2014 Bc1000xl Service Manual

BC1000XL Brush Chipper
Service
Manual
BC1000XL_S4_01
Serial No. 19527
Order No. 105400CN2
This manual contains information and procedures that This document may contain portions of technical
are intended for experienced service technicians. materials of various suppliers. Such component
Study and understand these procedures thoroughly suppliers shall not be responsible for the direct results
before servicing or repairing the machine. Do not of their technical materials being presented out of
attempt any service which you do not fully understand, context.
or cannot be done safely with tools and equipment
available to you. Failure to do so could result in Designations used by component suppliers to
personal injury or equipment damage. distinguish their products which appear in this manual
are the property of the respective trademark owner(s).
Vermeer dealer service technicians can access Vermeer Corporation is aware of the following
service-related training courses through Vermeer component suppliers trademarks.
University. Other service technicians should ensure
they are adequately trained to understand the CATERPILLAR and CAT are trademarks of Caterpillar,
information and procedures in this manual. Inc.
There are also many components which are not user- CUMMINS is a trademark of the Cummins Inc.
serviceable. If you have questions or encounter an
issue that you do not understand or cannot solve, FLUKE is a trademark of Fluke Corporation.
contact your Vermeer dealer service representative.
Deutz is a trademark of Kockner-Homboldt-Deutz.
The instructions, illustrations and specifications in this
manual are based on the latest information available at GM is a trademark of General Motors Corporation.
the time of publication. Your machine may have product
improvements and options not yet contained in this CHEVRON and DELCO are trademarks of Chevron
manual. Intellectual Property LLC.
Vermeer Corporation reserves the right to make MOBIL and DELVAC are trademarks of Exxon Mobil
changes at any time without notice or obligation. Corporation.
Additional copies of this manual are available. When SHELL and ROTELLA are trademarks of Shell
ordering, use the part number on the front cover. Trademark Management B.V.
VERMEER, VERMEER Logo, and ECOIDLE are

trademarks of Vermeer Manufacturing Company in the
U.S. and/or other countries.
No part of this manual may be reproduced in any form or by any means, electronic or
mechanical, including photocopying, recording, or by any information storage and retrieval
systems, without the express written consent of Vermeer Corporation.
Copyright 2013, 2015

Vermeer Corporation
All rights reserved.
1210 Vermeer Road East, P.O. Box 200
Pella, Iowa 50219-0200, USA
BC1000XL Brush Chipper Service Table of Contents
General Information......................................................................................................................... 1-1
Using the Manual ...............................................................................................................................................................1-1

Reference Publications............................................................................................................................................. 1-2
Vermeer Publications .........................................................................................................................................1-2
Vendor Publications ...........................................................................................................................................1-2
Warranty Considerations ..................................................................................................................................................1-2
Vermeer Warranty...................................................................................................................................................... 1-2
Engine Warranty ........................................................................................................................................................ 1-3
Safety ..................................................................................................................................................................................1-3
Do Not Modify Machine............................................................................................................................................. 1-3
Replace Shields ......................................................................................................................................................... 1-4
Safety Symbol Explanation ...................................................................................................................................... 1-4
Terminology .......................................................................................................................................................................1-7
System........................................................................................................................................................................ 1-7
Function ..................................................................................................................................................................... 1-7
Circuit ......................................................................................................................................................................... 1-7
Inputs and Outputs.................................................................................................................................................... 1-7
Reference Designators ............................................................................................................................................. 1-7
Diagrams and Schematics........................................................................................................................................ 1-8
Addendum ...........................................................................................................................................................1-8
Chapter Organization ................................................................................................................................................ 1-8
Introduction .........................................................................................................................................................1-8
Overview ..............................................................................................................................................................1-8
Theory of Operation ............................................................................................................................................1-8
Troubleshooting/Testing ....................................................................................................................................1-8
Repair ...................................................................................................................................................................1-9
Troubleshooting Guidelines ...........................................................................................................................................1-10
Problem-Solving Analysis ...................................................................................................................................... 1-10
Rule Out Operator Error ...................................................................................................................................1-10
Define the Problem ...........................................................................................................................................1-10
Research the System ........................................................................................................................................1-11
Required Tools......................................................................................................................................................... 1-12
Electrical Troubleshooting...................................................................................................................................... 1-13
Electrical Troubleshooting ...............................................................................................................................1-13
Common Electrical Problems ..........................................................................................................................1-13
Hydraulic Troubleshooting ..................................................................................................................................... 1-15
Leakage Path Analysis .....................................................................................................................................1-15
Pumps and Motors ............................................................................................................................................1-16
Directional Control Valves ...............................................................................................................................1-17
Cylinders ............................................................................................................................................................1-17
Hydraulic Connections ........................................................................................................................................... 1-18
Avoid Trapped Pressure...................................................................................................................................1-18
Avoid Oil Contamination ..................................................................................................................................1-19
Connecting Flow Meters...................................................................................................................................1-19
Connecting a Needle Valve ..............................................................................................................................1-20
Connecting Pressure Gauges ..........................................................................................................................1-20
Magnetic Base Thermometer or Pyrometer....................................................................................................1-20
Digital Multimeter .................................................................................................................................................... 1-21
Measuring Voltage ............................................................................................................................................1-21
Measuring Resistance ......................................................................................................................................1-21
Table of Contents BC1000XL Brush Chipper Service
Testing for Continuity .......................................................................................................................................1-22

Measuring Current ............................................................................................................................................1-22
Repair Guidelines ............................................................................................................................................................1-23
Safety Equipment .................................................................................................................................................... 1-23
Shop Requirements................................................................................................................................................. 1-23
Special Tools & Test Equipment......................................................................................................................1-23
Personnel and Lifting Requirements ..................................................................................................................... 1-23
Replacement Parts .................................................................................................................................................. 1-23
Part Numbers/Hose Lengths/Fitting Orientation............................................................................................1-23
Parts Ordering ...................................................................................................................................................1-23
Torque Values .......................................................................................................................................................... 1-24
System Information ......................................................................................................................... 2-1
Shutdown Procedure.........................................................................................................................................................2-1
Stopping the Machine ............................................................................................................................................... 2-1
Quick Stop Procedure ........................................................................................................................................2-2
Legend for Reference Designators ..................................................................................................................................2-2
Chapter 3 - Engine Functions................................................................................................................................... 2-2
Caterpillar ............................................................................................................................................................2-2
Cummins ..............................................................................................................................................................2-3
Deutz ....................................................................................................................................................................2-5
GM ........................................................................................................................................................................2-6
Optional Remote Controls..................................................................................................................................2-7
Chapter 4 - Feed Roller Function ............................................................................................................................. 2-8
Chapter 5 - Cutter Drum Drive Function.................................................................................................................. 2-8
Chapter 6 - Trailer Functions.................................................................................................................................... 2-9
BC1000XL Brush Chipper Specifications......................................................................................................................2-10
Machine Reference and Orientation ...................................................................................................................... 2-10
Serial Number Plate Locations............................................................................................................................... 2-10
Component Specifications ..................................................................................................................................... 2-11
Machine Specifications........................................................................................................................................... 2-11
Lubricants ................................................................................................................................................................ 2-13
System Interlocks ............................................................................................................................................................2-14
Engine and Electrical Power ........................................................................................................... 3-1
Introduction........................................................................................................................................................................3-1
Overview ..............................................................................................................................................................3-1
Troubleshooting ..................................................................................................................................................3-1
Repair ...................................................................................................................................................................3-1
Overview.............................................................................................................................................................................3-2
Functions/Components ............................................................................................................................................ 3-2
Caterpillar ............................................................................................................................................................3-2
Cummins ..............................................................................................................................................................3-3
Deutz ....................................................................................................................................................................3-5
GM ........................................................................................................................................................................3-6
Optional Remote Controls..................................................................................................................................3-7
Component Locations Caterpillar............................................................................................................................ 3-8
Component Locations Cummins ........................................................................................................................... 3-11
Component Locations Deutz 49 HP and 74 HP Engines ..................................................................................... 3-14
Component Locations GM - Gas/Propane ............................................................................................................ 3-18
Component Locations - Optional Remote Control............................................................................................... 3-21
Component Repair/Replace.................................................................................................................................... 3-22
Component Specifications ..................................................................................................................................... 3-22
Theory of Operation ........................................................................................................................................................3-24
Electrical Power Source.......................................................................................................................................... 3-24
Battery BT1 ........................................................................................................................................................3-24
Alternator G1 .....................................................................................................................................................3-25
Electrical Power Distribution.................................................................................................................................. 3-25
SmartFeed Controller A1 ..................................................................................................................................3-25
Circuit Breakers CB1 and CB2.........................................................................................................................3-26
Fuses F1 and F2 ................................................................................................................................................3-26
Ignition Switch Circuits ....................................................................................................................................3-28
Gauges - Caterpillar ................................................................................................................................................ 3-43
Hourmeter E3.....................................................................................................................................................3-43
Fuel Gauge E2 ...................................................................................................................................................3-44
Gauges - Cummins (Standard)............................................................................................................................... 3-44
Hourmeter E3 and Fuel Gauge E2 ...................................................................................................................3-44
Gauges - Cummins (Deluxe)................................................................................................................................... 3-45
Tachometer/Hourmeter E5 ...............................................................................................................................3-45
4-in-1 Gauge E4 .................................................................................................................................................3-46
Gauges - Deutz and GM .......................................................................................................................................... 3-48
Fuel Gauge E2 ...................................................................................................................................................3-48
Engine Information Display E35 ......................................................................................................................3-49
Optional Tree Commander Remote Control System ............................................................................................ 3-53
Remote Transmitter A6.....................................................................................................................................3-54
Remote Receiver A5 .........................................................................................................................................3-54
Remote Control/Console Selector Switches S24 and S25 ............................................................................3-54
Amber Beacon E34 ...........................................................................................................................................3-54
Remote Horn B8 ................................................................................................................................................3-54
Engine ENG1 – ENG5 .............................................................................................................................................. 3-55
Intake Air, Exhaust, Fuel, and Cooling Functions - Caterpillar ........................................................................... 3-57
Intake Air/Exhaust .............................................................................................................................................3-57
Coolant Delivery ................................................................................................................................................3-58
Fuel Enable and Delivery..................................................................................................................................3-58
Intake Air, Exhaust, Fuel, and Cooling Functions - Cummins ............................................................................ 3-60
Intake Air, Exhaust, Fuel, and Cooling Functions - Deutz ................................................................................... 3-63
Intake Air, Exhaust, Fuel, and Cooling Functions - GM (Gas)............................................................................. 3-66

Intake Air, Exhaust, Fuel, and Cooling Functions - GM (LP Version) ................................................................. 3-69
Throttle Function ..................................................................................................................................................... 3-72
Throttle - Increase/Decrease ............................................................................................................................3-72
EcoIdle Function - Deutz and GM ....................................................................................................................3-73
Glow Plug Function - 49 HP.................................................................................................................................... 3-75
Ignition Switch S1 in RUN/PREHEAT Position ...............................................................................................3-75
Grid Heater/Glow Plug Function - Cummins......................................................................................................... 3-76
Preheat ...............................................................................................................................................................3-76
While Cranking ..................................................................................................................................................3-77
Postheat .............................................................................................................................................................3-78
Preheat/Postheat Time Calculation Table.......................................................................................................3-78
Glow Plug Function - Deutz.................................................................................................................................... 3-79
Ignition Switch S1 in RUN/PREHEAT Position ...............................................................................................3-79
Postheat .............................................................................................................................................................3-79
Preheat/Postheat Time Calculation Table.......................................................................................................3-80
Engine Protection Interlocks.................................................................................................................................. 3-80
Engine Shutdown - Caterpillar .........................................................................................................................3-80
Engine Shutdown - Cummins ..........................................................................................................................3-81
Engine Shutdown - Deutz .................................................................................................................................3-82
Engine Shutdown - GM .....................................................................................................................................3-83
Troubleshooting ..............................................................................................................................................................3-83
Look for the Obvious ........................................................................................................................................3-83
Fault Indications................................................................................................................................................3-83
Methods of Diagnosing/Testing ............................................................................................................................. 3-84
Conventional Diagnosis/Testing......................................................................................................................3-84
Diagnosis Using Vermeer VCTool ...................................................................................................................3-85
Diagnostics Access ..........................................................................................................................................3-85
Test Equipment .................................................................................................................................................3-86
Electrical Power Source.......................................................................................................................................... 3-87
Battery Testing ..................................................................................................................................................3-87
EcoIdle Function ...............................................................................................................................................3-88
Gauges ..................................................................................................................................................................... 3-89
Fuel Gauge E2 and Sensor B1 .........................................................................................................................3-89
Hourmeter E3.....................................................................................................................................................3-89
Gauges - Cummins (Deluxe)................................................................................................................................... 3-90
Tachometer/Hourmeter E5 ...............................................................................................................................3-90
4-in-1 Gauge E4 Including, Oil Pressure/Coolant Temperature/Fuel Level/Voltmeter................................3-91
Engine and Associated Functions......................................................................................................................... 3-92
Intake Air, Exhaust, Fuel, and Cooling Functions ................................................................................................ 3-92
Fuel Function - Caterpillar................................................................................................................................3-93
Fuel Function - Cummins .................................................................................................................................3-94
Fuel Function - Deutz........................................................................................................................................3-95
Fuel Function - GM............................................................................................................................................3-96
Cooling Function...............................................................................................................................................3-98
Glow Plug Function - Caterpillar............................................................................................................................ 3-99
Glow Plug Function - Cummins ........................................................................................................................... 3-101
Glow Plug Function - Deutz............................................................................................................................3-103

Engine Protection Interlocks................................................................................................................................ 3-103
Repair .............................................................................................................................................................................3-104
Welding................................................................................................................................................................... 3-104
Welding Alert - Electronic Components.............................................................................................................. 3-105
Battery Cables ....................................................................................................................................................... 3-107
Disconnect/Remove ........................................................................................................................................3-107
Batteries - Charge/Replace................................................................................................................................... 3-107
Battery Charging .............................................................................................................................................3-107
Battery Maintenance .......................................................................................................................................3-107
Battery - Replace .............................................................................................................................................3-108
Engine .................................................................................................................................................................... 3-109
Engine Service ................................................................................................................................................3-109
Engine Maintenance .......................................................................................................................................3-109
Feed Roller Function ....................................................................................................................... 4-1
Introduction........................................................................................................................................................................4-1
Overview ..............................................................................................................................................................4-1
Repair ...................................................................................................................................................................4-1
Overview.............................................................................................................................................................................4-2
Component Locations............................................................................................................................................... 4-3
Reference Diagrams.................................................................................................................................................. 4-8
Component Specifications ....................................................................................................................................... 4-8
Theory of Operation ..........................................................................................................................................................4-9
Feed Roller Drive Function Components Overview............................................................................................... 4-9
Fluid Supply/Conditioning..................................................................................................................................4-9
Fluid Delivery.......................................................................................................................................................4-9
Feed Control Bar ...............................................................................................................................................4-10
SmartFeed Controller A1 ..................................................................................................................................4-11
Engine RPM - Droop Settings ..........................................................................................................................4-12
SmartFeed Controller A1 Input/Output Pin/Wire Color Designations ..........................................................4-13
Feed Roller Drive NEUTRAL Mode ........................................................................................................................ 4-15
Feed Roller Drive FORWARD Mode ....................................................................................................................... 4-16
Feed Roller Drive Interlocks.............................................................................................................................4-16
Feed Roller Drive REVERSE Mode ........................................................................................................................ 4-18
Feed Roller Drive Stop Mode.................................................................................................................................. 4-18
E-Stop Switch S11.............................................................................................................................................4-18
Reset Hold-to-Run Switches S6 (Left) S7 (Right) ..........................................................................................4-19
Sensitivity Select Switch S4.............................................................................................................................4-20
Sensitivity Switches S12 (Normal) and S13 (Reduced) .................................................................................4-20
General Guidelines When Testing and Servicing Hydraulic Components ........................................................ 4-22
Hydraulic Components .....................................................................................................................................4-22
Avoid Oil Contamination ..................................................................................................................................4-22
Pretest Inspection ................................................................................................................................................... 4-23
Look for the Obvious ........................................................................................................................................4-23

Mechanical .........................................................................................................................................................4-23
Electrical ............................................................................................................................................................4-23
Hydraulic ............................................................................................................................................................4-23
Feed Roller Drive Faults ......................................................................................................................................... 4-24
Fault Indications................................................................................................................................................4-24
Electrical Circuit Testing ..................................................................................................................................4-25
Hydraulic Circuit Testing..................................................................................................................................4-26
Hydraulic Flow and Pressure Checks ................................................................................................................... 4-27
Volumetric Efficiency........................................................................................................................................4-27
Hydraulic System Test Equipment ..................................................................................................................4-28
System Pressure Check ...................................................................................................................................4-29
Adjusting Relief Valve PV1...............................................................................................................................4-30
Pump Efficiency Testing ..................................................................................................................................4-31
Pump Test Graph - Caterpillar .........................................................................................................................4-33
Pump Flow Measurement Results - Caterpillar ..............................................................................................4-34
Pump Test Graph - Cummins...........................................................................................................................4-35
Pump Flow Measurement Results - Cummins ...............................................................................................4-36
Pump Test Graph - Deutz 49 hp and
74 hp ...................................................................................................................................................................4-37
Pump Flow Measurement Results - Deutz
49 hp and 74 hp .................................................................................................................................................4-38
Pump Test Graph - GM .....................................................................................................................................4-39
Pump Flow Measurement Results - GM ..........................................................................................................4-40
Excessive Heat ........................................................................................................................................................ 4-41
Excessive Noise or Vibration ................................................................................................................................. 4-42
Hydraulic Oil Sampling ........................................................................................................................................... 4-43
Preventive Maintenance ...................................................................................................................................4-43
After Repair........................................................................................................................................................4-43
Hydraulic Oil Sampling Tools................................................................................................................................. 4-44
Sample Gun Kit .................................................................................................................................................4-44
Hydraulic Wear Check Bottles - Case .............................................................................................................4-45
Hydraulic Oil Sample Hose ..............................................................................................................................4-45
Oil Sample Collection Point .............................................................................................................................4-45
Repair ...............................................................................................................................................................................4-46
Hydraulic Pump PMP3 and PMP9 .......................................................................................................................... 4-46
Remove ..............................................................................................................................................................4-46
Install ..................................................................................................................................................................4-46
Hydraulic Pump PMP10 .......................................................................................................................................... 4-47
Remove ..............................................................................................................................................................4-47
Install ..................................................................................................................................................................4-48
Pump Start-Up Procedure....................................................................................................................................... 4-49
Feed Roller Control Valve Assembly AH1 ............................................................................................................. 4-50
Remove ..............................................................................................................................................................4-50
Install ..................................................................................................................................................................4-50
Manifold Valve AH1 Components - Replace ...................................................................................................4-51
Hydraulic Motor MH1............................................................................................................................................... 4-53
Remove ..............................................................................................................................................................4-53
Install ..................................................................................................................................................................4-53
Hydraulic Fluid Tank RES1 ..................................................................................................................................... 4-53
Feed Roller Assembly ............................................................................................................................................. 4-54
Remove ..............................................................................................................................................................4-54
Install ..................................................................................................................................................................4-54
Feed Roller Disassemble..................................................................................................................................4-55

Feed Roller Assemble.......................................................................................................................................4-55
Adjust Upper Feed Control Bar Force ................................................................................................................... 4-56
Adjust Lower Feed Stop Bar Switches.................................................................................................................. 4-56
Cutter Drum Drive ............................................................................................................................ 5-1
Introduction........................................................................................................................................................................5-1
Overview ..............................................................................................................................................................5-1
Repair ...................................................................................................................................................................5-1
Overview.............................................................................................................................................................................5-2
Cutter Drum Drive...................................................................................................................................................... 5-4
Belt Tensioner .....................................................................................................................................................5-4
Cutter Drum .........................................................................................................................................................5-4
Troubleshooting ................................................................................................................................................................5-5
Cutter Drum Drive...................................................................................................................................................... 5-5
Drive Belt Slipping/Dragging..............................................................................................................................5-5
Drive Belt/Sheave Wear ......................................................................................................................................5-5
Cutter Drum .........................................................................................................................................................5-6
Repair .................................................................................................................................................................................5-7
Drive Belt.................................................................................................................................................................... 5-7
Remove/Replace .................................................................................................................................................5-7
Install ....................................................................................................................................................................5-8
Belt Tension - Check/Adjust...............................................................................................................................5-8
Cutter Drum ............................................................................................................................................................... 5-9
Remove ................................................................................................................................................................5-9
Install ..................................................................................................................................................................5-10
Cutter Drum - Inspect........................................................................................................................................5-10
Cutter Drum Shaft - Remove ............................................................................................................................5-11
Install ..................................................................................................................................................................5-12
Sheaves and Bushings ........................................................................................................................................... 5-14
Engine Drive Sheave - Remove/Replace.........................................................................................................5-14
Cutter Drum Sheave - Remove/Replace..........................................................................................................5-14
Install ..................................................................................................................................................................5-15
Driveline Assembly ................................................................................................................................................. 5-16
Remove/Replace ...............................................................................................................................................5-16
Install ..................................................................................................................................................................5-17
Cutter Drum Knives and Shear Bar ....................................................................................................................... 5-17
Trailer ................................................................................................................................................ 6-1
Introduction........................................................................................................................................................................6-1
Overview ..............................................................................................................................................................6-1
Repair ...................................................................................................................................................................6-1
Overview.............................................................................................................................................................................6-2
Component Specifications ....................................................................................................................................... 6-9
Running Light Functions .......................................................................................................................................... 6-9
Trailer Brake Functions............................................................................................................................................. 6-9
Domestic and Australian Axles with Electric Brakes ......................................................................................6-9
Domestic and Australian Axles with Hydraulic Surge Brakes......................................................................6-10
European Axles with Mechanical Surge Brakes ............................................................................................6-11
Safety Breakaway Function .................................................................................................................................... 6-11
Domestic and Australian Axles with Electric Brakes ....................................................................................6-11
Domestic and Australian Axles with Hydraulic Surge Brakes......................................................................6-12
European Axles with Mechanical Surge Brakes ............................................................................................6-12
Running Lights Functions ...................................................................................................................................... 6-13
Trailer Brake Functions........................................................................................................................................... 6-14
Brake Synchronization .....................................................................................................................................6-14
Brake Adjustment .............................................................................................................................................6-14
Brake Troubleshooting .....................................................................................................................................6-14
Fault Table - Domestic and Australian Axles Electric and Hydraulic Brakes .............................................6-15
Fault Table - European Axles ...........................................................................................................................6-18
Domestic and Australian Axles with Electric Brakes - Test..........................................................................6-19
Domestic and Australian Axles with Hydraulic Surge Brakes - Inspect ......................................................6-21
European Axles with Mechanical Surge Brakes - Inspect.............................................................................6-21
Brake Adjustment.................................................................................................................................................... 6-22
Domestic and Australian Axles with Electric and Hydraulic Brakes - Adjust .............................................6-22
European Axles with Mechanical Surge Brakes - Set-Up/Adjust .................................................................6-23
Safety Breakaway Function .................................................................................................................................... 6-25
Testing Switch S23 ...........................................................................................................................................6-25
Repair ...............................................................................................................................................................................6-26
Wheel Bearings - Replace/Repack......................................................................................................................... 6-26
Axle - Domestic and Australian.............................................................................................................................. 6-27
Remove/Replace ...............................................................................................................................................6-27
Install ..................................................................................................................................................................6-27
Electric Brake Drum Components - Replace ..................................................................................................6-28
Hydraulic Brake Drum Components - Replace...............................................................................................6-29
Hydraulic Surge Brake Actuator - Domestic and Australian Axles .................................................................... 6-30
Remove/Replace ...............................................................................................................................................6-30
Axle - European ....................................................................................................................................................... 6-33
Remove/Replace ...............................................................................................................................................6-33
Install ..................................................................................................................................................................6-34
Mechanical Brake Drum Components - Replace............................................................................................6-35

Breakaway Switch S23............................................................................................................................................ 6-36
Remove/Replace ...............................................................................................................................................6-36
Diagrams and Schematics ........................................................................................................ ADD-1
Legend for Reference Designators.................................................................................................................... ADD-1

Hydraulic Schematic - Caterpillar ..............................................................................................................................ADD-2
Hydraulic Schematic - Cummins................................................................................................................................ADD-3
Hydraulic Schematic - GM ..........................................................................................................................................ADD-4
Hydraulic Schematic - Deutz ......................................................................................................................................ADD-5
Hydraulic Hose Location.............................................................................................................................................ADD-6
Electrical Schematic - Caterpillar...............................................................................................................................ADD-7
Wire Harness - Front Caterpillar.................................................................................................................................ADD-8
Electrical Schematic - Cummins ................................................................................................................................ADD-9
Electrical Schematic - Cummins ..............................................................................................................................ADD-10
Electrical Schematic - Cummins ..............................................................................................................................ADD-11
Wire Harness - Front Cummins ................................................................................................................................ADD-12
Electrical Schematic - GM.........................................................................................................................................ADD-13
Wire Harness - Front GM...........................................................................................................................................ADD-16
Electrical Schematic - Deutz.....................................................................................................................................ADD-17
Wire Harness - Front Deutz.......................................................................................................................................ADD-20
Electrical Schematic - Domestic and Australian Trailer Lighting .........................................................................ADD-21
Electrical Schematic - European Trailer Lighting...................................................................................................ADD-22
Wire Harness - Rear .................................................................................................................................................ADD-23
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BC1000XL Brush Chipper Service Using the Manual
Chapter 1: General Information
USING THE MANUAL

This manual provides information and service procedures based upon
current machine knowledge and configuration at the time the manual was
written. The instructions, illustrations and specifications are based on the
latest information available at the time of publication. Due to ongoing efforts
to continuously improve the equipment, there may be changes on the
machine not yet reflected in this manual.
Vermeer Corporation reserves the right to make changes at any time

without notice or obligation.
Procedures given in this manual provide one method for completing a given
task. Additional information may be available through Vermeer Service
Support resources.
Additional copies of this manual are available through the Vermeer Parts
Center. Use the reorder number on the front cover to order additional
General Information
manuals.
Operating instructions are found in the BC1000XL Brush Chipper

Operator’s Manual. Lubrication and maintenance procedures are found in
the BC1000XL Brush Chipper Maintenance Manual. Refer to “Reference
Publications,” for ordering information.
Chapter titles located at the edge of the page aid in quickly locating
information.
1-1
Warranty Considerations BC1000XL Brush Chipper Service
Reference Publications
Vermeer The following Vermeer Corporation Publications are necessary for reference:
Publications
• BC1000XL Brush Chipper Operator’s Manual, order number 105400BD2,
cabled assembly order number 180018448.
• BC1000XL Brush Chipper Maintenance Manual, order number
105400BD4
• BC1000XL Brush Chipper Parts Manual, order number 105400YAU
• Vermeer Industrial Dealerships Technician’s Shop Manual, order number
105400V80
• Recommended Service Tools Users Guide, order number 105400T69 for
special tools and test equipment.
Contact the Vermeer Parts Center to order these publications.
Vendor Publications The following vendor publications are optional reference materials:
• Caterpillar Engine Manual for model C2.2L Tier 4 Interim/Stage IIIB

General Information
• Cummins Engine Manual for model B3.3 Tier 4 Interim/Stage IIIB

• General Motors Engine Manual for model 3.0L OPU
• General Motors Engine Manual for model 3.0L OPU GLP
• Deutz Engine Manual for model D2.9 L L4 Tier 4 Final
• Deutz Engine Manual for model TD2.9 L L4 Tier 4 Final
Contact the appropriate local dealer for this information. Vermeer
Corporation does not verify the validity of vendor information within the
context of the BC1000XL Brush Chipper machine configuration.
WARRANTY CONSIDERATIONS
Vermeer Warranty
Vermeer 1 year Limited Warranty is printed inside the front cover of the
Operator’s Manual. The warranty requires that all service work be
conducted by an authorized Vermeer representative or the warranty shall
become void.
1-2
BC1000XL Brush Chipper Service Safety
Engine Warranty
The engine is covered under the Caterpillar, Cummins, Power Solutions Inc.
(GM), or Deutz Engine Warranty.
Understand that only an authorized Caterpillar, Cummins, Power Solutions

Inc. (GM), or Deutz Engine Service Facility may work on the engine while
the warranty is in effect. Unauthorized service on the engine will void the
warranty.
For the nearest Caterpillar, Cummins, Power Solutions Inc. (GM), or Deutz
Engine authorized facility, consult the Yellow Pages of the phone directory or
contact Caterpillar, Cummins, General Motors, or Deutz Engine Warranty
Service Dept.
SAFETY
General safety messages appear in this Safety section of the manual.
Specific safety messages are located in the applicable sections of the manual
General Information
where a potential hazard may occur if the instructions or procedures are not
followed.
A signal word “DANGER”, “WARNING”, or “CAUTION” is used with the safety

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

located near specific hazards.
DANGER: Indicates a hazardous situation that, if not avoided, will

result in death or serious injury.
WARNING: Indicates a hazardous situation that, if not avoided, could
result in death or serious injury.
CAUTION: Indicates a hazardous situation that, if not avoided, could

result in minor or moderate injury.
NOTICE: Indicates information considered important, but not

hazard-related.
Do Not Modify Machine

Make no modifications to your equipment unless specifically recommended
or requested by Vermeer Corporation.
1-3
Safety BC1000XL Brush Chipper Service
Replace Shields
Be sure that all safety devices, including shields, are installed and
functioning properly after servicing the machine.
Safety Symbol Explanation

This is the safety alert symbol. This symbol is used in combination with an
exclamation mark or other symbols to alert you to the potential for bodily
injury or death.
This symbol indicates that at least one part of the machine is not operating correctly.
Shutting down the machine may not be necessary, but some maintenance may be
required.
General Information
WARNING: Read Operator’s Manual and safety signs before operating

machine. Allow only responsible, properly instructed individuals to operate
and service the machine.
WARNING: Check machine before operating. Machine must be in good

operating condition and all safety equipment installed and functioning
properly.
WARNING: Wear personal protective equipment. Wear close-fitting clothing

and confine long hair. Avoid wearing jewelry such as rings, wristwatches,
necklaces, or bracelets. Always wear a hard hat, safety glasses, and safety
shoes.
Continued on next page...
1-4
BC1000XL Brush Chipper Service Safety
WARNING: Keep spectators away.
WARNING: Exhaust fumes can be fatal.
If operating in an enclosed area, remove the exhaust fumes with an exhaust

pipe extension to the outside.
WARNING: Use Shutdown Procedure before servicing, cleaning, repairing, or

transporting machine. Refer to Shutdown Procedure, page 2-1 for
instructions.
General Information
WARNING: Pressurized fluid can penetrate body tissue and result in serious
injury or death. Leaks can be invisible. Keep away from any suspected leak.
Relieve pressure in the hydraulic system before searching for leaks,
disconnecting hoses, or performing any other work on the system. If you
must pressurize the system to find a suspected leak, use an object such as a
piece of wood or cardboard rather than your hands. When loosening a fitting
where some residual pressure may exist, slowly loosen the fitting until oil
begins to leak. Wait for leaking to stop before disconnecting the fitting. Fluid
injected under the skin must be removed immediately by a surgeon familiar
with this type of injury.
WARNING: Hot fluid under pressure can scald.
Allow engine to cool before opening radiator cap.
1-5
Safety BC1000XL Brush Chipper Service
WARNING: Fuel and fumes can explode and burn.
Shut off engine before refueling. No flame. No smoking.
WARNING: Batteries produce an explosive gas when in use or being charged.
Wear protective clothing and face shield while working around batteries. Do
not smoke, and keep flames and spark away from the battery area.
Battery posts, terminals, and related accessories contain lead and lead
compounds, chemicals known to the state of California to cause cancer and
General Information
reproductive harm. Wash hands after handling.
WARNING: Moving parts can crush fingers.
Close all shields before starting.
WARNING: Failure to follow any of the preceding safety instructions or those that
follow within this manual, could result in serious injury or death. This machine is to be
used only for those purposes for which it was intended as explained in the Operator’s
Manual.
1-6
BC1000XL Brush Chipper Service Terminology
TERMINOLOGY
System
The term system refers to the entire machine and comprises all individual
functions that make the machine work.
Function
A function is an operation of the machine generally performed by a specific
actuator or actuators with different operating modes.
Circuit
An identifiable grouping of electrical or hydraulic components that fill a
specific role within a function.
General Information
Inputs and Outputs
Inputs and outputs are shown on the schematics and other functional
diagrams by different line styles classified as hydraulic, electrical,
pneumatic, and mechanical. Arrows on the end of the lines represent
direction of electrical current flow, hydraulic oil flow, and air flow.
Reference Designators
Reference Designators are assigned to each component shown on the
schematics and other reference diagrams. The Addendum document for this
machine includes a legend describing the reference designators and symbols
and how they are used in the diagrams and text.
Each code-like designator identifies a specific component. The designator is

comprised of an uppercase letter or letters followed by a number. The letters
identify the type of component and the number specifies the exact
component.
1-7
Terminology BC1000XL Brush Chipper Service
Diagrams and Schematics

Functional diagrams, including schematics, wire harness connections, and
hydraulic hose connections, are located throughout the chapters. The
diagrams represent function circuitry and components.
Addendum Reference materials such as complete machine electrical and hydraulic

schematics as well as wire harness diagrams too large to fit on standard
pages, are located in the Addendum document for this machine on 11 x 17"
foldouts.
Chapter Organization
Other than the general and the system information (chapters 1 and 2), the
manual is divided up into chapters based on machine functions.
Introduction Each chapter starts with an introduction explaining what the function is
designed to do. There are also cross references to aid in locating specific
General Information
information in the Theory of Operation, Troubleshooting, and Repair

sections of each chapter.
Overview An overview which consists of a list of functions and components, along with
graphics depicting component locations and hydraulic hose connections, as
well as some general information is also given.
Theory of Operation Each individual function’s theory of operation begins by listing the required
operating conditions that must be met before normal operation can occur.
These would typically include any safety interlocks that must be in a specific
position and the position a switch, control lever, or other control device must
be in to actuate the function.
The normal operation will describe what happens when the controls are
actuated, and how components that comprise that function will operate
together to achieve the desired work. Illustrations, along with the text, will
aid in understanding how these functions work.
Troubleshooting/ The troubleshooting that follows the normal operation will describe how to
Testing test suspected faulty circuits and positively determine which components
have failed.
1-8
BC1000XL Brush Chipper Service Terminology
Repair When it is determined through troubleshooting that components are

malfunctioning, the repair sections at the end of the chapters contain
detailed instructions on how to repair or replace each component and any
special steps or procedures needed before returning the machine to service.
General Information
1-9
Troubleshooting Guidelines BC1000XL Brush Chipper Service
TROUBLESHOOTING GUIDELINES
Problem-Solving Analysis
First, look at the overall condition of the machine functions and determine
whether a technical problem even exists.
Rule Out Operator The operator may not be familiar with machine interlocks that must be in
Error the appropriate position to allow a certain function to perform. In other
words, the operator may not thoroughly understand the theory of operation.
Ensure you are familiar with the interlocks, refer to see the list of interlocks
used on this machine. Verify with the operator that all interlocks are
satisfied, and any (emergency) E-stop switches are closed and other simple
items are understood.
Define the Problem Once operator error is ruled out, analysis begins by asking questions and
making observations as follows:
• Discuss the defect with the operator. Learn what actuator or device is not
working and whether it is too slow, too fast or not working at all.
General Information
• Ask if the operator has recently used all the other actuators and whether
they seemed to be working normally. If not, ask the operator to try to use
these actuators. If there are multiple problems, there could be a common
cause to all of them.
• If possible inspect the machine. Verify that the problem is not something
obvious, like low hydraulic fluid, broken lines or wires. If you cannot
personally inspect the machine (such as when speaking over the phone),
ask the operator to check for these simple problems. Many problems are
solved this way.
• Ask other questions to further define the problem, such as:
—Did the problem appear suddenly, or did machine performance
deteriorate over time?
—When was the problem first noticed, and had there been any changes
made to the machine or the working conditions prior to the problem’s
appearance?
—Were any odd smells, sounds or machine actions noticed at the same
time as the problem?
—Is the problem intermittent or continuous?
— If intermittent, does it occur when the machine is cold, or fully
warmed up?
—Does it occur in cold weather, hot weather, dry weather, humid
weather?
1-10
BC1000XL Brush Chipper Service Troubleshooting Guidelines
• Compare the problem with others from past experiences on this machine
or machines similar to this one.
• Make an overall observation of the situation, noting symptoms and
relevant changes.
Research the Familiarize yourself with the Service Manual by reading the General and
System System Information chapters.
These chapters, explain in detail how the machine is comprised of multiple

separate functions and circuits as well as common functions and components
that are shared by all.
If you are not familiar with, or have limited knowledge of the machine’s
functions, read the theory of operation for all or selected functions.
Do not skip the analysis or research phase of troubleshooting. Simply

replacing a component may solve the problem if you make a lucky guess, but
it will waste time and money, as well as lessen your credibility with the
customer if it does not solve the problem. Do the analysis, do the research
General Information
and find the true cause of the problem.
If you are not familiar with this machine, simply reading the Operator’s
Manual and referring to your notes describing the problem may give you
insight that allows you to quickly and definitely locate the true cause of the
trouble.
Begin troubleshooting by doing the following:
• Describe and compare the problem situation with known operating

conditions prior to breakdown.
• Describe all known differences such as symptoms, noises, and smells
noticed when the failure occurred.
• Note which functions or circuits appear to behave normally and which do
not.
After doing the problem-solving analysis and noting the findings, use the
observations to decide how best to determine which circuits to investigate.
The troubleshooting procedures in this manual cover the electrical and

hydraulic circuits. First ensure a mechanical problem is not the cause of the
failure before using the troubleshooting procedures.
All functions with hydraulic circuits share the fluid conditioning subsystem
components. If all those subsystems experience related problems, these
components should be investigated.
1-11
Required Tools
The following test equipment is necessary for performing electrical and
hydraulic troubleshooting.
• VCTool diagnostic tool—for displaying status of controller inputs and

outputs, graphing inputs and outputs in real time, reporting errors, and
creating activity logs.
• Digital multimeter—for performing voltage, current and resistance tests
• Calculator—for doing simple arithmetic quickly and accurately
• Pyrometer or thermometer with a magnetic base—for temperature
readings
• Pressure gauges—for measuring system pressure
• Vacuum gauge—for measuring inlet pressure
• Flow meter—for measuring system flow
• Needle valve—for imposing an artificial load
• Combination flow meter/needle valve/pressure gauge—for measuring
flow, pressure, and imposing artificial loads with one tool
General Information
• Portable hydraulic tester (porta-power)
The required tools needed to perform a specific test will be listed along with
the test procedure.
1-12
Electrical Troubleshooting
Electrical When performing electrical troubleshooting, concentrate on testing INPUTS
Troubleshooting and OUTPUTS of components in circuits that do not work. Use a multimeter
to test for acceptable voltage (open circuit testing) in circuits testing at
component and wire harness connections. Refer to schematics shown in
circuit descriptions to see which terminals, pins, jacks, and wire harness
plugs to test.
If needed, refer to the Addendum chapter in back of this manual to view

large format schematics and wire harness diagrams if needed.
Working through failed circuit(s) will isolate failed component(s) by process

of elimination. If there is an open anywhere in circuit, current path is
broken. However, full battery voltage may be measured all the way to the
open circuit.
Common Electrical Listed below are some common problems to consider when troubleshooting
Problems the electrical circuits:
• Ground
General Information
Characteristic of ground problems can be no circuit or component function or
intermittent function. Ground problems can be blamed for about 50% of all
electrical problems.
• High Resistance
Higher than normal resistance in a circuit will result in a lower circuit
current. This can be caused by loose, corroded, or oily terminals (jacks) and
connections on wire and cables, broken strands in wire, or a poor ground
connection.
Measurements taken with a multimeter can be used to troubleshoot for

unwanted resistance. Use the meter to test for lower than normal battery
voltage (voltage drop) while moving to accessible points in the circuit wiring.
• Open Circuit
Characteristics of an open circuit are zero current, infinite resistance, and
higher than normal voltage. An open circuit can be found either on the
voltage side or the ground side of a circuit. If there is an open anywhere in
the circuit, the current path is broken and current will cease to flow through
the circuit.
An open circuit can occur when a component fails internally, a wire or cable
is broken or burned through or becomes detached, or when pins inside a
connector do not make contact.
1-13
In a normal working circuit, voltage is applied to the resistive load where it

is dropped proportionately over each resistor in the circuit. The amount of
voltage drop is dependent on the value of each resistor. Open circuits cannot
drop voltage.
Use a multimeter to test for voltage while moving to accessible input and
output pins/jacks of wire harness plugs and components in the circuit to find
the open and isolate the failed component or wire harness section.
Troubleshooters may find full battery voltage all the way to the open part of
circuit. If battery voltage is measured at all test points, continue next by
measuring for voltage on ground side.
Normal ground side voltage should measure 0.0–0.5 volts. If battery voltage
(+12 vDC) is measured on ground side, a poor connection or broken wire/
cable is indicated. Test wires connecting component for continuity or high
resistance. Replace faulty section of wire harness.
Once open is found, turn ignition switch OFF, unplug wire harness at
suspected component and test component for continuity. If component is OK,
test wires connecting component for continuity or high resistance. Replace
faulty component or section of wire harness. If a circuit breaker is found
General Information
open or a fuse is blown when testing inputs and outputs, a short should be
suspected. Open breaker or blown fuse would indicate circuit current has
increased to a level higher than circuit was designed to handle. Source of a
short must be fixed or breaker will continue to trip open.
• Short Circuit
Characteristics of a short circuit are higher than normal current, and zero
resistance. A short circuit, can be caused by a component being subjected to
heat, vibration, and so on as it ages. Over time this can cause abrasions in
the insulation on coils and wires and such. Exposed wires can provide a
short path for current reducing the resistance that was designed into the
circuit(s).
The resistance lowers causing the current to increase to a level higher than
the circuit fuse was designed to handle, resulting in a blown fuse or tripped
circuit breaker. The source of the short must be fixed or the replaced fuse
will blow or the breaker will continue to trip.
When testing for a short, turn the ignition switch OFF, set the multimeter to
measure resistance (ohms). Work through the circuit at the test points
shown on the circuit schematics of the circuit(s) suspected. If the meter
measures resistance through the complete circuit, it may be an intermittent
problem. In that case, repeat the procedure and move the wiring harness or
tap on components while watching for a sudden drop in the resistance
reading.
1-14
If the voltage side of the circuit is shorted to ground, the meter will read
0.0. This indicates no resistance between check points (a dead short). Work
through the circuit until the short is located. When the short is removed, the
meter will return to a resistance reading. Repair or replace faulty
component or section of wire harness. Check circuit for function.
When testing for a short, turn ignition switch OFF, set multimeter to
measure resistance (ohms). Work through circuit(s) in question. Use
schematics and wire harness located in the Addendum for reference if
needed.
If meter measures resistance through complete circuit, it may be an

intermittent problem. In that case, repeat procedure and move wiring
harness or tap on components while watching for a sudden drop in
resistance reading.
Expected result: If voltage side of circuit is shorted to ground, meter will

read 0.0. This indicates no resistance between check points (a dead
short). Work through circuit until short is located. When short is
removed, meter will return to a resistance reading. Repair or replace
faulty component, or section of wire harness. Check circuit for function.
General Information
Hydraulic Troubleshooting
Leakage Path The hydraulic troubleshooting procedures are based on leakage path
Analysis analysis. Using these methods, components are tested under no-load then
full-load. The measurements taken from the test equipment are compared to
the standard specifications listed at the beginning of each function chapter.
The specifications give values indicating the nominal operating parameters.
High leakage will cause system overheating and/or a decline in actuator

speed. The amount of leakage is influenced by four factors:
• pressure difference across clearances

• oil viscosity
• temperature
• size of clearances
Clearance related problems are generally viscosity sensitive. Increased

leakage will be less obvious when the fluid temperature is low and will
increase as the fluid temperature increases.
1-15
Pumps and Motors All pumps and motors have internal clearances (internal leakage), but some
design types have less leakage than others of the same displacement. Piston
pumps or motors leak less than gear or gerotor pumps and motors.
The general rule used at Vermeer for expected leakages is:
Theoretical flow is equal • Piston pumps and piston motors are expected to lose about 3% of
to displacement times theoretical flow at normal working pressures. This is a 97% volumetric
input shaft speed; i.e., efficiency.
CID X RPM.
• Gear pumps and motors are expected to lose about 15–20% of theoretical
Example: A pump with a flow at normal working pressures. This is an 80–85% volumetric
3.0 in displacement, efficiency. (This rises to 90% if the gear pump has pressure-compensated
turned at 2500 rpm, has wear plates.)
a theoretical flow of
7500 in/min. Through normal wear over time, the clearances between the moving parts in
the pump get larger, allowing more internal leakage. Eventually, the
clearances are large enough that the pump or motor is worn-out.
The guideline used at Vermeer for determining if a pump or motor is worn-

out is:
General Information
• When volumetric efficiency for the pump or motor declines to 70% or less,
the pump or motor should be replaced.
The most common symptoms associated with excessive pump/motor leakage

are:
• A loss of actuator speed as the fluid temperature increases.

