fuel Gauge
Gauge indicates how much fuel is in the tank.(2) Engine Display
Display can be set to show multiple items at once or one item.
Engine display shows the following machine parameters, with others pa available for display as customized by the operator:
Displayed Available• Tachometer • Fuel Pressure• Engine Hours • Fuel Temperature• Battery Voltage • Engine Boost• Engine Oil Pressure • Engine Intake Temperature• Engine Coolant Temperature • Engine Coolant Level
(A) Engine Warning Light Amber indicator light signals the presence of an engine warning diagnostic code displayed on monitor.(B) Engine Shutdown Light When Ignition Switch is ON and engine shutdown fault is detected indicator light will show.
(3) Wait-to-Start LightWhite light turns off when ignition is “ON” and engine is ready to start.
BC1200XL Brush Chipper
ers
1 AB
2
120-HP ENGINE (OPTION)
20-2 Controls
ENGINE MONITORS (TIER 4 INTERIM/STAGE IIIB)(1) Fuel Gauge
Gauge indicates how much fuel is in the tank.(2) Engine Display
Display can be set to show multiple items at once or one item.
Engine display shows the following machine parameters, with others paramet available for display as customized by the operator:
Displayed Available• Tachometer • Fuel Pressure• Engine Hours • Fuel Temperature• Battery Voltage • Engine Boost• Engine Oil Pressure • Engine Intake Temperature• Engine Coolant Temperature • Engine Coolant Level
(A) Engine Warning Light Amber indicator light signals the presence of an engine warning diagnostic code displayed on monitor.(B) Engine Shutdown Light When Ignition Switch is ON and engine shutdown fault is detected red indicator light will show. (C) Wait-To-Start Display When “Wait To Start” in display turns off, engine is ready to start.
Controls 20-3
3
BC1200XL Brush Chipper
(3) EcoIdle Switch
Push up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EcoIdle onEngine speed drops from high RPM to 1400 rpm when there has been no material chipped for 5 minutes.
Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EcoIdle off
Push down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EcoIdle onEngine speed drops from high RPM to 1400 rpm when there has been no material chipped for 1 minute.
Refer to EcoIdle RPM Control, page 50-7.
BC1200XL Brush Chipper
110-HP ENGINE (OPTION)
1
120-HP ENGINE (OPTION)
1
20-4 Controls
IGNITION SWITCH(1) Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vertical position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . engine off
1st position clockwise. . . . . . . . . . . . . . . . . . . . . . preheat/engine on
2nd position clockwise . . . . . . . . . . . . . . . . . . . . . . . . . . engine start
Controls 20-5
1
A
B
C
1
A
B
C
LEFT SIDE CONTROLS (OPTION)
BC1200XL Brush Chipper
THROTTLE/CUTTER ENGAGE
(1) Throttle Lever/Clutch Engage
(A) Down position . . . . . . . . . . . . . . . . . . . . . . . . . . disengaged, low RPM
(B) Up, toward operator (chipping position) . . . . . . engaged, high RPM
(C) Up, away from operator/toward machine . . . . . . engaged, low RPM
BC1200XL Brush Chipper
1
BC1200XLEUROPEAN
1
BC1200XL
20-6 Controls
FEED ROLLER CONTROLS
(1) Upper Feed Control Bar
Rear position . . . . . . . . . . . . . . . . . . . . feed roller emergency STOP
Second position from rear . . . . . . . . . . . . . . . feed roller FORWARD
Top/third position from rear . . . . . . . . . . . . . . . . . feed roller STOP
Forward position . . . . . . . . . . . . . . . . . . . . . . feed roller REVERSE
NOTE: Upper Feed Control Bar is spring-returned from REVERSE to STOP position and must be held to operate feed roller in REVERSE.
Controls 20-7
BC1200XL Brush ChipperNOTE: 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
2
2
3
BC1200XLEUROPEAN
3
1
1
20-8 Controls
(2) Lower Feed Stop BarBar pressed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . feed roller stops
To reset: Briefly press Hold-to-Run Button (see (4) on next page).
(3) Side Feed Stop Bars (BC1200XL European Only)Bar pressed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . feed roller stops
To reset: Briefly press Hold-to-Run Button (see (4) on next page).
Controls 20-9
t speed.
4
5
BC1200XL Brush Chipper
Feed roller will automatically restart when engine speed increases to a prese
(4) Hold-to-Run Button (Located on both sides of feed table)Press briefly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . feed roller operates and Lower Feed Stop Bar and Side Feed Stop Bars are ignored for one second.
Press and hold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . feed roller operates for 30 sec. maximum regardless of position of Upper Feed Control Bar (1), Lower Feed Stop Bar (2), and Side Feed Stop Bars (3). After 30 seconds, feed roller stops.
(5) Lower Feed Stop Bar Sensitivity Switch (BC1200XL)
Press top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Normal sensitivityFeed roller stops when stop bar is pushed a shorter distance.
Press bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reduced sensitivityFeed roller stops when stop bar is pushed a farther distance
NOTE: Each time engine key is turned OFF, the Lower Feed Stop Bar systemdefaults to the “Normal Sensitivity” selection.
BC1200XL Brush Chipper
(6)
6
6
BC1200XLEUROPEAN
BC1200XL
20-10 Controls
Rear Warning Light - CenterBC1200XL Only:Normal sensitivity setting selected . . . . . . . . . . . . . warning light offReduced sensitivity setting selected. . . . . . . . . . . . . warning light on
BC1200XL and BC1200XL European:Light flashes quickly when feed roller needs to be restarted after pressing Lower Feed Stop Bar or Side Feed Stop Bars, or pulling Upper Feed Control Bar.
NOTE: When the Rear Warning Light flashes quickly, the Hold-to-Run Button (4) must be pushed to reset stop system and stop warning light from flashing.
4
Controls 20-11
7
8
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) Feed Roller Down Pressure KnobClockwise . . . . . . . . . . . . . . . . . . increase feed roller down pressure
Counterclockwise . . . . . . . . . . . . decrease feed roller down pressure
BC1200XL Brush Chipper
9
A
20-12 Controls
(9) Feed Roller Lock BarFully raise and hold feed roller up with control lever. Install red lock bar over cylinder rod as shown on controls side of machine and secure with pin (A) as shown.
Raise feed roller, remove bar, and store as shown (photo below) before resuming operation.
LEFT SIDE CONTROLS (OPTION)
Controls 20-13
g p speed. speed.
itch (1).
1
BC1200XL Brush Chipper
Droop Set SwitchWith SmartFeed control operation, the feed roller will stop and reverse feedinmaterial when the engine RPM drops below a preset speed, referred to as drooFeed roller will automatically restart when engine speed increases to a preset
Droop speed can be adjusted to high, medium or low speed using Droop Set Sw
Press bottom . . . . . . . . . . . . . . . . . . . . . . . . .low speed droop (brush)
Center . . . . . . . . . . . . . . . . . . . . . medium speed droop (small limbs)
Press top . . . . . . . . . . . . .high speed droop (large limbs and trunks)
BC1200XL Brush Chipper
E
1
2
20-14 Controls
PARK BRAKE (BC1200XL EUROPEAN ONLY)
WHEEL CHOCKS (BC1200XL UROPEAN ONLY)Remove wheel chocks (1) from storage locations and place behind both rear wheels as shown (2) when machine is parked and handbrake is engaged.
The axle brakes have an automatic reverse function, even when handbrake is applied.
Be sure to use one chock behind each rear wheel; do not place them behind and ahead of the same wheel.
(1) Park Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Push back while facing forward . . . . . . . . . . . . . engage park brake
Pull forward to release lever. . . . . . . . . . . . . . disengage park brake
1
One on each side
Controls 20-15
r
2
1
43
5
BC1200XL Brush Chipper
DISCHARGE CHUTE CONTROLS(1) Chute Rotation Handles
Push handles clockwise chute rotates leftPush handles counterclockwise . . . . . . . . . . . . . . . . . . . chute rotates right
(2) Transport Lock PinCenter lever and release lock pin so pin engages hole . . . . . . . . . . . . locked Pull down and rotate lever to disengage lock pin from hole unlocked
(3) Chute DeflectorControls the distance chipped material is discharged.
Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .fartheDown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .closer
(4) Chute Deflector Lock - StandardLoosen to change deflector position.
(5) Chute Deflector Lock - Deluxe (Option)Pull down and rotate to change deflector position.
BC1200XL Brush Chipper
1
2
A
3
20-16 Controls
WINCH CONTROLS (BC1200XL ONLY)(1) Winch/Upper Feed Control Bar
Bar in center STOP or FORWARD . . . . . required to operate winch
Feed rollers will not operate while winch is engaged unless the Hold-to-Run button (A) has been pushed.
(2) Winch Interlock HookSlide hook up:(attach rope loop and pull with winch). . . . . . . . . . winch locked out
Feed rollers will operate if Control Bar (1) is in forward position and Hold-to-Run button (A) has been pushed.
Release and slide hook down: (rope unhooked and winch lever pulled out) . . . . . . winch unlocked
Winch Retract/Extend Lever (4) will move winch line if Winch Engage/Disengage Lever (3) is pushed in. Feed rollers are “OFF” when interlock hook is released.
Controls 20-17
GED ot lock into
Lower
tton must
4
3
5
BC1200XL Brush Chipper
(3) Winch Engage/Disengage LeverRotate lever up . . . . . . . . . . . . . . . . . . . . . . . . . . . winch ENGAGED
Rotate lever down . . . . . . . . . . . . . . . . . . . . . . winch DISENGAGEDAllows winch line to be manually pulled off winch drum.
IMPORTANT: Winch Engage/Disengage Lever must fully lock into ENGAposition in order to perform forward and reverse operation. If lever does nthe ENGAGED position, jog Retract/Extend Lever (4) until it does.
(4) Winch Retract/Extend Lever - With winch engaged:Right. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . retract winch line
Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . extend winch lineIMPORTANT: Maintain light tension on winch line when retracting, to create smooth wrapping onto winch drum.
(5) Rear Warning Light - SideAmber lights are located on both sides of winch mounting frame.Normal sensitivity setting selected . . . . . . . . . . . . warning light offReduced sensitivity setting selected. . . . . . . . . . . . warning light on
Light flashes quickly when feed rollers need to be restarted after pressingFeed Stop Bar, or pulling Upper Feed Control Bar.
NOTE: When the Rear Warning Light flashes quickly, the Hold-to-Run Bube pushed to reset stop system and stop warning light from flashing.
BC1200XL Brush Chipper
L 1
2
A3
20-18 Controls
WINCH CONTROLS - LEFT SIDE CONTROLS OPTION (BC1200XONLY)
(1) Winch/Upper Feed Control BarBar in center STOP or FORWARD . . . . . required to operate winch
Feed rollers will not operate while winch is engaged unless the Hold-to-Run button (A) has been pushed.
(2) Winch Interlock HookSlide hook up:(attach rope loop and pull with winch) . . . . . . . . . .winch locked out
Feed rollers will operate if Control Bar (1) is in forward position and Hold-to-Run button (A) has been pushed.
