Page 1 Operator’s Manual FORAGE HARVESTER Manual no. F6918E998E v1.5...
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.
Page 4: Dion-Ag Inc. Limited Warranty
DION-Ag Inc. for the purpose of inspection. Right to Make Design Changes – DION-Ag Inc. reserves the right to make changes in the design and other changes in its products at any time and from time to time without notice and without incurring any obligation of its part to modify, improve or add to products previously ordered from DION-Ag Inc.
Page 5 January 1 2019...
Page 6: Table Of Contents
TABLE OF CONTENTS FOREWORD ........................................ 3 SAFETY ........................................3 WARRANTY INFORMATION ..................................3 DION-AG INC. LIMITED WARRANTY ................................4 SPECIFICATIONS ......................................9 DIMENSIONS ......................................9 WEIGHT ......................................... 9 TRANSMISSIONS ....................................9 CUTTER HEAD ......................................9 TIRES AND WHEELS ....................................10 FEATURES ......................................
Page 7 DISABLING THE DRIVE FAILURE DETECTOR ............................62 LIQUID INCORPORATION SYSTEM................................ 63 PRESSURE ADJUSTEMENT ................................63 FLOW CALIBRATION PROCEDURE .............................. 64 TRANSPORT LIGHTS ..................................... 65 SET TRACK WIDTH ....................................66 GROUND CLEARANCE ..................................66 OPERATION PRACTICAL ADVICE................................67 HARVESTER DRAW BAR POSITION ............................. 67 STOPPING THE MACHINE ..................................
Page 8 SHARPENER FRAME ADJUSTMENT ..............................113 F-N-R TRANSMISSION SHIFTER ARM ADJUSTMENT ........................... 114 F-N-R TRANSMISSION SENSOR ADJUSTMENT ............................ 115 FEED ROLL STOPPING MECHANISM ADJUSTMENT ..........................116 SPEED SENSOR ADJUSTMENT ................................117 ELECTRONIC CONTROL UNIT & CONNECTOR CLEANLINESS ....................... 118 WELDING ON THE HARVESTER ................................118 STORAGE PROCEDURE ..................................
Page 9: Specifications
SPECIFICATIONS Specification and design are subject to change without notice and responsibility from the manufacturer. DIMENSIONS width (narrow axle position) OVERALL  With tires 31x13.50 - 15 TerraRib…….…………………………………….3.30 m (142”)  With tires 31x15.50 - 15 TerraGrip…..…………………………………….3.50 m (150”) (Spout in transport position) …....……….......6.22 m (244”) LENGTH min / max –...
Page 10: Tires And Wheels
SPECIFICATIONS TIRES AND WHEELS SINGLES  31, 13.5-15 TerraRib  31 x 15.5 TerraTrac TANDEM  31, 13.5-15 TerraRib  31 x 15.5 TerraTrac FEATURES STANDARD  Angle drive 1000/1000  Cutter head with 24 (8x3) tungsten carbide Duradrum knives ...
Page 11: Serial Number Location
SPECIFICATIONS SERIAL NUMBER LOCATION For your convenience, write down the full model and serial number of your machine in this manual, as shown on the name plate illustrated below. Always mention both the model and the serial number when ordering parts or regarding any other correspondence with your machine.
Page 12: Safety Rules
SAFETY RULES A WORD TO THE OPERATOR It is the responsibility of the OWNER to read and fully understand the safety section in this manual before operating your tractor. You must follow these safety instructions that will assist you step by step throughout your workday. After 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’s Manual, 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 alter alertness or coordination.
Page 14: Preparation And Operation
SAFETY RULES PREPARATION 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. Make any necessary adjustments.  Use a lift system with a minimum lifting capacity of 2500 lbs (1150 kg) to install a header on the forage harvester.
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 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 Sign Location
SAFETY RULES SAFEY SIGN LOCATION Several decals located around the hazard areas indicate the potential dangers. IMPORTANT: Decals must be kept clean to allow for visibility at all times. Figure 4 Safety Decals Figure 5 Safety Decals...
Page 18 SAFETY RULES Figure 6 Safety Decals Figure 7 Safety Decals...
Page 19 SAFETY RULES Figure 8 Safety Decals...
Page 20 SAFETY RULES Figure 9 Safety Decals...
Page 21 SAFETY RULES Figure 10 Safety Decals...
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 NOTE: Replace hardware with the same grade bolt. SAE 2 SAE 5 SAE 8 10.9 Figure 11 Bolt grades...
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 2430 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 valve manifold.
Page 25 SETUP 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
To increase the turning angle and eliminate vibration, position the tractor drawbar to a length “B” between 50 cm (20”) and 60 cm (24”). If the drawbar can’t achieve this setting, purchase a drawbar extension available at your DION-Ag Inc. dealer. Figure 17 Tractor drawbar length adjustment...
Page 27: Draw Bar Extension
SETUP CAUTION: Attach a safety chain (item 7, with a minimum capacity of 9071 kg (20 000 lbs) for transport. FIGURE 18) Figure 18 : Safety chain DRAW BAR EXTENSION In the case where the tractor drawbar is too short, proceed to install the drawbar extension. FOLLOW THESE INSTRUCTIONS TO INSTALL A CAT.