• A moderate to high increase in the operating temperature of the fluid.
• Actuator stalling at low pump or motor speed.
• An increase in case pressure which could result in shaft seal leakage.
Any increase in internal leakage will result in increased flow into case drain
lines of externally drained pumps and motors. If case drain flow increases,
case pressure will increase because of higher flow resistance through drain
port in the housing and case drain lines. Excessive case pressure could
result in shaft seal failure and case seal leakage.
1-16
The most common symptoms associated with excessive pump/motor case

pressure are:
• Shaft seal leakage

• Catastrophic shaft seal failure
• Case seal leakage
• Moderate to high increase in the operating temperature of the fluid
Directional Control Directional control valves have radial clearances between the valve bore and
Valves spool of between 5 to 15 micrometers. If fluid is heavily contaminated with
particles which are equal in size, the particles will cause abrasive wear.
Abrasive wear will gradually increase the radial and diametrical clearances,
resulting in increased cross-port leakage.
The most common symptoms associated with excessive directional control

valve leakage are:
• Increased actuator drifting while directional control valve is in the
General Information
NEUTRAL position.
• Moderate to high increase in the operating temperature of the fluid.
• Loss of precise position control.
Cylinders Hydraulic cylinders consists of a moveable piston and rod assemblies.

Pistons have seals to prevent leakage across the piston.
The most common symptoms associated with excessive cylinder leakage are:
• Cylinder fails to respond when directional control valve is actuated.

• Reduced cylinder rod velocity in one or both directions of travel.
• Moderate to high increase in the operating temperature of the oil.
• Cylinder rod speed reduction as the load increases.
• Actuator drifts when the directional control valve is in neutral position.
• Cylinder rod extends regardless of which port the oil enters.
1-17
Hydraulic Connections
WARNING: Pressurized fluid can penetrate body tissue and result in

serious injury or death. Leaks can be invisible. Keep away from any suspected
leak. Relieve pressure in the hydraulic system before searching for leaks,
disconnecting hoses, or performing any other work on the system. If you must
pressurize the system to find a suspected leak, use an object such as a piece
of wood or cardboard rather than your hands. When loosening a fitting where
some residual pressure may exist, slowly loosen the fitting until oil begins to
leak. Wait for leaking to stop before disconnecting the fitting. Fluid injected
under the skin must be removed immediately by a surgeon familiar with this
type of injury.
Avoid Trapped Never disconnect hoses or lines unless the engine is shut down.
Pressure
Remove all hydraulic pressure from hydraulic system before removing any
hydraulic hoses:
General Information
• When removing components, always remove as much of the load (weight)

from cylinders and other actuators. Lower any attachment completely,
support it with suitable blocking, or support it with a suitable lifting
device.
• Relieve pressure in the hydraulic system before disconnecting hoses.
Pressure in many of the circuits cannot be relieved simply by lowering
the attachment, shutting off the engine and cycling the control lever.
Most circuit pressures can be minimized by lowering the attachment to
the ground or onto suitable blocking and with the engine running,
position the attachment until it just touches the ground or blocking
without exerting a significant downforce, and shutting off engine.
• When loosening fittings in hoses where residual pressure may exist,
slowly loosen fittings until oil begins to leak. Wait for leaking to stop
before disconnecting fittings. Ensure all connections are tight and hoses
are in good condition before applying pressure to the system.
• Label hoses to make it easier to connect to the correct fitting or port
when reconnecting.
1-18
Avoid Oil
Contamination
Warranty claims may be Use care to avoid allowing dirt, dust, debris, water, or foreign fluids to enter
denied if damage is the hydraulic system. Contaminated oil will ruin a pump or motor in a short
caused by contaminated amount of time.
hydraulic fluid.
• Clean dirt from hose connections before loosening any connection.
• Use new, clean plugs to plug disconnected hoses. If clean plugs are not
available, place plastic bags (such as sandwich bags) over the ends of
hoses and hold them in place with rubber bands.
• When adding oil, use new oil filtered through a 10-micron absolute filter.
(New oil is full of particles from metal storage containers and is not
intended to be added directly to the hydraulic tank.)
• One source of contamination is dirt adhering to the cylinder rod and
being drawn into the system when the rod is retracted. The wiper seals
clean dirt from the rod as it retracts, but scratches in the rod will allow
dirt past the wipers. Take care to avoid scratching the cylinder rods and
regularly inspect rods for scratches. Draw your fingernail across any
scratches. If the scratch is deep enough to catch the fingernail, the
scratch should be polished out with fine emery cloth, or the rod replaced.
General Information
Connecting Flow Flow meters measure flow in one direction only. An arrow on the flow meter
Meters indicates the direction. The test setup instructions will state which way the
flow arrow must point.
Often, adapters will be needed to plumb the flow meter into the line. It is
important that the flow through the meter is not restricted (unintentionally)
by using a flow meter or adapters that are of smaller diameter than the
hose. Use a larger diameter flow meter if needed, and use adapters to
connect the smaller diameter hose to the larger diameter flow meter.
Use a flow meter that is rated to safely withstand the pressure in the circuit.
1-19
Connecting a Needle valves are used to impose artificial loads on pumps so pump
Needle Valve performance can be accurately measured. By slowly closing the needle valve
while watching the pressure gauge, you can easily set the pressure as
needed for the flow measurement.
As with flow meters, you can safely use a larger diameter needle valve, but
you must not use smaller diameters.
NOTICE: Do not attempt to use a ball valve in place of a needle valve. Ball
valves are not precise and tend to snap closed when higher pressures are
reached. This will send a destructive pressure spike back through the
system.
Connecting Pressure gauges are selected according to the expected maximum pressure
Pressure Gauges to be observed during the test. Since the gauge is most accurate at the
middle of its range, read through the test to determine the expected
maximum pressure and double that amount. Thus, if you expect to see 3000
psi as the greatest pressure during the test, select a 0–6000 psi gauge or a
General Information
0–7500 psi gauge.
NOTICE: If the gauge ever “pegs” (indicates pressure at the maximum

reading), the gauge is ruined. Discard it immediately so that another
technician does not use it and receive erroneous readings.
Magnetic Base A magnetic-base thermometer is placed on the oil tank to determine the
Thermometer or temperature of the oil. Allow time for the thermometer to react before taking
Pyrometer a temperature reading.
A pyrometer is a non-contact thermometer. Place the projected red dot on

the surface and wait at least one second. Surface temperature is shown in
the indicator window.
Several readings may be required during a test. It is important to take

readings with the projected dot focused on the same spot each time.
1-20
Digital Multimeter
A multimeter is used to measure voltage, current, and resistance. It is also
used to test wires for continuity.
Measuring Voltage Voltage is defined as a difference in electrical potential between two points.
Ensure the multimeter is in the appropriate setting to measure volts DC. (If
needed, see the instruction booklet for your multimeter to determine proper
settings.) Then do the following:
1. Turn off power to the circuit or device.

2. Connect positive (red) lead to the multimeter’s voltage or V port. Place
red probe on the wire or contact delivering power to the device.
3. Connect negative (black) lead to the common or COM port. Place black
probe on the wire or contact leading to ground for the device. In some
cases you may place the black probe on the metal structure of the vehicle
chassis. (The multimeter is in parallel with the circuit.)
4. Turn on power to the device.
The multimeter will indicate the voltage available to power the device.
General Information
Measuring Resistance, measured in Ohms () is defined as the opposition to current
Resistance flow. Set the multimeter to measure resistance. (If needed, see the
instruction booklet for your multimeter to determine proper settings.) Then
do the following:
1. Turn off power to the circuit and device to be tested.

2. Disconnect component from the circuit when testing resistance. The
multimeter sends a small current through the device and indicates the
amount of resistance encountered.
3. Connect positive (red) lead in the multimeter’s voltage or V port. Place
red probe on the wire or contact delivering power to the device.
4. Connect negative (black) lead in the common or COM port. Place black
probe on the wire or contact leading to ground for the device. (The
multimeter is in parallel with the circuit).
5. If resistance (Ohms or ) is greater than or less than published
tolerances this indicates the device is damaged and should be replaced.
1-21
Testing for Continuity is defined as the presence of a complete pathway for the flow of
Continuity current. With the multimeter set to test continuity, do the following:
1. Turn off power to the device or circuit.

2. Disconnect section of harness or device in question.
3. Connect positive (red) lead in the multimeter’s voltage or V port.
4. Connect negative (black) lead in the common or COM port.
5. Place one probe on one end of the wire or jack of the device. Place the
other probe on the other end of the same wire or opposite jack of the
same device.
An indication of zero or very low resistance (Ohms or ), indicates
continuity (good wire or closed switch). High resistance or an indication of
“OL” (overload) means there is no electrical contact between the two probes,
i.e., the wire is broken or the switch is open. In this manual, the results of a
continuity check are described as “continuity” or “open.”
Some multimeters or continuity testers produce a beep or illuminate a bulb

to indicate continuity.
General Information
Measuring Current Current, or amperage is defined as the flow of electrons. Set the multimeter
to measure amps DC or milliamps DC. (If needed, see the instruction booklet
for your multimeter to determine proper settings.) This involves plugging
the leads into the proper ports in the multimeter and setting the knobs and/
or range switches correctly for measuring the expected amount of current
(microamps, milliamps or amps). Then do the following:
1. Turn off power to the circuit or device.

2. Unplug the device from the wiring harness and install the proper
breakout box.
3. Disconnect exposed connector for the desired wire.
4. Place the red probe on one of the exposed connectors for the wire.
5. Place black probe on the other exposed connector for the wire. (The
multimeter is in series with the circuit.)
6. Turn on the power to the device.
The multimeter indicates the current in amps (A), milliamps (mA) or
microamps (A).
1-22
BC1000XL Brush Chipper Service Repair Guidelines
REPAIR GUIDELINES
Safety Equipment
Ensure all technicians have and use proper safety equipment, including
steel-toed shoes, protective eye wear, gloves, and hearing protection.
Do not allow spectators or bystanders in your shop unless they are wearing
adequate protective gear.
Ensure shop has proper fire prevention and fire-fighting equipment and that
all technicians know how and when to use it.
Shop Requirements
Special Tools & Test To perform some tasks, special tools— available through Vermeer—may be
Equipment required. These tools, are specified at the beginning of the procedure where
they are needed.
General Information
Refer to the Recommended Service Tools Users Guide (Vermeer P/N
105400T69) for special tools and test equipment.
Personnel and Lifting Requirements

Review each task to determine the number of personnel needed for safe
completion.
Determine if suitable lifting devices are needed to safely lift or lower the
component.
20General Information
Replacement Parts
Part Numbers/Hose Refer to the most current BC1000XL Parts Manuals, for part numbers, hose
Lengths/Fitting lengths, and fitting orientations. Refer to "Reference Publications," page 1-2
Orientation for ordering information.
Parts Ordering Contact the Vermeer Parts Center with part number information to order
replacement components.
1-23
Repair Guidelines BC1000XL Brush Chipper Service
Torque Values
Repair procedures in this manual will list torque values for any part that
needs to be tightened to an other-than-standard torque value. For (standard)
torques on other parts, refer to the torque tables, given in the Vermeer
Industrial Dealerships Technician’s Shop Manual, order number
105400V80.
General Information
1-24
BC1000XL Brush Chipper Service Shutdown Procedure
Chapter 2: System Information
SHUTDOWN PROCEDURE
Stopping the Machine
NOTICE: For your safety and the safety of others, use the shutdown
procedure before working on the machine for any reason, including
servicing, cleaning, unclogging, inspecting, or transporting the chipper.
A variation of this procedure may be used if so instructed within this

manual, or if an emergency requires it.
1. Return Upper Feed Control Bar to

top STOP position.
2. Place Cutter Engage/Throttle Lever
in the ENGAGED/LOW RPM
position.
NOTICE: Whenever practical and consistent with good safety practice, run
System Information
engine without load for a few minutes before shutting it off. This allows
engine temperatures to decrease and equalize, which will increase engine
life.
3. Wait for the cutter drum to slow.

4. Place Cutter Engage/Throttle
Lever in the DISENGAGED/LOW
RPM position.

5. Turn ignition key to OFF position.
6. Wait for the cutter drum and belt
to stop.
Cutter drum rotation can be
checked by looking at the end of
the shaft (1) on the left side of the cutter wheel housing.
NOTICE: The cutter drum will continue to turn for a short time after the
engine has stopped.
7. Remove ignition key.

8. Close and latch feed table.
2-1
Legend for Reference Designators BC1000XL Brush Chipper Service
Quick Stop 1. Turn ignition to OFF position while

To Stop Drum Quickly
Procedure cutter drum clutch is still engaged.
Remove key.
2. Wait for cutter drum and belt to
stop. Shut Off Engine With Clutch Engaged
3. Fully disengage cutter drum.
LEGEND FOR REFERENCE DESIGNATORS

The following is a list of all designators used on this machine. The list is
divided according to chapters and functions.
Chapter 3 - Engine Functions

Caterpillar Caterpillar functions in this chapter include the following components:
• Engine ENG1
System Information
• Controller A1
• Battery BT1
• CAN Resistor R5
• Alternator G1
• Alternator Diode V3
• Alternator Excite Resistor R14
• Circuit Breaker CB1 (Controls)
• Circuit Breaker CB2 (Glow Plug)
• Main Fuse F1
• Ignition Switch S1
• Fuel Gauge E2
• Hourmeter E3
• Amber Information Light E6
• Starter Motor M1
• Starter Solenoid L1
• Starter Diode V4
• Engine Coolant Temperature Sensor B4
• Engine Oil Pressure Sensor B2
• Magnetic Pickup Sensor B3
2-2
BC1000XL Brush Chipper Service Legend for Reference Designators
• Oil Filter FL5

• Fuel Filter FL1
• Fuel Transfer Pump PMP4
• Fuel Injector Pump PMP5
• Fuel Solenoid L2
• Glow Plug Relay K2
• Glow Plug Resistor R1
• Radiator HE1
• Coolant Recovery Tank RES3
• Fuel Tank RES2 including:
• Fuel Level Sensor B1
• Breather Filter FL3
• Air Cleaner Assembly A3, including:
• Primary Air Filter FL6
• Secondary Air Filter FL7
• Air Restriction Indicator E1
System Information
Cummins Cummins functions in this chapter include the following components:
• Engine ENG2
• Controller A1
• Battery BT1
• Alternator G1
• Circuit Breaker CB1
• Dash and Engine Fuse F1
• Feed Roller Control Fuse F2
• Fuel Gauge E2
• Hourmeter E3
• Wait-to-Start Light E25
2-3
• 4-in-1 Gauge E4 (Deluxe Gauge Package)

• Tachometer/Hourmeter E5 (Deluxe Gauge Package)
• Engine Oil Pressure Sensor B7 (Deluxe Gauge Package)
• Engine Coolant Temperature Sensor B5 (Deluxe Gauge Package)
• Oil Filter FL5
• Fuel Filter FL1
• Fuel Primer Pump PMP1
• Turbocharger
• Radiator HE3
System Information

• Grid Heat Relay K1
• CAN Resistor R5
2-4
Deutz Deutz functions in this chapter include the following components:

• Controller A1
• Fuel Gauge E2
• CAN Resistor R5
• Engine Information Display E35
• EcoIdle Switch S5
• Battery BT1
• Fuel Breather Filter FL3
• Fuel Pump Relay K4
System Information
• Glow Plug Resistor Relay K2
• Start Relay K3
• Controls Circuit Breaker CB1
• Coolant Recovery Bottle RES3
• Coolant Level Sensor B14
• Fuel Filter FL10
• Fuel Pre-Filter with Water Separator FL11
• Fuel Pump PMP6
• Air Cleaner Assembly A3 including:
2-5
• Alternator G1
• Water in Fuel Sensor B8
• Engine ENG 4 (74 HP)
• Diesel Oxidation Catalyst Filter FL9 (74 HP)
• Radiator HE4 (74 HP)
GM GM functions in this chapter include the following components:
• Controller A1
• Fuel Gauge E2
System Information
• CAN Resistor R5
• Engine Light (MIL) E36
• Battery BT1
• Fuel Level Sender B1
• Fuel Vent Filter FL16
2-6
• Radiator HE6
• Oil Filter FL5
• GM Engine ECM A4
• Catalytic Converter FL14
• Alternator G1
• Fuel Valve FV2
• Fuel Pump PMP7
• Throttle Switch S3
System Information
• Engine ENG5
• Engine ENG6 (Dual Gas/Propane Option)
• Left and Right LP Tanks RES5 and RES6
• LP Fuel Filter FL17
• Gas/Propane Switch S14
Optional Remote Optional remote control functions in this chapter include the following
Controls components:
• Remote Receiver A5
• Remote Transmitter A6
• Remote Control/Console Selector Switches S24 and S25
• Amber Beacon E34
• Remote Horn B15
2-7
Chapter 4 - Feed Roller Function

• Hydraulic Tank RES1 including:
• Suction Strainer SR1
• Breather Filler Cap FL2
• Return Filter FL4
• Hydraulic Pump PMP3 (Caterpillar)
• Hydraulic Pump PMP9 (Cummins, Deutz)
• Hydraulic Pump PMP10 (GM)
• Feed Roller Drive Motor MH1
• Feed Roller Control Valve Assembly AH1 including:
• Directional Control Valve DV1
• Pressure Relief Valve PV1
• Solenoid L3 (Forward Feed)
• Solenoid L4 (Reverse Feed)
• SmartFeed Controller A1
System Information
• Left Reset Hold-to-Run Switch S6

• Right Reset Hold-to-Run Switch S7
• Reverse Feed Switch S8
• Forward Feed Switch S10
• Feed Stop Switch S11
• Sensitivity Select Switch S4
• Normal Sensitivity Switch S12
• Reduced Sensitivity Switch S13
• Magnetic Pickup Sensor B3 (Caterpillar, Cummins)
Chapter 5 - Cutter Drum Drive Function

• Cutter Drum
• Cutter Knives
• Engine Sheave
• Cutter Drum Sheave
• Cutter Drum Drive Belt
• Belt Tensioner
2-8
Chapter 6 - Trailer Functions

The functions in this chapter include the following components:
• Breakaway Switch S23

• Brake Electromagnetic Brake Coils L5 and L6
• Left Front Side Marker Light (Domestic) E8
• Right Front Side Marker Light (Domestic) E9
• Left Rear Side Marker Light (Domestic) E10
• Right Rear Side Marker Light (Domestic) E11
• Right Stop/Turn/Taillight (Domestic) E12
• Left Stop/Turn/Taillight (Domestic) E13
• License Plate Light (Domestic) E14
• Left Front Side Marker Light (Australian) E15
• Right Front Side Marker Light (Australian) E16
• Left Rear Side Marker Light (Australian) E17
• Right Rear Side Marker Light (Australian) E18
System Information
• License Plate Light (Australian) E19
• Right Amber Turn light (Australian) E20 (Machines Prior to SN 22325)
• Left Amber Turn light (Australian) E21 (Machines Prior to SN 22325)
• Right Stop/Turn/Taillight (Australian) E22
• Left Stop/Turn/Taillight (Australian) E23
• License Plate Light (European) E24 and E34
• Left Front Clearance Light (European) E26
• Right Front Clearance Light (European) E27
• Right Stop Light (European) E28
• Right Turn Light (European) E29
• Right Fog Light (European) E30
• Left Fog Light (European) E31
• Left Turn Light (European) E32
• Left Stop Light (European) E33
2-9
BC1000XL Brush Chipper Specifications BC1000XL Brush Chipper Service
BC1000XL BRUSH CHIPPER SPECIFICATIONS

Machine Reference and Orientation
Left, right, front, and rear of the machine are noted from facing the direction
in which the machine is towed.
5HDU
5LJKW
System Information
/HIW
)URQW
Serial Number Plate Locations

The locations of all serial number plates are shown in the BC1000XL
Operator’s Manual.
2-10
BC1000XL Brush Chipper Service BC1000XL Brush Chipper Specifications
Component Specifications
Specific electrical and hydraulic specifications such as, hydraulic flows,
pressures, system and component pressure ratings, as well as solenoid coil
resistance ratings and so on, are listed in the overview section for each
chapter.
The following tables list the general engine and machine specifications as
well as fluid and lubricants used.
Machine Specifications
General
Overall length (tongue in, infeed
12.5 ft (3.8 m)
table up)
Overall length (tongue extended,
16.5 ft (5 m)
infeed table down)
Overall width 66.5" (169 cm)
System Information
Overall height 101" (257 cm)
Caterpillar-4,680 lb (2125 kg) / 49 hp-Deutz-4,960 lb (2250 kg) / 74 hp-Deutz-5000 lb
Total weight (estimated) (2270 kg)
Cummins-4,860 lb (2200 kg) / GM-4,800 lb (2180 kg)
Tongue weight (estimated) 485 lb (220 kg) Deutz 49 hp-620 lb (280 kg) / 74 hp-635 lb (290 kg)
Axle capacity 5,200 lb (2360 kg) or 7,000 lb (3175 kg) (Option)
Maximum log diameter 12" (30 cm)
Engine Caterpillar
Model C2.2L Tier 4 Interim/stage IIIB
No. cylinders/max torque 4 cyl., 103 ft-lb (140 Nm)
Fuel capacity and type 25 gal (95 L) Diesel
Liquid, 9 qt (8.5 L)
Use a 50/50 mixture of Extended Life (ELC) Nitrite Free (NF) Coolant and distilled or
Cooling medium and capacity deionized water. Never add pure antifreeze to the system; always dilute to a 50/50
mixture. Never use Supplemental Cooling Additives (SCA’s) with ELC coolant. Refer to
the Engine Operation Manual.
Maximum power 48.7 hp (36.3 kW) at 2800 rpm

High Idle Hertz 6,300 Hz at 3000 rpm
Alternator 65 amp
Engine Cummins
Model B3.3 Turbo Tier 4 Interim/stage IIIB
Liquid, 14 qt (13 L)
Cooling medium and capacity
deionized water. Never add pure antifreeze to the system; always dilute to a 50/50
2-11
BC1000XL Brush Chipper Specifications BC1000XL Brush Chipper Service
Maximum power 74 hp (55 kW) at 2600 rpm

High Idle Hertz 5091 Hz at 2782 rpm
Alternator 60 amp
Engine Deutz
Model D2.9 L4-Tier 4 Final/stage IIIB TD 2.9 L4-Tier 4 Final/stage IIIB (with turbo)
No. cylinders/max torque 4 cyl. - D2.9 108 ft-lb (146 Nm)1600 rpm DT 2.9 w/turbo 192 ft-lb (260 Nm)@1800 rpm
Maximum power D2.9 L4-49 hp (37 kW) @ 2600 rpm TD 2.9 L4 / (with turbo) 74 hp (55 kW)@2600 rpm
Liquid, 11.5 qt (10.9 L) Liquid, 13 qt (12.3 L)
Fuel capacity and type 25 gal (95 L) Diesel EN 590 (Sulphur <10 mg/kg) ASTM D975 Grade 1 & 2-D S15
Engine GM
Model CPIB2.9GLP (3.0L)
No. cylinders/max torque 4 cyl., 142 ft-lb @1600 rpm (193 Nm)
Fuel capacity and type 20 gal (76 L) Gasoline / Dual Fuel Optional Propane - Two 33 lb cylinders
Liquid, 14.4 qt (13.6L)
System Information

High Idle Hertz NA
Alternator 70 amp
Battery Cummins Caterpillar and GM Deutz
Size Group 31, 12 volts Group 24, 12 volts Group 31, 12 volts
Cold cranking amps 660 CCA 580 CCA 950 CCA
Tires
Tire size ST 235/80/R16 Load Range E
Tire pressure 80 psi (550 kPa)
Optional Caterpillar tire - size ST 225/75/R15 Load Range D
Optional Caterpillar tire -
65 psi (450 kPa)
pressure
95 ft-lb (129 Nm) - 5200 lb axle
Lug nut torque 135 ft-lb (183 Nm) - 7000 lb axle
196 ft-lb (266 Nm) Euro (Knott) axle
Refer to "Feed Roller Function," page 4-1 for hydraulic system specifications.
2-12
BC1000XL Brush Chipper Service BC1000XL Brush Chipper Specifications
Lubricants
Lubricant / Recommendation Capacity Specification / Notes

Cat DEO (Diesel Engine Oil) 10W-30, 15W-40; API CH-4 and API
CI-4 multigrade oils as specified in Engine Operation Manual
supplied with each machine. Refer to the manual for recommended
engine fluids.
Use engine oil viscosities according to ambient temperature
ranges:
SAE 15W-40: 15°–122°F (-9.5°–50°C)
Cat Engine Oil (with filter) 8.5 qt (8 L) SAE 10W-40: 0°–122°F (-18°–50°C)
SAE 10W-30: 0°–104°F (-18°–40°C)
SAE 5W-40: -22°–122°F (-30°–50°C)
SAE 5W-30: -22°–86°F (-30°–30°C)
SAE 0W-40: -40°–104°F (-40°–40°C)
SAE 0W-30: -40°–86°F (-40°–30°C)
SAE 0W-20: -40°–50°F (-40°–10°C)
Engine must be level when checking engine oil.
15W40, Cummins Premium Blue or equivalent, all seasons, 10 –
110°F (-12 – 43°C)
Cummins Engine Oil (with filter) Winter Conditions: 10W30, -15–68°F (-26–20°C)
8.5 qt (8 L)
System Information
Arctic Conditions: 5W30, -30–68°F (-34-20°C)
An Engine Operation Manual is supplied with each machine. Refer
to the manual for engine service requirements.
Use multigrade oils as specified in Engine Operation Manual
supplied with each machine. Refer to the manual for recommended
engine fluids.
Use engine oil viscosities according to ambient temperature
ranges:
SAE 15W-40: 5°–104°F (-15°–40°C)
Deutz Engine Oil (with filter) 8.4 qt (8 L) SAE 10W-40: -4°–104°F (-20°–40°C)
SAE 10W-30: -4°–86°F (-20°–30°C)
SAE 5W-40: -22°–104°F (-30°–40°C)
SAE 5W-30: -22°–86°F (-30°–30°C)
SAE 0W-40: -40°–104°F (-35°–40°C)
SAE 0W-30: -40°–86°F (-35°30°C)
Engine must be level when checking engine oil
Use multigrade oils as specified in Engine Operation Manual supplied
with each machine. Refer to the manual for recommended engine
fluids.
Use engine oil viscosities according to ambient temperature ranges:
SAE 15W-40: 15°–122°F (-9.5°–50°C)
SAE 10W-40: 0°–122°F (-18°–50°C)
GM Engine Oil (with filter) 4.5 qt (4.3 L)
SAE 10W-30: 0°–104°F (-18°–40°C)
SAE 5W-40: -22°–122°F (-30°–50°C)
SAE 5W-30: -22°–86°F (-30°–30°C)
SAE 0W-40: -40°–104°F (-40°–40°C)
SAE 0W-30: -40°–86°F (-40°–30°C)
SAE 0W-20: -40°–50°F (-40°–10°C)
2-13
System Interlocks BC1000XL Brush Chipper Service
Lubricant / Recommendation Capacity Specification / Notes

Phillips: Type HG; ISO STD or equivalent
If equipped with biodegradable hydraulic fluid, use Vermeer
Biodegradable Hydraulic Fluid, Mobil EAL-224H, or equivalent.
Hydraulic Fluid Use caution not to get dirt or other contaminants into the system(s)
7 gal (26.5 L)
Vermeer Ultra VMF Hydraulic Fluid when servicing. Filter all fluid through a 10-micron filter before
adding.
NOTICE: Use of any other hydraulic oil without written factory
approval will jeopardize warranty.
EP grease - Shell Alvania EP2 or equivalent
To minimize condensation in bearings, grease machine after it is
Grease
As required shut down for the day.
Vermeer Ultra LC Grease
Fittings and grease applicator nozzle must be clean before applying
grease. Replace all missing fittings.
Coat lightly
General Lubricating Oil
where 10W-30
Vermeer Ultra Gold 10W30
required.
SYSTEM INTERLOCKS
System Information
An interlock is a component or an arrangement of components by which the

functioning of one component is controlled by the functioning of another.
These separate components when in predetermined positions (closed or
opened), will complete or interrupt an electrical circuit.
Refer to:
• Engine Protection Interlocks (see page 3-80)

• Feed Roller Drive Interlocks (see page 4-16)
2-14
BC1000XL Brush Chipper Service Introduction
Chapter 3: Engine and Electrical Power
INTRODUCTION
This chapter describes the systems, circuits, and components needed to
produce and distribute the operating power for the machine’s electrical
functions. This chapter also includes functions and components needed for
starting and operating the engine.
This chapter explains only those items provided by Vermeer.

Troubleshooting and repair of the engine itself is beyond the scope of this
manual. For engine service, see an authorized Caterpillar or Cummins
engine repair facility.
The engine chapter is organized into four main categories to make it easier
to locate specific information.
Engine and Electrical Power

Overview Starting on page 3-2, includes:
• Complete list of functions and components

• Component location diagrams
• Component specifications table
Theory of Operation Starting on page 3-24, includes:
• Function and component normal operation
Troubleshooting Starting on page 3-83, includes:
• Circuit/component troubleshooting/testing procedures
Repair Starting on page 3-104, includes:
• Component removal, inspection, repair/replace, and installation

procedures
3-1
Overview BC1000XL Brush Chipper Service
OVERVIEW
Functions/Components
The following functions are included in this chapter:
• Engine Functions, including:

• Intake Air
• Exhaust
• Fuel
• Cooling
• Throttle
• Glow Plug Function
• Engine Protection Interlocks
• Electrical Power Source
• Electrical Power Distribution, including:
• Ignition Switch Circuits

• Gauges
• Optional Remote Control
Caterpillar Caterpillar functions in this chapter include the following components:
• Engine ENG1
• Controller A1
• Battery BT1
• CAN Resistor R5
• Alternator G1
• Alternator Diode V3
• Alternator Excite Resistor R14
• Circuit Breaker CB1 (Controls)
• Circuit Breaker CB2 (Glow Plug)
• Main Fuse F1
• Fuel Gauge E2
• Hourmeter E3
3-2
BC1000XL Brush Chipper Service Overview

• Starter Diode V4
• Oil Filter FL5
• Fuel Filter FL1
• Fuel Transfer Pump PMP4
• Glow Plug Relay K2

• Radiator HE1
• Coolant Recovery Tank RES3
Cummins Cummins functions in this chapter include the following components:
• Engine ENG2
• Controller A1
• Battery BT1
• Alternator G1
• Circuit Breaker CB1
3-3

• Fuel Gauge E2
• Hourmeter E3
• Wait-to-Start Light E25
• 4-in-1 Gauge E4 (Deluxe Gauge Package)
• Tachometer/Hourmeter E5 (Deluxe Gauge Package)
• Engine Oil Pressure Sensor B7 (Deluxe Gauge Package)
• Engine Coolant Temperature Sensor B5 (Deluxe Gauge Package)
• Oil Filter FL5
• Fuel Filter FL1

• Fuel Primer Pump PMP1
• Turbocharger
• Radiator HE3 (74 hp)
• Grid Heat Relay K1
• CAN Resistor R5
3-4
Deutz Deutz functions in this chapter include the following components:

• Controller A1
• Fuel Gauge E2
• CAN Resistor R5
• Battery BT1
• Fuel Breather Filter FL3

• Fuel Pump Relay K4
• Glow Plug Resistor Relay K2
• Start Relay K3
• Coolant Level Sensor B14
• Fuel Pre-Filter with Water Separator FL11
• Fuel Pump PMP6
3-5
• Alternator G1
• Water In Fuel Sensor B8
GM GM functions in this chapter include the following components:
• Controller A1
• Fuel Gauge E2
• CAN Resistor R5

• Engine Light (MIL) E36
• Battery BT1
• Fuel Level Sender B1
• Fuel Vent Filter FL16
• Radiator HE6
• Oil Filter FL5
• GM Engine ECM A4
3-6
• Catalytic Converter FL14

• Alternator G1
• Fuel Valve FV2
• Fuel Pump PMP7
• Throttle Switch S3
• Engine ENG5
• Engine ENG6 (Dual Gas/Propane Option)
• Left and Right LP Tanks RES5 and RES6
• LP Fuel Filter FL17
• Gas/Propane Switch S14
Optional Remote Optional remote control functions in this chapter include the following

Controls components:
• Remote Horn B15
3-7
Component Locations Caterpillar
A B
A B C D E F
3-8
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3-10
Component Locations Cummins
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3-13
Component Locations Deutz 49 HP and 74 HP Engines

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3-17
Component Locations GM - Gas/Propane

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3-20
Component Locations - Optional Remote Control
Remote Horn B15

Remote
Selector Switch
S24
Amber Beacon
E34

S25
Remote
Selector Switch
Antenna
A6 Remote Transmitter
A5
Remote Receiver
3-21
Component Repair/Replace
If troubleshooting procedures determine a component is in need of repair or
replacement, refer to the appropriate procedures at the back of the chapter
or other chapters where instructed.
Listed below are the specifications for components in this chapter.
Engine Caterpillar
Model C2.2L Tier 4 Interim/stage IIIB
Maximum rated power 48.7 hp (36.3 kW) at 2800 rpm
Alternator 65 amp
Engine Cummins
Model B3.3 Turbo Tier 4 Interim/stage IIIB
Maximum rated power 74 hp (55 kW) at 2600 rpm
Alternator 60 amp
Engine Deutz Deutz
Model D2.9 L4-Tier 4 Final/stage IIIB TD 2.9 L4-Tier 4 Final/stage IIIB (with turbo)
No. cylinders/max torque 4 cyl. - D2.9 108 ft-lb (146 Nm)1600 rpm DT 2.9 w/turbo 192 ft-lb (260 Nm)@1800 rpm
Maximum power D2.9 L4-49 hp (37 kW) @ 2600 rpm TD 2.9 L4 / (with turbo) 74 hp (55 kW)@2600 rpm
Fuel capacity and type 25 gal (95 L) Diesel EN 590 (Sulphur <10 mg/kg) ASTM D975 Grade 1 & 2-D S15
High Idle Hertz NA NA
Alternator 95 amp 95 amp
Engine GM
3-22
Model CPIB2.9GLP (3.0L)

No. cylinders/max torque 4 cyl., 142 ft-lb @1600 rpm (193 Nm)
Fuel capacity and type 20 gal (76 L) Gasoline / Dual Fuel Optional Propane - Two 33 lb cylinders
High Idle Hertz NA
Alternator 70 amp
Battery Caterpillar
Size Group 24, 12 volts
Cold cranking amps 580 CCA
Battery Cummins
Battery Deutz

Battery GM
3-23
Theory of Operation BC1000XL Brush Chipper Service
THEORY OF OPERATION
Electrical Power Source
Refer to the Addendum document for this machine to view complete
electrical schematic and wire harness diagrams.
Battery BT1 Normal Operation
Machine electrical power is supplied by %7

battery BT1, located inside the engine
enclosure.
Each engine version uses a different

battery as follows:
• The Caterpillar and GM engine

options use a 12-volt DC (negative
ground) BCI Group Size 24 battery
that provides 580 CCA (30 sec) 0°F (-18°C) cold cranking amps.
• The Cummins engine option uses a 12-volt DC (negative ground) BCI
Group Size 31 battery that provides
660 CCA (30 sec) 0°F (-18°C) cold cranking amps.
• The Deutz engine options uses a 12-volt DC (negative ground) BCI
Group Size 31 battery that provides
950 CCA (30 sec) 0°F (-18°C) cold cranking amps.
3-24
BC1000XL Brush Chipper Service Theory of Operation
Alternator G1 Normal Operation
Each engine version uses a different

alternator as follows: 'HXW]KS6KRZQ
• The CAT 49 hp option uses a 60- *

amp alternator.
• The Cummins 74 hp option uses a
65-amp alternator.
• The Deutz 49 hp and 74 hp option
use a 95-amp alternator.
• The GM 89 hp option uses a 70-amp
alternator.
Alternator G1 does not function until
engine has been started. Once engine is
started:
• +12 vDC is supplied from battery to

alternator at for field excitation.
• AC power from alternator is rectified and delivered to battery.
• Alternator G1 provides a trickle charge to replenish battery.
Electrical Power Distribution

SmartFeed Refer to "SmartFeed Controller A1," page 4-11 for normal operation of
Controller A1 controller A1.
3-25
Circuit Breakers Normal Operation:

CB1 and CB2
• Electrical circuits are protected by
main circuit breaker CB1. &%
• Circuit breaker CB1 allows a &%
maximum of 30 amps of current to
be distributed to ignition switch S1.
• Caterpillar 49hp option uses circuit
breaker CB2 to protect glow plug
&DWHUSLOODU
circuits. KS6KRZQ
• Circuit breaker CB2 allows a
maximum of 50 amps of current to
be distributed to the glow plug resistor rail R1 on 49 hp Caterpillar
engines.
• If current draw is more than the rated amps, the breaker will heat
causing it to trip. If the breaker trips and does not automatically reset in
a few seconds, it has probably failed and needs replaced.
Fuses F1 and F2 Normal Operation:

Caterpillar
Caterpillar engine option:
15A • The Caterpillar 49 hp engine option

&DWHUSLOODU
Cummins, Deutz, and GM has one main fuse F1. KS6KRZQ
• F1 allows a maximum of 15 amps of
current to be distributed to
controller A1 and components )
20A
providing input to A1.
10A
3-26
Cummins, Deutz, and GM engine

options:
'HXW]KS6KRZQ
• The Cummins and GM engine
options use 10 amp fuse F1 to )
protect the engine and control )
panel.
• F1 allows a maximum of 10 amps
of current to be distributed to
engine and control panel
components.
• The Deutz engine option use 20
amp fuse F1 to protect the engine
and control panel.
• F1 allows a maximum of 20 amps of current to be distributed to engine
and control panel components.
• 10 amp fuse F2, protects the feed roller electrical circuits.

• F2 allows a maximum of 10 amps of current to be distributed to
controller A1 and feed roller electrical components.
If a fuse blows, it would indicate a possible short in one of the electrical

circuits. Investigate to determine cause and always replace it with one of
same size and rating.
3-27
Ignition Switch Electrical power is distributed to the 'HXW]KS6KRZQ

Circuits various machine circuits by ignition
switch S1.
S1 delivers power to machine electrical

circuits based on switch position below:
• OFF
• RUN/PREHEAT
• START including:
• Charging Circuit 6
The following schematics use colored

lines to illustrate what circuits have power with the ignition switch S1 in the
OFF, RUN, and START positions. LEDs on controller A10 will also
illuminate to show power input to controller circuits.
Circuits start with the Caterpillar 49 hp engine option followed by the

Cummins 74 hp, Deutz 49 hp/74 hp, and GM 89 hp engine options.
Normal Operation - OFF Position Caterpillar
BT1
CB1 K2
CB2
R1
S1
M1/L1
G1
V4
F1 R14 V3
S23
3-28
Normal Operation - RUN/PREHEAT Position Caterpillar

15-3A 300A-BK-6 15-3
BT1 CHASSIS ENGINE BLOCK

12V BATTERY
100-RD-2 10 + 19 300-BK-2 15-1 15-2
K2 R1
CB1 CB2 GLOW PLUG RELAY GLOW PLUG (39A)
ENGINE BLOCK
CONTROLS BREAKER GLOW PLUG BREAKER 13-87

20-1 13-30
104-YL-10
20-2 103-YL-10
AUX BAT 100-RD-10 100-RD-8 8-1 BAT AUX 8-2 7-1
30A 50A
13-86 13-85 365-BK
101-RD-10
112-OR-12
100-RD-2
S1
KEYSWITCH
21-B 21-IGN 738-OR
M1/L1
112-OR-12 B I
STARTER
23-2 (B+)
G1
21-S 24-B+ ALTERNATOR
208-WH-12 290-YL
365-BK-12
S 11-E 11-F
23-1 (S) 24-D+
21-ACC STARTER DIODE
V4
201-YL-12
ACC
11-A 11-B 11-C 11-D
112-OR
290-YL
365-BK
26-A ALT EXCITE ALT DIODE
126-H F1 R14 V3
BREAKAWAY SWITCH MAIN FUSE
15A B1
S23 26-B
36-G FUEL LEVEL
36-B+ 36-S 37-S 37-G
260-YL 439-PU 365-BK
208-WH FUEL GAUGE

201-YL-14
33 OHM (FULL) - 250 OHM (EMPTY)

E2
SMARTFEED
1-1 1-12
260-YL-14 365-BK
POWER A1 GROUND

208-WH 2-1
CRANK KEY
1-3
(GREEN=CRANKING) GLOW PLUG 738-OR
B4 (GREEN=HEAT)
ENG TMP SW 51-1 51-2
45-1 45-2
260-YL 406-LB 2-5
(GREEN=TEMP OK) FUEL PUMP MOTOR M2
CLOSES @ 212 F
1-5 212-PK 47-1 47-2
OPENS @ 234 F (GREEN=RUN)
72-1 (GREEN=HOUR METER)
260-YL 65-1 65-2

765-DG 3-2
(GREEN=ACTIVE)
L2 FUEL SOL.
A B
28-S
LEFT HLD-T-RUN S7 28-G
365-BK
HOUR METER
260-YL 66-1 765-DG
66-2
E3
A B
R5
RIGHT HLD-T-RUN S6 1-7 985-YL-CAN
CAN TERMINATION
40-A
260-YL 63-1 CAN HI
63-3 3-7
763-LB 1-8
40-C 120 OHM
(GREEN=OK) 986-LG-CAN
63-2 R. SENS SW
CAN LO
260-YL 62-1
S13762-PK 40-B
62-3 3-8
(GREEN=OK) 365-BK
62-2 N. SENS SW
260-YL 64-1
64-3
S12
764-LG 3-9
(GREEN=OK)
64-2 E-STOP SW
260-YL 60-1 60-3
S11760-TN 3-10 (GREEN=UPPER
72-2
FWD FD SW (CAM) CONTROL BAR FWD)

60-2 S10
260-YL 61-1 61-3 761-WH 3-12 (GREEN=UPPER
CONTROL BAR REV)
REV FD SW (CAM)
61-2
S8
260-YL 59-A
59-B 732-LG 3-1 (GREEN=NORMAL)
59-C (RED=REDUCED) 3-3 68-1 68-2
SENS SW 766A-GY 365-BK
365-BK (GREEN=FWD FR)
S4 7.1 OHM
L3 FWD FD OUT
365-BK 46-2 46-1 441-GY 1-2
(RED=PRESSURE OK) 3-4 70-1 70-2
767A-DB 365-BK
5 PSI FALLING (GREEN=REV FR)
7.1 OHM
ENG. OIL PRES.
B2 L4 REV FD OUT
B3 33-A
401-WH 1-10 (GREEN=RED SENS) 3-6
426-PU 74-I 74-O 365-BK
(FLASH GREEN=STOP)
365-BK (OFF=NORM SENS)
ENG SPD
6300 HZ @ 3000 RPM
E6 INFO LIGHT
33-B
365-BK
The appropriate LEDs on face of controller A1 will be illuminated. Glow

plugs will heat up as well. See "Glow Plug Function - 49 HP," page 3-75.
3-29
Normal Operation - START Position Caterpillar

15-3A 300A-BK-6 15-3
BT1
12V BATTERY CHASSIS ENGINE BLOCK
100-RD-2 10 + 19 300-BK-2 15-1 15-2
K2 R1 ENGINE BLOCK
CB1 CB2 GLOW PLUG RELAY GLOW PLUG
20-1 13-30
104-YL-10
20-2 103-YL-10
30A 50A
13-86 13-85 365-BK
101-RD-10
112-OR-12
100-RD-2
S1
KEYSWITCH
21-B 21-IGN 738-OR
112-OR-12
M1/L1 23-2 (B+)
B I
STARTER G1
208-WH-12 290-YL
365-BK-12
S 11-E 11-F
23-1 (S) 24-D+
V4
201-YL-12
ACC
11-A 11-B 11-C 11-D
112-OR
290-YL
365-BK
26-A ALT EXCITE ALT DIODE
126-H F1 R14 V3
BREAKAWAY SWITCH MAIN FUSE
S23 15A B1
36-G FUEL LEVEL
26-B
36-B+ 36-S 37-S 37-G
260-YL 439-PU 365-BK
208-WH FUEL GAUGE

201-YL-14
E2 33 OHM (FULL) - 250 OHM (EMPTY)
SMARTFEED
1-1 1-12
260-YL-14 365-BK
A1 GROUND
POWER
208-WH 2-1
CRANK KEY
1-3
(GREEN=HEAT)
B4 51-1 51-2
ENG TMP SW
45-1 45-2
260-YL 406-LB 2-5
(GREEN=TEMP OK) FUEL PUMP MOTOR) M2
CLOSES @ 212 F
1-5 212-PK 47-1 47-2
260-YL 65-1 65-2

