CLAAS DOMINATOR 208 MEGA III DOMINATOR 204 MEGA III Operator's Manual

OPERATOR'S MANUAL

DOMINATOR 208 MEGA III DOMINATOR 204 MEGA III

Re ad an df oll ow sa fet y i ns

tru

ct i on

s!

1 Introduction

Introduction

Introduction INTRODUCTION

The present Operator's Manual applies to the CLAAS combine-harvesters DOMINATOR 208 MEGA DOMINATOR 204 MEGA

from serial no. 94503000 from serial no. 93503000

It is primarily intended to give the machine driver information on setting, using and operating the machine.

Texts and pictures apply, in general, to all combine models covered by this book, and the information given applies equally, except where reference is made to a particular model in captions to the pictures or in the main text.

Operation and maintenance of important ancillary equipment is also covered by this manual. Please read the instructions which apply to the appropriate ancillary equipment on your combine.

Provided you follow the advice on the care and servicing of your machine you will be rewarded with reliable and long service from your Combine Harvester.

We recommend that you allow your authorized CLAAS Dealer to carry out the regular maintenance.

Omissions of parts of the maintenance schedule or incorrect operation lead to a drop in performance and cost valuable time. By correct servicing and operation you can make full use of our sound experience and of the latest technical knowledge in Combine Harvesting with which your combine has been designed and thereby insure reliability of your Combine Harvester.

This Operator's Manual can be ordered from your CLAAS Dealer as well as the manuals listed below:

• Threshing Instructions for special crops • Fitting and Operating Instructions for ancillary equipment CLAAS Service Department

298 672.0 - BA DO 208 / 204 MEGA

1.1.1

Introduction

1.1.2

BA DO 208 / 204 MEGA - 298 672.0

2 Contents

Contents

Contents CONTENTS 1. Introduction Introduction ............................................................................ 1.1.1

2. Contents Contents ................................................................................ 2.1.1

3. General information Road traffic regulations .......................................................... 3.1.1 Important ................................................................................ 3.2.1 Identification plate / Serial number ......................................... 3.3.1 Identification plate ............................................................ 3.3.2 Combine serial number ................................................... 3.3.2 Engine serial number MERCEDES OM 906 LA ................................................. 3.3.2 Cutterbar identification plate ............................................ 3.3.3 Identification plate of folding cutterbar ............................. 3.3.3 Maize picker head serial number ..................................... 3.3.3 Multimaster ...................................................................... 3.3.3 Serial number of maize head stalk chopper .................... 3.3.4 Straw chopper ................................................................. 3.3.4 Cab serial number ........................................................... 3.3.4

4. Safety rules Safety rules ............................................................................ 4.1.1 Safety lock ....................................................................... 4.1.4 Fire extinguisher .............................................................. 4.1.4 Battery isolating switch .................................................... 4.1.5 Wheel chock (Not for all countries) ....................................................... 4.1.5 Safety decals with pictorials ................................................... 4.2.1

5. Specifications Conversion factors ................................................................. 5.1.1 CLAAS DOMINATOR 208 MEGA .......................................... 5.2.1 CLAAS DOMINATOR 204 MEGA .......................................... 5.3.1 Safety features ....................................................................... 5.4.1 Front attachments – weights, dimensions .............................. 5.5.1 Sectional view of combine ..................................................... 5.6.1 Description and function of the combine ......................... 5.6.2 Cutterbar .......................................................................... 5.6.2 Threshing mechanism ..................................................... 5.6.3 Straw walkers .................................................................. 5.6.3 Cleaning .......................................................................... 5.6.3 Disawning ........................................................................ 5.6.3 Basic rules for combining ................................................ 5.6.4

6. Prior to operation Before initial operation ........................................................... 6.1.1 Operator's platform ................................................................ 6.2.1 Cab .................................................................................. 6.2.2 Cab with ventilating system ............................................. 6.2.3 Cab with fan and compressor-type air conditioner .......... 6.2.3 Cab with ventilating system and heating ......................... 6.2.5 Reheat System (fogged windows) ............................................................ 6.2.5

298 672.0 - BA DO 208 / 204 MEGA

Problem, cause and / or remedy – Compressor-type air conditioner .................................... 6.2.6 Opening and closing the cabin roof ................................. 6.2.8 Opening the cabin roof .................................................... 6.2.8 Closing the cabin roof ..................................................... 6.2.8 Steering column .............................................................. 6.2.9 Ignition switch .................................................................. 6.2.9 Vehicle information unit ................................................. 6.2.10 Function of vehicle information unit ............................... 6.2.11 Operations display screen ............................................. 6.2.12 Function of operations display ...................................... 6.2.13 Switch console .............................................................. 6.2.14 Multi-function lever ........................................................ 6.2.15 Central terminal compartment ....................................... 6.2.15 Plug-in type module (P) CLAAS Autopilot ..................... 6.2.16 Grain tank discharge tube – swinging out and in .......... 6.2.17 Grain tank discharge engagement and disengagement ....................................................... 6.2.18 Threshing mechanism engagement / disengagement .............................................................. 6.2.18 Engaging and disengaging the cutterbar drive .............. 6.2.19 Positioning the cutterbar / maize picker head for road travel ................................................................ 6.2.19 Adjusting the threshing drum speed .............................. 6.2.20 Adjusting the steering column position .......................... 6.2.20 Driver's seat, mechanical .............................................. 6.2.21 Weight adjustment ........................................................ 6.2.21 Height adjustment ......................................................... 6.2.21 Seat angle adjustment .................................................. 6.2.22 Seat depth adjustment .................................................. 6.2.22 Lumbar support ............................................................. 6.2.22 Armrest angle ................................................................ 6.2.22 Adjusting the driver's seat horizontally .......................... 6.2.22 Access ladders .............................................................. 6.2.23 Front ladder ................................................................... 6.2.23 Access and ladder extension ........................................ 6.2.24 Rear ladder ................................................................... 6.2.28 Driving the combine ............................................................... 6.3.1 Engine speed turn switch ................................................ 6.3.1 Starting the engine .......................................................... 6.3.2 Adjusting stiffness of ground speed control lever ............ 6.3.3 Gear ranges .................................................................... 6.3.3 Stopping the combine ..................................................... 6.3.4 Driving behaviour ............................................................ 6.3.4 Steering ........................................................................... 6.3.4 Brakes ............................................................................. 6.3.5 Foot brake ....................................................................... 6.3.5 Handbrake ....................................................................... 6.3.5 Stopping the engine ........................................................ 6.3.6 CLAAS Autopilot ............................................................. 6.3.6 Rear axle ............................................................................... 6.4.1 Setting the adjustable rear axle ....................................... 6.4.1 Changing the rear axle from transport position to working position .......................................................... 6.4.2 CLAAS-4-Trac-System .................................................... 6.4.3 Towing a combine with driven rear axle .......................... 6.4.3

2.1.1

Contents Cutterbar cylinders ................................................................. 6.5.1 Hydraulic cylinders ........................................................... 6.5.1 Attaching the cutterbar hydraulic cylinders ...................... 6.5.1 Attaching the right-hand cutterbar cylinder ...................... 6.5.1 Attaching a third cutterbar cylinder .................................. 6.5.2 Towing and side walk railing .................................................. 6.6.1 Towing the combine ......................................................... 6.6.1 Forward ............................................................................ 6.6.1 Backward ......................................................................... 6.6.1 Side walk railing ............................................................... 6.6.2 Tilting the side walk railing ............................................... 6.6.2 Cab and lighting ..................................................................... 6.7.1 Cab .................................................................................. 6.7.1 Driving lights, worklights and mirrors ............................... 6.7.1

7. Operation – cutterbar Attaching the cutterbar ........................................................... 7.1.1 Adjusting the strippers DOMINATOR MEGA 204 ................................................ 7.1.1 Machine with CLAAS Auto Contour ................................. 7.1.1 Levelling the coupling lug cylinders ................................. 7.1.3 Machine without Auto Contour ......................................... 7.1.3 Levelling the cutterbar ..................................................... 7.1.4 Connecting the universal drive shafts DOMINATOR 208 MEGA ................................................ 7.1.5 Connecting the universal drive shafts DOMINATOR 204 MEGA ................................................ 7.1.5 Connecting hydraulic hoses ............................................. 7.1.6 Connecting the cables ..................................................... 7.1.6 Installing the stands ......................................................... 7.1.7 Adjustments at the cutterbar .................................................. 7.2.1 Dividers ............................................................................ 7.2.1 Grain lifters ...................................................................... 7.2.2 Knife ................................................................................. 7.2.3 Removing the knife .......................................................... 7.2.3 Installing the knife ............................................................ 7.2.3 Adjusting the height of the knife head .............................. 7.2.4 Adjusting the knife clips ................................................... 7.2.4 Spare knife ....................................................................... 7.2.4 Cutterbar skids ................................................................. 7.2.5 Reel ................................................................................. 7.2.5 Reel tines ......................................................................... 7.2.6 Reel drive ......................................................................... 7.2.6 Fore and aft reel adjustment (mechanical) .................................................................... 7.2.7 Fore and aft reel adjustment (hydraulic) ........................................................................ 7.2.7 Reel variable speed drive ................................................ 7.2.8 Main table auger .............................................................. 7.2.8 Adjust clearance to cutterbar trough ................................ 7.2.8 Adjusting position of auger fingers ................................... 7.2.9 Adjusting the stripper plates ............................................ 7.2.9 Replacing knife sections in the field ............................... 7.2.10

8. Operation – basic machine Feeder housing ...................................................................... 8.1.1 Chains .............................................................................. 8.1.1 Cutterbar reverse drive .................................................... 8.1.2

2.1.2

CLAAS Auto Contour Automatic cutting height control and lateral levelling system ............................................. 8.1.3 Cutterbar automatic pre-set height (machines with Auto Contour) ......................................... 8.1.5 Adjusting the cutterbar floatation springs ........................ 8.1.6 Checking the cutterbar floatation springs and checking the feeder house suspension for smooth movement ...................................................... 8.1.6 Setting the cutting height indicator .................................. 8.1.7 Cutterbar spring pressure indicator ................................. 8.1.7 Adjusting the cutterbar drop rate ..................................... 8.1.8 Putting the CLAAS Auto Contour System into operation ................................................................... 8.1.9 Operation with maize picker head ................................. 8.1.10 Programming the CLAAS Auto Contour System ........... 8.1.10 Setting chart for automatic cutting height control .......... 8.1.11 Putting the cutterbar automatic pre-set height system into operation (machines with Auto Contour) ....................................... 8.1.12 CLAAS Contour System (ground pressure control) .............................................. 8.1.13 Setting the cutterbar ground pressure ........................... 8.1.14 Putting the CLAAS Contour System into operation ....... 8.1.14 CLAAS cutterbar pre-set height .................................... 8.1.16 Putting the cutterbar pre-set height system into operation ................................................................. 8.1.16 Cutterbar adjusting range .............................................. 8.1.16 Clearance height ........................................................... 8.1.17 Cutterbar adjusting range without Auto Contour ........... 8.1.17 Clearance height to underside of cutterbar skid ............ 8.1.17 Cutterbar clutch ............................................................. 8.1.18 Engaging and disengaging the cutterbar ....................... 8.1.18 Threshing mechanism ........................................................... 8.2.1 Stone trap ........................................................................ 8.2.1 Engaging and disengaging the threshing mechanism ..... 8.2.1 Concave adjustment ........................................................ 8.2.2 Concave settings ............................................................. 8.2.3 Threshing drum ............................................................... 8.2.4 Cleaning dirty threshing parts .......................................... 8.2.4 Threshing drum speed .................................................... 8.2.5 Adjusting the threshing drum speed ................................ 8.2.6 Threshing drum speed display ........................................ 8.2.6 Threshing drum two-step variable speed drive ............... 8.2.6 Preconcave ..................................................................... 8.2.7 Disawning ........................................................................ 8.2.8 Threshing segment .......................................................... 8.2.9 Unslugging the threshing drum ..................................... 8.2.10 Impeller .......................................................................... 8.2.11 Deflector curtain ............................................................ 8.2.11 Straw walkers and cleaning ................................................... 8.3.1 Straw walkers .................................................................. 8.3.1 Intensive separation system ............................................ 8.3.1 Cleaning the straw walkers ............................................. 8.3.2 Straw walker risers .......................................................... 8.3.2 Warning signal ................................................................. 8.3.4 Sieve pan ........................................................................ 8.3.4 Preparation floor .............................................................. 8.3.5

