Blockage on grass when using the Dion-Ag Scorpion 300 can be caused by the feedrolls becoming clogged with crop. This may trigger the overload protection clutch on the transmission input pulley to slip, producing a growling sound. Additionally, a jammed stop pawl in the ratchet wheel can also contribute to feedroll speed errors and blockage.

This answer is automatically generated

Summary of Contents for Dion-Ag Scorpion 300

Page 1 Operator’s Manual FORAGE HARVESTER Manual No. F6918E003E v1.2...
Page 2 Manual No. F6918E003E v1.2...
Page 3: Foreword
FOREWORD We thank you for your confidence towards Dion-Ag Inc. agricultural equipment. We have prepared this manual with care and attention and have designed it as an essential tool that will allow you to use and maintain your machine adequately and safely. By following the instructions that it contains, you will obtain optimal performance and durability of the harvester for years to come.
Page 4: Dion-Ag Inc. Limited Warranty
Covered by Warranty – Under the warranty, Dion-Ag guarantees its new machinery and/or equipment to be free of defects, both in workmanship and material, for a period of one (1) year from the time of delivery by the dealer. Dion-Ag Inc. will repair or replace, at its discretion and without charge for service parts or labour, any defective part of the equipment on condition that the machinery and/or equipment has been operated in accordance with the instructions contained in the Dion-Ag Inc.
Page 5 Manual No. F6918E003E v1.2...
Page 6: Table Of Contents
TABLE OF CONTENTS FOREWORD ....................................3 DION-AG INC. LIMITED WARRANTY ............................. 4 SPECIFICATIONS ................................... 8 DIMENSIONS ......................................8 WEIGHT ......................................... 8 TRANSMISSIONS ....................................8 CUTTERHEAD ......................................8 TIRES AND WHEELS ....................................9 FEATURES ......................................9 SERIAL NUMBER LOCATION ................................. 10 SAFETY RULES ....................................
Page 7 TABLE DES MATIÈRES STOPPING THE MACHINE ..................................65 OPERATION ....................................66 OPERATION PRACTICAL ADVICE................................66 HARVESTER DRAWBAR POSITION ..............................66 METAL DETECTOR ................................... 66 FIELD WORK ......................................66 F-N-R TRANSMISSION SHIFTING ................................68 WITHOUT METAL DETECTOR, OR DEACTIVATED ..........................68 WITH METAL DETECTOR ..................................
Page 8: Specifications
SPECIFICATIONS Specification and design are subject to change without notice and responsibility from the manufacturer. DIMENSIONS OVERALL width (narrow axle position)  With tires 31x13.50 - 15 Terra Rib …………………………….3.30 m (142”)  With tires 31x15.50 - 15 Terra Grip …………………………..3.50 m (150”) LENGTH (Spout in transport position)..........
Page 9: Tires And Wheels
SPECIFICATIONS TIRES AND WHEELS SINGLES  31, 13.5-15 Terra Rib  31 x 15.5 Terra Trac TANDEM  31, 13.5-15 Terra Rib  31 x 15.5 Terra Trac FEATURES STANDARD  Angle drive 1000/1000  8 knives cutterhead  Tungsten carbide knife cutting edge ...
Page 10: Serial Number Location
SPECIFICATIONS SERIAL NUMBER LOCATION For your convenience, write down in full in this manual both the model and serial numbers of your machine, as shown on the name plate illustrated below. Always mention both the model and the serial numbers when ordering parts or regarding any other correspondence referring to your machine.
Page 11 Manual No. F6918E003E v1.2...
Page 12: Safety Rules
SAFETY RULES A WORD TO THE OPERATOR It is YOUR responsibility to read and understand the safety section in this manual before operating your tractor. You must follow these safety instructions that take you step by step through your working day. In reading this section, you will note that illustrations have been used to highlight certain situations.
Page 13: General Safety Rules
SAFETY RULES GENERAL SAFETY RULES CAUTION: In some of the illustrations used in this Operator Instruction Book, panels or guards may have been removed for clarity. Never operate the machine without these components in place. CAUTION: An operator should not be under the influence of alcohol or drugs which can change his alertness or coordination.
Page 14: Preperation And Operation
SAFETY RULES PREPERATION AND OPERATION  Before starting the tractor engine, make sure all guards, shields, and doors are in place and properly secured and check the machine thoroughly for possible loose parts or bolts and tighten them.  Use a lift system with a minimum capacity of 2500 lbs (1150 kg) to install a header on the forage harvester. Refer to the header specifications.