Release and slide hook down: (rope unhooked and winch lever pulled out) . . . . . . .winch unlocked
Winch Retract/Extend Lever (4) will move winch line if Winch Engage/Disengage Lever (3) is pushed in. Feed rollers are “OFF” when interlock hook is released.
Controls 20-19
GED ot lock into
g Lower
utton must
4
3
5
BC1200XL Brush Chipper
(3) Winch Engage/Disengage LeverRotate lever up . . . . . . . . . . . . . . . . . . . . . . . . . . . . winch ENGAGED
Rotate lever down . . . . . . . . . . . . . . . . . . . . . .winch DISENGAGEDAllows winch line to be manually pulled off winch drum.
IMPORTANT: Winch Engage/Disengage Lever must fully lock into ENGAposition in order to perform forward and reverse operation. If lever does nthe ENGAGED position, jog Retract/Extend Lever (4) until it does.
(4) Winch Retract/Extend Lever - With winch engaged:Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . retract winch line
Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . extend winch lineIMPORTANT: Maintain light tension on winch line when retracting, to create smooth wrapping onto winch drum.
(5) Rear Warning Light - SideAmber lights are located on both sides of winch mounting frame.Normal sensitivity setting selected. . . . . . . . . . . . . warning light offReduced sensitivity setting selected . . . . . . . . . . . . warning light on
Light flashes quickly when feed rollers need to be restarted after pressinFeed Stop Bar, or pulling Upper Feed Control Bar.
NOTE: When the Rear Warning Light flashes quickly, the Hold-to-Run Bbe pushed to reset stop system and stop warning light from flashing.
BC1200XL Brush Chipper
2
4
20-20 Controls
JACK CONTROLS(1) Jack Handle
Clockwise. . . . . . . . . . . . . . . . . extend jackCounterclockwise . . . . . . . . . . retract jack
(2) Transport Storage Position
(3) Lock PinSecure jack to tongue in either transport position or when machine is not attached to tow vehicle.
(4) Rear Jack Transport Storage Position (BC1200XL EURO Only)
3
1
Controls 20-21
1
BC1200XL Brush Chipper
FUSESFuses protect machine electrical circuits. Fuse box (1) is located in the enginecompartment, behind control panel. Fuse circuits are listed below and on the decal on back side of control panel.
Relay FusesForward Feed Solenoid F1 - emptyReverse Feed Solenoid F2 - 10A - Infeed
F3 - 10A - Feed RollersF4 - 5A - for future useF5 - emptyF6 - emptyF7 - 30A - Engine ControllerF8 - 2A - Engine DiagnosticsF9 - 10A - SmartFeed ControllerF10 - empty
This page intentionally left blank.
Starting Procedure 22-1
turns engine
y panel e
. Allow
r.
ly and
ation Manual for recommended
1
1
110-HP Engine
120-HP Engine
BC1200XL Brush Chipper
Section 22: Starting Procedure
STARTING THE ENGINEStep 1: Place Cutter Engage/Throttle Lever in DISENGAGED/LOW RPM.
Step 2: Place Upper Feed Control Bar in top STOP position.
Step 3: Turn keyswitch to preheat/ON position.
Step 4: 110-HP Engine (Option): After white Preheat Indicator Light (1) off, turn key fully clockwise to start the engine. Release key once thestarts.120-HP Engine (Option): After the wait to start turns off in displa(1), turn key fully clockwise to start the engine. Release key once thengine starts.
IMPORTANT: Never run the starter motor for more than 30 seconds at a timestarter motor to cool 1 minute between attempts.
Step 5: Allow engine to warm up for 3–5 minutes before engaging the cutte
IMPORTANT: Do not idle engine for more than 10 minutes. The resulting low temperatures in the combustion chamber will not allow fuel to burn completecan cause engine damage.
COLD WEATHER STARTING
EngineBefore operating in cold weather (below 32°F (0°C)), refer to the Engine Operengine oil, fuel, and starting procedures.
BC1200XL Brush Chipper
Hydraulic Fluidarm, let it run for a
ehicles in contact have a mper cable is connected or k of battery explosion.
ouch.
eep all burning materials away burn. Tools and cable clamps
22-2 Starting Procedure
In cold weather, take more time to warm up the hydraulic fluid. After the engine is wminimum of five more minutes at low RPM before operating any controls.
NOTE: Slow down engine if the hydraulic pump squeals due to insufficient oil.
JUMP-STARTING
Battery Explosion - Avoid
Do not jump-start or charge a battery that is frozen or low on electrolyte.
Avoid explosion hazard.
Do not allow vehicle used to jump-start to be in contact with the disabled machine. Vground connection which allows a spark to occur at the battery when the positive juremoved. If equipped with battery caps, they must be in place and tight to reduce ris
IMPORTANT: Use only a 12-volt system for jump-starting. Do not allow vehicles to t
WARNING: Battery fumes are flammable and can explode. Kfrom battery. Battery explosion can blind. Acid can blind and can make sparks.
Do not smoke. Shield eyes and face. Read instructions.
Starting Procedure 22-3
th eyes, skin, and clothing.
ater for 15 minutes and get
ia, beaten egg, or vegetable oil.
ries contain lead and lead cause cancer and reproductive
BC1200XL Brush Chipper
Battery Burns - AvoidBattery contains sulfuric acid which can cause severe burns. Avoid contact wi
In case of acid contact:
External: Flush with plenty of water. If eyes have been exposed, flush with wprompt medical attention.
Internal: Drink large quantities of water or milk, follow with milk of magnesCall a physician immediately.
Jump-Starting Procedure
WARNING: Battery post, terminals, and related accessocompounds, chemicals known to the state of California toharm.
Wash hands after handling.
Pb
BC1200XL Brush Chipper
IMPORTANT: Review battery service safety
, and moving parts.
the booster battery before
ve cable clamp on the
NGINETER
ERS
CONNECTTO FRAMEFOR GROUND
22-4 Starting Procedure
guidelines before jump-starting machine (refer to battery maintenance instructions in the “Maintenance - 500 Service Hours” section of the Maintenance Manual).
Step 1: Turn ignition switch to OFF.
Step 2: Connect jumper cables in the following order:
a. Red to discharged battery POSITIVE (+) terminal.
f. Red to booster battery POSITIVE (+) terminal.
g. Black to booster battery NEGATIVE (-) terminal.
h. Black to frame of machine with the discharged battery. Make connection away from battery, hydraulic lines
NOTE: To avoid sparks near the battery, always disconnect black jumper cable frommaking any adjustment to the red jumper cable.
Step 3: Start engine.
Step 4: Remove cables in REVERSE order and install the red cover over the positibattery.
MACHINEBATTERY
BOOSTERBATTERY
TO FRAMETO ESTAR
JUMPCABLE
Shutdown Procedure 23-1
dure before working on the or transporting the chipper.
, or if an emergency requires it.
osition.
on left
engine
1
BC1200XL Brush Chipper
Section 23: Shutdown Procedure
STOPPING THE MACHINEIMPORTANT: For your safety and the safety of others, use the shutdown procemachine for any reason, including servicing, cleaning, unclogging, inspecting,
A variation of this procedure may be used if so instructed within this manual
Step 1: Return Upper Feed Control Bar to top STOP position.
Step 2: Move Cutter Engage/Throttle Lever to ENGAGED/LOW RPM position.
IMPORTANT: Whenever practical and consistent with good safety practice, run engine without load for a few minutes before shutting it off. This allows engine temperatures to decrease and equalize, which will increase engine life.
Step 3: Wait for cutter drum to slow.
Step 4: Move Cutter Engage/Throttle Lever to DISENGAGED/LOW RPM p
Step 5: Turn ignition key to OFF position.
Step 6: Wait for cutter drum and belt to stop.
NOTE: Cutter drum rotation can be checked by looking at the end of shaft (1)side of cutter wheel housing.
IMPORTANT: The cutter drum will continue to turn for a short time after the has stopped.
Step 7: Remove ignition key.
Step 8: Close and latch feed table.
BC1200XL Brush Chipper
Quick Stop Procedure
.
To Stop Drum Quickly
Shut Off Engine With Clutch Engaged
23-2 Shutdown Procedure
Step 1: Turn ignition to OFF position while cutter drum clutch is still engaged.
Step 2: Wait for cutter drum and belt to stop.
Step 3: Move Cutter Engage/Throttle Lever to DISENGAGED/LOW RPM position
Step 4: Remove ignition key.
Transporting the Brush Chipper 30-1
Chipper
ash or could cause injury or death, tration (NHTSA) in addition to
finds that a safety defect exists in TSA cannot become involved in tact NHTSA, you may either call ), or file a report on-line at: rtation, 400 - 7th St. SW, ehicle safety from the Hotline.
Safety Department, Vermeer ll Free: 800.829.0051
a brake controller that
erated controller. If your towing one that can be applied both
ce damage to the front of the
BC1200XL Brush Chipper
Section 30: Transporting the Brush
REPORTING SAFETY DEFECTSFor Brush Chippers within the United States:
If you believe that your vehicle BC1200XL has a defect which could cause a cryou should immediately inform the National Highway Traffic Safety Adminisnotifying Vermeer Corporation.
If NHTSA receives similar complaints, it may open an investigation, and if it a group of vehicles, it may order a recall and remedy campaign. However, NHindividual problems between you, your dealer or Vermeer Corporation. To conthe DOT Auto Safety Hotline toll-free at 1-888-DASH-2DOT (1-888-327-4236www.nhtsa.dot.gov/hotline/, or write to: NHTSA, U.S. Department of TranspoWashington, D.C. 20590. You can also obtain other information about motor v
For Brush Chippers outside the United States:
Contact your local governmental road regulation authority or contact ProductCorporation; Email: [email protected]; Telephone: 641.628.3141; To
EQUIPPING THE TOWING VEHICLEIMPORTANT: (BC1200XL Only) The towing vehicle must be equipped with automatically applies the towed machine's electric brakes.
(BC1200XL Only) Do not use a brake controller that is purely a manually opvehicle is equipped with a manually operated controller, remove it and installautomatically and manually.
It is recommended that the towing vehicle be equipped with mud flaps to redutowed machine from road debris.
BC1200XL Brush Chipper
1
30-2 Transporting the Brush Chipper
HITCH HEIGHT - ADJUST (BC1200XL ONLY)Before attaching the machine to the towing vehicle, check the height of the hitch on the towing vehicle to the hitch on the machine. The height of the hitch needs to be approximately the same to keep the machine level during transport.
To adjust hitch:
Step 1: Remove two hitch bolts (1).
Step 2: Raise or lower hitch to match towing vehicle height.
Step 3: Replace the two hitch bolts and tighten. Torque to 210 ft-lb (285 Nm).
Transporting the Brush Chipper 30-3
two positions that allow a 16" (42
cut to allow tongue to be extended
e.
ath shielding
with holes in
specification.
oth inner and outer tubes. Damage to e length is 41" (104 cm).
arate from gue length.
1
BC1200XL Brush Chipper
TONGUE LENGTH - ADJUST (BC1200XL ONLY)The tongue can be lengthened or shortened to fit the towing vehicle. There arecm) total variation in tongue length.
NOTE: The wire harness is tied to the frame and the cable ties may need to be to its longer length.
Use the following steps to adjust the tongue length.