BA DO 208 / 204 MEGA - 298 672.0

Contents Cleaning fan .................................................................... 8.3.5 Electrical fan speed adjustment ....................................... 8.3.6 Fan speed display ........................................................... 8.3.6 Ventilated straw walker step ............................................ 8.3.7 Adjusting the butterfly valve ............................................. 8.3.7 Adjusting the wind board ................................................. 8.3.7 Sieves .............................................................................. 8.3.8 Adjusting the frogmouth sieves ....................................... 8.3.8 Hillside riser plates (machines without 3-D cleaning system) ......................... 8.3.8 Lower sieves .................................................................... 8.3.8 Removing upper sieves ................................................... 8.3.9 Installing upper sieves ..................................................... 8.3.9 Removing lower sieves .................................................... 8.3.9 Installing lower sieves ...................................................... 8.3.9 Tightening torques of the axial bolts for the upper and lower sieves ........................................ 8.3.9 Dynamic sidehill levelling (3-D cleaning system) .................................................... 8.3.10 Returns .......................................................................... 8.3.10 Combine performance monitor ...................................... 8.3.12 Adjusting monitor to crop type ....................................... 8.3.13 Adjusting sensitivity of sensors ...................................... 8.3.13 Grain delivery ......................................................................... 8.4.1 Augers and auger troughs ............................................... 8.4.1 Elevators .......................................................................... 8.4.1 Grain tank ........................................................................ 8.4.2 Grain tank covers ............................................................ 8.4.2 Unloading the tank ........................................................... 8.4.3 Rear ladder with safety switch ......................................... 8.4.4 Grain tank discharge auger ............................................. 8.4.4 Grain tank discharge – engage and disengage ............... 8.4.5 Clean-out door on grain tank discharge tube .................. 8.4.6 Drive to grain tank discharge augers ............................... 8.4.6 Shear bolt – grain tank discharge .................................... 8.4.7 Lateral auger drive ........................................................... 8.4.7 Grain tank fill indicator ..................................................... 8.4.8 Acoustic grain tank fill indicator ....................................... 8.4.8 Straw chopper / Chaff spreader ............................................. 8.5.1 Straw chopper ................................................................. 8.5.1 Before using the straw chopper, check ........................... 8.5.1 Putting the straw chopper into operation ......................... 8.5.2 Adjusting spreading width ................................................ 8.5.3 Electric deflector adjustment ........................................... 8.5.3 Adjusting the deflectors ................................................... 8.5.3 Adjusting the length of cut ............................................... 8.5.4 Adjusting cross knife ........................................................ 8.5.4 Putting the straw chopper out of operation and changing over to windrowing straw .......................... 8.5.5 Hitching the cutterbar trailer to the combine .................... 8.5.6 Chaff spreader ................................................................. 8.5.6 Setting the chaff spreader ............................................... 8.5.6 Sieve chart and suggested combine adjustments ................. 8.6.1 Sieve chart ....................................................................... 8.6.1 Suggested combine adjustments .................................... 8.6.2 Disawner plates ............................................................... 8.6.8 Threshing segment .......................................................... 8.6.8 Problem, cause and / or remedy – Basic machine ................ 8.7.1

298 672.0 - BA DO 208 / 204 MEGA

9. Maintenance – basic machine, cutterbar Important maintenance instructions ......................................

Important maintenance instructions and safety rules ......

Maintenance schedules and lubricants charts ......................

Maintenance schedules ..................................................

Lubricants charts .............................................................

Hydraulic system ...................................................................

Hydraulic accumulators ...................................................

Checking the oil level (Hydrostatic ground speed drive and working hydraulics) ..................................................

Changing hydraulic oil (Hydrostatic ground speed drive and working hydraulics) Linde HPV 75 and HMF 105 ...........................................

Changing the hydraulic oil filter .......................................

Refilling the system after hydraulic oil change ................

Hydrostatic pump adjustment ..........................................

Bleeding the reel cylinders ..............................................

Bleeding the hydraulic cylinders for cutterbar lateral levelling (Machines with Auto Contour System) ............................

Foot brake / brake fluid ...................................................

Transmission and gearboxes ................................................

Gear shift control adjustment ..........................................

Change-speed transmission gearbox .............................

Checking oil level ............................................................

Oil change .......................................................................

Final drives DOMINATOR 208 MEGA ................................................

Checking oil level ............................................................

Oil change .......................................................................

Final drives DOMINATOR 204 MEGA ................................................

Checking oil level ............................................................

Oil change .......................................................................

Rear wheel drive planetary gears CLAAS 4-Trac System ....................................................

Check oil level .................................................................

Oil change .......................................................................

Knife drive casing ............................................................

Checking the oil level / oil change ...................................

Threshing drum reduction gearbox .................................

Checking oil level ............................................................

Oil change .......................................................................

Grain tank ........................................................................

Angle drive on grain tank discharge auger ......................

Angle drive on grain tank (DOMINATOR 208 MEGA) .............................................

Feeder housing .....................................................................

Tension feeder chains .....................................................

Elevator chains ......................................................................

Tension grain elevator chain ...........................................

Tension returns elevator chain ........................................

Drive belts / drive chains – basic machine ............................

General notes ..................................................................

Drive diagram left ............................................................

Drive diagram right ..........................................................

9.1.1 9.1.1 9.2.1 9.2.1 9.2.4 9.3.1 9.3.1

9.3.2

9.3.2 9.3.3 9.3.4 9.3.4 9.3.5

9.3.6 9.3.7 9.4.1 9.4.1 9.4.1 9.4.1 9.4.1 9.4.2 9.4.2 9.4.2 9.4.2 9.4.2 9.4.2 9.4.3 9.4.3 9.4.3 9.4.3 9.4.3 9.4.4 9.4.4 9.4.4 9.4.4 9.4.4 9.4.4 9.5.1 9.5.1 9.6.1 9.6.1 9.6.2 9.7.1 9.7.1 9.7.2 9.7.3

2.1.3

Contents Drive belts / drive chains .................................................. 9.7.4 Removing cutterbar drive belt (1) .................................... 9.7.4 Fitting and tensioning cutterbar drive belt (1) .................. 9.7.5 Tensioning compressor drive belt (2) .............................. 9.7.6 Tensioning hydrostatic ground drive belt (3) .................... 9.7.7 Tensioning working hydraulics pump drive belt (4) .......... 9.7.8 Removing and installing the power band belt (3) ............. 9.7.9 Threshing mechanism drive belt (5) .............................. 9.7.10 Removing and installing the threshing mechanism drive belt (5) ................................................................... 9.7.11 Grain tank unloading drive belt (6) ................................. 9.7.13 Removing and installing the sieve pan drive belt (7) ..... 9.7.14 Removing and fitting fan variable-speed belt (8) ........... 9.7.15 Removing and installing the sieve pan drive belt (9) ..... 9.7.16 Removing and installing the sieve pan drive belt (10) ................................................................. 9.7.16 Removing and installing the straw walker drive belt (11) ................................................................. 9.7.17 Removing and installing the intensive separation system drive belt (12) ................................... 9.7.17 Removing and installing the chaff spreader drive belt (15) ................................................................. 9.7.18 Chaff spreader drive belt (16) ........................................ 9.7.18 Straw chopper intermediate drive belt (21) .................... 9.7.19 Tensioning suction blower drive belt (22) ...................... 9.7.22 Removing and fitting threshing drum variable speed drive belt (23) ........................................ 9.7.22 Removing and filtting the threshing drum drive belt (24) ................................................................. 9.7.24 Tensioning radiator screen intermediate drive belt (27) ................................................................. 9.7.25 Tensioning the grain tank unloading intermediate drive chain (31) (DOMINATOR 208 MEGA) ............................................ 9.7.25 Tensioning the grain tank unloading intermediate drive chain (32) (DOMINATOR 208 MEGA) ............................................ 9.7.25 Tensioning the grain tank unloading intermediate drive chain (31) (DOMINATOR 204 MEGA) ............................................ 9.7.26 Tensioning returns drive chain (33) ............................... 9.7.26 Removing and installing the accelerator drive belt (17) ................................................................. 9.7.27 Straw chopper drive belt (20) ......................................... 9.7.29 Drive belts / drive chains – cutterbar ...................................... 9.8.1 General notes .................................................................. 9.8.1 Drive diagram cutterbar ................................................... 9.8.2 Tensioning knife drive belt (40) ........................................ 9.8.3 Tensioning main table auger drive chain (41) .................. 9.8.3 Tensioning reel drive chain (42) ...................................... 9.8.4 Removing and fitting reel drive belt (43) .......................... 9.8.4 Tensioning reel drive chain (44) ...................................... 9.8.6 Tensioning reel drive chain (45) ...................................... 9.8.6 Cab / Compressor-type air conditioner .................................. 9.9.1 Cab .................................................................................. 9.9.1 Cleaning the filters ........................................................... 9.9.1 Compressor-type air conditioner ...................................... 9.9.1 Cleaning the condenser ................................................... 9.9.1

2.1.4

Checking refrigerant level ................................................ 9.9.2 Replacing the filter receiver drier ..................................... 9.9.2 Required refrigerant quantity – Refrigerant R 134 a ....... 9.9.2 Maintenance work before the harvest ............................. 9.9.3 Fire extinguisher .................................................................. 9.10.1 Have fire extinguisher checked for serviceable condition ................................................ 9.10.1 Speeds ................................................................................ 9.11.1 Checking the speed of the straw walker shaft ............... 9.11.1 Setting the magnetic pick-ups ....................................... 9.11.1 Machines equipped with fieldwork computer ................. 9.11.1 Straw chopper ..................................................................... 9.12.1 Changing the free-swinging knives ............................... 9.12.1 Removing knives ........................................................... 9.12.1 Installing knives ............................................................. 9.12.2 Changing the fixed stationary knives ............................. 9.12.2 Winter storage instructions for combines ............................ 9.13.1

10. Maintenance – engine Important maintenance instructions .....................................

Important maintenance instructions and safety rules .............................................................

Maintenance schedules and lubricants charts .....................

Maintenance schedule ..................................................

Lubricants chart .............................................................

Maintenance – engine .........................................................

Engine overview ............................................................

Fuel feed system ...........................................................

Fuel tank ........................................................................

Fuel shut-off tap ............................................................

Water separator / fuel prefilter (extra equipment – small version) .................................

Fuel prefilter ..................................................................

Water separator / fuel prefilter (extra equipment – large version) ..................................

Fuel filter ........................................................................

Bleeding the fuel system ...............................................

Checking engine oil level ...............................................

Engine oil change ..........................................................

Draining the old oil .........................................................

Oil filter ..........................................................................

Filling in engine oil .........................................................

Tensioning the alternator belt ........................................

Cooling system ....................................................................

Coolant ..........................................................................

Water drain plugs on the engine block ..........................

Water cooler ..................................................................

Filling the cooling system with coolant ..........................

Overpressure .................................................................

Antifreeze / corrosion protection ....................................

Warning notice ..............................................................

Cooling water temperature ............................................

Radiator chaff screen ....................................................

Cleaning the radiator chaff screen ................................

Folding up radiator chaff screen ....................................

Swinging up the oil cooler .............................................

Clean water cooler and intercooler ................................

Dry-type air cleaner .............................................................

Warning device ..............................................................

10.1.1 10.1.1 10.2.1 10.2.1 10.2.2 10.3.1 10.3.1 10.3.1 10.3.2 10.3.2 10.3.3 10.3.3 10.3.4 10.3.5 10.3.5 10.3.5 10.3.6 10.3.6 10.3.7 10.3.7 10.3.7 10.4.1 10.4.1 10.4.1 10.4.1 10.4.2 10.4.2 10.4.2 10.4.3 10.4.3 10.4.3 10.4.3 10.4.3 10.4.4 10.4.5 10.5.1 10.5.1

BA DO 208 / 204 MEGA - 298 672.0

Contents Cleaning the air cleaner intake screen .......................... 10.5.1 Cleaning the air cleaner ................................................. 10.5.1 Cleaning the dry-type air cleaner with dust extractor unit ................................................... 10.5.2 Removing the main filter cartridge ................................. 10.5.3 Installing the main filter cartridge ................................... 10.5.4 Safety cartridge ............................................................. 10.5.4 Electrical equipment ............................................................. 10.6.1 Battery ........................................................................... 10.6.1 Alternator ....................................................................... 10.6.2 Engine problems, cause and / or remedy ............................ 10.7.1 Engine winter storage .......................................................... 10.8.1 Engine preservation ....................................................... 10.8.1

11. Lubrication chart Lubricants and lubrication instructions ................................. 11.1.1

12. Index Index .................................................................................... 12.1.1

298 672.0 - BA DO 208 / 204 MEGA

2.1.5

Contents

2.1.6

BA DO 208 / 204 MEGA - 298 672.0

3 General information

General information

General information ROAD TRAFFIC REGULATIONS IMPORTANT: Road traffic regulations may vary between countries. In case of discrepancies between the instructions provided by the manufacturer and the traffic regulations of the relevant countries, the traffic regulations of the countries concerned apply.

