Dion-Ag F41 User manual

1
F41
Operator’s Manual
Forage Harvester
05/12/14 Manual No. F4112E952 V1.2

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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 instructions 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 main-
tain 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 ins-
tructions, misuse, lack of proper protection during storage, vandalism, the elements, collision or accident.
Securing Warranty Service – To secure warranty service, the purchaser must report the machinery and/
or equipment 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 authorized 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 commercial loss, and any or all incidental or consequential damages, over-
time 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 WARRANTIES INCLUDING THE WARRANTIES OF MERCHANTABILITY AND/OR FIT-
NESS 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 commencement of any covered
repairs. It is the purchaser’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 secu-
rity 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 comple-
tely and correctly. Nor will the warranty apply if the owner or any third party modies the machine without
Dion-AG’s knowledge 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 accordance 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 re-
sulting 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. F4112E952 V1.2

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FORAGE HARVESTER F41
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 machine. 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. F4112E952 V1.2

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SPECIFICATIONS....................................................................................................................................... 7
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
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
DELIVERY.................................................................................................................................................. 22
MATERIAL OR EQUIPMENT SUPPLIED WITH THE MACHINE ......................................................... 22
MATERIAL SUPPLIED SEPARATELY WITH THE MACHINE .............................................................. 22
HARVESTERS ARE SHIPPED TO OPERATE AS FOLLOWS............................................................. 22
OPTIONAL EQUIPMENT CHOICES .................................................................................................... 22
MANUAL JACK ..................................................................................................................................... 22
ASSEMBLING INSTRUCTIONS................................................................................................................ 23
RECEIVING YOUR FORAGE HARVESTER........................................................................................ 23
PREPARING THE FORAGE HARVESTER.......................................................................................... 23
INSTALLING THE CONTROL BOX ...................................................................................................... 23
CONNECTING THE POWER-TAKE-OFF (PTO).................................................................................. 25
INSTALLING THE STANDARD SPOUT ............................................................................................... 26
INSTALLING THE 12” (30 cm) SPOUT EXTENSION........................................................................... 27
INSTALLING THE 24” (60 cm) SPOUT EXTENSION........................................................................... 29
HOW TO MAKE THE ELECTRICAL CONNECTIONS ON THE SPOUT.............................................. 31
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 ........................................................................ 36
INSTALLING THE INSPECTION LIGHT............................................................................................... 37
ASSEMBLING INSTRUCTIONS - LIQUID INCORPORATION SYSTEM ................................................. 38
ASSEMBLING INSTRUCTIONS - MANUAL QUICK-DISCONNECT HITCH ........................................... 42
ASSEMBLING INSTRUCTIONS - ELECTRIC QUICK-DISCONNECT HITCH......................................... 43
ASSEMBLING INSTRUCTIONS - DRAW BAR EXTENSION................................................................... 45
ASSEMBLING INSTRUCTIONS - TRANSPORT LIGHTS........................................................................ 47
CORN CRACKER INSTALLATION INSTRUCTIONS ............................................................................... 48
TABLE OF CONTENTS
Manual no. F4112E952 V1.2