NOTE: Tongue is adjusted most easily with hitch detached from towing vehicl
Step 1: Support machine with the jack.
Step 2: Remove two tongue adjustment bolts (1). Second bolt is located beneon inner side of frame.
Step 3: Slide tongue to the new set of holes in tongue. Align holes in tongueframe.
Step 4: Insert both tongue adjustment bolts and secure with nuts, torque to
WARNING: Overextending tongue will allow only one bolt to engage btongue and separation of tongue possible. Maximum exposed inner tub
WARNING: A single tongue bolt could fail, allowing the chipper to septhe tow vehicle. Always install and secure both bolts after adjusting ton
BC1200XL Brush Chipper
hook latches are damaged or
3
1
2
30-4 Transporting the Brush Chipper
ATTACH TO TOWING VEHICLE (BC1200XL ONLY)
If chain hook latch is damaged, refer to “Maintenance As Required” section in the Maintenance Manual.
Step 1: Securely attach machine hitch to towing vehicle. Refer to instructions for specific hitch type.
Step 2: Cross safety chains (1) under the tongue and use one of the following methods to attach chains to the towing vehicle:
Secure each chain hook to an appropriate ring or loop (2) on towing vehicle hitch,
OR:
Loop each chain around towing vehicle frame or hitch cross member and clip the chain hook (3) back onto the chain. Ensure the spring-loaded latch snaps closed around the chain and rests snugly against the slip hook.
NOTE: Keep chains as short as possible, but leave enough slack to turn corners.
WARNING: Safety towing chains may uncouple from towing vehicle if chain missing. Do not tow vehicle with damaged or missing hook latches.
Transporting the Brush Chipper 30-5
hicle
to
ay ins
hway
4
5
6
7
8
BC1200XL Brush Chipper
To adjust chain length:
a. Remove bolt (4).
b. Slide chain loops through slots (5) to increase or decrease chain lengths.
c. Install bolt (4) to lock chain loops in place.
Step 3: Route breakaway cable (6) through loop (7) and attach to towing vebumper or frame.
Step 4: If equipped with optional hydraulic surge brake chain/hook, connecttowing vehicle.
IMPORTANT: The breakaway cable length should be adjusted so the breakawsystem applies the brakes only after both the hitch and the safety towing chahave disconnected.
Step 5: Attach electrical connector (8) to the towing vehicle. Check that higlights and electric brakes are functioning properly.
BC1200XL Brush Chipper
IMPORTANT: Inspect each safety chain slip hook latch
9
K
4
1
3
2
30-6 Transporting the Brush Chipper
system every time the machine is attached to a towing vehicle. If the latch is damaged, missing, or does not snap closed to the hook, the slip hook may not remain coupled. Refer to “Maintenance as Required” section for instructions on replacing damaged or missing safety towing chains and hooks.
Step 6: Fully raise jack (9), rotate 90° and secure to tongue with attachment pin.
Hitch - PintleStep 1: Open pintle (1).
Step 2: Back up towing vehicle until pintle is centered under pintle ring (2) of the hitch.
Step 3: Lower tongue until the pintle ring is seated in the pintle hook (3).
Step 4: Latch pintle and lock with cotter pin (4).
SPRING-LOADEDLATCH
SLIPHOO
Transporting the Brush Chipper 30-7
2
4
3
5
REAR JACK
BC1200XL Brush Chipper
ATTACH TO TOWING VEHICLE (BC1200XL EUROPEAN ONLY)
Step 1: Attach to vehicle hitch.
a. Squeeze on bottom side of handle (1) and lift to unlock the hitch.
b. After hitch is placed over the ball on the towing vehicle, push down on the locking handle (1) until hitch locks into place.
Step 2: Attach breakaway cable (2) to towing vehicle bumper or frame.
IMPORTANT: Adjust cable length so the breakaway system is triggered only after the machine has disconnected from the hitch.
Step 3: Connect electrical connector (3) to receptacle on towing vehicle. Check that highway lights function correctly.
Step 4: Push Park Brake Lever (4) back towards the machine to activate brakes, pull forward to release.
Step 5: Fully raise front and rear jacks (5), rotate 90°, and secure to frame with attachment pin as shown.
1
5
FRONT JACK
BC1200XL Brush Chipper
(
12
30-8 Transporting the Brush Chipper
BREAKAWAY ON HYDRAULIC SURGE BRAKE OPTION) - RESET
Step 1: Pry apart spring clips (1).
Step 2: Return lever (2) to reset position.
Transporting the Brush Chipper 30-9
to withstand high pressure water n or damage to any devices hit controls and electrical/electronic
component seals. Do not point air
riking other vehicles during
34
5
BC1200XL Brush Chipper
BREAKAWAY SYSTEM - RESET ELECTRIC BRAKE
Route breakaway cable assembly (1) through loop (2) and insert plastic plug (3) back into body of switch (4). Ensure switch body (4) pivots freely on mounting bolts (5).
MACHINE - CLEAN BEFORE TRANSPORTING
IMPORTANT: Machine controls and electrical/electronic devices are not rated and temperature power washers. Water intrusion will likely cause malfunctiodirectly by the water spray. Keep pressure washer stream away from machinedevices. Compressed air can also push moisture through some connector and nozzle directly at seal areas.
Ensure feed table is empty. Clean machine to keep debris off road and from sttransport.
1
2
BC1200XL Brush Chipper
3
2
1
1
2
3
BC1200XL
EuropeanBC1200XL
30-10 Transporting the Brush Chipper
PREPARE FOR TRANSPORTStep 1: Fold up feed table (1) and secure latch (2).
Step 2: Rotate discharge chute (3) forward.
Transporting the Brush Chipper 30-11
the feed
ook slides
achine in
1
2
LEFT SIDE CONTROLS (OPTION)
2
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) abovetable as shown.
Step 4: Using the Winch Retract/Extend Lever, retract winch line until the hback and locks. Leave the line taut.
Step 5: Follow Shutdown Procedure, page 23-1.
Step 6: Place separate chain choker in machine toolbox.
NOTE: Winch line must be in stored position for transporting and to operate mchipping mode.
BC1200XL Brush Chipper
2
3
30-12 Transporting the Brush Chipper
DETACH FROM TOWING VEHICLEPark machine on level ground and chock wheels. Use jack to support tongue. Store electrical connector (1), breakaway cable, and safety chains (2) on end of tongue.
On BC1200XL European machines, engage Park Brake Lever and use blocks (3) provided to chock wheels.
NOTE: If operating the BC1200XL European while unhitched from tow vehicle, both front and rear jacks must be used.
1
Preparing the Brush Chipper and Work Area 40-1
hipper and Work Area
ed solely for use in chipping
Operator's Manual, safety signs
ion of the machine. Do not use the
e supervision of a trained and
ns, and must be mentally and
and watch the operations and
BC1200XL Brush Chipper
Section 40: Preparing the Brush C
INTENDED USEThe Vermeer BC1200XL and BC1200XL European Brush Chippers are designorganic material such as wood, bark, limbs, brush, and undergrowth.
Always use the machine in accordance with the instructions contained in thison the machine, and other material provided by Vermeer Corporation.
Proper maintenance and repair is essential for safety, and for efficient operatmachine if it is not in suitable operating condition.
OPERATOR QUALIFICATIONS
Allow only responsible, properly instructed individuals to operate machine.
Become familiar with the controls, operation and use of the machine under thexperienced operator.
The operator must be familiar with the workplace’s safety rules and regulatiophysically capable of operating the machine safely.
WARNING: Read Operator’s Manual and safety signs,safety video, before operating machine.
BC1200XL Brush Chipper
ways wear a hard hat, uffs are not permitted), ng.
n devices provide differing ropriate for your specific conditions. To determine r local environmental noise
e equipment.
fitting clothing and ecklaces, or bracelets.
40-2 Preparing the Brush Chipper and Work Area
PERSONAL PROTECTION
Operating the machine will require you to wear protective equipment. You should alsafety shoes, loose-fitting gloves with narrow cuffs (gauntlet-type gloves with wide chearing protectors, and eye protection. If working near traffic, wear reflective clothi
Hearing protection is recommended when operating the machine. Hearing protectiolevels of sound reduction. It is important to select a device that is adequate and appwork environment. Actual sound levels may vary widely, depending on your workingthe level of hearing protection your work environment requires, enlist the help of youspecialist.
Eye protection must consist of wraparound safety glasses or goggles.
Other workers in immediate area must also wear the above listed required protectiv
Wear close-fitting clothing and confine long hair.
Avoid wearing jewelry, such as rings, wristwatches, necklaces, or bracelets.
WARNING: Wear personal protective equipment. Wear close-confine long hair. Avoid jewelry, such as rings, wristwatches, n
Preparing the Brush Chipper and Work Area 40-3
est procedures specified in
. . . . . . . . . . . 110 dB(A)
. . . . . . . . . . . 124 dB(A)
tion. Operating conditions may g conditions may be different.
y from the machine and work area
BC1200XL Brush Chipper
SOUND LEVELSThe following sound levels are determined while chipping wood according to tEN 13525.
Equivalent Continuous A-Weighted Sound Pressure Level at Operator’s Ear (per ISO 11201) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Guaranteed Sound Power Level (per 2000/14/EC, ISO 3744) . . . . . . . . . . . . . .
NOTE: The stated sound levels are representative for a given operating condivary at each jobsite. The actual sound levels for your application and operatin
PREPARE THE AREA
WARNING: Keep all spectators and other workers awawhile in operation.
BC1200XL Brush Chipper
hine on the jobsite.
and efficient movement of
bove ground when feeding
icle.
n traffic. Use all necessary
e in good operating condition
40-4 Preparing the Brush Chipper and Work Area
PREPARE THE BRUSH CHIPPER
• Survey area around the machine for persons or obstacles before positioning mac
• Set up machine in an area free of obstructions that could interfere with the safethe operator. Never set up beneath a tree being pruned or removed.
• Position machine so working surface of feed table is a minimum of 24" (61 cm) amaterial.
• During typical operation, the brush chipper must stay hitched to the towing veh
• The brush chipper may be operated while unattached to the towing vehicle if:
• Machine is parked on a level surface.• Tongue is supported by blocking.• Rear jack is supporting infeed end of machine (BC1200XL European Only).• Wheels are securely chocked.• Optional winch is not used.
• If operating along a road, properly warn and divert motor vehicle and pedestriasigns, cones, and flag persons needed for the work situation.
WARNING: Check machine before operating. Machine must band all safety equipment installed and functioning properly.
Preparing the Brush Chipper and Work Area 40-5
to withstand high pressure water n or damage to any devices hit controls and electrical/electronic
component seals. Do not point air
el tank clean of accumulated
BC1200XL Brush Chipper
Clean Flammable Materials from MachineIMPORTANT: Machine controls and electrical/electronic devices are not rated and temperature power washers. Water intrusion will likely cause malfunctiodirectly by the water spray. Keep pressure washer stream away from machinedevices. Compressed air can also push moisture through some connector and nozzle directly at seal areas.
Prevent fires by keeping engine compartment, battery, hydraulic lines, and futrash, grease, and debris.