Page 15: Inspection, Maintenance And Adjustments
SAFETY RULES INSPECTION, MAINTENANCE AND ADJUSTMENTS WARNING: Hydraulic ﬂuid under pressure can penetrate the skin or eyes and cause serious personal injury, blindness or death. Fluid leaks, under pressure, may not be visible. Use a piece of cardboard or wood to find leaks.
Page 16: Guards And Shields
SAFETY RULES GUARDS AND SHIELDS The Forage Harvester is equipped with guards and shields wherever eventual accidents can occur. These guards and shields do not affect the performance of the machine. Refer to Figure 3 to identify these guards and their location to make sure they remain in place for a safe operation.
Page 17: Safey Signs Location
SAFETY RULES SAFEY SIGNS LOCATION Several decals located around the hazard areas indicate the potential dangers. IMPORTANT: Decals must be kept clean to allow easy reading at all times. Figure 4 Safety Decals Manual No. F6918E003E v1.2...
Page 18 SAFETY RULES Figure 5 Safety Decals Figure 6 Safety Decals Manual No. F6918E003E v1.2...
Page 19 SAFETY RULES Figure 7 Safety Decals Figure 8 Safety Decals Manual No. F6918E003E v1.2...
Page 20 SAFETY RULES Figure 9 Safety Decals Manual No. F6918E003E v1.2...
Page 21 SAFETY RULES Figure 10 Safety Decals Manual No. F6918E003E v1.2...
Page 22: Setup
SETUP BOLT TORQUE SPECIFICATIONS The table below gives the correct torque values for bolts used on the machine. Check tightness of bolts periodically. Table 1 Bolt Torque Specifications Replace hardware with the same grade bolt. SAE 2 SAE 5 SAE 8 10.9 Figure 11 Bolt Grades Manual No.
Page 23: Manual Jack
SETUP MANUAL JACK FIGURE 12 The harvester is delivered with a manual jack (item 1) to support the drawbar when stored. When this jack is not used, it can be stored in its horizontal position using the locking pin (item 2). CAUTION: Securely block the forage harvester wheels before removing the tractor hitch pin.
Page 24: Control Box Installation
Figure 13 Control box Installation HYDRAULIC CONNECTION The Scorpion 300 harvester requires and continuous adjustable hydraulic flow from the tractor to operate correctly. Only two lines are required, P (flow/pressure) and T (Tank/Return). A reverse connection is prevented by a check valve in the harvester hydraulic manifold. Ideally, connect the tank line (T) to a motor return port on the tractor (often used for hydraulic motor return on planters or sprayers), that offer a low flow resistance.
Page 25 SETUP Figure 14: Hydraulic connection WARNING: Check the return pressure indicated on the pressure gauge located on the harvester valve manifold. A maximum pressure of 50 psi is required. A higher pressure can cause hydraulic system malfunctions. Figure 15: Pressure gauge The return pressure is affected by two factors: ...
Page 26: Connecting The Harvester To The Tractor
SETUP CONNECTING THE HARVESTER TO THE TRACTOR FIGURE 16 The tractor drawbar (item 1) must be centered and aligned with the PTO driveshaft (item 2). Align the harvester shaft (item 3) with the tractor PTO (item 5) by adjusting the height of the adjustable drawbar (item 4).
Page 27: Draw Bar Extension
SETUP CAUTION: To prevent the rotation of the PTO shields, fastening chains (item 6 on Figure 17) are provided and must be attached on both ends. CAUTION: Attach a safety chain (Figure 18, item 7) with a minimum capacity of 9071 kg (20000 lbs) for transport.
Page 28 SETUP STEP 5 Center the extension (item 3) with the draw bar (item 4). To center side to side, use the bolts (item 11). STEP 6 Insert pin (item 14) and lock with the safety pin (item 15). Note that items 14 and 15 are not supplied by the manufacturer.
Page 29 SETUP STEP 5 Center the extension (item 3) with the drawbar (item 4). To center side to side, use the bolts (item 11) then lock in place with the nuts (item 12 Center the extension (item 3) with the draw bar (item 4). To center side to side, use the bolts (item 11) then lock in place with the nuts (item 12).
Page 30: Configuring For Corn Harvest Setup
SETUP CONFIGURING FOR CORN HARVEST SETUP To harvest corn, the PROCESSOR must be partially re-assembled by installing the top roll in position. Follow the instructions: STEP 1 - FIGURE 21 Open the main guard then pivot the hydraulic manifold to free space around the accelerator belt binder. Figure 21 Main guard and manifold STEP 2 - FIGURE 22 Remove the lock pin (item 1) and the header lift cylinder locking arm (item 2).