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PARTIAL DISMANTLING OF THE CORN CRACKER FOR HAY CROP ................................................. 63
PARTIAL reassembling OF THE CORN CRACKER FOR CORN CROP................................................ 70
OPERATING INSTRUCTIONS .................................................................................................................. 75
OPERATION TIPS ................................................................................................................................ 75
BREAK-IN SPEED................................................................................................................................ 75
BOLT TORQUE SPECIFICATIONS ...................................................................................................... 75
METAL DETECTOR.............................................................................................................................. 75
STOPPING THE MACHINE.................................................................................................................. 75
TRANSPORTATION ON PUBLIC ROADS ........................................................................................... 75
PREPARING FOR FIELD OPERATION ............................................................................................... 76
HITCHING THE FORAGE HARVESTER TO THE TRACTOR ............................................................. 76
ADJUSTING THE ATTACHMENT GROUND CLEARANCE................................................................. 77
STARTING UP ...................................................................................................................................... 77
INFORMATION ON THE METAL DETECTOR ..................................................................................... 77
DAILY CHECKS ON THE METAL DETECTOR .................................................................................... 78
INITIALIZING THE METAL DETECTOR............................................................................................... 79
STOPPING THE MACHINE.................................................................................................................. 79
STARTING OPERATION ...................................................................................................................... 80
THE CONTROL BOX............................................................................................................................ 80
EMERGENCY STOP ............................................................................................................................ 80
WHAT TO DO WHEN THE MACHINE DETECTS A FERROUS METAL.............................................. 81
WHAT TO DO IF MATERIAL ACCUMULATION OCCURS (CLOGGING) ............................................ 81
HOW TO BY-PASS THE METAL DETECTOR...................................................................................... 82
SHEAR BOLT........................................................................................................................................ 83
PRESSURE AND FLOW CHARTS FOR STANDARD NOZZLE .......................................................... 84
HOW TO OPERATE THE LIQUID INCORPORATION SYSTEM ......................................................... 84
PRESSURE ADJUSTMENT ................................................................................................................. 84
DETECTION SYSTEM FOR SAFETY BOLT BREAKAGE OR FRICTION CLUTCH SLIPPAGE
ON THE CUTTER HEAD TRANSMISSION SHAFT............................................................................. 85
LUBRICATION ........................................................................................................................................... 87
HYDRAULIC CIRCUIT........................................................................................................................ 87
POWER-TAKE-OFF (PTO) ................................................................................................................. 87
LUBRICATION CHART ....................................................................................................................... 87
CHAINS............................................................................................................................................... 87
GEAR BOX LUBRICATION................................................................................................................. 87
CORN CRACKER LUBRICATION ...................................................................................................... 94
ADJUSTMENTS - MAINTENANCE........................................................................................................... 96
WHEEL POSITIONING......................................................................................................................... 96
GROUND CLEARANCE ....................................................................................................................... 97
DISMANTLING AND REASSEMBLY OF THE POWER-TAKE-OFF (PTO) ROTATING GUARDS ...... 97
FORAGE HARVESTER DRAW BAR.................................................................................................... 98
FEED ROLL BALANCING SPRINGS ................................................................................................... 98
UPPER FEED ROLL CHAIN TENSION................................................................................................ 99
LOWER FEED ROLL CHAIN TENSION............................................................................................... 99
STRAW CHOPPING ............................................................................................................................. 99
BALANCING SPRINGS ........................................................................................................................ 100
UPPER ROLL ADJUSTING BOLTS...................................................................................................... 101
SPOUT WEAR PLATE.......................................................................................................................... 101
TABLE OF CONTENTS
Manual no. F4112E952 V1.2