In addition to his driving licence, the operator must always carry the copy of the vehicle type approval registration issued by the Kraftfahrt-Bundesamt (the Federal Motor Vehicle Executive). A warning triangle and, on machines over 4 t permissible total weight, at least one wheel chock must always be carried on the combine.

When driving on public roads with the combine, comply with all the requirements stated under letter C in the copy of the vehicle type approval registration (§ 18 Section 5 StVZO) issued by the Kraftfahrt-Bundesamt (the Federal Motor Vehicle Executive).

If the combine is equipped with a maize picker head or folding cutterbar, the regulations and requirements of the machine's General Operating Permit must be observed, in particular the requirements concerning ballast weights and tyres.

Registration As a self-propelled working machine with a maximum speed of up to 20 km/h, the combine is not subject to the normal registration regulations and is not required to bear a registration plate. The machine must, however, be clearly and indelibly marked on the left-hand side with the Christian name and surname of the owner and his address.

The towing of trailers in the trailer hitch when driving on public roads is not permitted.

On machines with exceptional width (width over the tyres), a vehicle type approval registration for individual vehicles (single expert opinion) and an special approval in accordance with § 70, Section 1, clauses 1 and 2 of the StVZO must be carried instead of the machine's General Operating Permit.

Furthermore, all the requirements stated in the vehicle type approval registration for individual vehicles and in the special approval must be observed. The issue of a special approval differs from country to country. The excess width must be marked in accordance with the regulations for the marking of road vehicles with excess width (two marker boards at the front and back, protective bar, two amber flashing warning beacons).

If any part(s) of the combine is/are subsequently modified whose condition is/are prescribed or the operation of which (after being modified) could represent a hazard to other road users, then the vehicle type approval registration shall no longer be valid and application must be made for a new vehicle type approval registration. In this case the machine must be presented to the motor vehicle safety inspection authority responsible (TÜV) in order to obtain an expert opinion certificate (§ 19 section 2 STVZO).

If you are in any doubt as to whether this situation applies in your case, please contact us as manufacturers.

If a transport vehicle for front end attachments is towed behind the combine then the cable for the lighting system must be connected and the good condition of the lighting system assured.

298 672.0 - BA DO 208 / 204 MEGA

3.1.1

General information

3.1.2

BA DO 208 / 204 MEGA - 298 672.0

General information

General information IMPORTANT

The instructions contained in this manual should be carefully read and observed by all persons who are concerned with the operation, maintenance and inspection of this machine, in order to prevent accidents. Especially the «SAFETY RULES» in this manual should be read with the utmost care and adhered to.

The use of spare parts, accessories and ancillary equipment, which are not originally manufactured by CLAAS, can change the specified design characteristics of this CLAAS machine or can detract from its functional performance, with a possible adverse affect on the active and / or passive operational safety of the machine and its occupational safety standards (accident prevention).

CLAAS are in no way liable for any damage or personal injury caused through the use of other than original or approved CLAAS parts, accessories and ancillary equipment.

Technical data, dimensions and weights are given as an indication only. CLAAS reserve the right to make changes subsequently as technical developments continue. Responsibility for errors or omissions not accepted.

IMPORTANT: Front, rear, right and left refer to the direction of forward travel.

298 672.0 - BA DO 208 / 204 MEGA

3.2.1

General information

3.2.2

BA DO 208 / 204 MEGA - 298 672.0

General information

General information

B

C

E

D

F

G

H

A

J I

1

IDENTIFICATION PLATE / SERIAL NUMBER A B C D E F G H I J

= = = = = = = = = =

Optional equipment Authorized gross weight Type Identification no. (serial number of machine) Authorized front axle load Year of manufacture Rated performance of combine (KW) Authorized rear axle load Approval no. according to ECE-R 24 Absorption coefficient according to ECE-R 24

(Fig. 1)

298 672.0 - BA DO 208 / 204 MEGA

3.3.1

General information When ordering spare parts and requesting technical information concerning the engine, mounted implements, the cutterbar or maize picker head, always specify the respective serial numbers. This is necessary to prevent incorrect spare parts deliveries.

Identification plate The identification plate of the machine is located on the right-hand side on the operator's platform.

(Fig. 2)

2

Combine serial number The combine serial number is stamped on the engine frame underneath the operator's platform on the right-hand side of the machine.

(Fig. 3)

3

Engine serial number MERCEDES OM 906 LA The engine serial number is located next to the fuel filter.

(Fig. 4)

4

3.3.2

BA DO 208 / 204 MEGA - 298 672.0

General information Cutterbar identification plate The identification plate showing the serial number of the cutterbar is attached on the right-hand end.

(Fig. 5)

5

Identification plate of folding cutterbar The identification plate showing the serial number of the folding cutterbar is attached on the left-hand side of the cutterbar back panel.

(Fig. 6)

6

Maize picker head serial number The serial number of the maize picker head is stamped on the picker cross plate behind the right-hand coupling hole.

The identification plate with the picker number is attached to the right-hand end of the picker cross plate.

(Fig. 7)

7

Multimaster The identification plate with the picker head number is attached on the right-hand end of the header's back plate.

(Fig. 8)

8

298 672.0 - BA DO 208 / 204 MEGA

3.3.3

General information Serial number of maize head stalk chopper The serial number of the stalk chopper is stamped on the back of the chopper plate towards the right.

(Fig. 9)

9

Straw chopper The chopper serial number is stamped on the left-hand chopper side plate.

(Fig. 10)

10

Cab serial number The cab serial number is located at the top on the left-hand side.

(Fig. 11)

11

3.3.4

BA DO 208 / 204 MEGA - 298 672.0

4 Safety rules

Safety rules

Safety rules SAFETY RULES

Correct use of combine

Before putting the machine into operation, read the operator's manual and follow the safety precautions!

This self-propelled combine is designed solely for use in customary agricultural operations (intended use).

Identification of warning and danger signs

Use in any other way is considered as contrary to the intended use. The manufacturer accepts no liability for any damage or injury resulting from this misuse and these risks must be born solely by the user.

All parts of this manual having to do with your safety or the safe operation of the machine are marked with the following signs. Please pass all safety instructions on to other users, too.

DANGER! Sign to indicate instructions which must be observed. Failure to do so would cause danger to life and limb to the operator and the people around him.

☞ Preventive measures

ATTENTION! Sign to indicate instructions which must be observed. Failure to do so could result in damage to the machine.

☞ Measures to prevent damage to the machine.

NOTE! Sign to indicate instructions for a more effective and economic use of the machine.

ENVIRONMENT! Sign to indicate instructions which must be observed in order to avoid damage to the environment.

Danger to the environment is caused by irregular handling and incorrect disposal of toxic material (e.g. old oil).

The warning and instruction signs placed on the combine provide recommendations for safe operation. These instructions involve your safety – observe them at all times!

Compliance and strict adherence to the conditions of operation, service and repair as specified by the manufacturer also constitute essential elements for the intended use.

This combine should be operated, serviced and repaired only by persons familiar with all its particular characteristics and acquainted with the relevant safety rules (accident prevention).

The accident prevention regulations, all other generally recognised regulations on safety and occupational medicine and the road traffic regulations must be observed at all times.

Fitting and retrofitting of ancillary equipment which is not originally manufactured by CLAAS, and, in addition, also modifications and changes must only be carried out with the consent of CLAAS, as any such actions may have adverse affects on the safety and operational function of the machine.

Any arbitrary modifications carried out on the combine will relieve the manufacturer of all liability for any resulting damage or injury.

General safety and accident prevention regulations 1. In addition to the instructions contained in this operator's manual, also observe the general safety and accident preventive regulations.

2. Always comply with local traffic regulations when driving on public roads.

3. Before starting work, familiarize yourself with all the controls and instruments and their functions. During work or road travel it is too late.

4. Before starting the engine ensure that the transmission is in neutral and that all guards are installed and in their correct position.

5. Start the engine only from the operator's seat.

Never attempt to start the engine by shortening across the starting motor terminals as the machine may immediately start to move!

6. Before moving away, always check the immediate vicinity of the machine (e.g. for children).

Ensure adequate visibility – for a warning, always blow the horn before starting up!

298 672.0 - BA DO 208 / 204 MEGA

4.1.1

Safety rules 7. Never run the engine in a closed building!

8. Clothing worn by the operator must be closefitting! Avoid wearing loose jackets, shirts or ties.

9. Handle fuel with care as it is highly flammable.

Never refuel the machine in the vicinity of naked flames or sparks. Do not smoke during refuelling!

10. Always stop the engine and remove the main switch key (ignition key) before refuelling. Fill the fuel tank outdoors. Clean up any spilled fuel immediately!

11. Prevent fires by keeping the machine clean!

12. Take care when handling brake fluid and battery acid (toxic and corrosive).

13. Always blow the horn before starting the engine and engaging the threshing mechanism – watch for children!

Transporting passengers, co-driver, operating personnel 1. Passengers may only be carried if a proper passenger seat is fitted.

2. The carrying of passengers is otherwise not permitted!

Operation 1. Observe the maximum permissible axle loads and total weights.

2. The operating, steering and braking behaviour of the combine will be affected, e.g. by the road surface and by attaching implements. Therefore always adapt your speed to the terrain and ground conditions. It must be insisted that particular care is taken when operating and turning on a slope and when the grain tank is full.

Never take the transmission out of gear when driving on a slope or on uneven terrain!

3. The grain tank must be empty when driving on public roads and lanes.

4. Never leave the operator's platform / cab when driving.

5. Stay a safe distance away from low over-head power lines (watch radio and CB radio antennas, if installed).

6. When driving on roads with a raised front attachment, the safety rocker switch must be switched off.

4.1.2

7. Before driving the machine and before starting fieldwork adjust the mirrors to give full view of the road or lane and working area behind!

Leaving the combine harvester 1. When leaving the combine harvester, ensure that it will not roll away (apply handbrake, chock blocks). Shut off the engine, remove the main switch key (ignition key) and lock the operator's cab (if installed). – Turn off the battery isolating switch!

2. Never leave the combine unattended as long as the engine is still running.

3. Lower front attachments (cutterbars, maize picker head etc.) to the ground before leaving the combine.

Front attachments (cutterbar, maize picker head etc.) and other components 1. Work under raised attachments (cutterbar, maize picker head etc.) only when you are sure that the front attachment is safely supported!

2. Particular care must be taken when attaching front attachments (cutterbar, maize picker head etc.) or when coupling a trailer to the combine.

3. Knives, the cutterbar, intake auger and reel etc. cannot be completely shielded by constructional measures due to their function. For this reason, an adequate safety distance must be maintained to these moving elements during operation!

4. Gatherer chains and snapping rolls of the corn head (maize picker head) cannot be completely shielded by constructional measures due to their function. For this reason, an adequate safety distance must be maintained to these moving elements during operation also! These instructions apply analogously for all other attachments!

5. The straw chopper has safety guards surrounding dangerous rotating knives which continue to rotate for a while after the drive has been disengaged. For this reason, an adequate safety distance should be maintained to the straw chopper until the drive has come to a complete standstill.

6. The augers located inside the grain tank cannot be shielded completely against accidental contact due to their function. Use a rod to clear blockages and a scoop or similar vessel to take grain samples – never use your hands or feet.

BA DO 208 / 204 MEGA - 298 672.0

Safety rules 7. Before mounting or entering the grain tank, make sure that the drive is disengaged and that the engine has been stopped. Ensure that no other person can restart the engine.

8. When travelling on public roads and lanes, the finger bar and/or crop lifters must be covered when carrying the cutterbar.

Compressor-type air conditioner

Hydraulic accumulators Take particular care when working on hydraulic accumulators! Hydraulic accumulators are under high pressure!

In the case of valve-controlled accumulators such as for the Autopilot, the short-circuit screw has to be loosened before starting repair work on the accumulator so that the hydraulic pressure is relieved.

1. The air conditioning system is filled with HFC refrigerant R 134A. HFC refrigerants must not be vented to the atmosphere. – Therefore, please take appropriate precautions when working on the compressor-type air conditioner.

2. Maintenance and repairs are only to be carried out by authorized service centres qualified to handle refrigerants. Refrigerants must always be discharged by use of the correct recovery equipment and disposed of for recycling.

Service 1. Repair, service and cleaning work and the elimination of malfunctions should only be performed with the drive and engine switched off.

