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    Instrukcja napraw Claas Mega 202-218

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    115 views382 pages

    Instrukcja Napraw Claas Mega 202-218

    Uploaded by

    qrdziel

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
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    REPAIR MANUAL CLHAS CLAAS DOMINATOR 218 MEGA DOMINATOR 208 MEGA DOMINATOR 204 MEGA DOMINATOR 203 MEGA DOMINATOR 202 MEGA 188 056.0 - DO 218 - 202 MEGA-- GB - 10.96 - 350 -V +H. CONVERSION FACTORS Length milimetres (mm) x 0.03937 milimetres (mm) x 0.00328 centimetres (cm) x 0.9937 ‘metres (rn) 3.2808 kilometres (km) 0.6214 Area square metres (m2) x 1550 ‘square inches (sq in) square metres (m@) x 10.764 ‘square feet (sa ft) hectare (ha) x 2.4710 Cres Weight kilogrammes (kg) x 2.2046 = pounds (b) Torque foot pounds (fb) foot pounds (fb) 1ewton metre (Nm) ‘metre kilopond (mkp) x 7.283 newton metres (Nm) x 0.7376 ‘metre kilopond (mkp) x 9.81 Pressure bar x 14.504 pounds per square inch (psi) kg/sq em (at) x0,980665" =bar kg/sq em (at) 14.223 sounds per square inch (ps!) * Where feasible and for practical reasons, this factor is rounded to a whole unit to equal kg/sq cm (at) and bars. Volume and capacities ‘cubic centimetres (cm®) x 0.06102 ube inches (cu in) Iiters () x 0.2201 imperial gallons (Imp. gal) liters () x 0.8798 Imperial quarts (Imp. qt) liters () x 0.2642 S. gallons (U.S. gal) liters () x 1.05668 S. quarts (U.S. at) liters () x 0.0275 imp. bushels liters () x 0.02838 S. bushels Velocity Kilometresnour(kr/h) x 0.6215 = miles per hour (mph) Temperature To convert Celsius (Centigrade) temperature into Fahrenheit: mutply by 8, dive te result by § and add 92 27-0 2727 4664.90 =808°F 24°C = 12°F + 2°C = 495.6°F 44°C = 483.8°F Whilst great care has been taken to ensure accuracy in the compilation of the conversion factors, CLAAS cannot be held responsible for any errors or omissions. FOREWORD INTRODUCTION TO THE CLAAS REPAIR MANUAL This CLAAS REPAIR MANUAL has been prepared to assist all personnel concemed with the maintenance and service of CLAAS Forage Harvesters and to help preserve thelr permanent working order. ‘The experience of our Service engineers has been compiled in this CLAAS REPAIR MANUAL which explains the procedure of repairs, the different adjustments to be made, the use of CLAAS Special Tools etc. The illustrations included in support to the explanations show the sequence Cf major repairs so that minor repairs can easily be drawn out. ‘The CLAAS REPAIR MANUAL is filed in a folder which allows to insert supplementary pages as issued and to have always an updated manual at hand for reference. ‘To be sure, always compare settings and filing capacities with specifications stated in the Operator's Manual which applies to the Forage Harvester. CLAAS KGAa ‘Service Department ‘The present CLAS REPAIR MANUAL is devided into main ‘groups (see group index). Pages and illustrations are numbered consecutively throughout each main group. Page numbering starts always with the number 1 in each group. The first figure at the bottom if each page refers to the main group wheras the ‘second figure following the point indicates the numerical order of the pages. Where service operations apply to a specific Forage Harvester model only tis is clearly indicated by reference to that model. When a service procedure applies to all ‘machines covered by this book, the machine names are not especially mentioned. ‘Supplementary sections are numbered by an additional figure which is separated by a dash from the preceding figures. Any supplements should be inserted at the back of the relevant main group and the list of contents be changed accordingly. The symbols communicate brief messages when recurring service procedures are described. Their meaning is. explained at the beginnig ofthis book. ‘The section »GENERAL REPAIR INSTRUCTIONS« at the beginning ofthis book contains useful practical hints. Read and follow these fundamental instructions. They are the basis for reliable service and durability of pars after repairs hhave been carried out. “The description of a particular service procedure can easily be found by checking the list of contents of the ‘appropriate main group. KEY TO SYMBOLS In this CLAAS REPAIR MANUAL a limited number of symbols from the DIN 0600 have been used. which