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MAGNETIC DRAIN PLUGS.................................................................................................................. 101
FEED ROLL STOPPING SYSTEM....................................................................................................... 102
FAN BELT TENSION............................................................................................................................. 103
FAN AND TRANSMISSION BELT REPLACEMENT............................................................................. 103
CORN CRACKER BELT TENSION ...................................................................................................... 104
CORN CRACKER BELT REPLACEMENT ........................................................................................... 105
TRANSMISSION BOX BELTS .............................................................................................................. 106
REVERSE, NEUTRAL AND FORWARD SPEEDS POSITIONS .......................................................... 106
ANGLE DRIVE TRANSMISSION BOX SHEAVE.................................................................................. 107
FAN ADJUSTMENT .............................................................................................................................. 108
KNIFE ADJUSTMENT........................................................................................................................... 110
KNIFE GRINDING................................................................................................................................. 111
KNIFE REPLACEMENT........................................................................................................................ 113
KNIVES & SHEAR BAR GENERAL INFORMATION............................................................................ 113
SHEAR BAR ADJUSTMENT ................................................................................................................ 114
DAILY ADJUSTMENT ........................................................................................................................... 114
REPLACEMENT AND INITIAL ADJUSTMENT OF THE SHEAR BAR................................................ 115
CUTTING LENGTH SELECTION ......................................................................................................... 116
PROCEDURE FOR CHANGING THE CUTTING LENGTH ................................................................. 117
SMOOTH FEED ROLL CLEANER ADJUSTMENT............................................................................... 117
MAINTENANCE PROCEDURE FOR THE CUTTER HEAD BOTTOM PLATE ASSEMBLY ................ 118
CORN CRACKER SHEAVE ALIGNMENT............................................................................................ 119
CORN CRACKER Q.D. BUSHINGS..................................................................................................... 120
CORN CRACKER LOWER ROLL BEARINGS..................................................................................... 120
CORN CRACKER UPPER ROLL BEARINGS...................................................................................... 122
CORN CRACKER LOWER ROLL HALF BOTTOM PLATE.................................................................. 124
CORN CRACKER LOWER ROLL PROTECTOR................................................................................. 124
CORN CRACKER ROLL SCRAPER .................................................................................................... 125
UPPER CORN CRACKER ROLL “ZERO” POSITION ADJUSTMENT................................................. 126
UPPER CRACKER ROLL PRESSURE AND GAP ADJUSTMENT ...................................................... 127
CORN CRACKER INITIAL START UP ADJUSTMENT......................................................................... 128
LIFTING THE ATTACHMENT ............................................................................................................... 128
LIFTING ARMS ..................................................................................................................................... 128
STONE CARRIAGE ADJUSTMENT .................................................................................................... 129
STONE REPLACEMENT...................................................................................................................... 129
CUTTER HEAD SENSOR ADJUSTMENT ........................................................................................... 130
FEED ROLL SHAFT SENSOR ADJUSTMENT .................................................................................... 130
PTO FRICTION CLUTCH ADJUSTMENT (OPTION) ........................................................................... 131
VENTING THE CLUTCH ...................................................................................................................... 132
CLUTCH DISMANTLING PROCEDURE.............................................................................................. 133
CLUTCH ASSEMBLY PROCEDURE.................................................................................................... 134
CLUTCH TORQUE SETTING............................................................................................................... 135
TRANSMISSION CLUTCH LEVER POSITION SENSOR.................................................................... 136
STORAGE.................................................................................................................................................. 138
METAL DETECTOR DIAGNOSTIC SHORT PROCEDURE...................................................................... 139
«LED» DISPLAY ON METAL DETECTOR................................................................................................ 140
TROUBLESHOOTING............................................................................................................................... 141
TABLE OF CONTENTS
Manual no. F4112E952 V1.2

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Specifications and design are subject to change without notice
and without liability therefore.
WEIGHT (with 31 X 13.5 X 15” TERRA RIB tires)
with metal detector ..................................................................................... 5280 lbs (2400 Kg)
without metal detector ................................................................................ 5230 lbs (2380 Kg)
DIMENSIONS
Overall width:
with 31x13.50 tires - 15 Terra Rib 142” (361cm)
with 31x15.50 tires - 15 Terra Grip 150” (381 cm)
length...........................................................................................................228” (579 cm)
height...........................................................................................................129” (328 cm)
ANGLE DRIVE TRANSMISSION
540 or 1000 RPM (buyer’s choice)
MAIN TRANSMISSION
forward-neutral-reverse with torque limiter
three 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 (240˚ rotation)
deector
CUTTER HEAD
12 helicoidal knives
24” (61 cm) wide
22” (56 cm) diameter
speed: 815 to 1033 RPM
TIRES AND SINGLE WHEELS
31 X 13.5 X 15” TERRA RIB
16.5 X 16.1 - 8 ply DYNA RIB
TIRES AND TANDEM WHEELS
31 X 3.50 - 15 TERRA RIB
31 X 15.50 - 15 HIPPO
SPECIFICATIONS
Manual no. F4112E952 V1.2