Page 28 SETUP 8. Install the safety chain (item 16) between the tractor frame and the Forage Harvester. Refer to Figure 18 : Safety chain on page Figure 18 for more information on how to install the safety chain. : Safety chain Figure 19 Cat.
Page 29 SETUP 6. Center the extension (item 3) on the draw bar (item 4). To center side to side, use the bolts (item 11). Once centered, lock the bolts in place using the nuts (item 12). 7. Insert pin (item 14) and lock with the safety pin (item 15). NOTE: items 14 and 15 are not supplied by the manufacturer 8.
Page 30: Configuring For Corn Harvest Setup
SETUP CONFIGURING FOR CORN HARVEST SETUP To harvest corn, the PROCESSOR top roll must be re-installed. Follow the instructions below: STEP 1 - FIGURE 21 Open the main guard. Pull the release lever and swing the hydraulic valve manifold to free space around the accelerator belt tensioner.
Page 31 SETUP STEP 3 - FIGURE 23 Use the knife guide bar stored on the machine (item 1) to unlatch the accelerator tensioner. Unhook the spring (item 2) from the front bracket to completely lower the tensioner assembly. Remove the belt to access the roller opening in the frame.
Page 32 SETUP STEP 5 - FIGURE 25 Support the processor roll unit and loosen the processor roll fastening bolts at the rear (left and right) (item 1). Lower the processor roll unit carefully to gain access to the roller assembly. Remove the stainless cover plate (item 2) on the bottom roll (item 3) as shown and store the pieces.
Page 33 SETUP STEP 7 - FIGURE 27 Install the processor bearing plates on both sides (items 1 & 2). Each bearing plate must be fastened with using: 2ea - 1/2” dia. X 1” long flange bolts. Figure 27 Bearing supports STEP 8 - FIGURE 28 Ensure the tension on the pulley tensioning spring (item 3) is released by unscrewing the right-hand rod at the rear of the harvester (item 2) using the provided square head tool (item 4).
Page 34 SETUP STEP 9 - FIGURE 29 When the belts are installed, set the tension on the binding pulley (item 4) by resetting the tension on the pulley tensioning spring (item 3). Tighten (clockwise) the right-hand rod at the rear of the harvester (item 2) to stretch the spring (item 3) with the provided square headed tool (item 1).
Page 35 SETUP STEP 11 - FIGURE 30 Reinstall the accelerator belt and hook the spring back on (item 2). Use the knife guide bar (item 1) to reset the tension in the belts. (Reverse from Step 3 – Figure 23 Accelerator ). Figure 30 Accelerator tensioner STEP 12 - FIGURE 31 Install the cylinder lock lever (item 2) and insert the locking pin (item 1).
Page 36 SETUP STEP 13 - FIGURE 32 Install the front grain pan (item 4) with the three - 3/8’ dia. x 3/4” Long carriage bolts (item 1) and three - 3/8’’ flanged nuts (item 3) on the front of the pan (item 2). Ensure the nuts are installed on the outside as shown below. Figure 32 Front grain pan STEP 14 - FIGURE 33 Swing the hydraulic valve 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. Pull the release lever and swing the hydraulic valve manifold to free space around the accelerator belt tensioner.
Page 38 SETUP STEP 3 - FIGURE 36 Use the knife guide bar stored on the machine (item 1) to unlatch the accelerator tensioner. Unhook the spring (item 2) from the front bracket to completely lower the tensioner assembly. Remove the belt to access the roller opening in the frame.
Page 39 SETUP STEP 5 - FIGURE 38 The drive pulley (item 2) has 6 slots for 6 belts. If you consider the pulley slot closest to the machine body #6 and furthest from the machine body #1, remove the six belts, one belt at a time, in the following order: Start on the drive pulley side furthest from the machine body always rotating clockwise as shown in Figure 38 Removing the belts.
Page 40 SETUP STEP 7 - FIGURE 40 Remove the top roll assembly (item 3) and slide it onto the plastic guides. Grease the roller splines to prevent rust formation. Align one of the fastening holes with the stud (item 4) to prevent it from sliding laterally. Install the rubber cover (item 2) on the roll and clamp it down in place with the holding strap (item 1).
Page 41 SETUP STEP 9 - FIGURE 42 Support the processor roll unit and loosen the processor roll fastening bolts at the rear (left and right) (item 1). Lower the processor roll unit carefully to gain access to the roller assembly. Clean the channel pans and the bottom roll (item 3) and grease the bottom roller splines to prevent rust formation.
Page 42 SETUP STEP 11 - FIGURE 44 Reinstall the accelerator belt and hook the spring back on (item 2). Use the knife guide bar (item 1) to reset the tension in the belts. (Reverse from Step 3 – FIGURE 36 ACCELERATOR Figure 44 Accelerator belt tensioner STEP 12 - FIGURE 45 Install the cylinder lock lever (item 2) and insert the locking pin (item 1).