Remove the main switch key (ignition key)!

2. Escaping fluid (fuel or hydraulic oil) under high pressure can penetrate the skin and cause serious injury. If any fluid is injected into the skin, consult a doctor immediately as otherwise serious infections may result!

3. Be careful when opening the radiator filler cap.

As long as the engine is hot, the radiator is under pressure.

4. Dispose of oil, fuel and filters in a way that is harmless to the environment and in accordance with existing anti-pollution regulations.

5. Do not attempt to mount a tyre unless you have the proper equipment and experience to perform the job safely.

6. Retighten the wheel nuts and wheel bolts regularly.

7. Only have qualified workshops carry out repair work on the hydraulic system.

Basic rule Always check the operating and road safety of the combine before starting the machine.

Noise level The noise level at the ear of the driver in the cab with doors and windows closed is 82 db (A).

298 672.0 - BA DO 208 / 204 MEGA

4.1.3

Safety rules

Safety rules Safety lock DANGER! Always block the raised front attachment (cutterbar, maize picker head etc.) securely and set safety locks before going underneath the unit.

Raise the feeder housing to its full height.

Release safety lock (S) at latch (R) and lower the safety lock over the hydraulic piston.

(Fig. 1, 2) R

S 1 When operating the combine, secure the safety lock with latch (R).

(Fig. 1)

S

2

Fire extinguisher The agent for the fire extinguisher manufacturer should check the extinguisher at least every other year. The date of manufacture or the date last checked is shown on the extinguisher.

The fire extinguisher must be installed on the left-hand side of the machine, next to the engine compartment.

(Fig. 3)

3

4.1.4

BA DO 208 / 204 MEGA - 298 672.0

Safety rules Battery isolating switch The power supplied to the whole machine can be switched off at battery isolating switch (H).

H

E = ON (turn on by turning in clockwise direction)

A

A = OFF (turn off by turning in anti-clockwise direction) E

Turn off the battery isolating switch in an emergency and at the end of work every day.

4

ATTENTION! Do not turn off the battery isolating switch while the engine is running.

(Fig. 4)

Wheel chock (Not for all countries) At least one wheel chock (U) must be carried along on the combine at all times.

The wheel chock is located behind the sheet metal covering on the left-hand side of the machine.

(Fig. 5) U

5

298 672.0 - BA DO 208 / 204 MEGA

4.1.5

Safety rules

4.1.6

BA DO 208 / 204 MEGA - 298 672.0

Safety rules

Safety rules SAFETY DECALS WITH PICTORIALS

Safety pictorials are attached to the danger zones of the machine. These safety signs help to alert persons to hazards which can cause personal injury. The pictorials provide instructions to avoid the hazard.

These safety signs, their placement on the machine, and a brief explanatory text are shown on the following pages.

The CLAAS part number of every decal is stated ahead of the text.

The figures in ( ) refer to the adjacent picture and indicate the correct location of the decal on the machine.

Safety signs that are damaged or cannot be recognized any more must immediately be replaced by new ones.

When parts are replaced that have decals, always make sure to install the relevant new decals with each new part.

298 672.0 - BA DO 208 / 204 MEGA

4.2.1

Safety rules

Safety rules Cutterbar 3.60 - 5.10 m

2

1 Cutterbar 3.60 - 5.10 m

5 514 824.0 (2)

2

Danger: Do not go near feed mechanisms of front mounted harvesting units before the drive has been disengaged, the engine shut off and the ignition key removed. Wait for all mechanisms to stop and only then attempt to correct any problems.

2 Cutterbar 6.00 - 9.00 m

(Fig. 1, 2, 3, 4, 5)

2

3 Cutterbar 6.00 - 9.00 m

2

4

4.2.2

BA DO 208 / 204 MEGA - 298 672.0

Safety rules

3

6

8

3 514 806.0 (3)

Engage lift cylinder safety lock before entering area of potential hazard.

(Fig. 6, 7, 8) 7

298 672.0 - BA DO 208 / 204 MEGA

4.2.3

Safety rules

4

9

4 11 514 743.1 (4) Keep well clear of danger area between front attachment and machine.

(Fig. 9, 10, 11) 10

4.2.4

BA DO 208 / 204 MEGA - 298 672.0

Safety rules

5

12

5 15 514 808.0 (5) Danger: Stay clear of rotating machine parts to avoid personal injury.

(Fig. 12, 13, 14, 15) 13

5

14

298 672.0 - BA DO 208 / 204 MEGA

4.2.5

Safety rules

7

16

18 514 827.0 (7)

7

Do not allow riders on access ladder or platform.

(Fig. 16, 17, 18)

17

4.2.6

BA DO 208 / 204 MEGA - 298 672.0

Safety rules

10

19

10

21 514 828.0 (10) Avoid contact with overhead high voltage power lines.

Stay well clear. Watch antenna if installed.

(Fig. 19, 20, 21) 20

298 672.0 - BA DO 208 / 204 MEGA

4.2.7

Safety rules

11

22

23 514 837.0 (11) Stay well clear of hot surfaces.

(Fig. 22, 23)

4.2.8

BA DO 208 / 204 MEGA - 298 672.0

Safety rules

13

24

13 26 514 817.0 (13) Never reach into grain tank or enter grain tank when the engine is running.

(Fig. 24, 25, 26) 25

298 672.0 - BA DO 208 / 204 MEGA

4.2.9

Safety rules

14

27

30 514 809.0 (14) 14

Keep hands away from rotating augers.

(Fig. 27, 30)

28

14

29

4.2.10

BA DO 208 / 204 MEGA - 298 672.0

Safety rules

16

32 514 838.0 (16) 31

Keep clear when engine is running.

(Fig. 31, 32)

298 672.0 - BA DO 208 / 204 MEGA

4.2.11

Safety rules Straw chopper

16 37 514 838.0 (16) 33 Straw chopper

Keep clear when engine is running.

(Fig. 33, 34, 35, 36, 37)

16

34 Straw chopper

16

35 Chaff spreader

16

36

4.2.12

BA DO 208 / 204 MEGA - 298 672.0

Safety rules

17

39 514 839.0 (17) 38

Never touch any machine parts that are moving. Wait until all parts have stopped moving.

(Fig. 38, 39)

298 672.0 - BA DO 208 / 204 MEGA

4.2.13

Safety rules Chaff spreader

17

17

44 514 839.0 (17) 40 Straw chopper

Never touch any machine parts that are moving. Wait until all parts have stopped moving.

(Fig. 40, 41, 42, 43, 44)

17 41 Straw chopper

17 42 Straw chopper

17

43

4.2.14

BA DO 208 / 204 MEGA - 298 672.0

Safety rules

18

45

46 514 820.0 (18) Never enter the straw walker compartment or reach into the straw walkers when the engine is running.

(Fig. 45, 46)

298 672.0 - BA DO 208 / 204 MEGA

4.2.15

Safety rules

19

49 514 840.0 (19) 47

Keep hands away from rotating auger.

(Fig. 47, 48, 49)

19

48

4.2.16

BA DO 208 / 204 MEGA - 298 672.0

Safety rules

23

50

23 52 514 843.0 (23) Apply wheel chock before disconnecting or parking the machine.

(Fig. 50, 51, 52) 51

298 672.0 - BA DO 208 / 204 MEGA

4.2.17

Safety rules Cutterbar 3.60 - 5.10 m

33 33

33 53 Cutterbar 6.00 - 9.00 m

57 514 815.0 (33) 33

Do not attempt to open or remove safety guards while the engine is running.

(Fig. 53, 54, 55, 56, 57)

33 54 Cutterbar 6.00 - 9.00 m

33 33

55

33

56

4.2.18

BA DO 208 / 204 MEGA - 298 672.0

Safety rules

33

58

62 514 815.0 (33)

33

Do not attempt to open or remove safety guards while the engine is running.

(Fig. 58, 59, 60, 61, 62) 59

33

60

33

61

298 672.0 - BA DO 208 / 204 MEGA

4.2.19

Safety rules Chaff spreader

33

33 63

67 514 815.0 (33) 33

Do not attempt to open or remove safety guards while the engine is running.

(Fig. 63, 64, 65, 66, 67) 64

Straw chopper

33

65

33

66

4.2.20

BA DO 208 / 204 MEGA - 298 672.0

Safety rules

33

68

69 514 815.0 (33) Do not attempt to open or remove safety guards while the engine is running.

(Fig. 68, 69)

298 672.0 - BA DO 208 / 204 MEGA

4.2.21

Safety rules

35

70

71 514 826.0 (35) Before carrying out repair and maintenance work, shut off the engine and remove the ignition key.

(Fig. 70, 71)

4.2.22

BA DO 208 / 204 MEGA - 298 672.0

Safety rules

37

37 73 514 924.0 (37) 72

Danger: Stay clear of rotating machine parts to avoid personal injury.

(Fig. 72, 73)

298 672.0 - BA DO 208 / 204 MEGA

4.2.23

Safety rules

40

74

75 514 945.0 (40) Before putting the machine into operation, read and observe the operator's manual and follow the safety instructions.

(Fig. 74, 75)

4.2.24

BA DO 208 / 204 MEGA - 298 672.0

Safety rules

55

76

77 515 137.0 (55) Pay attention to escaping high-pressure hydraulic fluid. Observe the instructions in the technical manual.

(Fig. 76, 77)

298 672.0 - BA DO 208 / 204 MEGA

4.2.25

Safety rules

4.2.26

BA DO 208 / 204 MEGA - 298 672.0

5 Specifications

Specifications

Specifications

CONVERSION FACTORS Length millimetres (mm) millimetres (mm) centimetres (cm) metres (m) kilometres (km)

x x x x x

Area square metres (m2) square metres (m2) hectares (ha)

x x x

1550 = square inches (sq in) 10.764 = square feet (sq ft) 2.4710 = acres

Weight kilograms (kg)

x

2.2046 = pounds

Torque metre kilopounds (mkp) newton metres (Nm) metre kilopounds (mkp)

x x x

7.233 = foot pounds (ft lb) 0.7376 = foot pounds (ft lb) 9.81 = newton metres (Nm)

Pressure bar kg/sq cm (at) kg/sq cm (at)

x 14.504 = pounds per square inch (psi) x 0.980665* = bar x 14.223 = pounds per square inch (psi)

0.03937 0.00328 0.3937 3.2808 0.6214

= = = = =

inch feet (ft) inches (in) feet (ft) miles

* Where feasible and for practical reasons, this factor is rounded to a whole unit to equal kg/sq cm (at) and bars.

Volume capacities cubic centimetres (cm3) litres (l) litres (l) litres (l) litres (l) litres (l) litres (l)

x x x x x x x

Velocity kilometres/hour (km/h)

x

0.06102 0.2201 0.8798 0.2642 1.05668 0.0275 0.02838

= = = = = = =

cubic inches (cu in) Imperial gallons (lmp. gal.)

Imperial quarts (lmp. qt) U.S. gallons (U.S. gal.)

U.S. quarts (U.S. qt) Imp. bushels U.S. bushels

0.6215 = miles per hour (mph)

Temperature To convert Celsius (Centigrade) temperature into Fahrenheit: multiply by 9, divide the result by 5 and add 32.

9 × 27 = 48.6 + 32 = 80.6 °F +27 °C = --------------5 -24 °C =-11.2 °F +2 °C =+35.6 °F +1 °C =+33.8 °F While 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.

298 672.0 - BA DO 208 / 204 MEGA

5.1.1

Specifications

5.1.2

BA DO 208 / 204 MEGA - 298 672.0

Specifications

Specifications

CLAAS DOMINATOR 208 MEGA Specifications being determined on a machine equipped with 6-cylinder engine, 3-D cleaning unit, chaff spreader, adjustable rear axle, combine-mounted straw chopper, full fuel tank and cab (with driver).

