58
BXTR6438
Engine related issues.
Clutch related issues.
Brakes / wheel bearing
related issues.
Obstructed discharge.
Clear debris from discharge chute.
Ensure machine is off
Fluid coupler not
engaged
Check fluid level in the coupler is
correct, belt has proper tension.
Ensure machine is off
Rotor plugged.
Inspect and clear chipper hopper
lower rotor housing and rotor.
Ensure machine is off
Low engine / rotor
speed.
Set throttle to increase rotor RPM.
(1375 RPM)
Blades and/or knives
are dull.
Check rotor and ledger blades,
rotate, sharpen or replace.
Ensure machine is off
Rotor blade angle
wrong, improper
angle.
Re-sharpen rotor knives to specified
45° angle and check that blade is
installed properly.
Ensure machine is off
IntelliFeed
programing incorrect,
Adjust programming or return to
factory settings.
Filter is dirty, change filter
Hydraulic oil is contaminated,
inspect oil condition (dirt, foaming).
Replace oil.
Lower roller is
jammed (not cleaned
out from last use)
Open lower roller cleanout, and
clean out chips. Jams could freeze in
winter time.
Ensure machine is off
Obstructed discharge.
Clear debris from discharge chute.
Ensure machine is off
Broken or missing
blade .
Replace broken/missing blade.
Ensure machine is off.
Rotor may be bent
Check for rotor wobble. Replace
rotor.
Ensure machine is off, call
technician for repair
Upper rotor housing
open
Inspect upper rotor housing that it is
closed and secured & interlock cable
is connected.
Interlock switch
defective
Check interlock switch, replace if not
working
Ensure machine is off
Interlock wiring
harness damaged
Inspect wiring harness, repair or
replace.
Ensure machine is off
Obstructed discharge. Clear debris from discharge chute .
Ensure machine is off
Feeding in too much
material
IntelliFeed programing incorrect,
adjust programming
Feeding material too
quickly
IntelliFeed programing incorrect,
adjust programming
Rotor plugged.
Inspect and clear chipper hopper
lower rotor housing and rotor.
Ensure machine is off
Green material will
not discharge.
Allow material to dry or alternate
dry/wet material.
Chipper blade
clearance too large.
Set clearance to 1/32 to 1/16 " (.76 -
1.52 mm). Use chipper clearance
tool. (see accessories)
Ensure machine is off
Dull blades.
Check rotor and ledger blades,
rotate, sharpen or replace.
Ensure machine is off
Drive belts loose or
worn.
Inspect drive belts, adjust tension or
replace if needed.
Ensure machine is off.
Wrong replacement
belt
Inspect drive belts, replace with
(2B-82 ) double banded 'B' 70" dia
belts.
Ensure machine is off.
Sheaves misaligned
Check sheave alignment and adjust.
Rotor plugged.
Inspect and clear chipper hopper,
lower rotor housing and rotor.
Ensure machine is off
Belt tension too high Check belt tension and adjust
Sheaves worn
Inspect sheaves and bearings,
replace if required.
Ensure machine is off, call
technician for repair
Oil or grease on drive
system
Check for source of oil / grease and
correct. Clean sheaves and belts,
belts may require replacment.
Ensure machine is off
Dull blades.
Check rotor and ledger blades,
rotate, sharpen or replace.
Ensure machine is off
Drive belts loose or
worn.
Inspect drive belts, adjust or replace
if needed.
Ensure machine is off
Poor quality material
Material is small or rotting, mix with
higher quality material.
Feed roll control bar
set to stop.
move to forward / reverse position
RPM not at or above
minumum setting
Set engine throttle for maximum
RPM, ensure engine is tuned up,
ensure RPM is at or above
intellifeed "Upper RPM Limit"
setting.
Ensure machine is off
Intellifeed
programming
incorrect
Check that intellifeed settings are at
factory specifications, reset if
required.
Ensure machine is off
Inspect rotor sensor for damage,
replace unit if required.
Ensure machine is off, call
technician for repair
Inspect rotor sensor mount or
sheave mounted indicator plate for
damage or misalignment, repair or
replace.
Clearance between indicator plate
Ensure machine is off
Check IntelliFeed unit for output
signal, replace unit if required.
Ensure machine is off, call
technician for repair
Check harness for bad ground
connection.
Ensure machine is off
Inspect IntelliFeed wiring harness
for damage, repair or replace if
damaged.
Ensure machine is off, call
technician for repair
IntelliFeed hydraulic
block malfunction
Inspect hydraulic control unit for
damage, check functionality.
