Dion-Ag F41 User manual

Operator’s Manual

Forage Harvester

Manual No. F4117E987E V1.1

DION-AG INC. LIMITED WARRANTY TERMS AND CONDITIONS

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 in-

structions contained in the Dion-Ag Inc. Operator’s Manual.

Not covered by Warranty – This warranty does not cover: (1) service parts and labour needed to maintain the

unit; and (2) the replacement of parts due to normal wear and tear. The owner is responsible for these items. Some

examples of maintenance and normal wear parts are: oil, lubricants & other uids, belts, knives, clutch and clutch

discs, roller chain, paddles, etc. Dion-Ag Inc. is not responsible for depreciation or damage caused by normal wear,

lack of reasonable and proper maintenance, failure to follow operating instructions, misuse, lack of proper protec-

tion during storage, vandalism, the elements, collision or accident.

Securing Warranty Service – To secure warranty service, the purchaser must report the machinery and/or equip-

ment defect to an authorized dealer and request warranty service within the applicable warranty terms.

Owner’s Obligation – It is the responsibility of the Owner to transport the equipment to the service shop of an au-

thorized Dion-Ag Dealer or to reimburse the dealer for any travel or transportation expense involved in fullling this

warranty. This warranty does NOT cover rental of replacement equipment during the repair period, loss of prots,

or other coercial loss, and any or all incidental or consequential damages, overtime labour charges and/or freight

charges for replacement parts.

Limitations of This Warranty – No agent, employee or representative of Dion-Ag Inc. has the authority to amend,

or modify, in any manner whatsoever, the terms of the present warranty. The express warranties herein contained

exclude all other express, implied or statutory warranties. THIS WARRANTY IS IN LIEU OF ALL OTHER WAR-

RANTIES INCLUDING THE WARRANTIES OF MERCHANTABILITY AND/OR FITNESS FOR ANY PARTICULAR

PURPOSE.

Right to Inspect – Dion-Ag and its authorized agents reserve the right to inspect the purchaser’s Dion-Ag product

to determine if a defect in material or workmanship exists prior the coencement of any covered repairs. It is the pur-

chaser’s responsibility to ensure availability and/or delivery of the product to Dion-Ag for the purpose of inspection.

Right to Make Design Changes – Dion-ag 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 and sold or shipped by Dion-Ag.

Liability – Dion-Ag Inc. shall not be liable, if, during the use of the machinery and/or attachment, the security guards

have been removed, modied, or have not been properly maintained.

The Warranty shall not apply if the instructions mentioned in this manual have not been followed completely and

correctly. Nor will the warranty apply if the owner or any third party modies the machine without Dion-AG’s know-

ledge and/or authorization. Every purchaser, when buying a Dion-Ag machine, agrees and undertakes to use and

operate the machinery and its component parts safely, and in accordance with all applicable laws, and in accord-

ance with the Operator’s Manual. Furthermore, the purchaser agrees and accepts to indemnify and hold harmless

Dion-Ag for all losses and damages to any person or property resulting from the purchaser’s non-compliance with

the terms and conditions of this warranty. Each purchaser further agrees to bring the warranty to the attention of any

subsequent purchaser, and to obtain agreement therein as a condition of resale or transfer.

Manual No. F4117E987E V1.1

Forage Harvester F41 & F41 Stinger

TO OUR CUSTOMER

We appreciate your condence in Dion Farm Equipment and thank you for your trust. In preparing this

manual, we hope we have furnished you with a valuable tool for operating and maintaining this ne ma-

chine. Use this manual as your guide. Practicing the instructions given here will result in many years of

dependable service from your machine.

Your dealer can give you assistance with parts and specially trained personnel to assist you in repair and

maintenance.

Call your dealer if you need any assistance or information.