was prepared by the German Standard Institution (DIN). ‘The meaning of the symbols will son be learned by the user. The symbols help to quickly recognize recurring service procedures and they also help to communicate information shown by the illustrations. Remove, dismantle clea — Prevent damage to material Dismantle oi ‘Special tool Assemble Drain, Adjust, set “Yo | rain outer Unlock. release Secure Mark Overtiow i XS Lock Bound brie) Seal using adhesives Bleed Pe Possibly reusable Block up ‘Support Hold Renew on each assembly Note direction of installation Ka co 6 lH] 2 rea} si 170 (DIN ISO 2309) ‘The oll must have detergency properties. D0 218-202 MEGA 14 Specifications DOMINATOR 218 MEGA / 208 MEGA Oil capacities ‘Transmissions (ON MACHINE: FINAL DRIVE GEARBOXES ‘TRANSMISSION GEARBOX DRUM VARIABLE SPEED DRIVE ‘Two-step gearbox CLAAS 4-TRAC HYDROSTATIC DRIVEN REAR AXLE Planetary gearboxes FRONT ATTACHMENTS: CUTTERBAR KNIFE DRIVE ‘Wobble drive casing MAIZE PICKER HEAD SL. Picker head gearboxes 6-ROW MULTIMASTER ‘Auxiliary gearbox Picker head gearboxes 4.5 ites each SAE 90, 85 W-90 (MIL-L-2105 B) API GL - § - 90 hypoid transmission oil 5 litres SAE 90, 85 W-90 (MIL-L-2105 B) ‘API GL - 5 - 90 hypoid transmission oil 1.0 litre SAE 140 (MIL-L-2105) APL-GL-4- 140 transmission oll 0.8 ites each SAE 90, 85 W-90 (MIL: API GL - 5 - 90 hypoid transmission oil 0.75 litres SAE 90 (MIL-L-2105) APL-GL-4- 90 transmission oil 1.0 litre each SAE 90 (MIL-L-2105) APL-GL-4- 90 transmission oil 1.0 litre SAE 90 (MIL-L-2105) APL-GL-4- 90 transmission oil 1.25 litres each SAE 90 (MIL-L-2105) APL-GL-4- 90 transmission oil Engines, see engine operating manual and combine operating manual, ‘Tyre sizes and tyre pressures: Heme eee Maz tarts cram andics cutter coe Beak | Me | ron |e ronting | erou | sow | 30” | asirsom | aoiecom | a7i.10m naraaieon | re Sroat?| Seu | ermSoen| obtm | Zoecom | ionesom | laham Tas” | want | “ewan ‘are, nee | Cope | “ram omen zs. zen| 21m | ipa | 2000 | 20bw | 200m | 20vw | 20va | 20bw | 19m 4s-c@ spn | 2eba | e6vr | 23ta | 200 | 20t0 | 2aow | 20tw | 20tw | vebw msnevwone| tab | - =| 1960 | teu |= | tote | tebe | ter osneezen| 1aba | iste | ister | abu | 16b0 | t7ow | 17ew | 17bew | 1ebw osneveee| rapa | 170 | 14ter | zou | tate | tabu | tebe | t2ter | tba ‘wavo-21woPn| 28bar Babar sooen-225 Pn 20ber Star 1s-20 ern | 22mm | - - - - = Torque settings of wheel bolts Rear vhesls whee! nuts with thrust pioce H 22 BIN 7461 "10 = 860 Nv (86 mip) Front wheels wheel bots M 18x 1.5 = 225 Nm (2.5 mp) CLAAS 4-Trac rear wheel drive wheel bolts M 22x 1.5 -8.8 and spring washers C 22.5 DIN 74361 (Limes ring) = 520 Nm 12 D0 218-202 MEGA Specifications DOMINATOR 218 MEGA / 208 MEGA Basic setting Reel Intake auger Brakes Foot brake Hand brake Steering drive shaft perpendicular above knife bar, r06l tines perpendicular ‘approx. 15 mm clearance between auger fights and bottom plate of cutterbar trough full braking effect after first third of pedal travel brake must hold after the first 3 to 4 teeth of the segment With steering cylinder piston fully extended, the adjustable stop bolts must be contacting the steering arms D0 218-202 MEGA 13 Specifications DOMINATOR 204 MEGA / 203 MEGA SETTINGS AND CAPACITIES Hydraulic oil pressures. Pressure relief valve Lift hydraulic system Pressure relief valve Hydrostatic steering system Pressure relief valve Hydrostatic steering system ‘SAUER hydrostatic ground drive system (90 R075 / 90 M075) High pressur relief valve setting Purging pressure Charge pressure Oil capacities Hydraulic system ‘Work hydraulic system: Initia fling il change ‘SAUER hydrostatic ground drive system (90 R075 / 90 M075) il change 180 bar 120 bar + circuit flow pressure 20"? bar 450 bar 1875 bar 21" bar 8.5 litres of muit-grade hydraulic ol of viscosity classes 180-VG 32 or VG 46 to DIN 51524 Part * approx. 7 litres of mult-grade hydraulic oll of viscosity classes ISO-VG 92 or VG 46 to DIN 51524 Part 3" 19 litres of muit-grade hydraulic oil of viscosity classes 180-VG 32 or VG 46 to DIN 51524 Part * ‘approx. 8 litres of mult-grade hydraulic oll of viscosity classes ISO-VG 32 or VG 46 to DIN 51524 Part 3" * The following guide values must be observed when selecting the hydraulic oll Pour point lower than -25°C (DIN ISO 3016) Viscosity at °C - < 600 cSt. (DIN 81562) Viscosity at 40°C- max, 50.6 cSt. (DIN 51562) Viscosity index - > 170 (DIN ISO 2909) ‘The oll must have detergency properties. 