765-DG 3-2 FUEL SOL.
(GREEN=ACTIVE)
A B
28-S L2
LEFT HLD-T-RUN
S7 28-G
365-BK
HOUR METER
260-YL 66-1 765-DG
A B
66-2
E3
R5
RIGHT HLD-T-RUN
S6 1-7 985-YL-CAN
CAN TERMINATION
40-A
260-YL 63-1 CAN HI
63-3 3-7
763-LB 1-8
40-C 120 OHM
63-2 R. SENS SW
CAN LO
260-YL 62-1
62-3 S13762-PK 3-8
40-B
(GREEN=OK) 365-BK
62-2 N. SENS SW
260-YL 64-1
64-3 S12764-LG 3-9
(GREEN=OK)
64-2 E-STOP SW
260-YL 60-1 60-3 S11760-TN 3-10 (GREEN=UPPER
72-2
FWD FD SW (CAM) CONTROL BAR FWD)
260-YL 61-1
60-2
S10 3-12
61-3 761-WH (GREEN=UPPER
CONTROL BAR REV)
REV FD SW (CAM)
61-2
S8
260-YL 59-A
59-C (RED=REDUCED) 3-3 68-1 68-2
SENS SW 766A-GY 365-BK
S4 7.1 OHM
365-BK 46-2 46-1 441-GY 1-2

L3 FWD FD OUT

767A-DB 365-BK
7.1 OHM
ENG. OIL PRES.
L4 REV FD OUT
B2
33-A
426-PU 74-I 74-O 365-BK
(FLASH GREEN=STOP)
365-BK ENG SPD (OFF=NORM SENS)
33-B
6300 HZ @ 3000 RPM E6 INFO LIGHT (AMBER)
B3
365-BK
The appropriate LEDs on face of controller A1 will be illuminated.
3-30
Normal Operation - Charging Circuit Caterpillar
BT1
K2
CB1 CB2
R1
S1
M1/L1
G1
V4
F1
R14 V3
S23

Alternator

engine has been started.
Once engine is started:
• +12 vDC is supplied from battery

BT1 through ignition switch S1
resistor R14, and diode V3 (see
below) to alternator G1 for field
excitation.
• AC power from alternator is
rectified and delivered to battery.
• Alternator G1 also provides a
trickle charge to replenish *
batteries.
3-31
Resistor R14 and Diodes V3 and V4
• R14, V3, and V4 are integrated into
A B
the front wire harness assembly.
The 200-ohm resistor R14 controls
the amount of current going to the
alternator G1 from ignition switch
S1.
V3
• Diode V3 is used to direct the
A B C D E F
electrical current to G1. Diode V4 is V4
used in the START circuit to direct
the electrical current to starter R14
solenoid L1. Diodes V3 and V4 work
as one-way valves that will only allow current to pass in one direction.
Normal Operation - OFF Position Cummins

BT1 12V BATTERY + MAINFRAME
15-3A
100-RD-1 10 J19 300-BK-1/0 300A-BK-6
15-3
CB1 K1 R1 ENGINE BLOCK

GRID HEAT RELAY GLOW PLUGS
CONTROLS BREAKER
13-87
20-1
103-RD-4 15-1 15-2
20-2 13-30
AUX BAT 100-RD-10 7-1
30A
13-86 13-85 365A-BK
101-RD-10
12-2
112-OR-12
S1 DIODE GRID HEATER RELAY

KEYSWITCH
21-IGN 738-OR 12-1
21-B
112-OR-12 B I 23-2 (B+)
21-S 24-B 24-L

23-1 (S)
365A-BK-12
208-WH
S
STARTER 24-IG
ALTERNATOR
ACC M1/L1 G1
112-OR
126-H S23 201-YL

BREAKAWAY SWITCH
3-32
Normal Operation - RUN/PREHEAT Position Cummins

(Standard Gauges Shown) BT1
12V BATTERY MAINFRAME
+
15-3A
100-RD-1 10 J19 300-BK-1/0 300A-BK-6
15-3

GRID HEAT RELAY
CONTROLS BREAKER GLOW PLUGS
13-87
20-1
103-RD-4 15-1 15-2
20-2 13-30
AUX BAT 100-RD-10 7-1
30A
13-86 13-85 365A-BK
101-RD-10
12-2
112-OR-12
S1 DIODE GRID HEATER RELAY (4.0A)

KEYSWITCH
21-IGN 738-OR 12-1
21-B
112-OR-12 B 23-2 (B+)
21-S 23-1 (S)

M 24-B 24-L
365A-BK-12
208-WH G
S
24-IG
STARTER
M1/L1
ALTERNATOR
G1 E2 B1
ACC FUEL LEVEL
112-OR
FUEL GAUGE
36-B+ 36-S 37-B (S) 37-C (G)
439-PU 365A-BK
gal
126-H S23 201-YL 36-G
BREAKAWAY SWITCH
208-WH 260A-YL
365A-BK 365A-BK
REAR HARNESS
F2 DASH AND ENGINE F1
26-2AA 26-2A 26-1A 26-1AA
10A 201-YL-12 10A A1 SMARTFEED

1-2 46-1
441-GY 46-2 365A-BK
260C-YL
260A-YL OIL PRESSURE SW

260C-YL 1-1
POWER (+12V) ENG. OIL PRESSURE (10 PSI FALLING)
365A-BK 31-A
1-3
B2
31-B S2 731-BR 1-9
DROOP SW (3-WAY) GRID HEATER
738-OR
260A-YL 31-C
DROOP SWITCH
1-5 212-PK 47
33-A FUEL SOLENOID
401-WH 1-10
ENGINE SPEED SENSOR
32 FUEL SHUTOFF SOLENOID

365A-BK
TACHOMETER
28-S L2
33-B
ENG. SPEED SENSOR
B3 E3 28-G 365A-BK
HOUR METER hr
208-WH 2-1
KEY CRANK POS E25
WAIT TO START LIGHT
1-6
420-PU 34-1 34-2 365A-BK
WAIT-TO-START
72-1
R5
CAN TERMINATION
59-A
1-7 985-YL-CAN 40-A
260C-YL CAN HIGH
59-B 732-LG 3-1
SENSITIVITY SW 40-C 120 OHM
59-C 1-8
365C-BK 986-LG-CAN
SENSITIVITY SELECTION CAN LOW
40-B
S4 SHIELD
365A-BK
65-1 65-2 1-12
260C-YL 765-DG 3-2
HOLD-TO-RUN 365A-BK
A B GROUND
S6 LEFT RESET/HOLD-TO-RUN 72-2
1-4 PWM 4A/DIN H/L

2-5
406-LB
260C-YL 66-1 66-2 765-DG WATER TEMP SENSOR
B 2-2 PIN/AIN/DIN
A
2-3 DIN H/L ENG. WATER TEMP. SENSOR B6

S7 RIGHT RESET/HOLD-TO-RUN
2-4 AIN/DIN 2-6
205-YL
51-1 t 51-2 406-LB
+5V
3-5 PWM 4A/DIN

3-11 AIN/DIN
260C-YL 63-1 3-3
63-3 3-7 766A-GY 68-1 68-2 365C-BK
763-LB REDUCED SW OK FWD FEED
62-1
63-2 REDUCED SENS. STOP
S13 L3 3.27 A
260C-YL 62-3
FORWARD FEED SOLENOID
762-PK 3-8
NORM SW OK 3-4
767A-DB 70-1 70-2 365C-BK
62-2 NORMAL SENS. STOP REV FEED
260C-YL 64-1 S12 L4 3.27 A
64-3
764-LG 3-9
E-STOP SW OK REVERSE FEED SOLENOID
64-2 3-6
E-STOP 426-PU 74-I 74-O 365C-BK
60-1
S11 AMBER INFO LIGHT
260C-YL 60-3 760-TN 3-10

BAR FWD FEED
AMBER INFO LIGHT
FORWARD FEED (CAM)
60-2 S10 E6
61-1 761-WH 3-12
260C-YL 61-3 BAR REV FEED
REVERSE FEED (CAM)
61-2 S8

plugs will heat up as well. See "Grid Heater/Glow Plug Function - Cummins,"
page 3-76.
3-33
Normal Operation - START Position Cummins

BT1
(Standard Gauges Shown) 12V BATTERY
+
MAINFRAME
15-3A
100-RD-1 10 J19 300-BK-1/0 300A-BK-6
15-3

GRID HEAT RELAY
CONTROLS BREAKER GLOW PLUGS
13-87
20-1
103-RD-4 15-1 15-2
20-2 13-30
AUX BAT 100-RD-10 7-1
30A
13-86 13-85 365A-BK
101-RD-10
12-2
112-OR-12

KEYSWITCH
21-IGN 738-OR 12-1
21-B
112-OR-12 B 23-2 (B+)
21-S 23-1 (S)

M 24-B 24-L
365A-BK-12
208-WH G
S
24-IG
STARTER
M1/L1
ALTERNATOR
E2 B1
ACC
G1 FUEL LEVEL
112-OR
FUEL GAUGE
36-B+ 36-S 37-B (S) 37-C (G)
439-PU 365A-BK
gal
126-H S23 201-YL 36-G
BREAKAWAY SWITCH
208-WH 260A-YL
365A-BK 365A-BK
REAR HARNESS
F2 DASH AND ENGINE F1
26-2AA 26-2A 26-1A 26-1AA
201-YL-12
10A 10A A1 SMARTFEED
1-2 46-1
441-GY 46-2 365A-BK
260C-YL

260C-YL 1-1
365A-BK 31-A
B2
31-B S2 731-BR 1-9
1-3
738-OR
260A-YL 31-C
DROOP SWITCH
1-5 212-PK 47
33-A FUEL SOLENOID
401-WH 1-10
ENGINE SPEED SENSOR

365A-BK
TACHOMETER
33-B
B3 E3 28-S
28-G
L2
ENG. SPEED SENSOR 365A-BK
HOUR METER hr
208-WH 2-1
KEY CRANK POS E25
WAIT TO START LIGHT
1-6
420-PU 34-1 34-2 365A-BK
WAIT-TO-START
72-1
R5
CAN TERMINATION
59-A
1-7 985-YL-CAN 40-A
260C-YL CAN HIGH
59-B 732-LG 3-1
59-C 1-8
365C-BK 986-LG-CAN
SENSITIVITY SELECTION CAN LOW
40-B
S4 SHIELD
365A-BK
65-1 65-2 1-12
260C-YL 765-DG 3-2
HOLD-TO-RUN 365A-BK
A B GROUND
S6 LEFT RESET/HOLD-TO-RUN
72-2
1-4 PWM 4A/DIN H/L

2-5
406-LB
2-2 PIN/AIN/DIN
A B
2-3 DIN H/L ENG. WATER TEMP. SENSOR B6

2-4 AIN/DIN 2-6 51-1 t 51-2 406-LB
205-YL
+5V
3-5 PWM 4A/DIN

3-11 AIN/DIN
260C-YL 63-1 3-3
63-3 3-7 766A-GY 68-1 68-2 365C-BK
62-1
S13 L3 3.27 A
260C-YL 62-3
FORWARD FEED SOLENOID
762-PK 3-8
NORM SW OK 3-4
767A-DB 70-1 70-2 365C-BK
62-2 NORMAL SENS. STOP
260C-YL 64-1 S12 REV FEED
L4 3.27 A
64-3
764-LG 3-9
E-STOP SW OK REVERSE FEED SOLENOID
64-2 3-6
E-STOP
S11 AMBER INFO LIGHT 426-PU 74-I 74-O 365C-BK
60-1 760-TN 3-10
260C-YL 60-3 BAR FWD FEED
AMBER INFO LIGHT
FORWARD FEED (CAM)
60-2
S10 E6
61-1 761-WH 3-12
61-2
REVERSE FEED (CAM) S8
The appropriate LEDs on face of controller A1 will also be illuminated.
3-34
Normal Operation - Charging Circuit Cummins
BT1
+
15-3A
100-RD-1 10 J19 300-BK-1/0 300A-BK-6
15-3
CB1 K1 R1
GRID HEAT RELAY ENGINE BLOCK
GLOW PLUG
CONTROLS BREAKER
13-87
20-1
103-RD-4 15-1 15-2
20-2 13-30
AUX BAT 100-RD-10 7-1
30A
13-86 13-85 365A-BK
101-RD-10
12-2
112-OR-12

KEYSWITCH
21-IGN 738-OR 12-1
21-B
112-OR-12 B I 23-2 (B+)
21-S 24-B 24-L

23-1 (S)
365A-BK-12
208-WH
S
STARTER 24-IG
ALTERNATOR
ACC
M1/L1 G1
112-OR
126-H S23 201-YL

BREAKAWAY SWITCH
Alternator


BT1 through ignition switch S1 to
alternator G1 for field excitation.
• AC power from alternator is *
trickle charge to replenish
batteries.
3-35
Normal Operation - OFF Position Deutz

CB1 CONTROLS
BREAKER BT1
20-2 20-1 12V BATTERY MAINFRAME
AUX BAT 100-RD-10 +
15-3A
24-L 24-B 100-RD-10 10 J19 300-BK-1/0 300A-BK-6
15-3
112-OR
ECU D2.2 4-2
365-BK
ALTERNATOR ENGINE BLOCK
112-OR 4-1
+ POWER A2 GROUND -
4-4 365-BK
G1
112-OR 4-3
+ POWER
GROUND - 15-1 15-2
100-RD
4-6
112-OR 4-5 365-BK
+ POWER GROUND - 100
-RD
-1
4-28
- START RELAY
K2
GLOW PLUG RELAY
23-2 (B+)
4-73
+ START RELAY
47-85
85
K3 23-1 (S)
112-OR-12
86
30-87
100-RD
87A
365-BK
100-RD
30-30
4-35
104-RD
30
365A-BK-12
87
START SIGNAL 30-86 30-85
STARTER
210-BK
M1/L1
214-WH START RELAY
21-B 21-IGN
112-OR-12 B I
21-S
ACC
112-OR
208-WH
KEYSWITCH
126-H S23 S1
BREAKAWAY SWITCH
3-36
Normal Operation - RUN/PREHEAT Position Deutz

CONTROLS
BREAKER
20-2
AUX BAT
20-1
100-RD-10
12V BATTERY
+
BT1
CB1 24-L
G
24-B 100-RD-10 10 J19 300-BK-1/0
ECU
251-WH 5-45
ALTERNATOR
G1 GLOW PLUG RELAY
A2
100-RD
112-OR-12
100
-RD
-1
GLOW PLUG RELAY K2
R1
GLOW PLUG
47-86 47-85
85
5-35
GLOW PLUG RELAY
86
87A 252-BU
23-2 (B+) 129-1
K3 M GP 450-TN 87
30
30-87
23-1 (S)
S1 KEYSWITCH
100-RD 30-30
104-RD 450-TN
5-23
GLOW PLUG SIGNAL
21-B 21-IGN
30-86 30-85
STARTER
GLOW PLUG R6 129-2 100-RD
MAINFRAME
112-OR-12 B I
M1/L1 GP 450-TN
15-3A
300A-BK-6
21-S START RELAY 15-3
S
ECU
201A-YL
ENGINE BLOCK
201B-YL
4-2
365-BK
GROUND -
112-OR 4-1
ACC + POWER
A2
112-OR
15-1 15-2
4-4 365-BK
112-OR 4-3
+ POWER
GROUND -
4-6
126-H 365-BK
112-OR 4-5
+ POWER GROUND -
BREAKAWAY SWITCH
4-90
437-PU
S23 FUEL PUMP RELAY
+ FUEL PUMP RELAY
M2 47-86
86
47-85
85
438-DG 4-26
- FUEL PUMP RELAY
FUEL PUMP 87A
K4
M
365A-BK-12
30
87
260-YL
4-73
214-WH + START RELAY
4-28
210-BK
- START RELAY
4-35
208-WH START SIGNAL

365-BK
261-YL
365-BK
26-AA
REAR HARNESS
26-A
DASH AND ENGINE
27-A 27-AA
E2 B1
FUEL GAUGE FUEL LEVEL
F2 10A 10A F1 SMARTFEED 36-B+ 36-S 439-PU
37-B (S) 37-C (G)
365-BK
260-YL
gal
260-YL
261-YL
1-1 A1 36-G
POWER (+12V)
365-BK 31-A 365-BK

31-B 731-BR 1-9
261-YL 31-C DROOP SW (3-WAY)
DROOP SWITCH
S2 E35
CANBUS DISPLAY
38-1
POWER
261-YL 38-2
365-BK
S3 38-4
CAN HI
GROUND
HIGH RPM SWITCH 38-5
261-YL 25-1 25-3 733-WH 1-3 CAN LO

(GREEN=THROTTLE UP)
25-2
S5 ECO-IDLE SWITCH
261-YL 34-A
734-GY 1-4
365-BK 34-C
OFF
34-B (GREEN=ECO SETTING 1)
(RED=ECO SETTING 2)
(NONE=ECO-IDLE DISABLED)
1-7 985-YL-CAN
CAN TERMINATION
41-A
R5
CAN HIGH
1-8 120 OHM
986-LG-CAN
CAN LOW
41-B
72-1
59-A
S4
SENSITIVITY SELECTION
260-YL
59-B 1-12
732-LG 3-1
SENSITIVITY SW
365-BK
59-C GROUND
365-BK
72-2
65-1 65-2
260-YL 765-DG 3-2
HOLD-TO-RUN
A B
260-YL 66-1 66-2 765-DG

A B
260-YL 63-1 3-3

63-3 3-7 766A-GY 68-1 68-2 365-BK
63-2 REDUCED SENS. STOP 3.27 A
260-YL 62-1
62-3
762-PK S13 3-8
L3 FORWARD FEED SOLENOID
NORM SW OK 3-4 70-1 70-2
NORMAL SENS. STOP 767A-DB 365-BK
62-2 REV FEED
260-YL 64-1
64-3
764-LG
S12 3-9
E-STOP SW OK L4 REVERSE FEED SOLENOID
3.27 A
64-2 3-6
E-STOP
60-1
S11 760-TN 3-10
260-YL 60-3 BAR FWD FEED
FORWARD FEED (CAM)
260-YL 61-1
60-2
61-3 761-WH
S10 3-12
BAR REV FEED
REVERSE FEED (CAM)
61-2
S8

plugs will heat up as well. See "Glow Plug Function - Deutz," page 3-79.
3-37
Normal Operation - START Position Deutz

CONTROLS
BREAKER
20-2 20-1 12V BATTERY
AUX BAT 100-RD-10 + BT1
300-BK-1/0
CB1 24-L
G
24-B 100-RD-10 10 J19
ECU
251-WH 5-45
ALTERNATOR GLOW PLUG RELAY
A2
100-RD
G1
112-OR-12
100
-RD
-1
K2 GLOW PLUG RELAY
R1 47-86 47-85
85
5-35
GLOW PLUG RELAY
GLOW PLUG 86
87A 252-BU
23-2 (B+) 129-1
K3 M GP 450-TN
30
S1 100-RD 30-30
30-87
23-1 (S)
87
5-23
KEYSWITCH 104-RD
GLOW PLUG SIGNAL
21-B 21-IGN
30-86 30-85
STARTER
GLOW PLUG R6 129-2
450-TN
100-RD
MAINFRAME
112-OR-12 B I
GP 15-3A
21-S START RELAY

M1/L1 450-TN 300A-BK-6
15-3
S
ECU
201A-YL
ENGINE BLOCK
201B-YL
4-2
365-BK
GROUND -
112-OR 4-1
+ POWER
ACC
A2
112-OR
15-1 15-2
4-4 365-BK
112-OR 4-3
+ POWER
GROUND -
4-6
126-H 365-BK
112-OR 4-5
+ POWER GROUND -
BREAKAWAY SWITCH
S23 437-PU
FUEL PUMP RELAY
4-90
+ FUEL PUMP RELAY
M2 47-86
86
47-85
85
438-DG 4-26
- FUEL PUMP RELAY
FUEL PUMP 87A
M
K4
365A-BK-12
30
87
260-YL
4-73
4-28
210-BK
- START RELAY
4-35
208-WH START SIGNAL
365-BK
261-YL
365-BK
26-AA
REAR HARNESS
26-A 27-A
DASH AND ENGINE
27-AA E2 B1
FUEL LEVEL
FUEL GAUGE
10A 10A
F2 F1 SMARTFEED 36-B+ 36-S 439-PU
37-B (S) 37-C (G)
365-BK
260-YL
gal
261-YL
260-YL 1-1
POWER (+12V)
A1 36-G
365-BK 31-A 365-BK

31-B 731-BR 1-9
DROOP SWITCH
S2 E35
CANBUS DISPLAY
38-1
POWER
261-YL 38-2
365-BK
GROUND
S3 38-4
CAN HI
HIGH RPM SWITCH 38-5
261-YL 25-1 25-3 733-WH 1-3 CAN LO

(GREEN=THROTTLE UP)
25-2
261-YL
S5 34-A
ECO-IDLE SWITCH
734-GY 1-4
365-BK 34-C
OFF
(RED=ECO SETTING 2)
CAN HIGH
1-7 985-YL-CAN
CAN TERMINATION
41-A
R5
1-8 120 OHM
986-LG-CAN
CAN LOW
41-B
S4
72-1 SENSITIVITY SELECTION
260-YL 59-A
59-B 1-12
732-LG 3-1
SENSITIVITY SW
365-BK
59-C GROUND
365-BK
72-2
65-1 65-2
260-YL 765-DG 3-2
HOLD-TO-RUN
A B
260-YL 66-1 66-2 765-DG

A B
260-YL 63-1 3-3

63-3 3-7 766A-GY 68-1 68-2 365-BK
63-2 REDUCED SENS. STOP 3.27 A
260-YL 62-1
62-3 S13 L3 FORWARD FEED SOLENOID
762-PK 3-8
NORM SW OK 3-4
767A-DB 70-1 70-2
62-2 NORMAL SENS. STOP REV FEED 365-BK
260-YL 64-1
64-3
764-LG
S12 3-9
E-STOP SW OK L4 REVERSE FEED SOLENOID
3.27 A
64-2 3-6
60-1
S11 E-STOP
760-TN 3-10
260-YL 60-3 BAR FWD FEED
FORWARD FEED (CAM)
61-1
60-2
761-WH
S10 3-12
260-YL 61-3 BAR REV FEED
REVERSE FEED (CAM)
61-2
S8
3-38
Normal Operation - Charging

Circuit Deutz


alternator G1 for field excitation.
• AC power from alternator is *
batteries.

Normal Operation - OFF Position GM
BT1
+
15-3A
100-RD-1 10 J19 300-BK-1/0 300A-BK-6
15-3
CB1 ENGINE BLOCK

CONTROLS
BREAKER
20-2 20-1 15-1 15-2
AUX BAT 100-RD-10
30A
101-RD-10
112-OR-12
S1 D
365-BK
KEYSWITCH
21-B 21-IGN
112-OR-12 B I 23-2 (B+)
21-S 23-1 (S)

M 24-B 24-L
365A-BK-12
208-WH G
S
201B-YL-12
24-IG
201A-YL-12
STARTER
ALTERNATOR
ACC B
M1/L1 G1
112-OR
126-H
S23
BREAKAWAY SWITCH
3-39
Normal Operation - RUN Position GM

BT1
BT1: 12V BATTERY, 660 CCA MAINFRAME
+
15-3A
100-RD-1 10 J19 300-BK-1/0 300A-BK-6
15-3
CB1 A2: ECU
CB1: CONTROLS
5-A
POWER
A4 ENGINE BLOCK
260A-YL 5-B CHECK ENGINE
BREAKER 5-G
ALT EXCITE 127-2 127-1 15-1 15-2
20-2 20-1
AUX BAT 100-RD-10 MIL OUT
TACH OUT
421-PU
30A
101-RD-10
PROPANE OPTION E36
112-OR-12
S14: PROPANE SWITCH

S1 260A-YL 78-A 78-B
757-BU 5-H
365A-BK-12
PROPANE SWITCH
M2: FUEL PUMP
21-B
S1: KEYSWITCH
21-IGN S14 L2
5-D 47-1 47-2
FUEL PUMP +
112-OR-12 B I 23-2 (B+) 437-PU
G1 5-F 3.27 A
21-S 23-1 (S)

M 24-B 24-L
KEY START POS
FUEL PUMP -
5-C
208-WH G 438-BK
S D
365-BK
24-IG
M1, L1: STARTER
M1/L1
G1: ALTERNATOR E2 B1
ACC B1: FUEL LEVEL
112-OR
E2: FUEL GAUGE

208-WH 36-B+ 37-B (S) 37-C (G)
36-S 439-PU 365-BK
gal
S23
201A-YL-12
201B-YL-12
126-H 260A-YL
36-G
S23: BREAKAWAY SWITCH (SEE 163672393)
260A-YL
365A-BK 365-BK
F2: REAR HARNESS F1: DASH AND ENGINE

28-AA 28-A 29-A 29-AA
1-2
A1: SMARTFEED
10A 10A
F2 F1 CB02 (C130)
260C-YL
260A-YL A1 1-3
260C-YL 1-1
POWER (+12V)
365-BK 31-C S2
31-B 731-BR 1-9
260A-YL 31-A DROOP SW (3-WAY)
S2: DROOP SWITCH
1-6
S5: ECO-IDLE SWITCH
260C-YL 34-A 1-4
260C-YL
34-B 734-GY (GREEN=ECO SETTING 1)
365-BK 34-C
OFF (RED=ECO SETTING 2)
A3: CANBUS DISPLAY
S5 38-1
E35
POWER
38-2
GROUND
S3: HIGH RPM SWITCH 365-BK
72-5 985-YL-CAN 38-4
72-2 260C-YL 25-1 25-3 733-WH 1-2 CAN HI
(GREEN=THROTTLE UP)
38-5
72-1 S3 25-2 CAN LO
59-A S4: SENSITIVITY SELECTION

260C-YL
59-B 732-LG 3-1
59-C SENSITIVITY SW
365-BK
S4
S6
65-1 65-2
260C-YL 765-DG 3-2
HOLD-TO-RUN
A B R5
R5: CAN TERMINATION
S6: LEFT RESET/HOLD-TO-RUN 1-7 985-YL-CAN 40-A
CAN HIGH
S7 1-8
986-LG-CAN
40-C 120 OHM
66-1 765-DG CAN LOW

260C-YL 66-2 40-B
A B
1-12
S7: RIGHT RESET/HOLD-TO-RUN 365-BK
GROUND
72-2
2-5
260C-YL 63-1
63-3 3-7
763-LB REDUCED SW OK 2-6
62-1
S13 63-2 S13: REDUCED SENS. STOP
+5V
260C-YL 62-3 L3
762-PK 3-8
NORM SW OK
S12
64-1
62-2 S12: NORMAL SENS. STOP
FWD FEED
3-3
766A-GY 68-1 68-2 365-BK
260C-YL 3.27 A
64-3
764-LG 3-9
E-STOP SW OK
64-2 L3:FORWARD FEED SOLENOID
S11: E-STOP
60-1
S11 3-4
767A-DB 70-1 70-2
365-BK
260C-YL 60-3 760-TN 3-10
BAR FWD FEED REV FEED
S10: FORWARD FEED (CAM) 3.27 A
60-2
260C-YL 61-1
S10 61-3 761-WH 3-12 3-6
L4: REVERSE FEED SOLENOID
S8: REVERSE FEED (CAM)

BAR REV FEED
L4
S8 61-2
The appropriate LEDs on face of controller A1 will be illuminated.
3-40
Normal Operation - START Position GM

BT1
+
15-3A
100-RD-1 10 J19 300-BK-1/0 300A-BK-6
15-3
CB1 A2: ECU

E36
CB1: CONTROLS 260A-YL
5-A
POWER A4 ENGINE BLOCK
BREAKER 5-B CHECK ENGINE

ALT EXCITE 5-G 127-2 127-1
20-2 20-1 15-1 15-2
AUX BAT 100-RD-10 MIL OUT
TACH OUT
421-PU
30A
PROPANE OPTION
101-RD-10
112-OR-12
S14: PROPANE SWITCH
S1 260A-YL 78-A 78-B

757-BU 5-H
L2
365A-BK-12
PROPANE SWITCH
S1: KEYSWITCH M2: FUEL PUMP
21-B 21-IGN S14 5-D 47-1 47-2
FUEL PUMP +
112-OR-12 I 23-2 (B+) 437-PU
B
G1 5-F 3.27 A
21-S 23-1 (S)

M 24-B 24-L
KEY START POS
FUEL PUMP -
5-C
208-WH G 438-BK
S D
365-BK
24-IG
M1, L1: STARTER
G1: ALTERNATOR E2 B1
ACC M1/L1 B1: FUEL LEVEL
112-OR
E2: FUEL GAUGE

208-WH 36-B+ 37-B (S) 37-C (G)
36-S 439-PU 365-BK
gal
S23
201A-YL-12
201B-YL-12
126-H 260A-YL
36-G
260A-YL
365A-BK 365-BK

28-AA 28-A 29-A 29-AA
1-2
A1: SMARTFEED
10A 10A
F2 F1 CB02 (C130)
260C-YL
260A-YL
A1 1-3

260C-YL 1-1
POWER (+12V)
365-BK 31-C S2
31-B 731-BR 1-9
S2: DROOP SWITCH
1-6
S5: ECO-IDLE SWITCH
260C-YL 34-A 1-4
260C-YL
365-BK 34-C
A3: CANBUS DISPLAY
S5 38-1
E35
POWER
38-2
GROUND
S3: HIGH RPM SWITCH 365-BK
72-5 985-YL-CAN 38-4
72-2 260C-YL 25-1 25-3 733-WH 1-2 CAN HI
(GREEN=THROTTLE UP)
38-5
72-1 S3 25-2 CAN LO

260C-YL
59-B 732-LG 3-1
59-C SENSITIVITY SW
365-BK
S4
S6
65-1 65-2
260C-YL 765-DG 3-2
A B
HOLD-TO-RUN R5
R5: CAN TERMINATION
S6: LEFT RESET/HOLD-TO-RUN 1-7 985-YL-CAN 40-A
CAN HIGH
S7 1-8
986-LG-CAN
40-C 120 OHM
66-1 765-DG CAN LOW

260C-YL 66-2 40-B
A B
1-12
S7: RIGHT RESET/HOLD-TO-RUN 365-BK
GROUND
72-2
2-5
260C-YL 63-1
63-3 3-7
763-LB REDUCED SW OK 2-6
S13 63-2 S13: REDUCED SENS. STOP
+5V
260C-YL 62-1
62-3
L3
762-PK 3-8
NORM SW OK
S12 62-2 S12: NORMAL SENS. STOP
FWD FEED
3-3
766A-GY 68-1 68-2 365-BK
260C-YL 64-1
64-3 3.27 A
764-LG 3-9
E-STOP SW OK
L3:FORWARD FEED SOLENOID
S11 64-2 S11: E-STOP
3-4 70-1 70-2
60-1 760-TN 3-10 767A-DB 365-BK
260C-YL 60-3 BAR FWD FEED REV FEED
S10: FORWARD FEED (CAM) 3.27 A
S10 60-2
3-6
L4: REVERSE FEED SOLENOID
3-12
260C-YL 61-1 61-3 761-WH BAR REV FEED L4
S8 61-2
3-41
Normal Operation - Charging

Circuit GM


alternator G1 for field excitation. *
• AC power from alternator is
batteries.
3-42
Gauges - Caterpillar
15-2
365-BK-12
E2 B1
FUEL GAUGE
FUEL LEVEL
36-B+ 36-S 37-S 37-G
260-YL 439-PU 365-BK

36-G
SMARTFEED
260-YL-14 1-1
POWER A1 365-BK
M2
51-1 51-2
FUEL PUMP MOTOR
1-5 212-PK 47-1 47-2

(GREEN=RUN)
(GREEN=HOUR METER)
FUEL SOL. L2
28-S
28-G
365-BK
E3
HOUR METER

Hourmeter E3 Normal Operation:
• Hourmeter E3 indicates total

machine operating hours.
• E3 receives power from controller (
A1 at pin 1-5. The hourmeter will
have power after engine start and
begin to accumulate time.
• The fuel enable circuit is also
powered from pin 1-5. See "Fuel
Enable and Delivery," page 3-58.
3-43
Fuel Gauge E2 Normal Operation:
• Fuel gauge E2 indicates the level of

fuel in fuel tank RES2 during
machine operation.
(
• Fuel gauge E2 receives power from
fuse F1 once the ignition switch is
in the RUN or START positions.
Controller A1 also receives power at
the same time on pin 1-1.
• Fuel level sensor B1 mounted in
fuel tank, provides the signal to fuel
gauge E1. Resistance to current
varies according to fuel level,
changing amount of current flowing
through fuel gauge.
Resistance values from full to empty
should measure:
%
• Tank Full - 33 ± 1 ohms
• Tank Empty - 251 ± 6 ohms
Gauges - Cummins (Standard)

Hourmeter E3 and See "Hourmeter E3," page 3-43 for
Fuel Gauge E2 operating information.
( (
See “Fuel Gauge E2,” above for
operating information.
3-44
Gauges - Cummins (Deluxe)

E4 4-IN-1 GAUGE
2 36-S (B) 439-PU
7 1 27-1 442-GY
48
gal psi ENG. OIL
B7
PRESSURE SENSOR
3 36-B+ (B)
6 36-G (B) 365A-BK
ENG. WATER TEMP.

t° V
440-WH
B5 SENSOR
8 27-8
49
BACK LIGHTING LAMP
4 27-4
B1
F1 37-B (S)
FUEL LEVEL
37-C (G)
365A-BK
DASH AND ENGINE
26-1A
260A-YL
26-1AA
201-YL-12 10A
365A-BK
SMARTFEED
A1
1-1
POWER (+12V)
B3 1-5 47
212-PK
ENG. SPEED SENSOR 33-A FUEL SOLENOID
401-WH 1-10
ENGINE SPEED SENSOR

365A-BK
33-B L2
E5
TACHOMETER/HOUR GAUGE
SIG 401-WH
32 FROM MAIN HARNESS
rpm
B+ 212-PK
42-B+ 50-S 28-S (B)
G 365A-BK
42-G 50-G 28-G (B)
hr
Tachometer/ Normal Operation

Hourmeter E5
E5 gets power from pin 1-5 of controller A1 at the same time fuel solenoid L2
is energized.
3-45
Hourmeter:
(

• The hourmeter (1) indicates total
machine operating hours.
• When ignition switch is in the RUN
position, the hourmeter will have

power and begin to accumulate
time.
• The fuel enable circuit is also
powered from pin 1-5. See "Fuel
Enable and Delivery," page 3-62.
Tachometer:
• The tachometer portion of gauge (2) is a voltmeter. The scale on the

gauge face is reading RPM but the instrument itself is reading voltage.
• The tachometer works off a signal from the engine speed sensor B3.
Sensor B3 sends a signal measured in hertz.
• B3 is installed into the flywheel housing
and aligns with the starter ring gear on

the flywheel. It generates a small AC
voltage spike whenever a flywheel tooth
passes it.
• The faster the engine/flywheel spins the
more electrical pulses are sent to the
tachometer to move the dial around the %
face of the gauge.
• Controller A1 also receives a signal on
pin 1-10 and uses the input to control
feed roller function. See Chapter 4 for
feed roller information.
4-in-1 Gauge E4 Normal Operation
E4 indicates multiple parameters including:
• Fuel Gauge
• Engine Oil Pressure Gauge
• Voltmeter
• Engine Coolant Temperature Gauge
The 4-in-1 gauge E4 gets power from fuse F1.

3-46
Fuel Gauge:
• The fuel gauge (1) operates off of a

signal from fuel level sensor B1. See (
page 3-44 for operating information.

Oil Pressure Gauge:
• Oil pressure gauge (2) operates off a

signal from oil pressure sensor B4.
• Sensor B4 is an electronic
transducer which allows more
electricity to flow in direct
proportion to the pressure applied.
• That electrical signal is translated
to a pressure reading on the gauge.
Voltmeter:

• Voltmeter (3) measures electrical 442-GY
system in volts. Voltmeter (3)
48
directly measures the result of
charging-system performance. ENG. OIL
PRESSURE SENSOR
• With normal alternator/voltage- B7
regulator function, battery voltage
is maintained at 14.0 to 14.5 volts-
and this is reported directly by the
voltmeter. B5
440-WH
• In the event of alternator-system
49
failure, voltage will be low and
continue to drop as the battery ENG. WATER TEMP.
discharges. In the event of an SENSOR
"overcharge" condition, the
voltmeter will climb above its normal zone.
Coolant Temperature Gauge:
• The engine coolant temperature gauge (4) basically works like a

voltmeter. The scale on the gauge face is reading temperature but the
instrument itself is reading voltage.
• The temperature gauge works off a signal from coolant temperature
sensor B5. Sensor B5 is constructed of a temperature-sensitive material
that is part of a variable resistance, water-sealed unit that sits in the
coolant stream in the engine. B5 is the "ground" portion of the circuit.
3-47
• The resistor portion of B5 allows more electricity to flow in direct

proportion to the temperature applied. That electrical signal is
translated to a coolant temperature reading on the gauge.
• When the engine is cold, the resistance is high, so little current passes
through the gauge. As the engine warms and the sending unit's
resistance lowers, more current passes through the gauge and the needle
reads higher.
Gauges - Deutz and GM

MAINFRAME
15-3A
300A-BK-6
15-3
ENGINE BLOCK
15-1 15-2
365A-BK-12
F2 F1 E2 B1
FUEL GAUGE FUEL LEVEL
REAR HARNESS DASH AND ENGINE
260A-YL 36-B+ 36-S 37-B (S) 37-C (G)
28-AA 28-A 29-A 29-AA 439-PU 365-BK
gal
10A 10A
36-G
365-BK
CANBUS DISPLAY
260C-YL
SMARTFEED
E35
A1 38-1
POWER
GROUND
38-2
260C-YL 1-1 985-YL-CAN 38-4 365-BK

POWER (+12V) CAN HI
38-5
CAN LO
R5
CAN TERMINATION
1-7 985-YL-CAN 40-A
CAN HIGH
40-C 120 OHM
1-8
986-LG-CAN
CAN LOW
40-B
Fuel Gauge E2 See "Fuel Gauge E2," page 3-44 for

operating information. (
'HXW]&RQWURO3DQHO6KRZQ
3-48
Engine Information Normal Operation

Display E35
Engine Information Display E35 is
located on the control panel and (
incorporates diagnostic lamps and
LCD display of current machine
operating parameters as well as any
fault codes that may occur.
'HXW]&RQWURO3DQHO6KRZQ
Display Features
1 2
E35 incorporates the following features:

(1) Amber Warning Light - illuminates to
signal presence of an engine fault along
with a diagnostic code displayed on
monitor screen
(2) Red Shutdown Light - illuminates as 7

3
the result of a severe engine fault that
6
may result in engine shutdown
5 4
(3) Enter Key - used to select a menu or
parameter
(4) Scroll DOWN Key - used to scroll down through screens or parameters
(5) Scroll UP Key - used to scroll up through screens or parameters
(6) Escape Screen - used to exit a screen or go back
(7) Display Screen - used to display operating parameters and fault codes
3-49
Navigation and Keypad Functions
When display is powered ON, a start-up screen appears and the default
operator configured parameters will be displayed in a 1-up or 2-up format.
When operator presses enter key, the main

1 2
menu items are displayed including:
• (1) - 1 - UP Display
• (2) - 2 - UP Displays
• (3) - Settings
• (4) - Diagnostics
4 3
1 - UP Display 2 - UP Display Settings Diagnostic

To navigate the four main menu screens:
• Press arrow keys to move selector to other menu items.

• Pressing enter key on highlighted menu item will open that menu page.
• Pressing arrow keys will move selection bar to other menu items on that
page.
When desired item is highlighted by selection bar, pressing enter key will
select that item and display the corresponding screen.
The operator can configure the screen to display a single parameter (1-UP
Display), or two parameters at once (2-UP Display) by selecting the 1-UP or
2-UP display and pressing enter.
3-50
Parameter Options
There are three display parameter options including:
• Configure Signals - This option allows customized programming of which

parameters are displayed.
• Sort Signals - This option allows the operator to arrange the order in
which the selected parameters will be displayed.
• Load Defaults - This option contains a default set of engine parameters:
• Engine Coolant Temperature
• Engine Oil Temperature
• Engine Oil Level
• Engine Oil Pressure
• Engine Speed
• Engine Average Fuel Economy
• Fuel Level

• Charging System Potential
• Actual Engine Torque
Configure Signals
To configure parameter settings:
1. Select “Settings Menu” from the main manu and press Enter, then select
“Configure Signals” and press Enter.
2. Select option for “Select Signals” and press Enter. The list of parameter
options is displayed.
3. Parameters that are currently being broadcast on the CAN Bus are
identified by the value to the left of the signal name.
4. To remove a parameter from the active display, select the parameter and
press Enter.
5. To add a parameter to the active display, select the parameter and press
Enter. Once the custom parameter selection has been completed press
Escape to return to the “Configure Signals” menu.
3-51
Sort Signals
To sort signals:
1. From the “Configure Signals” menu, select the option for “Sort Signals”
and press Enter.
2. Using Arrow Keys scroll through the current order of parameters and
press Enter to select parameter to be moved. Once selected the
parameter will be displayed in bold text.
3. Use Arrow Keys to move selected parameter to the desired spot in
parameter order and press Enter to complete the change.
Load Defaults
To change load defaults:
1. From the “Configure Signals” menu select the option for Load Defaults
and press Enter.
2. Confirm selection by using Arrow Keys and press Enter.
3-52
Optional Tree Commander Remote Control System
Remote Horn B15

Remote
S24 Selector Switch
Amber Beacon
E34
S25

Remote
Selector Switch
Antenna
A6 Remote Transmitter
Remote Receiver A5
The following is an overview of the optional Tree Commander remote control

system components. For detailed information on remote control functions,
refer to the BC1000XL Brush Chipper Operator’s manual.
The optional Tree Commander remote control system consists of:
3-53

• Remote Horn B15
Remote control transmitter A6 sends radio signals to the remote control

receiver A5. Receiver A5 outputs signals via the CAN Bus interface to
SmartFeed controller A1. Input signals from transmitter A6 are processed
by controller A1. Output signals are sent to the appropriate control circuits
enabling or disabling feed roller function.
Remote Transmitter The remote control transmitter comprises

A6 the following features: 2
1
(1) LED Light - Battery indicator

3
(2) LED Light Communication Indicator/
Remote ON 4
3
(3) Engine Stop

5 2
(4) Feed Roller (Forward, Reset and Hold-

To-Run 1
6
(5) Feed Roller (Stop)
7
(6) Feed Roller (Reverse)
A6
(7) Remote ON/OFF
Remote Receiver A5 Remote receiver A5 receives signals from transmitter A6 via the antenna on
top of the remote control box installed on the machine.
Remote Control/ Selector switches S24 and S25 are installed on opposite sides of the rear
Console Selector shield. When either switch is pressed to the ON position, the remote control
Switches S24 and system will be activated as long as the upper feed control bar is in the STOP
S25 position. When switched to the OFF position, the remote control is disabled.
Amber Beacon E34 Once either switch S24 or S25 is enabled, amber beacon E34 will illuminate.
Remote Horn B8 Remote horn B15 is used to warn bystanders that the feed rollers have been
actuated to Forward rotation.
3-54
Engine ENG1 – ENG5

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3-55
Five engine versions are available for the BC1000XL:
• 4-cylinder Caterpillar Tier 4A diesel rated 48.7 hp (36.3 kW) at 2800

rpm.
• The Caterpillar engine full throttle speed is approximately 3000 rpm.
• 4-cylinder turbocharged Cummins Tier 4 Interim/Stage IIIB diesel rated
74 hp (55 kW) at 2600 rpm.
• The Cummins full throttle speed is approximately 2800 rpm.
• 4-cylinder Deutz Tier 4 Final diesel rated 49 hp (37 kW) at 2600 rpm.
• 4-cylinder turbocharged Deutz Tier 4 Final diesel rated 74 hp (55 kW) at

2600 rpm.
• The Deutz engines full throttle speed is approximately 2700 rpm.
• 4-cylinder GM gasoline and/or dual fuel option propane engine rated 89

hp (66 kW) at 2600 rpm.
• The GM engine full throttle speed is approximately 3000 rpm.
This manual explains only those items provided by Vermeer needed to

operate the engine. Troubleshooting and repair of the engine is beyond the
scope of this manual.
For information or service work involving the internal parts or engine

overhaul, refer to the engine manual supplied with the machine, and/or
contact an authorized Caterpillar, Cummins, Deutz, or GM Service Facility.
3-56
Intake Air, Exhaust, Fuel, and Cooling Functions - Caterpillar
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Intake Air/Exhaust Normal Operation
During engine operation, filtered ambient air flow from air cleaner assembly
A3 enters the intake manifold. Exhaust gases from the exhaust manifold are
expelled into the atmosphere.
3-57
Coolant Delivery Normal Operation
Engine coolant is supplied from radiator HE1. As the coolant in the engine’s
water jacket warms up to approximately 180°F (82°C), the thermostat opens
and the engine’s water pump circulates coolant from the radiator through
the water jacket and engine block back to the radiator.
The engine fan pulls air through the fins of the radiator to remove heat from
the coolant. The cap of the radiator will relieve pressure building inside the
radiator at 13 psi (90 kPa) above the ambient air pressure.
Fuel Enable and

Delivery
15-2
365-BK-12
E2 B1
FUEL GAUGE
FUEL LEVEL
36-B+ 36-S 37-S 37-G
260-YL 439-PU 365-BK

36-G
SMARTFEED
260-YL-14 1-1
POWER A1 365-BK
M2
51-1 51-2
FUEL PUMP MOTOR
1-5 212-PK 47-1 47-2

(GREEN=RUN)
(GREEN=HOUR METER)
FUEL SOL.
L2
28-S
28-G
365-BK
E3
HOUR METER
Normal Operation:
• The fuel tank RES2 holds up to 25 gal (95 L) of diesel fuel. Refer to the
engine manual supplied with the machine to select the proper grade and
blend of fuel for local conditions.
• Once the ignition switch is in the RUN or START positions, controller A1
provides power from pin 1-5 to energize fuel solenoid L2 and fuel
transfer pump PMP4 as well as the hourmeter E3.
If the engine has not been started within 10 seconds after ignition switch is
turned to the RUN position, the controller will shut of the fuel output on pin
1-5. The ignition switch must be turned OFF and then back to RUN to reset
the circuit.
3-58
• Fuel transfer pump PMP4 draws fuel from the tank and sends it to fuel
filter FL1, which filters and separates water from the fuel.
• The fuel then passes through the fuel injector pump PMP5. Another hose
carries overflow from the fuel injector rail back to the fuel tank.
• The electric fuel level sensor B1 sends a variable electric signal to the
electric fuel gauge E2, which is mounted in the engine control panel and
indicates the quantity of fuel in the tank. See "Fuel Gauge E2," page 3-44.
3-59
Intake Air, Exhaust, Fuel, and Cooling Functions - Cummins

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Intake Air/Exhaust Normal Operation:
• During engine operation, filtered air flow from air cleaner assembly A3
enters the inlet cold air passage of the turbocharger.
• The exhaust gases from the engine exhaust manifold enter the hot air
passage inlet of the turbocharger.
3-60
• The exhaust gases cause a turbine and compressor wheel inside the
turbo housing to spin. The spinning turbine wheel causes the compressor
wheel to spin. This compresses the cool inlet air, increasing the density of
the air.
• The compressed air is forced through the outlet of the turbocharger into
the engine intake manifold for combustion.
• The compressed air allows more fuel to be delivered to produce more
power.
Coolant Delivery Normal Operation:
• Engine coolant is supplied from the radiator HE3.

