Dion-Ag Scorpion 300 Operator'S Manual Download Page 104

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DIAGNOSTIC & TROUBLESHOOTING

104

SHARPENING

PROBLEMS

PROBABLE CAUSES

SOLUTIONS

Uneven knife sharpened
face

Grinder not parallel to cutterhead
drum

Adjust grinder frame alignment with shims

Grinding stone vibrates

Stone not assembled correctly

Check for the correct spring washers assembly.
Make sure the two set screws are well tightened and locked on the stone

Sharpening PTO speed too
low.

Run at 600 PTO RPM for 1000-1000 Harvester.
Run at 750 PTO RPM for 1000-800 Harvester.

DRIVE

PROBLEMS

PROBABLE CAUSES

SOLUTIONS

Excessive power
requirement

Excessive spacing between knives
and shear bar.

Adjust shear bar

Length of cut unnecessarily too
short

Increase/modify the length of cut

The crop channel is gummed

Use liquid incorporation system to avoid gumming

Smooth roll cleaner is not
adjusted

Clean and readjust smooth roll cleaner

Accelerator not correctly adjusted

Adjust the accelerator clearance

Insufficiently ground knives

Sharpen knives

Worn out shearbar

Remove and flip over shearbar or replace it. Always put the tungsten faces
upwards.

Manual

o. F6918E003E v1.2

Summary of Contents for Scorpion 300

Page 1: ...Operator s Manual FORAGE HARVESTER Manual No F6918E003E v1 2...

Page 2: ...Manual No F6918E003E v1 2 2...

Page 3: ...replacement parts and will be able to provide qualified technicians to repair maintain and adjust your machine This manual has been prepared with the available information at the time of publishing Th...

Page 4: ...esentative 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 s...

Page 5: ...Manual No F6918E003E v1 2 5...

Page 6: ...C CONNECTION 24 CONNECTING THE HARVESTER TO THE TRACTOR 26 DRAW BAR EXTENSION 27 CONFIGURING FOR CORN HARVEST SETUP 30 CONFIGURING THE HARVESTER FOR WINDROW HAY HARVESTING 37 SETTING THE LENTGH OF CUT...

Page 7: ...E PROCESSOR ROLLS 75 TRANSPORT 76 MAINTENANCE AND ADJUSTMENTS 78 HYDRAULIC CIRCUITS 78 POWER TAKE OFF PTO 78 DRIVE CHAINS 78 LUBRICATION CHART 79 GEARBOXES LUBRICATION 79 PROCESSOR ROLL LUBRICATION 86...

Page 8: ...e Metal detector short spout 2860 kg 6300 lb Processor rolls 300 kg 660 lb Stinger spout 110 kg 230 lb TRANSMISSIONS ANGLE DRIVE CONFIGURATIONS 540 800 540 rpm PTO 810rpm at the cutterhead 90 to 135 h...

Page 9: ...cut sprockets 17T 26T 34T Height adjustable spout with 310 rotation Feedroll grain pan Adjustable drawbar Cat II to IV OPTIONAL Angle drive 1000 800 or 540 800 12 knives cutterhead Spout extensions o...

Page 10: ...hine 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 yo...

Page 11: ...Manual No F6918E003E v1 2 11...

Page 12: ...NGER indicates an imminently hazardous situation that if not avoided will result in DEATH OR VERY SERIOUS INJURY WARNING This symbol together with the word WARNING indicates a potentially hazardous si...

Page 13: ...t any time The tractor ignition key must be removed every time the operator leaves the tractor Keep hands and body out of hitch area when attaching towing vehicle Carefully read the safety decals on t...

Page 14: ...eaning the machine throat Never stand underneath the forage harvester deflector or forage path when the machine is running Keep the discharge spout toward the forage box MANDATORY STOPPING PROCEDURE N...

Page 15: ...lock their movement to make the working environment safe Make sure that all wheel rim bolts are properly torqued When knives are being readjusted a piece of wood should be used to immobilize the cutti...

Page 16: ...O shaft cables and hose shield 2 Transmission shaft guard 3 Feedrolls transmission pulley guard 4 Main guard covering the power transmission components 5 Left Butterfly guard covering the processing e...

Page 17: ...AFEY SIGNS LOCATION Several decals located around the hazard areas indicate the potential dangers IMPORTANT Decals must be kept clean to allow easy reading at all times Figure 4 Safety Decals Manual N...