14 D0 218-202 MEGA Specifications DOMINATOR 204 MEGA / 203 MEGA Oil capacities ‘Transmissions (ON MACHINE: FINAL DRIVE GEARBOXES TRANSMISSION GEARBOX DRUM VARIABLE SPEED DRIVE ‘Two-step gearbox CLAAS 4-TRAG HYDROSTATIC DRIVEN REAR AXLE, Planetary gearboxes FRONT ATTACHMENTS: CUTTERBAR KNIFE DRIVE Wobble drive casing MAIZE PICKER HEAD SL Picker head gearboxes 6-ROW MULTIMASTER Auxiliary gearbox Picker head gearboxes Siitres each SAE 90, 85 W-90 (MIL-L-2105 B) API GL - 4 90 hypoid transmission oil 6.8 litres SAE 90, 85 W-90 (MIL-L-2105 B) API GL - 4-90 hypoid transmission oil 1.0 litre SAE 140 (MIL-L-2105) APL-GL-4- 140 transmission oll 0.8 litres each SAE 90, 85 W-80 (MIL-L-2105 B) API- GL- 5 - 90 hypoid transmission oil 0.75 litres SAE 90 (MIL-L-2105) APL-GL-4- 90 transmission oil 1.0 litre each SAE 90 (MIL-L-2105) API-GL-4- 90 transmission oil 1.0 litre SAE 90 (MIL-L-2105) API-GL-4-90 transmission oil 1.25 litres each SAE 90 (MIL-L-2105) API-GL-4- 90 transmission oil Engines, see engine operating manual and combine operating manual ‘Tyre sizes and tyre pressures ‘mur ye presures| wwesienpe | aru Maize picker bead Grain puteroat Doane wean vm | grow | Grow | Stow | stow | a0 | 287750m| 2016com | 7/810m | 19° BO2tSMEGA | igthives | folding | Som row 85 om 900m |22/660m | 18/850m | 1si4com | 390m “Tye size Grow | witetake | ow win tang” | 141420 witstak | chopper | tak copper ‘hopper 34-26 zoo | - | 29bw | 2ibw | 20bar 2abw | atta | 20ba | 19ber 234-30 2scw | 200% | 19be | 17o0 | 15bar sepa | 16ber | 15ber | 14ber 23.190 soba | tebe | 16bar | 15be | 19ber | 18be | Teta | i4be | iabw | 12ber 22190 ayer | \6ber | \bar | 1Sber | 19bar | 18bar | 16ber | taba | 1aber | 12bar 45-22 2ovar | 16ber | 1a4bar | 19ber | 1tbar | 16ber | aba | 12ber | 1.tbar | 1.0ber 24sRa2 soba | 1sbar | 1aber | 12ber | tba | 1Sber | 1b | tbe | 1Obar | 10bar 24sRa2 aobe | 1sbar | 1ober | 12be | ibe | 1Sber | 1b | tbe | 1Oba | Ober o0sRa2 soba | opba | o7tar | o6be | OSbar | o9ber | avba | OGba | Ovba | O7bar zoanae soe | — | t9bar | s7ber | 18ber separ | 1eber | 1Sber | 1.4ber soow0-225 8PR| 20be ober D0 218-202 MEGA 18 Specifications DOMINATOR 204 MEGA / 203 MEGA Torque settings of wheel bolts Front wheels Rear wheels CLAAS 4-Trac rear wheel drive Basic setting Reel Intake auger Brakes Foot brake Hand brake Steering Wheel nuts with thrust piece H 22 DIN 74961 - 10 = 860 Nm (86 mkp) wheel bolts M 18 x 1.6 = 925 Nm (32.5 mkp) Wheel bolts M 22x 1.5 -8.8 and spring washers C 22.5 DIN 74361 (Limes ring) = 520 Nm drive shaft perpendicular above knife bar, reel tines perpendicular ‘approx. 15 mm clearance between auger fights and bottom plate of cutterbar trough full braking effect after firs third of pedal travel brake must hold after the first 3 to 4 teeth of the segment With steering oylinder piston fully extended, the adjustable stop bolts must be contacting the steering arms 16 D0 218-202 MEGA Specifications DOMINATOR 202 MEGA SETTINGS AND CAPACITIES Hydraulic oil pressures Pressure relief valve Lift hydraulic system Pressure relief valve Hydrostatic steering system Pressure relief valve Hydrostatic steering system ‘SAUER hydrostatic ground drive system (0 R075 /90M075) High pressure relief valve setting Purging pressure Charge pressure Oil capacities Hydraulic system Work hydraulic system: Initia fling il change ‘SAUER hydrostatic ground drive system (90 R075 / 90 M075) Initia fling il change 180 bar 120 bar + circuit flow pressure 20%? bar 450 bar 18°75 bar 211 bar 7.Siitres of muit-grade hydraulic ol of viscosity classes 180-VG 32 or VG 46 to DIN 51524 Part" approx. 6 litres of mult-grade hydraulic oll of viscosity, classes |SO-VG 92 or VG 46 to DIN 51524 Part 3° 19 lites of mult-grade hydraulic oll of viscosity classes 1S0-VG 32 or VG 46 to DIN 51524 Part 3" ‘approx. 