Tyres: 24.5 - 32 and 14.9/80 - 24 Cutterbar Cutting widths

4.20 m (14'), 4.50 m (15'), 5.10 m (17'), 6.00 m (20'), 6.60 m (22'), 7.50 m (25'), 9.00 m (30')

Height adjustment

electro-hydraulic

Cutting height adjustment

– see page 8.1.16, Cutterbar adjusting range

Clearance height (under cutterbar skids)

– see page 8.1.16, Cutterbar adjusting range

Spring tine reel

6 sections

Reel drive

V-belt-operated variable speed drive, electric-controlled

Reel speed

with 4.20 m – 5.10 m cutterbars with 6.00 m – 9.00 m cutterbars

Reel height adjustment

electro-hydraulic

Fore and aft reel adjustment (option)

electro-hydraulic

Feed rake conveyor

chain conveyor

Cutterbar clutch

controlled by low-pressure hydraulics

from 12 to 47 rpm from 12 to 47 rpm from 15 to 57 rpm

Threshing mechanism Stone trap

standard

Threshing concaves

Torque adjustment, 1 adjusting lever width 1580 mm

Preconcave (Multi crop concave)

3 interchangeable segments – 6 bars, 6 rows of 6.5 x 38 perforations – 6 bars, 1 row of 12 x 30 perforations / 5 rows of 12 x 38 perforations – 6 bars, 6 rows of 19 x 38 perforations

Disawning – Main concave

1 bolt-in threshing segment

– Preconcave

2 disawner plates to be activated when needed

Main concave for maize and grain

12 bars

Main concave for CCM

Round bar concave

Accelerator

Paddle drum

298 672.0 - BA DO 208 / 204 MEGA

5.2.1

Specifications

CLAAS DOMINATOR 208 MEGA Threshing drum

width 1580 mm diameter 450 mm 6 rasp bars, 7 drum discs

Drum drive

infinitely variable from 650 to 1500 rpm

2-step speed drive (Extra equipment)

speed infinitely variable 1st step from 650 – 1500 rpm 2nd step from 280 – 650 rpm

Threshing drum engagement / disengagement

controlled by low pressure hydraulics

Straw walkers Intensive separation system (ISS)

no. of tine crankshafts no. of tines per crankshaft

Straw walkers

no. of walker racks no. of walker crankshafts speed of walker crankshafts walker area separating area

2 6 6 2 225 ± 5 rpm 7 m² 8.65 m²

Cleaning Forced air cleaning system

6-section turbine fan

Wind volume

electric controlled infinitely variable fan speed

Standard sieve pan

split, removable stepped preparation floor sections

3-D cleaning system (option)

aggressive spread of material on sloping land by movement of the top sieve in three directions

Upper sieve

long-lipped frogmouth sieve

Lower sieve

short-lipped frogmouth sieve

Total cleaning area

5.10 m²

Returns

return to accelerator

Grain tank Capacity

8000 litres

Unloading tube

electro-hydraulic position control

5.2.2

BA DO 208 / 204 MEGA - 298 672.0

Specifications

CLAAS DOMINATOR 208 MEGA Engines

MERCEDES OM 906 LA

Cubic capacity (cc)

6370

Maximum no-load speed rpm

2288 –30

Rated speed rpm

2200

Slow idling speed rpm

1350 ± 25

Reduced speed [rpm] in 3rd gear at 20 kph

1628 –30

Reduced speed [rpm] in 3rd gear at 25 kph

2035 –30

kW (DIN HP), gross

190 (258)

kW (DIN HP), ECE (net)

180 (245)

Coolant

approx. 36.5 litres

Alternator

115 A

+20

+20

+20

Fuel tank Capacity

500 litres

Battery

12 V, 110 Ah

Ground drive

hydrostatic controlled by lever on operator's platform

Transmission gearbox

3 gear ranges in both forward and reverse 1st and 2nd gear range for field operations 3rd gear range for road travel

Ground speeds Gear ranges

on 30.5 R 32 / 24.5 - R 32 tyres 1. from 0 to 7.6 km/h 2. from 0 to 12.3 km/h 3. from 0 to 20.0 km/h

(from 0 to 25.0 km/h)

Reverse speed is 70% that of forward speed.

Ground speeds in brackets apply to certain countries only.

In countries with a speed limit of 20 km/h for agricultural motor vehicles, the hydrostatic ground drive system incorporates a device that limits the ground speed accordingly.

Traction wheel drive

via final drive gears in oil bath

Steering

hydrostatic

Brakes Foot brake

hydraulic, designed to work independently when the pedal lock is removed

Hand brake

mechanical, independent of foot brake

298 672.0 - BA DO 208 / 204 MEGA

5.2.3

Specifications

CLAAS DOMINATOR 208 MEGA Tyre sizes and pressures

1

5.2.4

BA DO 208 / 204 MEGA - 298 672.0

Specifications

CLAAS DOMINATOR 208 MEGA Tightening torques for wheel bolts and wheel nuts Front axle

wheel nuts with thrust washer H 22 DIN 74361-H22-10-DAC500B-TNT = 700 Nm ATTENTION! Collar nuts with «Dacromet coating» (silvery grey) must only be torqued to 700 Nm.

Rear axle

wheel bolts M 18 x 1.5 = 325 Nm

Rear wheel drive axle

wheel bolts M 22 x 1.5 - 8.8 and special lock washers (Limes) C 22.5 DIN 74361= 520 Nm

Weights Determine the total weight of the machine by adding the weight with the equipment option concerned to the weight of the basic machine – see page 5.5.1, Front attachments – weights, dimensions.

Basic machine without front attachment Straw chopper with straw spreader

298 672.0 - BA DO 208 / 204 MEGA

11400 kg 310 kg + 136 kg

5.2.5

Specifications

CLAAS DOMINATOR 208 MEGA Combine dimensions Wheel tread

front

rear

with 24.5 R 32 tyres with 24.5 R 32 tyres (rim reversed, valve inside) with 24.5 R 32 tyres (not with 2-step variable speed drive) with 30.5 LR 32 tyres fixed rear axle (2.40 m) with 14.5/75 - 20 tyres adjustable rear axle with 14.5/75 - 20 tyres

with 500/60 - 22.5 tyres

Width over tyres

front

rear

with 14.9/80 - 24 tyres rear wheel drive axle with 500/60 - 22.5 tyres with 24.5 R 32 tyres with 24.5 R 32 tyres (rim reversed, valve inside) with 24.5 R 32 tyres (not with 2-step variable speed drive) with 30.5 R 32 tyres fixed rear axle (2.40 m) with 14.5/75 - 20 tyres adjustable rear axle with 14.5/75 - 20tyres

with 500/60 - 22.5 tyres with 14.9/80 - 24 tyres rear wheel drive axle with 500/60 - 22.5 tyres Wheel base Ground clearance

Turning cycle diameter conforming to DIN 70020

5.2.6

2747 mm 2812 mm 2676 mm 2946 mm 2495 mm 2395 mm 2595 mm 2795 mm 2645 mm 2845 mm 2750 mm 2610 mm 3400 mm 3450 mm 3300 mm 3750 mm 2880 mm 2780 mm 2980 mm 3180 mm 3130 mm 3330 mm 3130 mm 3120 mm 3816 mm

with 24.5 - 32 R 1 tyres up to elevator boot up to fan housing * Variations up to 50 mm are possible, depending on the make of tyre. left right

420 mm* 395 mm*

16800 mm 17700 mm

BA DO 208 / 204 MEGA - 298 672.0

Specifications

CLAAS DOMINATOR 208 MEGA

36075

H

L

B

Transport position / operating position Transport position Operating position WIDTH B

without front attachment – see page 5.2.6, Width over tyres

3400 mm

–

to top of grain tank on 24.5 R 32 tyres when grain tank lid is open

3850 mm

3850 mm + 550 mm

to top of cab to bottom edge of grain tank unloading tube to bottom edge of long grain tank unloading tube

3820 mm – –

3820 mm 3944 mm 4400 mm

8832 mm 10140 mm 11490 mm 11240 mm 10805 mm 10901 mm 11220 mm 11170 mm – –

– 10090 mm 11440 mm 11190 mm 10760 mm 10541 mm 10930 mm 11070 mm + 100 mm + 550 mm

– + 815 mm

+ 300 mm

with cutterbar or maize picker head – see page 5.5.1, Front attachments – weights, dimensions HEIGHT H

Deduct approx. 40 mm from height dimensions if 23.1 - 30 tyres are fitted.

Variations up to 50 mm are possible, depending on the make of tyre.

LENGTH L

without front attachment with standard cutterbar with long crop divider with short crop divider with special crop divider with folding cutterbar with 6-row folding maize picker head with maize picker head with straw chopper with straw spreader with rear hood back panel adjusted to rearward position with long grain tank discharge tube

298 672.0 - BA DO 208 / 204 MEGA

5.2.7

Specifications

5.2.8

BA DO 208 / 204 MEGA - 298 672.0

Specifications

Specifications

CLAAS DOMINATOR 204 MEGA Specifications being determined on a machine equipped with 6-cylinder engine, 3-D cleaning unit, chaff spreader, adjustable rear axle, combine-mounted straw chopper, full fuel tank and cab (with driver).

Tyres: 24.5 - 32 and 14.9/80 - 24 Cutterbar Cutting widths

3.60 m (12'), 3.90 m (13'), 4.20 m (14'), 4.50 m (15'), 5.10 m (17'), 6.00 m (20'), 6.60 m (22'), 7.50 m (25')

Height adjustment

electro-hydraulic

Cutting height adjustment

– see page 8.1.16, Cutterbar adjusting range

Clearance height (under cutterbar skids)

– see page 8.1.16, Cutterbar adjusting range

Spring tine reel

6-sections

Reel drive

V-belt-operated variable speed drive, electric-controlled

Reel speed

with 3.60 m – 5.10 m cutterbars with 6.00 m – 7.50 m cutterbars

Reel height adjustment

electro-hydraulic

Fore and aft reel adjustment (option)

electro-hydraulic

Feed rake conveyor

chain conveyor

Cutterbar clutch

controlled by low-pressure hydraulics

from 12 – 47 rpm from 12 – 47 rpm from 15 – 57 rpm

Threshing mechanism Stone trap

standard

Threshing concaves

Torque adjustment, 1 adjusting lever width 1320 mm

Preconcave (Multi crop concave)

3 interchangeable segments – 6 bars, 6 rows of 6.5 x 38 perforations – 6 bars, 1 row of 12 x 30 perforations / 5 rows of 12 x 38 perforations – 6 bars, 6 rows of 19 x 38 perforations

Disawning – Main concave

1 bolt-in threshing segment

– Preconcave

2 disawner plates to be activated when needed

Main concave for maize and grain

12 bars

Main concave for CCM

Round bar concave

Accelerator

Paddle drum

298 672.0 - BA DO 208 / 204 MEGA

5.3.1

Specifications

CLAAS DOMINATOR 204 MEGA Threshing drum

width 1320 mm diameter 450 mm 6 rasp bars, 6 drum discs

Drum drive

infinitely variable from 650 to 1500 rpm

2-step speed drive (Extra equipment)

speed infinitely variable 1st step from 650 – 1500 rpm 2nd step from 280 – 650 rpm

Threshing drum engagement / disengagement

controlled by low pressure hydraulics

Straw walkers Intensive separation system (ISS)

no. of tine crankshafts no. of tines per crankshaft

Straw walkers

no. of walker racks no. of walker crankshafts speed of walker crankshafts walker area separating area

2 5 5 2 225 ± 5 rpm 5.81 m² 7.22 m²

Cleaning Forced air cleaning system

paddle-type cleaning fan

Wind volume

controlled by infinitely variable fan speed

Standard sieve pan

split, preparation floor sections can be removed

3-D cleaning system (option)

aggressive spread of material on sloping land by movement of the top sieve in three directions

Upper sieve

long-lipped frogmouth sieve

Lower sieve

short-lipped frogmouth sieve

Total cleaning area

4.25 m²

Returns

return to accelarator

Grain tank Capacity

6200 litres

Unloading tube

hydraulic-operated position control

5.3.2

BA DO 208 / 204 MEGA - 298 672.0

Specifications

CLAAS DOMINATOR 204 MEGA Engines

MERCEDES OM 906 LA

Cubic capacity (cc)

6370

Maximum no-load speed rpm

2392 –30

Rated speed rpm

2200

Slow idling speed rpm

1350 ± 25

Reduced speed [rpm] in 3rd gear at 20 kph

1628 –30

Reduced speed [rpm] in 3rd gear at 25 kph

2035 –30

kW (DIN HP), gross

170 (231)

kW (DIN HP), ECE (net)

162 (220)

Coolant

approx. 37 litres

Alternator

115 A

+20

+20

+20

Fuel tank Capacity

400 litres

Battery

12 V, 110 Ah

Ground drive

hydrostatic controlled by lever on operator's platform

Transmission gearbox

3 gear ranges in both forward and reverse 1st and 2nd gear range for field operations 3rd gear range for road travel

Ground speeds Gear ranges

on 24.5 - 32 tyres 1. from 0 to 7.1 km/h 2. from 0 to 11.5 km/h 3. from 0 to 20.0 km/h (from 0 to 25.0 km/h) on 23.1 R 30 tyres 1. from 0 to 6.7 km/h 2. from 0 to 10.8 km/h 3. from 0 to 20.0 km/h (from 0 to 25.0 km/h) Reverse speed is 70% that of forward speed.