Page 18: ...SAFETY RULES 18 Figure 5 Safety Decals Figure 6 Safety Decals Manual No F6918E003E v1 2...

Page 19: ...SAFETY RULES 19 Figure 7 Safety Decals Figure 8 Safety Decals Manual No F6918E003E v1 2...

Page 20: ...SAFETY RULES 20 Figure 9 Safety Decals Manual No F6918E003E v1 2...

Page 21: ...SAFETY RULES 21 Figure 10 Safety Decals Manual No F6918E003E v1 2...

Page 22: ...ives the correct torque values for bolts used on the machine Check tightness of bolts periodically Table 1 Bolt Torque Specifications Replace hardware with the same grade bolt SAE 2 SAE 5 SAE 8 10 9 F...

Page 23: ...tor may require in operation up to 25 Amps for short periods The control box may be connected directly in the cab standard AMP 3pin 12V plug as long as it offers a circuit protection of at least 25A I...

Page 24: ...rn A reverse connection is prevented by a check valve in the harvester hydraulic manifold Ideally connect the tank line T to a motor return port on the tractor often used for hydraulic motor return on...

Page 25: ...equired A higher pressure can cause hydraulic system malfunctions Figure 15 Pressure gauge The return pressure is affected by two factors T connection Connecting the T line to the tractor SCV may crea...

Page 26: ...gure 16 PTO shaft alignment Figure 17 Ensure the distance A see next figure of the driveshaft guard is superior to zero when the tractor is at its maximum turning angle To increase the turning angle a...

Page 27: ...1 and 2 inside extension item3 Insert extension with shim inside the draw bar item 4 You need at least the thickness of one shim item 2 to clear the bolt head STEP 2 Insert bolt item 6 through the ex...

Page 28: ...ension item 3 Insert extension with shim inside the draw bar item 4 You need at least the thickness of one shim item 2 to clear the bolt head STEP 2 Insert two stove bolts item 6 through the shims as...

Page 29: ...ide use the bolts item 11 then lock in place with the nuts item 12 STEP 6 Insert pin item 14 and lock with the safety pin item 15 Note that items 14 and 15 are not supplied by the manufacturer STEP 7...

Page 30: ...1 FIGURE 21 Open the main guard then pivot the hydraulic manifold to free space around the accelerator belt binder Figure 21 Main guard and manifold STEP 2 FIGURE 22 Remove the lock pin item 1 and the...

Page 31: ...e binder assembly Remove the belt to access the roller opening in the frame Figure 23 Accelerator binder ATTENTION Work safely when you work or operate the harvester STEP 4 FIGURE 24 Loosen the two le...

Page 32: ...cleaned Tightened the bolts item 1 back to the required torque See Table 1 Bolt Torque Specifications page 22 Figure 25 Processor roll unit STEP 6 FIGURE 26 Remove the strap from the top roll item 1...

Page 33: ...andle item 4 Install the six belts item 1 in the following order Install the first three one by one from the back of the driving pulley item 2 by turning the pulley in the direction shown Install the...

Page 34: ...EP 10 Ensure the processor roll is properly greased adjusted and the bolts properly fastened See page 22 Table 1 Bolt Torque Specifications Check that no part is loose or free at low PTO speed approx...

Page 35: ...tor binder STEP 12 FIGURE 31 Install the cylinder lock lever item 2 and insert the locking pin item 1 Install the binder locking bolt item 3 and 4 Figure 31 Cylinder lock lever and binder locking bolt...

Page 36: ...em 2 Ensure the nuts are installed on the outside Figure 32 Front grain pan STEP 14 FIGURE 33 Pivot the hydraulic manifold back in place Fasten the bottom roll stainless plate item 2 on the plastic gu...

Page 37: ...1 FIGURE 34 Open the main guard then pivot the hydraulic manifold to free space around the accelerator belt binder Figure 34 Main guard and valve manifold STEP 2 FIGURE 35 Remove the lock pin item 1...

Page 38: ...TION Work safely when you work or operate the harvester STEP 4 FIGURE 37 Open the right butterfly guard item 1 then the side guard item 2 Release the tension from the processor belt binder item 6 To d...

Page 39: ...s STEP 6 FIGURE 39 Unbolt the top roll bearing plates left item 1 and right item 2 Each plate is supported by two 1 2 dia X 1 lg flange bolts Figure 39 Supports de roulement STEP 7 FIGURE 40 Remove th...

Page 40: ...URE 42 Remove both holding bolts at the rear of the processor frame item 1 and lower the assembly Clean the channel pans and the bottom roll item 3 and grease the later to prevent rust formation Insta...