• As the coolant in the engine’s water jacket warms up to approximately
180°F (82°C), the thermostat opens and the engine’s water pump
circulates coolant from the radiator through the water jacket and engine
block back to the radiator.
• The engine fan pulls air through the fins of the radiator to remove heat
from the coolant. The cap of the radiator will relieve pressure building

inside the radiator at 10 psi (69 kPa) above the ambient air pressure.
3-61
Fuel Enable and

Delivery
MAINFRAME
15-3A
300A-BK-6
15-3
ENGINE BLOCK
15-1 15-2
F2 F1 E2 B1
DASH AND ENGINE FUEL GAUGE FUEL LEVEL
REAR HARNESS
260A-YL 36-B+ 36-S 37-B (S) 37-C (G)
26-2AA 26-2A 26-1A 26-1AA 439-PU 365A-BK
gal
10A 201-YL-12 10A
36-G
SMARTFEED 365A-BK
A1
1-5 212-PK 47
260C-YL 1-1 FUEL SOLENOID
365A-BK-12
POWER (+12V)
FUEL SHUTOFF SOLENOID L2

28-S
E3 28-G 365A-BK
HOUR METER hr
Normal Operation:
• Once the ignition switch is in the RUN or START positions, controller A1
provides power from pin 1-5 to energize fuel solenoid L2 as well as the
hourmeter E3. See "Hourmeter E3," page 3-43.
If the engine has not been started within 10 seconds after ignition switch is
turned to the RUN position, the controller will shut of the fuel output on pin
1-5. The ignition switch must be turned OFF and then back to RUN to reset
the circuit.
• Fuel lift pump PMP1 draws fuel from the tank through fuel filter FL1,
which filters and separates water from the fuel. The fuel then passes
through the fuel injector pump PMP2. Another hose carries overflow
from the fuel injector rail back to the fuel tank.
3-62
Intake Air, Exhaust, Fuel, and Cooling Functions - Deutz

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• During engine operation, filtered air flow from air cleaner assembly A3
enters the inlet cold air passage of the turbocharger.
• The exhaust gases from the engine exhaust manifold enter the hot air
passage inlet of the turbocharger.
• The exhaust gases cause a turbine and compressor wheel inside the
turbo housing to spin. The spinning turbine wheel causes the compressor
wheel to spin. This compresses the cool inlet air, increasing the density of
the air.
3-63
• The compressed air is forced through the outlet of the turbocharger into
the engine intake manifold for combustion.
• The compressed air allows more fuel to be delivered to produce more
power.

• The engine fan pulls air through the fins of the radiator to remove heat
3-64
Fuel Enable and

Delivery
112-OR-12 ECU 4-2

365-BK
GROUND -
112-OR
S1 4-1
+ POWER A2 MAINFRAME
KEYSWITCH 4-4 365-BK
21-B 21-IGN 112-OR 4-3
+ POWER
GROUND - 15-3A
300A-BK-6
B I 4-6
112-OR 4-5 365-BK 15-3
+ POWER GROUND -
21-S
437-PU 4-90 ENGINE BLOCK
S + FUEL PUMP RELAY
K4 FUEL PUMP RELAY
201A-YL
201B-YL
M2 47-86 47-85
438-DG 4-26
- FUEL PUMP RELAY
15-1 15-2
ACC 86 85
FUEL PUMP 87A
M 87
30
260-YL
+ START RELAY
- START RELAY
4-35
208-WH
365A-BK-12
START SIGNAL
365-BK
REAR HARNESS DASH AND ENGINE
26-AA 26-A 27-A 27-AA 261-YL
10A 10A
E3 B1
F2 F1 FUEL GAUGE FUEL LEVEL
36-B+ 36-S 37-B (S) 37-C (G)
439-PU 365-BK
gal
36-G
365-BK

Normal Operation:
• Once the ignition switch S1 is in the RUN or START position, controller
A2 provides power from pin 4-90 to energize fuel pump relay K4,
providing current to fuel pump motor M2.
• Fuel pump PMP6 draws fuel from the tank through fuel filter FL11,
which filters and separates water from the fuel. The fuel then passes
through fuel filter FL10 to fuel injector. Another hose carries overflow
from the fuel injector rail back to the fuel tank.
3-65
Intake Air, Exhaust, Fuel, and Cooling Functions - GM (Gas)

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• During engine operation, filtered ambient air flow from air cleaner
assembly A3 enters the intake manifold. Exhaust gases from the exhaust
manifold are expelled into the atmosphere.
3-66
Fuel Enable and

Delivery
ECU
5-A MAINFRAME
POWER
A4 300A-BK-6
15-3A
L2 15-3
S1 FUEL PUMP ENGINE BLOCK

KEYSWITCH 5-D 47-1 47-2
21-B 21-IGN FUEL PUMP +
437-PU 3.27 A
15-1 15-2
112-OR-12 B I 5-F
KEY START POS 5-C
FUEL PUMP -
21-S 438-BK
208-WH
365A-BK-12
S
E2 B1
201A-YL-12
201B-YL-12
ACC FUEL GAUGE FUEL LEVEL
36-B+ 36-S 37-B (S) 37-C (G)
439-PU 365-BK
F2 F1 gal
REAR HARNESS DASH AND ENGINE 36-G

28-AA 28-A 29-A 29-AA 260A-YL
365-BK
10A 10A
260C-YL
260C-YL
CANBUS DISPLAY
SMARTFEED
A1 38-1
E35
POWER
38-2
1-1 GROUND
POWER (+12V)
985-YL-CAN 38-4 365-BK
CAN HI
38-5
CAN LO
R5
CAN TERMINATION
1-7 985-YL-CAN 40-A
CAN HIGH
40-C 120 OHM
1-8
986-LG-CAN
CAN LOW
40-B

Normal Operation:
• The fuel tank RES4 holds up to 20 gal (76 L) of gasoline. Refer to the

• The engine fan pushes air through the fins of the radiator to remove heat
• Once the ignition switch is in the RUN or START position, controller A4
provides power from pin 5-D to energize fuel solenoid L2.
• Fuel pump PMP7 draws fuel from the tank through strainer SR2, to
pump, and through fuel filter FL13. The fuel then passes through the
fuel manifold DV2.
3-67
• Fuel pressure is regulated by the ECU pulse width modulating signal.

Engine ECU also monitors fuel pressure and temperature at manifold
DV2.
• Manifold DV2 includes a return circuit that bleeds excess fuel and vapor
to fuel tank RES4.
• Fuel is then delivered to the engine ENG5 fuel injector rail.
3-68
Intake Air, Exhaust, Fuel, and Cooling Functions - GM (LP Version)
FL15 Precleaner
Air Cleaner Assembly
A3
E1
Air Restriction LP Fuel Filter
Indicator
FL17 Exhaust

HE6 Radiator
RES5
Left LP Tank
Right LP Tank RES6
• During engine operation, filtered ambient air flow from air cleaner
assembly A3 enters the intake manifold. Exhaust gases from the exhaust
manifold are expelled into the atmosphere.
3-69

• The engine fan pushes air through the fins of the radiator to remove heat
3-70
Fuel Enable and

Delivery
A2: ECU MAINFRAME

5-A
POWER
A4 E36
260A-YL 5-B CHECK ENGINE 15-3A
ALT EXCITE 5-G 127-2 127-1 300A-BK-6
MIL OUT 15-3
TACH OUT
421-PU
PROPANE OPTION
ENGINE BLOCK
S14
S1 260A-YL
S14: PROPANE SWITCH
78-A 78-B
757-BU 5-H
PROPANE SWITCH
L2 15-1 15-2
S1: KEYSWITCH M2: FUEL PUMP
21-B 21-IGN
5-D 47-1 47-2
365A-BK-12
FUEL PUMP +
112-OR-12 B I
5-F 437-PU 3.27 A
KEY START POS
5-C
21-S FUEL PUMP -
208-WH 438-BK
S 208-WH D
365-BK
ACC
E2
E2: FUEL GAUGE B1: FUEL LEVEL
36-B+ 36-S 37-B (S) 37-C (G)
439-PU 365-BK
gal
201A-YL-12
201B-YL-12
260A-YL
36-G
260A-YL B1
365A-BK 365-BK
F2 F1
28-AA 28-A 29-A 29-AA
1-2 260C-YL
A1: SMARTFEED
10A 10A A1 CB02 (C130) A3: CANBUS DISPLAY
260C-YL
1-3
38-1
E35
260C-YL 1-1 POWER
38-2
POWER (+12V) GROUND

985-YL-CAN 38-4 365-BK
CAN HI
38-5
CAN LO
1-6
R5
R5: CAN TERMINATION
1-7 985-YL-CAN 40-A
CAN HIGH
40-C 120 OHM
1-8 986-LG-CAN
CAN LOW
40-B
Normal Operation:
• When switch S14 is enabled, liquid propane is delivered from two 33 lb

(15 kg) tanks RES5 and RES6.
• Once the ignition switch is in the RUN or START position, controller A4
provides power from pin 5-D to energize fuel solenoid L2.
• Fuel pump PMP7 draws fuel through filter FL17 from the LP tanks. The
fuel then passes through the fuel manifold DV2.
• Fuel pressure is regulated by the ECU pulse width modulating signal.
Engine ECU also monitors fuel pressure and temperature at manifold
DV2.
• Fuel is then delivered to the engine ENG5 fuel injector rail.
3-71
Throttle Function
Throttle - Increase/ Normal Operation:
Decrease
• Engine throttle and clutch

engage functions work in
conjunction with one
another using a common
control handle (1).
• Control handle (1) includes
clutch engage linkage (2).

• Machines equipped with
Caterpillar or Cummins

engine options employ a
throttle cable (3) to adjust
engine RPM.
• Machines equipped with
Deutz or GM engine options
6
employ throttle switch S3
that sends current to

controller A1.

Controller A1 then signals
engine ECU to increase 'HXW]DQG*0
engine RPM. (QJLQH2SWLRQV
• Engine speed is
automatically adjusted as the cutter drum is engaged.
• Control handle (1) incorporates four different control position
configurations including:
(4) - Clutch Disengaged, Engine LOW RPM
(5) - Clutch Engaged, Engine LOW RPM
(6) - Clutch Disengaged, Engine HIGH RPM
(7) - Clutch Engaged, Engine HIGH RPM
3-72
EcoIdle Function -
Deutz and GM
To Ignition EcoIdle Off

witch S1
SMARTFEED
F1
S5 A1
DASH AND ENGINE
ECO-IDLE SWITCH
27-A 27-AA 261-YL 34-A 1-4 (GREEN=ECO SETTING 1)
34-B
(RED=ECO SETTING 2)
10A
OFF
34-C 734-GY (NONE=ECO-IDLE DISABLED)
365-BK
EcoIdle
To Ignition 1-minute Delay
Switch S1
SMARTFEED
F1 A1
DASH AND ENGINE
S5
ECO-IDLE SWITCH
27-A 27-AA 261-YL 34-A 1-4

(RED=ECO SETTING 2)
10A
OFF
365-BK
EcoIdle
5-minute Delay
To Ignition
Switch S1
SMARTFEED
F1 S5
DASH AND ENGINE
A1
ECO-IDLE SWITCH
34-B
(RED=ECO SETTING 2)
10A
OFF
365-BK
Normal Operation
The EcoIdle function automatically lowers engine speed if no material has

been chipped for a selected length of time (1-minute or 5-minute delay),
helping to consume less fuel if the feeding process has frequent
interruptions.
3-73
To activate the EcoIdle function the following conditions must be true:
• EcoIdle switch S5 is in the ON position in the one minute or five minute

position.
• Engine is at HIGH RPM
EcoIdle timer will be reset when:
• Feed stop bar changes position

• Dropping below set engine RPM
• Pressing hold-to-run switch S6 or S7
• Droop setting changed
While the EcoIdle is engaged the machine will:
• Stop forward feed

• Flash info light E6
• Remain at 1500 rpm

• Ignore upper and lower bar stops
• Allow reverse feed with the use of the control bar
To deactivate EcoIdle to high engine RPM:
• Press hold-to-run switch S6 or S7

• Move EcoIdle switch to the OFF position
To deactivate EcoIdle to low engine RPM:
• Disengage cutter drum
3-74
Glow Plug Function - 49 HP

15-3A 300A-BK-6 15-3
BT1
100-RD-2 10 + 19 300-BK-2 15-1 15-2
CB1 K2 R1
CB2 GLOW PLUG RELAY GLOW PLUG
ENGINE BLOCK

20-1 13-30
104-YL-10
20-2 103-YL-10
30A 50A
13-86 13-85 365-BK
101-RD-10
S1 100-RD-2
KEYSWITCH
21-B 21-IGN
M1/L1 738-OR
112-OR-12 B I
STARTER
23-2 (B+)
G1
208-WH-12 290-YL
365-BK-12
S 11-E 11-F
23-1 (S) 24-D+
201-YL-12
ACC V4 11-A 11-B 11-C 11-D

290-YL
ALT EXCITE ALT DIODE
26-A
F1
MAIN FUSE R14 V3
15A
26-B
SMARTFEED
260-YL-14 1-1
POWER A1
1-3
GLOW PLUG 738-OR

(GREEN=HEAT)
Ignition Switch S1 in Normal Operation

RUN/PREHEAT
Position The engine contains four glow plugs
one for each cylinder. Each glow plug is
connected by a common rail R1.
When electricity is applied to the glow 5

plug rail, they take on the
characteristics of their name and glow
bright orange while putting out a large
amount of heat into the combustion
chambers.
While ignition switch S1 is in RUN/

PREHEAT position:
• Controller A1 outputs power to the

coil of the glow plug relay K2 at pin
86.
• Relay K2 is energized to complete a voltage path through relay K2, then
to glow plug rail R1 to each glow plug.
• Controller A1 will allow relay K2 to stay energized for a duration of 10
seconds to provide adequate heating time.
• If the engine starter is cranked before the 10 second time cycle is up, the
glow plug function will be turned OFF.
3-75
Grid Heater/Glow Plug Function - Cummins

Preheat
BT1 12V BATTERY
+
MAINFRAME
15-3A
100-RD-1 10 J19 300-BK-1/0 300A-BK-6
15-3
K1 R1
CB1 GRID HEAT RELAY ENGINE BLOCK
GLOW PLUG
CONTROLS BREAKER
13-87
20-1
103-RD-4 15-1 15-2
20-2 13-30
AUX BAT 100-RD-10 7-1
30A
13-86 13-85 365A-BK
101-RD-10
12-2
112-OR-12

KEYSWITCH
21-IGN 738-OR 12-1
21-B
112-OR-12 B 23-2 (B+)
21-S 24-B 24-L

23-1 (S)
365A-BK-12
208-WH
S
24-IG
STARTER
ALTERNATOR E2 B1
ACC M1/L1 G1 FUEL GAUGE FUEL LEVEL
36-B+ 36-S 37-B (S) 37-C (G)
439-PU 365A-BK
gal
201-YL 36-G
208-WH 260A-YL
365A-BK 365A-BK
F2 REAR HARNESS F1 DASH AND ENGINE

26-2AA 26-2A 26-1A 26-1AA
10A 201-YL-12 10A B2

SMARTFEED
1-2 441-GY 46-1 46-2
A1OIL PRESSURE SW 365A-BK
260C-YL
260A-YL
260C-YL 1-1
365A-BK 31-A
1-3
31-B 731-BR 1-9 738-OR
260A-YL 31-C
DROOP SWITCH S2 1-5 47
212-PK
33-A FUEL SOLENOID
401-WH 1-10
ENGINE SPEED SENSOR
365A-BK 32 FUEL SHUTOFF SOLENOID L2

TACHOMETER
33-B E3 28-S
B3 ENG. SPEED SENSOR

HOUR METER hr
28-G 365A-BK
2-1
208-WH
KEY CRANK POS E25
WAIT TO START LIGHT
1-6
420-PU 34-1 34-2 365A-BK
WAIT-TO-START
2-5
406-LB
WATER TEMP SENSOR
ENG. WATER TEMP. SENSOR

B6
2-6 51-1 51-2 406-LB
205-YL t
+5V
Normal Operation
While ignition switch S1 is in the RUN position:
• Power is provided through fuse F2 to SmartFeed controller A1 on pin 1-1.

• Controller A1 then checks for:
• An input signal from grid heater coolant temperature sensor B6 on pin
2-5.
• That there is no input signal from key crank position on pin 2-1.
3-76
• Relay K1 sends power through pin 87 to glow plug R1.

• Controller A1 also outputs power on pin 1-6 to illuminate the wait-to-
start light E25.
• Light E25 will stay illuminated as long as the glow plug is on. Preheat
continues for a length of time determined by control module A1
according to the resistance being received from engine coolant
temperature sensor B6. See "Preheat/Postheat Time Calculation Table,"
page 3-78 for preheat times.
• After preheat time has expired, both glow plug R1 and wait-to-start light
E25 will be off.
While Cranking
BT1 12V BATTERY
+
MAINFRAME
15-3A
100-RD-1 10 J19 300-BK-1/0 300A-BK-6
15-3
K1 R1

Glow Plug
CONTROLS BREAKER
13-87
20-1
103-RD-4 15-1 15-2
20-2 13-30
AUX BAT 100-RD-10 7-1
30A
13-86 13-85 365A-BK
101-RD-10
S1 12-2
112-OR-12
DIODE GRID HEATER RELAY (4.0A)

KEYSWITCH
21-IGN 738-OR 12-1
21-B
112-OR-12 B 23-2 (B+)
21-S 24-B 24-L

23-1 (S)
365A-BK-12
208-WH
S
24-IG
STARTER
E2 B1
ALTERNATOR
ACC FUEL GAUGE FUEL LEVEL
M1/L1 G1 36-B+ 36-S 37-B (S) 37-C (G)
365A-BK
gal 439-PU
201-YL 36-G
208-WH 260A-YL
365A-BK 365A-BK

26-2AA 26-2A 26-1A 26-1AA
10A 201-YL-12 10A SMARTFEED

1-2 441-GY 46-1
B2 46-2 365A-BK
A1
260C-YL
260C-YL 1-1
365A-BK 31-A
1-3
31-B 731-BR 1-9
GRID HEATER
738-OR
260A-YL 31-C DROOP SW (3-WAY)
212-PK
33-A FUEL SOLENOID
401-WH 1-10
ENGINE SPEED SENSOR
365A-BK 32 FUEL SHUTOFF SOLENOID

L2
33-B
TACHOMETER E3 28-S

E3: HOUR METER hr
28-G 365A-BK
208-WH 2-1
KEY CRANK POS
E25
WAIT TO START LIGHT
1-6
420-PU 34-1 34-2 365A-BK
WAIT-TO-START
2-5
406-LB
WATER TEMP SENSOR
ENG. WATER TEMP. SENSOR B6

2-6 51-1 51-2 406-LB
205-YL t
+5V
3-77
Normal Operation
While ignition switch S1 is in START position:
• Power is provided through fuse F2 to SmartFeed controller A1 on pin 1-1.

Power is also provided to starter solenoid L1 and motor M1. See "Normal
Operation - START Position Cummins," page 3-34.
• Controller A1 then checks for an input from key crank position on pin
2-1. The preheat period will end regardless if time is expired or not.
• Both glow plug R1 and wait-to-start light E25 will be off to ensure there
is enough power to starter motor M1 for starting the engine.
Postheat Normal Operation
Once engine is started and ignition switch S1 is returned to the RUN

position:
• Postheat time delay is

applied. A1 SMARTFEED
2-5
406-LB
• During this period, glow WATER TEMP SENSOR
B6 ENG. WATER TEMP. SENSOR

plug R1 will be on for a 205-YL
2-6 51-1
406-LB t 51-2
+5V
length of time determined by
control module A1 according
to the resistance being received from engine coolant temperature sensor
B6. See table below for postheat times.
• Wait-to-start light E25 will remain off during the postheat period.
Preheat/Postheat
Time Calculation
Table
Engine Coolant Temperature Preheat ON Time Post Heat ON Time

-4°F (-20°C) and Below 30 seconds 30 seconds
5°F (-15°C) 20 seconds 30 seconds
32°F (0°C) 10 seconds 30 seconds
53°F (12°C) and Above 5 seconds 10 seconds
3-78
Glow Plug Function - Deutz

CB1
CONTROLS BT1
BREAKER
20-2 20-1 12V BATTERY
AUX BAT 100-RD-10 +
24-L 24-B 100-RD-10 10 J19 300-BK-1/0

G
ECU
251-WH 5-45
A2
100-RD
112-OR-12
GLOW PLUG RELAY

G1 100
-RD
-1
K2
R1 47-86 47-85
85
5-35
GLOW PLUG RELAY
GLOW PLUG 86
87A 252-BU
23-2 (B+) 129-1
K3 M GP 450-TN
30
S1 100-RD 30-30
30-87
23-1 (S)
87
5-23
KEYSWITCH
104-RD R6 450-TN
GLOW PLUG SIGNAL
21-B 30-86 30-85 GLOW PLUG MAINFRAME

STARTER 129-2 100-RD
B I
M1/L1 GP 450-TN
15-3A
300A-BK-6
21-S
15-3
S
ECU 4-2
365-BK ENGINE BLOCK
GROUND -
112-OR 4-1
ACC + POWER A2 15-1 15-2
4-4 365-BK
112-OR 4-3
+ POWER
GROUND -
4-6
112-OR 4-5
GROUND -
365-BK
+ POWER
365A-BK-12
4-73
4-28
210-BK
- START RELAY
4-35
208-WH START SIGNAL

Ignition Switch S1 in Normal Operation
RUN/PREHEAT
Position While ignition switch S1 is in RUN/PREHEAT position:
• Engine ECU A2 outputs power to glow plug relay K2.

• Relay K2 is energized to complete a voltage path through relay K2, then
to glow plugs R1 and R6.
• Engine information display E35 will display a wait-to-start message.
• During preheat engine ECU A2 will not energize start relay K3 if
ignition switch S1 is turned to the start position.
Engine ECU A2, glow plugs R1 and R2, and coolant temperature sensor B12
are engine components covered under Deutz warranty. Unauthorized service
on the Deutz engine or Deutz components will void warranty. Contact an
authorized Deutz Engine service facility.
Postheat Normal Operation
Once engine is started and ignition switch S1 is returned to the RUN

position:
• Glow plugs R1 and R6 may be on for a length of time determined by

engine ECU A2 according to the resistance being received from engine
coolant temperature sensor B12.
3-79
Preheat/Postheat
Time Calculation
Table
Engine Coolant Temperature Preheat ON Time Post Heat ON Time

-40°F (-40°C) 8 seconds 180 seconds
32°F (0°C) 1.5 seconds 20 seconds
Engine Protection Interlocks

An interlock is a component or an arrangement of components by which the

functioning of one component is controlled by the functioning of another.
These separate components when in predetermined positions (closed or
opened), will complete or interrupt an electrical circuit.
Engine Shutdown -
Caterpillar
15-2
B4 M2
SMARTFEED
ENG TMP SW 51-1 51-2
45-1 45-2
A1
260-YL 406-LB 2-5
(GREEN=TEMP OK) FUEL PUMP MOTOR
CLOSES @ 212 F
1-5 212-PK 47-1 47-2
(GREEN=HOUR METER)
46-2
B2 46-1
FUEL SOL.
441-GY 1-2
(RED=PRESSURE OK) 28-S L2
5 PSI FALLING 28-G
365-BK
ENG. OIL PRES.
E3 HOUR METER
365-BK
The engine can be shut down by two engine protection interlocks as well as
by conventional means using the ignition switch S1. Engine shutdown will
be initiated if either of the following conditions occurs:
• Low Engine Oil Pressure - if oil pressure drops to 5 psi (34.5 kPa) or
below.
• High Engine Coolant Temperature - if engine coolant temperature
reaches 234°F (112°C).
3-80
Normal Operation:
• Coolant temperature sensor B4 is normally-closed. In its normal

operating state it provides an input signal to controller A1 at pin 2-5.
The LED on pin 2-5 will illuminate green.
• If coolant temperature reaches 234°F (112°C), the sensor will open and
the LED will go dark.
• Controller A1 responds by removing the power at pin 1-5 to the fuel
circuit and the engine will shut down. The LED on pin 1-5 will also go
dark.
• Oil pressure sensor B2 is a normally-open with key ON, engine not
started. In its normal operating state with engine running, it is grounded
and provides an input signal to controller A1 at pin 1-2. The LED on pin
1-2 will illuminate red.
• If oil pressure drops to approximately 5 psi (34.5 kPa), the sensor will
open and the LED will go dark.
• Controller A1 reacts by removing the power at pin 1-5 to the fuel circuit
and the engine will shut down. The LED on pin 1-5 will also go dark.

Engine Shutdown -
Cummins
MAINFRAME
15-3A
300A-BK-6
15-3
ENGINE BLOCK
15-1 15-2
SMARTFEED
B2
A1 1-2 441-GY 46-1 46-2 365A-BK
OIL PRESSURE SW
260C-YL 1-1
365A-BK-12
212-PK 47
FUEL SOLENOID
1-5 FUEL SHUTOFF SOLENOID
28-S L2
E3 28-G 365A-BK
HOUR METER hr
2-5
406-LB
WATER TEMP SENSOR
ENG. WATER TEMP. SENSOR B6

2-6 51-1 51-2 406-LB
205-YL t
+5V
The engine can be shut down by two engine protection interlocks as well as
by conventional means using the ignition switch S1. Engine shutdown will
3-81
• Low engine Oil Pressure - if oil pressure drops to 10 psi (69 kPa) or
below.
Normal Operation:
• Coolant temperature sensor B6 in its normal operating state provides an

variable input signal to controller A1 at pin 2-5. The LED on pin 2-5 will
illuminate green.
• If coolant temperature reaches 212°F (100°C), controller A1 responds by
removing the power at pin 1-5 to the fuel circuit and the engine will shut
down. The LED on pin 1-5 will also go dark.
• Oil pressure sensor B2 is a normally-open. In its normal operating state
it is grounded and provides an input signal to controller A1 at pin 1-2.
The LED on pin 1-2 will illuminate red.
• If oil pressure drops to 10 psi (69 kPa), the sensor will open and the LED
will go dark. Controller A1 reacts by removing the power at pin 1-5 to the
fuel circuit and the engine will shut down. The LED on pin 1-5 will also
go dark.
Engine Shutdown - The engine can be shut down by two engine protection interlocks as well as
Deutz by conventional means using the ignition switch S1. Engine shutdown can
• Low engine Oil Pressure - if oil pressure drops to 20 psi (140 kPa) or
below.
All input and output information from these sensors is controlled by the
Deutz engine ECU A2 and are covered under Deutz warranty. Unauthorized
service on the Deutz engine or Deutz components will void warranty.
Contact an authorized Deutz Engine service facility.
3-82
BC1000XL Brush Chipper Service Troubleshooting
Engine Shutdown - The engine can be shut down by two engine protection interlocks as well as
GM by conventional means using the ignition switch S1. Engine shutdown wil be
initiated if either of the following conditions occurs:
• Low engine Oil Pressure - if oil pressure drops to 8 psi (55 kPa) or below
for more than 5 seconds.
reaches 250°F (121°C) or more for more than 5 seconds.
All input and output information from these sensors is controlled by the GM
engine ECU A4 and are covered under Power Solutions Inc. (GM) warranty.
Unauthorized service on the GM engine or GM components will void
warranty. Contact an authorized Power Solutions Inc. (GM) Engine service
facility.
TROUBLESHOOTING

Look for the Before beginning any extensive troubleshooting or testing procedures,
Obvious perform machine walk-around inspection to look for any obvious signs of
damage and so on that could be causing the fault(s). See "Pretest Inspection,"
page 4-23 for instructions on what to look for. If problem is found, repair/
replace faulty component(s).
Fault Indications Before any testing is performed, refer to "Methods of Diagnosing/Testing,"

page 3-84 for information on testing using the Vermeer VCTool.
Troubleshoot based on the possible following fault indications.
Fault Action Refer TO

Test battery page 3-87
Caterpillar - page 3-30
Engine does not turn over Cummins - page 3-34
Test ignition circuit
Deutz - page 3-38
GM - page 3-41
check engine interlocks page 3-80
check glow plugs Cummins - page 3-76
Deutz - page 3-79
GM - Refer to engine
Engine turns over but will not start Check spark plugs operation manual supplied
with machine
Inspect air intake and Cummins - page 3-60
exhaust system Deutz - page 3-63
GM - page 3-66
Inspect air intake, exhaust,
Engine runs but performance is not
fuel, and cooling functions page 3-92
adequate
system
3-83
Troubleshooting BC1000XL Brush Chipper Service
Fault Action Refer TO

Check engine protection
Engine shuts down page 3-80
interlocks
Gauge appears faulty check gauge page 3-89
Methods of Diagnosing/Testing
Conventional Conventional diagnosis involves a logical approach to isolating the circuit
Diagnosis/Testing and components that are faulty by viewing the input and output LEDs on
face of controller A1. The technician would then use a multimeter to
measure for normal voltage, current, resistance, and continuity. See "Test
Equipment," page 3-86.
Refer to "Electrical Troubleshooting," page 1-13 for instructions on performing

basic electrical tests. Complete schematics and wire harness diagrams are
located in the Addendum document for this machine to assist in circuit
troubleshooting if needed.
Checking Controller A1 LEDs

Indicator lights on the face of controller A1, provide a quick means for
checking if the inputs and outputs required for a circuit are working as
expected. When troubleshooting a circuit that provides input to, or output
from controller A1, begin by checking that the appropriate controller
indicator lights are illuminated when the circuit is actuated.
Troubleshooting procedures for the electric-over hydraulic operated

functions in the following chapters will first concentrate on electrical faults
based on these LEDs. If LEDs are normal, procedures for troubleshooting
the hydraulic side of the circuits are given.
See appropriate function chapter for information on which LEDs should be

illuminated on controller A1.
3-84
Diagnosis Using Another method of troubleshooting would involve using Vermeer VCTool.
Vermeer VCTool Service technicians can obtain diagnostic information helpful in locating,
isolating, and diagnosing faulty electrical circuits and components.
Conventional test equipment can then be used to verify the findings.
Diagnostics Access To utilize diagnostic capabilities,

remove plug (1) and install data cable
and PC to controller access port. See
"Test Equipment," page 3-86.
VCTool is a diagnostic tool that:
• Displays status of input and

outputs of controller A1
• Graphs inputs/outputs in real time
• Reports errors
• Creates logs of activity 'HXW]&RQWURO3DQHO6KRZQ

Complete instructions on downloading the needed software, files, and
instructions for using the VCTool are located on Vermeer Compass.
To find necessary downloads:
1. Log into Vermeer Compass.

2. Click on Vermeer Compass Industrial.
3. Click on the Service tab.
4. Click on Downloads.
To locate VCTool and Reflash Software Downloads:
• Click on PC Based Software.

• Click on desired download(s).
To locate the latest BC1000XL software update and diagnostic (JYSM file)
Downloads:
5. Click on Environmental.
6. Click on BC1000XL.
7. Click on desired download(s).
3-85
Test Equipment To perform electrical troubleshooting procedures in this chapter, the

following test equipment will be needed:
• Digital multimeter - for

continuity tests, voltage,
current measurements, and
resistance measurements in
various electrical circuits.
• Oscilloscope - for monitoring
CAN Bus communication
signals.
• Laptop Computer
• USB/CAN Gateway Kit
Multimeter Oscilloscope
PLUS1 (CG150) Part #
296276088
• Latest version of VCTool CG150
available for download on
Vermeer Compass
• Access to latest version of

the BC1000XL JSYM file
available for download on
Vermeer Compass.
Laptop Computer
CG150
USB Port
3-86
Electrical Power Source

Battery Testing Refer to the Addendum document for this machine to view complete
electrical schematics.
Battery may test OK providing +12 vDC with ignition switch in ACC or
RUN positions. Adequate voltage may not be available when it is loaded,
such as turning engine over. To thoroughly test battery, it should be tested
under load. Battery can be tested by using a suitable load tester and
following manufacturer’s instructions.
No-Load Battery Test
1. Check electrolyte levels of battery. If low, add distilled water to proper

level.
2. Test battery BT1 for acceptable voltage. Disconnect battery cables. With
multimeter set to measure DC voltage, connect probes to positive and
negative terminals of battery.

Expected result: Multimeter should read approximately:
• 12.66 volts @ 100% state of charge

3. If battery measures under 12.66 volts:

• Try charging battery then retest.
• If battery still measures below 12.66 volts after sufficient charging time,
replace battery.
• If battery fails to stay charged, refer to the Vermeer Industrial
Dealerships Technician’s Shop Manual for instructions on checking
alternator output and battery discharge tests.
• Consult Engine Operation/Maintenance Manual.
Alternator G1 is considered to be part of the engine and is covered under the

Engine warranty. You can void this warranty by attempting to repair this
component before warranty has lapsed. If warranty is still in effect, take
machine to an authorized Engine Service Facility.
3-87
EcoIdle Function If EcoIdle function is faulty, first confirm control panel switch S5 is working
and power is being supplied to smartfeed controller A1.
1. Access smartfeed controller A1. Turn ignition switch S1 to RUN/

PREHEAT position. With the EcoIdle switch S5 in the 1-minute delay
EcoIdle LED should be illuminated green. With the EcoIdle switch S5 in
the 5-minute delay EcoIdle LED should be illuminated red. If LED is
illuminated continue to step 3. If not, troubleshoot EcoIdle switch S5. If
OK, continue below.
2. Test switch S5 circuit for opens or shorts using a multimeter. Refer to
"Electrical Troubleshooting," page 1-13 for information on testing circuits
with a multimeter.
To Ignition
Switch S1
SMARTFEED
F1 S5
DASH AND ENGINE
A1
ECO-IDLE SWITCH
34-B
(RED=ECO SETTING 2)
10A
OFF
34-C 734-GY
365-BK
3. Start machine and ensure the required operating conditions are present,
see "EcoIdle Function - Deutz and GM," page 3-73. LEDs on face of
smartfeed controller will be illuminated idndicating which inputs are
present.
Troubleshoot any circuit or component that does not have the LED
illuminated. See appropriate chapter for troubleshooting information
specific to input circuit in question.
3-88
Gauges
Fuel Gauge E2 and If the fuel gauge does not register correctly ensure there is fuel in the tank.
Sensor B1 If so, the problem is either in the gauge E2 itself, the sending unit B1, or the
wiring in between.
1. With the ignition switch on, remove

the purple signal wire from the fuel
tank sending unit B1 and ground it %
to the machine frame. This removes
the resistance supplied by the
sending unit.
Expected result: Fuel gauge E2
needle should swing over to the
FULL position.
If so, the gauge and wiring are good.

The problem is most likely with the
sending unit. See step 2.

If not, the power supply to the gauge has been interrupted, the gauge is
defective, or the wire from the gauge to the sending unit is open or has a
break in it. See step 4.
2. Remove the remaining wire on sensor and check for corrosion/dirt or

break in studs at top of sensor. Thoroughly clean contact areas and
reattach wires. If the gauge now registers, the problem was found. If not,
continue with step 3.
3. Check sensor power and ground wires for continuity. If no continuity,
replace faulty segment of wire harness.
4. Check gauge power and ground
wires for continuity. If no continuity,
replace faulty segment of wire ( (
harness. If there is continuity,
replace fuel gauge E2.
Sensor resistance values from full to
empty should measure:
• Tank Full - 33 ± 1 ohms

• Tank Empty - 250 ± 6 ohms
Hourmeter E3 If hourmeter E3 is faulty, check gauge power and ground wires for
continuity. If no continuity, replace faulty segment of wire harness. If there
is continuity, replace hourmeter E3.
3-89
Gauges - Cummins (Deluxe)

E4 4-IN-1 GAUGE
2 36-S (B) 439-PU
7 1 27-1 442-GY
48
gal psi ENG. OIL
B7
PRESSURE SENSOR
3 36-B+ (B)
6 36-G (B) 365A-BK
ENG. WATER TEMP.

t° V
440-WH
B5 SENSOR
8 27-8
49
BACK LIGHTING LAMP
4 27-4
B1
F1 37-B (S)
FUEL LEVEL
37-C (G)
365A-BK
DASH AND ENGINE
26-1A
260A-YL
26-1AA
201-YL-12 10A
365A-BK
SMARTFEED
A1
1-1
POWER (+12V)
B3 1-5 47
212-PK
ENG. SPEED SENSOR 33-A FUEL SOLENOID
401-WH 1-10
ENGINE SPEED SENSOR

365A-BK
33-B L2
E5
TACHOMETER/HOUR GAUGE
SIG 401-WH
rpm
B+ 212-PK
42-B+ 50-S 28-S (B)
G 365A-BK
42-G 50-G 28-G (B)
hr
Tachometer/ Tachometers usually exhibit the following symptoms:

Hourmeter E5
• Dead
• Erratic
Dead:
1. This is usually caused by no power applied or by no signal applied.

Ensure the tachometer is connected properly. If the tachometer is
connected properly, check the voltage between the “B+” and “G”
terminals on the tachometer.
Expected result: They should have a voltage between 12–16 vDC. If
correct voltage is not present, check the ground and ignition connections
to the tachometer and the continuity of the wires making these
connections. If no continuity, replace faulty segment of wire harness.
3-90
2. If correct voltage is present, check for the presence of a signal. Measure

the signal between the “SIG” and “G” terminals on the tachometer.
Expected result: Signal strength should be in excess of 2 vDC.
Erratic:
1. This is usually caused by a loose or intermittent connection on the back

of the tachometer. Check to see if the connections are tight and that the
terminal hardware is making contact with the wires conductor.
2. Erratic action can be caused by the wrong air-gap between the sensor B3
and the flywheel teeth. A .050" air-gap is what is recommended. To
achieve a .050" air-gap, turn the sensor into the housing until it touches
the flywheel teeth and then back the sensor out ¼ turn.
4-in-1 Gauge E4 If any of the four gauges fails to operate and troubleshooting determines the
Including, Oil gauge is bad, the complete gauge assembly will need to be replaced.

Pressure/Coolant
Temperature/Fuel Gauge is inoperative:
Level/Voltmeter
1. To test the gauge, disconnect the
(
sensor terminal. Turn the ignition
switch on.
Expected result: The gauge pointer
should be pegged fully to the low
reading side of the gauge.
2. If it does not, test to see if the

ignition voltage is present by
connecting a multimeter between
the number 3 and 6 terminals.
Expected result: Voltage should measure (approximately 12 volts DC). If
not, troubleshoot the wiring from the ignition and to ground. Test the
continuity of the wires making these connections. If no continuity,
replace faulty segment of wire harness.
3. If the gauge pointer does peg to the left, short the sensor terminal of the
gauge to ground, the pointer should deflect fully to the right. If it does
not, the gauge is faulty. If the pointer does peg to the right, and the
ignition voltage is present, the problem is with the sensor or the wiring
from the sensor to the gauge.
4. Test the continuity of the sensor wire. If no continuity, replace faulty
segment of wire harness.
3-91
Engine and Associated Functions

Most engine components are covered under the engine warranty. You can
void this warranty by attempting to remove or repair these systems before
the warranty has lapsed. If the warranty is still in effect, take the machine
or engine to an authorized engine service facility.
Intake Air, Exhaust, Fuel, and Cooling Functions

Intake Air/Exhaust When the engine is running at full
speed, check air inlet restriction
indicator E1:
• If the yellow ring is in the red zone,

shut down and replace the air filter
elements, as described in the (
BC1000XL Brush Chipper
Maintenance Manual.
• If the yellow ring is in the green
zone, but above the bottom of the
indicator, filters appear to be
normal.
• If the yellow ring is resting on the bottom of the indicator, filter may be
torn, or not sealed against the housing, allowing unfiltered air into the
engine. Shut down the engine. Remove and inspect air filter elements for
damage. Replace element if damaged.
If no damage is evident, carefully install the elements, ensuring they

seal properly in the housing. Also inspect housing for dents, holes or air
leaks at duct joints. Restart the engine and recheck the indicator.
Replace filters if indicator is still at the bottom of the green zone.
If the intake air intake/exhaust function is OK, inspect fuel function. See
"Fuel Function - Caterpillar," page 3-93.
3-92
Fuel Function -
Caterpillar
If the engine will not run, or performance is not adequate, resulting in a lack
of power, a fuel pump may be faulty or the fuel filter may be clogged or
partially clogged. The engine may run at idle, but stall when the throttle is
positioned to HIGH. A clogged filter will hinder fuel flow to the injector
pump PMP5.
1. Ensure fuel level is OK. If

the level is OK, ensure fuel

transfer pump PMP4 is
pulling fuel from fuel tank
RES2.
2. Remove hose (1) from filter
FL1. Turn ignition ON to see
if pump is pulling fuel from
tank RES2. If so, pump is
OK, see step 3. If not,
replace pump PMP4.
3. Replace fuel filter FL1 as
described in the BC1000XL
Maintenance Manual and )/ 303
engine manual supplied
with the machine. If the
problem persists with new filter, contact an authorized Caterpillar
service facility.
NOTICE: The engine fuel solenoid, fuel injector pump, and fuel injectors
are considered to be part of the Caterpillar engine and are covered under
Caterpillar’s warranty. You can void this warranty by attempting to remove
or repair this system before the warranty has lapsed. If the warranty is still
in effect, take the machine to an authorized Caterpillar Service Facility.
3-93
Fuel Function -
Cummins
of power, a fuel pump may be faulty or the fuel filter or fuel filter inlet
supply screen may be clogged or partially clogged. The engine may run at
idle, but stall when the throttle is positioned to HIGH. A clogged filter will
hinder fuel flow to the injector pump PMP2.
1. Ensure fuel level is OK.

The Cummins engines have a

serviceable screen (2) integrated
into the banjo bolt (1) on inlet
fitting to the fuel filter. The
screen helps to protect the check
valves in fuel priming pump
that is integrated into fuel filter
FL1 head.
Occasionally this screen can

become plugged with debris
from the fuel tank resulting in
low power or surging.
2. Remove banjo bolt. The

white plastic screen (2)
unscrews from the center of
the banjo bolt with a flat
head screwdriver. Clean the
screen with a blast of compressed air. If OK, continue.
3. Replace fuel filter FL1 as described in the BC1000XL Maintenance
Manual and engine manual supplied with the machine. If the problem
persists with new filter, contact an authorized Caterpillar or Cummins
service facility.
3-94
are considered to be part of the Cummins engine and are covered under
Cummins warranty. You can void this warranty by attempting to remove or
repair this system before the warranty has lapsed. If the warranty is still in
effect, take the machine to an authorized Cummins Service Facility.
Fuel Function -
Deutz

of power, a fuel pump may be faulty or the fuel filters may be clogged or
positioned to HIGH. A clogged filter will hinder fuel flow to the injector
pump PMP8.
1. Ensure fuel level is OK. If

the level is OK, ensure fuel
pump PMP6 is pulling fuel
from fuel tank RES2.
)/
2. Remove hose (1) from filter
FL10. Turn ignition ON to
see if pump is pulling fuel
from tank RES2. If so, pump )/
is OK, see step 3. If not,
replace fuel filter FL11 test
303
again.
If pump is now pulling fuel
from tank, pump appears to
be OK. If not, replace pump
PMP6.
3-95
3. Replace fuel filter FL10 as described in the BC1000XL Maintenance

Manual and engine manual supplied with the machine. If the issue
persists with new filters, contact an authorized Deutz service facility.
are considered to be part of the Deutz engine and are covered under Deutz’s
warranty. You can void this warranty by attempting to remove or repair this
system before the warranty has lapsed. If the warranty is still in effect, take
the machine to an authorized Deutz Service Facility.
Fuel Function - GM

of power, a fuel pump may be faulty or the fuel filter may be clogged or
positioned to HIGH. A clogged filter will hinder fuel flow to the engine.
Gas:
1. View fuel gauge E2 on

control panel to ensure fuel
level is OK. If the level is
OK, ensure fuel transfer )XHO7DQN
pump PMP7 is pulling fuel )XHO6WUDLQHU 5(6
from fuel tank RES4.
65
2. Remove hose from filter
FL13. Turn ignition ON to
see if pump is pulling fuel
from tank RES4. If so, pump
is OK, see step 3. If not,
replace pump PMP4. 303
)XHO3XPS
)/
)XHO)LOWHU
3-96
3. Remove and inspect fuel strainer SR2. If OK, see step 4. If not, replace
strainer.
4. Replace fuel filter FL13. If the problem persists after installing new
filter, contact an authorized Power Solutions Inc. (GM) Service Facility.
Liquid Propane:
1. View sight gauge (1) on LP

tanks to ensure they are not
empty. If LP level is OK,
continue. If not, refill tanks
to proper level.
2

CAUTION: LPG metal components can become very cold. Always
wear gloves when changing tanks to prevent frostbite.
2. Ensure knob (2) is closed before removing fuel line.

