Dion-Ag F41 User manual

Operator’s Manual
Forage Harvester
Manual No. F4117E987E V1.1

2
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

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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

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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

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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

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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

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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

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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

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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

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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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DAILY CHECKS
Check metal detection system. Always check metal detector system after tractor
engine has been shut off.
Remove all crop residue and wipe off oil and dirt.
Lubricate and service the machine according to the Servicing section.
Check tension of belts and chains. Check all sheaves and sprockets for correct
alignment.
Check tire pressure. See Specications.
Make sure harvester is hooked to tractor correctly, and that the safety chain is
safely installed. Make sure all controls are operable.
Sharpen knives and adjust shearbar once or twice a day.
CHECK LIST
Manual No. F4117E987E V1.1

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TO OUR CUSTOMER
The following pages and illustrations are printed to help
supply you with the knowledge to better operate and
service your Dion Forage Harvester.
Any piece of equipment needs, and must have a cer-
tain amount of service and maintenance to keep it in
top running condition. We have attempted to cover all
the adjustments required to t most conditions; however,
there may be times when special care must be taken to
t a condition.
Study this operator’s manual carefully and become ac-
quainted with all the adjustments and operating proce-
dures before attempting to operate your new equipment.
Remember, it is a machine and it has been designed and
tested to do an efcient job in most operating conditions
and will perform in relation to the service it receives.
If special attention is required for some conditions, ask
your Dion Dealer; its Parts and Service department will
be glad to help and answer any questions on the opera-
tion and service of your new machine.
THIS MANUAL SHOULD REMAIN WITH THE
MACHINE WHEN SOLD
This manual was prepared from the latest product in-
formation available at publication time. The Company
reserves the right to make changes at any time without
notice.
The Safety section of your Operator’s manual is intend-
ed to point out some of the basic safety situations which
may be encountered during the normal operation and
maintenance of your Forage Harvester, and to suggest
possible ways of dealing with these situations. This sec-
tion is NOT a replacement for other safety practices fea-
tured in other sections of this book.
WARRANTY INFORMATION
The warranty for this machine is located at the beginning
of this manual.
If the Forage Harvester is used with an attachment from
another manufacturer, the warranty is limited to the For-
age Harvester.
You, the equipment purchaser, shall assume charges for
service calls or transportation of equipment to and from
the location of servicing Dion dealer.
WARRANTY ON THE METAL DETECTOR
Because of its limitations, the metal detector cannot
and must not be expected to be a full proof device.
WARRANTY COVERAGE DOES NOT EXTEND TO
CONSEQUENTIAL DAMAGES.
SAFETY
The safety of the operator is one of the main concerns in
designing and developing a new Forage
Harvester. Designers build in as many safety features
as possible. However, every year accidents occur which
could have been avoided by a few seconds thought and
a more careful approach to handling farm machinery
and implements.
Read and implement the safety instructions detailed in
the safety section of this manual.
FOREWORD
Manual No. F4117E987E V1.1

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SAFETY ALERT SYMBOL
The symbol above calls your attention to instructions concerning
your personal safety. It is found throughout the manual as well as
on the machine to point out specic hazards and ways to avoid
them. Always follow the instructions to minimize the risk of per-
sonal injury or death.
DANGER, WARNING AND CAUTION
Whenever you see the words and symbols shown below, used in
this manual and on decals, you MUST take note of their instruc-
tions as they relate to personal safety.
DANGER: This symbol together with the word
DANGER indicates an iinently hazardous situa-
tion that, if not avoided, will result in DEATH OR
VERY SERIOUS INJURY.
WARNING: This symbol together with the word
WARNING indicates a potentially hazardous situ-
ation that, if not avoided, could result in DEATH
OR SERIOUS INJURY.
CAUTION: This symbol together with the word
CAUTION is used to indicate a potentially hazard-
ous situation that, if not avoided, may result in
MINOR INJURY.
IMPORTANT: The word IMPORTANT is used to identify spe-
cial instructions or procedure which, if not strictly observed,
could result in damage to, or destruction of the machine, pro-
cess or its surroundings.
NOTE: The word NOTE is used to indicate points of particular
interest for a more efcient and convenient service and operation
of the machine.
DECALS:
WARNING: DO NOT remove or obscure Danger,
Warning, Caution or Instruction Decals that are
not readable or are missing. Replacement decals
are available from your Dealer in the event of loss
or damage. The actual location of these Safety
Decals is illustrated on page 17.
FOLLOW A SAFETY PROGRAM
For safe operation of a Forage Harvester, you must be a quali-
ed and authorized operator. To be qualied, you must read and
understand the written instructions supplied in this Operator’s
Manual, have training, and know the safety rules and regulations
for the job.
Some regulations specify that no one under the age of 16 years,
for example, may operate power machinery. This includes trac-
tors. It is your responsibility to know what these regulations are,
and obey them, in the operating area or situation.
These will include, but are not limited to, the following instructions
for proper operation:
WARNING: An operator should not use alcohol or
drugs which can change his alertness or coordi-
nation. An operator on prescription or “over the
counter” drugs needs medical advice on whether
or not he or she can operate machines
A WORD TO THE OPERATOR
It is YOUR responsibility to read and understand the safety sec-
tion 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. Each illustration
is numbered and the same number appears in the text in
parenthesis.
Remember that YOU are the key to safety. Good safety practices
not only protect you, but also the people around you. Study the
features in this manual and make them a working part of your
safety program.
Think SAFETY! Work SAFELY.
WARNING: In some of the illustrations used in
this Operator Instruction Book, panels or guards
may have been removed for clarity. Never oper-
ate the machine without these components in
position. If the removal of panels or guards is
necessary to make a repair, they MUST be re-
placed before operation.
SAFETY RULES
Manual No. F4117E987E V1.1