Manual No. F4117E987E V1.1

SPECIFICATIONS.....................................................................................................................8

SERIAL NUMBER LOCATION ................................................................................................. 9

CHECK LIST............................................................................................................................. 10

PRE-SEASON CHECKS.....................................................................................................................10

DAILY CHECKS ..................................................................................................................................11

FOREWORD .............................................................................................................................12

TO OUR CUSTOMER.........................................................................................................................12

THIS MANUAL SHOULD REMAIN WITH THE MACHINE WHEN SOLD...........................................12

WARRANTY INFORMATION..............................................................................................................12

WARRANTY ON THE METAL DETECTOR ........................................................................................12

SAFETY ..............................................................................................................................................12

SAFETY RULES .......................................................................................................................13

SAFETY ALERT SYMBOL ..................................................................................................................13

DANGER, WARNING AND CAUTION ................................................................................................13

DECALS:.............................................................................................................................................13

FOLLOW A SAFETY PROGRAM........................................................................................................13

A WORD TO THE OPERATOR...........................................................................................................13

PTO OPERATION ...............................................................................................................................15

MANDATORY STOPPING PROCEDURE ..........................................................................................15

GUARDS AND SHIELDS ....................................................................................................................16

SAFETY SIGN LOCATION ....................................................................................................... 17

SAFETY SIGN APPLICATION PROCEDURE ...................................................................................21

MATERIAL SUPPLIED SEPARATELY WITH THE MACHINE: ...........................................................22

HARVESTERS ARE SHIPPED TO OPERATE AS FOLLOWS:..........................................................22

OPTIONAL EQUIPMENT CHOICES:..................................................................................................22

DELIVERY.................................................................................................................................22

MANUAL JACK ...................................................................................................................................23

RECEIVING YOUR FORAGE HARVESTER ......................................................................................23

PREPARING THE FORAGE HARVESTER ........................................................................................23

ASSEMBLING INSTRUCTIONS............................................................................................... 23

INSTALLING THE CONTROL BOX ....................................................................................................24

INSTALLING THE CONTROL BOX (F41 STINGER MODEL ONLY)..................................................24

CONNECTING THE POWER-TAKE-OFF (PTO) ...............................................................................26

INSTALLING THE FOLDABLE SPOUT (F41 MODEL ONLY).............................................................27

INSTALLING THE 12” (30 cm) SPOUT EXTENSION (F41 MODEL ONLY) FIGURE 12....................28

INSTALLING THE 24” (60 CM) SPOUT EXTENSION (F41 MODEL ONLY) ......................................29

HOW TO MAKE THE ELECTRICAL CONNECTIONS ON THE SPOUT (F41 MODEL ONLY)..........31

INSTALLING THE CLOSING PLATE ON THE SPOUT ......................................................................32

INSTALLING MUDGUARDS OVER TANDEM WHEELS ...................................................................32

INSTALLING AN ATTACHMENT ON THE FORAGE HARVESTER ..................................................33

INSTALLING THE RECUTTER BAR ASSEMBLY FOR CORN CROP ..............................................35

INSTALLING THE GRAIN PAN AND FRONT RUBBER PAD ASSEMBLY FOR CORN CROP..........35

INSTALLING A LIGHT ON THE SPOUT DEFLECTOR (F41 MODEL ONLY) ....................................36

INSTALLING THE INSPECTION LIGHT ............................................................................................37

ASSEMBLING INSTRUCTIONS - LIQUID INCORPORATION SYSTEM ................................ 38

INSTALLING A SECOND TANK..........................................................................................................47

ASSEMBLING INSTRUCTIONS - MANUAL QUICK-DISCONNECT HITCH .......................... 50

ASSEMBLING INSTRUCTIONS - ELECTRIC QUICK-DISCONNECT HITCH (UP TO 2017) 52

ASSEMBLING INSTRUCTIONS - ELECTRIC QUICK-DISCONNECT HITCH (2017+) .......... 54

ASSEMBLING INSTRUCTIONS - DRAW BAR EXTENSION.................................................. 58

ASSEMBLING INSTRUCTIONS - TRANSPORT LIGHTS....................................................... 60

TABLE OF CONTENTS

Manual No. F4117E987E V1.1

CORN CRACKER INSTALLATION INSTRUCTIONS .............................................................. 61

PARTIAL DISMANTLING OF THE CORN CRACKER FOR HAY CROP ................................ 76

PARTIAL REASSEMBLING OF THE CORN CRACKER FOR CORN CROP......................... 83

HYDRAULIC SPOUT CONVERSION ...................................................................................... 88

BREAK-IN SPEED ..............................................................................................................................88

BOLT TORQUE SPECIFICATIONS ....................................................................................................88

METAL DETECTOR............................................................................................................................88

STOPPING THE MACHINE ................................................................................................................88

TRANSPORTATION ON PUBLIC ROADS .........................................................................................88