BC1200XL Brush Chipper
Discharge Chute
turning. Direct discharge
1
3
2
40-6 Preparing the Brush Chipper and Work Area
Step 1: Pull down and rotate transport lock pin (3).
Step 2: Rotate discharge chute (1) to the direction you want to deposit the chippedmaterial by moving the rotation handles (2) in that direction.
Step 3: Engage lock pin (3).
WARNING: Thrown objects can blind you.
Keep everyone away from discharge area while cutter drum ischute away from people. Wear eye protection.
Preparing the Brush Chipper and Work Area 40-7
terial over s to the
e over right
CHIPDISCHARGE
AREA
OPERATORAREAWHEN
FEEDING BRUSH
4
BC1200XL Brush Chipper
NOTE: The discharge chute is equipped with a stop to prevent discharging mathe feed table area. The discharge chute can be rotated 270° to direct the chipdesired position.
NOTE: If unable to reach the deflector or lock handle, position discharge chutfender, and use step (4) on right front of frame.
BC1200XL Brush Chipper
Step 4: To adjust discharge distance, raise or lower discharge chute deflector (5).
o
65
7
40-8 Preparing the Brush Chipper and Work Area
• Standard deflector
Loosen locking handle (6). Adjust deflector height, tighten locking handle tsecure the adjusted deflector.
• Deluxe deflector (option)
Pull down on spring-loaded handle (7) to adjust deflector height.
aring the Brush Chipper and Work Area 40-9
1
3
2
1
3
4
2
BC1200XL
BC1200XLEuropean
BC1200XL Brush Chipper
Feed TableUnlatch feed table and lower to operating position. The feed table provides an important measure of safety by increasing the distance between the feed roller (1) (behind curtain) and the operator. Never operate brush chipper with the feed table removed.
Feed Control Bars - CheckThe brush chipper is equipped with an Upper Feed Control Bar (2) located across the top and sides of the feed table, and a Lower Feed Stop Bar (3) along the bottom of the feed table; also Side Feed Stop Bars along both sides (4) of the BC1200XL European. Do not operate brush chipper unless the control bars are installed and operating properly. Refer to Feed Roller Controls, page 20-6.
Prep
This page intentionally left blank.
Operating the Brush Chipper 50-1
hipper
end (1) ver is in ssary.
1
1
1
LEFT SIDE CONTROLS (OPTION)
BC1200XL Brush Chipper
Section 50: Operating the Brush C
CUTTER SHAFT - CHECKStart engine. Refer to Starting Procedure, page 22-1. Check cutter drum shaftto see that the cutter drum does not turn while the Cutter Engage/Throttle Lethe DISENGAGED/LOW RPM position. If rotation occurs, adjustment is neceRefer to the Maintenance Manual, 50 Service Hours section for instructions.
CUTTER DRUM - ENGAGEAfter engine has warmed up, grip Cutter Engage/Throttle Lever (1) firmly and move it slowly to the ENGAGED/HIGH RPM position.
BC1200XL Brush Chipper
gine RPM drops below
b and pull you in faster than you can let go
Never climb onto feed table.
Use wood object to push short material.
Keep away from rotating feed rollers and blades.
ncrease in engine speed. Place working on or near feed roller ed intake area.
50-2 Operating the Brush Chipper
FEED ROLLER OPERATION
With SmartFeed control operation, the feed roller will stop feeding material when enpreset speeds, and will automatically restart when engine speed increases.
DANGER: Limbs can snag clothing. Rollers or blades can graof limb. Cutting injury or death will result.
Feed material only from side of feed table.
Feed base of limb or branch first.
Wear gloves with narrow tight-fitting cuffs.
WARNING: Feed roller may start unexpectedly with a small iUpper Feed Control Bar in Center Stop and stop engine beforefor any reason including cleaning, servicing and unclogging fe
Operating the Brush Chipper 50-3
stop feed
European ged by a and must ower Feed
r (2) or the it possible
ars, the s for
p Bar and of s.
2
1
BC1200XL
BC1200XLEuropean
3
2
BC1200XL Brush Chipper
Upper Feed Control BarThe Upper Feed Control Bar (1) provides a means for the operator to quickly rollers as well as selecting forward or reverse operation.
Lower Feed Stop Bar and Side Feed Stop BarsThe Lower Feed Stop Bar system (2) and Side Feed Stop Bars (3) (BC1200XLonly) provides a means for the operator to quickly stop the feed rollers if snagbranch and pulled toward the machine. This system is intended for your safetybe maintained in good operating condition. Do not operate the machine if the LStop Bar or Side Feed Stop Bars are not functioning properly.
Stopping the feed rollers is accomplished by bumping the Lower Feed Stop BaSide Feed Stop Bars (3). The Feed Stop Bars are strategically located to makefor an operator to strike the bars and shut off the feed either intentionally or automatically in an emergency situation. If the operator does not strike the bfeed will not stop. It is therefore very important to follow all safety instructionfeeding material into the chipper.
IMPORTANT: Proper operation of the Upper Feed Control Bar, Lower Feed StoSide Feed Stop Bars (BC1200XL European) should be checked every 10 hoursoperation or daily. Refer to the Maintenance Manual for adjustment instruction
BC1200XL Brush Chipper
top
he
y. cy
4
3
5
6
50-4 Operating the Brush Chipper
Sensitivity Levels (BC1200XL ONLY)The Lower Feed Stop Bar has two levels of sensitivity. When the NORMAL setting (of the Sensitivity Switch) is selected (3), the stop bar is depressed a shorter distancebefore the feed rollers stop. When the REDUCED setting (bottom of the Sensitivity Switch) is selected (4), the stop bar is depressed farther before feed rollers stop.
The amber warning lights located on the rear of the machine (5), and on the sides ofoptional winch assembly (6), turn on when the REDUCED setting of the SensitivitySwitch is selected.
Each time the engine key is turned OFF, the lower feed stop bar system defaults to tNORMAL setting.
IMPORTANT: The NORMAL sensitivity setting provides the most protection for the operator since a leg is more likely to strike the bar and shut off feed in an emergencUse NORMAL sensitivity setting whenever jobsite conditions permit. If the size andshape of limbs cause branches to strike the bar, resulting in an unacceptable frequenof feed stops, REDUCED sensitivity setting may be temporarily selected when thesedifficult conditions have passed, select the NORMAL setting to continue chipping.
Operating the Brush Chipper 50-5
Stop Bar
ss of ed Stop by
3
1
BC1200XL Brush Chipper
Feed Roller - EngageStart feed roller:
• Pull Upper Feed Control Bar (1) to FORWARD feeding position.
• Press Hold-to-Run Button (2).
• Pressing it briefly causes feed rollers to operate and the Lower Feed and Side Feed Stop Bars to be ignored for one second.
• Holding it causes feed rollers to operate for up to 30 seconds regardleposition of Upper Feed Control Bar, Lower Feed Stop Bar and Side FeBars (European). After 30 seconds, feed rollers stop, and can be resetreleasing the Hold-to-Run Button and pressing it again.
BC1200XL Brush Chipper
IMPORTANT: When Hold-to-Run Button is released:
al before
ckly, and
2
3
LEFT SIDE CONTROLS (OPTION) SHOWN
50-6 Operating the Brush Chipper
• Feed rollers stop if either bar is in the STOP position.
• Feed rollers run if both bars are in the RUN position.
If material continues to strike the bar and stop the feed roller, trim or shorten materifeeding it into the chipper.
NOTE: Each time the engine key is turned ON, the rear warning lights (3) flash quiHold-to-Run Button (2) must be pushed to start feed rollers.
NOTE: Engine throttle must be set at HIGH RPM before feed rollers will start.
Operating the Brush Chipper 50-7
1
BC1200XL Brush Chipper
EcoIdle RPM ControlThe EcoIdle system is a fuel saving technology that drops the engine speed to 1500 rpm when the control system determines there has been no material chipped for 1 or 5 minutes depending on switch setting. The system is turned on by pushing EcoIdle switch (1) up or down. The machine must have EcoIdle selected, must be in high idle, and must have the clutch engaged.
• Push switch up: Engine speed drops from high RPM to 1500 rpm when there has been no material chipped for 5 minutes.
• Push switch down: Engine speed drops from high RPM to 1500 rpm when there has been no material chipped for 1 minute.
The system will exit EcoIdle mode whenever any of the following occur:
• Engine detects a load
• Operator adjusts engine speed
• Hold-to-Run button is selected
• EcoIdle is turned off
• Winch operation is selected
• Clutch is disengaged
• Switch is in center position
BC1200XL Brush Chipper
Lower Feed Roller - Access Doorallow lug,
cut off fingers and toes.
re approaching the feed roller.
1
50-8 Operating the Brush Chipper
Bottom of lower feed roller is enclosed in a housing with a bottom access door (1) to for cleaning and removing build-up around the feed roller. Refer to Feed Roller - Unppage 51-3.
WARNING: Rotating feed roller above cover will
Stay away from rotating feed roller.
Stop feed roller, stop engine and remove key befo+ =
Operating the Brush Chipper 50-9
2
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 orice build-up that cannot be easily removed, it is acceptable to operate the chipper with the access door (2) open. This will allow some of the material contamination to drop out the lower feed roller access door and not be carriedthrough the chipper. Shut machine down before opening or closing the bottomaccess door. Follow Shutdown Procedure, page 23-1. Stay away from rotating feed roller if bottom access door is open.
BC1200XL Brush Chipper
ain optimum engine they are heavily loaded.
Bars and Upper Feed
ence that reverses the feed rollers for a short aterial begins feeding. The length of time the material does not feed after five tries, the
-
1
50-10 Operating the Brush Chipper
SMARTFEED OPERATIONSmartFeed monitors and automatically controls various machine functions to maintperformance. Its primary function is to control the infeed and cutting systems when
The controller also does the following:
• controls the engine hourmeter
• controls engine low oil and high temperature shutdown system
• provides control and reset functions for the Lower Feed Stop Bar, Side Feed StopControl Bar.
Infeed SystemWhen the feed rollers are overloaded or stall, SmartFeed automatically starts a sequtime, then resumes forward feeding. The sequence occurs up to five times, or until mfeed rollers are reversed starts at 1/2 second and increases slightly each time. If thewhole process starts over.
Cutting System When engine speed drops below a selected RPM because of heavy chipping, SmartFeed momentarily reverses, then stops the feed rollers. Feed rollers start againonce engine speed recovers. This sequence may occur several times before the material completely passes through the machine. The RPM setting depends on whichof three positions the Droop Set Switch (1) is set. Refer to Droop Set Switch, page 2013.
Operating the Brush Chipper 50-11
; never
curbside.
r and stops (BC1200XL
d may strike ly after it
log to aid feeding it into the
tones, wire, or other objects us projectiles.
BC1200XL Brush Chipper
CHIP MATERIAL
Feeding Tips• If feeding material by hand, always feed from the side of the infeed chute
directly behind it.
• Feed large end of log or branch into chipper first.
• To stay out of traffic while operating along a road, feed material from the
• If feeding brushy material that frequently catches on Lower Feed Stop Bathe feed rollers, change sensitivity setting to REDUCED SENSITIVITY. only)
• Sometimes during feeding, a limb will suddenly turn or move sideways anyou. To reduce the possibility of being struck, release the limb immediatebegins feeding and then turn away.