Ensure machine is off, call
technician for repair
Feed control bar
malfunction
Check feed control bar switches,
replace, reposition pickup trigger.
Ensure machine is off
Filter is dirty, change filter.
Ensure machine is off
Hydraulic oil is contaminated,
inspect oil condition (dirt, foaming).
Replace oil.
No electrical power
Check battery, engine charging
system for power.
Hydraulic motor slow
Check hydraulics, contaminated
hydraulic fluid, check motor
condition, replace if required.
Ensure machine is off, call
technician for repair
Tank level is too low, Inspect and fill tank.
Filter is dirty
Change filter.
Hydraulic oil is
contaminated,
Inspect oil condition (dirt, foaming).
Replace oil
Feed rollers binding
Inspect bearings, lubricate or
replace
Ensure machine is off, call
technician for repair
Lines is crimped or
pinched
Inspect, repair or replace lines
Ensure machine is off, call
technician for repair
Pump is worn
Check and replace
Ensure machine is off, call
technician for repair
Line leak
Inspect hydraulic lines / fittings for
leaks, repair or replace.
Ensure machine is off, call
technician for repair
Pump leak
Pump seals are worn, inspect seals,
replace.
Ensure machine is off, call
technician for repair
Pump noisy at startup
Oil temperature too, low allow
machine to warm up.
Ensure machine is off
Unusual vibration while
running.
Refer to the Kohler CH980 engine operators manual for specific trouble shooting instructions / requirements.
Refer to the Transfluid Fluid Coupler installation & maintainance manual for specific trouble shooting instructions /
requirements.
Refer to the Dexter Axle Torflex 3500 lb Axle, Brake and Hub Ass'y operation, maintenance, service manual for specific trouble
shooting instructions / requirements.
PROBLEM
CAUSE
SOLUTION
CAUTION
Engine won't start
Machine requires excessive
power or stalls.
Rotor does not turn
Slow feeding.
Slow hydraulic flow
Squeeling Belt / premature
belt wear.
Poor Quality Chips
Hydraulic oil overheating /
Hydraulic pump makes
noise
Feed rollers intermittent or
not turning
Intellifeed not
receiving signal
Slow hydraulic flow
Engine related issues.
Clutch related issues.
Brakes / wheel bearing
related issues.
Obstructed discharge.
Clear debris from discharge chute.
Ensure machine is off
Fluid coupler not
engaged
Check fluid level in the coupler is
correct, belt has proper tension.
Ensure machine is off
Rotor plugged.
Inspect and clear chipper hopper
lower rotor housing and rotor.
Ensure machine is off
Low engine / rotor
speed.
Set throttle to increase rotor RPM.
(1375 RPM)
Blades and/or knives
are dull.
Check rotor and ledger blades,
rotate, sharpen or replace.
Ensure machine is off
Rotor blade angle
wrong, improper
angle.
Re-sharpen rotor knives to specified
45° angle and check that blade is
installed properly.
Ensure machine is off
IntelliFeed
programing incorrect,
Adjust programming or return to
factory settings.
Filter is dirty, change filter
Hydraulic oil is contaminated,
inspect oil condition (dirt, foaming).
Replace oil.
Lower roller is
jammed (not cleaned
out from last use)
Open lower roller cleanout, and
clean out chips. Jams could freeze in
winter time.
Ensure machine is off
Obstructed discharge.
Clear debris from discharge chute.
Ensure machine is off
Broken or missing
blade .
Replace broken/missing blade.
Ensure machine is off.
Rotor may be bent
Check for rotor wobble. Replace
rotor.
Ensure machine is off, call
technician for repair
Upper rotor housing
open
Inspect upper rotor housing that it is
closed and secured & interlock cable
is connected.
Interlock switch
defective
Check interlock switch, replace if not
working
Ensure machine is off
Interlock wiring
harness damaged
Inspect wiring harness, repair or
replace.
Ensure machine is off
Obstructed discharge. Clear debris from discharge chute .
Ensure machine is off
Feeding in too much
material
IntelliFeed programing incorrect,
adjust programming
Feeding material too
quickly
IntelliFeed programing incorrect,
adjust programming
Rotor plugged.
Inspect and clear chipper hopper
lower rotor housing and rotor.
Ensure machine is off
Green material will
not discharge.
Allow material to dry or alternate
dry/wet material.
Chipper blade
clearance too large.