Page 41: ...annel half pans item 4 as shown Replace and tighten the frame bolts item 2 to proper torque See Table 1 Bolt Torque Specifications page 22 Figure 43 Half pans alignment STEP 11 FIGURE 44 Reinstall the...

Page 42: ...belt binder STEP 12 FIGURE 45 Install the lift cylinder lever item 2 back on and insert the locking clip item 1 Replace the binder locking bolt item 3 and 4 Figure 45 Locking lever and binder locking...

Page 43: ...em 2 Figure 47 Removing the front grain pan STEP 15 Ensure all bolts are properly fastened Ensure not parts are loose of free and run the machine at moderate speed approx 500 rpm Then run the machine...

Page 44: ...olls Refer to the following chart for the appropriate settings Optional length of cut LOC range LOC L and LOC H are factory installed but can be modified from one to the other with conversion kit avai...

Page 45: ...LENGTH OF CUT STEP 1 Figure 49 Open the main guard Figure 49 Ouvrir le garde principal STEP 2 FIGURE 50 Completely remove the chain tension item 1 by loosening the tension rod item 2 Figure 50 Chain...

Page 46: ...e washer item 3 and clip item 2 back on STEP 5 FIGURE 50 Set the tension back on the chain item 1 by tightening the rod item 2 Tighten until the proper tension is achieved see Figure 48 Close the main...

Page 47: ...the 1 1 4 stroke limiting pin item 4 provided with the harvester to avoid contact between the header and the harvester Figure 53 Stroke limit pin and header lifting mechanism STEP 2 FIGURE 54 Move th...

Page 48: ...them so they will not come in contact with the feed rolls STEP 4 FIGURE 56 When the header is installed on the harvester install the square locking pins in place item 10 and the safety locks clips ite...

Page 49: ...oner item 18 Move the header sprocket item 21 on the shaft to align it with the harvester driving sprocket if necessary Adjust the chain tension 6 mm 1 4in of deflection for 7 kg 15lb force Tighten th...

Page 50: ...T FIGURE 60 The header height adjustment is done through a double acting hydraulic cylinder for which the control switch is located on the control box For windrow pickups refer to the related operator...

Page 51: ...o 6 hours a day we recommend grinding the knives once a day However if work is performed on an excessively muddy or sandy terrain or with highly abrasive crop two daily grindings are recommended Refer...

Page 52: ...ety brake is engaged DANGER To prevent serious injury or death from rotating knives stand on the ground when knives are turning Keep others away DANGER Wear safety goggles and do not wear baggy or loo...

Page 53: ...he shearbar Figure 63 1 After the knife grinding with the PTO engaged lower the tractor engine speed to minimum 2 Loosen the shearbar locking bolt item 1 3 Loosen the lock nut item 2 and make the adju...

Page 54: ...s are controlled through the control box and operated along with the hydraulic system Only one control box is offered equipped with all optional function switches even if not installed on the harveste...

Page 55: ...ted function with metal detector models see page 68 METAL DETECTOR GENERAL INFORMATION NOTE Warranty coverage will not extend to consequential damages The metal detector is used for stopping the feed...

Page 56: ...for best performance according to specific conditions It uses a variable threshold that adjusts itself to the harvest conditions length of cut vibrations impacts etc to maximise the detection power Th...

Page 57: ...king condition using the following procedure 1 Check wire harnesses connectors connections etc 2 Check the stop pawl system for free motion Check the alignment of the NEUTRAL REVERSE sensors and perfo...

Page 58: ...uickly several times to confirm the new level Figure 65 Metal detector sensitivity adjustment DISABLING THE METAL DETECTOR NOTE Warranty coverage does not apply to damage or failures caused by the mal...

Page 59: ...k the stop pawl spring item 1 back to its original position before using the metal detector Figure 66 Disabling the metal detector DRIVE FAILURE DETECTOR As part of the controls included in the metal...

Page 60: ...lt detector is run on the harvester controller The indicator light item 3 on Figure 69 show the state of the detector Green Active Orange Deactivated Red Shearbolt breakage or slip clutch slippage det...

Page 61: ...ntroller indicator light on the harvester will appear orange when deactivated The metal detector remains active NOTE Every time the control box is turned ON the drive failure detector is reactivated a...

Page 62: ...ntrol switch location PRESSURE ADJUSTEMENT FIGURE 71 TABLE 2 To adjust the pressure 1 Refer to the table below to select the right pressure to obtain the correct amount of liquid applied to the crop 2...