Page 43 SETUP STEP 13 - FIGURE 46 Swing the hydraulic valve manifold back in place. Figure 46 Valve manifold STEP 14 - FIGURE 47 Remove the front grain pan (item 4) with the three 3/8’ dia. x 3/4” Long carriage bolts (item 1) and three 3/8’’ flanged nuts (item 3) on the front pan (item 2).
Page 44: Setting The Length Of Cut
SETUP SETTING THE LENGTH OF CUT FIGURE 48 Two factors will determine the length of cut: 1. The number of knives on the cutter head. 2. The length of cut (LOC) sprocket (item A) driving the feed rolls. LOC L (Low speed) or LOC H (High speed). Refer to the following chart for the appropriate settings.
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 Open the main guard STEP 2 – FIGURE 50 Completely remove the chain tension (item 1) by loosening the tensioning rod (item 2). Figure 50 Chain tensioner...
Page 46: Spout Extension Removal
SETUP STEP 3 - FIGURE 51 Remove the quick link of the chain before attempting to remove the sprocket. Remove the LOC double sprocket (item 1), by removing the spring clip (item 2) and washer (item 3). You may need to clean the shaft with fine sand paper to remove paint or dirt before the sprocket can be removed.
Page 47 SETUP STEP 2 1. Remove the two bolts (item 4) on the deflector module. The module is equipped with hooks (Item 5) that will keep it in place during this operation. 2. Securely fasten the module with lifting straps and lift it to remove it. Figure 52 Spout conversion STEP 3 1.
Page 48: Header Installation
SETUP HEADER INSTALLATION Ensure the harvester and header rest on a flat and level surface. The headers are equipped with a single point lift (item 1, Figure 54 Header lift point) allowing the use of a lift chain (1350kg -3000lbs min capacity) and hook for easy maneuvering.
Page 49 SETUP STEP 2 - FIGURE 56 Move the harvester towards the header slowly while ensuring the pivots receptacles (item 12) are aligned with the header brackets (item 13, Figure 56 Header attach points). Figure 56 Header attach points STEP 3 - FIGURE 57 Align and adjust the 2 feed roll throat guards (items 14) to fit between the harvester throat sides and feed rolls.
Page 50 SETUP STEP 4 - FIGURE 58 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. Figure 58 Header locking pins STEP 5 - FIGURE 59 Use the following drive chain setup for the corresponding head: Corn Head: Use the provided #80 X 35”...
Page 51: Header Suspension
SETUP HEADER SUSPENSION STEP 1 - FIGURE 60 The suspension springs (item 1, Figure 60 Header lift springs) function is to control the header ground pressure. In general, the tension must be set to result in a weight of about 35 kg (75 lb) at the front of the header. The spring adjustment varies from one header to another.
Page 52: Header Height Adjustment
SETUP HEADER HEIGHT ADJUSTMENT FIGURE 62 The header height adjustment is achieved through a double acting hydraulic cylinder which is controlled by a switch located on the control box. For windrow pickups, refer to the operator’s manual to set the minimal working height with gauge wheels.
Page 53: Shear Bar Design
SETUP SHEAR BAR DESIGN Refer to for the following explanations. FIGURE 63  The DION shear bar contains two notches on each side. Specially designed bolts (items 2) sit in these notches and are used only to initially adjust the shear bar parallel to the knife drum. ...
Page 54: Knife Sharpening
SETUP KNIFE SHARPENING DANGER: To prevent serious injury or death, the operator should be the only person to perform the knife grinding operation. DANGER: The main transmission should be in the NEUTRAL position. Switch off the tractor engine before removing the cover on the cutter head. Make sure the safety brake is engaged. DANGER: To prevent serious injury or death from rotating knives, stand on the ground with one foot in front of the other to keep your body weight centered when knives are turning.
Page 55: Daily Shear Bar Adjustement
SETUP DAILY SHEAR BAR ADJUSTEMENT To adjust the shear bar (Figure 65): 1. After knife grinding, with the PTO engaged, lower the tractor engine speed to the minimum. 2. Loosen the shear bar locking bolt (item 1) completely. Both sides loosen at the same time. WARNING: Always fully loosen the shear bar clamping bolts before attempting to adjust clearance.
Page 56: Control Box Functions
SETUP CONTROL BOX FUNCTIONS FIGURE 66 All harvester functions are controlled through the control box along with the hydraulic system. There is only one model of controller offered and it’s equipped with all functions even though the options may not be installed on the harvester (Metal detector or inoculant kit for example).
Page 57: Metal Detector General Information
SETUP METAL DETECTOR GENERAL INFORMATION NOTE: Warranty coverage will not extend to consequential damages. The metal detector is used for stopping the feed rolls when ferrous material is detected between them. The metal detector antenna is mounted inside the lower front feed roll. When the system is working properly, the following or similar objects will be detected with approximately 95% accuracy: ...
Page 58: 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 59: 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 valve manifold (Figure 71). FIGURE 67 1. Stop the PTO and wait for all parts to stop rotating before opening the main guard. 2.