Ground speeds in brackets apply to certain countries only.

In countries with a speed limit of 20 km/h for agricultural motor vehicles, the hydrostatic ground drive system incorporates a device that limits the ground speed accordingly.

Traction wheel drive

via final drive gears in oil bath

Steering

hydrostatic

Brakes Foot brake

hydraulic, designed to work independently when the pedal lock is removed

Hand brake

mechanical, independent of foot brake

298 672.0 - BA DO 208 / 204 MEGA

5.3.3

Specifications

CLAAS DOMINATOR 204 MEGA Tyre sizes and pressures

1

5.3.4

BA DO 208 / 204 MEGA - 298 672.0

Specifications

CLAAS DOMINATOR 204 MEGA Tightening torques for wheel bolts and wheel nuts Front axle

wheel nuts with thrust washer H 22 DIN 74361-H22-10-DAC500B-TNT = 700 Nm ATTENTION! Collar nuts with «Dacromet coating» (silvery grey) must only be torqued to 700 Nm

Rear axle

wheel bolts M 18 x 1.5 = 325 Nm

Rear wheel drive axle

wheel bolts M 22 x 1.5 - 8.8 and special lock washers (Limes) C 22.5 DIN 74361 = 520 Nm

Weights Determine the total weight of the machine by adding the weight with the equipment option concerned to the weight of the basic machine – see page 5.5.1, Front attachments – weights, dimensions.

Basic machine without front attachment Straw chopper with straw spreader

298 672.0 - BA DO 208 / 204 MEGA

10200 kg 290 kg + 129 kg

5.3.5

Specifications

CLAAS DOMINATOR 204 MEGA Combine dimensions Wheel tread

front

rear

with 23.1 R 30 (F 16) tyres with 23.1 R 30 (F 20) tyres with 24.5 R 32 tyres with 24.5 - 32 tyres with 30.5 LR 32 tyres fixed rear axle (2.05 m) with 12.5/80 - 18 tyres with 14.5/75 - 20 tyres fixed rear axle (2.40 m) with 12.5/80 - 18 tyres with 14.5/75 - 20 tyres adjustable rear axle with 12.5/80 - 18 tyres

with 14.5/75 - 20 tyres

with 500/60 - 22.5 tyres

Width over tyres

front

rear

with 14.9/80 - 24 tyres rear wheel drive axle with 14.5/75 - 20 tyres with 500/60 - 22.5 tyres with 23.1 R 30 (F 16) tyres with 23.1 R 30 (F 20) tyres with 24.5 R 32 tyres with 24.5 - 32 tyres with 30.5 LR 32 tyres fixed rear axle (2.05 m) with 12.5/80 - 18 tyres with 14.5/75 - 20 tyres fixed rear axle (2.40 m) with 12.5/80 - 18 tyres with 14.5/75 - 20 tyres adjustable rear axle with 12.5/80 - 18 tyres

with 14.5/75 - 20 tyres

with 500/60 - 22.5 tyres with 14.9/80 - 24 tyres rear wheel drive axle with 500/60 - 22.5 tyres

5.3.6

2450 mm 2630 mm 2630 mm 2630 mm 2690 mm 2150 mm 2145 mm 2500 mm 2145 mm 2400 mm 2600 mm 2800 mm 2395 mm 2595 mm 2795 mm 2645 mm 2845 mm 2750 mm 2605 mm 2610 mm 3000 mm 3230 mm 3260 mm 3260 mm 3500 mm 2490 mm 2530 mm 2840 mm 2880 mm 2740 mm 2940 mm 3140 mm 2780 mm 2980 mm 3180 mm 3130 mm 3330 mm 3130 mm 3120 mm

BA DO 208 / 204 MEGA - 298 672.0

Specifications CLAAS DOMINATOR 204 MEGA Combine dimensions Wheel base Ground clearance

Turning cycle diameter conforming to DIN 70020

298 672.0 - BA DO 208 / 204 MEGA

3816 mm with 23.1 - 30 tyres up to elevator boot up to fan housing * Variations up to 50 mm are possible, depending on the make of tyre. left right

420 mm* 405 mm*

17300 mm 17400 mm

5.3.7

Specifications

CLAAS DOMINATOR 204 MEGA

36075

H

L

B

Transport position / operating position Transport position Operating position WIDTH B

without front attachment – see page 5.3.6, Width over tyres

3260 mm

–

to top of grain tank on 23.1 R 30 tyres when grain tank lid is open

3820 mm

3820 mm + 550 mm

to top of cab to bottom edge of grain tank unloading tube to bottom edge of long grain tank unloading tube

3790 mm – –

3790 mm 3850 mm 4350 mm

8830 mm 11300 mm 10140 mm 11490 mm 11240 mm 10805 mm 11220 mm 11170 mm – –

– 10940 mm 10090 mm 11440 mm 11190 mm 10760 mm 10930 mm 1170 mm + 100 mm + 550 mm

– + 815 mm

+ 300 mm

with cutterbar or maize picker head – see page 5.5.1, Front attachments – weights, dimensions HEIGHT H

Variations up to 50 mm are possible, depending on the make of tyre.

LENGTH L

5.3.8

without front attachment with folding cutterbar with standard cutterbar with long crop divider with short crop divider with special crop divider with 6-row folding maize picker head with 4 to 6-row maize picker head with straw chopper with straw spreader with rear hood back panel adjusted to rearward position with long grain tank discharge tube

BA DO 208 / 204 MEGA - 298 672.0

Specifications

Specifications

SAFETY FEATURES Slip clutches Reel Cutterbars up to 5.10 m

430 ± 30 Nm

6.00 m cutterbars and over

430 ± 30 Nm

4.50 m folding cutterbar

200 ± 40 Nm

Main table auger Grain and rice cutterbars up to 4.50 m

700 ± 30 Nm

Grain and rice cutterbars 5.10 m and over, and soy bean (flex head) cutterbars from 3.90 m to 7.50 m

700 ± 30 Nm

4.50 m folding cutterbar

300 ± 40 Nm

Upper feed rake shaft

430 ± 30 Nm

Shear bolt Grain tank unloading

DOMINATOR 208 MEGA Hex. bolt M 10 x 50 DIN 931-8.8 Self-locking nut VM 10 DOMINATOR 204 MEGA Hex. bolt M 10 x 40 DIN 931-8.8 Self-locking nut VM 10

298 672.0 - BA DO 208 / 204 MEGA

5.4.1

Specifications

5.4.2

BA DO 208 / 204 MEGA - 298 672.0

Specifications

Specifications

FRONT ATTACHMENTS – WEIGHTS, DIMENSIONS Weight

Operating width*

Transport width

Grain cutterbar: 3.60 m (12') 3.90 m (13') 4.20 m (14') 4.50 m (15') 4.50 m (15') folding 5.10 m (17') 6.00 m (20') 6.60 m (22') 7.50 m (25') 9.00 m (30')

910 kg 950 kg 1000 kg 1080 kg 1620 kg 1160 kg 1550 kg 1750 kg 1900 kg 2350 kg

3985 mm 4290 mm 4595 mm 4900 mm 5060 mm 5510 mm 6580 mm 7190 mm 8105 mm 9630 mm

3985 mm 4290 mm 4595 mm 4900 mm – 5510 mm 6580 mm 7190 mm 8105 mm 9630 mm

two short dividers two long dividers two special dividers

37 kg 45 kg 10 kg

*

With dividers installed, always add the dimensions of the extended outer deflectors.

Rice cutterbar: 4.20 m (14') 4.50 m (15') 5.10 m (17') 6.00 m (20') 6.60 m (22') 7.50 m (25')

1050 kg 1100 kg 1180 kg 1580 kg 1780 kg 1950 kg

4595 mm 4900 mm 5510 mm 6580 mm 7190 mm 8105 mm

4595 mm 4900 mm 5510 mm 6580 mm 7190 mm 8105 mm

Soybean cutterbar: 4.50 m (15') 5.10 m (17') 6.00 m (20') 7.50 m (25')

1300 kg 1450 kg 1700 kg 2130 kg

5080 mm 5690 mm 6600 mm 7210 mm

5080 mm 5690 mm 6600 mm 7210 mm

Maize picker head: 4 – 70 SL 4 – 75 SL 4 – 80 SL 4 – 95 SL

1300 kg 1300 kg 1300 kg 1300 kg

3000 mm 3050 mm 3100 mm 3810 mm

3000 mm 3000 mm 3000 mm 3810 mm

5 – 70 SL 5 – 75 SL 5 – 80 SL

1550 kg 1550 kg 1550 kg

3800 mm 3800 mm 3930 mm

3800 mm 3800 mm 3800 mm

6 – 70 SL 6 – 75 SL 6 – 80 SL

1850 kg 1850 kg 1850 kg

4600 mm 4600 mm 4760 mm

4600 mm 4600 mm 4600 mm

8 – 75 SL

2820 kg

6060 mm

5930 mm

298 672.0 - BA DO 208 / 204 MEGA

5.5.1

Specifications FRONT ATTACHMENTS – WEIGHTS, DIMENSIONS Maize picker head MULTIMASTER: 6 – 70 6 – 75 6 – 80

Weight

Operating width*

Transport width

2200 kg 2200 kg 2200 kg

4630 mm 4630 mm 4800 mm

3000 mm 3000 mm 3000 mm

Picker head stalk chopper (flail-type): 4 – 75 4 – 80 5 – 75 5 – 80 6 – 80

413 kg 413 kg 440 kg 440 kg 580 kg

Picker head stalk chopper (blade-type): 4-row 5-row

250 kg 300 kg

5.5.2

BA DO 208 / 204 MEGA - 298 672.0

Specifications

Specifications

1

SECTIONAL VIEW OF COMBINE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

Three-sectional divider Reel Reel tines Reel intermediate drive Reel variable speed drive Reel cylinder Crop lifter Intake auger Feeder house Feed rake Cutterbar cylinder Stone trap Preconcave Concave Accelerator Threshing drum Impeller Deflector curtain, concave exit Straw walkers Intensive separation system, crankshafts with tines Under-walker return pan Grain tank unloading tube Rear hood Preparation floor Sieve pan Upper sieves

298 672.0 - BA DO 208 / 204 MEGA

27 Lower sieves 28 Cleaning fan 29 Ventilated straw walker step, adjustable butterfly valve (DOMINATOR 208 MEGA) 30 Windboards 31 Clean grain auger 32 Returns auger 33 Deflector curtain, straw walker house 34 Horizontal discharge auger 35 Lateral augers (DOMINATOR 208 MEGA) 36 Clean grain elevator 37 Grain tank filler auger 38 Grain tank 39 Grain tank lid 40 Returns elevator 41 Returns back-to-drum auger 42 Operator's platform 43 Cab 44 Engine 45 Air cleaner 46 Final drive gearbox 47 Transmission gearbox 48 Traction wheels 49 Rear wheels 50 Straw chopper (Fig. 1)

5.6.1

Specifications

2

Description and function of the combine

Crop

Cutterbar

Grain, chaff, short straw

Dividers separate the standing grain from the grain which is to be cut.

Grain

Grain lifters lift lodged crops and avoid cutting losses in crops with hanging heads.

Returns

The reel moves the cut crop to the main table auger.

The auger flights move the material to the cutterbar centre where the feed rake delivers it to the drum for threshing. The stone trap collects solid objects brought up by the feed rake. This helps to protect the threshing parts from damage through foreign objects.

Chaff

5.6.2

Straw

(Fig. 2)

BA DO 208 / 204 MEGA - 298 672.0

Specifications Threshing mechanism The threshing drum and main concave perform the threshing. The grain together with the chaff and short straw is delivered by the concave onto the preparation floor of the sieve pan. The impeller guides the remaining grains with the straw onto the straw walkers.

A deflector curtain behind the impeller holds back bouncing grains and deflects the kernels down onto the front of the straw walkers.

Straw walkers The straw walkers separate the remaining grain from the straw. The straw leaves the combine via the straw hood. It may be further processed by mounted attachments (e.g. straw chopper). The separated grains pass over the under-walker return floor also to the sieve pan. Crankshafts with agitator tines intensify the loosening of the straw on the straw walkers.

Cleaning The swinging movement loosens the grain / chaff / short straw mixture on the preparation floor and at the same time transports it to the sieves.

The wind created by the cleaning fan carries all the light material (chaff) out of the rear of the combine.

The grain falls through the upper and lower sieves into the trough of the grain auger and are transported into the grain tank by the grain elevator. All parts which are heavier than the chaff and larger than the grain pass over the upper and lower sieves into the trough of the returns auger. From here they are returned to the threshing mechanism by the returns elevator for further threshing. When the grain tank unloading tube is swung out, the grain tank can be emptied within a short time directly into a waiting wagon alongside the combine.

