Vermeer BC1000XL User manual

BC1000XL
Brush Chipper
BC1000XL_m3_06
Serial No. 5001 -
Order No. 105400V87
Maintenance
Manual

Introduction BC1000XL Brush Chipper Maintenance
INTRODUCTION
This manual explains the proper operation of your machine. Study and understand these instructions thoroughly before operating or
maintaining the machine. Failure to do so could result in personal injury or equipment damage. Consult your Vermeer dealer if you
do not understand the instructions in this manual, or need additional information.
The instructions, illustrations, and specifications in this manual are based on the latest information available at time of publication.
Your machine may have product improvements and features not yet contained in this manual.
The maintenance intervals are based on normal operating conditions. When operating under severe conditions, the maintenance
intervals should be shortened.
To provide a better view, some photographs or illustrations in the maintenance sections may show the machine shields removed.
Never operate the machine with the shields removed - keep all shields in place. If removing a shield is necessary, return it
to its operating position before operating the machine.
Vermeer Manufacturing Company reserves the right to make changes at any time without notice or obligation.
This manual is supplied with each machine. Refer to it for all lubrication and maintenance procedures. Keep this manual with the
machine for ready reference. Store it in a protected location when not in use.
Copies of this manual are available in Spanish from your dealer.
Se dispone de ejemplares de este manual en español.
NOTICE TO OWNER
You are requested to notify Vermeer Manufacturing Company when you have purchased a used Vermeer machine. Notify the
Customer Data Department by telephone: [phone] or 641-628-3141; email: [e-mail]; internet:
www.vermeer.com or www.vermeerag.com; or, letter: Customer Data Dept., Vermeer Manufacturing Company, PO Box 200, Pella IA
50219 USA. Upon request, an owner of a used Vermeer machine will receive one free set of Operator’s, Maintenance and Parts
manuals.
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BC1000XL Brush Chipper Maintenance Introduction
SERVICE
Service instructions are contained in a separate service manual. Service manuals can be obtained by contacting your Vermeer dealer.
If you are considering servicing the machine without the assistance of a Vermeer dealer, remember this is a complex machine which
often involves complex service procedures.
There are also many components which are not user-serviceable. Do not attempt any service which you do not fully understand, nor
any service that you cannot do accurately and safely with proper tools and equipment. If you encounter a problem that you do not
understand or cannot solve, contact your Vermeer dealer.
TRADEMARKS
VERMEER and VERMEER Logo are trademarks of Vermeer Manufacturing Company.
CUMMINS and FLEETGUARD are trademarks of Cummins Engine Company, Inc.
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BC1000XL Brush Chipper Maintenance Table of Contents i
Table of Contents
Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1
Safety Symbol Explanation . . . . . . . . . . . . . . . . . . . . . . . . .10-1
Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-1
Stopping the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-1
Quick Stop Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . .15-2
5 Service Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-1
Cutter Drum Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-1
Clutch Arm Bearings - Grease. . . . . . . . . . . . . . . . . . . . . . .20-2
10 Service Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25-1
Machine - Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25-1
Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25-1
Engine Cooling System - Check . . . . . . . . . . . . . . . . . . . . .25-2
Hydraulic Fluid Level - Check . . . . . . . . . . . . . . . . . . . . . . .25-3
Fuel Tank - Fill. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25-4
Air Cleaner Restriction Indicator - Check. . . . . . . . . . . . . . .25-5
Deluxe Gauge Panel (Option). . . . . . . . . . . . . . . . . . . . .25-5
Basic Gauge Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . .25-5
Fuel/Water Separator - Drain. . . . . . . . . . . . . . . . . . . . . . . .25-6
Hydraulic Surge Brake (Option) Fluid Level - Check. . . . . .25-6
Hydraulic Surge Brakes (Option) - Check Function. . . . . . .25-7
Brake System - Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . .25-8
Electric Brakes - Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25-8
Discharge Chute Rotation Gear - Lubricate. . . . . . . . . . . . .25-9