Page 31 SETUP STEP 3 - FIGURE 23 Use the knife guide bar stored on the machine (item 1) to unlatch the accelerator binder. Unhook the spring (item 2) from the front bracket to completely lower the binder assembly. Remove the belt to access the roller opening in the frame.
Page 32 SETUP STEP 5 - FIGURE 25 Loosen the processor roll holding bolts at the rear (left and right) (item 1) and lower the bottom frame assembly. Remove the stainless cover plate (item 2) on the bottom roll (item 3) as shown. Lift the bottom frame back up while ensuring no parts are being pinched and the contact areas are carefully cleaned.
Page 33 SETUP STEP 7 - FIGURE 27 Bolt the processor bearing plates (item 1) on both sides (item 2). Each plate must be fastened with two 1/2” dia. X 1” lg flange bolts. Figure 27 Bearing supports STEP 8 - FIGURE 28 Ensure the pulley tensioning pulley is loosen by unscrewing the right-hand rod at the rear (item 2) using the provided handle (item 4).
Page 34 SETUP STEP 9 - FIGURE 29 When the belts are installed, set the tension on the binding pulley (item 4). Screw in the right-hand rod (item 2) to stretch the spring (item 3) with the provided handle (item 1). Adjust to a spacing of 1/16” (1,5 mm) between the spring coils to obtain the proper pre-tension.
Page 35 SETUP Figure 30 Accelerator binder STEP 12 - FIGURE 31 Install the cylinder lock lever (item 2) and insert the locking pin (item 1). Install the binder locking bolt (item 3 and 4). Figure 31 Cylinder lock lever and binder locking bolt. Manual No.
Page 36 SETUP STEP 13 - FIGURE 32 Install the front plate of the grain pan (item 4) with the three carriage bolts 3/8’ dia. x 3/4” Lg (item 1) and three flange nuts 3/8’’ (item 3) on the front pan (item 2). Ensure the nuts are installed on the outside. Figure 32 Front grain pan STEP 14 - FIGURE 33 Pivot the hydraulic manifold back in place.
Page 37: Configuring The Harvester For Windrow (Hay) Harvesting
SETUP CONFIGURING THE HARVESTER FOR WINDROW (HAY) HARVESTING For hay harvesting or any other crop not requiring processor rolls, the top roll must be removed. Follow the instructions below: STEP 1 - FIGURE 34 Open the main guard, then pivot the hydraulic manifold to free space around the accelerator belt binder. Figure 34 Main guard and valve manifold STEP 2 - FIGURE 35 Remove the lock pin (item 1) and the header lift cylinder locking arm (item 2).
Page 38 SETUP STEP 3 - FIGURE 36 Use the knife guide bar stored on the machine (item 1) to unlatch the accelerator binder. Unhook the spring (item 2) from the front bracket to completely lower the binder assembly. Remove the belt to access the roller opening in the frame.
Page 39 SETUP STEP 5 - FIGURE 38 Remove the 6 belts (item 1): Remove the first three belts from the front of the pulley (item 3). Remove the three others from the back of the pulley (item 4) as shown. Turn the driving pulley (item 2) in the direction shown to ease the task.
Page 40 SETUP Figure 40 Clamping the top processor roll STEP 8 - FIGURE 41 Install the cover plates, left (item 1) and right, (item 2) using 1/2” dia. X 1” lg. flange bolts. Figure 41 Cover plates STEP 9 - FIGURE 42 Remove both holding bolts at the rear of the processor frame (item 1) and lower the assembly.
Page 41 SETUP Figure 42 Processor roll unit STEP 10 - FIGURE 43 Lift the processor roll bottom assembly (item 1) while making sure the stainless cover (item 3) sits properly under the channel half-pans (item 4) as shown. Replace and tighten the frame bolts (item 2) to proper torque (See Table 1 Bolt Torque Specifications, page 22).
Page 42 SETUP Figure 44 Accelerator belt binder STEP 12 - FIGURE 45 Install the lift cylinder lever (item 2) back on and insert the locking clip (item 1). Replace the binder locking bolt (item 3 and 4). Figure 45 Locking lever and binder locking bolt Manual No.
Page 43 SETUP STEP 13 - FIGURE 46 Pivot the hydraulic manifold back in place. Figure 46 Valve manifold STEP 14 - FIGURE 47 Remove the front grain pan section (item 4) with three 3/8" dia. x 3/4" Lg carriage bolts (item 1) and three 3/8"...
Page 44: Setting The Lentgh Of Cut
SETUP SETTING THE LENTGH OF CUT FIGURE 48 Two factors determine the length of cut setting: firstly, the number of knives installed and the length of cut sprocket (item A) driving the feedrolls. Refer to the following chart for the appropriate settings. Optional length of cut (LOC) range LOC «...