OPERATING INSTRUCTIONS ................................................................................................. 90

TRANSPORT POSITION - F41 STINGER..........................................................................................91

PREPARING FOR FIELD OPERATION..............................................................................................92

HITCHING THE FORAGE HARVESTER TO THE TRACTOR .........................................................92

ADJUSTING THE ATTACHMENT GROUND CLEARANCE..............................................................93

STARTING UP.....................................................................................................................................93

INFORMATION ON THE METAL DETECTOR....................................................................................94

DAILY CHECKS ON THE METAL DETECTOR ..................................................................................94

INITIALIZING THE METAL DETECTOR

(STARTING UP THE MACHINE WITH METAL DETECTOR) ............................................................95

STOPPING THE MACHINE ................................................................................................................95

STARTING OPERATION.....................................................................................................................96

THE CONTROL BOX .........................................................................................................................96

EMERGENCY STOP ..........................................................................................................................96

OPERATING INSTRUCTION FOR THE F41 STINGER SPOUT .......................................................96

WHAT TO DO WHEN THE MACHINE DETECTS A FERROUS METAL............................................97

WHAT TO DO IF MATERIAL ACCUMULATION OCCURS (CLOGGING) ..........................................98

HOW TO BY-PASS THE METAL DETECTOR ...................................................................................99

SHEAR BOLT .....................................................................................................................................100

PRESSURE AND FLOW CHARTS FOR STANDARD NOZZLE.........................................................101

STANDARD NOZZLE FOR WATER SPRAYING TEEJET XR8004VS ...............................................101

HOW TO OPERATE THE LIQUID INCORPORATION SYSTEM........................................................101

CALIBRATION PROCEDURES .........................................................................................................101

PRESSURE ADJUSTMENT ...............................................................................................................101

DETECTION SYSTEM FOR SAFETY BOLT BREAKAGE OR

FRICTION CLUTCH SLIPPAGE ON THE CUTTER HEAD TRANSMISSION SHAFT. ......................102

TRANSPORT LIGHT ..........................................................................................................................103

HYDRAULIC CIRCUIT........................................................................................................................104

POWER-TAKE-OFF (PTO) .................................................................................................................104

LUBRICATION CHART .......................................................................................................................104

CHAINS LUBRICATION......................................................................................................................104

GEAR BOX LUBRICATION.................................................................................................................104

LUBRICATION .......................................................................................................................... 104

CORN CRACKER LUBRICATION ......................................................................................................111

ADJUSTMENTS - MAINTENANCE.......................................................................................... 113

WHEEL POSITIONING ......................................................................................................................113

GROUND CLEARANCE .....................................................................................................................114

DISMANTLING AND REASSEMBLY OF THE POWER-TAKE-OFF (PTO) ROTATING GUARDS.....114

FORAGE HARVESTER DRAW BAR..................................................................................................115

FEED ROLL BALANCING SPRINGS ................................................................................................115

UPPER FEED ROLL CHAIN TENSION .............................................................................................116

LOWER FEED ROLL CHAIN TENSION ............................................................................................116

STRAW CHOPPING ...........................................................................................................................116

BALANCING SPRINGS 2 ...................................................................................................................117

UPPER ROLL ADJUSTING BOLTS ...................................................................................................118

TABLE OF CONTENTS

Manual No. F4117E987E V1.1

MAGNETIC DRAIN PLUGS................................................................................................................118

SPOUT WEAR PLATE (F41) ..............................................................................................................119

SPOUT WEAR PLATE (F41

STINGER

) .............................................................................................119

HYDRAULIC SPOUT CYLINDER STROKE ADJUSTMENT (F41 STINGER) ...................................120

ADJUSTING THE FREE ROTATION OF THE SPOUT ......................................................................121

ROTATION MOTOR ADJUSTMENT (F41 STINGER) .......................................................................122

FEED ROLL STOPPING SYSTEM ....................................................................................................123

FAN BELT TENSION .........................................................................................................................124

FAN AND TRANSMISSION BELT REPLACEMENT ..........................................................................124

CORN CRACKER BELT TENSION ....................................................................................................125

CORN CRACKER BELT REPLACEMENT .........................................................................................126

TRANSMISSION BOX BELTS ............................................................................................................127