Material Size• The brush chipper will chip logs approximately 12" (30 cm) in diameter.
• Sometimes a log, due to its size and shape, will not go in. Trim or shortenchipper.
WARNING: Check material being chipped. Avoid swhich may damage the knives and become dangero
the
BC1200XL Brush Chipper
Plugs or Stallson. Refer to Removing Plugs
ine.
e material that caused the
chine by feeding in rial with hands,
Procedure, page 23-
50-12 Operating the Brush Chipper
• Discharge chute, cutter drum, or feed roller may become plugged during operatifrom the Brush Chipper, page 51-1.
• If the engine stalls while chipping, disengage cutter drum before restarting eng
• Start engine and, before engaging cutter drum, reverse feed rollers to remove thstall.
Finishing• Chipped material that accumulates in the infeed chute can be pulled into the ma
a piece of brush, or by pushing it in with a long limb. Never push chipped matefeet, rake, shovel, or any other object.
• Shut down machine when the chipping operation is complete. Follow Shutdown 1.
Operating the Brush Chipper 50-13
bs or inch can
core drum
n the drum, where one layer e pull and line speed, established
. Winch line may break or suddenly ot use towing vehicle pulling power to
2
1
BC1200XL Brush Chipper
OPERATING THE OPTIONAL WINCH (BC1200XL ONLY)
Winch CapacityThe intended use of the winch is to assist the operator in pulling large tree limtrunks to the brush chipper feed rollers without having to lift and carry. The whandle material up to 12" (30 cm) in diameter.
The line assembly includes a 150 ft (46 m), 7/16" line double-braided Spectra®with a polyester jacket (1) and a separate chain choker (2). The recommendedstorage capacity is 150 ft (46 m). This conforms to SAE J706 using a wireline compensation factor, K = 0.8.
Line Pull and SpeedThe line pull and speed of the winch vary based on the number of line layers oequals one row of wraps covering the drum surface. The chart shows rated linin accordance with SAE J706.
Winch Line Layer Line Pull Line Speed
1 2000 lb/907 kg 73 ft/min (22 m/min)
2 1804 lb/818 kg 84 ft/min (26 m/min)
3 1609 lb/730 kg 96 ft/min (29 m/min)
4 1413 lb/641 kg 108 ft/min (33 m/min)
5 1217 lb/552 kg 119 ft/min (36 m/min)
WARNING: Never exceed the rated winch capacity of 2000 lb (900 kg)release while pulling. Serious injury or death may occur if struck. Do nincrease the pulling capacity of winch.
BC1200XL Brush Chipper
Brush Chipper Preparation for Winching
ehicle. Load may move brush
2
50-14 Operating the Brush Chipper
Step 1: Position brush chipper for best alignment of winch inlet, feed table, and load. Repeated side loading will shorten winch line life.
Step 2: Set transport vehicle park brake or chock vehicle wheels to prevent rolling when pulling a load with the winch.
Step 3: Open feed table.
Step 4: With engine running, push Retract/Extend Lever (1) for one second to slacken winch line.
Step 5: Pull Winch Engage/Disengage Lever (2) down to disable feed rollers, enable winch, and disengage winch clutch.
WARNING: Never operate winch with brush chipper detached from towing vchipper or pull tongue off of support blocking.
1
Operating the Brush Chipper 50-15
2
3
LEFT SIDE CONTROLS (OPTION)
4
5
BC1200XL Brush Chipper
Step 6: Unhook rope loop from interlock hook (3) above feed table.
NOTE: When winch is enabled, the amber rear warning lights (4) will flash quickly.
Step 7: Remove chain choker from storage box (5).
1
4
BC1200XL Brush Chipper
Winch Operationth two persons, one to
pull in line and anything
knives.
age to machine and choker. possible.
50-16 Operating the Brush Chipper
Winching limbs to the brush chipper is possible with one operator but works best wioperate the winch controls, and one working the winch line and chain choker.
WARNING: Brush can snag winch line. Knives can grab and attached to it at high speed. Death or serious injury possible.
Do not allow winch line to be snagged and pulled into chipper
WARNING: Chain choker struck by chipper knives will result in serious damMetal can be ejected from infeed chute at high speed. Death or serious injury
WARNING: Choker pulled in at high speed can kill.
Keep choker and winch line separate when pulling out line.
Operating the Brush Chipper 50-17
iously injure you.
igh speed. Death or serious injury
at high speed. Death or serious
bs are feeding into machine.
BC1200XL Brush Chipper
WARNING: Winch line pulled in at high speed can ser
Never pull out winch line while material is feeding.
WARNING: Winch line can pull you into machine at hpossible.
Never put winch line loop over arm or hand.
WARNING: Limbs attached to winch line can be pulleinjury possible.
Never attach winch line to installed choker if other lim
d in
BC1200XL Brush Chipper
Step 1: Refer to Starting Procedure, page 22-1.1
LEFT SIDE CONTROLS (OPTION)
50-18 Operating the Brush Chipper
Step 2: With winch disengaged (Engage/Disengage Lever (1) down), manually pull winch line out as far as needed. Take chain choker with you in other hand.
IMPORTANT:
• Keep chain choker and winch line separated when pulling out line.
• Never pull out winch line while brush or limbs are feeding into the chipper.
• Never put winch line loop over arm or hand.
Step 3: Inspect line and chain choker for damage or wear before each pull. See Maintenance Manual for procedures.
1
Operating the Brush Chipper 50-19
limb and through ring as shown loop (3) to end of chain.
mb while
jury or
3 2
BC1200XL Brush Chipper
Step 4: Securely attach choker chain to limb by passing end of chain around(2). Pull end of chain to tighten on limb, and then attach winch line
IMPORTANT: Never attach the winch line to a choker that is connected to a limaterial is feeding into the chipper.
NOTE: For larger limbs, attach chain near large end of limb.
WARNING: Winch line can break or release. Serious indeath is possible.
Stay clear when winching.
7000B-095
BC1200XL Brush Chipper
Step 5: Push Winch Engage/Disengage Lever (1) 4
50-20 Operating the Brush Chipper
up to engage winch clutch.
IMPORTANT: Winch Engage/Disengage Lever must fully lock into ENGAGED position in order to perform forward and reverse operation. If lever does not lock into ENGAGED position, jog Winch Retract/Extend Lever (4) slightly until it does.
IMPORTANT: Ground personnel must be visibly clear of load and winch line before pulling begins.
1
Operating the Brush Chipper 50-21
hain choker to slacken.
n limb. Further extend winch line
ccur if struck. Stabilize limb on
4
LEFT SIDE CONTROLS (OPTION)
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.)
IMPORTANT: Do not move Winch Engage/Disengage Lever (1) while winch line is under load. Limb on end of line may roll or fall back toward other workers.
Step 7: Continue pulling limb forward until front of limb rests on feed table.
Step 8: Use Winch Retract/Extend Lever (4) to extend winch line to allow c
Step 9: Remove winch line from choker and reposition choker farther back oand re-attach loop to end of choker.
WARNING: Unstable limb may fall off feed table. Serious injury may ofeed table before repositioning chain.
1
BC1200XL Brush Chipper
Step 10: Retract winch line to move limb forward 4
7
6
5
LEFT SIDE CONTROLS (OPTION)
50-22 Operating the Brush Chipper
until it reaches feed rollers.
Step 11: Briefly press Hold-to-Run Button (5) to start limb into feed rollers.
Step 12: When limb is in the grip of the feed rollers, release Hold-to-Run Button (5).
Step 13: Detach choker from limb and remove winch line and choker from path of feeding materials.
Step 14: Hook winch line loop on interlock hook (6).
Step 15: Use Winch Retract/Extend Lever (4) to retract winch line until the interlock hook (6) slides back and locks.
Step 16: If necessary, place Upper Feed Control Bar (7) in FORWARD to feed remainder of limb into chipper. Press Hold-to-Run Button (5) to start feeding.
Step 17: To continue pulling limbs, repeat Steps 2–16.
Step 18: Store winch line and choker. Refer to Winch Line - Store (BC1200XL Only), page 30-11.
WARNING: Failure to detach chain choker from limb before continuing to feed will result in severe equipment damage and may result in injury or death.
4
7
6
5
Operating the Brush Chipper 50-23
h
" (25
tion. ne.
iately
1
BC1200XL Brush Chipper
WINCH LINE AND CHOKER - REPAIR/REPLACE1. Always use a winch line approved by Vermeer Corporation for your brus
chipper winch.
2. If winch line loop is repaired by a qualified rigger, original loop size of 10cm) must be maintained as shown (1).
3. Always use a removable choker assembly approved by Vermeer CorporaNever permanently attach metal or heavy objects to loop end of winch li
4. If your original chain choker is worn, damaged, or lost, replace it immedfrom your authorized Vermeer dealer.
This page intentionally left blank.
Removing Plugs from the Brush Chipper 51-1
the Brush Chipper
an grab and pull you in faster than lt.
BC1200XL Brush Chipper
Section 51: Removing Plugs from
DANGER: Limbs can snag clothing. Rollers or blades cyou can let go of limb. Cutting injury or death will resu
Never climb onto feed table.
Use wood object to push short material.
Keep away from rotating feed rollers and blades.
BC1200XL Brush Chipper
51-2 Removing Plugs from the Brush ChipperWARNING: Rotating knives behind cover can cut off hand.Thrown objects can strike you.
Stop engine, wait for drum to stop, then open access cover.
Removing Plugs from the Brush Chipper 51-3
trol Bar. event it from lug:
cutter drum ped.
r lock bar (2)
storage tab.
d properly. ock bar
1
2
BC1200XL Brush Chipper
FEED ROLLER - UNPLUGIf the upper feed roller becomes plugged, reverse it using the Upper Feed ConInspect dislodged material, ensuring it is not too large or has branches that prbeing fed into the machine. If reversing the feed roller does not dislodge the p
Step 1: Reduce engine speed to idle and wait for cutter drum speed to slow.
Step 2: Disengage Clutch Lever and wait for cutter drum to stop. Check thatrotation has stopped by looking to see if drum shaft end (1) has stop
Step 3: Use Feed Roller Raise Lever to raise feed roller and install feed rolleonto lift cylinder as shown.
Step 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
Step 7: Operate machine without chipping additional material to blow out cremaining in the chipper housing.
WARNING: Raised feed roller can fall if not supporteCrushing injury or death possible. Install feed roller lbefore working near raised feed roller.
hips
BC1200XL Brush Chipper
If the lower feed roller becomes plugged, reverse it using the Upper Feed Control Bar. tion
oor (3) and remove any build-up
cut
re
3
51-4 Removing Plugs from the Brush Chipper
Follow Shutdown Procedure, page 23-1. Remove any dislodged material or contaminathat is preventing the lower feed roller from rotating.
If required, access the bottom of the lower feed roller by opening the bottom access dcontamination. Refer to Lower Feed Roller - Access Door, page 50-8.
WARNING: Rotating feed roller above cover willoff fingers and toes.
Stay away from rotating feed roller.
Stop feed roller, stop engine and remove key befoapproaching the feed roller.