Cutter Drum Drive Belt Tension - Initial Check . . . . . . . . . .25-9
Wheel Lug Nut Torque - Initial Check . . . . . . . . . . . . . . . . . 25-9
Pintle Hitch - Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-10
Knife/Drum Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . 25-10
Knife Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-11
Knife Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-13
Bolt Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-14
Knife Mount Surface Inspection. . . . . . . . . . . . . . . . . . 25-15
Drum Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-16
Knife Sharpening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-17
Knife Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-18
Feed Roller Controls - Check . . . . . . . . . . . . . . . . . . . . . . 25-19
Upper Feed Control Bar. . . . . . . . . . . . . . . . . . . . . . . . 25-20
Lower Feed Stop Sensitivity Switch
(BC1000XL Only) . . . . . . . . . . . . . . . . . . . . . . . . 25-20
Lower Feed Stop Bar . . . . . . . . . . . . . . . . . . . . . . . . . . 25-21
50 Service Hours. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1
Engine Spark Arrestor - Clean Out . . . . . . . . . . . . . . . . . . . 30-1
Hydraulic Fluid Filter - Initial Replacement . . . . . . . . . . . . . 30-1
Machine Components - Inspect. . . . . . . . . . . . . . . . . . . . . . 30-1
Cutter Drum Drive Belt Tension - Check/Adjust . . . . . . . . . 30-1
Cutter Drum Drive Belt Tension - Check/Adjust
(S/N 101-10310) . . . . . . . . . . . . . . . . . . . . . . . . . . 30-2
Cutter Drum Drive Belt Tension - Check/Adjust
(S/N 10311 - Up) or With Kit IK001380. . . . . . . . . 30-3
Belt Drive Pivots - Grease. . . . . . . . . . . . . . . . . . . . . . . . . . 30-4
Belt Drive U-Joints - Grease . . . . . . . . . . . . . . . . . . . . . . . . 30-4
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ii Table of Contents BC1000XL Brush Chipper Maintenance
Feed Roller Arm Pivots - Grease . . . . . . . . . . . . . . . . . . . . 30-5
Muffler - Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-6
100 Service Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-1
Engine Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-1
Machine Components - Inspect . . . . . . . . . . . . . . . . . . . . . 35-1
Safety Signs - Maintain . . . . . . . . . . . . . . . . . . . . . . . . . 35-2
Hydraulic System - Check . . . . . . . . . . . . . . . . . . . . . . . . . 35-2
Hydraulic Tank - Keep Clean. . . . . . . . . . . . . . . . . . . . . 35-3
Tires and Rims - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-3
Upper Feed Control Bar Force - Adjust . . . . . . . . . . . . . . . 35-4
Lower Feed Stop Bar Switch - Adjust - BC1000XL . . . . . . 35-5
Lower Feed Stop Bar Switch - Adjust - BC1000XL
European. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-6
250 Service Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1
Engine Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1
Jack - Lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1
Cutter Belt Wear - Check . . . . . . . . . . . . . . . . . . . . . . . . . . 40-2
Fuel Filters - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-3
Fuel Strainer - Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-3
Corrosion Inhibitors - Add to Coolant . . . . . . . . . . . . . . . . . 40-4
Hydraulic Fluid Filter - Replace. . . . . . . . . . . . . . . . . . . . . . 40-4
Air Cleaner - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-6
Automatic Brake Controller with Manual Override
(Option) - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-7
Brake Controller - Adjust . . . . . . . . . . . . . . . . . . . . . . . . 40-7
Brakes - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-8
500 Service Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-1
Engine Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-1
Ball Coupler - Lubricate and Inspect . . . . . . . . . . . . . . . . . .45-1
Pintle Hitch - Inspect/Maintain . . . . . . . . . . . . . . . . . . . . . . .45-2
Hydraulic Fluid - Change . . . . . . . . . . . . . . . . . . . . . . . . . . .45-3
Hydraulic Fluid Strainer - Inspect . . . . . . . . . . . . . . . . . 45-4
Wheel Bearings - Check . . . . . . . . . . . . . . . . . . . . . . . . . . .45-5
Bearings - Repack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45-6
Battery Electrolyte Levels and Terminals - Check . . . . . . . .45-8
Battery Electrolyte Levels and Terminals - Check . . . . .45-9
Battery Terminals - Clean . . . . . . . . . . . . . . . . . . . . . .45-11
Feed Table Curtains - Replace . . . . .. . . . . . . . . . . . . . . .45-11
Cutter Drum Drive Belt - Replace. . . . . . . . . . . . . . . . . . . .45-12