8 litres of mult-grade hydraulic ol of viscosity classes |SO-VG 22 or VG 46 to DIN 51524 Part 3° * The following guide values must be observed when selecting the hydraulic ol: Pour point lower than -25°C (DIN ISO 3016) Viscosity 0°C - < 600 cSt. (DIN 51562) Viscosity 40°C - max. 60.6 cSt. (DIN 51562) Viscosity index - > 170 (DIN ISO 2908) ‘The oil must have detergency properties. D0 218-202 MEGA 17 Specifications DOMINATOR 202 MEGA Oil capacities ‘Transmissions (ON MACHINE: FINAL DRIVE GEARBOXES Sires each SAE 90, 85 W-90 (MIL-L-2105 B) API GL - 4-90 hypoid transmission oil ‘TRANSMISSION GEARBOX 6.8 ites SAE 90, 85 W-90 (MIL-L-2105 B) API GL - 4-90 hypoid transmission oil DRUM VARIABLE SPEED DRIVE. ‘Two-step gearbox 1.0 litre SAE 140 (MIL-L-2105) API-GL-4- 140 transmission oll CLAAS 4-TRAC HYDROSTATIC DRIVEN REAR AXLE Planetary gearboxes 0.8 ites each SAE 90, 85 W-90 (MIL-L-2105 B) API GL - 5 - 90 hypoid transmission oil FRONT ATTACHMENTS: CUTTERBAR KNIFE DRIVE ‘Wobble drive casing 0.75 litres SAE 90 (MIL-L-2105) APL-GL- 4-90 transmission oll MAIZE PICKER HEAD SL. Picker head gearboxes 1.0 litre each SAE 90 (MIL-L-2105) APL-GL-4- 90 transmission oil 6-ROW MULTIMASTER Auxiliary gearbox 1.0 litre SAE 90 (MIL-L-2108) APL-GL- 4 - 90 transmission oll Picket head gearboxes 1.25 litres each SAE 90 (MiL-L-2105) APL-GL- 4 - 90 transmission oll Engines, see engine operating manual and combine operating manual, ‘Tyre sizes and tyre pressures imum ye proses SBSE, | unman Wairoa Gran and cuter “ase | glee | (econ, | tron | tow | get | aoiecom | wissom | igganm | 1/450 “Croer_| “oppor | "| am tiiezom | 7oeem | ra ata vwen| ester | cava | zit | 2oter | eater | attr | 20cr | tebe | - sa wen| veuer | seear | s7ew | ster | sete | seer | 1seer | tape | — asco 4pn| ester | sebar | 1ster | rater | sete | tater | sate | tab | 17ber aims teiaa| e7ter | tsar | saver | sate | saber | sate | voter | t1bar | 1ster usmseisoma| tater | s2bar | titer | saber | 12ber | 1obw | 1ote | oabe | 1ater taseo-18 10PR| sober 22ter ‘4575-20 0PR| _a0bar bar scoeo-225 ern| 2ober oper 4990-24 10PR | 2.9bar ater 18 D0 218-202 MEGA Specifications DOMINATOR 202 MEGA ‘Torque settings of wheel bolts Front wheels Rear wheels CLAAS 4-Trac rear wheel drive Basie setting Reel Intake auger Brakes Foot brake Hand brake Steering wheel nuts with thrust piece H 22 DIN 74961 - 10 = 860 Nm (86 mkp) wheel bolts M 18 x 1.6 = 925 Nm (32.5 mkp) Wheel bolts M 22x 1.5 -8.8 and spring washers C 22.5 DIN 74361 (Limes ring) = 520 Nm drive shaft perpendicular above knife bar, ree! tines perpendicular ‘approx. 15 mm clearance between auger fights and bottom plate of cutterbar trough full braking effect after first third of pedal travel bbrake must hold after the first 3 to 4 teeth of the segment With steering cylinder piston fully extended, the adjustable stop bolts must be contacting the steering arms D0 218-202 MEGA 19 Specifications DOMINATOR 218 MEGA - 202 MEGA Safety features Slip clutches Upper feed rake shaft 430 Nm - double spring Reel: Grain cutterbar up to 5.10 m 300Nm Grain cutterbar above 6.0 m 430Nm 4.50 m folding grain cutterbar 200 Nm each Rice cutterbar 300Nm Soybean cutterbar 300 Nm Intake auger 300 Nm Grain cutterbar up to 4.50.m 300 Nm Grain cutterbar above 5.10 m 700Nm Rice cutterbar up to 4.50 m 300 Nm Rice cutterbar above 5.10 m 700 Nm Soybean cutterbar 3.90 m - 7.50 m 700Nm 4-row maize picker head SL 250 + 40Nm S:row maize picker head SL 250 + 40Nm 6-row maize picker head SL 250 + 40Nm ‘row maize picker head SL 250 + 40.Nm 6-row maize picker head, folding 250 + 40Nm (Mutimaster) Cam-type cut-out clutch Picker-head gearboxes: S-row maize picker head SL 650 + 50Nm S-row maize picker head SL 770 + 80Nm 6-row maize picker head SL 990 + 50Nm ‘Brow maize picker head SL 2x650 + 50 Nm 6-row maize picker head, folding 1400 Nm (Mutimaster) Shear bolt Grain tank unloading Hexagon head bolt MEGA 218/208 M10 x50 MK (Vp) DIN 931 -8.8 Selocking nut VM 10 MEGA 204 / 202 M10 x 40 MK (Vp) DIN 931 - 8.8 Selfocking nut VM 10 1.10 D0 218-202 MEGA Specifications Basic setting for concave DOMINATOR 218 MEGA - 202 MEGA Concave settings Dimensions in mm a — “a Ve | Ve HE | OA | VE HE | oA om_|avse | aces | narmeane|__avse | senrote | oot 3 = z a = a 3 3 : = = a = fs = s : = a a a = x = 5 = = = = = = = n = = = 2m = = = 2 = z = 7m = = = = fi = = = « = * cI F * - » * = 2 a # * * = F @ « D0 218-202 MEGA 11 2 Sectional view of machine 2 SECTIONAL VIEW OF MACHINE Sectional view of machine Sectional view of machine 20108. 