Page 45: Procedure To Modify The Length Of Cut
SETUP PROCEDURE TO MODIFY THE LENGTH OF CUT STEP 1 - Figure 49 Open the main guard. Figure 49 Ouvrir le garde principal STEP 2 - FIGURE 50 Completely remove the chain tension (item 1) by loosening the tension rod (item 2). Figure 50 Chain binder Manual No.
Page 46: Header Installation
SETUP STEP 3 - FIGURE 51 Remove the LOC double sprocket (item 1), by removing the spring clip (item 2) and washer (item 3). It may be easier to remove disconnect the chain when removing the 34tooth sprocket. Figure 51 Double sprocket STEP 4 Apply anti-seizing lubricant on the shaft and slide in the required sprocket from the table in Figure 48.
Page 47 SETUP DANGER: Never use the harvester without installing a header prior. STEP 1 - FIGURE 53 Swing the tongue open (item 2) (see arrow) and position the suspension spring (item 3). Refer to HEADER SUSPENSION section page 49 for proper functioning of the suspension according to the header used. When using a 4-row corn head, install the 1 1/4"stroke limiting pin (item 4) provided with the harvester to avoid contact between the header and the harvester.
Page 48 SETUP Figure 55 Feedroll guards CAUTION: If the throat sides (item 14) of Hay or Corn crop attachments are bent or damaged, it is necessary to repair them so they will not come in contact with the feed rolls. STEP 4 - FIGURE 56 When the header is installed on the harvester, install the square locking pins in place (item 10) and the safety locks clips (item 11) on both sides.
Page 49: Header Suspension
SETUP STEP 6 - FIGURE 57 To install the corn head drive chain (item 16), use the provided #80 X 35” lg with a single #80 connecting link. To install the windrow pickup drive chain (item 17), use the provided #80 X 35” lg with a #80 half link plus one #80 connecting link provided.
Page 50: Header Height Adjustment
SETUP Figure 58 Header lift springs FIGURE 59 Position the springs to the appropriate setting. Figure 59 Suspension spring position HEADER HEIGHT ADJUSTMENT FIGURE 60 The header height adjustment is done through a double acting hydraulic cylinder for which the control switch is located on the control box.
Page 51: Starting Up And Break In
SETUP Figure 60 Header lift lock STARTING UP AND BREAK IN Always engage the tractor’s power-take-off (PTO) at low speed (engine speed at idle) in order to prevent the eventual breaking of the safety bolt on the transmission line. The harvester has a high inertia and applies a high load on the PTO when starting.
Page 52: Knive Sharpening
SETUP  The condition of the shearbar is just as important as the knives for a high-quality cut. This bar features two cutting faces covered with tungsten (item 4). When the edge loses its sharpness, it can be rotated around to use the other edge. NOTE: For daily adjustments, after sharpening the knives for example, only the side adjustment (item 3) is used.
Page 53: Daily Shearbar Adjustement
SETUP 5. Lower the stone sufficiently to produce sparks when passing over the knives. 6. When the sharpening is completed, raise the stone slightly by pushing the carriage at stroke end several times. The stone will raise at every click heard. 7.
Page 54: Control Box Functions
SETUP Figure 63 Shearbar adjustment CONTROL BOX FUNCTIONS FIGURE 64 All harvester functions are controlled through the control box and operated along with the hydraulic system. Only one control box is offered, equipped with all optional function switches, even if not installed on the harvester (Metal detector or inoculant kit for example).
Page 55: Metal Detector General Information
SETUP 1. Trailer quick disconnect with safety cap (OFF/MOMENTARILY ON) – Optional 2. Liquid/inoculant incorporation system (ON/OFF) – Optional 3. Spout and work light (ON/OFF) – Optional 4. Spout height switch (UP/STOP/DOWN) 5. Spout rotation (LEFT/STOP/RIGHT) and deflector (UP/STOP/DOWN) joystick 6.
Page 56 SETUP CONTROLLER - FIGURE 69 The metal detector is managed by the electronic controller located on the harvester above the hydraulic manifold. It controls the transmission F-N-R and the emergency stop system. An indicator light on the controller shows the state of the system. ...
Page 57: Daily Checks On The Metal Detector
SETUP CAUTION! An intensive magnetic field may be present, therefore, people with a pacemaker, hearing aid and/or any other type of devices of this nature, MUST BE CAREFUL around the machine. The magnets could affect these types of devices. IMPORTANT! Because of the limitations of the system, there is an area at both ends of the lower feed roll where the sensitivity is reduced.