+ =
Removing Plugs from the Brush Chipper 51-5
ands away from sharp knives.
m shaft end (1) has stopped.
).
shing on the outside surface (4) of
bar access door located under
aining chips from chipper
43
BC1200XL Brush Chipper
CUTTER DRUM - UNPLUG
IMPORTANT: Wear gloves when working near the cutter drum knives. Keep h
Step 1: Follow Shutdown Procedure, page 23-1.
Step 2: Check that cutter drum rotation has stopped by looking to see if dru
Step 3: Remove six bolts (2) and washers and open top cutter access door (3
Step 4: Manually reverse rotation of the cutter drum to dislodge chips by puthe drum. Stay well away from cutter knives.
Step 5: If necessary to access bottom of drum, remove four bolts and lower shmachine (refer to the “Maintenance as Required” section).
Step 6: Remove chips.
Step 7: Close and bolt the access doors.
Step 8: Operate machine, without chipping additional material, to blow remhousing.
2
1
ear
BC1200XL Brush Chipper
t
)
1
2
51-6 Removing Plugs from the Brush Chipper
DISCHARGE CHUTE - CLEAN OUT
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 shafend (1) has stopped.
Step 3: Rotate discharge chute over left side of machine.
Step 4: Stand on the non-slip material in front of the fender and push a stick or wooden broom handle, if available, down the end of the discharge chute (2to dislodge the plugged material.
WARNING: Thrown objects can blind you.
Keep everyone away from discharge area while cutter drum isturning. Direct discharge chute away from people. Wear eye protection.
emoving Plugs from the Brush Chipper 51-7
chute at plugged
the
chips 3
BC1200XL Brush Chipper
Step 5: If you are unable to dislodge the plugged material, unbolt dischargethe rotation ring (3) and remove chute from machine to clean out thematerial.
Step 6: Install cleaned discharge chute.
IMPORTANT: Use an appropriate lifting system when removing and installingdischarge chute. Chute weighs approximately 79 lb (36 kg).
Step 7: Operate machine, without chipping additional material, to blow outthat remain in the chipper housing and discharge chute.
R
This page intentionally left blank.
Maintenance Intervals 60-1
requested by Vermeer
n. Refer to Controls, page 20-1. To and for other information.
ions given below:
ers, or other similar cleaners that
rature of the mounting surface dry.
also.
r.
cleaning, repairing, or transporting
BC1200XL Brush Chipper
Section 60: Maintenance Intervals
Visually inspect machine daily before starting the machine.
Make no modifications to your equipment unless specifically recommended orCorporation.
SAFETY SIGNSSafety signs located on your machine contain important and useful informatiohelp you operate your equipment safely, refer to the Parts Manual for locations
To assure that all signs remain in place and in good condition, follow instruct
• Keep signs clean. Use soap and water - not mineral spirits, abrasive cleanwill damage the safety sign.
• Replace any damaged or missing signs. When attaching signs, the tempemust be at least 40°F (5°C). The mounting surface must also be clean and
• When replacing a machine component with a sign attached, replace sign
• Replacement signs can be purchased from your Vermeer equipment deale
WARNING: Use Shutdown Procedure before servicing,machine. Follow Shutdown Procedure, page 23-1.
BC1200XL Brush Chipper
tenance, refer to the
he machine. The hourmeter
under severe conditions, the
different.
terval - Service Hours
250 500 1000 2000As
Reqd.
60-2 Maintenance Intervals
MAINTENANCE MANUALMaintenance intervals are included for reference only. Before performing any mainMaintenance Manual for safety guidelines and correct procedures.
HOURMETER - CHECK FOR MAINTENANCE INTERVALThe hourmeter on the power unit is used to determine maintenance intervals for tindicates the total number of hours the engine has been in operation.
Maintenance intervals are based on normal operating conditions. When operating maintenance intervals should be shortened.
MAINTENANCE INTERVALSInitial = Initial maintenance on new machine. Regular maintenance interval may be
= Regular maintenance interval.
Service
Maintenance In
5 10 50 100Cutter Drum Bearings - Grease
Feed Roller Bearings - Grease
Engine Drive Belt -Inspect
Engine Systems - Check
Engine Cooling System - Check
Crankcase Breather Tube - Inspect
Engine Oil Level - Check
Air Cleaner Restriction Indicator - Check
Maintenance Intervals 60-3
nce Interval - Service Hours
100 250 500 1000 2000As
Reqd.
BC1200XL Brush Chipper
Engine Oil Level - Check
Fuel/Water Separator - Drain
Crankcase Breather Tube - Check
Hydraulic Fluid Level - Check
Engine Cooling System - Check
Fuel Tank - Fill
Brake System - Check
Drum and Knives - Maintain
Fluid Level in Optional Hydraulic Surge Brake - Check
Feed Roller Controls - Check
Wheel Lug Nut Torque - Check Initial
Cutter Drum Drive Belt Tension - Check/Adjust Initial
Pintle Hitch - Check
Lower Feed Stop Bar Switch - Check
Function of Optional Hydraulic Surge Brakes - Check
Electric Brakes - Test
Machine - Grease
Engine Oil and Filters - Change and Replace Initial
Hydraulic Fluid Filter - Initial Replacement Initial
Feed Roller Arm Pivot Pins - Grease
Feed Roller Lift Arms - Grease
Feed Roller Lift Cylinders - Grease
Belt Drive U-Joints - Grease
Belt Drive Pivots - Grease
Service
Maintena
5 10 50
BC1200XL Brush Chipper
erval - Service Hours
250 500 1000 2000As
Reqd.
60-4 Maintenance Intervals
Cutter Drum Drive Belt Tension - Check/Adjust
Machine Components - Inspect
Cutter Shaft - Check
Shear Bar Mounting Hardware - Check
Winch (Option) Line - Clean
Hydraulic System - Check
Overall Machine - Check
Safety Sign Maintenance
Upper Feed Control Bar Force - Check/Adjust
Lower Feed Stop Bar Switch - Check/Adjust
Tires and Rims - Check
Winch (Option) Line - Check
Winch (Option) Line and Choker - Repair/Replace
Winch (Option) Interlock - Check
Engine Oil and Filter - Change and Replace
Cutter Drum Drive Belt Wear - Check
Air Intake System - Check
Corrosion Inhibitors - Add to Coolant
Radiator Hose - Check
Hydraulic Fluid Filter - Replace
Jack - Lubricate
Automatic Brake Controller - Check
Air Cleaner Element(s) - Inspect/Replace (if indicated)
Brakes - Adjust
Winch (Option) Bearings - Grease
Service
Maintenance Int
5 10 50 100
Maintenance Intervals 60-5
ce Interval - Service Hours
100 250 500 1000 2000As
Reqd.
BC1200XL Brush Chipper
Cooling System - Check
Injection Pump - Vent
Fuel Filter - Change
Fuel Supply Lines - Vent
Hydraulic Fluid - Change
Battery Electrolyte Level and Terminals - Check
Cutter Drum Drive Belt - Replace
Feed Table Curtains - Replace
Wheel Bearings - Check/Repack
Ball Coupler - Lubricate and Inspect
Engine Drive Belt Tension/Tensioner - Check
Cooling System - Drain and Clean
Air Cleaner Secondary Element - Replace
Surge Brake Actuator (European)
Park Brake Lever (European) - Grease
Battery - Replace
Valve Lash - Adjustment
Crankcase Breather Element - Replace
Cooling System - Check
Air Cleaner - Inspect
Highway Lights - Replace
SmartFeed System Fuse - Replace
Shear Bar - Check/Adjust/Replace
Knife-Mounting Surface - Check
Slip Hook - Replace
Service
Maintenan
5 10 50
BC1200XL Brush Chipper
erval - Service Hours
250 500 1000 2000As
Reqd.
60-6 Maintenance Intervals
Towing Chain - Replace
Storage
Service
Maintenance Int
5 10 50 100
Knife/Drum Maintenance 61-1
cervice hours. However, the actual s, depending upon the wood being
sibility of the knives becoming
nd.
er
BC1200XL Brush Chipper
Section 61: Knife/Drum MaintenanThe recommended service interval to check the cutter knives is 10 seservice hours interval before knife maintenance is required may be more or leschipped and chipping conditions.
Performing the following maintenance procedures will aid in reducing the posloose, failing, and being ejected from the machine.
WARNING: Rotating knives under cover can cut off haThrown objects can strike you.
Stop engine, wait for drum to stop, then open access cov
BC1200XL Brush Chipper
cted if matched knives are
cutting injuries will result if
2
3
61-2 Knife/Drum Maintenance
KNIFE REMOVAL
IMPORTANT: Always remove and replace knives as sets. Chipper balance can be affenot kept together.
To remove knives:
Step 1: Refer to Shutdown Procedure, page 23-1.
Step 2: Check that cutter drum rotation has stopped by looking to see if drum shaft end (1) has stopped.
Step 3: Remove six bolts and washers (2), and open cutter drum access door (3).
WARNING: Wear gloves when working with the cutter drum knives. Seriouscontact is made with the knives while removing or installing them.
WARNING: Knives can cut off hand.
Lock drum before servicing knives.
1
Knife/Drum Maintenance 61-3
on knives. in (4).
t use
s per the instructions that follow.
4
5
6
BC1200XL Brush Chipper
Step 4: Lock cutter drum to prevent the drum from rotating while working Align one of the two lock holes in the cutter drum and engage lock p
Step 5: Remove four bolts (5) from first knife (6). To prevent damage, do noimpact tool to remove bolts.
Step 6: Lift off knife from drum.
Step 7: Unlock cutter drum and rotate 1/2 turn to the next cutter knife.
NOTE: Rotate by pushing on the outside surface of the drum.
Step 8: Lock cutter drum.
Step 9: Repeat Steps 3–6 to remove both knives.
Step 10: Clean and inspect the drum, mounting surfaces, knives, and bolts a
BC1200XL Brush Chipper
Knife Inspection
s.
n
o
t n the knife surface and the be replaced.
1
2
3
61-4 Knife/Drum Maintenance
• Cracks — Thoroughly clean the knives and inspect both sides of each knife forcracks. If any are found, discard the knife and install a new one.
Cracks (1) that start at the mounting hole and progress outward result from the mounting bolts being improperly torqued.
NOTE: Knife sizes and number of mounting holes may vary between machine model
If cracked knives are reused, the cracks will extend across the knife and the knife caseparate from the cutter drum.
• Distortion — Check the mounting side of the knife for distortion. Bolting a distorted knife to the cutter drum will add stresses in the knife and possibly cause knife cracking and failure.
Step 1: Place a straightedge (2) on the mounting side of the knife (3) and parallel tthe mounting holes as shown.
Step 2: Move straightedge slowly across the knife surface, and monitor for any lighthat shows between the knife and straightedge. If any light appears betweestraightedge, this indicates that the knife is distorted, and the knife must
Step 3: Turn straightedge perpendicular to mounting holes and repeat Step 2.