REVERSE, NEUTRAL AND FORWARD SPEEDS POSITIONS ........................................................127

ANGLE DRIVE TRANSMISSION BOX SHEAVE ...............................................................................128

FAN ADJUSTMENT ...........................................................................................................................129

KNIFE ADJUSTMENT ........................................................................................................................131

KNIFE GRINDING ..............................................................................................................................132

KNIFE REPLACEMENT .....................................................................................................................134

KNIVES & SHEAR BAR GENERAL INFORMATION..........................................................................134

SHEAR BAR ADJUSTMENT ..............................................................................................................135

DAILY ADJUSTMENT (AFTER KNIVES HAVE BEEN GROUND)......................................................135

REPLACEMENT AND INITIAL ADJUSTMENT OF THE SHEAR BAR .............................................136

CUTTING LENGTH SELECTION .......................................................................................................137

PROCEDURE FOR CHANGING THE CUTTING LENGTH ...............................................................138

PROCEDURE TO INCREASE THE FORAGE HARVESTER’S FEEDING SPEED BY 33% .............139

SMOOTH FEED ROLL CLEANER ADJUSTMENT.............................................................................140

MAINTENANCE PROCEDURE FOR THE CUTTER HEAD BOTTOM PLATE ASSEMBLY ..............141

MAINTENANCE PROCEDURE FOR THE FAN BOTTOM PLATE ASSEMBLY .................................142

CORN CRACKER SHEAVE ALIGNMENT .........................................................................................144

CORN CRACKER Q.D. BUSHINGS ..................................................................................................155

CORN CRACKER LOWER ROLL BEARINGS ...................................................................................145

CORN CRACKER UPPER ROLL BEARINGS ...................................................................................147

CORN CRACKER LOWER ROLL HALF BOTTOM PLATE ...............................................................149

CORN CRACKER ROLL SCRAPER .................................................................................................151

UPPER CORN CRACKER ROLL “ZERO” POSITION ADJUSTMENT .............................................152

UPPER CRACKER ROLL PRESSURE AND GAP ADJUSTMENT ....................................................153

CORN CRACKER INITIAL START UP ADJUSTMENT ......................................................................154

LIFTING THE ATTACHMENT .............................................................................................................154

LIFTING ARMS ..................................................................................................................................154

STONE CARRIAGE ADJUSTMENT ...................................................................................................155

STONE REPLACEMENT....................................................................................................................155

CUTTER HEAD SENSOR ADJUSTMENT..........................................................................................156

FEED ROLL SHAFT SENSOR ADJUSTMENT...................................................................................156

PTO FRICTION CLUTCH ADJUSTMENT (OPTION) .........................................................................157

VENTING THE CLUTCH.....................................................................................................................158

CLUTCH DISMANTLING PROCEDURE ............................................................................................159

CLUTCH ASSEMBLING PROCEDURE..............................................................................................160

CLUTCH TORQUE SETTING ............................................................................................................161

TRANSMISSION CLUTCH LEVER POSITION SENSOR .................................................................162

DISASSEMBLING AND ASSEMBLING THE RADIAL PIN CLUTCH (TORQUE LIMITER)................163

AT THE END OF THE SEASON, IT IS RECOENDED TO PROCEED AS FOLLOWS:......................167

METAL DETECTOR DIAGNOSTIC SHORT PROCEDURE..................................................... 168

«LED» DISPLAY ON METAL DETECTOR............................................................................... 169

JUMPER POSITION ................................................................................................................. 169

TROUBLESHOOTING.............................................................................................................. 170

TABLE OF CONTENTS

Manual No. F4117E987E V1.1

Specications and design are subject to change without notice

and without liability therefore.

WEIGHT (with 1100X16 tires)

with metal detector .................................................................................... 5280 lbs (2400 Kg)

without metal detector ............................................................................... 5230 lbs (2380 Kg)

DIMENSIONS

Overall width

With 31x13.50 - 15 Terra Rib tires. 142” (361cm) - Narrow tandem 130” (330 cm)

With 31x15.50 - 15 Terra Grip tires 150” (381cm) - Narrow tandem 138” (350 cm)

Length..........................................................................................................228” (579 cm)

Height ..........................................................................................................129” (328 cm)

Minimum height - F41 Stinger ....................................................................120” (305 cm)

Maximum height - F41 Stinger ....................................................................222” (565 cm)

Spout turning radius - F41 Stinger...............................................................200” (508 cm)