Page 58: Metal Detector Sensitivity Ajustement
SETUP METAL DETECTOR SENSITIVITY AJUSTEMENT The sensitivity adjustment can be done at any time on the controller itself, located over the hydraulic manifold (Figure 69). FIGURE 65 1. Stop the PTO and wait for all parts to stop rotating before opening the main guard. 2.
Page 59: Drive Failure Detector
SETUP If the solenoid is not functional, apply step "A", then attach the stop pawl spring (item 4, Figure 66) back to the second hook (see the arrow). Make sure the stop pawl clears the ratchet cam wheel. Reactivate the hydraulic flow and resume work. NOTE: Every time the secondary breaker (item 4) is switch ON, the metal detector is automatically reactivated.
Page 60 SETUP Figure 67 Cutterhead speed sensor FEEDROLL SPEED SENSOR It reads the speed of the top feedroll shaft on the F-N-R gearbox and can be used to detect incoherence between the shifter position and feedroll speed (Item 1, Figure 68). Maintain a gap of less than 1mm between the tip of the sensor and the encoding wheel.
Page 61: Disabling The Drive Failure Detector
SETUP Figure 69 : Controller and indicator lights DISABLING THE DRIVE FAILURE DETECTOR In the cases where a speed sensor has failed or other reason requiring to disable the drive failure detector, proceed as described on Figure 66 : 1. Turn off the main control box switch 2.
Page 62: Pressure Adjustement
SETUP Figure 70 Default location of the liquid incorporation nozzle The flow is regulated by adjusting the pressure at the pump. It must be adjusted to match the average throughput with to obtain constant application rate. See Figure 64 for the control switch location. PRESSURE ADJUSTEMENT FIGURE 71- TABLE 2 To adjust the pressure:...
Page 63 SETUP 0,91 0,24 1,12 0,28 0,23 1,29 0,35 0,29 1,58 0,33 1,82 0,49 Table 2 Flow vs pressure of XR TEEJET XR8004 nozzle NOTE: The electrical connection must be made through a load-protected circuit. Use the harness provided in the incorporation kit which includes an activation relay. This harness and the standard harvester wiring can be used for other liquid incorporation systems as long as it drives to the relay harness (part# 30896) and cable extension (#31511) available from the Dion Parts department.
Page 64: Calibration Procedure
SETUP CALIBRATION PROCEDURE FIGURE 72 The system must be calibrated to obtain the right dosage of liquid in the crop. Fill the reservoir with water, 10-15l (3-4gal.) are sufficient. Adjust the pressure to the pressure corresponding to the desired flow (Figure 71). Put an empty bucket (item 1) under the nozzle (item 2) to collect the liquid (inside the accelerator chamber if standard nozzle location is used).
Page 65: Transport Lights
SETUP TRANSPORT LIGHTS FIGURE 73 The transport lights on the right-hand side can be raised to reduce the harvester overall width when storing he machine or circulating in narrow spaces. To raise, remove the pin (item 1 configuration 2), then raise the light assembly and reinstall the locking pin (item 1 configuration 3).
Page 66: Operation
OPERATION OPERATION PRACTICAL ADVICE WARNING: A forage harvester can pose a severe health risk if not used properly. Make sure the safety rules are followed by everyone operating or in the vicinity of the machine. Refer to page 12 for the safety rules. NOTE: Generally, we suggest to be safe and perform an adjustment check and inspection before starting up the harvester.
Page 67 OPERATION  Unlock the header lift cylinder (Figure 76) Figure 76 Unlocking the header lift cylinder  Unlock the drawbar by removing the transport locking pin (item 1) Figure 77 Unlocking the drawbar  Turn on the control box –Figure 78, Item 1 ...
Page 68: F-N-R Transmission Shifting
OPERATION F-N-R TRANSMISSION SHIFTING NOTE: The tractor SCV must be set in continuous mode to shift the transmission. WITHOUT METAL DETECTOR, OR DEACTIVATED FIGURE 78 In this configuration, the transmission control is fully manual.  REVERSE o Press « R » on the shifter switch to move the shifter to the reverse position. Make sure the button is pressed until the shifter has move to the end of its stroke.
Page 69: Initializing The Metal Detector
OPERATION Figure 78 Control box INITIALIZING THE METAL DETECTOR For models equipped with the metal detector, follow these instructions, referring to Figure 78, to initialize the FerroDtec system. This must be done at the system start-up: Start the tractor engine and activate the SVC connected to the harvester in continuous flow mode. Turn ON the main and metal detector breaker (item 1 and 2).