3. Replace fuel filter FL17. If To To
the problem persists with LP Tank FL17 Engine
new filter, contact an
authorized Power Solutions
Inc. (GM) Service Facility.
NOTICE: The engine fuel
system components are
considered to be part of the GM
engine and are covered under
Power Solutions Inc. (GM)
warranty. You can void this
warranty by attempting to
remove or repair this system
before the warranty has lapsed.
If the warranty is still in effect, To
take the machine to an LP Tank
authorized Power Solutions Inc.
(GM) Service Facility.
3-97
Cooling Function Troubleshooting the cooling function involves inspecting the coolant level
and the radiator fins for debris and/or damage.
After shutdown, the engine will not restart until it cools down. If this
happens, after the engine cools down, do the following:
1. Inspect coolant level in the radiator HE3 (Cummins), or coolant recovery

tank RES3 (Caterpillar, Deutz, and GM). Add coolant as needed to bring
level within 1/2" (13 mm) of the filler neck (Cummins) or to the full line
on coolant recovery tank RES3 (Caterpillar, Deutz, and GM). Refer to the
engine manual supplied with the machine to determine the best coolant
mixture to use for the local conditions.
2. Inspect radiator for leaks.
3. Inspect radiator fins for grease or dirt. Clean fins as needed. If fins are
dry, compressed air will remove dust and dirt. If fins are greasy, use a
spray bottle with a mixture of water and degreasing detergent to remove
grease, use compressed air to dry the fins.
Do not start engine in a dusty environment until fins are dry. If the fan
pulls dust onto wet fins, the dirt will stick and insulate the fins, reducing
heat exchange.
3-98
Glow Plug Function - Caterpillar

15-3A 300A-BK-6 15-3
BT1
100-RD-2 10 + 19 300-BK-2 15-1 15-2
CB1 K2 R1
CB2 GLOW PLUG RELAY GLOW PLUG
ENGINE BLOCK

20-1 13-30
104-YL-10
20-2 103-YL-10
30A 50A
13-86 13-85 365-BK
101-RD-10
S1 100-RD-2
KEYSWITCH
21-B 21-IGN
M1/L1 738-OR
112-OR-12 B I
STARTER
23-2 (B+) G1
208-WH-12 290-YL
365-BK-12
S 11-E 11-F
23-1 (S) 24-D+
201-YL-12
ACC V4 11-A 11-C 11-D

11-B
290-YL
26-A
F1 ALT EXCITE ALT DIODE
MAIN FUSE
R14 V3
15A
26-B
SMARTFEED
260-YL-14 1-1
POWER A1
1-3
738-OR

GLOW PLUG
(GREEN=HEAT)
NOTICE: The glow plugs are considered to be part of the Caterpillar engine
and are covered under Caterpillar’s warranty. You can void this warranty by
attempting to remove or repair this component before the warranty has
lapsed. If the warranty is still in effect, take the machine to an authorized
Caterpillar service facility.
1. Check glow plug circuit breaker CB2 to see if it has tripped. If the
breaker trips and does not automatically reset in a few seconds, it has
probably failed and needs replaced. If so, replace CB2 with circuit
breaker of same size and rating. If OK, continue.
During normal operation, controller A1 will energize the glow plug circuit
for total of 10 seconds when ignition switch S1 is in the PREHEAT/RUN
position. If testing is not completed in this time frame the ignition switch
will need to be turned OFF then ON again to restart the cycle time.
3-99
2. Turn ignition switch S1 to RUN position. Check LED on face of controller

A1 at pin 1-3.
Expected result: Glow plug LED illuminates green, indicating controller
A1 is outputting power to glow plug relay K2. The LED should go out in
approximately 10 seconds. If so, continue. If LED does not illuminate,
replace controller A1.
Several LEDs will normally be illuminated when the ignition switch S1 is in

the RUN position. However, for clarity purposes, the illustration below will
only show what LED should be illuminated for the glow plug function.
CP02 KEY CRANK 2-1 - LED-A POWER 1-1
BC1000XL - INFO LIGHT 3-6 LED-B OIL PRES. 1-2
LT SENS SW 3-1 FUEL SOL 1-5 ENGINE SPD 1-10 -
hOLD-TO-RUN 3-2 - - WATER TEMP 2-5

RED SENS SW 3-7 FWD FD OUT 3-3 - FWD FD SW 3-10
NOR SENS SW 3-8 REV FD OUT 3-4 GLOW PLUGS 1-3 -
E-STOP SW 3-9 - - REV FD SW 3-12
3. Remove wire at R1 and test voltage

with ignition switch in PREHEAT/
RUN position.
Expected result: Multimeter should
measure approximately 12 volts for 5
approximately 10 seconds. If not,
continue with step 4.
If so, the problem is with the glow

plugs. Refer to a Caterpillar service
manual or an authorized
Caterpillar service facility.
4. Test power and ground wires going

to and from relay K2 for continuity.
Replace any faulty wires. If wires
are OK, replace relay K2.
3-100
Glow Plug Function - Cummins

BT1 12V BATTERY
+
MAINFRAME
15-3A
100-RD-1 10 J19 300-BK-1/0 300A-BK-6
15-3
K1 R1
GLOW PLUG
CONTROLS BREAKER
13-87
20-1
103-RD-4 15-1 15-2
20-2 13-30
AUX BAT 100-RD-10 7-1
30A
13-86 13-85 365A-BK
101-RD-10
12-2
112-OR-12

KEYSWITCH
21-IGN 738-OR 12-1
21-B
112-OR-12 B 23-2 (B+)
21-S 24-B 24-L

23-1 (S)
365A-BK-12
208-WH
S
24-IG
STARTER
ALTERNATOR E2 B1
ACC M1/L1 G1 FUEL GAUGE FUEL LEVEL
36-B+ 36-S 37-B (S) 37-C (G)
439-PU 365A-BK
gal
201-YL 36-G
208-WH 260A-YL
365A-BK 365A-BK

26-2AA 26-2A 26-1A 26-1AA
10A 201-YL-12 10A SMARTFEED

1-2 46-1
B2
441-GY 46-2 365A-BK
A1OIL PRESSURE SW
260C-YL
260A-YL
260C-YL 1-1
ENG. OIL PRESSURE (10 PSI FALLING)

POWER (+12V)
365A-BK 31-A
1-3
31-B 731-BR 1-9 738-OR
260A-YL 31-C
212-PK
33-A FUEL SOLENOID
401-WH 1-10
ENGINE SPEED SENSOR
365A-BK 32 FUEL SHUTOFF SOLENOID L2

TACHOMETER
33-B E3 28-S

HOUR METER hr
28-G 365A-BK
2-1
208-WH
KEY CRANK POS E25
WAIT TO START LIGHT
1-6
420-PU 34-1 34-2 365A-BK
WAIT-TO-START
2-5
406-LB
WATER TEMP SENSOR
ENG. WATER TEMP. SENSOR

B6
2-6 51-1 51-2 406-LB
205-YL t
+5V
NOTICE: The glow plugs are considered to be part of the Cummins engine
and is covered under Cummins warranty. You can void this warranty by
attempting to remove or repair this component before the warranty has
lapsed. If the warranty is still in effect, take the machine to an authorized
Cummins service facility.
To begin troubleshooting:
1. Turn ignition switch S1 to RUN position. Check LEDs on face of

controller A1 at pin 1-3 and 1-6.
Expected result: Grid heater LEDs illuminate green, indicating
controller A1 is outputting power to grid heat relay K1 and wait-to-start
light E25. If so, continue. If LEDs do not illuminate, replace controller
A1.
3-101
Several LEDs will normally be illuminated when the ignition switch S1 is in

the RUN position. However, for clarity purposes, the illustration below will
only show what LEDs should be illuminated for the grid heat function with
engine OFF.
CP02 KEY CRANK 2-1 WAIT LAMP 1-6 LED-A POWER 1-1
BC1000XL - INFO LIGHT 3-6 LED-B OIL PRES. 1-2
SENS SW 3-1 FUEL SOL 1-5 ENGINE SPD 1-10 -
hOLD-TO-RUN 3-2 - - WATER TEMP 2-5
RED SENS SW 3-7 FWD FD OUT 3-3 - FWD FD SW 3-10
NOR SENS SW 3-8 REV FD OUT 3-4 GLOW PLUGS 1-3 -
E-STOP SW 3-9 DROOP SWITCH 1-9 - REV FD SW 3-12
2. Check for voltage in the glow plug power circuit components starting at
glow plug R1 and working back through the circuit. If needed, refer to
"Electrical Troubleshooting," page 1-13 for information on checking
electrical circuits using a multimeter.
Expected result: A reading of approximately 12 volts at each component’s
power pins indicates acceptable voltage in the circuit. If complete circuit
does not have acceptable voltage, continue at step 3.
3. Test continuity of harness segments. Repair or replace faulty harness

segment.
3-102
Glow Plug Function NOTICE: The glow plug function consisting of controller, harness, and glow
- Deutz plugs is considered to be part of the Deutz engine and is covered under
Deutz warranty. You can void this warranty by attempting to remove or
repair these components before the warranty has lapsed. If the warranty is
still in effect, take the machine to an authorized Deutz service facility.
CONTROLS
BREAKER
CB1 BT1
20-2 20-1 12V BATTERY
AUX BAT 100-RD-10 +
24-L 24-B 100-RD-10 10 J19 300-BK-1/0

G
ECU
251-WH 5-45
A2
100-RD
112-OR-12
GLOW PLUG RELAY

G1 100
-RD
-1
K2
47-86 47-85 5-35
GLOW PLUG
R1 86
87A
85
252-BU
GLOW PLUG RELAY
23-2 (B+) 129-1
K3 M GP 450-TN 87
30
S1 100-RD 30-30
30-87
23-1 (S)
5-23
KEYSWITCH GLOW PLUG SIGNAL
104-RD 450-TN
21-B 30-86 30-85 GLOW PLUG R6 MAINFRAME
STARTER 129-2 100-RD
B I
M1/L1 GP 450-TN
15-3A
300A-BK-6
21-S
15-3
S
ECU 4-2
365-BK ENGINE BLOCK
GROUND -
112-OR 4-1
ACC + POWER
A2 15-1 15-2
4-4 365-BK
112-OR 4-3
+ POWER
GROUND -

4-6
112-OR 4-5
GROUND -
365-BK
+ POWER
365A-BK-12
4-73
4-28
210-BK
- START RELAY
4-35
208-WH START SIGNAL
1. Turn ignition switch S1 to RUN/PREHEAT position.Check for voltage in

the glow plug power circuit components starting at glow plug R1 and R6
working back through the circuit. If needed, refer to "Electrical
Troubleshooting," page 1-13 for information on checking electrical circuits
using a multimeter.
Expected result: A reading of approximately 12 volts at each component’s
power pins indicates acceptable voltage in the circuit. If circuit does not
have acceptable voltage, continue at step 2. If nothing is found contact an
authorized Deutz service facility.
2. Test continuity of harness segments. Repair or replace faulty harness
segment or components.
Engine Protection Interlocks

NOTICE: The engine protection interlock components are considered to be
part of the engine and are covered under the engine warranty. You can void
this warranty by attempting to remove or repair these systems before the
warranty has lapsed. If the warranty is still in effect, take the machine or
engine to an authorized engine service facility.
3-103
Repair BC1000XL Brush Chipper Service
REPAIR
Most electrical repair involves removing and replacing components that
were determined faulty in the troubleshooting procedures. Replacing items
such controllers, switches, relays, fuses, light bulbs, and so on, is relatively
straight-forward and simple. Therefore specific procedures are not given.
NOTICE: When removing any electrical connection, it is a good idea to

remove negative battery cable from battery before proceeding. If welding on
the machine for any reason, it is important to follow the welding guidelines
below.
Welding
Before welding, the following precautions must be observed:
• Turn ignition keyswitch to the OFF position. Refer to Shutdown

Procedure, page 2-1.

• Disconnect negative battery cable and unplug controller A1, engine ECU
A2 or A4, optional remote control receiver A5. See “Welding Alert -
Electronic Components,” below.
• Clamp welding ground as close to welding location as possible. Do not
allow welding current to pass through a bearing or other joints of a
moving component.
• Do not connect welding ground to any electrical component or controller.
• Protect wiring and wiring harnesses from weld splatter and debris.
• Use proper welding procedures.
NOTICE: Before welding, clean all grease, dirt, oil, moisture, or any other
foreign material and sand paint from area to be welded.
3-104
BC1000XL Brush Chipper Service Repair
Welding Alert - Electronic Components

NOTICE: Electronic modules and controllers will be
damaged from stray voltages and currents generated
during welding if not unplugged before welding.
To prevent extensive and costly damage to the
electrical components:
1. Disconnect negative battery cable

(1). 1

NOTICE: Disconnecting the battery
ground will not prevent damage to the 1
electronic components during welding.
Each of the modules must have the
electrical connector unplugged from the
module.
2. Unplug connectors on controller A1

(2) under rear control cover.
3-105
3. Unplug connectors on ECU A2 or A4 if applicable.
GM Engine A4 Deutz Engine A2
A4
A2
4. Unplug connector on remote

receiver A5 if applicable.
A5
3-106
Battery Cables
Disconnect/Remove
WARNING: Battery post, terminals, and related accessories contain lead and
lead compounds, chemicals known to the state of California to cause cancer
and reproductive harm.
Wash hands after handling.
1. Gain access to battery box inside

engine enclosure.
2. Remove negative (-) cable (1).

3. Remove positive (+) cable (2).
4. Pull cables from battery
compartment away from battery.

5. Apply a light coating of petroleum
jelly around base of each terminal.
6. Install positive (+) cable (2). Then
install negative (-) cable (1) and tighten.
7. Check that caps over cable clamps are properly installed.
Batteries - Charge/Replace
Battery Charging • Follow instructions from the battery charger manufacturer.
• Provide good ventilation.
• Never attempt to charge a battery that has frozen electrolyte.
• Always confirm correct connection between battery and charger before
turning on charger.
Battery Maintenance Batteries are perishable items which require periodic servicing. A properly
maintained battery will give long and trouble-free service.
• Keep top of the battery clean.

3-107
• Inspect and clean the cables, clamps, and hold-down bracket regularly.
Clean the cable clamps when necessary. Replace any corroded or
damaged parts. Red caps must remain installed over the positive cable
clamps.
• Check electrical system if the battery repeatedly becomes discharged or
low on electrolyte.
• If battery is not maintenance free, periodically check electrolyte level
and specific gravity.
• Use only distilled water to restore electrolyte level. Never add acid. In
freezing weather, run the engine for a few minutes immediately after
filling the battery to mix the water and the electrolyte.
Battery - Replace
WARNING: Battery post, terminals, and related accessories contain lead and
lead compounds, chemicals known to the state of California to cause cancer
and reproductive harm.
Wash hands after handling.
1. Follow Shutdown Procedure, page 2-

1, unlatch and open battery
compartment door.

2. Disconnect and remove negative
and positive cables. See "Battery
Cables," page 3-107.
3. Remove two screws (1) from battery
hold-down bracket (2).
4. Remove battery hold-down bracket
(2).
5. Lift battery and remove from compartment.
6. Install new battery.
7. Apply a light coating of petroleum jelly around base of each terminal and
connect cables. Torque retainer bolts to 27 ft-lb (36 Nm). Check that the
red cap is over the positive cable clamp.
8. Install hold-down bracket (2) and secure with the two screws (1).
3-108
Engine
As stated in this chapter Introduction, repair of the engine itself is beyond
the scope of this manual.
NOTICE: Most engine components are considered to be part of the engine

and are covered under the engine warranty. You can void this warranty by
attempting to remove or repair these systems before the warranty has
lapsed. If the warranty is still in effect, take the machine or engine to an
authorized engine service facility.
Engine Service For information or service work involving the internal parts or engine
overhaul, refer to the engine manual supplied with the machine, and/or
contact an authorized engine service facility.
Engine Maintenance Refer to the BC1000XL Brush Chipper Maintenance Manual for information
on regular engine maintenance schedules and procedures including, engine
oil filter, fuel filters, and air cleaner component replacement.
3-109
Chapter 4: Feed Roller Function
INTRODUCTION
This chapter describes the Feed Roller function and consists of the hydraulic
components that are involved in operating the feed roller, as well as the
SmartFeed controller used to regulate operation of the feed roller.
The feed roller chapter is organized into three main categories to make it
easier to locate specific information.

Feed Roller Function

• Specifications table
• Troubleshooting steps
• Hydraulic flow/pressure checks
• Pump specification table
• Component testing procedures
• Hydraulic fluid sampling

procedures
4-1
OVERVIEW
• Fluid Supply, Fluid Delivery, and Fluid Conditioning Functions

• Fluid Sampling
• Feed Roller Forward and Reverse Drive Function
• Feed Roller Stop Function
• SmartFeed Function
• Hydraulic Tank RES1 including:

• Suction Strainer SR1
• Breather Filler Cap FL2
• Return Filter FL4
• Hydraulic Pump PMP3 (Caterpillar)

• Hydraulic Pump PMP9 (Cummins, Deutz)
• Hydraulic Pump PMP10 (GM)
• Feed Roller Drive Motor MH1
• Feed Roller Control Valve Assembly AH1 including:
• Directional Control Valve DV1
• Pressure Relief Valve PV1
• Solenoid L3 (Forward Feed)
• Solenoid L4 (Reverse Feed)
• SmartFeed Controller A1
• Left Reset Hold-to-Run Switch S6
• Right Reset Hold-to-Run Switch S7
• Reverse Feed Switch S8
• Forward Feed Switch S10
• Feed Stop Switch S11
• Sensitivity Select Switch S4
• Normal Sensitivity Switch S12
• Reduced Sensitivity Switch S13
• Magnetic Pickup Sensor B3 (Caterpillar, Cummins)
4-2
Component Locations
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4-7
Reference Diagrams
Schematic representations are shown along with the text to help explain the
operation of the different functions of this chapter. Photographs are also
shown in some situations to better represent components.
Large format 11 x 17" foldouts of the complete machine hydraulic
schematics hose locations are located in the Addendum document for this
machine to be used if needed.
Listed below are the electrical and hydraulic specifications for the feed roller
components. These specifications are repeated throughout the various test
procedures in this chapter.
Hydraulic
Hydraulic oil tank RES1 capacity 7 gal (26.5 L)
Feed roller drive system pressure relief PV1 setting 2500 psi (172 bar) max.
Feed roller drive pump PMP3 (no-load) flow 1:.6875 ratio 2.72 gpm (10.3 L/min) @ 3000 rpm 100%
(Caterpillar) efficiency (no-load)
Feed roller drive pump PMP9 (no-load) flow 1:1 ratio 2.94 gpm (11.1 L/min) @ 2782 rpm 100%
(Cummins) efficiency (no-load)
Feed roller drive pump PMP9 (no-load) flow 1:1.17 ratio 3.37 gpm (12.8 L/min) @ 2730 rpm 100%
(Deutz 49 hp and 74 hp) efficiency (no-load)
Feed roller drive pump PMP10 (no-load) flow 1:.959 ratio 3.04 gpm (11.5 L/min) @ 3000 rpm 100%
(GM) efficiency (no-load)
18–22 rpm 80–100% efficiency (Caterpillar)
19–24 rpm 80–100% efficiency (Cummins)
Feed roller drive motor MH1 speed
22–27 rpm 80–100% efficiency (Deutz)
20–25 rpm 80–100% efficiency (GM)
Directional control valve DV1 coil resistance Coil L3 and L4 - 7.1 ohms @ 68°F (20°C)
4-8
THEORY OF OPERATION
Feed Roller Drive Function Components Overview
Fluid Supply/ Normal Operation:
Conditioning
• Hydraulic tank RES1
supplies the hydraulic fluid 5(6
and is sized according to the
system so that oil returning )/
65
to the tank has time to cool,
for entrapped air to float out
of the oil, and for
contaminants to settle out of
suspension. RES1 holds a
maximum of 7 gal (26.5 L) of
fluid.
• Breather filler FL2 filters air
entering and exiting the
tank.

• FL2 also incorporates a )/
dipstick to give the operator
a visual reference of the fluid level. The fluid should be between the
Filter Head Bypass marks when the machine is at rest.
• Fluid is drawn from oil tank RES1 through suction strainer SR1 to inlet
port of pump PMP3.
• Filter FL4 conditions the fluid by filtering it as it returns to the oil tank.
• The filter head contains a bypass feature (1) designed to direct fluid
straight to the oil tank if the filter element were to become plugged
during operation.
• If fluid is bypassing, the filter element should be replaced immediately to
prevent contamination from entering the system.
Fluid Delivery Normal Operation:
• Hydraulic fluid is delivered to the feed roller function by hydraulic

pump:
• Caterpillar - PMP3
• Cummins and Deutz - PMP9
• GM - PMP10
See "Component Locations," page 4-3 for pump location on the various engine
options.
4-9
Feed Control Bar Normal Operation
The operator uses the upper feed

control bar (1) to control the feed roller.
The bar has four positions:
• STOP (NEUTRAL)—the upper feed

control bar is vertical. The roller is
stopped.
• FORWARD—bar is pulled
rearwards to the first detent. The
roller turns forward, feeding
material into the cutter drum.
• E-STOP—bar is pulled fully
rearward. The roller stops.
• REVERSE—bar is pushed forward
beyond vertical. This is a spring-
loaded position. Holding the bar
forward will reverse the roller,
pushing material back out toward
the feed table, away from the cutter

drum. Once released, the bar will
spring back to the vertical STOP
(NEUTRAL) position.
The upper feed bar operates three
switches, S8, S10, and S11, that open
and close depending on the position of 6
the cam attached to the feed bar.
The lower feed stop bar (2) is also used 6

to stop the feed roller. On the
BC1000XL model, the amount of force 6
required to trip the stop bar can be set
by selecting NORMAL or REDUCED
using the stop bar sensitivity select switch S4.
REDUCED means it takes more force than NORMAL to trip the stop bar
and stop the feed roller.
European BC1000XL machines us REDUCED sensitivity for the lower feed

stop bar and NORMAL sensitivity for the side feed stop bars.
4-10
SmartFeed The following is an overview of the

Controller A1 SmartFeed Controller A1 features. For $
normal FORWARD feed operating
information, see "Feed Roller Drive
FORWARD Mode," page 4-16.
Normal Operation:
• SmartFeed refers to the controller’s

ability to forward feed into the
chipper drum based on engine
speed.
• SmartFeed is a control that outputs a feed roller command by taking
engine speed into account. Under normal conditions, controller A1
commands forward feed to pull material into the machine.
• If controller A1 detects the engine is lugging down (i.e. engine power is
not high enough to handle the amount of material fed into cutter drum),
it will stop the feed roller in order to let the engine speed recover before
it resumes forward feeding.
Droop Point

Droop point refers to the lowest desirable engine speed while chipping. If
engine lugs down to a preset “droop point”, controller will command feed
control to go to neutral until the engine recovers speed.
Droop reset is the engine RPM that controller will command feed control to
begin feeding material in again.
4-11
Droop Settings by Engine Option

Settings Caterpillar Cummins Deutz 49 hp Deutz 74 hp GM
Reset RPM 2875 2698 2550 2550 2875
Low RPM NA 2168 1600 1700 2100
Middle RPM 2725 * 2398 1950 2000 2300
High RPM NA 2549 2300 2300 2600
* Caterpillar droop setting is fixed at 2725 rpm and can not be adjusted.
Engine RPM - Droop Normal Operation:

Settings
Caterpillar and Cummins engine options use magnetic pickup sensors to
determine engine RPM.
Deutz and GM engine options use sensors integral to the engine and read by
the Deutz or GM engine ECU. These inputs are then sent to the SmartFeed
controller via CAN bus.
• Engine speed signal is received by

&XPPLQV
controller A1 on pin 1-10 from
magnetic pickup sensor B3.

• Sensor B3 outputs a pulse-width
modulated frequency signal by
reading the flywheel teeth while the
engine is running.
• The controller counts the number %
(frequency) of voltage spikes per
second. Frequency (Hz) = number of &DWHUSLOODU
teeth on the flywheel x the engine
RPM divided by 60 (to convert from
minutes to seconds).
%
4-12
SmartFeed
Controller A1 Input/
Output Pin/Wire
Color Designations
1-1
SMARTFEED
1-12
A1 SMARTFEED
260-YL-14 365-BK 1-2 441-GY
POWER A1 GROUND
Cummins OIL PRESSURE SW
Caterpillar 260C-YL 1-1

POWER (+12V)
2-1
208-WH CRANK KEY 1-3
1-3
(GREEN=CRANKING) GLOW PLUG 738-OR 731-BR 1-9
GRID HEATER
DROOP SW (3-WAY)
(GREEN=HEAT)
1-5 212-PK
FUEL SOLENOID
2-5 401-WH 1-10
ENGINE SPEED SENSOR
406-LB
(GREEN=TEMP OK)
1-5 212-PK
(GREEN=RUN)
(GREEN=HOUR METER)
3-2
765-DG (GREEN=ACTIVE) 2-1
208-WH
KEY CRANK POS
1-6
420-PU
WAIT-TO-START
1-7 985-YL-CAN
CAN HIGH
1-7 985-YL-CAN 732-LG 3-1
SENSITIVITY SW 1-8
3-7 CAN HI 986-LG-CAN
763-LB 1-8
CAN LOW

CAN LO
3-8
762-PK
(GREEN=OK)
765-DG 3-2 1-12
HOLD-TO-RUN 365A-BK
GROUND
3-9
764-LG (GREEN=OK)
3-10 1-4 PWM 4A/DIN H/L

760-TN (GREEN=UPPER
2-5
CONTROL BAR FWD) 406-LB
WATER TEMP SENSOR
2-2 PIN/AIN/DIN
3-12
761-WH (GREEN=UPPER 2-3 DIN H/L
CONTROL BAR REV) 2-6
2-4 AIN/DIN 205-YL
+5V
3-5 PWM 4A/DIN

3-1
732-LG (GREEN=NORMAL) 3-11 AIN/DIN
(RED=REDUCED) 3-3 3-3
766A-GY 763-LB
3-7 766A-GY
(GREEN=FWD FR) REDUCED SW OK FWD FEED
1-2
441-GY 3-4 762-PK 3-8
3-4
(RED=PRESSURE OK) NORM SW OK
767A-DB 767A-DB
(GREEN=REV FR) REV FEED
764-LG 3-9
E-STOP SW OK
3-6
AMBER INFO LIGHT 426-PU
401-WH 1-10 3-6 760-TN 3-10
(GREEN=RED SENS) 426-PU BAR FWD FEED
(FLASH GREEN=STOP)
(OFF=NORM SENS)
761-WH 3-12
BAR REV FEED
4-13
SMARTFEED SMARTFEED
1-2
A1 A1
260-YL 1-1 Deutz 260C-YL 1-1
GM
POWER (+12V) POWER (+12V)
1-9 1-9 1-3

731-BR 731-BR
DROOP SW (3-WAY) DROOP SW (3-WAY)
1-5 212-PK
734-GY 1-4 (GREEN=ECO SETTING 1)

(RED=ECO SETTING 2)
1-3 1-2
733-WH 733-WH
(GREEN=THROTTLE UP) (GREEN=THROTTLE UP)
1-6
734-GY 1-4 (GREEN=ECO SETTING 1)

732-LG 3-1
(RED=ECO SETTING 2)
1-7 985-YL-CAN SENSITIVITY SW 1-7 985-YL-CAN
CAN HIGH CAN HIGH
1-8 1-8
986-LG-CAN 986-LG-CAN
CAN LOW CAN LOW
3-2
765-DG HOLD-TO-RUN
1-12 1-12
732-LG 3-1
SENSITIVITY SW
365-BK 365-BK
GROUND GROUND
2-5
765-DG
3-2
HOLD-TO-RUN
2-6
+5V
3-3 3-7 3-3

3-7 766A-GY 763-LB 766A-GY
763-LB REDUCED SW OK FWD FEED REDUCED SW OK FWD FEED
3-8
762-PK 3-8
NORM SW OK 3-4 762-PK NORM SW OK 3-4
767A-DB 767A-DB
REV FEED REV FEED
3-9
764-LG 3-9
E-STOP SW OK
764-LG E-STOP SW OK
3-6 3-6
3-10
760-TN 3-10
BAR FWD FEED
760-TN BAR FWD FEED
3-12 3-12
761-WH 761-WH BAR REV FEED
BAR REV FEED
4-14
Feed Roller Drive NEUTRAL Mode

Suction Line
Pressure Line AH1 A B
Return Line
DV1
A B
L4 L3 MH1
2500 PSI
PV1
ENG1 - Caterpillar
ENG2 - Cummins P T
ENG3 - Deutz 49 hp
ENG4 - Deutz 74 hp
ENG5 - GM FL4

PMP3 - Caterpillar
PMP9 - Cummins SR1
PMP9 - Deutz 49 hp
PMP9 - Deutz 74 hp RES1
PMP10 - GM
Normal Operation:
• Refer to "Component Specifications," page 4-8 for pump displacements,

flow rates, and drive ratios.
• With engine running and feed control bar in NEUTRAL position pump
draws oil from the hydraulic tank RES1 through suction strainer SR1.
• Fluid passes through feed roller control valve manifold AH1, directional
control valve DV1, return filter FL4, and then is directed back to the oil
tank RES1.
4-15
Feed Roller Drive FORWARD Mode

Feed Roller Drive The following interlock (pre-operating) conditions must exist before
Interlocks controller A1 will allow the feed roller to move FORWARD:
• Feed bar must be in FORWARD drive position.

• Engine must be at full throttle.
• Lower feed stop bar must not be tripped.
• Hold-to-run button S6 or S7 must be pushed on machine.
From Ignition Switch S1
SMARTFEED
260C-YL 1-1
POWER (+12V)
A1
63-1 1-12
260C-YL 63-3 3-7 365-BK
763-LB REDUCED SW OK
GROUND
260C-YL 62-1
62-3
S13
762-PK 3-8
NORM SW OK
62-2 NORMAL SENS. STOP 3-3
766A-GY
260C-YL 64-1
64-3
S12 FWD FEED
764-LG 3-9
E-STOP SW OK
64-2 E-STOP
60-1
S11 3-4
260C-YL 60-3 760-TN 3-10
BAR FWD FEED REV FEED
FORWARD FEED (CAM)
60-2 S10 3-12
260C-YL 61-1 761-WH
61-3 BAR REV FEED

REVERSE FEED (CAM)
61-2
S8
767A-DB
A B
MH1
A B
DV1
L4 L3
2500 PSI
PV1 AH1
ENG1 - Caterpillar
ENG2 - Cummins P T
ENG3 - Deutz 49 hp
ENG4 - Deutz 74 hp FL4 Suction Line
ENG5 - GM Pressure Line
Return Line
Current
PMP3 - Caterpillar
PMP9 - Cummins SR1
PMP9 - Deutz 49 hp
PMP9 - Deutz 74 hp RES1
PMP10 - GM
4-16
Normal Operation
Once pre-operating conditions are met, feed drive roller will function in
FORWARD drive mode as explained below:
• When feed bar is in FORWARD feed

position, forward feed switch S10
provides power to controller A1 at
input pin 3-10.
• Controller A1 responds by providing
power from output pin
3-3 to energize solenoid L3 of
directional control valve DV1. 6
• Valve DV1 will shift to the cross-

over position to allow hydraulic flow from pump to enter feed roller drive
motor MH1 at A port.
• Drive motor MH1 will rotate in a clockwise direction, to pull material
into the chipper infeed and cutter drum area to be chipped.
• Return flow from B port of motor MH1, returns through valve DV1 and is
directed through return filter FL4 and back to the oil tank RES1.

• Feed roller valve assembly AH1 contains a relief valve PV1 set at 2500
psi (172 bar) that protects the system components from
over-pressurization. If an over-pressure condition occurs during
operation, relief valve PV1 will open, returning pump flow back through
return filter FL4 and then to the oil tank RES1.
Feed Roller Speed
The feed roller is rotated by hydraulic motor MH1. When factoring in the
efficiencies of pump PMP3 and motor MH1 (somewhere in the range of
80–100%), feed roller maximum speed at full engine RPM should be in the
range of 15–27 rpm.
4-17
Feed Roller Drive REVERSE Mode

Normal Operation
When feed bar is in REVERSE feed

position, reverse feed switch S8
provides power to controller A1 at input
pin 3-12.
Feed roller REVERSE mode works the

same way as FORWARD drive mode
except the following will change: 6
• Directional control valve DV1 will

shift to the opposite position of what is shown on schematic on page 4-16.
• REV FD SW LED on pin 3-12 of controller A1 will illuminate green.
• REV FD OUT LED on pin 3-4 of controller A1 will illuminate green.
Feed Roller Drive Stop Mode

E-Stop Switch S11 Normal Operation
The feed roller will be stopped by E-stop switch S11 when upper feed control
bar is pulled fully rearward.
When upper feed control bar is pulled

fully rearward:
6
• Voltage will not be detected at pin
3-9.
• E-STOP LED on controller A1 shuts 6
off.
6
• Controller A1 will not allow the feed
roller to FORWARD feed until the
machine is reset.
The machine can be reset by:
• Pressing one of the reset/hold-to-run switches.
4-18
Reset Hold-to-Run Normal Operation

Switches S6 (Left)
S7 (Right) The reset/hold-to-run switches
S6 S6 and S7 allow the operator to
resume chipping quickly. 6
6
When the operator presses
S7 either of the switches:
• Controller A1 interprets 12
volts at pin 3-2 as a request
to reset.
• HOLD-TO-RUN LED illuminates.
Before the controller resets, it checks that:
• There is battery voltage at pin 3-7 if the controller is in reduced

sensitivity mode, meaning that reduced sensitivity switch S13 on the
lower feed stop bar is closed.
• There is battery voltage at both pins 3-7 and 3-8 in normal sensitivity
mode, meaning that both normal sensitivity switch S12 and reduced

sensitivity switch S13 on the lower feed stop bar are closed.
• There is battery voltage at pin 3-9, meaning that the upper feed bar is
not in the STOP position.
If hold-to-run switch is held for 30 seconds or more, regardless of
position of upper feed control bar and lower feed stop bar, feed roller
stops.When pressed and held again, feed roller operates.
4-19
Sensitivity Select Normal Operation

Switch S4
Sensitivity switch S4 is used to change
the lower feed stop bar sensitivity
settings. Normal sensitivity is the
default operating mode of the machine.
Anytime the machine is started, it 6
begins in normal sensitivity mode.
With machine running in FORWARD

feed and S4 set to NORMAL
Sensitivity:
• Amber warning light E6 is OFF. 'HXW]&RQWURO3DQHO6KRZQ

• AMBER INFO LED on controller
A1 is OFF.
• REDUCED SENS LED on controller A1 is illuminated.
• NORM SENS LED on controller A1 is illuminated.
• UPPER FWD FEED LED on controller A1 is illuminated.
Sensitivity Switches Normal Operation

S12 (Normal) and
S13 (Reduced) With machine running in
FORWARD feed and S4 set to
S13 NORMAL Sensitivity and lower
feed stop bar is pushed:
S12
• Voltage will not be detected
on input pin 3-8.
6
• Voltage will not be detected (
on output pins 3-3.
• Switch S12 is open.
E6
FORWARD feed is stopped.
6
4-20
• Switch S13 voltage is ignored at pin 3-7.

• NORM SENS LED on the controller A1 shuts OFF.
• UPPER FWD FEED LED on controller A1 shuts OFF.
• Amber warning light E6 will blink fast.
With machine running in FORWARD feed and S4 set to REDUCED

Sensitivity:
• AMBER INFO LED E6 on controller A1 is ON.

• REDUCED SENS LED on controller A1 is illuminated
• NORM SENS LED on controller A1 is illuminated
• UPPER FWD FEED LED on controller A1 is illuminated
With machine running in FORWARD feed and S4 set to REDUCED

Sensitivity and lower stop feed bar is pushed:
• Voltage will not be detected on input pin 3-7.

• Voltage will not be detected on output pin 3-3.

• Switch S13 is open. FORWARD feed is stopped.
• NORM SENS LED on the controller A1 shuts OFF.
• UPPER FWD FEED LED on controller A1 shuts OFF.
• Amber info light E6 will blink fast.
TROUBLESHOOTING

type of injury.
4-21
General Guidelines When Testing and Servicing Hydraulic Components

The beginning of the troubleshooting procedures for each function in the
different chapters of the manual, instruct the service technician to first
perform the pretest inspection to look for obvious clues to malfunctions. See
"Pretest Inspection," page 4-23. If obvious signs of faults are not found, then
more exhaustive checks must be carried out.
Hydraulic Cleanliness is extremely important when replacing or repairing hydraulic

Components components. Work in a clean area. Use care to avoid allowing dirt, dust or
debris to enter the hydraulic system. Thoroughly clean outside of each
component to be reinstalled.
Avoid Oil
Contamination
Warranty claims may be 1. Remove all hydraulic pressure from hydraulic system before removing
denied if damage is any hydraulic hoses or components.
caused by contaminated
hydraulic fluid. 2. When loosening fittings in hoses where residual pressure may exist,
slowly loosen fittings until oil begins to leak. Wait for leaking to stop
before disconnecting fittings.
3. Label hoses to make it easier to connect to the correct fitting or port

when reconnecting. Plug hoses and cap fittings to keep out dirt.
4. Ensure all connections are tight and hoses are in good condition before
applying pressure to the system.
5. Take an oil sample from the system whenever replacing components or
before setting relief valves. Refer to "Hydraulic Oil Sampling," page 4-43
for oil sampling criteria.
4-22
Pretest Inspection
Before beginning any troubleshooting or testing, review information in the
General Information chapter under "Troubleshooting Guidelines," page 1-10.
In any troubleshooting situation, no matter how simple or complex the
system, always start with the basics. This ensures that the obvious is never
overlooked.
Look for the Often problems can be solved by simply doing a walk-around inspection of
Obvious the machine looking for the obvious. Do the following visual checks to
inspect for signs of failures before any exhaustive troubleshooting or testing
is performed.
Mechanical Inspect mechanical control linkages for damage, misalignment, proper

adjustment.
Electrical Inspect electrical circuits for clues to malfunction. Always check the
following items before turning on switches or running the unit.
• Look for blown fuses/tripped circuit breakers.

• Look for bare wires that could cause grounds or shorts.

• Look for broken, missing, corroded, or loose connections on the power
wires that supply electrical circuit components.
• Check all ground connections on the machine and chassis for tight
connections. Cleaning harness connections or ground connections can
often correct what appears to be a malfunctioning component.
• Check for overheated components after the unit has been stopped for
awhile. They will often smell like burned insulation.
Hydraulic Check hydraulic circuits for any failures such as:
• Broken, kinked, loose, or leaking hoses and fittings on supply, pressure,

and return to hydraulic components.
• Check level of hydraulic fluid in hydraulic tank. Low hydraulic fluid can
cause erratic behaviors in hydraulic circuits. Correct fluid level must fall
between the two lines on dipstick.
• If needed, add new hydraulic fluid that has been filtered through a
10-micron filter.
4-23
Feed Roller Drive Faults

Hydraulic Power
The three factors that transmit and control power in the feed roller
hydraulic circuit are:
• flow - governs velocity (speed) of motor MH1

• pressure - governs force and torque
• direction of flow - governs direction of motor movement
The actuator (a motor in this case) in the circuit performs the actual work
and is commonly the component that fails in the circuit. Typical motor
failures would include damaged or broken output shaft, leaky shaft seals,
too much case pressure, or internal wear causing leakage across inlet and
outlet ports.
A faulty motor can operate incorrectly in the following ways:
• incorrect speed
• incorrect force and rotation
• no movement
• movement in wrong direction
• erratic movement
• actuator creep
A failure or leak in the manifold valve assembly can also affect the output
flow to motor MH1.
Fault Indications Troubleshoot feed roller drive function based on the possible fault
indications below:
Fault Action Refer To

Feed roller drive does not work or works in only one
Test electrical circuits page 4-25
direction
Feed roller drive is sluggish or slow Test hydraulic circuit page 4-26
Feed roller drive is creating excessive heat Test hydraulic circuit page 4-41
Feed roller drive has excessive noise and/or
Test hydraulic circuit page 4-42
vibration
4-24
Electrical Circuit Before any testing is performed, refer to "Methods of Diagnosing/Testing,"

Testing page 3-84 for information on testing using the Vermeer CAN Tool (VCTool).
If not using VCTool, continue troubleshooting based on controller LED
observation. See complete electrical schematics and wire harness diagrams
in the Addendum document for this machine if needed.
LED Observation
Test input and output circuits based on what LEDs do or do not illuminate
when initiating the feed functions. Testing the circuits would involve
checking for adequate voltage, resistance, and continuity to and from the
electrical components involved in the circuit not operating normally. Refer to
"Electrical Troubleshooting," page 1-13 for detailed information on testing
electrical components using a multimeter if needed.
Below is an example of the troubleshooting approach to take if the machine

does not operate in FORWARD feed mode. Use this method when
troubleshooting the REVERSE feed, STOP feed, or any other input or output
circuits to and from controller A1.
Example: The feed roller will not work in FORWARD feed:

1. With engine running, watch LEDs on face of controller A1 as a helper
initiates a normal FORWARD feed cycle. Refer to "Feed Roller Drive
FORWARD Mode," page 4-16 to see normal operation and LED functions.
Possible Results:
• All appropriate LEDs are illuminated normally. Go to step 2. If coil
resistance is OK, the problem is in the hydraulic circuit. See "Hydraulic
Circuit Testing," page 4-26.
• All LEDs are normal except for FWD FEED OUT LED on pin 3-3 is not
illuminated. If all appropriate input LEDs are illuminated, the
problem is in the output circuit between pin 3-3 of the controller and
the solenoid coil L3 of feed roller directional control valve DV1, or the
controller itself. See step 2.
• One or more input LEDs are not illuminated. If one or more input
LEDs is not illuminated, see step 6.
2. Locate solenoid L3 and disconnect from wire harness.
4-25
3. Using a multimeter, check resistance of coil L3.

Expected result: Coil resistance should measure approximately 7.1 ± 1
ohms. If the coil resistance was not correct, replace it. If resistance is OK,
the problem is somewhere in the wire harness plugs or wires in the
harness itself from the coil back to the controller, or the controller itself
is faulty. Continue at step 4.
4. Before doing any exhaustive testing of the wire harness assembly, first
check output voltage at pin 3-3 of controller A1 to verify the controller is
OK. If adequate voltage is not present, replace controller A1. If voltage is
OK, continue at step 5.
5. Test output circuit wire harness assembly power and ground circuits
from controller A1 to coil L3 for continuity. If a short or open is found,
repair or replace faulty section of wire harness.
6. Test affected input circuit for LEDs not illuminating normally. For
example, if the FWD FD SW LED on pin 3-10 is dark, test the complete
circuit including switch S10 and power and ground circuits to and from
S10 for proper voltage, and continuity. If a short or open is found, repair
or replace faulty section of wire harness.
Hydraulic Circuit Before beginning any hydraulic troubleshooting, refer to "General Guidelines
Testing When Testing and Servicing Hydraulic Components," page 4-22.
If feed roller drive function is stalled, sluggish, or slow:
1. Check system pressure. See "Hydraulic Flow and Pressure Checks," page
4-27. If out of range, try adjusting relief valve PV9. See "Adjusting Relief
Valve PV1," page 4-30.
2. If in range, test volumetric efficiency of pump. See "Pump Efficiency
Testing," page 4-31. If pump tests OK, continue at step 3.
3. Inspect directional control valve DV1 integral to control valve manifold
assembly AH1 for contamination and/or damage. If faulty, repair or
replace DV1. See "Feed Roller Control Valve Assembly AH1," page 4-50. If
OK, continue.
4. Replace feed roller drive motor MH1. See "Hydraulic Motor MH1," page 4-
53.
4-26
Hydraulic Flow and Pressure Checks

Volumetric When a pump is worn or damaged, internal leakage increases and therefore
Efficiency the flow available to do useful work decreases. The condition of the pump
can be determined by measuring loaded flow and expressing it as a
percentage of its theoretical or design flow (volumetric efficiency).
Some fluid leaks through clearances between moving parts of pump. When
pump is working against greater pressure, this leakage increases. Leakage
collects in pump case and is drained away through the low pressure case
drain return line in an externally drained pump, or recirculated back to the
outlet of an internally drained pump.
4-27
Hydraulic System The following test equipment is needed for checking flows and pressures.
Test Equipment
• Vermeer Dual 600 psi (41 bar) 7500
psi (517 bar) pressure check gauge 1
assembly (1) or equivalent.
• Hydraulic test tool incorporating:
A flow meter (4) that will measure
the highest expected flow. See
"Component Specifications," page 4-8.
A pressure gauge (2) that will
2
measure the highest expected
pressure. See "Component 4
Specifications," page 4-8.
A needle valve (3) sized to handle the
highest expected flow. See
"Component Specifications," page 4-8.
• Miscellaneous hoses and fittings as
needed to connect to existing fittings
or hydraulic component ports.