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Specifications 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 mm) standard upon delivery
and 34 teeth for 1/2” (13 mm)
Shear bar adjustment on one side
240orotation spout
OPTIONAL EQUIPMENT
Metal detector
Spout extension (12” or 24”) (30 or 60 cm)
Single wheels or tandem wheels
Double sprocket wheels for lengths of cut: 17 teeth for 1/4” (6.35 mm)
Deector light
Inspection light
Manual (cord) quick-disconnect hitch
Electrical heavy-duty quick-disconnect hitch
Liquid incorporation system
Recuperation grain pan
Recuter bar (for corn only)
Corn Cracker
Draw Bar Hooker
Draw Bar Extension
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. F4112E952 V1.2

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For your convenience, write down in full in this manual both the model and serial numbers of
your machine, as shown on the name plate illustrated below. Always mention both the model and
the serial numbers when ordering parts or regarding any other correspondence referring to your
machine.
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. F4112E952 V1.2

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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. F4112E952 V1.2

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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. F4112E952 V1.2

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TO OUR CUSTOMER
The following pages and illustrations are printed to
help supply you with the knowledge to better oper-
ate and service your Dion Forage Harvester.
Any piece of equipment needs, and must have a
certain amount of service and maintenance to keep
it in top running condition. We have attempted to
cover all the adjustments required to t most con-
ditions; however, there may be times when special
care must be taken to t a condition.
Study this operator’s manual carefully and become
acquainted with all the adjustments and operating
procedures 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 rela-
tion to the service it receives.
If special attention is required for some conditions,
ask your Dion Dealer; its Parts and Service depart-
ment will be glad to help and answer any questions
on the operation and service of your new machine.
THIS MANUAL SHOULD REMAIN WITH THE
MACHINE WHEN SOLD
This manual was prepared from the latest product
information available at publication time. The Com-
pany reserves the right to make changes at any time
without notice.
The Safety section of your Operator’s manual is in-
tended to point out some of the basic safety situa-
tions which may be encountered during the normal
operation and maintenance of your Forage Har-
vester, and to suggest possible ways of dealing with
these situations. This section is NOT a replacement
for other safety practices featured in other sections
of this book.
WARRANTY INFORMATION
The warranty for this machine is located at the be-
ginning of this manual.
If the Forage Harvester is used with an attachment
from another manufacturer, the warranty is limited to
the Forage Harvester.
You, the equipment purchaser, shall assume char-
ges 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 con-
cerns in designing and developing a new Forage
Harvester. Designers build in as many safety fea-
tures as possible. However, every year accidents
occur which could have been avoided by a few sec-
onds thought and a more careful approach to han-
dling farm machinery and implements.
Read and implement the safety instructions detailed
in the safety section of this manual.
FOREWORD
Manual no. F4112E952 V1.2