Page 60: Disabling The Metal Detector
SETUP DISABLING THE METAL DETECTOR NOTE: Warranty coverage does not apply to damage or failures caused by the malfunction of the metal detector or its disabling. When the metal detector fails to operate, it can be useful to by-pass the system in order to complete a full harvest day. However, when doing so, it must be taken into consideration that this is an emergency and exceptional situation.
Page 61: Drive Failure Detector
SETUP DRIVE FAILURE DETECTOR As part of the controls included in the metal detector controller, a speed sensor measures the speed of the cutter head (Figure 69) and one reads the speed of the top feed rolls (Figure 70), to check for their relative speed. CUTTER HEAD SPEED SENSOR This sensor reads the speed directly on the cutter head shaft behind the pulley.
Page 62: Disabling The Drive Failure Detector
SETUP The shear bolt (drive failure) detector is run on the harvester controller. The indicator light (item 3 on ) shows FIGURE 71 the state of the detector.  Green – Active.  Orange – Deactivated.  Red – Shear bolt breakage or slip clutch slippage detected. TYPE OF FAILURE OR DETECTABLE ERRORS ...
Page 63: Liquid Incorporation System
SETUP LIQUID INCORPORATION SYSTEM The system can be used to add preservative to the silage or to lubricate the crop channel and spout to maintain the throwing capacity of the harvester in gummy conditions. The harvester is pre-wired for a liquid/inoculant incorporation system.
Page 64: Flow Calibration Procedure
This harness and the standard harvester wiring can be used for other Tier liquid incorporation systems as long as it drives through the DION-Ag relay harness. These parts are available through DION-Ag parts department: Relay Cable (part# 30896) and Extension Cable (#31511).
Page 65: Transport Lights
SETUP TRANSPORT LIGHTS FIGURE 75 The transport lights on the right-hand side can be raised to reduce the harvester overall width when storing the 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: Set Track Width
SETUP SET TRACK WIDTH FIGURE 76 The right-hand side of the machine is equipped with a 3-hole, adjustable axle which purpose is to better distribute the weight or track with crop rows. The hole closest to the wheels is #1 and furthest from the wheels is #3. Hole #1 and #2 - Transport and operating position Hole #3 - Position is reserved for maintenance and for installing or removing the processor roll.
Page 67: Operation Practical Advice
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 the machine or in its vicinity. Refer to SAFETY RULES, page 12. NOTE: With safety in mind, we suggest to perform a general inspection and adjustment verification before starting the harvester.
Page 68 OPERATION 2. Push the handle in towards the harvester to unlock the header lift cylinder (Figure 80). Figure 80 Unlocking the header lift cylinder 3. Unlock the drawbar by removing the transport locking pin (item 1). Store the pin in the toolbox. Figure 81 Unlocking the drawbar 4.
Page 69: F-N-R Transmission Shifting
OPERATION F-N-R TRANSMISSION SHIFTING FIGURE 83 NOTE: The tractor SCV must be set in continuous mode to shift the transmission. Figure 82 Shifter indicator WITHOUT METAL DETECTOR, OR DEACTIVATED In this configuration, the transmission control is fully manual. REVERSE: Press and hold ‘R’ on the shifter switch (item 5) to move the shifter to the reverse position. Make sure the button is pressed until the shifter has moved to the end of its stroke.
Page 70: Initializing The Metal Detector
OPERATION INITIALIZING THE METAL DETECTOR For models equipped with the FerroDtec metal detector system, referring to , follow these instructions to FIGURE 83 initialize the system. This must be done at the system start-up: 1. Start the tractor engine and activate the SVC, connected to the harvester, in continuous flow mode. 2.
Page 71: Metal Detection Procedure
OPERATION METAL DETECTION PROCEDURE When a ferrous material is detected, the alarm is activated and the feed rolls and header are stopped within milliseconds. The transmission will also shift to NEUTRAL automatically. The transmission overload clutch will momentarily emit a loud clacking while the transmission shifts to Neutral.
Page 72: Processor Roll Clearance Adjustment Procedure
OPERATION PROCESSOR ROLL CLEARANCE ADJUSTMENT PROCEDURE To facilitate the processor roll adjustment and obtain the desired silage quality (Figure 85): 1. Adjust the roll spacing to position 2 shown on the decal (item 1). Each level (2, 4, 6 & 8) represents a 3mm (1/8in) additional clearance.
Page 73: Shear Bolt Failure
OPERATION When an overload happens: 1. Press the Emergency Stop button (FIGURE 83, item 3) or quickly shift the transmission to NEUTRAL to avoid clutch overheating. 2. In case of minor blockages, reduce the PTO rpm to the minimum, then shift the transmission to REVERSE for as long as necessary to unclog the jammed silage.
Page 74: Friction Clutch (Optional)
OPERATION FRICTION CLUTCH (OPTIONAL) As an option, a friction clutch can replace the shear bolt overload protection (on demand and for specific cases, contact your dealer). NOTE: When a friction clutch is used, power is still transmitted to the cutter head during slippage, but may burn quickly if not stopped during an overload situation.