1000 Service Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-1
Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-1
Surge Brake Actuator - Grease (BC1000XL EU Only). . . . .50-1
Park Brake Lever - Grease (BC1000XL EU Only). . . . . . . .50-2
Cooling System - Drain and Clean. . . . . . . . . . . . . . . . . . . .50-3
2000 Service Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55-1
Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55-1
Battery - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55-1
Maintenance As Required. . . . . . . . . . . . . . . . . . . . . . . . . . .60-1
Air Cleaner - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-1
Knife-Mounting Surface - Inspect. . . . . . . . . . . . . . . . . . . . .60-1
Shear Bar - Check/Adjust. . . . . . . . . . . . . . . . . . . . . . . . . . .60-2
Shear Bar - Replace. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-4
Highway Lights - Replace . . . . . . . . . . . . . . . . . . . . . . . . . .60-5
SmartFeed System Fuse - Replace. . . . . . . . . . . . . . . . . . .60-6
Slip Hook - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-6
Towing Chain - Replace. . . . . . . . . . . . . . . . . . . . . . . . . . . .60-7
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BC1000XL Brush Chipper Maintenance Table of Contents iii
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-7
Preparing for Storage . . . . . . . . . . . . . . . . . . . . . . . . . . .60-7
Removing from Storage . . . . . . . . . . . . . . . . . . . . . . . . .60-8
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65-1
Power System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65-1
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65-2
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65-3
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65-4
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-1
Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-1
Machine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-2
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BC1000XL Brush Chipper Maintenance Safety Messages 10-1
Section 10: Safety Messages
General safety messages appear in this Safety Messages section. Specific safety messages are located in
appropriate sections of the manual where a potential hazard may occur if the instructions or procedures are not
followed.
A signal word “DANGER”, “WARNING”, or “CAUTION” is used with the safety alert symbol.
Safety signs with signal word “DANGER”, “WARNING”, or “CAUTION” are located near specific hazards.
SAFETY SYMBOL EXPLANATION
DANGER Indicates a hazardous situation which, if not avoided, will result in death or serious injury.
WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
This is the safety alert symbol. This symbol is used in combination with an
exclamation mark or other symbols to alert you to the potential for bodily injury
or death.
WARNING: Read Operator’s Manual and safety signs before operating machine.
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10-2 Safety Messages BC1000XL Brush Chipper Maintenance
DANGER: Limbs can snag clothing. Roller or blades can grab and pull you in faster than you can let go
of limb. Cutting injury or death will result.
Feed material only from side of feed table. Never climb onto feed table.
Feed base of limb or branch first. Use wood object to push short material.
Wear gloves with narrow tight-fitting
cuffs.
Keep away from rotating feed roller and
blades.
WARNING: Wear personal protective equipment. Dress properly.
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BC1000XL Brush Chipper Maintenance Safety Messages 10-3
WARNING: Exhaust fumes can be fatal.
If operating in an enclosed area, remove exhaust fumes with an exhaust pipe extension to
the outside.
WARNING: Moving parts can crush fingers.
Close all shields before starting.
WARNING: Use Shutdown Procedure before servicing, cleaning, repairing or transporting
machine. Refer to Shutdown Procedure, page 15-1,for instructions.
WARNING: Failure to follow any of the preceding safety instructions or those that follow within
this manual, could result in serious injury or death. This machine is to be used only for those
purposes for which it was intended as explained in the Operator’s Manual.

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BC1000XL Brush Chipper Maintenance Shutdown Procedure 15-1
Section 15: Shutdown Procedure
STOPPING THE MACHINE
IMPORTANT: For your safety and the safety of others, use shutdown procedure before working on the machine
for any reason, including servicing, cleaning, unclogging, inspecting, or transporting the chipper.
A variation of this procedure may be used if so instructed within this manual, or if an emergency requires it.