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SAFETY ALERT SYMBOL
The symbol above calls your attention to instructions con-
cerning your personal safety. It is found throughout the man-
ual 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 personal 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 instructions as they relate to personal safety.
DANGER: This symbol together with the
word DANGER indicates an imminently haz-
ardous situation that, if not avoided, will re-
sult in DEATH OR VERY SERIOUS INJURY.
WARNING: This symbol together with the
word WARNING indicates a potentially haz-
ardous situation that, if not avoided, could
result in DEATH OR SERIOUS INJURY.
CAUTION: This symbol together with the
word CAUTION is used to indicate a poten-
tially hazardous situation that, if not avoided,
may result in MINOR INJURY.
IMPORTANT: The word IMPORTANT is used to identify
special instructions or procedure which, if not strictly
observed, could result in damage to, or destruction of
the machine, process or its surroundings.
NOTE: The word NOTE is used to indicate points of particu-
lar interest for a more efcient and convenient service and
operation of the machine.
DECALS:
WARNING: DO NOT remove or obscure Dan-
ger, Warning, Caution or Instruction Decals
that are not readable or are missing. Replace-
ment decals are available from your Dealer in
the event of loss or damage. The actual loca-
tion of these Safety Decals is illustrated on
pages 17 to 21.
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 in-
cludes tractors. It is your responsibility to know what these
regulations are, and obey them, in the operating area or situ-
ation.
These will include, but are not limited to, the following instruc-
tions for proper operation:
WARNING: An operator should not use alco-
hol or drugs which can change his alertness
or coordination. An operator on prescription
or “over the counter” drugs needs medical
advice on whether or not he or she can oper-
ate machines
A WORD TO THE OPERATOR
It is YOUR responsibility to read and understand the safety
section in this manual before operating your tractor. You must
follow these safety instructions that take you step by step
through your working day.
In reading this section, you will note that illustrations
have been used to highlight certain situations. Each
illustration is numbered and the same number appears
in the text in parenthesis.
Remember that YOU are the key to safety. Good safety prac-
tices 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 operate the machine without these
components in position. If the removal of
panels or guards is necessary to make a
repair, they MUST be replaced before opera-
tion.
SAFETY RULES
Manual no. F4112E952 V1.2

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• Disengage the PTO and shut off engine before
leaving the operator’s seat for refueling, lubricat-
ing or adjusting 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, any-
time 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 during 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-disconnect 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.
• Never hook a loaded trailer behind a Forage Har-
vester 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 imme-
diately.
•If a feeding or throwing mechanism should be-
come jammed, never attempt to unblock it or
remove any material when the machine is in mo-
tion 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
having 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
machine is running.
•Make sure all rotating parts are stopped and the
tractor engine is turned off before cleaning the
machine throat.
• Never park the Forage Harvester in its transport
position. 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 thor-
oughly for possible loose parts or bolts and
tighten them.
•When knives are being readjusted, a piece of
wood should be used to immobilize 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 ad-
justment.
• Never allow riders on any part of a machine.
• Block elevated components before servicing
equipment.
•Do not unhook a farm wagon when the land is
slopping down, or service the machine without
rst blocking wheels.
• Never lubricate or clean any part while the ma-
chine or tractor engine is running.
• Keep hands and body out of hitch area when
attaching towing vehicle.
WARNING: Hydraulic uid under pressure
can penetrate the skin or eyes and cause seri-
ous personal injury, blindness or death. Fluid
leaks, under pressure, 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 surgically re-
moved within a few hours by a doctor familiar
with this type of injury.
•Securely block the wheels from moving before
working 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. F4112E952 V1.2

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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 safety chain to the tractor frame.
• Never wear loose clothing and keep people, es-
pecially 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 machine equipped with a 1000 RPM drive.
• Never proceed to the starting of the machine
before 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
extremely hazardous to perform any kind of main-
tenance work while the machine is running. It could
lead to serious injuries or even death. Before clean-
ing, adjusting or greasing the machine, the follow-
ing 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. F4112E952 V1.2

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 operating 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 transmis-
sion shaft (on its full length) from the front
bearing up to the angle 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
transmission shaft between the angle drive
transmission and the cutting head, the driv-
ing belts for the forward-neutral-reverse trans-
mission and the driving system for the feeding
rolls and the attachments.
Item 5 An hinged guard covers the 4 blowing fan riv-
ing 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 sys-
tem.
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. F4112E952 V1.2

17
SAFETY SIGN LOCATION
IMPORTANT: Decals must be kept clean to allow easy reading at all times.
Manual no. F4112E952 V1.2

18
SAFETY SIGN LOCATION
IMPORTANT: Decals must be kept clean to allow easy reading at all times.
Manual no. F4112E952 V1.2

19
SAFETY SIGN LOCATION
IMPORTANT: Decals must be kept clean to allow easy reading at all times.
3
17
11
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
Manual no. F4112E952 V1.2

20
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. F4112E952 V1.2