Page 75: Transport
OPERATION TRANSPORT TRANSPORT ON PUBLIC ROADS - FIGURE 90 WARNING: When a trailer or other piece of equipment is attached to a forage harvester using a manual, electric or hydraulic quick release coupler (item 3), the locking pin (item 4) must be installed before accessing a public road or hilly terrain.
Page 76 OPERATION 5. For models with short spout, ensure it does not protrude from either side of the harvester and that the tip height is well below the allowable public road max height. 6. Shut off the hydraulic flow to the harvester. 7.
Page 77: Hydraulic Circuits
MAINTENANCE & AJUSTEMENTS DANGER: Never lubricate or service the machine when the PTO is operating and/or the tractor engine is running. WARNING: Never open guards/shields/doors 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 78: Lubrication Chart
The gearbox oil level 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. Synthetic 80W140 oil is recommended (available in 1l containers from DION-Ag Inc. - Parts Department - # 30671) for both gearboxes.
Page 79 MAINTENANCE & AJUSTEMENTS Figure 91 Universal joint and drawbar bearings Figure 92 Front PTO Figure 93 Angle drive gearbox...
Page 80 MAINTENANCE & AJUSTEMENTS Figure 94 Main gearbox, spout rotation and hydraulic trailer disconnect...
Page 81 MAINTENANCE & AJUSTEMENTS Figure 95 Knife grinder, suspension springs and transmission shifter...
Page 82 MAINTENANCE & AJUSTEMENTS Figure 96 Cutter head and blower bearings (each side – 4 points) Figure 97 Feed roll slider, shear bar spring plunger (each side – 4 points)
Page 83 MAINTENANCE & AJUSTEMENTS Figure 98 Universal joints, transmission chain...
Page 84 MAINTENANCE & AJUSTEMENTS Figure 99 Feed rolls linkage, bearings and chains...
Page 85: Processor Roll Lubrication
MAINTENANCE & AJUSTEMENTS Figure 100 Header lift arms and cylinder PROCESSOR ROLL LUBRICATION In wet conditions, harvesting silage may produce large amounts of fluid when passing through the processor rolls. This fluid 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 86 MAINTENANCE & AJUSTEMENTS Figure 101 Sealed grease chamber behind the roller bearings Figure 102 Processor rolls lubrication...
Page 87 MAINTENANCE & AJUSTEMENTS Figure 103 Processor rolls lubrication...
Page 88: Smooth Feed Roll Scraper Adjustment
MAINTENANCE & AJUSTEMENTS SMOOTH FEED ROLL SCRAPER ADJUSTMENT FIGURE 104 The scraper (item 1) should always be installed as close as possible to the smooth feed roll (item 4). To adjust, loosen bolts (item 2) and nuts (item 3). To make the adjustment easier, remove the cutter head cover and the guard used as support for the cutter head cover (items 10 and 11 in Figure 200).
Page 89: Knife Adjustment
MAINTENANCE & AJUSTEMENTS KNIFE ADJUSTMENT FIGURE 105 WARNING: Always disconnect the harvester from the tractor for the knife adjustment operation. WARNING: Always proceed with the knife adjustment with great precautions. WARNING: Be careful when working inside the cutting chamber. A piece of wood should block the cutting head in order to prevent any sudden rotating motions from the latter.
Page 90: Knife Replacement
MAINTENANCE & AJUSTEMENTS Figure 106 Knife guide installation 5. With a hammer, lightly tap on the knives to bring them forward until they contact with the adjustment guide across the full width. 6. Slightly tighten the three knife bolts (item 1) and verify knife adjustment against the guide bar. Readjust, as necessary, repeat for each knife.
Page 91: Shear Bar Replacement
MAINTENANCE & AJUSTEMENTS SHEAR BAR REPLACEMENT FIGURE 108, FIGURE 109, FIGURE 110 NOTE: Always position the tungsten edges facing upwards (on top). The shear bar cutting edge will remain sharp longer providing all knives have been properly sharpened and the shear bar is adjusted every time the knives are sharpened.
Page 92 MAINTENANCE & AJUSTEMENTS 3. Remove the shear bar adjuster module (item 8, see note above for serial# 8XXXXX1.) by removing bolts (item 7). 4. Remove the shear bar (Figure 110 Removing the shear bar), clean it, and verify the condition of the cutting edge. a.
Page 93: Shear Bar Initial Adjustment
MAINTENANCE & AJUSTEMENTS SHEAR BAR INITIAL ADJUSTMENT To make the initial adjustment of the shear bar, do the following: NOTE: Ensure the tungsten faces upwards. NOTE: This adjustment must always be performed after sharpening the knives. 1. Position the bar while ensuring the pointers (item 1) are properly inserted in the bar notches. 2.
Page 94: Shear Bar Clamping Adjustment
MAINTENANCE & AJUSTEMENTS SHEAR BAR CLAMPING ADJUSTMENT FIGURE 112 TO FIGURE 115 NOTE: Inspect and verify the clamping adjustment approximately every 100 hours of operation or at the start of each season. NOTE: Do this only after checking that the initial shear bar adjustment is adequate. See SHEAR BAR INITIAL ADJUSTMENT.