Knife/Drum Maintenance 61-5
xisting mounting bolts e their clamping ill cause the knives to
y are found, discard
bolts can cause the knives to become detached nives are ejected from the machine and strike will probably occur if the knives become
re sharpened or replaced. Bolts may be reused replace bolts can cause knife/drum separation
ood to pack under the knife. Distorted knives age. Use a straightedge and check all knives
1
BC1200XL Brush Chipper
Bolt Inspection
IMPORTANT: When installing a new or sharpened set of knives, discard the eand use new Vermeer-approved bolts. Repeated reuse of the bolts will decreascapacity each time the bolts are torqued. Inadequate clamping of the knives wloosen and fail.
Bolts —Inspect bolts (1) for damaged threads, corrosion, and distortion. If anthe bolt and install a new one.
WARNING: Incorrect maintenance and torquing of the knife-mountingfrom the cutter drum. Death or serious injury is possible if the failed ksomeone. Extensive and costly damage to the cutter drum and machinedetached.
WARNING: Knife-mounting bolts must be replaced each time knives aONLY ONCE when rotating knife to its second cutting edge. Failure toresulting in death or serious injury, and machine damage.
WARNING: Overtightened bolts can cause knife distortion, allowing wcan crack and fail resulting in death or serious injury, and machine damfor distortion; discard any that are distorted.
BC1200XL Brush Chipper
Knife Mount Surface Inspection drum
ng t ns can
d, or
2
1
61-6 Knife/Drum Maintenance
When a cutting knife is removed from the drum, the knife-mounting surfaces on themust be cleaned and inspected.
IMPORTANT: Any debris left on the mounting surface can prevent the knife from lyiperfectly flat on its mating surface. Any dirty or damaged threads will affect the boltorque, and prevent the knives from being properly clamped. Either of these conditiolead to knife failure during operation.
Thoroughly clean and inspect the following:
• Knife Mount Surface — Remove all wood chips and other material from the mounting pocket area (1).
• Replaceable Thread Bars (2) — Replace when threads become worn, distortedamaged.
Knife/Drum Maintenance 61-7
e following:
d deformation.
drum sides are joined to the
(3) for damage or cracks.
begin at the pockets and migrate
ermeer dealer.
43
BC1200XL Brush Chipper
DRUM INSPECTION
The cutter drum must be free of any damage. Thoroughly clean and inspect th
• Air Paddles — Inspect air paddles (1) and their gussets for cracking an
• Edge Welds — Inspect entire drum for cracks in the welds (2) where thedrum. Use a mirror to aid in this inspection.
• Pockets — Closely inspect area in and around knife mount and pockets
• Cutter Drum Surface — Inspect drum surface (4) for cracks that may outward.
If any drum damage or cracks are found, contact an authorized independent V
2
2
21
BC1200XL Brush Chipper
(51 mm) a knife that
(Minimum)
30°
2.00" (51 mm)
(Minimum)2.00" (51 mm)
30°
61-8 Knife/Drum Maintenance
KNIFE SHARPENING• Sharpen knives at a 30° angle.
• Use a soft “J” grade grinding wheel with 36 to 46 grit.
• Use adequate coolant while grinding.
• Hone knives between sharpenings with an oil honing stone.
IMPORTANT: The knives are double-edged and have a minimum usable size of 2.00"measured from the centerline of the bolt holes to the knife edge. Do not use a side ofmeasures less than this.
Knife/Drum Maintenance 61-9
instructions.
bar (2) in place
g holes to the nted the same way
bolts to hold the
he center bolts. Torque in the
harpened or replaced. Bolts dge. Failure to replace bolts d machine damage.
ife/drum bolts.
ood to pack under the knife. and machine damage. Use a istorted.
31
2
BC1200XL Brush Chipper
Knife InstallationStep 1: Clean and inspect all cutter drum components as per the preceding
Step 2: Lock cutter drum.
Step 3: Install knife (1) with the bevel oriented as shown, and with thread inside drum.
IMPORTANT: On resharpened knives, measure the distance from the mountinsharpened edges. Mount knives so edges with the same measurement are orieat both locations.
Step 4: Lubricate bolts (3) with light oil and install. Lightly tighten all fourknife in place.
Step 5: Torque bolts with a torque wrench to 210 ft-lb (285 Nm) beginning wsame sequence again after the last bolt is tightened.
Step 6: Unlock cutter drum and rotate 1/2 turn to the next cutter knife.
Step 7: Lock cutter drum.
WARNING: Mounting bolts (3) must be replaced each time knives are smay be reused ONLY ONCE when rotating knife to its second cutting ecan cause knife/drum separation resulting in death or serious injury, anAlso, to prevent bolt damage, do not use a power or impact tool to insta
WARNING: Overtightened bolts can cause knife distortion, allowing wDistorted knives can crack and fail resulting in death or serious injury, straightedge and check all knives for distortion; discard any that are d
ith t
ll kn
BC1200XL Brush Chipper
Step 8: Repeat Steps 3–5 to install both knives.
eased and stored.
n, “Shear Bar - Check/
adjust or replace the shear djust”.
61-10 Knife/Drum Maintenance
Step 9: Release drum lock, close and secure cutter drum access door.
NOTE: The cutter drum access door will not fully close until the drum lock pin is rel
Step 10: Adjust shear bar (refer to the Maintenance Manual, 50 Service Hours sectioAdjust”).
IMPORTANT: The shear bar bolts must be checked weekly, even if you do not need tobar. Refer to the Maintenance Manual, 50 Service Hours section, “Shear Bar - Check/A
Engine Fault Codes (110/120-HP Engine) 62-1
10/120-HP Engine)tanding and recording engine fault
actions. Always contact your uble codes which are displayed for
SPN) which identifies the system or ) code which identifies the type of both parts of the code are needed.
CORRECTIVE ACTION
re - Bad Contact Servicing Dealer
Sensor Circuit or - Data Erratic, Check Sensor and Wiring
Sensor Circuit - rce)
Contact Servicing Dealer
Sensor Circuit - rce)
Contact Servicing Dealer
1 Air Pressure - ge - Moderately Contact Servicing Dealer
e Normal, or Check Switch and Wiring
BC1200XL Brush Chipper
Section 62: Engine Fault Codes (1Refer to the Engine Operation Manual for additional information on underscodes displayed on engine multifunction display, and appropriate remedial Vermeer dealer or engine service dealer for help in correcting diagnostic troyour engine.
NOTE: The first part of the code is a six-digit Suspect Parameter Number (component that failed, followed by a two-digit Failure Mode Identifier (FMIfailure (example: high temperature). In order to determine the exact failure
Fault Code
SPN FMI Light DESCRIPTION
111 000629 12 RedECU Programming Error (Critical Internal FailuIntelligent Device or Component)
115 000612 02 RedSystem Diagnostic #2 (Engine Speed/PositionLost Both Signals from Magnetic Pickup SensIntermittent, or Incorrect)
122 000102 03 AmberBoost Pressure (Intake Manifold Air Pressure Voltage Above Normal or Shorted to High Sou
123 000102 04 AmberBoost Pressure (Intake Manifold Air Pressure Voltage Below Normal, or Shorted to Low Sou
124 000102 16 Amber(110-hp only) Boost Pressure (Intake ManifoldData Valid but Above Normal Operational RanSevere Level)
131 000091 03 RedThrottle Position Sensor Circuit - Voltage AbovShorted to High Source
BC1200XL Brush Chipper
l, or Check Switch and Wiring
ve Non Engine Fault. Check Other Shutdown Devices
w Non Engine Fault. Check Other Shutdown Devices
al Check Oil Level
Above Check Sensor and Wiring
Below Check Sensor and Wiring
Normal Check Cooling System, Reduce Power
Normal ut down
Check Cooling System, Reduce Power
e Above Check Sensor and Wiring
e Below Check Sensor and Wiring
ata Valid Check Air Cleaner, Aftercooler, or Room Temperature
Contact Servicing Dealer
CORRECTIVE ACTION
62-2 Engine Fault Codes (110/120-HP Engine)
132 00091 04 RedThrottle Position Sensor Circuit - Voltage Below NormaShorted to Low Source
133 000974 03 RedRemote Throttle (Position Sensor Circuit - Voltage AboNormal, or Shorted to High Source)
134 000974 04 RedRemote Throttle (Position Sensor Circuit - Voltage BeloNormal, or Shorted to Low Source)
143 000100 18 AmberEngine Oil Pressure Low - (Data Valid but Below NormOperational Range - Moderately Severe)
144 000110 03 AmberEngine Coolant Temperature (Sensor Circuit - Voltage Normal, or Shorted to High Source)
145 000110 04 AmberEngine Coolant Temperature (Sensor Circuit - Voltage Normal, or Shorted to Low Source)
146 000110 16 AmberEngine Coolant Temperature High (Data Valid but AboveOperational Range - Moderately Severe)
151 000110 00 RedEngine Coolant Temperature High (Data Valid but AboveOperational Range - Most Severe Level - Engine will sh30 seconds after light stops flashing)
153 000105 03 AmberIntake Manifold #1 Temperature (Sensor Circuit - VoltagNormal, or Shorted to High Source)
154 000105 04 AmberIntake Manifold #1 Temperature (Sensor Circuit - VoltagNormal, or Shorted to Low Source)
155 000105 00 RedIntake Manifold #1 Temperature (Temperature High - Dbut Above Normal Operational Range - Most Severe Le
221 000108 03 AmberBarometric Air Pressure (Sensor Circuit - Voltage AbovNormal, or Shorted to High Source)
Fault Code
SPN FMI Light DESCRIPTION
vel)
e
Engine Fault Codes (110/120-HP Engine) 62-3
Below Normal, Contact Servicing Dealer
al Operational Reduce Engine Speed
age #3 Circuit - e)
Check Sensor and Wiring
age #3 Circuit - e)
Check Sensor and Wiring
l Pressure r Shorted to Check Pump Wiring
l Pressure r Shorted to Check Pump Wiring
low Normal, or Check Injector Wiring or Injector Solenoid
ormal, or Check Injector Wiring or Injector Solenoid
ormal, or Check Injector Wiring or Injector Solenoid
low Normal, or Check Injector Wiring or Injector Solenoid
nternal ponent)
Contact Servicing Dealer
CORRECTIVE ACTION
BC1200XL Brush Chipper
222 000108 04 AmberBarometric Air Pressure (Sensor Circuit - Voltageor Shorted to Low Source)