Page 63: ...nection must be made through a load protected circuit Use the harness provided in the incorporation kit which includes an activation relay This harness and the standard harvester wiring can be used fo...

Page 64: ...e pressure corresponding to the desired flow Figure 71 3 Put an empty bucket item 1 under the nozzle item 2 to collect the liquid inside the accelerator chamber if standard nozzle location is used 4 R...

Page 65: ...e of the harvester including the header in transport position Check with your local authorities for the applicable requirements On the left hand side unbolt the support and move to the next set of hol...

Page 66: ...n operating in the field to reduce the driveshaft angles This will increase the life of the universal joints and reduce vibrations Also with a straighter drawbar position pulled behind trailers will t...

Page 67: ...on the control box Figure 78 Item 1 Activate the hydraulic valve of the tractor connected to the harvester Make sure the flow is limited to less than 11 l min 3 gpm and the back pressure on the manifo...

Page 68: ...ss R to go change from FORWARD to NEUTRAL and stop in mid range to the Neutral position WITH METAL DETECTOR FIGURE 78 The transmission is operated in a semi automatic mode for models equipped with Fer...

Page 69: ...in in place if already in NEUTRAL 3 Validate that the transmission is in NEUTRAL 4 Engage the PTO on at this time or after the initialisation 5 Shift the transmission in REVERSE The alarm will turn of...

Page 70: ...Turn off the control box and tractor engine IMPORTANT If the tractor engine is turn off for several minutes turn off the control box main switch to avoid discharging the batteries METAL DETECTION PROC...

Page 71: ...5 mm 1 16 space is obtained between the spring coils NOTE A linkage system maintains the rolls parallel and a uniform clearance over the width of the rollers 1 Adjust the upper roll gap by tightening...

Page 72: ...ce by half a mark 1 5mm to start 4 Repeat steps 2 and 3 until the required result is obtained NOTE A larger clearance requires less tractor power For the best efficiency maintain the largest gap possi...

Page 73: ...e the feedrolls from accumulated crop 9 Shift the transmission to FORWARD and resume harvesting NOTE It is not necessary to initialize the harvester after a blockage since the controller has not been...

Page 74: ...cases contact your dealer NOTE When a friction clutch is used power is still transmitted to the cutterhead during slippage but may burn quickly if not stopped When slippage occurs and the feedrolls a...

Page 75: ...pe material out through the cleaning slotted holes item 2 or 4 5 When the cleaning is done close the top cover and the small cleaning doors Engage PTO to completely clean the area between the rolls an...

Page 76: ...tem 6 4 For models equipped with the STINGER spout extension turn it in transport position full forward position and lower it completely The cylinder shortest position is limited to maintain a suspens...

Page 77: ...hain of appropriate capacity must also be installed between the harvester and trailer Finally the trailer disconnect switch safety cover on the control box must be lowered and the hydraulic flow cut o...

Page 78: ...Ensure all moving pats have come to a complete stop before servicing the harvester IMPORTANT Lubrication and greasing at the proper frequency and quantity will minimize the wear and tear of the compon...

Page 79: ...gearbox oil lever must be checked and adjusted after the first ten 10 hours of operation at the beginning of every season and at least every 100h of operation Synthetic 80W140 oil is recommended avail...

Page 80: ...MAINTENANCE AND ADJUSTMENTS 80 Figure 86 Universal joint and drawbar bearings Figure 87 Front PTO Figure 88 Angle drive gearbox Manual No F6918E003E v1 2...

Page 81: ...MAINTENANCE AND ADJUSTMENTS 81 Figure 89 Main gearbox spout rotation and hydraulic trailer disconnect Manual No F6918E003E v1 2...

Page 82: ...MAINTENANCE AND ADJUSTMENTS 82 Figure 90 Knife grinder suspension springs and transmission shifter Manual No F6918E003E v1 2...

Page 83: ...MAINTENANCE AND ADJUSTMENTS 83 Figure 91 Cutterhead and blower bearings each side 4 points Figure 92 Feedroll slider shearbar spring plunger each side 4 points Manual No F6918E003E v1 2...

Page 84: ...MAINTENANCE AND ADJUSTMENTS 84 Figure 93 Universal joints transmission chain Manual No F6918E003E v1 2...

Page 85: ...MAINTENANCE AND ADJUSTMENTS 85 Figure 94 Feedrolls linkage bearings and chains Manual No F6918E003E v1 2...