3
• Pyrometer (5) 5
NOTICE: Ensure any hoses or fittings

that are added to the test equipment are
the same size and rating as hoses and
fittings installed in the hydraulic circuit.
Mismatched hose or fitting sizes can
result in erroneous pressure indications.
Mismatched pressure ratings can result
in leakage or personal injury.
4-28
Prior to opening a hydraulic system for any reason or installing test

equipment, review the following safety message.

type of injury.
System Pressure To check system pressure:

Check
1. Remove cap from diagnostic fitting
(1), located on feed roller control
valve AH1.

• Install Vermeer Dual 600 psi (41
bar) 7500 psi (517 bar) pressure
check gauge assembly (2) or
equivalent to fitting (1).

2. Start engine and run at full throttle
(clutch disengaged HIGH RPM). $+
Allow hydraulic oil to achieve
operating temperature.
NOTICE: Do not engage cutter drum.
3. Feed a 4x4 piece of wood into the

feed roller. The roller motor will stall when the wood presses up against
the stationary cutter drum.
4. Note pressure on gauge.
Expected result: The gauge should measure 2500 psi (172 bar). This is
the setting of the feed roller system pressure relief valve PV1.
5. If not within specification, adjust valve. See "Adjusting Relief Valve PV1,"
page 4-30. If valve cannot be adjusted, remove and inspect for damage or
contamination. See "Manifold Valve AH1 Components - Replace," page 4-
51. If OK, remove gauge and install cap (1).
4-29
Adjusting Relief Before adjusting a relief valve pressure setting, follow pressure check steps
Valve PV1 outlined on the preceding page. If it has been determined that the pressure
needs to be adjusted, follow the steps listed below to adjust it.
To adjust relief valve PV1:
1. Using an Allen wrench, remove cap 39

(1).
2. Using an Allen wrench, turn the
internal screw counterclockwise to
decrease the pressure setting,
clockwise to increase the pressure

setting. Count each turn while
making adjustments. That way it
can be returned to its original
setting if necessary.
3. Set pressure to 2500 psi (172 bar).
4. Install cap (1).
5. Remove test equipment.
If the system pressure is too low and does not respond to adjustment, the
problem is most likely not in the relief. In most cases, lack of pressure is
due to internal leakage somewhere in the system that will not allow the
system to build pressure.
If this is the case, return the relief to its original setting and begin
troubleshooting the other components of the hydraulic system. See
"Pump Efficiency Testing," page 4-31.
In some cases a relief valve can be contaminated or damaged internally.
In that case, the only way to verify its condition is to remove the relief
valve from the manifold assembly and to do a visual inspection of the
components. If any damage is found, repair/replace valve cartridge or
seals. See "Feed Roller Control Valve Assembly AH1," page 4-50 for repair
information.
4-30
Pump Efficiency High internal leakage (usually associated with pumps and motors) will
Testing cause system overheating and/or a decline in actuator speed. The amount of
leakage is influenced by four factors:
• pressure difference across internal clearances

• oil viscosity
• temperature
• size of internal clearances
Clearance-related problems are generally viscosity sensitive. Increased

leakage will be less obvious when the fluid temperature is low and increases
as the fluid temperature increases.
The most common symptoms associated with excessive pump and

motor leakage are:
• a loss of rotation speed as the fluid temperature increases

• a moderate to high increase in the operating temperature of the fluid
• feed roller stalling at low pump speed

• increase in pump case pressure which could result in shaft seal leakage
If leakage in a motor or pump approaches or exceeds 30% of the theoretical
(no-load) flow at full-load (maximum-rated pressure), it should be replaced.

type of injury.
4-31
Ensure any hoses or fittings that are added to the test equipment are the
same size and rating as hoses and fittings installed in the hydraulic circuit.
Mismatched hose or fitting sizes can result in erroneous pressure
indications. Mismatched pressure ratings can result in leakage or personal
injury.
Test Equipment Needed:
• Hydraulic test tool

incorporating: &XPPLQV(QJLQH2SWLRQ6KRZQ
• a flow meter (1) that
measures at least 5 gpm
(19 L/min)
• a pressure gauge (2) that
measures at least 2500 psi
(172 bar)
• a needle valve (3) sized to 303
handle the highest
6XFWLRQ
expected flow
/LQH
• miscellaneous fittings/test
hose

To test flow from feed roller drive

pump: 7R7DQN
NOTICE: By plumbing the needle valve and flow meter in the system
according to this test procedure, you have bypassed the system relief valve.
Therefore, be sure the needle valve is completely open before starting the
machine and be sure not to raise the pressure above 2500 psi (172 bar).
1. With the machine shut down, carefully disconnect hose (4) from
manifold valve assembly AH1.
2. Connect hose (4) to inlet of needle valve (3).
3. Connect one end of a test hose (5) to flow meter (1) and the other end to
a return port on hydraulic tank. Ensure flow meter (1) is connected so
the flow direction arrow aligns with the flow out of pump PMP3.
4. Turn out knob on the needle valve (3) to ensure it is all the way open.
5. Follow normal starting procedure to start engine.
6. Set engine RPM to full throttle.
4-32
7. Record flow at different pressures on test graph below. Turn in the

needle valve (3) to raise the pressure to values on graph and note flow
(gpm) for the pressure. Stop testing when pressure indicated reaches
2500 psi (172 bar).
8. When the test is complete, shut down and remove test equipment and
install hoses to original configuration.
9. Analyze results. See pump flow measurement results on the following
page.
Pump Test Graph -

Caterpillar
L/min GPM Volumetric

Efficiency
10.3 2.72 100%
9.6 2.5

7.6 2
70%
5.7 1.5
3.8 1
1.9 .5
0 0
PSI 0 300 600 900 1200 1500 1800 2100 2500

bar 0 21 41 62 83 103 124 145 172
4-33
Pump Flow At full displacement, the pump delivers .305 cubic inches of fluid for each
Measurement engine revolution. The pump turns at a 1: .6875 ratio between the engine
Results - Caterpillar and the pump. Therefore, 3000 rpm engine speed equals 2062.5 rpm pump
speed.
.305 cid x 2062.5 rpm = 629 231 = 2.72 gpm (10.3 L/min)
This is a gear pump, with an expected volumetric efficiency between 80–

100%. When in good condition, this pump will lose up to 20% of its flow to
internal leakage when operating under load.
2.72 gpm (10.3 L/min) x 0.80 = 2.2 gpm (8.3 L/min)
This pump is considered worn beyond its useful life when it loses 30% or
more of its flow to internal leakage under load.
The graph of the test should reveal that when unloaded, or pumping against
low pressure, even a worn-out pump produces near this amount.
Turning in the needle valve applies a “load” to the pump. The high pressure
relief valve for the feed roller drive system is set to open at 2500 psi
(172 bar). Normally, pump flow decreases gradually as the needle valve
increases the pressure.
Minimum allowable flow from this pump under full load at 2500 psi
(172 bar) is 1.9 gpm (7.2 L/min). If the pump does not produce at least this
amount, replace pump. If it produces at least 1.9 gpm (7.2 L/min) at 2500 psi
(172 bar), the pump appears to be operating within normal parameters.
However, it may need to be replaced in the near future if it is close to the
minimal flow specification.
If the pump efficiency test proved the pump to be OK, the components of
manifold valve assembly should be investigated for excessive leakage. See
"Feed Roller Control Valve Assembly AH1," page 4-50.
4-34
Pump Test Graph -

Cummins

Efficiency
11 2.94 100%
9.6 2.5
7.6 2 70%
5.7 1.5
3.8 1
1.9 .5
0 0

PSI 0 300 600 900 1200 1500 1800 2100 2500
bar 0 21 41 62 83 103 124 145 172
4-35
Measurement engine revolution. The pump turns at a 1:1 ratio between the engine and the
Results - Cummins pump. Therefore, 2782 rpm engine speed equals 2782 rpm pump speed.
.244 cid x 2782 rpm = 679 by 231 = 2.94 gpm (11 L/min)

2.94 gpm (11 L/min) x 0.80 = 2.35 gpm (8.9 L/min)
2.94 gpm (11 L/min) x 0.70 = 2 gpm (7.8 L/min)
(172 bar) is 2 gpm (7.8 L/min). If the pump does not produce at least this
amount, replace pump. If it produces at least 2 gpm (7.8 L/min) at 2500 psi
4-36
Pump Test Graph -

Deutz 49 hp and
74 hp

Efficiency
12.8 3.37 100%
9.6 2.5
70%
7.6 2
5.7 1.5
3.8 1
1.9 .5
0 0

PSI 0 300 600 900 1200 1500 1800 2100 2500
bar 0 21 41 62 83 103 124 145 172
4-37
Measurement engine revolution. The pump turns at a 1:1.17 ratio between the engine and
Results - Deutz the pump. Therefore, 2730 rpm engine speed equals 3194 rpm pump speed.
49 hp and 74 hp
.244 cid x 3194 rpm = 779 by 231 = 3.37 gpm (12.8 L/min)

amount, replace pump. If it produces at least 2.4 gpm (9.1 L/min) at 2500 psi
4-38
Pump Test Graph -

GM

Efficiency
11.5 3.04 100%
9.6 2.5
7.6 2 70%
5.7 1.5
3.8 1
1.9 .5
0 0

PSI 0 300 600 900 1200 1500 1800 2100 2500
bar 0 21 41 62 83 103 124 145 172
4-39
Measurement engine revolution. The pump turns at a 1:.959 ratio between the engine and
Results - GM the pump. Therefore, 3000 rpm engine speed equals 2877 rpm pump speed.
.244 cid x 2877 rpm = 702 by 231 = 3.04 gpm (11.5 L/min)

3.04 gpm (11 L/min) x 0.70 = 2.13 gpm (8.1 L/min)
amount, replace pump. If it produces at least 2.13 gpm (8.1 L/min) at 2500
psi (172 bar), the pump appears to be operating within normal parameters.
4-40
Excessive Heat
Inefficiency in the form of heat can be expected in all hydraulic systems.
Hydraulic fluid temperatures above 180°F (82°C) damage most seal
compounds and accelerate degradation of the oil.
If high hydraulic temperature is suspected:
1. Use a pyrometer to measure the temperature of the oil in the hydraulic

tank. If using a dial thermometer, ensure it is located below the level of
the oil in tank. If high temperature is confirmed, continue.
2. Inspect fluid level in oil tank RES1.
Fluid should be visible between the
FULL and ADD marks on dipstick.
If not, filter new fluid through a 10-
)8// $''
micron filter before adding it to the
oil tank RES1. If fluid level is OK,
continue.
3. Inspect area around hydraulic tank
that may block air flow.

4. Follow hoses or drain lines upstream from the tank to try and locate the
source of the heat. The pyrometer readings should increase or maintain
temperature to the restriction, then decrease dramatically as it is moved
upstream from the restriction.
If the problem is found, refer to "Repair," page 4-46 for component repair
instructions.
5. A low setting on the high pressure relief valve, can cause heat to be
added when crossing relief valve. Perform system pressure check. See
"System Pressure Check," page 4-29.
6. Excess internal leakage in pumps or motor will add significant heat. If
nothing else is found, test pump efficiency. See "Pump Efficiency Testing,"
page 4-31.
4-41
Excessive Noise or Vibration

Noise or vibration that occurs while functions are at idle or while operating,
may come from a pump cavitating or sucking air. Another source may be a
relief valve that is faulty or set incorrectly.
If excessive noise and/or vibration occurs in hydraulic pump or relief valve:
1. Check fluid level in Hydraulic oil

tank RES1. Fluid should be visible
between FULL and ADD lines on
dipstick. If not, filter new fluid )8// $''
through a 10-micron filter before
adding it to hydraulic oil tank
RES1. If OK, continue.
Cavitation is the formation of gaseous
cavities in the liquid. Cavitation will interfere with lubrication and destroy
metal surfaces in pump. If allowed to continue, pump will ultimately fail and
contaminate entire system.
Cavitation can be caused by restricted fluid flow at the inlet of the pump or if
air is allowed to enter the inlet port of pump. The most pronounced
indication of a pump either cavitating or sucking air are high pitched
sounds. A cavitating pump will have a steady, high-pitched sound. A pump
sucking air will have somewhat of an erratic sound and aerate the oil.
2. If it is determined that excessive noise is coming from the pump,

continue with step 3. If it is determined that excessive noise is coming
from the relief valve continue with step 6.
3. Inspect suction line for restriction or collapse, loose connection, leaking
connection, or hose deterioration. Inspect pump for shaft seal leakage.
Repair or replace as necessary. Ensure mounting hardware is tight. If
nothing is found, continue.
4. Inspect tank outlet suction strainer SR1 for clogs. Suction strainer must
be totally clean. Clean or replace as necessary. Refer to the BC1000XL
Maintenance Manual for information.
5. If nothing is found, the pump may be damaged and/or worn, causing
excessive internal leakage. Perform pump efficiency test. See "Pump
Efficiency Testing," page 4-31.
A noisy high pressure relief valve will have a steady high-pitched screeching
or screaming noise.
6. If it is determined that excessive noise is coming from a relief valve as

noted above, refer to "System Pressure Check," page 4-29 for testing and
adjustment procedures.
4-42
Hydraulic Oil Sampling

Preventive Oil sampling can be performed as preventive maintenance. Analyzing the
Maintenance condition of the oil in the oil tank may head off potential future system
faults.
After Repair Once a problem is found and the required repairs have been made, inspect
condition of the oil by taking a sample before returning the machine to work.
Remove oil cap and smell hydraulic oil. The oil should have a bland or
non-descriptive odor. If the oil smells burnt or has a pungent odor, heat or
oxidation may have ruined the oil.
Draw and inspect a sample of the oil and compare it to a sample of new oil.
The fluid should appear clean, clear and amber in color. A milky haze or
smoky appearance indicates there is water in the oil. If so, replace fluid and
filter. Refer to the BC1000XL Brush Chipper Maintenance Manual for details.
Further sampling of the hydraulic oil should be performed after repairing

before start-up of a closed or open-loop circuit to determine levels of particles
of dirt and metals in the oil. Samples should be taken using an automatic,
portable particle counter which uses light dimming technique.

The particle counter must be able to display ISO codes at 4, 6, & 14-micron
levels and also be able to produce a hard copy of data. The equipment must
also be rated for at least 6000 psi (414 bar).
Using this method offers a multitude of uses and benefits which:
• verifies filter performance

• verifies pump condition
• verifies stored oil cleanliness
• verifies changing atmospheric contamination
• confirms system flushing
• helps to troubleshoot and isolate problems
• determines optimum filter replacement intervals
• identifies new filter defects
• detects high corrosive wear
• identifies abrasive wear conditions
• confirms target cleanliness levels are achieved
• verifies breather condition
• recognizes filter bypass condition
4-43
• determines new oil cleanliness

• identifies cavitation conditions
• identifies oil film failure problems
If not equipped with this type of sampling machine, oil samples can be
obtained using hydraulic sampling tools as shown on the following page.
Hydraulic Oil Sampling Tools

Samples are drawn from either the oil tank or diagnostic port location at
pump, then sealed in the bottle supplied and sent to address supplied with
kit.
Contact Vermeer Parts Distribution Center to order sampling tools or for

additional information.
Sample Gun Kit Vermeer P/N (108891001)

Kit includes pump with fitting (1) and

100 feet of 1/8" tubing (2). 2
1
Order additional tubing per foot,
Vermeer P/N 121839001.
Use sample gun kit with wear check

bottles and fluid sample hose.
4-44
Hydraulic Wear (1) Vermeer P/N for: 10-bottle case -

Check Bottles - 271935001)
Case
Hydraulic Oil (1) Vermeer P/N (104159001) attaches

Sample Hose to diagnostic ports for sampling 1
hydraulic oil directly from system.

Hydraulic oil Sampling Criteria:
• Ensure hydraulic oil is warmed to

at least 100°F (38°C). Warm oil by
running the feed roller drive.
• Engine speed must be set to low
idle.
Oil Sample To collect sample:

Collection Point
• Shut down machine.
• Draw oil sample directly from oil tank or diagnostic port on pump as
instructed in sampling kit.
4-45
Ak
REPAIR
type of injury.
Before removing or servicing hydraulic components, refer to "General

Guidelines When Testing and Servicing Hydraulic Components," page 4-22.
Hydraulic Pump PMP3 and PMP9

Remove 1. Follow Shutdown Procedure, page 2-1.
2. Open engine cover to access pump.
3
3
4
4
PMP3 PMP9
2
2
Cummins
1 Deutz 49 hp
1
Caterpillar Deutz 74 hp
3. Remove hoses (1). Plug hoses and cap fittings (2).

4. Remove hardware (3), pump, and O-ring or gasket (4).
Install Install new O-ring or gasket (4) between engine block and pump
when replacing pump.
4-46
Reverse removal procedure to install new pump:
• Transfer fittings to new pump if reusing.

• Torque fittings, hoses, and mounting bolts according to torque
specifications found in the Vermeer Industrial Dealerships Technician’s
Shop Manual.
• Perform pump start-up procedure. See "Pump Start-Up Procedure," page
4-49.
Hydraulic Pump PMP10

2. Remove hoses (1). Cap fittings (2)
and plug hoses.


GM
3. Loosen pump mounting hardware (3)
to remove belt tension. Remove belt
(4).
4. Remove pump mounting hardware
(3). Remove pump PMP10.

303
4-47
5. Remove three screws (5) from sheave

(6) and install into three threaded
holes.

6. Tighten equally to remove sheave (6)
and bushing (7) from pump.
7KUHDGHG+ROH
Install 1. Install pump PMP10 to engine

bracket using mounting hardware
(3). Do not tighten.

303
2. Install sheave (6) and bushing (7) on

pump shaft.
3. Use a straight edge align sheave (6) 6WUDLJKW(GJH
with engine sheave.
4. Tighten screws (5) equally in a
circular pattern until each screw is
torqued to 108 in-lb (12.2 Nm).

4-48
5. Install belt (4). Rotate pump in

mounting slot until belt is tensioned
to 40 lb and tighten mounting
hardware (3).
3XPS0RXQWLQJ
6ORW
6. Install fittings (2) if installing new
pump.
7. Install hoses (1).
8. Perform “Pump Start-Up Procedure,”

see below.

Pump Start-Up Procedure

1. After pump is installed, fill pump case at least half full with oil that has
been filtered through a 10-micron filter. Install all fittings and hoses and
tighten to normal torque specifications.
2. Ensure oil level in tank is between FULL and ADD marks. If not, add oil
that has been filtered through a 10-micron filter. Leave fill cap loose so
any trapped air will escape.
3. Start machine and operate feed roller function to purge the system of air.
4. Continue operating system slowly with no load until it responds fully.
5. Check oil level in tank and refill if necessary to proper level with oil that
has been filtered through a 10-micron filter.
6. Check all connections for leaks, tighten if necessary.
4-49
Feed Roller Control Valve Assembly AH1

Remove 1. Follow Shutdown Procedure, page 2-
1.
2. Access hydraulic tank RES1.

3. Remove dirt and debris from valve
and surrounding area.
4. Loosen screws (1).
5. Remove valve cover (2).
6. Label and disconnect hoses (3). Plug

hoses and cap fittings (4).

7. Remove bolts (1) attaching valve to
top of oil tank RES1. Remove valve
AH1.


$+

5(6
Install Reverse removal procedures to install:
• Transfer fittings to new valve if reusing.

• Torque fittings, hoses, and mounting nuts/bolts according to torque
specifications found in the Vermeer Industrial Dealerships Technician’s
Shop Manual.
4-50
Manifold Valve AH1 To replace directional control valve

Components - cartridge DV1:
Replace
1.
2. Clean dirt and debris from around

cartridge assembly.
3. Loosen cartridge DV1 at hex (1) by
turning counterclockwise. Remove
cartridge valve. 39
4. Inspect new cartridge to ensure no

'9
external contaminant is present.
5. Inspect manifold cavity for burrs or other irregularities which could
damage O-rings during installation.
6. Dip new cartridge in clean, filtered oil.
7. Screw cartridge in by hand until top O-ring is met, then torque to 25 ft-lb
(33.9 Nm).

To replace DV1 cartridge seals:
2
1. Remove cartridge per instructions above.
L3
2. Note orientation of O-rings and back-up washers
(3) before removing.
3. Remove old seals.
4. Apply small amount of hydraulic oil to seals and L4
install onto cartridge in the same orientation
noted in step 2.
5. Install cartridge per instructions above.
To replace solenoid coils L3/L4: 3
1. Remove nut (2) and slide coils L3 and L4 off

spool.
2. Torque nut (2) to 5 ft-lb (6.8 Nm).
4-51
To replace relief valve cartridge PV1:
1. Follow Shutdown Procedure, page 2-1.

1
2. Clean dirt and debris from around cartridge
assembly.
3. Loosen cartridge PV1 at hex (1) by turning
counterclockwise. Remove cartridge valve.
4. Inspect new cartridge to ensure no external
contaminant is present.
2
5. Inspect manifold cavity for burrs or other
irregularities which could damage O-rings during
installation.
6. Dip new cartridge in clean, filtered oil.
7. Screw cartridge in by hand until top O-ring is met, then torque to 20 ft-lb
(27.1 Nm).
To replace PV1 cartridge seals:

1. Remove cartridge per instructions above.

2. Note orientation of O-rings and back-up washers (2) before removing.
3. Remove old seals.
4. Apply small amount of hydraulic oil to seals and install onto cartridge in
the same orientation noted in step 2.
5. Install cartridge per instructions above.
4-52
Hydraulic Motor MH1

Remove To remove motor MH1:

2. Clean motor, hoses, and
surrounding area.
3. Remove hoses (4) from motor and

plug. Cap fittings (3).
4. Remove four bolts (1).
5. Slide motor (2) out of roller shaft
and remove key (5). Retain key for 0+
reuse.

Install Reverse removal procedures to install new motor.
• Transfer fittings to new motor if reusing.

• Apply anti-seize compound to hydraulic motor shaft before installing.
• Apply thread locker 242 to threads and torque hydraulic motor bolts (1)
to 81 ft-lb (110 Nm).
• Torque fittings and hoses according to torque specifications found in the
Vermeer Industrial Dealerships Technician’s Shop Manual.
Hydraulic Fluid Tank RES1

Refer to the BC1000XL Brush Chipper Maintenance Manual for all
information on replacing suction screen SR1, return filter FL4 and hydraulic
fluid in tank RES1.
4-53
Feed Roller Assembly

Remove To remove feed roller:
1. Remove bolts (1) and shield (2).

1.
3. Remove hydraulic feed roller motor.
See "Hydraulic Motor MH1," page 4-
53.
4. Rotate feed roller so lift hook hole is

orientated on top of roller.

5. Install a lifting hook (3) into feed
roller (4).
6. Remove four bolts and washers (5).
7. Using a suitable lifting device
capable of supporting 400 lb (181
kg) in conjunction with lift hook (3),
lift drum assembly (4) from
housing.
8. Place roller assembly on a suitable
workbench or floor.
9. If disassembly of the feed roller is necessary, see "Feed Roller
Disassemble," page 4-55.
Install Reverse removal procedure to install feed roller assembly:
• Torque bolts (5) to 65 ft-lb (88 Nm).
4-54
Feed Roller 1. Remove locking cover (1) from

Disassemble roller (2).
2. Slide roller shaft (3) and feed roller

carriage (4) from feed roller.
Feed Roller Reverse disassembly procedure to assemble feed roller:

Assemble
• Position square to side of feed roller.
Measure and set carriage 2.7" ± .05"
(68.6 mm ± 1.3 mm) from roller
edge to carriage edge.

• Tighten locking screws in (6)
gradually in several stages to
30 ft-lb (41 Nm) using a
diametrically opposite tightening
sequence, with the following
exception:
• Screws adjacent to slit should be
torqued one after the other.
• After installation, check torque

again.

4-55
Adjust Upper Feed Control Bar Force

For instructions on adjusting the force needed to move the upper feed control
bar, refer to the BC1000XL Brush Chipper Maintenance Manual.
Adjust Lower Feed Stop Bar Switches

For instructions on adjusting the lower feed stop bar switches, refer to the
BC1000XL Brush Chipper Maintenance Manual.
4-56
Chapter 5: Cutter Drum Drive
INTRODUCTION
This chapter describes the components involved in the cutter drum drive
function. The cutter drum is driven mechanically by the engine, cutter drum
sheaves, and the drive belt. When the belt tensioner is engaged, the engine
torque is transmitted to the cutter drum sheave through the drive belt. The
size difference of the engine sheave and cutter drum sheave causes the
cutter drum to turn slower than the engine at full throttle.
This chapter contains instructions for adjusting, removing, and installing

the components of the driveline and cutter drum assemblies. These
assemblies also include the engine sheave, cutter drum sheave, drive belt,
and belt tensioner.
Cutter Drum Drive chapter is organized into three main categories to make
it easier to locate specific information.
Cutter Drum Drive

• complete list of functions and components

• component location diagrams
• Belt Tensioner
• Sheaves and Drive Belt
• Cutter Drum

procedures
5-1
OVERVIEW
• Cutter Drum Drive Function
• Cutter Drum
• Cutter Knives
• Engine Sheave
• Cutter Drum Sheave
• Cutter Drum Drive Belt
• Belt Tensioner
Cutter Drum Drive
5-2
Component Locations
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Cutter Drum Drive

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5-3
THEORY OF OPERATION
Cutter Drum Drive
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Belt Tensioner Belt drive tensioner is engaged and disengaged by the operator manually
moving a lever. To turn the cutter drum, the belt tensioner must be engaged.
Once engaged, engine power is transmitted to the cutter drum through the
belt and sheaves.
Cutter Drum Cutter drum chips the incoming material and creates air flow to blow the
chipped material up and out the chute. The drum has two opposing
staggered blades bolted to its perimeter. On either end of the drum are air
paddles that provide air flow to flush light materials up and out of the chute.
Cutter knives installed on the cutter drum pass by the shear bar mounted to
the floor of the infeed chute. The close clearance ensures even small
diameter twigs and branches are chopped up by the blades, and not pulled
through. As the cutter drum blades wear and the shear bar wears, the
clearance between them must be adjusted. A strip of metal is provided for
use as a gauge.
5-4
The drum pockets under the knives hold chips until the pocket rotates to the
outlet of the cutter drum chamber. Centrifugal force throws the chips up and
out the chute, assisted by the flow of air caused by the air paddles.
Each of the blades are double-edged. When one edge becomes dull, the blade
can be removed and turned around to present a sharp edge to the incoming
material. Blade sharpening instructions are in the BC1000XL Brush
Chipper Maintenance Manual.
TROUBLESHOOTING
Cutter Drum Drive
The driving sheave on the engine output shaft rotates another sheave on the
cutter drum. Tension is maintained on the belt by the belt tensioner. The
driving sheave is smaller in diameter than the driven sheave; therefore,
there is more torque at the cutter drum.
To turn the cutter drum, the belt tensioner must be engaged. Once engaged,
Cutter Drum Drive

the power of the engine is transferred to the cutter drum using the sheaves
and belt. Every time the belt tensioner is engaged, the components are
subjected to considerable heat, friction, and wear. These may result in the
drive belt slipping or dragging.
Drive Belt Slipping/ As the belt wears or stretches, free travel of the belt tensioner linkage will
Dragging increase, creating the need for adjustment. Inspect drive belt for proper
tension. See "Belt Tension - Check/Adjust," page 5-8 for adjustment procedure.
Grease and oil on the belt can also cause slippage. When this occurs, locate
the leak and stop any leakage, thoroughly clean the belt and components.
Drive Belt/Sheave The sheaves and drive belt

Contacting
Wear transmit power through friction Surfaces
of the sides of the vee of the belts Belt or Sheave
with the sides of the vee in the Normal Worn Out
sheave. The belt does not make
contact with the bottom of the
vee in the sheave.
5-5
On a relatively new belt and sheave in good condition, the walls of each vee
in the sheave will be polished, but the bottom of the vee and the tops of the
ridges between the vees will not be polished.
Since the chipper works in an environment with a lot Straightedge

of abrasive dust in the air, the walls of the vees on the
sheaves may be subject to greater than normal wear.
Always inspect the side of the vee with a straightedge
or belt gauge. If the wall is dished out more than 1/
32" (1 mm), replace the sheave.
Sheave Alignment
If the belt is wearing out before its expected life,

inspect the sheaves for wear, and proper alignment.
To inspect sheaves:
Sheave Groove Gauge
1. Open belt shield and remove belt as described on
page 5-7. Check alignment of sheaves using a long sturdy straight edge
or a laser alignment tool.
Cutter Drum Drive
Ensure the sheaves are mounted correctly on their shafts and do not
wobble as the sheave rotates.
Any wobble will be plainly visible. This misalignment is usually due to

uneven tightening of the bolts that hold the sheave to the hub.
2. If not aligned, or worn, loosen or remove the sheaves and install them
correctly or replace if necessary. See "Sheaves and Bushings," page 5-14.
Cutter Drum Anytime the belt is removed, take the opportunity to grab the sheave on the
cutter drum shaft and attempt to shake it. If you feel any play in the cutter
drum shaft bearings, replace them. Any radial play or axial play means the
bearing is about to fail.
The clearance between the drum housing walls and the drum, and more
critically, between the cutter drum blades and the shear bar, do not allow for
any movement of the cutter drum shaft.
Replacement of the drum bearings, blades and the shear bar is covered in
"Cutter Drum," page 5-9.
5-6
REPAIR
WARNING: Moving parts can crush fingers.
Close all shields before starting.
Drive Belt
Remove/Replace 1. Follow Shutdown Procedure, page 2-1.
2. Remove mounting bolts (1) and front panel of belt shield (2).
Cutter Drum Drive

3. Loosen lower belt support bracket and bolts (3).

5-7
4. Press down on bottom side of belt and remove it from grooves on sheave.
If belt is difficult to remove, turnbuckle may require loosening. Retighten
turnbuckle after adjusting belt tension. See below.
Install 1. Install new belt onto sheaves.
2. Tension drive belt according to instructions. See below.
3. Adjust top panel (4) 1/8" (3 mm) above engaged belt. Tighten panel bolts.
NOTICE: Ensure belt does not contact the top panel (4).
4. Adjust lower support bracket (3) 1/8" (3 mm) below engaged belt.
Tighten support bracket bolts.
5. Install front panel of belt shield (2). Tighten panel bolts (1).
Belt Tension - Proper tension is important for longer life and proper machine operation. If
Check/Adjust the belts are excessively tight, drive sheave bearing failure or cutter drum
bearing failure may occur. If the belts are too loose, slippage will occur.
Cutter Drum Drive
To check belt tension:
1. Move clutch handle (1) to

engaged position.

2. Set a torque wrench (2) to
125 ft-lb (170 Nm), and
attach wrench to clutch cable
pivot (3).
3. Adjust linkage by rotating
turnbuckle (4) until clutch
handle (1) just reaches the
bottom of detent slot when
applying 125 ft-lb (170 Nm)
force using torque wrench.
4. Tighten jam nuts (5) on
turnbuckle assembly.

5-8
Cutter Drum
Cutter Drum Drive

2. Remove cutter drum drive
belt, see page 5-7.
3. Secure chute assembly (1)
with a suitable lifting device.
4. Remove mounting bolts and
chip chute assembly (1).

5. Remove cutter drum sheave
and hub assembly. See page
5-14.

6. Remove bolt (2) and end cap
(3) from drum shaft.

7. Remove four bolts and
washers (4) securing each
bearing (5).
8. Loosen Allen screws in bearing collars and remove both left and right
bearings (5).
5-9
9. Attach suitable straps or chains around both sides of drum shaft and
attach to lifting device capable of lifting 1600 lb (726 kg).
10. Lift cutter drum (6) out of cutter housing.
11. Inspect cutter drum, as described below. For shaft removal procedure,
see page 5-11.
Install Reverse steps 1 through 11 in the cutter drum removal section to install the
drum into machine.
• Degrease cutter shaft area where bearings install. Degrease inside

diameter of bearings (5).
• Ensure bearings and shaft are approximately 70°F (21°C).
• Apply a bead of retaining compound 680 all the way around shaft where
bearing starts to go on. Slide and twist bearings into correct position.
• Apply thread locker 242 to all bolts (4) that go through bearing flanges
and torque to 196 ft-lb (266 Nm).
• Apply thread locker 242 to Allen screws in bearing collars then torque to
38 ft-lb (51.5 Nm).
• Apply thread locker 242 to bolt (2) securing end cap (3) then tighten.
Cutter Drum Drive
NOTICE: Do not use an impact wrench to install bolts into bearing flanges.
• After installing the cutter drum, grease bearings and adjust the shear
bar, as described in the BC1000XL Maintenance Manual.
Cutter Drum - The cutter drum must be free of any

Inspect damage. Thoroughly clean and inspect
the following:
• Air Paddles—Inspect air paddles

(1) and their gussets (2) for
cracking and deformation.
• Edge Welds—Inspect entire drum
for cracks in the welds where the
drum sides are joined to the drum.
Use a mirror to aid in this

inspection.
• Pockets—Closely inspect the area
in and around knife mount and
pockets (3) for damage or cracks.
• Cutter Drum Surface—Inspect drum surface (4) for cracks that may
begin at the pockets and migrate outward.
If any drum damage or cracks are found, replace the cutter drum.
5-10
Cutter Drum Shaft -

Remove
Cutter Drum Drive

Refer to the diagram above to see how the drum is assembled to the shaft.
1. To remove shaft (1) from the drum (2), remove all bolts from locking
collar assemblies (3), then screw 4 bolts into threaded holes in each
locking collar.
2. Tighten four screws sequentially to force the tapered elements of the
locking collars away from the ring in the drum and from the shaft.
3. Cushion the end of the shaft with a wooden block and tap the tapered
end of the shaft to drive it from the locking collars and drum.
4. Inspect shaft (1). Replace if damaged.
5-11
Install NOTICE: Do not use impact wrenches when installing locking collars.

Cutter Drum Drive
1. Ensure all surfaces are clean. Apply a light coat of oil to the mating
surfaces of the shaft (1) and the collars (2) and (3).
2. Position shaft (1) through ends of drum.
3. Loosen all screws in lock collars two full turns and lightly oil the threads
of the screws.
4. Orient collar assembly (2) as shown and slide assembly onto shaft. The
collar will slide up to a raised ring on the shaft and stop.
5. Apply thread locker 242 to last 4–5 threads of screws. Ensure thread
locker does not get on drum shaft, hubs, or tapers of locking device.
6. Tighten the screws one quarter turn at a time in a clockwise sequence to
snug down the locking collar screws.
5-12
7. Orient other locking collar assembly (3) as shown and slide it over the
tapered end until in nests in the ring in the drum.
8. Apply thread locker 242 to last 4–5 threads of screws. Ensure thread
locker does not get on drum shaft, hubs, or tapers of locking device.
9. Hand-tighten screws one quarter turn at a time in a clockwise sequence,
to snug down the locking collar screws.
10. Torque all screws on the non-tapered end of the shaft first, then torque
all the screws in the tapered end. Torque all locking collar screws to 60
ft-lb (81 Nm).
11. Install assembled drum (see page 5-10).
Cutter Drum Drive
5-13
Sheaves and Bushings

Engine Drive Sheave If removing or replacing the engine drive sheave, refer to "Driveline
- Remove/Replace Assembly," page 5-16 for instructions.
Cutter Drum Sheave 1. Remove drive belt shields and drive belt. See page 5-7.
- Remove/Replace
2. Measure distance from outer face of hub (1) to edge of cutter drum shaft
(2). This will help with sheave alignment during reassembly.
3. Remove three bolts (3) that attach sheave to hub.
Cutter Drum Drive
NOTICE: Excessive or unequal pressure on the bolts can break the hub
flange, making removal nearly impossible without destroying the sheave.
Wedging a screwdriver into the slot on the hub can also break the hub.
If lubricants such as penetrating oil are used to remove the bolts, thoroughly
clean all lubricants off the threads in the holes and on the bolts before
threading them into the threaded holes.
5-14
4. Start bolts (3) in adjacent threaded holes in hub. Continue turning in the
bolts until hub (1) and sheave (4) separate. (Note the orientation of the
hub, sheave and key for reassembly.)
5. Remove cutter drum sheave (4).
Install Reverse removal procedure to install.
1. Check sheaves for cleanliness, damage, and

wear. Do not install damaged or worn sheaves;
replace with new ones.
2. Use a stiff brush to remove rust and dirt. Use a
soft cloth to wipe off oil and grease. Use a
sheave groove gauge to check for wear.
3. Select the proper sheave groove gauge for the Sheave Groove Gauge
sheave diameter. Insert gauge in the groove and
look for voids that indicate dishing or other uneven and abnormal wear.
An alternative method for
Like This Not This
checking for sheave groove wear is
to place a new belt in the sheave
Cutter Drum Drive

groove. Note that the top of the
belt should be flush with or
slightly above the outer diameter
of the sheave. If the belt top is
below the sheave’s outer diameter,
the groove is worn. Perform
further inspection if possible.
4. Install bushing (1) and sheave (4) with key onto shaft at points where
measurement was taken in the disassembly procedure.
5. Align drilled holes in sheave (4) with tapped holes in bushing (1). Insert
bolts and tighten 2–3 threads.
NOTICE: Do not use lubricants during assembly. Lubricants can cause
sheave breakage.
6. Alternately tighten hub bolts (3) in small equal amounts until tapers are
seated (at approximately 30 ft-lb (41 Nm) torque).
7. Check alignment of sheaves using a long sturdy straight edge or a laser
alignment tool. Ensure the sheave is mounted correctly on the shaft and
does not wobble as the sheave rotates.
Any wobble will be plainly visible. This misalignment is usually due to

uneven tightening of the bolts that hold the sheave to the hub.
8. Alternately tighten bolts (3) in small equal increments. Torque to 90 ft-lb

(122 Nm) sequentially.
5-15
9. Tension drive belt according to instructions under "Belt Tension - Check/

Adjust," page 5-8.
10. Install drive belt shields. See page 5-7.
Driveline Assembly

Cutter Drum Drive

Remove/Replace 1. Release belt tension by disengaging tensioner lever and open belt shield.
See page 5-7.
2. Loosen setscrews in collar of bearing (1).
3. Remove two bolts and nuts (2) from each side of bearing (1). Remove
bearing and spacer (3).
4. Remove three bolts and washers (4) that attach sheave (5) to hub
bushing (6).
5-16
NOTICE: Excessive or unequal pressure on the bolts can break the hub
flange, making removal nearly impossible without destroying the sheave.
Wedging a screwdriver into the slot on the hub can also break the hub.
If lubricants such as penetrating oil are used to remove the bolts, thoroughly
clean all lubricants off the threads in the holes and on the bolts before
threading them into the threaded holes.
5. Start bolts (4) in adjacent threaded holes in hub bushing (6). Continue
turning in the bolts until hub (6) and sheave (5) separate. (Note the
orientation of the hub, sheave and key (11) for reassembly.)
6. Remove sheave (5) and spacer (7).
7. Loosen setscrews in collar of bearing (8).
8. Remove two bolts and nuts (9) from each side of bearing (8). Remove
bearing.
9. Remove four bolts (12) from yoke (10). Remove yoke.
10. Remove four bolts (14) securing driveshaft to flywheel adapter (15).
Install Reverse removal procedure to install.
Cutter Drum Drive

NOTICE: Do not use lubricants during assembly. Lubricants can cause
sheave breakage.
• Apply thread locker 242 to setscrews in bearing collars (1) and (8) and
drive hub bushing (6). Torque setscrews in both bearings collars (1) and
(8) to 170 in-lb (19 Nm).
• Apply thread locker 242 to bolts (12) and (14) and torque to 35 ft-lb (47.5
Nm) in a crisscross pattern.
• Apply thread locker 271 to bolts (2) and (9) and torque to 195 ft-lb (264
Nm).
• Align drilled holes in sheave (5) with tapped holes in bushing (6) and
tighten 2–3 threads.
• Alternately tighten hub bushing bolts (4) in small equal amounts until
tapers are seated (at approximately 15 ft-lb (20 Nm) torque).
Cutter Drum Knives and Shear Bar

Refer to the BC1000XL Maintenance Manual for all information on
inspecting, adjusting, sharpening, or replacing the cutter drum knives and
shear bar.
5-17
Chapter 6: Trailer
INTRODUCTION
This chapter describes the functions and components involved in supplying
and actuating the trailer brakes, safety breakaway function, and
illuminating the trailer running lights.
The Trailer chapter is organized into four main categories to make it easier
to locate specific information.

• Component specifications table
Trailer
• Fault logic charts

• Circuit/component testing procedures

procedures
6-1
OVERVIEW
• Running Lights Function

• Trailer Brake Functions including:
• Electric Brake Function - Domestic and Australian Axles
• Hydraulic Surge Brake Function - Domestic and Australian Axles
• Mechanical Surge Brake Function - European Axles
• Safety Breakaway Function including:
• Domestic and Australian Axles
• European Axles
• Breakaway Switch S23

• Brake Electromagnetic Brake Coils L5 and L6
• Left Front Side Marker Light (Domestic) E8
Trailer
• Right Front Side Marker Light (Domestic) E9

• Left Rear Side Marker Light (Domestic) E10
• Right Rear Side Marker Light (Domestic) E11
• Right Stop/Turn/Taillight (Domestic) E12
• Left Stop/Turn/Taillight (Domestic) E13
• License Plate Light (Domestic) E14
• Left Front Side Marker Light (Australian) E15
• Right Front Side Marker Light (Australian) E16
• Left Rear Side Marker Light (Australian) E17
• Right Rear Side Marker Light (Australian) E18
• License Plate Light (Australian) E19
• Right Amber Turn light (Australian) E20
• Left Amber Turn light (Australian) E21
• Right Stop/Turn/Taillight (Australian) E22
• Left Stop/Turn/Taillight (Australian) E23
• License Plate Light (European) E24 and E34
6-2
• Left Front Clearance Light (European) E26

• Right Front Clearance Light (European) E27
• Right Stop Light (European) E28
• Right Turn Light (European) E29
• Right Fog Light (European) E30
• Left Fog Light (European) E31
• Left Turn Light (European) E32
• Left Stop Light (European) E33
Trailer
6-3
Component Locations
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/LJKW(
/HIW)URQW6LGH
0DUNHU/LJKW(
Trailer
/HIW6WRS7XUQ7DLO
/LJKW(
/LFHQVH3ODWH
/LJKW(
/HIW5HDU6LGH
0DUNHU/LJKW(
6-4
Machines (Prior to SN 22325)
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5LJKW5HDU6LGH
5LJKW)URQW6LGH 0DUNHU/LJKW(
0DUNHU/LJKW(
Trailer
/HIW)URQW6LGH
0DUNHU/LJKW( 5LJKW$PEHU7XUQ
/LJKW(
/LFHQVH3ODWH
/LJKW(
/HIW$PEHU7XUQ
/LJKW(
5LJKW6WRS7DLO/LJKW(
/HIW5HDU6LGH
0DUNHU/LJKW( /HIW6WRS7DLO/LJKW(
6-5
Machines (Starting With SN 22325 -)

Trailer
6-6
7UDLOHU/LJKWV(XURSHDQ
)RJ/LJKW(
5LJKW6WRS7DLO
5LJKW)URQW&OHDUDQFH /LJKW(
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5LJKW7XUQ/LJKW(
Trailer
/LFHQVH3ODWH /LFHQVH3ODWH
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6-7
Trailer
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6-8
Listed below are specifications for components in this chapter.
Electrical
Nominal system voltage 12 volts DC
Electromagnetic brake coils L5–L6
2.6 ohms each
resistance
Breakaway switch S23 Normally open
THEORY OF OPERATION
Running Light Functions
All running lights and electric brake functions get power and ground from
the tow vehicles 12-volt battery through the plug on the trailer wire harness.
Trailer Brake Functions
Trailer
Domestic and Australian machines may be equipped with either electric
brakes or hydraulic surge brake functions. European machines are equipped
with a mechanical surge brake function.
Domestic and Normal Operation:

Australian Axles
with Electric Brakes • Power for the brakes is provided
from the tow vehicle through the
trailer harness.
• Electric brakes on the machine are
actuated by electromagnets L5 and
L6. Current flows through these
electromagnets in the brake
assemblies. L5
L6
6-9
• Energized magnets are attracted to the rotating armature surface of the

drums. This occurs when the driver steps on the brakes. The more
current provided the stronger the braking pressure.
• Electromagnets expand the shoes of the brakes against the brake drums.
Springs pull the brake shoes away from the drum when the
electromagnets de-energize.