Page 70: Starting Up
OPERATION STARTING UP Before feeding crop through the forage harvester, the power-takeoff (PTO) should run at the required speed e.g. 540 or 1000 rpm as the case may be in order to prevent any material accumulation (clogging), breaking of the shear bolts or slipping of the friction clutch.
Page 71: Processor Roll Pressure And Spacing
OPERATION PROCESSOR ROLL PRESSURE AND SPACING The operator can select the silage condition by varying the pressure and clearance of the upper cracker roll (item 1). Refer to Figure 79. Adjust the pressure using the handle (item 3). Turn the left-hand spring threaded rod (item 4) until a 1.5 mm (1/16”) space is obtained between the spring coils.
Page 72: Processor Roll Clearance Adjustment Procedure
OPERATION PROCESSOR ROLL CLEARANCE ADJUSTMENT PROCEDURE To facilitate the processor rolls adjustment to obtain the desired silage quality (Figure 80): Adjust the roll spacing to position 2 shown on the decal (item 1). Each level represents a 3mm (1/8po) additional clearance. Level 2 6mm (1/4in). Harvest over several tens of meters (few hundred feet), then check the silage obtained.
Page 73: Shearbolt Failure
OPERATION Figure 81 F-N-R transmission overload clutch When an overload happens: Press the Emergency Stop button (Figure 78, item 3) or quickly shift the transmission to NEUTRAL to avoid clutch overheating. In case of minor blockages, reduce the PTO rpm to the minimum, then shift the transmission in REVERSE for a few seconds to unclog the jammed silage.
Page 74: Friction Clutch (Option)
OPERATION Shift the transmission to REVERSE to empty the feedroll throat and shift back to NEUTRAL. Stop the PTO, turn off the tractor and replace the brocket shearbolt. Clear the feedrolls or header if any crop remains. Start the tractor, engage the PTO at low speed with the harvester in NEUTRAL, and accelerate the engine speed quickly to clear the harvester.
Page 75: Cleaning The Processor Rolls
OPERATION CLEANING THE PROCESSOR ROLLS FIGURE 83 Every time a safety shear bolt is broken or the PTO has been accidentally stopped while operating, material accumulated between the cracker rolls and the cutter head must be removed. Follow this cleaning procedure: Open the top cover (item 1) Open the cleaning doors (item 2) Bring the scraper (item 3) down between the cutterhead and the upper roll.
Page 76: Transport
OPERATION TRANSPORT TRANSPORT ON PUBLIC ROADS FIGURE 85 Before transporting the harvester on the road, take the following precautions. 1. Clean the harvester from any debris that may fall on the road. 2. Set the drawbar (item 3) in transport position lock it with the locking pin (item 4) provided. 3.
Page 77 OPERATION Figure 85 Transport on public roads CAUTION: When a trailer is pulled behind the harvester and the latter is equipped with the hydraulic remote trailer disconnect (option) or other disconnect system (item 1), the safety pin (item 2) must be set in place before driving on public roads or hilly terrain.
Page 78: Maintenance And Adjustments
MAINTENANCE AND ADJUSTMENTS DANGER: Never lubricate or service the machine when the PTO is operating and/or the tractor engine is running. WARNING: Never remove guards or make adjustments while the machine or tractor engine is running. WARNING: Make sure all guards, shields and doors are in place and properly secured before starting the tractor engine.
Page 79: Lubrication Chart
MAINTENANCE AND ADJUSTMENTS LUBRICATION CHART The symbols in the chart below indicate specific points which should be greased, oiled and verified: GEARBOXES LUBRICATION The gearbox oil lever must be checked and adjusted after the first ten (10) hours of operation, at the beginning of every season and at least every 100h of operation.
Page 80 MAINTENANCE AND ADJUSTMENTS Figure 86 Universal joint and drawbar bearings Figure 87 Front PTO Figure 88 Angle drive gearbox Manual No. F6918E003E v1.2...
Page 81 MAINTENANCE AND ADJUSTMENTS Figure 89 Main gearbox, spout rotation and hydraulic trailer disconnect Manual No. F6918E003E v1.2...
Page 82 MAINTENANCE AND ADJUSTMENTS Figure 90 Knife grinder, suspension springs and transmission shifter Manual No. F6918E003E v1.2...
Page 83 MAINTENANCE AND ADJUSTMENTS Figure 91 Cutterhead and blower bearings (each side – 4 points) Figure 92 Feedroll slider, shearbar spring plunger (each side – 4 points) Manual No. F6918E003E v1.2...
Page 84 MAINTENANCE AND ADJUSTMENTS Figure 93 Universal joints, transmission chain Manual No. F6918E003E v1.2...