Page 95 MAINTENANCE & AJUSTEMENTS 4. Place the rack (item 3 - 112) so that it protrudes by 65mm (2.5'') from the rack support (see Figure 117 Processor plates adjustment). Figure 113 Positioning the rack and pinion 5. Insert the gear on the left side hex rod (item 5) so that it sits in place with the rack (item 3). If the gear teeth do not align with the rack teeth, lift the gear off of the hex rod and try a different orientation by rotating the gear.
Page 96 MAINTENANCE & AJUSTEMENTS 7. Using a wrench (item 8), maintain a tightening torque on the left rod while inserting the gear on the right side (item 4). Ideally the gear should be installed so that there is very little or no slack between the gear teeth and the rack teeth.
Page 97: Cutterhead Liner Replacement
MAINTENANCE & AJUSTEMENTS CUTTERHEAD LINER REPLACEMENT FIGURE 116 The bottom plate under the cutter head can be replaced by sliding it backwards. 1. Unbolt the bottom plate by removing the support (item 1), the two 3/8” X 3” lg carriage bolts (item 6) and 3/8” lock nuts (item 7).
Page 98: Processor Liner Adjustment
MAINTENANCE & AJUSTEMENTS PROCESSOR LINER ADJUSTMENT FIGURE 117 Adjust the front half bottom plate (item 1): Loosen all 8 bolts (item 6) and leave a lengthwise clearance of 1/16” to 1/8” (1.5 to 3) between the front half bottom plate and the lower roll (item 3) as shown below. NOTE: The front half bottom plate (item 1) must always be bolted under the cutter head bottom plate (item 4).
Page 99 MAINTENANCE & AJUSTEMENTS 1. Hand tighten the two bolts on each side (item 1). 2. Insert a 1/32” spacer (item 3) at each end of the roll, between the roll and the half bottom (item 2). 3. Using a vise grip clamp (item 5 - Figure 119 Processor roll adjustment), lock the half bottom and roll together. Tighten the two bolts on each side properly (item 1 - Figure 118 Processor roll adjustment) 4.
Page 100: Processor Minimum Gap Adjustment
MAINTENANCE & AJUSTEMENTS PROCESSOR MINIMUM GAP ADJUSTMENT FIGURE 120 1. Loosen bolts on the levelling plate (item 7). 2. Use a 1/16” (1.5) gauge between the 6” top roll and 10” bottom roll. 3. There are 2 adjustment bolts. One on each side of the processor rolls. The head of these bolts (item 2) rest against the underneath of the support flanges (item 3).
Page 101: Accelerator Liner Replacement
MAINTENANCE & AJUSTEMENTS ACCELERATOR LINER REPLACEMENT FIGURE 121, FIGURE 122, FIGURE 123 1. Remove the rear guards. 2. Remove the 6” upper processor roll (if installed) from the forage harvester (see CONFIGURING FOR CORN HARVEST SETUP). 3. Remove the lower half bottom plate of the processor roll (9 bolts). 4.
Page 102: Accelerator Adjustment
MAINTENANCE & AJUSTEMENTS 8. Remove the 2 bottom bolts (item 6) from both of the bearing assemblies, on both sides. Leave the two top bolts on each side (in the top holes of the bearings) in order to keep the accelerator assembly in the raised position. 9.
Page 103: Accelerator Paddle Replacement And Balancing
MAINTENANCE & AJUSTEMENTS NOTE: Because of particular operating conditions and the power of the tractor, the accelerator on the forage harvester may become noisy. Inspect all the surfaces throughout the accelerator chamber for dried material or defective surfaces. If the noise continues, progressively increase the clearance at 6H (6 o’clock) in 0.015” (0.4) increments until noise is no longer noticeable.
Page 104: Spout Rotation Motor And Gear Adjustment
MAINTENANCE & AJUSTEMENTS SPOUT ROTATION MOTOR AND GEAR ADJUSTMENT FIGURE 125, FIGURE 126 To ensure optimal durability of the motor and the chute rotation gear, adjust as necessary. 1. Rotate spout to the left-hand side of the machine. 2. Remove top shield (item 1) to access spout motor gear. 3.
Page 105: Spout Cylinder Travel Sensor Adjustment
MAINTENANCE & AJUSTEMENTS SPOUT CYLINDER TRAVEL SENSOR ADJUSTMENT FIGURE 127 Adjusting the cylinder sensor to maintain travel on the drop cylinder is essential to ensuring proper suspension operation, especially with the Stinger chute extension, during transport mode (item 4). IMPORTANT: Operating the chute with the Stinger configuration without proper cylinder clearance can damage the structure of the forage harvester or the chute itself.
Page 106: Spout Liner Replacement
MAINTENANCE & AJUSTEMENTS SPOUT LINER REPLACEMENT FIGURE 128 When the main wear strip (item 1) or that of the "Stinger" extension is worn or punctured: 1. Lower the chute completely. 2. Unbolt the wear plate (item 3), the hoses while leaving the support remain in place. 3.
Page 107: Feed Roll Spring Tension
MAINTENANCE & AJUSTEMENTS FEED ROLL SPRING TENSION FIGURE 129 Both upper feed rolls are under tension and maintain the ability to open and close to a controlled extent. Their vertical motion is limited by four springs (item 1). The vertical displacement of these rolls is interdependent and controlled by stabilizing bars (item 2).
