IK003633 Service Bulletin/Repair Instructions

Vermeer Corporation

Environmental

Pella, Iowa 50219 USA
FIELD CAMPAIGN KIT #: IK003633 Rev. 1
DATE:
RELEASED
For Dealer Reference: Service Bulletin #: SVC2020-005 Rev. 1
Kit to Move Controller

CAMPAIGN

TYPE:
Customer Choice/Enhancements
CAMPAIGN

CATEGORY:
Kit and Bulletin
MACHINE/

ATTACHMENT

MODEL(S):
Included
Excluded
Kit version
BC1200XL
1001 – 3365 Tier 3 Engine
2364
IK01
BC1200XL
1001 – 3365 Tier 4 Engine
2364
IK02
BC1200XL
1001 – 3365 Gasoline Engine
2364
IK03
SERIAL NUMBERS:
Purpose: This kit includes parts and instructions to move controller to the right front corner of

machine.

Reason for revision: Part number of amber decal included in bill of material for IK01 has been

updated.

Special tools and conditions:

 None
Vermeer and the Vermeer logo are trademarks of Vermeer Manufacturing Company in the U.S and/or other

countries. © 2021 Vermeer Corporation. All Rights Reserved.
Page 1 of 37
WARNING: Use the following shutdown procedure before attempting to do any of the

work described in this kit.

1. Return Upper Feed Control Bar to top

STOP position.

2. Move Cutter Engage/Throttle Lever to

ENGAGED/LOW RPM position.

3. Wait for cutter drum to slow.

4. Move Cutter Engage/Throttle Lever to

DISENGAGED/LOW RPM position.
A
5. If equipped, shut off remote control if in

use.

6. Turn ignition key to OFF position.

7. Wait for cutter drum and belt to stop.

Notice: Cutter drum rotation can be checked

by looking at the end of shaft (A) on left side of

cutter wheel housing. The cutter drum will

continue to turn for a short time after the

engine has stopped.

8. Remove ignition key.
 Unless indicated, new parts from kit have callouts with numbers. Callouts with letters indicate

existing parts or general items.
Page 2 of 37
IK003633Rev. 1
RELEASED
PROCEDURE 1: Controller move (IK01, IK02, IK03)

1.
B
Remove and retain battery access panel (A) and

hardware (B) securing panel to machine.
A

2.
Remove negative (-) battery cable (C) from battery.
3.
Remove positive (+) battery cable (D) from battery.

D
C
Page 3 of 37
IK003633Rev. 1
RELEASED
4.
Remove and discard battery side cover (E) and

mounting hardware (F).
E
F

5.
For machines with 110 hp Tier 3 engine, pull battery

cables through hole on side of engine enclosure.

(IK01)
6.
Remove and retain battery retainer (G), nuts (H) and

battery rods (I). Remove and retain battery (J). (IK01)
7.
Remove and discard grommet (K). Use weld blankets

or suitable covers to protect wiring and surrounding

area. Use a suitable tool and enlarge hole to 2.5 in

(63.5 mm) diameter.
8.
Install new grommet (8) P/N 1865047 to enlarged hole.

Install retained battery using retained battery retainer

(G), nuts (H) and battery rod (I). Pull battery cables

into battery compartment. (IK01)
K

H
G
I

J
Page 4 of 37
IK003633Rev. 1
RELEASED
9.
Install new battery cover (1) P/N 163709704 using new

screws (2) P/N 507612020.
1
10. Install new reflector (3) to battery cover.






(IK01) P/N 163811485 Tier 3 engine option (not

shown)

(IK02) P/N 308000149 Tier 4 engine option (not

shown)

(IK03) P/N 163733738 gasoline engine option
3
2
11. Remove and retain screw (L) from hydraulic tank.
2

4
12. Install new controller box (4) using new screw (2) P/N

507612020 and retained screw (L).
L
Page 5 of 37
IK003633Rev. 1
RELEASED
13. Remove harness connections (M) from controller.

O
14. Remove and retain controller (N) and controller

hardware (O) from infeed frame.