Australian Axles
with Hydraulic • The "surge" or "push" of the chipper
Surge Brakes toward the tow vehicle during
deceleration automatically
synchronizes the trailer brakes with
the tow vehicle brakes.
• As the chipper pushes against the
tow vehicle, the actuator telescopes
together and applies force to its
master cylinder (1), supplying
hydraulic pressure to the trailer
brakes.
• Two dampers internal to the
actuator assembly are used to prevent minor decelerations of the towing
vehicle from compressing the master cylinder.
Trailer
• When the chipper trailer slows to the speed of the towing vehicle, springs
on the brake shoes pull the shoes away from the drum and force back the
brake cylinder pistons. The oil in the brake cylinders returns to the
master cylinder.
6-10
European Axles with Normal Operation:

Mechanical Surge
Brakes • The European chipper axle brakes are mechanically operated by a surge
brake system or park brake lever. Surge braking is accomplished by the
use of an actuator located at the trailer coupler.
• When the towing vehicle slows down or stops, the momentum or “surge”
of the chipper moving toward the towing vehicle automatically applies
force to the tongue assembly on the chipper.
• As the force increases, the drawbar force increases on the deflector. The
deflector pivots, tensioning the brake rod and Bowden cable applying the
brakes.
• The more force applied to the tongue assembly of the chipper results in
more tension on the Bowden cable which applies more braking power.
Drawbar Force Drawbar Force Wheel Brake
Deflector
Breakaway Cable
Brake Rod Bowden
Clamping Force Cable
Trailer
Safety Breakaway Function
The safety breakaway function is designed to apply the trailer brakes in case
the machine were to uncouple from the tow vehicle during transport.

Australian Axles
with Electric Brakes • Safety breakaway switch
S23 installed on the trailer
tongue is normally open. It
6
closes if a tether to the
towing vehicle is pulled, as
in the case of the hitch
failing while the chipper is
being towed.
• If the breakaway switch is
closed, power from the brush
chipper battery is applied to
electric brake
electromagnets L5 and L6 to
stop the machine.
6-11

Australian Axles
with Hydraulic • On this type of brake, if the
Surge Brakes trailer uncouples from the
tow vehicle while being

transported, a chain
attached to the tow vehicle
pulls the breakaway lever
(1) from horizontal to
vertical position.
• The lever presses against
the piston of the master
cylinder, sending fluid to
extend the brake cylinders.
European Axles with Normal Operation:

Mechanical Surge
Brakes • The breakaway cable (1) is
attached to the park brake
lever (2) and to the tow
Trailer
vehicle.
• It applies the brakes by
setting the park brake if the
machine uncouples from the
tow vehicle and the cable is
pulled.
Park Brake Operation:

• The park brake applies the
brakes when the park brake lever (2) is pulled rearward over-center.
• This pulls the brake actuator cable (3), which moves the brake linings,
pressing them against the inside of the brake drums.
• This prevents the machine from moving when it is not attached to a tow
vehicle.
6-12
TROUBLESHOOTING
Running Lights Functions
Voltage to activate the trailer lights is supplied by the tow vehicle light
circuits through the trailer harness. When light functions of the tow vehicle
are actuated, the corresponding light functions of the trailer are actuated.
The ground connection accounts for approximately 50% of wiring failures.

Do not assume that because some lights are working, that the main ground
is OK. Some circuits will feed back through other circuits in an attempt to
find a ground. If lights that are not supposed to flash are flashing and so on,
it is most likely a faulty ground problem.
If tow vehicle's running lights are working properly, then the problem is
either at the socket connection or the wiring between there and the trailer
wiring. If tow vehicle lights are not working, look for blown fuses or bad
connections somewhere in the tow vehicle and correct.
1. Check ground circuit. The electrical current needs a good return path
from all the other circuits in order to allow everything to operate
properly.
2. To establish a good ground, thoroughly clean or replace the connections
Trailer
and grounding screws on both the tow vehicle and machine.
3. Ensure there is power from tow vehicle running light circuit to trailer
harness socket. With the trailer harness disconnected from tow vehicle,
test tow vehicle for power at the plug socket. Connect a test light to a
good ground and probe the appropriate contact on the tow vehicle socket.
Expected result: The socket should have power at the power pin. If so,
continue with Step 4. If no power is present, check for a blown fuse in the
tow vehicle, corrosion, or faulty connections at the socket and correct.
4. If some of the running lights are working, the trailer plug is probably
alright. If none of the trailer lights are working, and there is power at the
to vehicle socket, check the trailer harness plug. Check for damage,
corrosion, or broken pin sockets. Replace plug if necessary.
5. Check each non-operating light for a burnt out bulb, corrosion on the
bulb and terminals, or a faulty ground connection. Use an emery cloth
and sand the bulbs and terminal surfaces.
Expected result: The non-working lights should work. If not, continue.
6-13
6. Check wiring for short circuits. A short circuit can be caused by wire
with its insulation worn off exposing the bare wiring to the frame or
other metal objects. This can cause intermittent operation.
7. Carefully inspect all wires supplying power to the lights that are not
working. Replace any wires that are suspect.
8. If in doubt, unplug wire harness and check continuity of wires supplying
power and ground to the individual lights not working
Trailer Brake Functions

Most brake malfunctions can be corrected by either brake adjustments or
synchronization adjustments.
Brake The trailer brakes are designed to work in synchronization with the tow
Synchronization vehicle brakes. Axles with electric brakes need a brake controller installed
in the tow vehicle which must be set up accordingly to ensure proper
synchronization between the tow vehicle and the trailer. Refer to the brake
controller user guide for procedures to properly synchronize tow vehicle and
trailer.
Brake Adjustment Brake adjustment becomes necessary after initial break in and as brake
Trailer
shoes wear over time. Refer to the BC1000XL Maintenance Manual for
recommended mileage intervals. For brake adjustment procedures, see
"Domestic and Australian Axles with Electric and Hydraulic Brakes - Adjust,"
page 6-22 or "European Axles with Mechanical Surge Brakes - Set-Up/Adjust,"
page 6-23.
Brake Brake malfunctions that cannot be corrected by either brake adjustments or
Troubleshooting synchronization adjustments, can generally be traced to mechanical system
failure, electrical system failure, or hydraulic system failure depending on
the specific type of brakes installed.
Before doing any extensive troubleshooting, use the fault tables below as a
guide to help determine what symptoms the brake system may be
experiencing, what may have caused the brake malfunction, possible
remedies, and reference to inspecting, testing, and repair information.
6-14
Fault Table -
Domestic and
Australian Axles
Electric and
Hydraulic Brakes
Symptom Causes Remedies Refer to
Open Circuits Find & Correct page 6-19
Severe Under-Adjustment Adjust Brakes page 6-22
See Brake
Faulty Controller Test & Correct Controller User
No Brakes Guide
Short Circuits Find & Correct page 6-19
Broken or Kinked Brake Line Repair or Replace -
Troubleshoot Actuator
Malfunctioning Actuation System page 6-30
System
Grease or Oil on Magnets or page 6-28
Clean or Replace
Linings page 6-29
Clean & Correct Cause of
Corroded Connections page 6-19
Corrosion
Worn Linings or Magnets Replace page 6-28
page 6-28
Scored or Grooved Brake Drums Machine or Replace
page 6-29
See Brake
Trailer
Improper Synchronization Correct Controller User
Guide
Under-Adjustment Adjust Brakes page 6-22
Weak Brakes
page 6-28
Glazed Linings Reburnish or Replace
page 6-29
Install Correct Shoe and page 6-28
Incorrect Linings
Lining page 6-29
Frozen Master Cylinder or Wheel Recondition or Replace
page 6-30
Cylinder Pistons Cylinders, Brake Fluid
page 6-28
Excessive Drum Wear Replace
page 6-29
Trapped Air in Lines Bleed System -
Troubleshoot Actuator
Malfunctioning Actuation System page 6-30
System
6-15

page 6-22
Under-Adjustment Adjust
page 6-23
See Brake
Guide
See Brake
Locking Brakes Guide
Loose, Bent or Broken Brake page 6-28
Replace Components
Components page 6-29
page 6-28
Out-of-Round Brake Drums Machine or Replace
page 6-29
See Brake
Adjust System Resistor and
Insufficient Wheel Load Controller User
Synchronize
Guide
See Brake
Guide
Intermittent Brakes
Broken Wires Repair or Replace page 6-19
Loose Connections Find & Repair page 6-19
Faulty Ground Find & Repair page 6-19
Wrong Magnet Lead Wire Color Correct page 6-19
Incorrect Adjustment Adjust page 6-22
Trailer

Clean or Replace
Linings page 6-29
Broken Wires Find & Repair page 6-19
Bad Connections Find & Repair page 6-19
Inflate Both Tires to
Brakes Pull to One Incorrect Tire Pressure page 2-11
Required Pressure
Side
Unmatched Tires on Same Axle Match Tires on Axle
Restricted Brake Lines or Hoses Repair or Replace
Check for Stuck or Sluggish
Malfunctioning Cylinder Assembly page 6-30
Pistons
Defective or Damaged Shoe and page 6-28
Install new Shoe and Lining
Lining page 6-29
One Side Out of Adjustment Adjust page 6-22
Under-Adjustment Adjust page 6-22
See Brake
Guide
See Brake
Improper Controller Change Controller User
Harsh Brakes
Guide
See Brake
Guide
page 6-28
Grease or Fluid on Linings Replace Shoes and Linings
page 6-29
6-16

Under-Adjustment Adjust page 6-22
page 6-28
Lack of Lubrication Lubricate
page 6-29
Noisy Brakes page 6-28
Broken Brake Components Replace Component
page 6-29
page 6-28
Incorrect Brake Components Correct
page 6-29
Clean or Replace
Linings page 6-29
Out-of-Round or Cracked Brake page 6-28
Machine or Replace
Surging Brakes Drums page 6-29
See Brake
Guide
Over-Adjustment Readjust page 6-22
page 6-28
Out-of-Round Brake Drums Machine or Replace
page 6-29
page 6-28
Incorrect Brake Components Replace
page 6-29
Loose, Bent or Broken Brake page 6-28
Replace
Components page 6-29
Faulty Breakaway Switch Repair or Replace page 6-36
Trailer
Loose Wheel Bearing Adjustment Adjust
Dragging Brakes page 6-28
Bent Spindle Replace Axle
page 6-29
Replace Rubber
Improper Fluid Components and Fill With
DOT4 Fluid
Open With Compressed Air
Blocked Master Cylinder page 6-30
or Replace Cylinder
Parking Brake Cable Frozen Free Cable and Lubricate page 6-36
Improper Lining Thickness or Install New Shoes and page 6-28
Location Linings page 6-29
6-17
Fault Table - O Likely Cause

European Axles
X Most Likely Cause
Symptoms A B C D E F G H I J K L M N O P
Brakes over-heating x o o o
o o o o
Trailer failing to auto reverse o o o x
o o o o o o
Hand brake not working efficiently o o x o
o o
Brakes not working efficiently o o x o
o o o o
Brakes snatching o o o
o x o o
Trailer "snaking" o o o x o o
Trailer swerving to one side o o o o o x o
Brakes remaining on after hand brake release o o o x o o
Trailer failing to tow easily (resistance) x o o o o o o
Trailer brakes "jerky" o o o o o x o o
Causes Remedies Refer To

A - Brake Shoes Adjusted too Tight, Wheels Difficult Reset Brakes According to Reset
page 6-23
to Rotate Procedure
B - Brake Cable Sticking, Dirty, Trapped or Remove Cables, Clean, Re-Grease, Fit
Trailer
page 6-23
Corroded to Reset Procedure
Remove Hubs, Clean Brakes and
C - Brake Spring Broken or Dislodged Drums, Refit New Springs and Brake page 6-35
Shoes
Remove Hubs, Clean Brakes and
D - Brake Shoes Worn page 6-35
Drums, Replace Brake Shoes
E - Hitch Incorrectly Adjusted Follow Adjustment Procedure page 6-23
F - Cable Linkage System Incorrectly Adjusted, Remove Linkages, Cables, Rods, Clean,
page 6-23
Sticking Refit, Readjust Linkage System
G - Cable System Insufficiently Supported or Refit Flexible Supports Under Trailer to
page 6-23
Supports Broken Reduce Friction in System
See
Use Manual Stop on Over-Run Coupling
H - Reversing Vehicle or Slippery Surface BC1000XL
of Fitted
Parts Manual
Ensure Hand Brake is Fully OFF, if
Vehicle has been driven Extensively with See
I - Hand Brake Left "ON" or "Partially ON" Hand Brake ON, Remove Hubs, Check BC1000XL
Brakes and Hub Bearing, Replace if Parts Manual
Damaged
See
J - Damper Failure in Coupling Replace Damper BC1000XL
Parts Manual
6-18
Causes Remedies Refer To

See
K - Coupling Shaft Jammed or Damaged/Rusty Replace Coupling BC1000XL
Parts Manual
L - Incorrect Tongue Weight on Trailer Coupling Adjust Load for Correct Tongue Weight page 2-11
Remove Hubs/Drums, Clean away Rust,
M - Rust Formation or Hub Grease in Brake Drum page 6-35
Oil, Refit
Remove Hubs and Brakes, Clean Carrier
N - Brake Shoe Carrier Rollers Rusty, Damaged, or Shoe with Wire Brush, Grease Rollers
page 6-35
Worn with "Copperslip" or Similar Material,
Refit and Adjust
O - Brakes not Equally Adjusted on all Wheels Jack-Up Trailer and Adjust page 6-23
Check Tire Pressures and Correctly
P - Wrong Pressures page 2-11
Inflate to Correct Specification
Domestic and Most electric brake malfunctions that cannot be corrected by adjustments or
Australian Axles replacing faulty parts, can generally be traced to electrical system failure.
with Electric Brakes The most common electrical problem is low or no voltage and amperage at
- Test the brakes. Common causes of this condition are:
Trailer
• poor electrical connections
• open circuits
• insufficient wire size
• broken wires
• improperly functioning controllers
Another common electrical problem is shorted or partially shorted circuits
(indicated by abnormally high system amperage). These are occasionally the
most difficult to find. Possible causes are:
• shorted magnet coils

• defective controllers
• bare wires contacting a grounded object
All electrical troubleshooting procedures should start at the controller. Most
complaints regarding brake harshness or malfunctions are traceable to
improperly adjusted or non-functioning controllers. See the controller
manufacturer’s data for proper adjustment and testing procedures.
6-19
How to Measure Voltage:

1. To test system voltage coming from controller, hitch machine to the tow
vehicle and plug in the wire harness.
2. Start engine of tow vehicle. This will ensure a low battery will not affect
the readings.
3. Measure system voltage by using a pin probe inserted through the
insulation of the lead wires at brake magnets.
Expected result: Voltage in the system should begin with 0 volts DC. As
the controller is slowly actuated, voltage should gradually increase. 12
volt DC output at the controller should equate to approximately 12 volt
DC at each magnet.
This is referred to as modulation. No modulation would mean the

controller immediately sends out high voltage, which causes the brakes
to fully apply instead of gradually.
The threshold voltage of the controller is the voltage applied to the

brakes when controller first turns on. The lower the threshold voltage
the smoother the brakes will operate. Too high of a threshold voltage (in
excess of 2 volts DC) can cause grabby, harsh brakes.
How to Test System Amperage:

Trailer
System amperage is the current flowing in the system when all magnets are
energized. Amperage will vary in proportion to voltage. The engine of the
tow vehicle should be running with the machine connected when checking
trailer braking system.
1. Disconnect the blue wire of the tow vehicle controller, which is the output
to the brakes.
2. Connect ammeter in series into the line and unplug the trailer. If
amperage reading drops to zero by unplugging the trailer, then the short
is in the trailer.
3. Disconnect magnets at brake assemblies. If the amperage reading
remains high with all the brake magnets disconnected, the short is in the
trailer wiring.
4. Attach the ammeter in series with the disconnected power wires at each
magnet.
Expected result: Nominal system amperage at 12 volts DC with magnets
at normal operating temperatures with the controller at maximum gain,
should be approximately 3 amps at each magnet. If amperage is higher
than specification, continue.
6-20
5. Test resistance across the two wires at magnet. Resistance should

measure 3.2 ohms. If not replace magnet. If resistance is OK, continue
testing all wires and connections for continuity. Replace faulty section of
wire harness. See to replace faulty components.
6. Ensure all wires are properly connected and sealed after testing is
complete.
Domestic and Problems involving the hydraulic brakes usually involve leaking line,
Australian Axles pinched lines, or mechanical problems with the surge brake actuator on the
with Hydraulic tongue, or the brake shoes and operating components inside the brake drum.
Surge Brakes -
Inspect 1. Inspect for leaks in lines and fittings. Tighten leaky connections if loose.
Replace if tightening does not stop leak.
2. Inspect lines for pinched points. Replace line if found.
3. Check fluid level of brake reservoir on tongue, as discussed in the
Maintenance Manual. If surge brake actuator is faulty, see "Remove/
Replace," page 6-30
4. Remove wheel and hub, inspect brake components in brake drum. See .
5. Inspect wheel cylinders and repair/replace if needed.
Trailer
European Axles with Problems involving the mechanical brakes usually involve sticking, dirty,
Mechanical Surge corroded, damaged brake cables, incorrectly adjusted surge brake actuator,
Brakes - Inspect or mechanical problems with the surge brake actuator, or brake shoes and
operating components inside the brake drum.
See "Fault Table - European Axles," page 6-18 for possible symptoms, faults,
and remedies.
6-21
Brake Adjustment
Domestic and To adjust brake shoes on electric and hydraulic axles:
Australian Axles
with Electric and 1. Jack up one wheel until it
To
Hydraulic Brakes - is off the ground. Block
Adjust machine.
2. Remove dirt plug (2) in
backing plate of axle.
3. While spinning the wheel, To Loosen
turn adjuster screw (1)
1
clockwise until the wheel
has a heavy drag. Then
turn adjuster screw
counterclockwise only until
the wheel turns freely. 2
To Tighten
Rotate drum only in the
direction of forward rotation when adjusting the brakes. The adjuster
screw may be turned with a screwdriver blade or with a standard brake
adjusting tool.
4. Install dirt plug.
Trailer
5. Remove blocking and jack.

6. Repeat Steps 1–5 for the opposite brake.
6-22
European Axles with The brake system must be set-up and adjusted for correct operation when
Mechanical Surge new axle or brake components are installed or to compensate for normal
Brakes - Set-Up/ brake shoe wear.
Adjust
Preparation:
• Ensure machine is on level ground 1

and then jack up machine to raise
wheels off the ground.
• Support machine with suitable
blocking.
• Release handbrake and ensure draw
tube (1) is fully extended out of Direction of drum rotation
overrun coupling. in FORWARD direction.
General Requirements:
• Always start set-up procedure at the

wheel brakes.
• During set-up turn wheel in just the
FORWARD direction at all times.
• Ensure brake expander (2) cables (3)
Trailer
and brake rod (4) are not under
tension. If necessary, loosen brake 2
3
rod (4) at balance bar (5).
Never adjust the brakes at brake rod 4

(4) or with turnbuckle (6). These are
only for adjusting the length of the 6
brake rod.
5
Set-Up/Adjustment Procedure:
1. Turn adjuster bolt (7) located at top

of back plate, opposite cable inlet (8)
in a clockwise direction until wheel 8 7
can no longer be turned or until it
can only be turned or becomes very
hard to turn.
2. Loosen adjuster bolt (7) by turning
counterclockwise (approximately 1/2
turn) until wheel turns freely. Slight
dragging noises, which do not impede
the motion of the wheel are normal.
3. Repeat adjustment procedure on
opposite wheel/brake assembly.
6-23
4. Adjust the length of brake rod (4)

using turnbuckle (6) so that there is
neither play or tension on it. Axle
5. Firmly actuate handbrake lever (9)

repeatedly in order to re-seat
braking components. 6
3
6. Check position of cable balance bar
(5) to ensure it is perpendicular to 5
direction of travel.
4
7. Check operation of handbrake lever
(9). Over center lever resistance
begins about 10–15 mm (.4–.6 in) Handle Forward to
above over center point. Release Park Brakes
8. Ensure all hardware is tight on rods,

turnbuckle and balance bar.
9. With handbrake lever (9) released,
test brakes with tow vehicle on a
short drive to ensure proper 10
9
operation. Under normal braking a
maximum of two thirds of the overall
drawtube should be used.
Trailer
10. After road test, recheck for play on brake rods and readjust if necessary.
Readjustment of Brake System for Normal Wear:
• Readjust the brake system as needed to compensate for normal brake

lining wear. This is usually sufficiently accomplished by readjusting the
wheel brakes as outlined in steps 1 and 2.
• Check and adjust brake rod (4) if necessary, to ensure there is no play at
overrun lever (10).
6-24
Safety Breakaway Function

Testing Switch S23 The following is a simple test to check the function of the switch:
1. Pull pin (1) out of

breakaway switch S23.
2. Attempt moving the trailer 6
with the tow vehicle.
Expected result:
Substantial brake drag
should be noticed. If no
brake drag is noticed, check
brush chipper battery
condition and switch circuit.

3. Disconnect switch form wire
harness and check
continuity across the pins. If
open, replace switch. See page 6-36.
Trailer
6-25
REPAIR
Wheel Bearings - Replace/Repack
2. If attached to vehicle, raise machine and support with suitable blocking.
If unattached, chock both sides of opposite wheel and support tongue
with blocking. Raise machine and support with suitable blocking.
10
9
8
6
Trailer
5
2
1
3. Remove wheel and tire.

4. Remove dust cap (1) from brake drum (7). Straighten cotter pin (3) and
remove.
5. Remove nut (2) and washer (4). Support drum and remove outer bearing
(5).
6. Slide brake drum (7) off axle. Remove inner bearing seal, (10) and inner
bearing (9).
7. Clean and inspect seals, bearings, and race surfaces for wear or damage
and replace if necessary.
8. Install components in reverse of removal.
9. If replacing bearings, remove inner and outer bearing races (6 & 8) using
a brass drift punch to carefully tap around edges of the race.
6-26
10. Grease bearings with Vermeer LF Ultra, Shell Alvania EP2 or similar
grease.
11. When installing hub on spindle, rotate wheel while tightening nut until
drag is felt on the wheel. Back off nut one notch and install cotter pin.
12. Install wheel assembly. Torque domestic and Australian wheel nuts to 95
ft-lb (129 Nm) - 5200 lb 6-stud axles, 135 ft-lb (183 Nm) - 7000 lb
8-stud axles. Torque European axle wheel nuts to 196 ft-lb (266 Nm).
Axle - Domestic and Australian

Remove/Replace The brush chipper trailer is mounted on one torsion arm-type suspension
system axle, which is completely self-contained within the axle tube. If an
axle is damaged, it must be replaced as a single unit.
1. Ensure machine is on level

ground. Using a suitable
lifting device, raise machine
off the ground to allow
adequate room to remove
axle (1). Place blocking
Trailer
under trailer frame and
remove lifting device.
2. Remove wheel assembly
from each side of machine.
3. If equipped with electric
brakes, disconnect electric
brake connectors (not
shown) on each brake hub
from wiring harness.
4. Support axle, and loosen and
remove nuts (3) and bolts (2) from each side of machine. Lower axle to
the ground and remove from under trailer.
Install 5. Reverse removal procedures to install axle.
• Torque axle mounting nuts (3) to 196 ft-lb (266 Nm).
• Torque wheel nuts to 95 ft-lb (129 Nm) - 5200 lb 6-stud axles, 135 ft-lb
(183 Nm) - 7000 lb 8-stud axles.
6-27
Electric Brake Drum 1. If attached to tow vehicle, raise machine and support with suitable
Components - blocking. If unattached, chock both sides of opposite wheel and support
Replace tongue with blocking. Raise machine and support with suitable blocking.
Trailer
2. Remove wheel and tire assembly.

3. Remove drum assembly. See page 6-26.
4. Inspect brakes, looking for:
• bent or broken parts
• seized lever arms or shoes
• scored drums
• loose parts
• worn-out brake linings or magnets
Replace brake shoes if lining is:
• worn to within 1/16" (1.6 mm) or less
• contaminated with grease or oil
• abnormally scored or gouged
• To retain the balance of the brakes, if one brake shoe requires
replacement, replace both shoes on both wheels.
6-28
5. Disassemble brake components on one side of axle at a time.

6. Replace brake shoes or any other faulty components.
7. Repack wheel bearings if necessary. See "Wheel Bearings - Replace/
Repack," page 6-26.
8. Reverse removal procedures to install brake components using the
opposite side of axle for reference if needed.
9. Install wheel assemblies and torque wheel nuts to 95 ft-lb (129 Nm) -
5200 lb 6-stud axles, 135 ft-lb (183 Nm) - 7000 lb 8-stud axles.
10. Adjust brakes. See "Domestic and Australian Axles with Electric and
Hydraulic Brakes - Adjust," page 6-22.
Hydraulic Brake 1. If attached to tow vehicle, raise machine and support with suitable
Drum Components - blocking. If unattached, chock both sides of opposite wheel and support
2. Remove wheel and tire
assembly.
3. Remove drum assembly. See
.
Trailer
• scored drums
• loose parts
• leaking wheel cylinders
• worn-out brake linings
• contaminated with grease or fluid
6-29

Repack," page 6-26.
9. Install wheel assemblies and torque wheel nuts to 95 ft-lb (129 Nm) -
5200 lb 6-stud axles, 135 ft-lb (183 Nm) - 7000 lb 8-stud axles.
10. Adjust brakes. See "Domestic and Australian Axles with Electric and
Hydraulic Brakes - Adjust," page 6-22.
Hydraulic Surge Brake Actuator - Domestic and Australian Axles

Remove/Replace 1. Chock in front and back of both wheels.
2. Raise and support tongue.
3. Disconnect brake hose from master cylinder.
4. Remove bolts (1) and washers (2)
6 7
that attach hitch (3) to front of brake
actuator (4).
Trailer
5. Support surge brake actuator (4) and

remove bolts (5) and washers (6) 2
that attach surge brake actuator to
3
the tongue (7).
5
4
1
6. Remove cotter pins (8) and pins (9).
7. Slide front half of actuator (10) out 11
of rear half (11).
10
8
9
6-30
8. If replacing dampers (12), remove

push rod stock (13), cotter pins 14 15
(14), pins (15), rollers (16) and
dampers (12) from front half of
actuator (17).
13
16
17
12
9. If replacing master cylinder, remove

bolts (18), lock washers (19), left 18
breakaway lever lock (20), right 20
19
breakaway lever lock (21), weather seal
(22), safety lever and chain (23). 22
21
23
Trailer
10. Remove nuts (24), washers (25), and bolts
(26) that hold master cylinder in outer
case (27). Slide master cylinder forward
and remove.
24 25
29
28
27 26
11. Remove push rod assembly (28) from master cylinder (29).
6-31
12. Remove nuts (30), washers (31),

30
and bolts (32) and remove left (33) 34
and right (34) cylinder bracket 35
assemblies to master cylinder (35).
33
Reverse removal procedures to install
master cylinder.
• Torque tongue and hitch mounting 31

bolts to 180–200 ft-lb (244–271
Nm). 32
• Refer to the BC1000XL Brush
Chipper Maintenance Manual for bleeding and adjustment procedures.
Trailer
6-32
Axle - European
Remove/Replace The brush chipper trailer is mounted on one torsion arm-type suspension
system axle, which is completely self-contained within the axle tube. If an
axle is damaged, it must be replaced as a single unit.
Trailer

6-33
1. Ensure machine is on level ground. Using a suitable lifting device, raise

machine off the ground to allow adequate room to remove axle.
2. Support machine frame with suitable blocking.
3. Release handbrake.
4. Disconnect brake rod (6) at balance bar (7).
5. Remove nuts (8) at balance bar (7).
6. Remove nuts (5) on cable mount. Pull cables through mounting holes on
axle.
7. Remove cables (2) from both
brake cable inlets on drum
backing plates.
8. Remove both tire and wheel
assemblies (4).
9. Support axle with a
hydraulic jack.
10. Remove four mounting bolts
(1) and nuts (3) securing 2
axle to machine frame and
Trailer
lower axle from machine

frame.
Install Reverse removal procedure to install axle.
• Torque axle mounting nuts (3) to 196 ft-lb (266 Nm).

• Torque wheel nuts to 210 ft-lb (285 Nm).
• Adjust brakes according to instructions under "European Axles with
Mechanical Surge Brakes - Set-Up/Adjust," page 6-23.
6-34
Mechanical Brake 1. If attached to tow vehicle, raise machine and support with suitable
Drum Components - blocking. If unattached, chock both sides of opposite wheel and support
2. Remove wheel and tire assembly.

3. Remove drum assembly. See page 6-26.
Trailer
• scored drums
• loose parts
• worn-out brake linings
• contaminated with grease or fluid
Repack," page 6-26.
6-35

• Install wheel assemblies and torque wheel nuts to 210 ft-lb (285 Nm).
• Adjust brakes. See "European Axles with Mechanical Surge Brakes - Set-
Up/Adjust," page 6-23.
Breakaway Switch S23

Remove/Replace 1. Remove bolt and nut (1) and
remove old switch. Pull off or
clip off old connectors if
attached to trailer harness.
2. Strip wires as needed. The
wires each need 1/4" (6 mm)
of bare wire exposed.
6
3. Cut two sleeves of insulation
approximately twice as long
as the crimp connectors.
Slide one sleeve piece onto
each wire on the switch.
Trailer
4. Slide connectors onto

exposed wire ends from switch and from harness and crimp connectors.
5. Slide insulation sleeves over crimped connectors.
6. Apply heat from a heat gun to shrink insulation sleeves down over
connectors and seal out moisture.
7. Bolt switch onto tongue. Torque nut onto bolt to 6 ft-lb (8 Nm).
8. If new switch is not equipped with new cable and wedge, install wedge
and cable from old switch into new switch (the wedge forces the two
contacts apart inside the body of the switch).
NOTICE: Breakaway switch S23 is not intended to be used as a trailer park
brake. Rapid brush chipper battery discharge will occur when switch
plunger is pulled out of switch.
6-36
BC1000XL Bruch Chipper Service Index
A electrical test equipment, 3-86

addendum electrical troubleshooting
explanation of terminology, ADD-1 general guidelines, 1-13
alternator G1, 3-25 engine, 3-55
engine cooling function
B caterpillar, 3-58
battery BT1, 3-24 cummins, 3-61
battery replace, 3-108 deutz, 3-64
battery testing, 3-87 GM, 3-67, 3-70
belt drive tensioner, 5-4 engine information display, 3-49
brake shoes replace, 6-28 engine protection interlocks, 3-80
breakaway switch S23 replace, 6-36 engine shutdown
caterpillar, 3-80
C cummins, 3-81
charging circuit deutz, 3-82
caterpillar, 3-31 GM, 3-83
cummins, 3-35 engine warranty, 1-3
deutz, 3-39 E-stop switch S11, 4-18
GM, 3-42
circuit breakers CB1 and CB2, 3-26 F
component locations feed roller drive faults, 4-24
cutter drum drive function, 5-3 feed roller drive function, 4-10
engine and electrical power electrical testing, 4-25
caterpillar, 3-8 hydraulic testing, 4-26
cummins, 3-11 feed roller stop function, 4-18
deutz, 3-14 fuel function
GM, 3-18 caterpillar, 3-58
feed roller function, 4-3 cummins, 3-62
trailer, 6-4 deutz, 3-65
cutter drum, 5-4 GM, 3-67, 3-71
cutter drum drive belt adjust, 5-8 fuel gauge E2, 3-44
cutter drum inspect, 5-10 functions/components
cutter drum knives, 5-4 cutter drum drive, 5-2
engine and electrical power, 3-2
D feed roller function, 4-2
diagrams and schematics trailer, 6-2
legend for reference designators, ADD-1 fuses F1-F3, 3-26
digital multimeter
measuring current, 1-22 G
measuring resistance, 1-21 gauge testing, 3-89
measuring voltage, 1-21 gauges
testing for continuity, 1-22 caterpillar, 3-43
cummins - deluxe, 3-45
E cummins - standard, 3-44
electric brake function, 6-9 deutz, 3-48
electrical power distribution, 3-25 engine information display, 3-49
electrical power source, 3-24 GM, 3-48
electrical schematic
caterpillar, ADD-7 H
cummins, ADD-9, ADD-10, ADD-11 hourmeter E3, 3-43
deutz, ADD-17, ADD-18, ADD-19 hydraulic connections
GM, ADD-13, ADD-14, ADD-15 avoiding oil contamination, 1-19
lighting - domestic and australian, ADD-21 avoiding trapped pressure, 1-18
lighting - european, ADD-22 connecting a needle valve, 1-20
Index BC1000XL Bruch Chipper Service
connecting flow meters, 1-19 P

connecting pressure gauges, 1-20 preheat function
using a thermometer or pyrometer, 1-20 caterpillar, 3-75
hydraulic flow and pressure checks, 4-27 cummins, 3-76
hydraulic fluid sampling, 4-43 deutz, 3-79
tools, 4-44 pretest inspection, 4-23
hydraulic pump flow pump efficiency testing, 4-31
caterpillar, 4-34 Pump Start-Up Procedure, 4-49
cummins, 4-36
deutz, 4-38 R
GM, 4-40 reference designators, 2-2
hydraulic pump start-up procedure, 4-49 relief valve PV1 adjust, 4-30
hydraulic return filter FL4, 4-9 repair
hydraulic schematic axle, 6-27
caterpillar, ADD-2 axle - european, 6-33
cummins, ADD-3 cutter drum, 5-9
deutz, ADD-5 cutter drum drive function, 5-7
GM, ADD-4 drive belt, 5-7
hose location, ADD-6 driveline assembly, 5-16
hydraulic system pressure check, 4-29 engine and electrical power, 3-104
hydraulic tank feed roller assembly, 4-54
breather FL2, 4-9 feed roller control valve assembly AH1, 4-50
hydraulic tank RES1, 4-9 feed roller drive function, 4-46
hydraulic tank suction screen SR1, 4-9 hydraulic feed roller drive motor MH1, 4-53
hydraulic test equipment, 4-28 hydraulic pump PMP10, 4-47
hydraulic testing guidelines, 4-22 hydraulic pump PMP3, 4-46
hydraulic pump PMP9, 4-46
I trailer functions, 6-26
ignition switch circuits repair guidelines
caterpillar, 3-28 personnel and lifting requirements, 1-23
cummins, 3-32 replacement parts, 1-23
deutz, 3-36 safety equipment, 1-23
GM, 3-39 shop requirements, 1-23
ignition switch S1, 3-28 torque values, 1-24
information light E6, 4-20 reset hold-to-run switches S6 and S7, 4-19
intake air/exhaust function running light functions, 6-9
caterpillar, 3-57
cummins, 3-60 S
deutz, 3-63 safety breakaway switch S23, 6-11
GM, 3-66, 3-69 safety breakaway test, 6-25
interlocks safety messages, 1-3
feed roller drive, 4-16 safety symbol explanation, 1-4
introduction sensitivity select switch S4, 4-20
cutter drum drive function, 5-1 sensitivity switch
electrical, 3-1 normal S12, 4-20
engine, 3-1 sensitivity switch S13
feed roller function, 4-1 reduced, 4-20
trailer, 6-1 shutdown procedure, 2-1
SmartFeed
M controller pin/wire designations, 4-13
machine droop point, 4-11
specifications, 2-11 SmartFeed controller A1, 4-11
machine orientation, 2-10 specifications
magnetic pickup sensor B3, 3-46, 4-12 engine, 3-22
BC1000XL Bruch Chipper Service Index
feed roller function, 4-8 fuel function - cummins, 3-94

fluid and lubricants, 2-13 fuel function - deutz, 3-95
machine, 2-11 fuel function - GM, 3-96
trailer, 6-9 guidelines, 1-10
hydraulic leakage path analysis, 1-15
T preheat function - caterpillar, 3-99
terminology preheat function - cummins, 3-101
diagrams and schematics, 1-8 preheat function - deutz, 3-103
theory of operation running lights function, 6-13
cutter drum drive function, 5-4 tools required, 1-12
engine, 3-24 trailer brakes, 6-14
feed roller function, 4-9 trailer fault-logic charts, 6-13
trailer functions, 6-9 trailer functions, 6-13
throttle function, 3-72
trailer brakes setup and adjustment, 6-23 V
trailer safety breakaway, 6-11 VCTool, 3-85
troubleshooting Vermeer warranty, 1-2
air intake/exhaust function, 3-92
common electrical problems, 1-13
W
cooling function, 3-98 warranty information, 1-2
cutter drum drive belt, 5-5 welding alert, 3-105
cutter drum drive function, 5-5 welding on machine, 3-104
electric brake function, 6-14 wheel bearings replace/repack, 6-26
engine, 3-92 wire harness
engine and electrical power, 3-83 front - caterpillar, ADD-8
excessive heat, 4-41 front - cummins, ADD-12
excessive noise or vibration, 4-42 front - deutz, ADD-20
feed roller drive function, 4-21 front - GM, ADD-16
fuel function - caterpillar, 3-93 rear, ADD-23
BC1000XL Brush Chipper Service
Revision History
Revision Date Page(s) Description
S1_00 05/06 All 1st edition manual released.
Tier 3 engine upgrade. 2nd edition manual
S2_00 06/08 All
released.
New 49 horsepower option added. 3rd
S3_00 12-09 All
edition manual released.
Miscellaneous updates as well new Tier 4
S3_01 02/12 All Interim/stage IIIB 74 horsepower engine
option added.
Miscellaneous updates, new Deutz Tier 4
Final 49 and 74 horsepower engine
S4_00 06/13 All options and GM 89 horsepower gas
engine option added, Cummins 85
horsepower engine option removed.
front cover, 2-7, 2-9, 2-11, 2-12, 3-7, 3-18,
3-19, 3-21–3-23, 3-39, 3-40, 3-41, 3-53, 3- GM propane option added, change in
S4_01 06/15 54, 3-69, 3-71, 3-96, 3-97, 3-104–3-106, Australian lighting, Optional Tree
6-2, 6-5, 6-6, ADD-14, ADD-16, back Commander Remote controls added.
cover
WARNING CALIFORNIA
Proposition 65 Warning
The engine exhaust from this product
Diesel engine exhaust and some of its
contains chemicals known to the State
constituents are known to the State
of California to cause cancer, birth
of California to cause cancer, birth
defects, or other reproductive harm.
defects, and other reproductive harm.
When operated in California, any off-road diesel vehicle may

be subject to the California Air Resources Board In-Use Off-
Road Diesel Vehicle Regulation. It therefore could be subject
to retrofit or accelerated turnover requirements to reduce
emissions of air pollutants. For more information, please
visit the California Air Resources Board website at
http://www.arb.ca.gov/msprog/ordiesel/ordiesel.htm.
Diagrams and Schematics

Legend for Reference Designators
Functional diagrams display inputs and • G—generator, alternator, battery charger,
outputs involved in system operation. oscillator
• GA—gauge (hydraulic)
Different line weights and types are used to
display electric, hydraulic, mechanical and • GB—gear box or planetary drive
airborne inputs and outputs. Dash-dot lines • HE—heat exchanger, radiator, oil cooler
indicate that devices within are included in a
• HR—hose reel
larger assembly.
• J—jack or (female connector, receptacle)
Reference designator codes are used to identify • K—relay
the types of the devices, the number after the
letter code identifies the specific device. • L—inductor such as induction coil and
solenoid
• A—assemblies, controller, modules • M—electric motor
(electrical)
• MH—hydraulic motor or rotary actuator
• ACC—accumulator
• N—regulator, voltage stabilizer
• AH—assembly such as a valve manifold or
• P—plug or (male connector)
sectional valve
• PMP—pump
• B—transducer, pulse pickup, sensors,
audible device • PV—pressure control valve (relief sequence,
counterbalance, reducing/regulating, and
• BT—battery
unloading valves)
• C—capacitor
• Q—isolator, power switch gear
• CB—circuit breaker
• R—resistor, potentiometer, rheostat
• CP—quick coupler or diagnostic port
• RES—reservoir
(hydraulic)
• S—switch
• CV—check valve
• SR—strainer
• CY—cylinder
• SV—shuttle valve
• D—delay device, storage devices, resistors,
recorders • T—transformer
• DV—directional control valve • U—modulator, converter, inverter
• E—display device, heating, signaling, • V—diode, semiconductor, transistor
lighting • W—wire, cable, harness
• ENG—engine • X—test jack
• F—protective device, fuse, arrester • Z—electrical filtering elements, equalizer,
• FL—filter limiter
• FV—flow control valves including orifices
and needle valves
Add-1
Add-2
22 RPM
100% EFF.
A B
28.33 CIR
HYDRAULIC SCHEMATIC - CATERPILLAR
A B
S2 S1
2500 PSI
P T
49 HP
@ 2800 RPM 2.72 GPM
HIGH IDLE
3000 RPM
.305 CIR
CW
1:.6875 RATIO
Hydraulic Schematic - Caterpillar
Hydraulic Schematic - Cummins BC1000XL Brush Chipper Service
HYDRAULIC SCHEMATIC - CUMMINS
S1
T
B
A
2.84 GPM
2500 PSI
CCW
.244 CIR
S2
B
100% EFF.
28.33 CIR
24 RPM
@ 2600 RPM
HIGH IDLE
2782 RPM
85 HP
Add-3
Add-4
24.3 RPM
100% EFF.
HYDRAULIC SCHEMATIC - GM
A B
28.33 CIR
A B
S2 S1
2500 PSI
P T
2.78 GPM
OUTPUT
=.959
INPUT
85 HP
@ 3000 RPM
.244 CIR
HIGH IDLE CW
3000 RPM
Hydraulic Schematic - GM
Hydraulic Schematic - Deutz
24 RPM
100% EFF.
A B
HYDRAULIC SCHEMATIC - DEUTZ
28.33 CIR
A B
S2 S1
2500 PSI
P T
2.94 GPM
RATED
2600 RPM
.244 CIR
HIGH IDLE CCW
2730 RPM
Add-5
BC1000XL Brush Chipper Service Hydraulic Hose Location
HYDRAULIC HOSE LOCATION
3UHVVXUH5HWXUQ
3UHVVXUH
'LUHFWLRQ
6XFWLRQ
5HWXUQ
Add-6
Electrical Schematic - Caterpillar
BC1000XL 49HP T4A 163672189 REV C
STARTING, ENGINE, DASH AND FEED CONTROLS
15-3A 300A-BK-6 15-3
BT1: 12V BATTERY, 580 CCA CHASSIS ENGINE BLOCK

10 + 19 300-BK-2 15-1 15-2
100-RD-2
ENGINE BLOCK
K2: GLOW PLUG RELAY R1: GLOW PLUG (39A)
CB1: CONTROLS BREAKER CB2: GLOW PLUG BREAKER 13-87
20-1 13-30
104-YL-10
20-2 103-YL-10 7-1
AUX BAT 100-RD-10 100-RD-8 8-1 BAT AUX 8-2
30A 50A
13-86 13-85 365-BK
ELECTRICAL SCHEMATIC - CATERPILLAR
101-RD-10
100-RD-2
S1: KEYSWITCH
112-OR-12
21-B 21-IGN 738-OR
112-OR-12 B I 23-2 (B+)
M1, L1: STARTER
(600A DRAWDOWN) M 24-B+ ALTERNATOR (65 AMP)
21-S
208-WH-12 G1 290-YL
S 11-E 11-F
23-1 (S) 24-D+
21-ACC V4: STARTER DIODE (6A, 600V)
(60A PULL, 16A HOLD)
365-BK-12
ACC
11-A 11-B 11-C 11-D
290-YL
201-YL-12
365-BK
R14: ALT EXCITE (200 OHM) V3: ALT DIODE (6A, 600V)
112-OR
26-A
126-H
S23: BREAKAWAY SWITCH (SHEET 2) F1: MAIN FUSE
15A
36-G B1: FUEL LEVEL
26-B
36-B+ 36-S 37-S 37-G
260-YL
E2 439-PU 365-BK
208-WH FUEL GAUGE

A1: SMARTFEED
1-12
201-YL-14
260-YL-14 1-1 365-BK
POWER GROUND
208-WH 2-1
CRANK KEY
1-3
(GREEN=HEAT)
B4: ENG TMP SW 51-1 51-2
45-1 45-2
M2
260-YL 406-LB 2-5
(GREEN=TEMP OK) FUEL PUMP MOTOR (0.7 A)
CLOSES @ 212 F
1-5 212-PK 47-1 47-2
260-YL 65-1 65-2 3-2 L2: FUEL SOL. (1.0 A)

765-DG (GREEN=ACTIVE)
A B
28-S
S6: LEFT HLD-T-RUN 28-G
365-BK
E3
HOUR METER
260-YL 66-1 66-2 765-DG
A B
S7: RIGHT HLD-T-RUN