Step 1: Return Upper Feed Control Bar to stop position.
Step 2: Place Cutter Engage/Throttle Lever in the 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 the cutter drum to slow.
Step 4: Place Cutter Engage/Throttle Lever in the DISENGAGED/LOW RPM
position.
Step 5: Turn ignition key to OFF position.
Step 6: Wait for the cutter drum and belt to stop.
NOTE: Cutter drum rotation can be checked by looking at the end of the shaft (1) on
the left side of the cutter wheel housing.
IMPORTANT: The cutter drum will continue to turn for a short time after the engine
has stopped.
Step 7: Remove ignition key.
Step 8: Close and latch feed table.
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15-2 Shutdown Procedure BC1000XL Brush Chipper Maintenance
Quick Stop Procedure
Step 1: Turn ignition to the OFF position while cutter drum clutch is still engaged.
Step 2: Wait for cutter drum and belt to stop.
Step 3: Fully disengage cutter drum.
To Stop Drum Quickly
Shut Off Engine with Clutch Engage
d

BC1000XL Brush Chipper Maintenance 5 Service Hours 20-1
Section 20: 5 Service Hours
CUTTER DRUM BEARINGS
(1) Purge with grease ....................................................................two fittings
To ensure grease will be evenly distributed in bearing:
Step 1: Disengage cutter drum belt drive.
Step 2: Shut off engine.
Step 3: Grease when cutter drum has almost stopped turning.
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20-2 5 Service Hours BC1000XL Brush Chipper Maintenance
CLUTCH ARM BEARINGS - GREASE
Applies to Serial No. 10311 and up, or as equipped.
(1) Purge with grease....................................................................two fittings
Visually inspect grease that is purged from bearings and if contaminated,
grease more often.
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BC1000XL Brush Chipper Maintenance 10 Service Hours 25-1
Section 25: 10 Service Hours
MACHINE - GREASE
As a general rule, grease machine after it is shut down for the day. This protects metal under seals from
corrosion caused by condensation as temperature drops.
Ensure all fittings and nozzle of grease applicator are clean before applying grease. If any grease fittings are
missing, replace them immediately.
ENGINE MAINTENANCE
•Inspect engine drive belt.
•Inspect for leaks.
•Check engine oil level.
Refer to the Engine Operation Manual supplied with the machine for instructions.
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25-2 10 Service Hours BC1000XL Brush Chipper Maintenance
ENGINE COOLING SYSTEM - CHECK
•Check coolant level.
Fill to within 1/2" (13 mm) of the bottom of the fill pipe with a low-silicate (ethylene glycol) antifreeze and clean
water mixture.
NOTE: Never add pure antifreeze to a cooling system. Vermeer recommends using a 50/50 mixture. Never use
high-silicate antifreeze or antifreeze that is higher than a 60/40 mixture.
•Inspect hose clamps and overflow tubes.
•Check/clean grill, radiator and fins.
•Check fan for cracks, loose rivets, and bent or loose blades.
WARNING: Hot fluid under pressure can erupt and scald if opened.
Allow to cool before opening.
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BC1000XL Brush Chipper Maintenance 10 Service Hours 25-3
HYDRAULIC FLUID LEVEL - CHECK
Clean hydraulic fluid is very important. Do not spill dirt or other contaminants into
the tank. Filter all hydraulic fluid through a 10-micron filter before adding it to the
tank.
Pull fill/check cap (1) off. Hydraulic fluid level must be between the two lines on the
dipstick located beneath cap. Refer to Specifications section, “Lubricants,” page 70-1,
for fluid requirements. Push cap back on until fully seated.
The hydraulic fluid must be free of bubbles. Bubbles indicate trapped air in the
hydraulic system. 1
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25-4 10 Service Hours BC1000XL Brush Chipper Maintenance
FUEL TANK - FILL
Fill tank at the end of each day to prevent condensation. Do not fill tank to the very
top; leave room for expansion.
(1) Fill Cap
WARNING: Fuel and fumes can explode and burn.
Shut off engine before refueling. No flame. No smoking.
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