Page 85 MAINTENANCE AND ADJUSTMENTS Figure 94 Feedrolls linkage, bearings and chains Manual No. F6918E003E v1.2...
Page 86: Processor Roll Lubrication
MAINTENANCE AND ADJUSTMENTS Figure 95 Header lift arms and cylinder PROCESSOR ROLL LUBRICATION In wet conditions, the silage rejects large amounts of fluids when passing through the processor rolls that may contaminate the roller bearings. It is highly recommended to increase the greasing frequency of the grease chambers behind the bearing (item 1) every 4 hours of operation.
Page 87 MAINTENANCE AND ADJUSTMENTS Figure 96 Sealed grease chamber behind the roller bearings Figure 97 Processor rolls lubrification Manual No. F6918E003E v1.2...
Page 88 MAINTENANCE AND ADJUSTMENTS Figure 98 Processor rolls lubrification Manual No. F6918E003E v1.2...
Page 89: Feedroll Spring Tension
MAINTENANCE AND ADJUSTMENTS FEEDROLL SPRING TENSION FIGURE 99 Both upper feedrolls are ﬂoating over the crop under tension, and their vertical motions are limited by four springs (item 1). The vertical displacement of these rolls is interdependent and controlled by stabilizing bars (item 2). There are two springs on each outer sides of the feeding inlet;...
Page 90: Feedrolls Chain Tension
MAINTENANCE AND ADJUSTMENTS Figure 100 Ajustement pour hacher la paille FEEDROLLS CHAIN TENSION FIGURE 101 - FIGURE 102 To tighten the top feedroll chain (item 1), loosen binder bolts (item 2) completely and remove spacers (item 3) from the binder plate (item4) to obtain the required tension. Make sure the binder is centered with the chain rollers (item 5).
Page 91: Transmission Belt Tension
MAINTENANCE AND ADJUSTMENTS To adjust the bottom feedroll chain (item 1) tension, loosen the bolts (item 2), and then push the binder (item 3) upwards until the proper tension is set before reinstalling the bolt. Make sure the binder plate is centered on the chain (item 4) by adjusting the number of shims (item 5).
Page 92: Accelerator Belt Tension
MAINTENANCE AND ADJUSTMENTS ACCELERATOR BELT TENSION FIGURE 104 The 4-stripe banded belt (item 1) of the accelerator is driven by the pulley on the cutterhead shaft. Its tension is adjusted with the spring (item 2): 1. Loosen the locking nut (item 4). 2.
Page 93: Storage Procedure
MAINTENANCE AND ADJUSTMENTS Figure 105 Corn processor bel tension adjustment STORAGE PROCEDURE NOTE: Never pressure wash the electronic controls, bearings, solenoid valves, hydraulic manifolds or other component containing seals (Figure 106). Figure 106 Pressure washing STEP 1 To prevent any accumulation of dirt, soil, material, excess of grease, or any other substance which could absorb water and cause moisture and rust, clean the forage harvester thoroughly.
Page 94 MAINTENANCE AND ADJUSTMENTS NOTE: A regular inspection of the processor high speed bearings is essential to ensure a long-term durability. STEP 3 Lubricate the entire machine and check oil levels. STEP 4 Clean and lubricate all chains. STEP 5 To prevent rust when paint is damaged, apply a new coat of paint on exposed surfaces. STEP 6 Order the necessary spare parts and repair the forage harvester before beginning the new season.
Page 95: Diagnostic & Troubleshooting
DIAGNOSTIC & TROUBLESHOOTING CONTROLLER ALARMS AND LOGIC This graph represents the states of the harvester controller, beginning with powering on of the control box and metal detector. The details are explained in the table below titled « CONTROL BOX, TRANSMISSION AND METAL DETECTOR”. Power ON Power Off Lock State...
Page 96: Transmission Shifter Logic
DIAGNOSTIC & TROUBLESHOOTING TRANSMISSION SHIFTER LOGIC This Figure shows the A-R transmission shifter logic (with FerroDtec system), starting with powering the control box power. It displays the interactions between the commands from the operator, the shifter reaction and shifter position sensors. Power On Reverse switch held depressed Transmission in Forward...
Page 97: Control Box, Transmission And Metal Detector
DIAGNOSTIC & TROUBLESHOOTING CONTROL BOX, TRANSMISSION AND METAL DETECTOR PROBLEM/ALARM PROBABLE CAUSES EXPLANATION/SOLUTIONS The machine starts in lock mode and prevents forward rotation of the transmission. The transmission shifter moves automatically to neutral. System Start-up Lock State The operator must shift to reverse to initialize the system and turn off the alarm. (Alarm) System not initialized When initialized, the system is in active sate, ready to be shift in forward and the...