1 SECTIONAL VIEW OF MACHINE 1. Three-sectional divider 28 Cleaning fan 2 Roel 29. Primary wind duct with 3. Reel tines adjustable deflector (D0 218 - 204 MEGA) 4. Real intermediate drive 30. Windboard, adjustable 5 Reel variable drive 31 Clean grain auger 6 Reel cylinder 932 Retums auger 7 Croplifter 33. Deflector curtain, straw walker compartment 8 Main table auger 34. Horizontal unloading auger 9 Feeder house 35 Lateral augers 10 Feed rake 36 Grain elevator 11. Cutterbar cylinder 37. Grain tank filer auger 12 Stone trap 38. Grain tank 13. Pre-concave 39. Grain tank tid 14 Main concave 40. Retums elevator 15 Accelerator 41 Retums back-to-drum auger 16 Threshing drum 42. Operators platform 17 Impeller 43 Cab 18 Deflector curtain, concave exit 44 Engine 19 Straw walkers 45 Aircleaner 20 Intensive separation system, cranks with tines 46 Final drive 21. Under-walker return pan 47 Transmission 22 Grain tank unloading tube 48. Traction wheels 23. Rear hood 49. Rear wheels 24 Preparation floor 50. Straw chopper 25 Straw sieve pan 26 Upper sieves 27 Lower sieves D0 218-202 MEGA a4 3 Drive Schematic 3 DRIVE SCHEMATIC V-belt and chain diagram DOMINATOR 218 MEGA / 208 MEGA V-belt and chain diagram DOMINATOR 204 MEGA / 203 MEGA V-belt and chain diagram DOMINATOR 202 MEGA Drive Schematic D0 218-202 MEGA 32 Drive Schematic V-belt and chain diagram DOMINATOR 218 MEGA / 208 MEGA, 1. Hydraulic pump power band belt, ground drive 2. Hydraulic pump drive belt (ift hydraulic system, steering system, low pressure hydraulic system) 3. Compressor drive belt, air conditioner 4. Grain tank clutch power band belt 5. Threshing mechanism clutch power band belt 6 Intermediate cleaning fan drive belt 7. Intermediate sieve pan drive 8 Tine crankshaft drive belt 9. Reel drive chain (4.50 m 5.10 m cutterbars) 10. Intermediate reel drive chain (4.50 m -5.10 m cutterbars) 11 Variable speed reel drive belt (4.50 m -5.10 m cutterbars) 12 Chain - intermediate variable speed reel drive (4.50 m -5.10 m cutterbars) 13. Power band belt for snapping units (maize picker head) 14 Chain - intake auger drive (maize picker head) 15 Chain - intermediate drive shaft (maize picker head) 16 V-belt - knife drive casing (6.00 m - 9.00 m cutterbars) 17 Intake auger drive chain (6.00 m- 9.00 m cutterbars) 18 V-belt - knife drive casing (4.50 m- 5.10 m cutterbars) 19 Intake auger drive chain (4.50 m - 5.10 m cutterbars) 20 Cutterbar drive belt (two) 21 Power band belt - accelerator Wide-section belt - fan drive Power band belt - sieve pan and auger drive ‘Straw walker drive belt ‘Straw spreader drive belt ‘Chain - grain tank filler auger drive \V-belt- straw chopper intermediate drive assembly Drive chain - grain tank unloading auger Chain - grain tank intermediate drive assembly Footary screen drive belt Rotary screen intermediate drive belt Chain - returns elevator Straw chopper drive belt Wide section belt - threshing drum variable speed drive ‘Threshing drum drive power band belt Reel variable speed drive belt (6.00 m - 9.00 mcutterbars) Chain - ree! intermediate drive assembly (6.00 m - 9.00 mcutterbars) Chain - reel intermediate variable speed drive (6.00 m - 9.00 mcutterbars) Reel drive chain (6.00 m- 9.00 m cutterbars) ‘Cogged drive belt for maize picker head (stalk chopper) Power band belt for stalk chopper intermediate drive assembly 42. Suction blower drive V-belt SRRERLSBBLBRRGR 8 288 D0 218-202 MEGA 33 Drive Schematic 34 D0 218-202 MEGA Drive Schematic V-belt and chain diagram DOMINATOR 204 MEGA / 203 MEGA, 1. Hydraulic purnp power band belt, ground drive 2. Hydraulic purnp drive belt (ift hydraulic system, steering system, low pressure hydraulic system) 3 Compressor drive belt, air conditioner 4. Grain tank clutch power band belt 5. Threshing mechanism clutch power band belt 6 Intermediate cleaning fan drive belt 7. Intermediate sieve pan drive 8 Tine crank shaft drive belt 9. Reel drive chain (3.90 m- 5.10 m cutterbars) 10. Intermediate reel drive chain (3.90 m -5.10mcutterbars) 11 Variable speed reel drive belt (8.90 m -5.10 m cutterbars) 12 Chain - intermediate variable speed reel drive (3.90 m -5.10 mcutterbars) 13. Power band belt for snapping units (maize picker head) 14 Chain - intake auger drive (maize picker head) 15 Chain - intermediate drive shaft (maize picker head) 16 V-belt - knife drive casing (6.00 m - 7.50 m cutterbars) 17 Intake auger drive chain (6.00 m - 7.50 m cutterbars) 18 V-belt - knife drive casing (3.90 m- 5.10 m cutterbars) 19 Intake auger drive chain (3.90 m - 5.10 m cutterbars) 20 Cutterbar drive belt (two) 21 Power band belt - accelerator Wide-section belt - fan drive Power band belt - sieve pan and auger drive ‘Straw walker drive belt ‘Straw spreader drive belt ‘Chain - grain tank filler