Page 108: Feed Rolls Chain Tension
MAINTENANCE & AJUSTEMENTS FEED ROLLS CHAIN TENSION FIGURE 131 - FIGURE 132 To adjust the tension of the top feed roll chain (item 1), loosen the bolts (item 2) completely and add/remove spacers (item 3) as needed from beneath the tensioner plate (item 4) to obtain the required tension. Make sure the tensioner is centered with the chain rollers (item 5).
Page 109: Transmission Belt Tension
MAINTENANCE & AJUSTEMENTS TRANSMISSION BELT TENSION FIGURE 133 The 4-banded belt (item 1) driving the main transmission is tensioned by a floating tensioner pulley arm (item 2). To maintain full power transfer to the transmission, the tensioner pulley arm spring should be adjusted to obtain a gap of 1,5 to 2,5 mm (1/16 - 3/32 in) between the coils.
Page 110: Accelerator Belt Tension
MAINTENANCE & AJUSTEMENTS ACCELERATOR BELT TENSION FIGURE 134 The 4-banded belt (item 1) of the accelerator is driven by the pulley on the cutter head shaft. Its tension is adjusted with the spring (item 2): WARNING: Always make sure all rotating components have stopped before servicing the harvester. 1.
Page 111: Header Lift Cylinder Adjustment
MAINTENANCE & AJUSTEMENTS HEADER LIFT CYLINDER ADJUSTMENT FIGURE 136 When the header is lifted to the maximum, it should not make contact with the forage harvester. If there is contact, adjust the length of the cylinder by adjusting the position of the attachment link. NOTE: Always position the cylinder locking pin (item 5) upwards.
Page 112: Stone Carriage Adjustment
MAINTENANCE & AJUSTEMENTS STONE CARRIAGE ADJUSTMENT To ensure precision when sharpening, all wheels must be properly seated on the roller shafts. Make adjustments so that all the wheels roll when operating the carriage. Any wheels that do not turn during sharpening must be adjusted to prevent vibrations.
Page 113: Sharpening Stone Replacement
MAINTENANCE & AJUSTEMENTS SHARPENING STONE REPLACEMENT FIGURE 137 1. Remove the elastic jam nut (item 5), the flat washer (item 6) and the spring washer (item 9). 2. Pull up the adjusting arm (item 13) and the stone assembly. 3. Loosen the two nuts (item 8) and the two set screws (item 7). 4.
Page 114: F-N-R Transmission Shifter Arm Adjustment
MAINTENANCE & AJUSTEMENTS F-N-R TRANSMISSION SHIFTER ARM ADJUSTMENT FIGURE 139 To adjust shifting on the main transmission: 1. Shift the transmission to NEUTRAL before proceeding. 2. Hold the rod (item 1) in place with pliers to unscrew the nut (item 2). Remove the rod, noting the order of the spacers (item 3).
Page 115: F-N-R Transmission Sensor Adjustment
MAINTENANCE & AJUSTEMENTS F-N-R TRANSMISSION SENSOR ADJUSTMENT The 3 sensors on the transmission (item 1) are used for semi-automatic control of the clutch cylinder (item 5). To adjust these sensors, follow the following procedure: NOTE: Adjusting the REVERSE, NEUTRAL and FORWARD shifting of the clutch arm should be done before adjusting the sensors.
Page 116: Feed Roll Stopping Mechanism Adjustment
MAINTENANCE & AJUSTEMENTS FEED ROLL STOPPING MECHANISM ADJUSTMENT The mechanical system stop of the metal detector allows the feed rolls to stop within 1/20 of a second when ferrous metal is detected. This mechanism includes a stop pawl (item 1) controlled by a solenoid (item 2), a ratchet wheel (item 3), a rubber disc shock absorber (item 4), an overload clutch (item 5) and a transmission actuator that switches from the FORWARD to the NEUTRAL position automatically.
Page 117: Speed Sensor Adjustment
MAINTENANCE & AJUSTEMENTS SPEED SENSOR ADJUSTMENT Speed sensors are required for the various forage harvester control systems. One sensor is located on the cutting head shaft (item 1) and another is located on the top feed roller drive shaft on the A-N-R transmission (item 2). The feed roll sensor (item 2) is necessary for the operation of the metal detector.
Page 118: Electronic Control Unit & Connector Cleanliness
MAINTENANCE & AJUSTEMENTS ELECTRONIC CONTROL UNIT & CONNECTOR CLEANLINESS Electrical and electronic problems can cause intermittent or one-time problems that are difficult to diagnose. To ensure long term durability and proper operation, follow these recommendations: 1. Never wash connectors or controllers. Clean with an air jet or cloth only. 2.