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• Disengage the PTO and shut off engine before leav-
ing the operator’s seat for refueling, lubricating or ad-
justing the machine.
•Always use a hitch pin large enough for the load to
be transported with a safety lock between the tractor
and the Forage Harvester and between the Forage
Harvester and the Forage Box, anytime the machine
is moved.
•The tractor engine ignition key must be removed
each time the operator leaves the tractor.
•Wear appropriate clothing, safety boots or shoes. Do
not operate the machine when visibility is bad, or dur-
ing night, in poor lighting.
•When driving on a public road, or on hilly land you
must remove the electrical box ignition key and put
the locking pin in the stop pawl of the quick-dis-
connect hitch to prevent unlocking. This locking pin
should also be used for the manual quick-disconnect
hitch.
•Attach a safety chain of at least 20,000 lbs (9071 Kg)
capacity for transportation.
•On F41 Stinger models, deactivate the spout hy-
draulic circuit and close the safety valve for road
transportation.
•Never hook a loaded trailer behind a Forage Harvest-
er when travelling on public roads.
•Keep children away from the machine at all times.
Maximum traveling speed of a forage harvester
should not exceed 20 mph (34 km/h).
•Carefully read all safety signs applied on the ma-
chine. If they are damaged, replace them iediately.
•If a feeding or throwing mechanism should become
jaed, never attempt to unblock it or remove any ma-
terial when the machine is in motion or the tractor
engine running.
• Never manually feed the Forage Harvester.
•When making a metal detection test, stop the PTO
and the tractor engine, then wait until all mobile parts
are stopped.
•Never operate a Forage Harvester without rst hav-
ing installed an attachment.
•Never remove guards or make adjustments while the
machine or tractor engine is running.
•Never attempt to check or adjust chains while the ma-
chine is running.
•Make sure all rotating parts are stopped and the trac-
tor engine is turned off before cleaning the machine
throat.
•Never park the Forage Harvester in its transport posi-
tion. Lower the attachment to the ground rst.
•Before starting the tractor engine, make sure all
guards, shields, and doors are in place and properly
secured and check the machine thoroughly for pos-
sible loose parts or bolts and tighten them.
•When knives are being readjusted, a piece of wood
should be used to iobilize the cutting head.
•Never stand underneath the forage harvester de-
ector or forage path when the machine is running.
Put the discharge toward the forage box.
•Always pick-up tools after performing any adjust-
ment.
• Never allow riders on any part of a machine.
•Block elevated components before servicing equip-
ment.
•Do not unhook a farm wagon when the land is slop-
ping down, or service the machine without rst
blocking wheels.
•Never lubricate or clean any part while the machine
or tractor engine is running.
•Keep hands and body out of hitch area when attach-
ing towing vehicle.
WARNING: Hydraulic uid under pressure can pen-
etrate the skin or eyes and cause serious personal
injury, blindness or death. Fluid leaks, under pres-
sure, may not be visible. Use a piece of cardboard
or wood to nd leaks. DO NOT use your bare hand.
Wear gloves and safety goggles for eye protection.
If any uid is injected into the skin, it MUST be sur-
gically removed within a few hours by a doctor fa-
miliar with this type of injury.
•Securely block the wheels from moving before work-
ing on or under the machine.
•Use a lift system with a minimum capacity of 2000 lbs
(900 kg) to install a Corn Attachment on the Forage
Harvester.
•Make sure that all wheel rim bolts are properly torqued.
•Make sure to meet local regulations for excessive
width on public roads.
SAFETY RULES
Manual No. F4117E987E V1.1