Disawning For crop and fruit types which are difficult to disawn, additional disawner filler rasp bars can be placed in the preconcave.

298 672.0 - BA DO 208 / 204 MEGA

5.6.3

Specifications Basic rules for combining

Please consider when combining: 1. Wait until the crop has fully ripened – do not combine beforehand. (Higher yield, less moisture content and easier threshing are the result.)

2. Where the heads are bent, install crop lifters close together. Where the crop is lodged, install crop lifters further apart (on every 4th to 6th cutterbar finger).

3. Where straw and grain are brittle, set the threshing concave wider and reduce the threshing drum speed. Too much short straw impedes the cleaning process, cracked grain lowers the quality.

4. Where the straw is long, damp and tough, narrow the threshing concave clearance and increase the threshing drum speed.

5. Under damp conditions and where badly lodged crops are also grown through with greenstuff, clean the threshing concave, straw walkers, preparation floor and sieves at regular intervals.

6. Remember that the vital part of the cleaning process is the blast of the fan. Prevent the formation of «mats» on the sieves and unnecessary grain losses by using enough wind, adjusting the frogmouth sieves correctly or using flat sieves of sufficient hole size.

7. For crop and fruit types which are difficult to disawn, additional disawner filler rasp bars can be placed in the concave.

8. To get the best results from your combine, run it at the right speed. Check the speed at the straw walker shaft before the harvest. The correct speed is 225 ± 5 rpm.

9. Regular cleaning of the air cleaner as well as clean fuel and regular oil changes are essential for high performance and long service life of the engine.

5.6.4

BA DO 208 / 204 MEGA - 298 672.0

6 Prior to operation

Prior to operation

Prior to operation BEFORE INITIAL OPERATION

24. Check the function of the cooling system and heater compressor, if installed.

1. Install final drives, if necessary.

2. Install front and rear wheels, if necessary.

If possible, use the «CLAAS loading device».

3. Remove the locking wire from the unloading tube and all flaps.

ATTENTION! Maintenance instructions – see the corresponding maintenance charts.

4. Remove or unpack all parts supplied loose or attached to the combine with wire.

5. Unbolt the transport lock for the cab roof and grain tank cover.

6. Bolt on all railings in their intended positions.

NOTE! The ignition key (central key) is located under the operator's seat.

7. Bolt on ladder extension or adjust the ladder to the installed tyre size. Bolt the lower step (plastic) to the ladder.

8. Set the adjustable rear axle to the prescribed wheel track.

Remove the rear wheel turn limiters.

9. Move the driven rear axle from transport to working position.

Adjust to the prescribed wheel track.

Remove the turn limiters.

10. Install the warning beacons, if necessary.

11. Install the fire extinguisher in the prescribed position.

12. Install the rear view mirrors and worklights, where necessary.

13. Fill and charge the battery, if necessary.

14. Tighten wheel nuts or wheel bolts to the prescribed torque – see page 5.2.5 or page 5.3.5.

15. Check the tyre inflation pressure and correct, if necessary. Check the condition of the tyres.

16. Check the oil level in all transmissions, including the front attachment, and top up, if necessary.

17. Check the engine oil level.

18. Check the engine coolant level.

19. Check that the air filter element is correctly installed.

20. Check the fittings of the coolant and air intake hoses.

21. Check all guards and move to the protection position, if necessary.

Check all flap locks for proper function.

22. Check the hydraulic oil level and check the system for leaks.

23. Check the brake fluid filling level.

Check the brakes for proper function.

298 672.0 - BA DO 208 / 204 MEGA

6.1.1

Prior to operation

6.1.2

BA DO 208 / 204 MEGA - 298 672.0

Prior to operation

Prior to operation

5

8

6 7

10

9

4 3

11 2

12 18

1

13

19 20 21

17

16

15

14

22

1

OPERATOR'S PLATFORM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

Operations display screen Combine performance monitor Switch console Door for checking returns Gear shift lever Multi-function lever and hydrostatic drive control Concave adjustment lever Adjustable arm rest Comfort operator's seat Passenger seat (extra equipment) Vehicle information unit Steering wheel Turn indicator and horn switch Foot-operated switch, grain tank discharge ON / OFF Foot-operated switch, cutterbar OFF (quick stop) Steering column locking pedal Windscreen wiper switch Handbrake lever Headlight switch Ignition switch Drum speed adjustment lever Foot brake pedals

(Fig. 1)

298 672.0 - BA DO 208 / 204 MEGA

6.2.1

Prior to operation

22

22 21

20

20 19

10 9

12 11

14 13

18

16 15

17

8 5 6

4

7

3 1

2

Cab 1 2 3 4 5 6 7 8 9 10 11 12 13 14

15

Air louvres, adjustable and lockable Air louvres – windscreen Sun visor Air louvres, adjustable Bracket for hand-held microphone – CB radio Opening for CB radio Opening for radio Storage compartment, cooling compartment with air conditioning system free Thermostatic rotary switch for air conditioner 3-speed switch, twin fan Rotary knob, heater control valve free Rotary switch for side lights, driving lights and main switch for worklights: Position 1 = Side lights Position 2 = Driving lights Rotary switch for switching over the driving lights (option, necessary e.g. with Multimaster) Position 1 = Driving lights bottom Position 2 = Driving lights top

6.2.2

2

2

1

2 16 Rotary switch for worklights: Position 1 = Worklights on cab roof Position 2 = Additional worklights for grain tank unloading tube and on the rear of the rear hood Function only when the engine is running and the safety switch is turned on.

Switch 14 must be in position 1 or 2.

17 Rotary switch for warning beacons: Position 1 = Warning beacons are automatically switched on when the grain tank is 70% full Position 2 = Road travel 18 Cab light and reading light, can be switched on and off separately 19 Recirculating air grille, air conditioning system 20 Loudspeakers, radio preparation (option) 21 Lever for opening the cab roof 22 Clothes hanger (Fig. 2)

BA DO 208 / 204 MEGA - 298 672.0

Prior to operation

Prior to operation Cab with ventilating system The cab is equipped with an efficient double fan which blows fresh air into the cab.

The fan can be set to three different speeds by means of 3-position switch (11). Air louvres (1 and 4) allow the operator to control the direction of air flow.

(Fig. 2) Clean the filters in the cab roof regularly – see page 9.9.1, Cleaning the filters.

Cab with fan and compressor-type air conditioner DANGER! Important instructions regarding the compressor-type air conditioning system: 1. Avoid any contact with refrigerant!

Wear protective gloves and goggles.

2. If refrigerant splashes into the eyes, consult a doctor immediately!

3. Have maintenance and repair work carried out by specialist air conditioning system workshops only.

4. Do not weld on or in the vicinity of refrigerant circuit components. – Danger of poisoning!

5. Maximum ambient temperature for refrigerant is 80 °C! The compressor-type air conditioning system is filled with refrigerant R 134a at the factory.

The refrigerant volume is approx. 1.8 kg.

The compressor is filled with Sandenoil (PAG-OIL).

The cab is equipped with an efficient fresh air fan.

The fan can be set to any one of three positions by means of 3-position switch (11).

298 672.0 - BA DO 208 / 204 MEGA

6.2.3

Prior to operation Putting the air conditioner into operation: Start the diesel engine. Switch on the fan to the desired speed 1 – 3 with three-position switch (11).

Turn infinitely variable thermostatic switch (10) in clockwise direction to select the desired temperature.

The air conditioner is now switched on.

Air from inside the cab is now drawn out through recirculating air grille (19), cooled and mixed with filtered fresh air from outside. The blend is then further cooled and pushed into the cab via air louvres (4 and 1).

Adjustable air louvres (4 and 1) allow the operator to control the direction of air flow. Air louvres (1) can be closed, if desired.

When the desired temperature is reached, a thermostat switch in conjunction with an electro-magnetic clutch disengages the compressor.

The compressor is automatically engaged again as the temperature rises.

The compressor-type air conditioner can only function properly if door and windows are kept closed.

(Fig. 2)

The air conditioner system switches off automatically in the event of malfunctions: The warning and indicator lamp in the operations display screen lights up.

The system has been switched off by the high pressure switch.

When the system has cooled down, the air conditioner will be switched on again automatically.

If the system cuts out frequently at very short intervals, check the system for faults.

For possible causes – see page 6.2.6, Problem, cause and / or remedy – Compressor-type air conditioner.

WARNING: Your health is at risk when the difference in temperature between the inside air and outside air exceeds 8 °C to 10 °C (46 °F to 50 °F).

6.2.4

BA DO 208 / 204 MEGA - 298 672.0

Prior to operation Cab with ventilating system and heating A water heater is installed downline of the fresh air fan.

The hot water flow rate and thus the performance of the heater can be controlled with rotary knob (12).

Putting the heater into operation: Open the taps on the engine. Turn switch (12) in clockwise direction. Heating capacity increases, when the switch is turned further in clockwise direction. The adjustable air louvres (4 and 1) allow the operator to control the direction of air flow (heated air and fresh air).

(Fig. 2)

Reheat System (fogged windows) The demister system can be used if the machine is equipped with heater and air conditioning system.

The system can be used, e.g. for clearing fogged windows.

For this purpose, switch on the air conditioning system together with the heater. The evaporator of the air conditioning system is installed ahead of the heater. This allows the damp air to be taken up and removed by the air conditioning system.

298 672.0 - BA DO 208 / 204 MEGA

6.2.5

Prior to operation

Prior to operation Problem, cause and / or remedy – Compressor-type air conditioner Problem

Possible cause and / or remedy

Air conditioner system automatically shuts down.

Warning and indicator lights in the operations display come on.

1. Extremely high ambient temperature, allow the system to cool down. The system switches on again automatically when it has cooled down.

Close windows and doors.

Compressor-type air conditioner does not cool.

Only uncooled air comes out of the air louvres.

1. Electromagnetic clutch does not switch.

Have clutch replaced.

2. V-belt slack.

Tension or replace V-belt.

3. Cable connections loose.

Tighten loose cable connections.

4. Fuse B17 or relay 68 defective.

Replace fuse or relay.

5. Compressor does not pump refrigerant, expansion valve frozen. Saturation point of the moisture indicator reached (blue bead has turned pink).

Have filter-drier replaced. For this, the refrigerant has to be drawn off and then the system recharged.

Cool air is blown through the air louvres, but the air flow is insufficient to cool the cab.

1. Evaporator in cab roof is soiled.

Clean evaporator.

2. Evaporator defective. Replace evaporator.

(Draw off the refrigerant and then have the system recharged.)

3. Condenser in front of the radiator soiled.

Clean condenser.

4. Refrigerant level too low. White bead does not float, it is at the bottom of the sight glass.

Have cooling system checked by the air conditioning service company.

5. Outside air enters the cab.

Close all windows and doors tightly.

Air conditioner provides cool air for a time, then discharges warm air again.

1. Ice formation in the expansion valve.

Filter-drier saturated. Blue bead has turned pink. Have filter-drier replaced.

(Draw off the refrigerant and then have the system recharged.)

6.2.6

BA DO 208 / 204 MEGA - 298 672.0

Prior to operation

Problem

Possible cause and / or remedy

Compressor too noisy.

1. Compressor bearing damaged.

Have compressor repaired or replace compressor. For this, the refrigerant has to be drawn off and then the system recharged.

2. Oil level in the compressor too low (identifiable from external leakage).

Have repair carried out by a specialist workshop. Check the compressor oil level only when the refrigerant has been drawn off from the system.

Moisture in cab.

Water dripping from air louvres.

1. Water drain hoses clogged or not properly routed.

Check water drain hoses for free passage.

If necessary, blow out hoses with compressed air.

298 672.0 - BA DO 208 / 204 MEGA

6.2.7

Prior to operation

Prior to operation Opening and closing the cabin roof Opening the cabin roof Set lever (H) to position (O) by turning to the left.

H

Now fully swing up the cabin roof until the left-hand gas strut is blocked by stop (S).

O

Z

(Fig. 3, 4)

3

S

4 Closing the cabin roof Lift stop (S) to release the gas strut.

Now press the cabin roof downward.

Then set lever (H) to position (Z) by turning to the right.

This locks the cabin roof.

(Fig. 3, 4)

6.2.8

BA DO 208 / 204 MEGA - 298 672.0

Prior to operation Steering column Ignition switch Position 0 = Ignition OFF Position 1 = Ignition ON Turn ignition key (S) to the first stop Position 2 = Preheat engine (Perkins engine only) Turn ignition key (S) to the second stop and hold for max. 15 seconds S 5

Position 3 = Start engine Turn ignition key (S) further to the end stop (Fig. 5)

ATTENTION! Never operate the starter for more than 10 to 15 seconds at a time.