Page 119: Storage Procedure
MAINTENANCE & AJUSTEMENTS STORAGE PROCEDURE NOTE: Never pressure wash the electronic controls, bearings, solenoid valves, hydraulic valve manifolds or other component containing seals (Figure 144). Figure 144 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 120 MAINTENANCE & AJUSTEMENTS STEP 8 Check condition of guards and safety decals. Replace them if necessary. STEP 9 - FIGURE 145 At the end of the season, drain the liquid incorporation system using antifreeze. Figure 145 Liquid incorporation system NOTE: After cleaning and complete lubrication, run the forage harvester for a few minutes to spread the grease evenly within the bearings and on the roller chains.
Page 121: Diagnostics & Troubleshooting
DIAGNOSTICS & TROUBLESHOOTING CONTROLLER ALARMS AND LOGIC This flowchart represents possible 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. Figure 146 Harvester controller logic...
Page 122: Transmission Shifter Logic
DIAGNOSTICS & TROUBLESHOOTING TRANSMISSION SHIFTER LOGIC This flowchart shows the F-R transmission shifter logic (with FerroDtec system), starting with powering up the control box. It displays the link between the commands of the operator, the shifter reaction and shifter position sensors. Power On Reverse switch held depressed Transmission in Forward...
Page 123: Control Box, Transmission And Metal Detector
DIAGNOSTICS & TROUBLESHOOTING CONTROL BOX, TRANSMISSION AND METAL DETECTOR PROBLEM/ALARM PROBABLE CAUSES EXPLANATION/SOLUTION 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.
Page 124 DIAGNOSTICS & TROUBLESHOOTING Impedance between the colored wire is less than 800Ω or higher than 1kΩ would indicate that antenna coil wire is damaged or short, there is a short circuit between the signal wires and the ground, the epoxy mould housing the magnet-coil assembly is broken or detached from the casing OR the fasteners holding the sensor on the shafts are damaged or loose.
Page 125 DIAGNOSTICS & TROUBLESHOOTING Make sure the emergency stop button on the control box is not damaged, stuck in the Emergency stop error. The emergency stop stays depressed position or that the cable is not cut or disconnected. (Alarm) active. Replace or repair depending on the case. If an overload has occurred and the feed rolls become clogged, the overload protection Feed rolls are clogged with crop clutch on the transmission input pulley will slip and emit a growling sound.
Page 126: Ejection
DIAGNOSTICS & TROUBLESHOOTING The control will correct this behavior automatically by shifting back to full stroke in forward. Return pressure spike or air in If the error persists, turn OFF the PTO and cycle the shifter cylinder several times between the shifter cylinder caused it to FORWARD and REVERSE to bleed off any air in the hydraulic lines.
Page 127: Feeding
DIAGNOSTICS & 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.
Page 128: Cutting
DIAGNOSTICS & TROUBLESHOOTING CUTTING PROBLEMS PROBABLE CAUSES SOLUTIONS Shear bar is not parallel to the knives or is too far away. Adjust and correct the shear bar alignment. Insufficient crop flow. Increase forward speed or windrow size. Knife cutting edge(s) worn out. Sharpen the knives.
Page 129: Drive
DIAGNOSTICS & TROUBLESHOOTING DRIVE PROBLEMS PROBABLE CAUSES SOLUTIONS Excessive spacing between knives and shear bar. Adjust shear bar. Length of cut unnecessarily too short. Increase/modify the length of cut. The crop channel is gummed. Use liquid incorporation system to avoid gumming. Excessive power Smooth roll cleaner is not adjusted.
Page 130: Electro-Hydraulic Functions
DIAGNOSTICS & TROUBLESHOOTING ELECTRO-HYDRAULIC FUNCTIONS PROBLEMS PROBABLE CAUSES SOLUTIONS Make sure the switch on the control box is ON and power is available. Check that Electric power cut off. power is available to the controller and valves. Make sure the tractor SCV is in continuous mode with a flow of approx. 8-11l/min (2- Hydraulic supply is cut off.
Page 131 HYDRAULIC CIRCUIT STINGER OPTION BARRE DE TIRE EMBRAYAGE TRANSMISSION ROTATION DE CHUTE LEVAGE DE CHUTE TÊTE DE RÉCOLTE DÉCROCHEUR REMORQUE DÉFLECTEUR DE CHUTE (OPTION) DRAWBAR HEADER TRANSMISSION SHIFTER TRAILER DISCONNECT SPOUT DEFLECTOR SPOUT ROTATION SPOUT LIFT ORF 1/16" ORF 1/16" ACC1 ACC2 ORF5 - 0.020"...
Page 132 ELECTRICAL CIRCUITS...
Page 133 ELECTRICAL CIRCUITS...
Page 134 ELECTRICAL CIRCUITS...
Page 135 ELECTRICAL CIRCUITS...
Page 136 ELECTRICAL CIRCUITS...
Page 137 ELECTRICAL CIRCUITS...
Page 138 ELECTRICAL CIRCUITS...
Page 139 ELECTRICAL CIRCUITS...
Page 140: Checklist
CHECKLIST PRE-SEASON CHECKLIST Check condition of knives and shear bar. Check that knives and shear bar 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.

Dion-Ag 2430 Operator's Manual

Quick Links

Need help?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Dion-Ag 2430

Summary of Contents for Dion-Ag 2430

Table of Contents