234 000190 00 RedEngine Speed High (Data Valid but Above NormRange - Most Severe Level)
238 000611 04 AmberSystem Diagnostic Code #1 (Sensor Supply VoltVoltage Below Normal, or Shorted to Low Sourc
239 003511 03 AmberSystem Diagnostic Code #2 (Sensor Supply VoltVoltage Above Normal, or Shorted to High Sourc
271 001347 04 AmberFuel Pump Pressurizing Assembly #1 (High FueSolenoid Valve Circuit - Voltage Below Normal, oLow Source)
272 001347 03 AmberFuel Pump Pressurizing Assembly #1 (High FueSolenoid Valve Circuit - Voltage Above Normal, oHigh Source)
322 000651 05 AmberInjector Solenoid Cylinder #1 Circuit (Current BeOpen Circuit)
324 00653 05 AmberInjector Solenoid Cylinder #3 Circuit (Current BeOpen Circuit
331 000652 05 AmberInjector Solenoid Cylinder #2 Circuit (Current BeOpen Circuit)
332 000654 05 AmberInjector Solenoid Cylinder #4 Circuit (Current BeOpen Circuit)
343 000629 12 AmberController #1 (Engine Control Module Warning IHardware Failure - Bad Intelligent Device or Com
Fault Code
SPN FMI Light DESCRIPTION
low N
low N
BC1200XL Brush Chipper
evice or Contact Servicing Dealer
Voltage Check Wiring
Voltage Check Wiring
al Check Oil Level
e Above Check Sensor and Wiring
e Below Check Sensor and Wiring
atic, Contact Servicing Dealer
Contact Servicing Dealer
Erratic, Check Sensor and Wiring
Data y Severe Contact Servicing Dealer
Data ere Contact Servicing Dealer
CORRECTIVE ACTION
62-4 Engine Fault Codes (110/120-HP Engine)
351 000629 12 AmberController #1 (Injector Power Supply - Bad Intelligent DComponent)
352 001079 04 Amber5 Volts DC Supply (Sensor Supply Voltage #1 Circuit - Below Normal, or Shorted to Low Source)
386 001079 03 Amber5 Volts DC Supply (Sensor Supply Voltage #1 Circuit - Above Normal, or Shorted to High Source)
415 000100 01 RedEngine Oil Pressure Low - (Data Valid but Below NormOperational Range - Most Severe Level)
428 000097 03 AmberWater in Fuel Indicator (Water in Sensor Circuit - VoltagNormal, or Shorted to High Source)
429 000097 04 AmberWater in Fuel Indicator (Water in Sensor Circuit - VoltagNormal, or Shorted to Low Source)
431 000558 02 AmberAccelerator Low Idle Switch (Validation Circuit Data ErrIntermittent, or Incorrect)
432 000558 13 RedAccelerator Low Idle Switch (Validation Circuit Out of Calibration)
435 000100 02 AmberEngine Oil Pressure (Oil Pressure Sensor Circuit - DataIntermittent, or Incorrect)
441 000168 18 AmberElectrical Potential (Voltage) (Battery #1 Voltage Low - Valid but Below Normal Operational Range - ModeratelLevel)
442 000168 16 AmberElectrical Potential (Voltage) (Battery #1 Voltage High -Valid but Above Normal Operational Range - ModeratelLevel)
Fault Code
SPN FMI Light DESCRIPTION
y Sev
ngine Fault Codes (110/120-HP Engine) 62-5
nsor Circuit - ce)
Contact Servicing Dealer
nsor Circuit - e)
Contact Servicing Dealer
- Data Valid but Severe Level)
Check Air Cleaner, Aftercooler, or Room Temperature
tion Switch - Check Sensor and Wiring
gh - Data Valid tely Severe Contact Servicing Dealer
w - Data Valid ely Severe Contact Servicing Dealer
rror - Data Reduce Engine Speed
n #2 d Crankshaft
Properly or Out Reduce Engine Speed
r (Camshaft) Reduce Engine Speed
ta Erratic, Contact Servicing Dealer
CORRECTIVE ACTION
BC1200XL Brush Chipper
449 000157 00 RedInjector Metering Rail #1 Pressure (Pressure SeVoltage Above Normal, or Shorted to High Sour
451 000157 03 AmberInjector Metering Rail #1 Pressure (Pressure SeVoltage Below Normal, or Shorted to Low Sourc
488 000105 16 AmberIntake Manifold (Intake Manifold 1 Temperature Above Normal Operational Range - Moderately
528 00093 02 AmberSwitch - Data (Auxiliary Alternate Torque ValidaData Erratic, Intermittent, or Incorrect)
553 000157 16 AmberInjector Metering Rail #1 Pressure (Pressure Hibut Above Normal Operational Range - ModeraLevel)
559 000157 03 AmberInjector Metering Rail #1 Pressure (Pressure Lobut Below Normal Operational Range - ModeratLevel)
689 000190 02 AmberEngine Speed (Primary Engine Speed Sensor EErratic, Intermittent, or Incorrect)
731 000723 07 Amber
Engine Speed Sensor #2 (Engine Speed/PositioMechanical Misalignment Between Camshaft anSensors - Mechanical System Not Responding of Adjustment)
778 000723 2 AmberEngine Speed Sensor #2 (Engine Speed SensoError - Data Erratic, Intermittent, or Incorrect)
1117 000627 02 NonePower Supply (Power Lost With Ignition On - DaIntermittent, or Incorrect)
Fault Code
SPN FMI Light DESCRIPTION
E
BC1200XL Brush Chipper
orted to in the Contact Servicing Dealer
orted to in the Contact Servicing Dealer
CORRECTIVE ACTION
62-6 Engine Fault Codes (110/120-HP Engine)
1695 003513 03 AmberSensor Supply Voltage #5 (Voltage Above Normal or ShHigh Source. High Voltage Detect at Sensor Supply #5OEM Harness.)
1696 003513 04 AmberSensor Supply Voltage #5 (Voltage Below Normal or ShLow Source. High Voltage Detect at Sensor Supply #5 OEM Harness.)
Fault Code
SPN FMI Light DESCRIPTION
ute - Clean Out, 51-6ute Controls, 20-15ute, 40-6itch, 20-13ion, 61-7
Control, 50-7Codes (110/120-HP Engine), 62-1fication Numbers - Record, viors (Tier 3/Stage IIIA), 20-1ors (Tier 4 Interim/Stage IIIB), 20-2
Towing Vehicle, 30-1
Bars - Check, 40-9 Engage, 50-5 Unplug, 51-3ontrols, 20-6peration, 50-2
, 50-1112
BC1200XL Brush Chipper
IndexAAttach to Towing Vehicle (BC1200XL European Only), 30-7Attach to Towing Vehicle (BC1200XL Only), 30-4
BBattery Burns - Avoid, 22-3Battery Explosion - Avoid, 22-2Bolt Inspection, 61-5Breakaway on Hydraulic Surge Brake (Option) - Reset, 30-8Breakaway System - Reset Electric Brake, 30-9Brush Chipper Preparation for Winching , 50-14Brush Chipper, iii
CChip Material, 50-11Clean Flammable Materials from Machine, 40-5Cold Weather Starting, 22-1Controls, 20-1Cutter Drum - Engage, 50-1Cutter Drum - Unplug, 51-5Cutter Shaft - Check, 50-1Cutting System , 50-10
DDealer Prep, iDealer/Customer Information, ivDelivery, iiiDetach from Towing Vehicle, 30-12
Discharge ChDischarge ChDischarge ChDroop Set SwDrum Inspect
EEcoIdle RPMEngine Fault Engine IdentiEngine MonitEngine MonitEngine, 22-1Equipping the
FFeed ControlFeed Roller -Feed Roller -Feed Roller CFeed Roller OFeeding TipsFinishing, 50-Fuses, 20-21
G
BC1200XL Brush Chipper
H Mfore Transporting, 30-9n Decal, vn Numbers - Record, vls, 60-1ls, 60-2l, 60-2
Chipper, 50-1al Winch (BC1200XL Only), 50-13ns, 40-1
XL European Only), 20-14 40-22rt, 30-10-3hipper, 40-4 Chipper and Work Area, 40-1
-2
Hitch - Pintle, 30-6Hitch Height - Adjust (BC1200XL Only), 30-2Hourmeter - Check for Maintenance Interval, 60-2Hydraulic Fluid, 22-2
IIgnition Switch, 20-4Infeed System, 50-10Intended Use, 40-1
JJack Controls, 20-20Jump-Starting Procedure, 22-3Jump-Starting, 22-2
KKnife Inspection, 61-4Knife Installation, 61-9Knife Mount Surface Inspection, 61-6Knife Removal, 61-2Knife Sharpening, 61-8Knife/Drum Maintenance, 61-1
LLine Pull and Speed, 50-13Lower Feed Roller - Access Door, 50-8Lower Feed Stop Bar and Side Feed Stop Bars, 50-3
Machine - Clean BeMachine IdentificatioMachine IdentificatioMaintenance IntervaMaintenance IntervaMaintenance ManuaMaterial Size, 50-11
N
OOperating the BrushOperating the OptionOperator Qualificatio
PPark Brake (BC1200Personal Protection,Plugs or Stalls, 50-1Prepare for TranspoPrepare the Area, 40Prepare the Brush CPreparing the Brush
QQuick Stop Procedu
re, 23BC1200XL Brush Chipper
R (BC1200XL Only), 20-181200XL Only), 20-16BC1200XL Only), 30-11ker - Repair/Replace, 50-23-16
Removing Plugs from the Brush Chipper, 51-1Reporting Safety Defects, 30-1Review of Operation, iii
SSafety Messages, 10-1Safety Signs, 60-1Safety Symbol Explanation, 10-1Sensitivity Levels (BC1200XL Only), 50-4Shutdown Procedure, 23-1SmartFeed Operation, 50-10Sound Levels, 40-3Starting Procedure, 22-1Starting the Engine, 22-1Stopping the Machine, 23-1
TThrottle/Cutter Engage, 20-5Tongue Length - Adjust (BC1200XL Only), 30-3Transporting the Brush Chipper, 30-1
UUpper Feed Control Bar, 50-3
V
WWheel Chocks (BC1200XL European Only), 20-14Winch Capacity, 50-13Winch Controls - Left Side Controls Option
Winch Controls (BCWinch Line - Store (Winch Line and ChoWinch Operation, 50
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Description
1st Edition Operator’s Manual released.
1,4, .
Added left side controls (option), 85-hp engine (option), engine fault codes; misc. updates.
0- Added maintenance items; updated Safety message.
Added EU Side Feed Stop Bars, Safety Updates.
Model number, Typing errors
Control panel update, Updated maintenance intervals
TIER-4 enine update
BC1200XL Brush Chipper
Revision HistoryRevision Date Page(s)
o1_00 06/09 All
o1_01 08/09R&D, v; TOC; Controls, 20-1,2,8,10,12–14; Starting, 21-1; Shutdown, 22-1; Transport, 30-10; Prep, 40-6; Operating, 50-5,11,14,16,17; Removing Plugs, 51-4; Maint. Int., 60-3; Index
o1_02 10/09Intro.; Safety, p. 10-1; Preparing, p. 40-1; Maint. Intervals, p. 62,3.
o1_03 03/10 Controls, Transporting, Preparing, Operating.
o1_04 02/11 Introduction; TOC; Controls; Engine fault codes; Index
o1_05 10/11 Controls, Starting, Operating, Maintenance Interval
o2_00 01/12 All
ALIFORNIAsition 65 Warning
e exhaust and some of its are known to the State of cause cancer, birth other reproductive harm.
vehicle may In-Use Off-
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WARNINGThe Engine Exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
CPropo
Diesel enginconstituentsCalifornia todefects, and
Copyright 2012. All rights reserved.Vermeer Corporation
1210 Vermeer Road East, P.O. Box 200Pella, Iowa 50219-0200
When operated in California, any off-road diesel be subject to the California Air Resources BoardRoad Diesel Vehicle Regulation. It therefore coulto retrofit or accelerated turnover requirements emissions of air pollutants. For more informatiovisit the California Air Resources Board websitehttp://www.arb.ca.gov/msprog/ordiesel/ordiesel