auger drive \V-belt- straw chopper intermediate drive assembly Drive chain - grain tank unloading auger Rotary screen drive belt Footary screen intermediate drive belt Chain - returns elevator Straw chopper drive belt Wide section belt - threshing drum variable speed drive ‘Threshing drum drive power band belt Reel variable speed drive belt (6.00 m - 7.50 mcutterbars) Chain - reel intermediate drive assembly (6.00 m- 7.50 m cutterbars) ‘Suction blower drive V-belt Chain - reel intermediate variable speed drive (6.00 m- 7.50 mcutterbars) 39. Reel drive chain (6.00 m- 7.50 m cutterbars) 40. Cogged drive belt for maize picker head (stalk chopper) 41 Power band belt for stalk chopper intermediate drive assembly 42. Suction blower drive V-belt 43. Set of rotary screen intermediate drive belts 8 SRBRLSBBLBRRBR 8S D0 218-202 MEGA 35 Drive Schematic D0 218-202 MEGA 36 Drive Schematic V-belt and chain diagram DOMINATOR 202 MEGA 1. Hydraulic pump power band belt, ground drive 2. Hydraulic pump drive belt (ift hydraulic system, steering system, low pressure hydraulic system) 3. Compressor drive belt, air conditioner 4. Grain tank clutch power band belt 5. Threshing mechanism clutch power band belt 6 Intermediate cleaning fan drive belt 7. Intermediate sieve pan drive 8 Tine crank shaft drive belt 9. Reel drive chain (3.60 m- 5.10 m cutterbars) 10. Intermediate reel drive chain (3.60 m -5.10mcutterbars) 11 Variable speed reel drive belt (8.60 m -5.10 m cutterbars) 12 Chain - intermediate variable speed reel drive (3.60 m -5.10 mcutterbars) 13. Power band belt for snapping units (maize picker head) 14 Chain - intake auger drive (maize picker head) 15 Chain - intermediate drive shaft (maize picker head) 16 V-belt - knife drive casing (6.00 m - 6.60 m cutterbars) 17 Intake auger drive chain (6.00 m - 6.60 m cutterbars) 18 V-belt - knife drive casing (3.60 m - 5.10 m cutterbars) 19 Intake auger drive chain (3.60 m - 5.10 m cutterbars) 20 Cutterbar drive belt (two) 21 Power band belt - accelerator Wide-section belt - fan drive Power band belt - sieve pan and auger drive ‘Straw walker drive belt ‘Straw spreader drive belt ‘Chain - grain tank filler auger drive \V-belt- straw chopper intermediate drive assembly Drive chain - grain tank unloading auger Rotary screen drive belt Footary screen intermediate drive belt Chain - returns elevator Straw chopper drive belt Wide section belt - threshing drum variable speed drive ‘Threshing drum drive power band belt Reel variable speed drive belt (6.00 m - 6.60 mcutterbars) Chain - reel intermediate drive assembly (6.00 m - 6.60 mcutterbars) ‘Suetion blower drive V-belt Chain - reel intermediate variable speed drive (6.00 m - 6,60 mcutterbars) 39 Reel drive chain (6.00 m- 6.60 m cutterbars) 40. Cogged drive belt for maize picker head (stalk chopper) 41 Power band belt for stalk chopper intermediate drive assembly 42. Suction blower drive V-belt 43. Set of rotary screen intermediate drive belts 8 SRBRLSBBLBRRBR 8S D0 218-202 MEGA a7 4 Cutterbar 4 CUTTERBAR (CUTTERBARS: Drives Removal of reel variable speed belt Removal of spring-loaded variable speed pulley Removal of reel lower variable speed pulley Reel speed control disassembled Assembly and installation of electric reel ‘speed controls Installation of ree! lower variable speed pulley Removal of reel Removal of wobble drive unit for knife drive Disassembly of wobble drive unit Wobble drive unit disassembled ‘Assembling and installing the wobble drive unit for knife drive Removing the fingers ofthe intake auger Installing the fingers ofthe intake auger Removing the finger shaft from the intake auger Intake auger disassembled 4,50 m- 5.10 m cutterbar to machine no. Intake auger disassembled 6.00 m - 9.00 m cutterbar to machine no. Intake auger disassembled 4,50 - 9.00 m cutterbar from machine no, Installing the finger shaft in the intake auger Flemoval of intake auger Setting the slip clutch ofthe intake auger FEEDER HOUSING Removal of lower feed rake drum Lower feed rake drum disassembled DO 218 - 208 MEGA Lower feed rake drum disassembled DO 204-202 MEGA ‘Assembly of lower feed rake drum Installation of lower feed rake drum TTensioning the feed chains Removal of feeder housing Removal of upper feed rake drum Upper feed rake shaft cisassembied DO 218-208 MEGA Upper feed rake shaft disassembled DO 204-202 MEGA Installation of upper feed