R5: CAN TERMINATION
1-7 985-YL-CAN 40-A
260-YL 63-1 CAN HI
63-3 3-7
763-LB 40-C 120 OHM
(GREEN=OK) 1-8
63-2 S13: R. SENS SW
986-LG-CAN
CAN LO
260-YL 62-1 40-B
62-3 3-8
762-PK
(GREEN=OK) 365-BK
62-2 S12: N. SENS SW
260-YL 64-1
64-3 3-9
764-LG (GREEN=OK)
64-2 S11: E-STOP SW
72-2
260-YL 60-1 60-3 760-TN 3-10 (GREEN=UPPER
S10: FWD FD SW (CAM) CONTROL BAR FWD)
60-2
260-YL 61-1 761-WH 3-12 (GREEN=UPPER
61-3
CONTROL BAR REV)
S8: REV FD SW (CAM)
61-2
260-YL 59-A
59-C (RED=REDUCED) 3-3 68-1 68-2
S4: SENS SW 766A-GY 365-BK
7.1 OHM
L3: FWD FD OUT (3.27 A)
365-BK 46-2 46-1 441-GY 1-2
767A-DB 365-BK
7.1 OHM
B2: ENG. OIL PRES.
L4: REV FD OUT (3.27 A)
33-A
426-PU 74-I 74-O 365-BK
(FLASH GREEN=STOP)
365-BK B3: ENG SPD (OFF=NORM SENS)
E6: INFO LIGHT (AMBER)
6300 HZ @ 3000 RPM
33-B
365-BK
Add-7
BC1000XL Brush Chipper Service Wire Harness - Front Caterpillar
WIRE HARNESS - FRONT CATERPILLAR

87
6
B
J/P13 [GLOW PLUG RELAY]
ALIGN
C PN-NO-COL
11 87 103-YL-10
A
TIE WIRES IN BUNDLE 30 30 104-YL-10
P40 [CAN] 6" FROM J13 RING TERMINAL 85 365-BK (PIN-2)
J72 [REAR HARNESS] 86 738-OR (PIN-1)
10
PN-NO-COL J8-AUX [GLOW PLUG BREAKER]
P2 [SMARTFEED]
1 260-YL
2 365-BK A NO-COL
PN-NO-COL 103-YL-10 6 (12 TOTAL)
1 208-WH
4
5
6
2 C
2 PLUG 1
J40 [CAN]
1
2
3
3 PLUG B
4 PLUG 6 B+
5 406-LB PN-NO-COL J24 [ALTERNATOR]
6 PLUG A 985-YL-CAN-GOLD PIN
B 986-DG-CAN-GOLD PIN 16 6 PN-NO-COL
C 365-BK-CAN-GOLD PIN J20-2 [SYSTEM BREAKER] B+ 101-RD-10
10 D+
(SPLICE PIN C TO CAN D+ 290-YL-12
8 AND 365 WIRES) NO-COL
112-OR-12
8
28 P46 [ENG OIL PSI]
15
P1 [SMARTFEED] NO BEND 2 1
PN-NO-COL
PN-NO-COL 1-441-GY
1 260-YL-14 10 2 365-BK
2 441-GY
3 738-OR J15-2 [GROUND]
1
7
4 PLUG
J37 [FUEL SENDER] NO-COL
5 212-PK 6
6 PLUG 365-BK-12
PN-NO-COL 4 P45 [ENGINE TEMP SENSOR]
7 985-YL-CAN-GOLD PIN 5
S-439-PU 2 1
8 986-DG-CAN-GOLD PIN 7
G 365-BK 4 B+ 12 PN-NO-COL
9 PLUG
10 401-WH 8 1 260-YL
11 PLUG 2-406-LB
12 365-BK-14 16
52 7
1
J23 [STARTER]
NO BEND SPLICE 365-1 PN-NO-COL J126-H [BREAKAWAY SWITCH]

B+ 101-RD-10
SPLICE 212 1 208-WH-12 NO-COL
4
4 4 82 9 3 4 7 13 112-OR
SPLICE 112 SPLICE 365-2

SPLICE 260
6
4 J36 [FUEL GAUGE]
6 17 P33 [ENG RPM]
PN-NO-COL 4
SPLICE 208 6 B+ 260-YL 2 1 PN-NO-COL
G 365-BK 1 401-WH
S 439-PU 2 365-BK
16
10
P51 [FUEL PUMP]

P26 [CONTROLS FUSE] 4
4 7 J28 [HOUR GAUGE] 2 1 PN-NO-COL
PN-NO-COL 1 212-PK
6 7 2 365-BK
A 201-YL-14 PN-NO-COL
B 260-YL-14 G 365-BK
A B
S 212-PK
J7-1 [GLOW PLUG]
NO-COL 9 3 P47 [FUEL SHUTOFF SOL]

104-YL-10 2 1
J11 [DIODES/RESISTORS]
PN-NO-COL
PN-NO-COL 1 212-PK
A 201-YL 4 2 365-BK
B 290-YL
C 290-YL (ANODE)
D 290-YL-12 (CATHODE) 6
E 208-WH-14 (ANODE)
F 208-WH-12 (CATHODE)
A B C D E F
5 B
J21 [KEYSWITCH]
5 IGN
PN-NO-COL
5
B 112-OR-12
S IGN 201-YL-14 (DOUBLE WIRE)
S 208-WH-14
Add-8
Electrical Schematic - Cummins
BC1000XL 85HP T3 & 74HP T4i SHEET 1 OF 3 163667605 REV B

+
15-3A
300A-BK-6
ELECTRICAL SCHEMATIC - CUMMINS
100-RD-1 10 J19 300-BK-1/0

15-3
ALL INTERNALLY GROUNDED ITEMS COMMON TO ENGINE BLOCK AND FRAME

ENGINE BLOCK
CB1: CONTROLS K1: GRID HEAT RELAY R1: GRID HEATER (85HP ONLY)
BREAKER 13-87
20-1
103-RD-4 15-1 15-2
20-2 13-30
AUX BAT 100-RD-10 7-1
30A
13-86 13-85 365A-BK
101-RD-10
12-2
S1: KEYSWITCH
21-IGN 738-OR 12-1
112-OR-12
21-B
112-OR-12 B I 23-2 (B+)
21-S M 24-B 24-L

23-1 (S)
208-WH G
S
M1, L1: STARTER 24-IG
G1: ALTERNATOR (60 AMP)
365A-BK-12
(600A DRAWDOWN)
ACC (60A PULL, 15A HOLD) B1: FUEL LEVEL
E2: FUEL GAUGE
36-B+ 36-S 37-B (S) 37-C (G)
439-PU 365A-BK
gal
112-OR
126-H
201-YL 36-G
S23: BREAKAWAY SWITCH (SHEET 2)
208-WH 260A-YL
365A-BK 365A-BK

26-2AA 26-2A 26-1A 26-1AA
201-YL-12 A1: SMARTFEED
10A 10A
CB02 (C130)
1-2 441-GY 46-1 46-2
260A-YL 365A-BK
OIL PRESSURE SW
260C-YL
260C-YL 1-1
POWER (+12V) B2-ENG. OIL PRESSURE (10 PSI FALLING)
365A-BK 31-A
1-3
31-B 731-BR 1-9 738-OR
260A-YL 31-C
S2: DROOP SWITCH
1-5 212-PK 47
33-A FUEL SOLENOID
401-WH 1-10
ENGINE SPEED SENSOR
32 L2: FUEL SHUTOFF SOLENOID (1.7 A)

365A-BK
TACHOMETER
33-B 28-S
28-G 365A-BK
B3-ENG. SPEED SENSOR
E3: HOUR METER hr
208-WH 2-1
KEY CRANK POS
E25: WAIT TO START LIGHT
1-6 34-1 34-2
420-PU 365A-BK
WAIT-TO-START
72-1
R5: CAN TERMINATION

1-7 985-YL-CAN
260C-YL 59-A 40-A
CAN HIGH
59-B 732-LG 3-1
59-C 1-8
365C-BK 986-LG-CAN
S4: SENSITIVITY SELECTION CAN LOW
40-B
SHIELD
365A-BK
65-1 65-2 3-2 1-12
260C-YL 765-DG HOLD-TO-RUN 365A-BK
A B GROUND
S6: LEFT RESET/HOLD-TO-RUN

72-2
1-4 PWM 4A/DIN H/L

2-5
406-LB
A B 2-2 PIN/AIN/DIN
2-3 DIN H/L B6-ENG. WATER TEMP. SENSOR
S7: RIGHT RESET/HOLD-TO-RUN
2-4 AIN/DIN 2-6 51-1 51-2 406-LB
205-YL t
+5V
3-5 PWM 4A/DIN

3-11 AIN/DIN
260C-YL 63-1 3-3
63-3 3-7 766A-GY 68-1 68-2 365C-BK
63-2 S13: REDUCED SENS. STOP 3.27 A
260C-YL 62-3
762-PK 3-8
NORM SW OK 3-4 70-1 70-2
S12: NORMAL SENS. STOP 767A-DB 365C-BK
62-2 REV FEED
260C-YL 64-1 3.27 A
64-3 3-9
764-LG E-STOP SW OK L4: REVERSE FEED SOLENOID
64-2 3-6
S11: E-STOP 426-PU 74-I 74-O 365C-BK
AMBER INFO LIGHT
60-1 60-3 760-TN 3-10
260C-YL BAR FWD FEED
E6: AMBER INFO LIGHT
S10: FORWARD FEED (CAM)
60-2
61-1 761-WH 3-12
61-2
Add-9
Add-10
163667605 REV B
BC1000XL 85HP T3 & 74HP T4i SHEET 2 OF 3

DELUXE GAUGE OPTION
DELUXE GAUGE OPTION (SEE SHEET 1 FOR CONNECTIONS)):

REPLACE GA1: FUEL GAUGE AND GA2: HOUR GAUGE

WITH GA3: 4-IN-1 GAUGE AND GA4: TACHOMETER/HOUR GAUGE
REUSE RING TERMINAL #'S 28 AND 36 FROM MAIN HARNESS
GA3: 4-IN-1 GAUGE
2 36-S (B) 439-PU
7 1 27-1 442-GY
48
gal psi B4: ENG. OIL
PRESSURE SENSOR
3 36-B+ (B) 260 YL
6 36-G (B) 365A-BK
t° V
8 27-8 440-WH
49
4 27-4
B5: ENG. WATER TEMP.

BACK LIGHTING LAMP
SENSOR
GA4: TACHOMETER/HOUR GAUGE
SIG 401-WH
rpm
B+ 212-PK
42-B+ 50-S 28-S (B)
G 365A-BK
42-G 50-G 28-G (B)
hr
Electrical Schematic - Cummins
Electrical Schematic - Cummins BC1000XL Brush Chipper Service
BC1000XL 74HP T4i ONLY SHEET 3 OF 3 163667605 REV B
K1: GRID HEAT RELAY R1: GLOW PLUGS

13-87
103-RD-4
13-30
7-1
13-86 13-85 365A-BK

12-2
12-1
Add-11
BC1000XL Brush Chipper Service Wire Harness - Front Cummins
WIRE HARNESS - FRONT CUMMINS

PIN#1 PIN#2
CIRCUIT DWG.
J12 [DIODE]
12
INSTALL
J20 [30A BREAKER]
P12 [DIODE CONNECTOR]
2-112-OR-12
21 1-738-OR
2-365B-BK
P52 [ENGINE TEMP SENSOR]
1
4
3 1-205-YL
B
2-406-LB
C
P40 [CAN] 7
4
J72 [REAR HARNESS] 5 J47 [FUEL PUMP]
P2 [SMARTFEED]
1-260C-YL A
32
2-365A-BK 212-PK
1-208-WH
2-PLUG
4
5
6
C
2 J15-2 [GND]
3-PLUG 1
J40 [CAN]
1
2
3
4-PLUG B 7 365A-BK-12
5-406-LB
6-205-YL A-985-YL-GOLD PIN 4 4 2 4 6
B-986-LG-GOLD PIN
4
C-365A-BK-GOLD PIN
SPLICE 738 SPLICE 365B S-208-WH
(SPLICE CAN SHIELD TO 365A-BK) P13 [GRID HEAT RELAY]
J23 [STARTER]
5
86-738-OR 6
8 S-208-WH
8 85-365B-BK J23 [STARTER] B+-101-RD-10
28
4
6 B+-101-RD-10
4
1
6 4
52
4 3 3 16 4
7
(A) SPLICE 112

6 J126 [BREAKAWAY SWITCH]
10 J37 [FUEL SENDER]
P1 [SMARTFEED] H-112-OR
1-260C-YL S-439-PU 4 6
G-365A-BK 2 1
2-441-GY
3-738-OR SPLICE 212
4-PLUG P33 [ENG RPM]
4
5-212-PK
6-420-PU 1-401-WH
2
7-985-YL-GOLD PIN 2-365A-BK
8-986-LG-GOLD PIN 48 2 46
9-731-BR
10-401-WH SPLICE 365A SPLICE 208
11-PLUG 2
12-356A-BK 8 1
14
J36 [FUEL GAUGE]
6 J46 [ENG OIL PSI]
SPLICE 260A 6 B+-260A-YL
G-365A-BK 1-441-GY
P31 [DROOP SWITCH] 6 S-439-PU 2-365A-BK
2
A-365A-BK 4
C
B-731-BR
B
SPLICE 401
TAPE BACK TO LOOM. COVER RING TERMINAL FULLY (DOUBLE WALL).
A
C-260A-YL
C
9
MYLAR TAG J32 [TACHOMETER] J24-B [ALTERNATOR]
"DROOP SW" 4
14 4 A-401-WH 101-RD-10
10
P24 [ALTERNATOR]
4
7 J28 [HOUR GAUGE] T-PLUG
SPLICE 260C J26-2 [10A FUSE] IG-201-YL
7 L-PLUG
MYLAR TAG S-212-PK
A-201-YL G-365A-BK T IG L
"10A FUSE
REAR, CTRL" AA-260C-YL
2
1 2 J21 [IGNITION SWITCH]
SPLICE 201
5
BAT-112-OR-12
5 S-208-WH
2 IGN-201-YL-12
4 5
1 2
MYLAR TAG 5
J26-1 [10A FUSE] J34 [WAIT-TO-START LAMP]
"10A FUSE"
DASH, ENG" 2 1
A-201-YL 1-420-PU
AA-260A-YL 2-365A-BK
Add-12
BC1000XL GAS SHEET 1 OF 3 163673081 REV B

+
15-3A
100-RD-1 10 J19 300-BK-1/0 300A-BK-6
15-3
ENGINE BLOCK
CB1: CONTROLS
BREAKER
20-2 20-1 15-1 15-2
AUX BAT 100-RD-10
30A
101-RD-10
Electrical Schematic - GM
D
365-BK
S1: KEYSWITCH
21-IGN
112-OR-12
21-B
112-OR-12 B I 23-2 (B+)
21-S M 24-B 24-L

23-1 (S)
208-WH G
S
M1, L1: STARTER 24-IG
G1: ALTERNATOR (60 AMP)
365A-BK-12
(600A DRAWDOWN)
ACC (60A PULL, 15A HOLD) B1: FUEL LEVEL
E2: FUEL GAUGE
36-B+ 36-S 37-B (S) 37-C (G)
439-PU 365-BK
gal
112-OR
ELECTRICAL SCHEMATIC - GM
126-H
36-G
260A-YL
201A-YL-12
201B-YL-12
365A-BK 365-BK

28-AA 28-A 29-A 29-AA
A
A1: SMARTFEED
10A 10A
CB02 (C130)
1-2
260A-YL
260C-YL
260C-YL 1-1
POWER (+12V)
365-BK 31-C
1-3
31-B 731-BR 1-9
S2: DROOP SWITCH
1-5 212-PK
S5: ECO-IDLE SWITCH
260C-YL 34-A 1-4
365-BK 34-C (NONE=ECO-IDLE DISABLED)
28-S
28-G 365-BK
260C-YL E3: HOUR METER hr
C
S3: HIGH RPM SWITCH
72-2 260C-YL 25-1 25-3 733-WH 72-5 1-2
(GREEN=THROTTLE UP) E
1-6
72-1 25-2 F

260C-YL
59-B 732-LG 3-1 R5: CAN TERMINATION
SENSITIVITY SW 1-7 985-YL-CAN
59-C 40-A
365-BK CAN HIGH
40-C 120 OHM
1-8
986-LG-CAN
CAN LOW
40-B
65-1 65-2 3-2

260C-YL 765-DG HOLD-TO-RUN
A B
1-12
S6: LEFT RESET/HOLD-TO-RUN 365-BK
GROUND
72-2
260C-YL 66-1 66-2 765-DG

A B 2-5
2-6
+5V
260C-YL 63-1 3-3

63-3 3-7 766A-GY 68-1 68-2 365-BK
260C-YL 62-3
762-PK 3-8
NORM SW OK 3-4 70-1 70-2
S12: NORMAL SENS. STOP 767A-DB 365-BK
62-2 REV FEED
260C-YL 64-1 3.27 A
64-3 3-9
64-2 3-6
S11: E-STOP
60-1 60-3 760-TN 3-10
260C-YL BAR FWD FEED
60-2
61-1 761-WH 3-12
61-2
Add-13
BC1000XL Brush Chipper Service Electrical Schematic - GM
BC1000XL GAS
SHEET 2 OF 3
A2: ECU
5-A
A POWER
260A-YL 5-B CHECK ENGINE
ALT EXCITE 5-G 127-2 127-1
MIL OUT
TACH OUT
421-PU
PROPANE OPTION
S14: PROPANE SWITCH

78-B 5-H
260A-YL 78-A 757-BU
PROPANE SWITCH
M2: FUEL PUMP
5-D 47-1 47-2
FUEL PUMP +
437-PU 3.27 A
5-C
FUEL PUMP -
438-BK
E
5-F
B KEY START POS
208-WH R5: CAN TERMINATION
5-N 985-YL-CAN 40-A
40-C 120 OHM

5-P 986-LG-CAN
40-B
Add-14
Electrical Schematic - GM BC1000XL Brush Chipper Service
BC1000XL GAS 163673081 REV B
DELUXE GAUGE OPTION SHEET 3 OF 3
DELUXE GAUGE OPTION (SEE SHEET 1 FOR CONNECTIONS)):
REPLACE GA2: HOUR GAUGE

WITH GA3: CANBUS DISPLAY
USE P38
GA3: CANBUS DISPLAY
A3: CANBUS DISPLAY
260C-YL 38-1
C POWER
38-2
GROUND
365-BK
D
985-YL-CAN 38-4
F CAN HI
38-5
986-LG-CAN
E CAN LO
Add-15
BC1000XL Brush Chipper Service Wire Harness - Front GM
WIRE HARNESS - FRONT GM

P5 [ENGINE CONNECTION]
A 260A-YL
B 260A-YL
C 438-BK
A
D 437-PU
G 421-PU
H 757-BU-18
F 208-WH
N 985-YL
P 986-GN DEUTSCH
IPD-USA
J40 [CAN]
DT04-3P
A-985-YL-GOLD PIN
B-986-LG-GOLD PIN
C-PLUG
J33 [GAS HARNESS
A
C
INTERFACE]
A 800-BK-18 3
B 802-LG-18
C 803-DG-18
J72 [REAR HARNESS] J20 [30A BREAKER]
D 801-WH-18 4
P1 [CB02 CONN 1] 1-260C-YL
2-112-OR-12
1-260C-YL 2-365-BK
2-733-WH
2
3-PLUG 1 6
4-734-GY
5-PLUG J15-2 [GND]
6-758-YL 365-BK-12
7-985-YL-GOLD PIN 3
8-986-LG-GOLD PIN
9-731-BR 8
6
10-PLUG J37 [FUEL SENDER]
11-PLUG S-439-PU 36
12-365-BK 3 G-365-BK
1 4
4 6
(A)
7 36
6
10
54 4
SPLICE 112
J47 [FUEL PUMP]
1 437-PU J126 [BREAKAWAY SWITCH]
2 438-BK H-112-OR
SPLICE 365A
1
+ 5 6 J32 [FUEL MANIFOLD]
01 800-BK-18
24 MYLAR TAG 5 02 802-LG-18
P99 [REMOTE
03 803-DG-18
OPTION] 2 -
PN NO-COL 04 804-WH-18 32
01 26OC-OR
02 365-BK 24
04 758-YL
05 985-YL-18
P25 [HIGH RPM SW]
06 986-GN-18
PN NO-COL
58
38 01 260C-OR
6 1
12 03 733-WH
1 6
2 5 5 2
3 4 4 3
SPLICE 365C
SPLICE 365B SPLICE 208
X1A SPLICE 260A
SPLICE 260C
12
J36 [FUEL GAUGE] MYLAR TAG J28 [10A FUSE A]

B+-260A-YL "10A FUSE A-201A-YL
G-365-BK REAR, CTRL" AA-260C-YL
S-439-PU 3
1 2 J21 [IGNITION SWITCH]
3 5
6 4 BAT-112-OR-12
3 5 S-208-WH
IGN-201A-YL-12
5 IGN-201B-YL-12
1 2 5
4
MYLAR TAG
1 2 J29 [10A FUSE B]
"10A FUSE"
DASH, ENG" A-201B-YL
J127 [CHECK ENGINE LAMP] AA-260A-YL
1-260A-YL
2-421-PU 4
P34 [ECO-IDLE SWITCH]

PN NO-COL
B
B A A 260C-YL
7
C
B 734-GY
4 C 365-BK
C
P31 [DROOP SWITCH]

A-260A-YL 9 P38 [CANBUS DISPLAY]
B-731-BR 6
PN NO-COL
01 260C-YL
1
C-365-BK 5 2
B B A B
4 3 02 365-BK
04 985-YL-18
6
A
C
C
05 986-LG-18
C
A
P78 [PROPANE SWITCH]

C
A-260A-YL
B-757-BU
J41 [CAN]
B B A B
A-985-YL-GOLD PIN
A
C
C
B-986-LG-GOLD PIN
C C-PLUG
Add-16
Electrical Schematic - Deutz
BC1000XL(DEUTZ) SHEET 1 OF 3 163673106

CB1: CONTROLS
BREAKER
20-2 20-1 BT1: 12V BATTERY, 660 CCA MAINFRAME
AUX BAT 100-RD-10 +
ELECTRICAL SCHEMATIC - DEUTZ
15-3A
24-L 24-B 100-RD-10 10 J19 300-BK-1/0 300A-BK-6
G 15-3
G1: ALTERNATOR (60 AMP) ENGINE BLOCK
15-1 15-2
112-OR-12
30A
100
100-RD
-RD
A -1
SEE PAGE 2
F
S1: KEYSWITCH 23-2 (B+)
21-B 21-IGN SEE PAGE 2
112-OR-12 I 23-1 (S)

M
B 30-87
100-RD 30-30
M 104-RD
21-S
30-86 30-85
C D
M1, L1: STARTER
S 210-BK (600A DRAWDOWN)
214-WH
SEE PAGE 2 SEE PAGE 2 (60A PULL, 15A HOLD)
365A-BK-12
START RELAY (K3)

ACC (50A)
E2: FUEL GAUGE B1: FUEL LEVEL
208-WH 36-B+ 36-S 37-B (S) 37-C (G)
B 439-PU 365-BK
gal
112-OR
SEE PAGE 2
126-H
36-G
261-YL
201A-YL
201B-YL
365-BK 365-BK
261-YL
26-AA 26-A 27-A 27-AA
A1: SMARTFEED
10A 20A
CB02 (C130)
261-YL
A3: CANBUS DISPLAY
260-YL
260-YL 1-1 38-1
POWER (+12V) POWER
38-2
GROUND
365-BK
365-BK 31-A 38-4
31-B CAN HI
731-BR 1-9
38-5
S2: DROOP SWITCH
CAN LO
S3: HIGH RPM SWITCH

261-YL 25-1 25-3 733-WH 1-3
(GREEN=THROTTLE UP)
25-2
S5: ECO-IDLE SWITCH

261-YL 34-A 1-4
R5: CAN TERMINATION
365-BK 34-C 1-7 985-YL-CAN
(NONE=ECO-IDLE DISABLED) 41-A
CAN HIGH
1-8 120 OHM
260-YL 986-LG-CAN
G CAN LOW
41-B
72-1 S4: SENSITIVITY SELECTION

260-YL 59-A
59-B 3-1 1-12
732-LG SENSITIVITY SW
365-BK
59-C GROUND
365-BK
72-2
65-1 65-2 3-2

260-YL 765-DG HOLD-TO-RUN
A B
S6: LEFT RESET/HOLD-TO-RUN
260-YL 66-1 66-2 765-DG

A B
260-YL 63-1 3-3

63-3 3-7 766A-GY 68-1 68-2 365-BK
260-YL 62-3
762-PK 3-8
NORM SW OK 3-4 70-1 70-2
S12: NORMAL SENS. STOP 767A-DB 365-BK
62-2 REV FEED
260-YL 64-1 3.27 A
64-3 3-9
64-2 3-6
S11: E-STOP
60-1 60-3 760-TN 3-10
260-YL BAR FWD FEED
60-2
61-1 761-WH 3-12
260-YL 61-3 BAR REV FEED
61-2
Add-17
Add-18
SHEET 2 OF 3
A SEE PAGE 1 SEE PAGE 1 F
365-BK
112-OR
A2: ECU D2.2 4-2
365-BK
4-1 GROUND -
112-OR + POWER
4-4 365-BK
4-3
112-OR GROUND -
+ POWER
4-6
4-5 365-BK
112-OR + POWER GROUND -
4-61 794-BK 17-17

K
4-29
403-DB + COOLANT LVL SW
S14: COOLANT LEVEL

50-1 50-3 4-13
443-DG S COOLANT LVL SW 4-85
701-LB 17-50
OFF
50-2 EGR +
4-87
444-BK - COOLANT LVL SW 4-44 702-OR 17-46
EGR S
4-15
460-DG
CLUTCH JUMPER 365-BK
17-51
4-68
460-DG CLUTCH JUMPER
4-90
437-PU + FUEL PUMP RELAY
FUEL PUMP
RELAY (K2)
47-86 47-85 4-26

438-DG - FUEL PUMP RELAY
86 85
87A
365-BK 260-YL G
F
M 30
87
M2: FUEL PUMP

4-28
C
210-BK - START RELAY
4-73
D 214-WH + START RELAY
R2: CAN TERMINATION

4-35 42-A
B 208-WH START SIGNAL
120 OHM
42-B
R3: CAN TERMINATION

39-A
120 OHM
39-B
ENGINE DIAGNOSTIC
4-75
130-H
130-B
988-YL-CAN
S:15 H20 IN FUEL 4-53 130-G 365-BK
135-2 135-1 456-LB 4-57 989-LG-CAN 130-F 130-A
+ H2O IN FUEL
A
130-M 260A-YL
SEE PAGE 1
457-BK 4-64
- H2O IN FUEL
H
R1: CAN TERMINATION

4-54
40-A
985-YL-CAN
4-76 120 OHM
986-LG-CAN 40-B
SHEET 3 OF 3
A SEE PAGE 1 SEE PAGE 1 F
A2: ECU D2.1

17-61 775-WH 5-2 5-20 704-BR 17-48

INJECTOR 3 EGR
M
M2: EGR
17-38 774-BK 5-32 5-19 703-YL 17-47
L9: INJ1
INJECTOR 3 EGR
17-41 777-WH 5-3

INJECTOR 2
5-37 783-WH 17-14
CAMSHAFT
17-40 776-BK 5-46
SPEED
L8: INJ2
INJECTOR 2
5-53 795-WH 17-9

SHIELD
17-35 771-WH 5-16
INJECTOR 1
U n
S22: CAMSHAFT SPEED
CAMSHAFT
5-52 784-BK 17-13
17-62 770-BK 5-33 SPEED
L7: INJ3
INJECTOR 1
17-37 773-WH 5-18

INJECTOR 4 5-39 785-WH 17-15
CRANKSHAFT
SPEED
17-42 772-BK 5-48
L6: INJ4
INJECTOR 4
5-38 796-BK 17-1
SHIELD
U n
17-19 779-WH 5-4

S24: CRANKSHAFT SPEED
ACTUATOR MPROP 5-54 786-BK 17-21

CRANKSHAFT
SPEED
17-20 778-BK 5-5
ACTUATOR MPROP
L5: ACTUATOR PROP

17-32 782-BK 5-7
RAIL PRESSURE FUEL
U
17-25 781-WH 5-26
RAIL PRESSURE FUEL
P
17-31 780-BK 5-25
RAIL PRESSURE FUEL
S21: RAIL PRESSURE

5-45
251-WH GLOW PLUG RELAY
GLOW PLUG
RELAY(K1)
47-86 47-85 5-35

252-BU GLOW PLUG RELAY
86 85
87A
450-TN 129-1 100-RD M
GP 30
87
GP1: GLOW PLUG
450-TN 129-2 450-TN 5-23

GLOW PLUG SIGNAL
GP
GP2: GLOW PLUG
794-BK K
17-27 788-BK 5-29

U
17-22 791-WH 5-24

P
17-26 793-WH 5-44

S20: FUEL LOW PRESS
17-23 792-BK 5-43

U
17-28 5-40
P
789-WH
S19: OIL PRESS
17-24 787-WH 5-28
17-29 790-BK 5-27

p&t
U
S18: BOOST PRESS/TEMP
t
U
S17: COOLING TEMP
t U
S16: AIR INLET TEMP

Add-19
BC1000XL Brush Chipper Service Wire Harness - Front Deutz
WIRE HARNESS - FRONT DEUTZ

J42 [CAN RESISTOR 2]
A A
PN NO-COL
DEUTSCH
IPD-USA
DT04-3P
C
A 988-YL-18
C
B 989-LG-18
3
NOTES: 5 94
1) CIRCUITS WITH TWISTED PAIR:

46 60
3
J39 [CAN RESISTOR 3]
703-YL AND 704-BR 1 15
J40 [CAN RESISTOR 1] PN NO-COL
770-BK AND 771-WH 1 28
PN NO-COL A 988-YL-18
A 985-YL-18 B 989-LG-18
772-BK AND 773-WH B 986-LG-18
774-BK AND 775-WH P130 [ENGINE
776-BK AND 777-WH DIAGNOSTIC]
778-BK AND 779-WH PN NO-COL
A 260-YL
A A
P5 [D2.1]
DEUTSCH
IPD-USA
DT04-3P
A A
HCSTUED
ASU-DPI
C
P3-40TD
B 365-BK
C
2) CIRCUITS WITH TWISTED SHIELD PAIR: PN NO-COL C C
02 775-WH-18 989
-2 F 986-LG-18
E
783-WH AND 784-BK WITH SHIELD 795-WH 03 777-WH-18 SPLIC 3 G 989-LG-18
P4 [D2.2] -2
04 779-WH-18 988 H 988-YL-18
P8 [X17] 785-WH AND 786-BK WITH SHIELD 796-BK ICE
PN NO-COL SPL 3
M 985-YL-18
PN NO-COL 05 778-BK-18
01 112-OR-14
01 796-BK-18 07 782-BK-18
02 365-BK-14
02 210-WH-18 18 16 771-WH-18
03 112-OR-14
03 214-BK-18 18 773-WH-18
04 365-BK-14 10 4
09 795-WH-18 19 703-YL
05 112-OR-14
13 784-BK-18 20 704-BR
06 365-BK-14
14 783-WH-18 23 450-TN-18
13 443-DG-18
15 785-WH-18 24 791-WH-18
15 460-DG-18 6
17 794-BK-18 25 780-BK-18
26 438-BK-18
19 779-WH-18 26 781-WH-18
28 214-BK-18
20 778-BK-18 27 790-BK-18
J131 [FUEL 29 403-DB-18
21 786-BK-18 28 787-WH-18
SPLICE 989-2
35 208-WH
22 791-WH-18 PUMP POWER] 29 788-BK-18
SPLICE 988-2
44 702-OR-18
23 792-BK-18 PN NO-COL 32 774-BK-18
3 3 53 989-LG-18
SPLICE 985-1
24 787-WH-18 01 270-DG 33 770-BK-18
02 365-BK
J135 [WATER IN FUEL] 54 985-YL-18
35 252-BU-18
SPLICE 986-1
25 781-WH-18 PN NO-COL 57 456-LB-18
26 793-WH-18 01 456-LB-18 37 783-WH-18
P50 [COOLANT LEVEL] 61 794-BK-18
27 788-BK-18 02 457-BK-18 38 796-BK-18
PN NO-COL 64 457-BK-18
P1 [CB02 CONN 1] 28 789-WH-18 39 785-WH-18
01 403-DB-18 68 460-DG-18
PN NO-COL 29 790-BK-18 40 789-WH-18
1 02 444-BK-18 73 210-WH-18 SPLICE 112-2
01 260-YL 2
J72 [REAR 31 780-BK-18 8 43 792-BK-18
03 443-DG-18 75 988-YL-18
02 733-WH 1 32 782-BK-18 44 793-WH-18
(A) HARNESS] 76 986-GN-18
04 734-GY PN NO-COL 35 771-WH-18 5 45 251-WH-18 SPLICE 365D
85 701-LB-18
06 757-YL 01 260-YL 37 773-WH-18 46 776-BK-18
P44 [FUEL PRESSURE 87 444-BK-18 SPLICE 422
07 985-YL-18
7
02 365-BK 38 774-BK-18 48 772-BK-18
SENSOR] 88 260-YL-18
08 986-LG-18 40 776-BK-18 52 784-BK-18
12 PN NO-COL 90 437-PU-18 SPLICE 460
09 731-BR 41 777-WH-18 53 795-WH-18
42 772-BK-18 01 462-OR 54 786-BK-18
12 365-BK 02 463-BK SPLICE 260-1
46 701-LB-18 5
47 703-YL 04 464-BU
6 3 48 704-BR
50 702-OR-18 J20 [30A BREAKER]
51 365-BK-18 P43 [FUEL PRESSURE] 36 PN NO-COL
61 775-WH-18 PN NO-COL 40 02 112-OR-10
62 770-BK-18 01 462-OR 10
02 463-BK 12
04 464-BU
-1
03
E4
7
LIC
SP
SP
LIC
E9 10
85
SP -2 J15 [GND] 24
LIC
E9 PN NO-COL 13
86
-2 02 365-BK-10
J129 [X18] SPLICE 365A 8

PN NO-COL 4 J37 [FUEL SENDER] 2
30 E 11
12 01 450-TN-10 PN NO-COL SPLIC
4 B 365-BK
02 450-TN-10
1 6 S 439-LG
2 5 30
66
3 4
J47 [FUEL
5
16
PUMP RELAY]
3
1
4
12 PN NO-COL
2
12 85 01 260-YL
6 1
J126 [BREAKAWAY SWITCH]
5
4
2
3
J36 [FUEL GAUGE] PN NO-COL 02 438-BK-18
PN NO-COL H 112-OR 04 270-DG
SPLICE 365B 05 437-PU-18
36 B+ 261-YL 3 85
X1A G 365-BK 4
P99 [REMOTE 3
OPTION] S 439-LG 86
PN NO-COL P25 [HIGH RPM SW] 3 J132 [GLOW PLUG RELAY]
01 261-OR PN NO-COL 3 87 PN NO-COL
01 261-YL P31 [DROOP SWITCH] 3 85 252-BU-18
02 365-BK
04 757-YL 03 733-WH PN NO-COL 3 87 86 251-WH-18
05 985-YL-18 A 261-YL 3
3 87 450-TN-18
C
B 731-BR
B
06 986-GN-18 87 87 450-TN-10
A
C 365-BK
C
87 450-TN-10
J26 [20A FUSE A] 7
SPLICE 365C
SPLICE 261
SPLICE 260
MYLAR TAG PN NO-COL 4

"20A FUSE" A 201A-YL-12
AA 260-YL-12
1 2
10 4
1 2
10
B
MYLAR TAG J27 [20A FUSE B]
PN NO-COL
C
"20A FUSE"
J41 [CAN DIAGNOSTIC]
A 201B-YL-12
PN NO-COL
AA 261-YL-12
A 985-YL-18
B 986-LG-18
5 P34 [ECO-IDLE SWITCH]
3 6
J21 [IGNITION SWITCH] PN NO-COL
PN NO-COL
B
B A A 261-YL
3 C
B 734-GY
B 112-OR-12 C 365-BK
I 201A-YL-12 3 C
I 201B-YL-12
S 208-WH 3
P38 [CANBUS DISPLAY]
9 PN NO-COL
6
01 261-YL
1
5 2
4 3 02 365-BK
04 985-YL-18
05 986-LG-18
Add-20
BC1000XL 163672393 REV A
DOMESTIC & AUSTRALIAN

Electrical Schematic - Domestic and Australian Trailer Lighting
100-7
100-1
100-4
100-3
100-2
100-5
100-6
645-BR 110-I 110-O 370-WH

LF SIDE MARK
101-54
101-58L
101-31
101-58R
101-R
101-L
7 POLE (AUSTRALIA ONLY)
NOT USED
WH*31 111-I 111-O

645-BR 370-WH
BR*58L
RF SIDE MARK
DG*R
YL*L
RD
YL
DB
RD
DG
BR
118-I
WH
645-BR 118-O 370-WH

RD*54 DB*58R LR SIDE MARK
100-4
100-3
100-7
100-1
100-6
100-2
100-5
370-WH
645-BR
AUSTRALIAN TRAILER PLUG (TO TRAILER HARNESS) 119-I 119-O

645-BR 370-WH
RR SIDE MARK
6-WAY ROUND
ELECTRICAL SCHEMATIC - DOMESTIC AND AUSTRALIAN TRAILER LIGHTING
641-LG
240-DB
125-I 125-O
644-YL
645-BR 370-WH
643-YL/RD
642-LG/RD
DG*RT DB*S LICENSE PLATE LIGHT
122-1 122-2
NOT USED BR*TM
370-WH
AUS. ONLY LEFT AMBER TURN

101-TM
101-GD
101-S
101-RT
101-LT
122-3
644-YL
YL*LT WH*GD
YL
DB
DG
BR
WH
645-BR 122-1 122-2 370-WH

7-WAY RV
LEFT RED S/T/T
BR*TM
NOT USED 122-3
643-YL/RD
3 4 123-1 123-2
645-BR 370-WH
YL
DG
5 AUX 6
YL*LT 7 DG*RT
1 2
RT. RED S/T/T
123-3
100-4
100-3
100-7
100-1
100-6
100-2
100-5
642-LG/RD
WH*GD DB*S
121-1 121-2
370-WH
DOMESTIC TRAILER PLUG (TO TRAILER HARNESS)
AUS. ONLY RT. AMBER TURN
121-3
641-LG
240-DB 102-P 102-G 370-WH
BREAKAWAY SWITCH (TONGUE) LEFT BRAKE

126-H 126-S
240-DB
103-P 103-G
240-DB 370-WH
RIGHT BRAKE
370-WH
15-2 (ENGINE BLOCK GROUND)

Add-21
Add-22
BC1000XL 163672393 REV A
EUROPEAN
100-3
100-1
100-6
100-8
100-2
100-4
100-7
100-5
647-BK WS1-2 WS1-1 370-WH

LF SIDE MARKER LIGHT
645-BR WS2-2 WS2-1 370-WH

RF SIDE MARKER LIGHT
ELECTRICAL SCHEMATIC - EUROPEAN TRAILER LIGHTING
13 PIN
(PINS 9 - 13 NOT USED)
101-8
101-2
101-5
101-3
101-1
101-4
101-7
101-6
647-BK 16-A 16-B 370-WH
8
9 7 LICENSE PLATE LIGHT #1
1
10 6
2 4
642-RD
648-PK
646-DB
644-YL
645-BR
641-LG
647-BK
370-WH
11 5
648-PK
647-BK
642-RD
644-YL
646-DB
641-LG
645-BR
3
370-WH
647-BK 17-A 17-B 370-WH

12 13
LICENSE PLATE LIGHT #2
P101
100-8
100-6
100-2
100-3
100-1
100-5
100-4
100-7
646-DB 50-3 50-1 370-WH

EUROPEAN TRAILER PLUG (TO TRAILER HARNESS)
FOG LIGHT
648-PK 40-3 40-1 370-WH

REVERSE LIGHT
122-1 122-2
370-WH
LEFT AMBER TURN

122-3
644-YL
647-BK 122-1 122-2 370-WH

LEFT RED STOP/TAIL
122-3
642-RD
645-BR 123-1 123-2

370-WH
RIGHT RED STOP/TAIL

123-3
642-RD
121-1 121-2
370-WH
RIGHT AMBER TURN
121-3
641-LG
370-WH
15-2 (ENGINE BLOCK GROUND)

Electrical Schematic - European Trailer Lighting
Wire Harness - Rear BC1000XL Brush Chipper Service
WIRE HARNESS - REAR

P65 [HOLD TO RUN] 6
1 260C-YL
2 765-DG
2 1
O I 9
P74 [INFO LIGHT]

I 426-PU
O 765C-BK
5
P66 [HOLD TO RUN]
1 260C-YL
2 765-DG 2 1
37 31 4 SPLICE
765 DG
MYLAR TAG
P59 [SENSITIVITY SW] "E-STOP"
A 260C-YL
B 732-LG
6 SPLICE
2
C 365C-BK 4 260C-1 YL
P64 [BAR E-STOP SW]
B A 1 260C-YL
2 764-LG
3-PLUG
C 4-PLUG SPLICE 6
14
4 1
3 2
365C BK P72 [FRONT HARNESS]
1 260C-YL NICKEL
2 365C-BK NICKEL
1 2
MYLAR TAG
"REVERSE
FEED"
MYLAR TAG
"NORMAL P3 [C130 MRC]
5
4
SENSITIVITY" P61 [REVESE FEED SW]
4 1 732-LG
P62 [FEED STOP SW NORMAL] 1 260C-YL 2 765-DG
1 260C-YL 2 PLUG 9 3 766A-GY NICKEL
2 762-PK 4 3 761-WH 4 767A-DB NICKEL
3 PLUG 4 PLUG 5 PLUG
4
4 PLUG
1
NICKEL
3 2 1 2 3 4 5 6 6 426-PU
7 763-LB
4
3
1 12 11 10 9 8 7 8 762-PK
2
MYLAR TAG 9 764-LG
"FOWARD 10 760-TN
FEED" 11 PLUG
12 761-WH
P60 [FORWARD FEED SW]
1 260C-YL
4
2 PLUG
3 760-TN
4 PLUG
4 1
3 2
4
16
SPLICE
260C-2 YL
4
73 30 9
59
16
MYLAR TAG
"REDUCED
SENSITIVITY"
P63 [FEED STOP SW REDUCED]

1 260C-YL
4 P68 [UPPER FORWARD SOL]
2 763-LB
1 766A-GY 5
3 PLUG
2 365-BK
4 PLUG
4 1 2 1
3 2
P70 [UPPER REVERSE SOL]

1 767A-DB 5
2 365-BK
2 1
Add-23

2014 Bc1000xl Service Manual

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2014 Bc1000xl Service Manual

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BC1000XL Brush Chipper

VERMEER, VERMEER Logo, and ECOIDLE are

Copyright 2013, 2015

General Information......................................................................................................................... 1-1

Using the Manual ...............................................................................................................................................................1-1

Testing for Continuity .......................................................................................................................................1-22

System Information ......................................................................................................................... 2-1

Engine and Electrical Power ........................................................................................................... 3-1

Coolant Delivery ................................................................................................................................................3-67

Glow Plug Function - Deutz............................................................................................................................3-103

Feed Roller Function ....................................................................................................................... 4-1

Look for the Obvious ........................................................................................................................................4-23

Feed Roller Disassemble..................................................................................................................................4-55

Cutter Drum Drive ............................................................................................................................ 5-1

Trailer ................................................................................................................................................ 6-1

Mechanical Brake Drum Components - Replace............................................................................................6-35

Diagrams and Schematics ........................................................................................................ ADD-1

Legend for Reference Designators.................................................................................................................... ADD-1

Chapter 1: General Information

USING THE MANUAL

Vermeer Corporation reserves the right to make changes at any time

Operating instructions are found in the BC1000XL Brush Chipper

Contact the Vermeer Parts Center to order these publications.

• Caterpillar Engine Manual for model C2.2L Tier 4 Interim/Stage IIIB

• Cummins Engine Manual for model B3.3 Tier 4 Interim/Stage IIIB

Understand that only an authorized Caterpillar, Cummins, Power Solutions

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

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

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

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

NOTICE: Indicates information considered important, but not

Do Not Modify Machine

Safety Symbol Explanation

WARNING: Read Operator’s Manual and safety signs before operating

WARNING: Check machine before operating. Machine must be in good

WARNING: Wear personal protective equipment. Wear close-fitting clothing

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WARNING: Keep spectators away.

WARNING: Exhaust fumes can be fatal.

If operating in an enclosed area, remove the exhaust fumes with an exhaust

WARNING: Use Shutdown Procedure before servicing, cleaning, repairing, or

WARNING: Hot fluid under pressure can scald.

Allow engine to cool before opening radiator cap.

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WARNING: Fuel and fumes can explode and burn.

Shut off engine before refueling. No flame. No smoking.

WARNING: Batteries produce an explosive gas when in use or being charged.

reproductive harm. Wash hands after handling.

WARNING: Moving parts can crush fingers.

Close all shields before starting.

Each code-like designator identifies a specific component. The designator is

Diagrams and Schematics

Addendum Reference materials such as complete machine electrical and hydraulic

information in the Theory of Operation, Troubleshooting, and Repair

Repair When it is determined through troubleshooting that components are

These chapters, explain in detail how the machine is comprised of multiple

Do not skip the analysis or research phase of troubleshooting. Simply

Begin troubleshooting by doing the following:

• Describe and compare the problem situation with known operating

The troubleshooting procedures in this manual cover the electrical and

• VCTool diagnostic tool—for displaying status of controller inputs and

• Portable hydraulic tester (porta-power)

If needed, refer to the Addendum chapter in back of this manual to view

Working through failed circuit(s) will isolate failed component(s) by process