ANGLE DRIVE TRANSMISSION

540 or 1000 RPM (buyer’s choice)

MAIN TRANSMISSION

3 speed transmission with overload clutch

3 lengths of cut

OPERATING CAPACITY

540 RPM to 730 RPM - 90 to 135 HP

1000 RPM to 815 RPM - 90 to 180 HP

1000 RPM to 1033 RPM - 160 to 300 HP

ELECTRICAL CONTROLS

Transmission

Spout (230˚ rotation)

Deector

CUTTER HEAD

12 helicoidal knives (or 8 knives - buyer’s choice)

24” (61 cm) wide

22” (56 cm) diameter

speed: 815 or 1033 RPM

SINGLE TIRES AND WHEELS

1100 X 16 - 8 ply DYNA RIB

16.5 X 16.1 - 8 ply DYNA RIB

TANDEM TIRES AND WHEELS

31x13.50 - 15 Terra Rib

31x15.50 - 15 Hippo

29x10.5-15 - Trac Chief

SPECIFICATIONS

Manual No. F4117E987E V1.1

Specications and design are subject to change without notice

and without liability therefore.

STANDARD EQUIPMENT

Hydraulic lift control

Hydraulic tongue control

Cutting edges of the cylinder knives with tungsten carbide treatment

Built-in grinder

Transmission, spout and deector electrical controls

Double sprocket wheel for lengths of cut: 26 teeth for 3/8” (9.5 ) standard upon delivery

and 34 teeth for 1/2” (13 )

Shear bar adjustment on one side

F41: 240orotation spout

F41 Stinger: 310orotation spout

OPTIONAL EQUIPMENT

8 or 12 knife cutter head

Metal detector (standard on F41 Stinger model)

Spout extension (12” or 24”) (30 or 60 cm) (F41 model only)

Single wheels or tandem wheels

Double sprocket wheels for lengths of cut: 17 teeth for 1/4” (6.35 )

Deector light

Inspection light

Manual (cord) quick-disconnect hitch

Electrical heavy-duty quick-disconnect hitch (N/A on F41 Stinger model)

Liquid incorporation system

Extra tank for liquid incorporation system

Recuperation grain pan

Recuter bar (for corn only)

Corn Cracker

Draw Bar Hooker

Draw Bar Extension

Detection system for safety bolt breakage

System to increase Forage Harvester’s feeding speed by 33%

OIL CAPACITY

Angle drive transmission: 1.8 imperial gallons - 2.0 US gallons - 8 liters

Main transmission: 0.88 imperial gallon - 1.1 US gallons - 4 liters

SPECIFICATIONS

Manual No. F4117E987E V1.1

For your convenience, write down in full in this manual both the model and serial numbers of your ma-

chine, as shown on the name plate illustrated below. Always mention both the model and the serial num-

bers when ordering parts or regarding any other correspondence referring to your machine.

Write down your number here:

MODEL NO. SERIAL NUMBER

SERIAL NUMBER LOCATION

MADE IN CANADA

DION-AG INC.

BOISBRIAND QUE.

MODEL NO.

SERIAL NO.

Dion-Ag Inc.

DFE

MADEIN CANADA

D.F.E.INC.

BOISBRIANDQUE.

MODELNO.

SERIALNO.

PAR/BY

REAR

RIGHT

LEFT

FRONT

Manual No. F4117E987E V1.1

PRE-SEASON CHECKS

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

correctly done (fan, etc)

Check tire pressure. See specications.

Check wheel rim bolt torque. See Specications.

Perform complete lubrication and servicing of the machine. Make sure all grease ttings

are in place and taking grease properly. Check gearbox and transmission uid levels.

Look for loose or missing bolts and parts.

Run the machine in a stationary position at half-speed for a short period of time.

Shut off tractor engine. Make sure all moving parts have stopped, then inspect

bearings for over-heating, excessive wear, or loose anges and lock collars.

Check metal detection system for proper operation (if installed on machine). Always

service metal detector when tractor engine is switched off.

Make sure the proper operating adjustments have been made for current crop

conditions.

Make sure SMV emblem (Slow Moving Vehicle) is in good condition and visible.

Make sure all safety shields are installed. Review Safety Precautions.

Check parts for wear (paddles, fan bottom, spout liner, etc.).

CHECK LIST

Manual No. F4117E987E V1.1

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