rake shaft Seiting the feed rake drive slip clutch Removal of cutterbar intermediate drive shaft Installation of cutterbar intermediate drive shaft RS8s BSSBR8 REBER 7 18 24 25 Cutterbar CUTTERBARS The service work was carried out on a 6.00 m special cutterbar but applies equally to all cutterbar sizes. Where differences exist, this is specifically mentioned, especially in the description of adjustment procedures. Drives Left-hand side: CCutterbar intermediate shat, UH Drive shaft for intake auger Knife drive ‘Steel roller chain - intake auger drive Knife drive belt (Fig. 1) Right-hand side: (on cutterbars up to 5.10 m these elements are installed fon the LH side too) 6 Cutterbar intermediate drive shaft F/H 7 Reel variable speed drive 8 Reel intermediate drive assembly 9. Reel sprocket with slip clutch 10 Steel roller chain for rel variable speed drive 11. Reel variable speed belt 42. Steel roller chain for reel intermediate drive assembly 13. Steel roller chain for reel drive (Fig. 2) Removal of variable speed belt Be careful when removing the belt. Never reach between spring-loaded pulley halves. 1. Start the engine. Engage the threshing mechanism, and operate the reel speed variator so thatthe reel runs at full speed. (Pulley A operated tothe “open” positon, pulley “Bto the “closed” positon) Fig. 3) D0 218-202 MEGA 4a Cutterbar 2. Stop the engine. Leave the ignition on and leave the threshing mechanism and cutterbar engaged. Remove the guard located in front of the variable speed pulleys. Hold the switch for reel speed variation in the “slow speed” position until the pulley (B) is fully spread. Remove the variable speed belt. (Fig. 3) Removal of spring-loaded variable speed pulley Remove variable speed bett Remove bot (S) together withthe retainer washer and remove the variable speed pulley from the shaft. Ifthe variable speed pulley is not pushed off the shaft, through the pressure ofthe spring while the bolt (S) is being turned out, leave the bolt (8) far enough in the shaft and free the pulley by light hammer blows from a plastic mallet. Bolt (S) should not be turned entirely out until the pulley is free. (Fig. 4) Removal of ree! lower variable speed pulley Remove variable speed belt. Undo the adjusting linkage for reel speed variation at (B) using a second spanner to hold the adjusting nut stationary, (Fig. 5) Unscrew the grease nipple located behind the sprocket of the lower variable speed pulley (N). (Fig. 6) 42 DO 218-202 MEGA Remove the front pulley ha. (Fig. 7) Slacken off stee! roller chain (10) and remove. (Fig. 8) Loosen grub screw (@), Fig. 9) emove parallel key from the shaft and remove the rear half (H) ofthe variable speed pulley. (Fig. 10) D0 218-202 MEGA 43 Cutterbar | Babes " é Reel speed control disassembled: 18.5 x 28 x5 seal washer (to machine no...) Flange M6 x 16 DIN 912 socket head cap screw Parallel key Coupling M6 hox. nut (to machine no. ..) Contact washer (to machine no...) Quick fastener (from machine no...) 7 Flange 8 Axial washer 9 Needle bearings 10 Adjusting nut 41 Bush 12 Clamping piece 13 Hex. bolts M 6 x 60 DIN 931-8.8 AB DIN 128 lock washer 14 Connecting rod 15 Spacer tube 16 Hub 17 M6x 110 DIN912-8.8 socket head cap screw ‘AG DIN 128 lock washer hex. nut M 6 DIN 934 (to machine no...) 18 M 10x20 DIN 933 hex. bolt ‘A10 contact washer 19 Geared motor (Fig. 11) 4a DO 218-202 MEGA Cutterbar 23578 9 10111213 14 16 (24669. Assembly and installation of electric reel speed controls. IMPORTANT! Prior to assembly apply K2K DIN 51825 lithium-saporified multi-purpose grease (e.g. Shell Alvania G2 or similar produc) to all siding faces, to the seals, washers and bearings. Up to machine no... install sealing ing (1), Push flange (2) onto electric motor and secure with the socket head cap screws (6). Torque the socket head cap screws to 8 Nm. Insert parallel key (4) into the grove of the output shaft and fit coupler (6), paying attention to position. For machines Up to machine no. .. ft contact washer (6). On machines. above no... it quick fastener instead of hex. nut and, contact washer. Fit flange (7) and axial washers (8) with needle bearing (8) and adjusting nut (10). Install bush (11) and secure clamping piece (12) with the hex. bolts (13). Use two cables and ft female connectors to one end of teach cable. At the other end of the cable, make one loop each and attach one cable each