Page 98 DIAGNOSTIC & TROUBLESHOOTING Top feedroll plastic stop worn out Check the condition of the red plastic feedroll stop. If worn out, there will be a direct or absent metal-metal contact that may cause severe vibrations. Inspect the antenna cable over its whole length and on every angle. Measure the Damaged or squeezed sensor resistance between each of the 3 antenna wires.
Page 99 DIAGNOSTIC & TROUBLESHOOTING Electrical resistance between the colored wires is less than 800Ω or higher than 1kΩ signaling that antenna coil wire are damaged or short. Or, there is a short circuit Antenna internal damage between the signal wires and the ground. Replace the antenna inside the detector roll.
Page 100 DIAGNOSTIC & TROUBLESHOOTING Make sure the control box feed voltage exceeds 12V. Check all connections and clean them with contact cleaner if necessary. With the PTO turned off and disconnected from the tractor, initialize the detector and check the voltage at the solenoid to be above 12V (disconnect the wires from the The solenoid does not receive coil under the rubber boot).
Page 101: Ejection
DIAGNOSTIC & TROUBLESHOOTING With the control box ON, but PTO turned off, check that the sensors are properly One of both proximity shifter working but placing a steel piece at their sensing tip and verifying that the indicator sensor is damaged light on the sensor turns on.
Page 102: Feeding
DIAGNOSTIC & TROUBLESHOOTING FEEDING PROBLEM PROBABLE CAUSES SOLUTIONS Very dry or short hay or straw Loosen the feed roll spring tension. Check the smooth roll cleaner adjustment. Excessive lubrication Disassemble the clutch to remove excess grease Damaged internal springs Disassemble the clutch to replace broken springs or worn cams. Replace clutch. Front grain pan is installed when Remove the front pan (item 4,Figure 32 on page 36) windrow harvesting...
Page 103: Cutting
DIAGNOSTIC & TROUBLESHOOTING CUTTING PROBLEMS PROBABLE CAUSES SOLUTIONS Shear bar is not adjusted in straight line and too far away Adjust and correct the shearbar alignment from knives Insufficient crop flow Increase forward speed or windrow size Silage fraying and uneven edge lengths Knives cutting edge worn out Sharpen the knives...
Page 104: Sharpening
DIAGNOSTIC & TROUBLESHOOTING SHARPENING PROBLEMS PROBABLE CAUSES SOLUTIONS Uneven knife sharpened Grinder not parallel to cutterhead Adjust grinder frame alignment with shims face drum Check for the correct spring washers assembly. Stone not assembled correctly Make sure the two set screws are well tightened and locked on the stone Grinding stone vibrates Sharpening PTO speed too Run at 600 PTO RPM for 1000-1000 Harvester.
Page 105 DIAGNOSTIC & TROUBLESHOOTING Implement and tractor PTO shafts Adjust the height of the front bracket are not aligned The universal joint yokes at both ends of the harvester PTO shaft Align joints at both heads to be parallel. The mating spline ends contain a special are not groove that forces the right alignment, make sure it has not been tampered with.
Page 106: Processor Rolls
DIAGNOSTIC & TROUBLESHOOTING PROCESSOR ROLLS PROBLEMS PROBABLE CAUSES SOLUTIONS Side deflectors in front of top rolls Replace the deflectors are worn Incorrect adjustment of the rear Adjust clearance to 0.5mm (1/64”) channel pan Loss of corn silage under The processor rolls. Hay crop residue stuck on edge of When reconfiguring from hay to corn silage, always clean the channel plates and rear channel pan...
Page 107: Electro-Hydraulic Functions
DIAGNOSTIC & TROUBLESHOOTING ELECTRO-HYDRAULIC FUNCTIONS PROBLEMS PROBABLE CAUSES SOLUTIONS Make sure the switch on the control box is ON and power is available Electric power cut off Check that power is available to the controller and valves. Make sure tractor SCV is in continuous mode with approx. 8--11l/min (2-3 gpm) flow. No functions are Hydraulic supply is cut off Make sure flow is directed to the “P”...
Page 108: Checklists
CHECKLISTS PRE-SEASON CHECKLIST Check condition of knives and shearbar. Check that knives and shearbar are set at “zero” clearance. Check tension of belts and chains. Make sure sheaves and sprockets are correctly aligned. Check all adjustable components for correct setting. Make sure adjustments are correct (accelerator, etc.) Check tire pressure.
Page 109 Manual No. F6918E003E v1.2...

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