15
SAFETY RULES
PTO OPERATION
•POWER-TAKE-OFF DRIVE - Before starting the
tractor engine, make sure that the PTO driveline
locking device is properly engaged onto both the
tractor and equipment drive shafts. Secure the safe-
ty chain to the tractor frame.
•Never wear loose clothing and keep people, espe-
cially children away from the driveline.
•Do not hook a tractor with a PTO speed of 1000
RPM on a machine equipped with a 540 RPM drive
or a tractor with a PTO speed of 540 RPM on a ma-
chine equipped with a 1000 RPM drive.
•Never proceed to the starting of the machine be-
fore making sure all driveline, machine and tractor
shields are well installed in place
•The PTO driveline shields should turn freely, be well
connected and kept in good condition.
• Never step across any PTO driveline.
• Never use the PTO driveline as a step.
•Keep a good distance away from a rotating driveline
(approximately the distance equal to your height).
MANDATORY STOPPING PROCEDURE
No matter what type of machine is being used, it is ex-
tremely hazardous to perform any kind of maintenance
work while the machine is running. It could lead to seri-
ous injuries or even death. Before cleaning, adjusting or
greasing the machine, the following procedure should
be followed to stop the Forage Harvester:
1. Place the transmission in neutral.
2. Disengage the tractor power-take-off (PTO).
3. Turn OFF the metal detector.
4. Switch off the tractor engine.
5. Engage the tractor parking brake.
6. Wait until all rotating parts have completely
stopped.
7. Remove the PTO from the tractor output shaft.
8. Block all equipment wheels.
WARNING: Rotating driveline contact may cause
serious injury or death.
Manual No. F4117E987E V1.1

16
GUARDS AND SHIELDS - FIGURE 1
The Forage Harvester is equipped with guards and
shields wherever eventual accidents can occur. These
guards and shields do not keep the machine from oper-
ating properly. Observe various safety signs indicating
these hazardous locations that are properly applied to
the machine.
CAUTION: All guards and shields factory in-
stalled should be in place and maintained in good
condition.
Item 1 A bolted guard covers the transmission shaft (on
its full length) from the front bearing up to the an-
gle drive transmission.
Item 2 A hinged guard covers the universal joints.
Item 3 The telescopic driveline which attaches to the
tractor PTO is covered with a non-rotating shield.
Item 4 An hinged guard covers the tool box, the transmis-
sion shaft between the angle drive transmission
and the cutting head, the driving belts for the for-
ward-neutral-reverse transmission and the driving
system for the feeding rolls and the attachments.
Item 5 An hinged guard covers the 4 blowing fan riving
belts.
Item 6 An hinged guard covers the corn cracker roll belts
and the front feeding roll drive system belts.
Item 7 An hinged guard covers the sharpening system.
Item 8 An hinged guard covers the cutter head.
Item 9 An hinged guard covers the fan.
1
3
2
4
5
6
9
7
7
8
Figure 1 Guards and shields
SAFETY RULES
Manual No. F4117E987E V1.1

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SAFETY SIGN LOCATION
IMPORTANT: Decals must be kept clean to allow easy reading at all times.
Manual No. F4117E987E V1.1

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SAFETY SIGN LOCATION
IMPORTANT: Decals must be kept clean to allow easy reading at all times.
Manual No. F4117E987E V1.1

19
SAFETY SIGN LOCATION
IMPORTANT: Decals must be kept clean to allow easy reading at all times.
3A
3B
17
11 42
1
16
16
23
15 4
4
4
16
28 27 4
30-31
22
2
17
18
18
6
18
28
27
29
16
1000
CAUTION
AVERTISSEMENT
FOR CORN ONLY
POUR MAÏS SEULEMENT
F41-30751P
Manual No. F4117E987E V1.1

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SAFETY SIGN LOCATION
14
7
15
24
35
16 26 4
32
8
4
20
12
12
12
12-13
4
IMPORTANT: Decals must be kept clean to allow easy reading at all times.
Manual No. F4117E987E V1.1