to the (+) terminal post and to the (-) terminal post of a 12 V battery. Connect the cables to the terminal spades of the geared electric motor to start the motor (change cables for correct direction of rotation, if required) 2 DO 218-202 MEGA, 45 Cutterbar bp [ee ‘Smear the thread of the thrust piece (14, with connecting rod) with K2K DIN 51825 grease (e.g. Shell Alvania G2 or similar). Hold the threaded thrust piece against the adjusting ‘nut (10) s0 thatthe holes are aligned with each other. Install the spacer tube (15), feed the connecting rod through the reel support tube and secure the geared motor with the socket head cap screws (17). Torque screws to 10 Nm, (Figs. 11 and 12) Install ion of reel lower variable speed pulley 41. Install fixed variable speed pulley hat. 2. Position variable speed pulley half. Turn the Bowden ‘cable by means of the crank or operate the electric, ‘motor unti the adjuster rod in the reel support tube locates against the stop. 3. Screw on the adjusting nut in the outside end of the variable speed pulley until a distance of approx. 1 mm. Is obtained between the hub of the moveable pulley half and the fixed pulley half when the pulleys are in the ‘fast speed” position. Lock the adjusting nut Relining the reel slip clutch Remove pin (S). Pull on the reel drive chain (K) until the hole (2) inthe spring-loaded cylinder is accessible. Insert pin (S) in that hole. Fomove the slackened chain from the sprocket (H). (Fig. 13) Remove all nuts from the studs and remove the pressure springs. Remove thrust piece (0), the front clutch ning (B) and the sprocket (H). Fig. 14) 46 DO 218-202 MEGA Remove the set collar located infront of the hub of the clutch and withdraw hub (N). (Fig. 15) When relining the slip clutch, the pressure springs should be replaced at the same time. Evenly adjust all springs unt the slip clutch reaches the prescribed slip torque. Refer to Specifications »Salety Features (Fig. 16) Check by using the following tools: 1. Assembly pin - part no. 181 835.1 2 Torque wrench (Fig. 16) Removal of ree! Remove pin (S). Pull on the reel drive chain (K) until the hole (2) in the spring-loaded cylinder is accessible. Insert pin (S) in that hole. Femove the slackened chain from the reel sprocket (H). (Fig. 17) D0 218-202 MEGA 47 Cutterbar Loosen set collar (Fi) and remove the complete sprocket and slip clutch assembly. (Fig. 18) Detach chain tensioning linkage (G) at (1) and hydraulic cylinder (Z) at (2 and 3). To do this, remove the spit pins and pins. (Fig. 19) Undo the support (V) of the guard paneling, Fig. 20) Detach the hydraulic cylinder at (4). To do this, remove the split pin and pin. Undo self-locking nut (5). Use suitable lifting tackle, hoist, front end loader or similar ‘equipment and lft the reel from its support arms. (Fig. 21) 48 DO 218-202 MEGA Remove the set collar ( R ) located in front ofthe reel tine adjuster. Note shims. (Fig. 22) Pull spring-loaded pin (F) and remove bearing bracket (8). (Fig. 23) Damaged reel tines can be replaced once the bearings on the tine tubes have been loosened. (Fig. 24) Removal of wobble drive unit for knife drive Move the knife to its L/H dead centre by turing the knife drive components, Unbot knife head (F) from the rocker arm. (Fig. 25) 2311759 24 D0 218-202 MEGA 49 Cutterbar ‘Loosen the clamping bolt on rocker arm (S) and remove the rocker arm, (Fig. 28) Remove idler pulley (R.) and belt (K) for knife drive, (Fig. 27) Slacken all bolts on pulley (V) and remove bolt (1) (Fig. 28) Loosen clamping screw (2) and withdraw the pulley. (Fig. 28) 4.10 DO 218-202 MEGA Unscrew base ot wobble drive case and remove the complete wobble drive assembly. Remove drain plug (A) and drain the oil from the wobble drive case. Catch the oil In a container of adequate size. Dispose of the oll so as not to harm the environment. (Fig. 30) Disassembly of wobble drive unit g at Unscrew cover (0). Remove the screws securing the housing (L). D0 218-202 MEGA an Remove the wobble bearing assembly and wobble shaft as ‘a complete unit (Fig. 34) Unlock slotted nut (N) (up to machine no...) or (rom ‘machine no. ..) applying a torque of 100 Nm and remove. (Fig. 35) Drive the wobble shaft and wobble bearing out of the wobble bearing housing (6). (Fig. 36) ‘Slacken the set screws at (2) and remove the small axles by

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