Set clearance to 1/32 to 1/16 " (.76 -
1.52 mm). Use chipper clearance
tool. (see accessories)
Ensure machine is off
Dull blades.
Check rotor and ledger blades,
rotate, sharpen or replace.
Ensure machine is off
Drive belts loose or
worn.
Inspect drive belts, adjust tension or
replace if needed.
Ensure machine is off.
Wrong replacement
belt
Inspect drive belts, replace with
(2B-82 ) double banded 'B' 70" dia
belts.
Ensure machine is off.
Sheaves misaligned
Check sheave alignment and adjust.
Rotor plugged.
Inspect and clear chipper hopper,
lower rotor housing and rotor.
Ensure machine is off
Belt tension too high Check belt tension and adjust
Sheaves worn
Inspect sheaves and bearings,
replace if required.
Ensure machine is off, call
technician for repair
Oil or grease on drive
system
Check for source of oil / grease and
correct. Clean sheaves and belts,
belts may require replacment.
Ensure machine is off
Dull blades.
Check rotor and ledger blades,
rotate, sharpen or replace.
Ensure machine is off
Drive belts loose or
worn.
Inspect drive belts, adjust or replace
if needed.
Ensure machine is off
Poor quality material
Material is small or rotting, mix with
higher quality material.
Feed roll control bar
set to stop.
move to forward / reverse position
RPM not at or above
minumum setting
Set engine throttle for maximum
RPM, ensure engine is tuned up,
ensure RPM is at or above
intellifeed "Upper RPM Limit"
setting.
Ensure machine is off
Intellifeed
programming
incorrect
Check that intellifeed settings are at
factory specifications, reset if
required.
Ensure machine is off
Inspect rotor sensor for damage,
replace unit if required.
Ensure machine is off, call
technician for repair
Inspect rotor sensor mount or
sheave mounted indicator plate for
damage or misalignment, repair or
replace.
Clearance between indicator plate
Ensure machine is off
Check IntelliFeed unit for output
signal, replace unit if required.
Ensure machine is off, call
technician for repair
Check harness for bad ground
connection.
Ensure machine is off
Inspect IntelliFeed wiring harness
for damage, repair or replace if
damaged.
Ensure machine is off, call
technician for repair
IntelliFeed hydraulic
block malfunction
Inspect hydraulic control unit for
damage, check functionality.
Ensure machine is off, call
technician for repair
Feed control bar
malfunction
Check feed control bar switches,
replace, reposition pickup trigger.
Ensure machine is off
Filter is dirty, change filter.
Ensure machine is off
Hydraulic oil is contaminated,
inspect oil condition (dirt, foaming).
Replace oil.
No electrical power
Check battery, engine charging
system for power.
Hydraulic motor slow
Check hydraulics, contaminated
hydraulic fluid, check motor
condition, replace if required.
Ensure machine is off, call
technician for repair
Tank level is too low, Inspect and fill tank.
Filter is dirty
Change filter.
Hydraulic oil is
contaminated,
Inspect oil condition (dirt, foaming).
Replace oil
Feed rollers binding
Inspect bearings, lubricate or
replace
Ensure machine is off, call
technician for repair
Lines is crimped or
pinched
Inspect, repair or replace lines
Ensure machine is off, call
technician for repair
Pump is worn
Check and replace
Ensure machine is off, call
technician for repair
Line leak
Inspect hydraulic lines / fittings for
leaks, repair or replace.
Ensure machine is off, call
technician for repair
Pump leak
Pump seals are worn, inspect seals,
replace.
Ensure machine is off, call
technician for repair
Pump noisy at startup
Oil temperature too, low allow
machine to warm up.
Ensure machine is off
Unusual vibration while
running.
Refer to the Kohler CH980 engine operators manual for specific trouble shooting instructions / requirements.
Refer to the Transfluid Fluid Coupler installation & maintainance manual for specific trouble shooting instructions /
requirements.
Refer to the Dexter Axle Torflex 3500 lb Axle, Brake and Hub Ass'y operation, maintenance, service manual for specific trouble
shooting instructions / requirements.
PROBLEM
CAUSE
SOLUTION
CAUTION
Engine won't start
Machine requires excessive
power or stalls.
Rotor does not turn
Slow feeding.
Slow hydraulic flow
Squeeling Belt / premature
belt wear.
Poor Quality Chips
Hydraulic oil overheating /
Hydraulic pump makes
noise
Feed rollers intermittent or
not turning
Intellifeed not
receiving signal
Slow hydraulic flow