15. Remove and discard the front and rear harness from

the machine. Note where harness is secured to

machine with ny-ties to aid in installation of new

harness assemblies. Retain hardware securing

harness ground connections and electronic

components.
M

N
4
16. Install retained controller (N) to controller box (4) using

retained hardware (O).
O
N
Page 6 of 37
IK003633Rev. 1
RELEASED
PROCEDURE 2: Front harness installation (IK03)

1. Route new harness (5) P/N 163673872 controller

connections, wire harness tag numbers P1 and P3,

through grommet (A) in the side of engine enclosure.
P3
P1
2. Install Deutsch plug harness tag number P1 to

controller port J1.
A
3. Install Deutsch plug harness tag number P3 to

controller port J3.
5
4. Install harness ring terminal, harness tag number P140,

to circuit breaker using retained hardware. Reinstall

insulation boot.

P140
Page 7 of 37
IK003633Rev. 1
RELEASED
5. Install harness ring terminal, harness tag number P80,

to retained frame ground screw. Ensure connection is

free of dirt and/or debris that may prohibit proper

ground connection.
P80
6.
Install harness Packard connector, harness tag

number J75, to engine (connection not shown).

J75
7.
Install harness Delphi connector, harness tag number

P189, to engine (connection not shown).
P189
Page 8 of 37
IK003633Rev. 1
RELEASED
8.
Install Deutsch socket, harness tag number P52, to

fuel level sensor (B).
9.
Install Bosch plug, harness tag number P194, to fuel

manifold (C).
P52
B
10. Install positive and negative terminals, harness tag

number P54, to fuel pump (D).
D
P194
P54
C
11. Install Deutsch connector, harness tag number P22, to

throttle switch (E).
E
P22
Page 9 of 37
IK003633Rev. 1
RELEASED
12. Install CAN receptacle, harness tag number J124, to

control panel using retained hardware.
J124
13. Install Deutsch connector, harness tag number P8, to

multifunction display.

14. Install Deutsch connector, harness tag number P26, to

droop set switch.
P53
P8
15. Install Deutsch connector, harness tag number P197,

to check engine light.
P26
16. Install Deutsch connector, harness tag number P25, to

EcoIdle switch.

17. Deutsch connector, harness tag number J170, will be

connected to rear harness in the next procedure.
P9
18. Install ring terminals. harness tag number P53, to fuel

gauge terminals marked on gauge:






P25
P197
Orange wire to fuel gauge terminal B+

Black wire to fuel gauge terminal G

Purple wire to fuel gauge terminal S
J170
Front view
19. Install ring terminals, harness tag number P9, to

ignition switch:








Red wire to ignition switch to battery terminal

White wire to ignition switch to start terminal

Yellow wire to ignition switch to ignition terminal

Yellow wire to ignition switch to accessory terminal
Rear view

Ignition

Start
Accessory
Battery
Page 10 of 37
IK003633Rev. 1
RELEASED
20. If machine has remote option installed, connect

Deutsch plug, harness tag number P202, to remote

harness tag number P202.

21. Deutsch connector, harness tag number J130, is

connected to rear harness later in the next procedure.
P202
22. If machine is equipped with telematics controller (not

shown), connect harness tag number P5 to control

unit.

J130
P5
PROCEDURE 3: Rear harness installation (IK03)

1. Install new harness (6) P/N 163673873 Deutsch plug,

harness tag number P24, to right hold-to-run switch.

2.
6
Install Trucklite connector, harness tag number P61, to

information light.

P24
P61
Page 11 of 37
IK003633Rev. 1
RELEASED
3.
Install Deutsch plug, harness tag number P23, to left

hold-to-run switch.

P23
4.
5.
6.
Install rear harness Deutsch plug, harness tag number

P130, to front harness Deutsch connector, harness tag

number J130.
B
J130
If winch option is installed on machine, install Deutsch

plug, harness tag number P181, to winch harness

Deutsch connector, harness tag number J56 (not

shown).

Install Deutsch plug, harness tag number P34, to

forward feed switch (A).
7.
Install Deutsch plug, harness tag number P30, to feed

stop switch (B).
8.
Install Deutsch plug, harness tag number P35, to

reverse feed switch (C).
P181
C

A
P35
P34

P30
Page 12 of 37

12 3

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