Page 86: ...wet conditions the silage rejects large amounts of fluids when passing through the processor rolls that may contaminate the roller bearings It is highly recommended to increase the greasing frequency...

Page 87: ...MAINTENANCE AND ADJUSTMENTS 87 Figure 96 Sealed grease chamber behind the roller bearings Figure 97 Processor rolls lubrification Manual No F6918E003E v1 2...

Page 88: ...MAINTENANCE AND ADJUSTMENTS 88 Figure 98 Processor rolls lubrification Manual No F6918E003E v1 2...

Page 89: ...alent to approximately 12 5cm 0 5in The basic adjustment consists in tightening the springs down to 1 5mm 1 16in between the bolt head item 3 and the support plate item 4 Adjust with the lock nut item...

Page 90: ...ll chain item 1 loosen binder bolts item 2 completely and remove spacers item 3 from the binder plate item4 to obtain the required tension Make sure the binder is centered with the chain rollers item...

Page 91: ...n tension TRANSMISSION BELT TENSION FIGURE 103 The banded belt item 1 driving the main transmission is tightened by a floating binder pulley arm item 2 To maintain full power transmission capacity the...

Page 92: ...d before servicing the harvester Figure 104 Accelerator belt tension PROCESSOR BELTS TENSION FIGURE 105 The tension is maintained through the tensioner idler item 4 Tighten the belts item 5 by turning...

Page 93: ...106 Pressure washing STEP 1 To prevent any accumulation of dirt soil material excess of grease or any other substance which could absorb water and cause moisture and rust clean the forage harvester t...

Page 94: ...e necessary spare parts and repair the forage harvester before beginning the new season STEP 7 Remove tension of the belts STEP 8 Check condition of guards and safety decals Replace them if necessary...

Page 95: ...ransmission unlocked FORWARD available No alarm except if error1 Error State A R transmission unlocked Manual shifter mode Error alarm once Power ON Return to lock state Metal detection OR Drive failu...

Page 96: ...Shifter logic Power On Shifter moves to Neutral Transmission in Reverse Shifter moves to Reverse Transmission in Neutral Shifter moves to Forward Transmission in Forward Transmission error Faulty sen...

Page 97: ...d objects can be difficult to find in the crop mat Metal detection but no ferrous material found false detection Alarm Severe impact of the feedrolls Certain conditions in dry corn for example can cau...

Page 98: ...sting holding the magnet coil assembly is broken or detached from the casing Or the fasteners holding the sensor on the shafts are damaged or loose With the PTO stopped and disconnected turn on the co...

Page 99: ...p error Alarm The emergency stop stays active Make sure the emergency stop button on the control box is not damaged stuck in depressed position or that the cable is not cut or disconnected Replace or...

Page 100: ...re turning the speed sensor may be the issue Check the clearance and alignment of the sensor to be centered with approx 1 mm or 1 32 between the sensor tip and the encoding wheel Or replace the sensor...

Page 101: ...ation system to lubricated the crop channel Accelerator misadjusted Adjust according to specifications See service manual Insufficient throwing capacity or distance PTO speed is too low Maintain recom...

Page 102: ...ut Replace or flip over the red feedroll stops PTO is stopped before the crop has gone through the channel Disengage the PTO and lower the tractor engine rpm only when all the crop has passed through...

Page 103: ...worn out Sharpen the knives Worn shearbar Remove and flip over shearbar or replace it Always put the tungsten faces upwards Crop stems not aligned with windrow Adjust crop merger or harvest untouched...

Page 104: ...n at 750 PTO RPM for 1000 800 Harvester DRIVE PROBLEMS PROBABLE CAUSES SOLUTIONS Excessive power requirement Excessive spacing between knives and shear bar Adjust shear bar Length of cut unnecessarily...

Page 105: ...alignment make sure it has not been tampered with Cross bearings are worn Replace cross bearings The draw bar is too short Lengthen the draw bar in order to respect the correct dimension see page 24 C...

Page 106: ...e to 0 5mm 1 64 Hay crop residue stuck on edge of rear channel pan When reconfiguring from hay to corn silage always clean the channel plates and pans around the processor rolls to remove any residue...

Page 107: ...wer when any of the function is activated Check connections and valve coil or replace valve One of the functions is not available i e the spout de ector can be lifted but can t be brought down Valve d...

Page 108: ...on 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 cond...

Page 109: ...Manual No F6918E003E v1 2 109...

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