Once the engine has started, release the ignition key immediately.

Repeating the starting procedure: If the starting procedure has to be repeated, turn the ignition key back to position «0» and wait for a short time before repeating the starting procedure.

(Fig. 5)

Control lever (A) for turn flasher and horn: R = Right turn flasher L = Left turn flasher H = Horn R

(Fig. 6)

H A L 6

298 672.0 - BA DO 208 / 204 MEGA

6.2.9

Prior to operation

Prior to operation

1

2

3

17

16

4

15

5

14

6 13

7 12

8 11

9 10

7

Vehicle information unit 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Fuel gauge Engine temperature gauge Engine oil pressure, light-red Air cleaner, light-red Battery charging, light-red Coolant temperature, light-red spare Warning light, cooling water temperature Direction of steering – right, light-red (only on rice machines) Hazard warning, light-red Direction of steering – left, light-red (only on rice machines) Threshing mechanism, STOP, light-red CLAAS-4-Trac-system, green Turning signal (trailer), green Turning signal, green CLAAS-Autopilot, green Handbrake, light-red wear indicator on machines with disc brakes Warning flasher switch Windscreen wiper switch

NOTE! On DOMINATOR 204 MEGA machines only 5/6 of the speed of the transmission input shaft are indicated.

(Fig. 7, 8)

D = Rev. counter, gearbox input shaft (ground speed)

6.2.10

BA DO 208 / 204 MEGA - 298 672.0

Prior to operation

Prior to operation Function of vehicle information unit 18 19

(Warning lights 3, 4, 5, 6, 8, 10 and 17) 3 = The warning light comes on when engine oil pressure is too low, at the same time light (8) comes on, light (10) blinks, and the warning buzzer sounds intermittently.

Stop the engine immediately. Investigate reason to prevent damage and remedy the trouble.

8

4 = The warning light comes on when the air cleaner is dirty, at the same time light (8) comes on, light (10) blinks, and the warning buzzer sounds intermittently.

Stop the engine immediately. Clean air filter and intake screen.

5 = The charge light glows when the ignition is on and the engine is stopped. The charge light goes out after the engine has fired. The charge light comes on and the buzzer sounds continuously when, with the engine running, the alternator fails to work properly or stops rotating.

6 = The warning light comes on if the engine coolant overheats, at the same time light (8) comes on, light (10) blinks and the buzzer sounds intermittently.

Stop the engine immediately. Clean air intake to radiator, and check fan belt tension.

17 = The warning light glows when the handbrake is on.

Machines with disc brakes: When the brake pads are worn, the warning light will come on once the brake pedals are fully depressed. This will work only when the handbrake is released and the ignition is switched on.

DANGER! If the warning light comes on it is essential to have all brake pads immediately replaced by an authorized workshop.

(Fig. 7, 8)

298 672.0 - BA DO 208 / 204 MEGA

6.2.11

Prior to operation

Prior to operation

20

21

23

22

S 24

25

24

26

T

29

30

31

32

35

36

27

28

33

34

37

38

9

Operations display screen 20 Hourmeter, rev. counter for threshing drum and fan 21 Cutting height gauge 22 Cutterbar ground pressure gauge 23 Performance monitor S = Sieve pan T = Straw walkers 24 Warning light, red – «Stop» 25 Warning light, red – feed rake speed-loss monitor 26 Warning light, red – clean grain elevator speed-loss monitor 27 Warning light, red – straw walker / intensive separation speed-loss monitor 28 Warning light, orange – coolant level 29 Warning light, red – returns elevator speed-loss monitor 30 Warning light, red – straw chopper speed-loss monitor 31 Warning light, red – grain tank discharge tube swung out 32 Warning light, red – grain tank discharge engaged

6.2.12

33 Warning light, red – blockage in straw walker compartment 34 Warning light, red – grain tank 100% full 35 Warning light, green – for threshing drum speed 36 Warning light, green – for fan speed 37 Warning light, green – grain tank 70% full 38 Warning light, red – problem with air conditioning system (Fig. 9)

BA DO 208 / 204 MEGA - 298 672.0

Prior to operation

Prior to operation Function of operations display The operations display monitors performance and working speeds (revolutions).

Speed loss monitor: The speed monitor operates with the engine at full revs., and threshing mechanism and cutterbar drives engaged.

If a speed loss occurs on feed rake (25), grain elevator (26), straw walkers (27), returns elevator (29) and straw chopper (30) the warning light with the relevant symbol lights up. At the same time the warning light (24 STOP) blinks on the display, and warning light (12) on the information unit lights up, and warning light (10) blinks, and the buzzer (44) sounds intermittently. On the rev. counter (20), rocker switch (59) changes reading from drum speed to fan speed.

Performance monitor: The performance monitor operates when the ignition is switched on. When the grain tank discharge tube is swung out (31), the tank discharge drive is engaged (32), the grain tank is 100% full (34) and there is an air conditioning problem (38), the warning light comes on with the appropriate symbol.

The warning light on the rev. counter (35 and 36) lights with the appropriate symbol, depending on which service is selected with rocker switch (59).

When the grain tank is 70% full (37) the warning light with appropriate symbol comes on.

Gauge (21) shows cutting height.

Gauge (22) shows cutterbar ground pressure.

Gauge (23) monitors grain loss.

When the ignition is switched on and the engine is at standstill, gauge (28) indicates the coolant level.

If the coolant level is too low, the orange warning light comes on. If the warning light comes on, top up the coolant level.

The gauge has no function when the engine is running.

(Fig. 7, 9, 10)

298 672.0 - BA DO 208 / 204 MEGA

6.2.13

Operation – basic machine

Operation – basic machine

39

43

41 40

45

46

44

42

47

48 49 50 51 54 55 52

53 69

58 56

57

59

61 60

62 66

63

65 64

68

67

10

Switch console 39 Rocker switch with lock for CLAAS 4-Trac System ON / OFF 40 free 41 free 42 free 43 free 44 Buzzer 45 Switch, engage / disengage threshing mechanism 46 Switch, engage cutterbar 47 Push button, «grain tank full buzzer» OFF 48 free 49 free 50 Centralizer switch, CLAAS Autopilot 51 Rocker switch with lock, CLAAS Autopilot 52 Turn button for pre-set cutting height, CLAAS Auto Contour and CLAAS Contour 53 Turn button, cutting height control CLAAS Auto Contour 54 Rocker switch (master switch) for CLAAS Auto Contour ON / OFF 55 Rocker switch for manual lateral levelling of cutterbar with Auto Contour 56 Turn knob for sieve pan performance monitor 57 Turn knob for straw walker performance monitor 58 Rocker switch for fan speed adjustment

6.2.14

59 Switch for rev. counter Rocker switch locked = threshing drum Rocker switch unlocked / ON = fan 60 Rocker switch for reel speed adjustment 61 Rocker switch, grain tank discharge tube swing 62 Rotary switch, chopper deflector adjustment 63 Momentary switch with lock for cutterbar reverser ON / OFF 64 Planned for CLAAS Contour master switch CLAAS Contour System 65 Master safety rocker switch with lock, ON / OFF 66 Ashtray 67 12 Volts outlet 68 Rotary switch, engine speed 69 Shelf (Fig. 10)

BA DO 208 / 204 MEGA - 298 672.0

Prior to operation

Prior to operation Multi-function lever

3 1

5

2

6

7 4 8

11

1 Cutterbar up, CLAAS Contour OFF or CLAAS Auto Contour OFF 2 Cutterbar down (only with engine running) – the cutterbar cylinder lines are automatically kept closed when the engine is stopped (safety measure).

3 Reel up 4 Reel down 5 Reel forward 6 Reel backward 7 Preset height ON 8 CLAAS Contour System ON or CLAAS Auto Contour ON (Fig. 11) Central terminal compartment The central terminal compartment is located under the instrument panel (A).

(Fig. 12)

A

12 When the instrument panel (A) is folded away, cover (S) can be seen. The symbols on the cover identify the location of all relays, modules and fuse links.

S

(Fig. 12, 13)

13

298 672.0 - BA DO 208 / 204 MEGA

6.2.15

Prior to operation With protective cover removed, access to the plug-in type modules, relays and fuse links is obtained.

P

F

R

F P A R D

A R

= = = = =

Plug-in type module for functions monitor Plug-in type module for CLAAS Autopilot Plug-in type module for CLAAS Auto Contour Relay Fuse links

(Fig. 14)

R D

D

14 Plug-in type module (P) CLAAS Autopilot P

1

2

Functions of module: 5

3 4

6

15

1 Steering angle adjustment 2 Sensitivity control adjustment 3 Indicator lights, glow yellow when solenoid valves are being operated 4 Indicator lights, glow yellow when solenoid valves are being operated 5 Indicator light, shows red in case of short circuit 6 Indicator light, shows green when ignition is ON – the CLAAS Autopilot System is operational (Fig. 15)

6.2.16

BA DO 208 / 204 MEGA - 298 672.0

Prior to operation Grain tank discharge tube – swinging out and in DANGER! Make sure everybody is clear of the discharge tube's swing area.

Swinging the grain tank discharge tube: Start the engine and turn on safety rocker switch (65).

E

A = Swinging the discharge chute out E = Swinging the discharge chute in A

61

Press the respective end of rocker switch (61). A time relay (25 seconds) swings the discharge chute into the respective end position.

65

Set rocker switch (61) to the middle position if movement of the discharge chute is to be interrupted.

16

(Fig. 16)

Warning device: When the grain tank discharge tube is in the out position a warning light (31) shows on the display panel.

(Fig. 9, 16)

DANGER! When driving on public roads the grain tank discharge tube must be swung completely in, and safety rocker switch (65) must be switched off (Fig. 16).

298 672.0 - BA DO 208 / 204 MEGA

6.2.17

Prior to operation Grain tank discharge engagement and disengagement

S

By means of foot-operated switch (F) the grain tank discharge can be put in and out of drive, with the discharge tube swung out.

When driving on public roads, security lock (S) must be folded over the switch.

F

(Fig. 17)

17 Threshing mechanism engagement / disengagement

45

The threshing mechanism can be engaged and disengaged with switch (45).

Engage = Turn switch (45) briefly to the right and release.

(Fig. 18)

65 18 Disengage = Press switch (45) in until it locks in position.

45

(Fig. 19)

19

6.2.18

BA DO 208 / 204 MEGA - 298 672.0

Prior to operation Engaging and disengaging the cutterbar drive 46

Engaging the cutterbar drive: First engage the threshing mechanism.

Then operate pressure switch (46) to engage the cutterbar drive.

(Fig. 20)

20 Disengaging the cutterbar drive: S

Operate foot-operated switch (D) to disengage the cutterbar drive.

The cutterbar can only be re-engaged by way of pressure switch (46).

(Fig. 20, 21)

D 21 Positioning the cutterbar / maize picker head for road travel Raise the cutterbar or maize picker head to maximum height (bottom edge of protective bar approx. 600 mm above road level).

(Fig. 22)

22

298 672.0 - BA DO 208 / 204 MEGA

6.2.19

Prior to operation Switch off safety rocker switch (65).

The cutterbar can now not be lowered by mistake.

(Fig. 22, 23) DANGER! When moving the combine on public roads and lanes, the transport width of the front attachment must not exceed 3.00 m.

65 23 Adjusting the threshing drum speed Only adjust the threshing drum speed with threshing mechanism engaged and running.

B

Operate lever (H) in direction (A) to increase drum speed.

Operate lever (H) in direction (B) to reduce drum speed.

H

(Fig. 24) A 24

Adjusting the steering column position DANGER! P

Never adjust the steering column while driving the machine. The steering column can be unlocked and adjusted to the desired position by depressing pedal (P).

(Fig. 25) 25

6.2.20

BA DO 208 / 204 MEGA - 298 672.0

Prior to operation Driver's seat, mechanical DANGER! Never adjust the driver's seat when on the move!

1 1 2

7 3

4 5

6

26

1 Arm rest angle (right-hand arm rest = option) 2 Horizontal adjustment 3 Seat depth adjustment 4 Seat angle adjustment 5 Weight adjustment 6 Weight adjustment indicator 7 Backrest adjustment 8 Lumbar support 9 Net (Fig. 26, 27)

9 8

27 Weight adjustment Set the operator's weight with the combine at standstill. Fold out adjustment lever (5).

The set weight can be read off from indicator (6).

(Fig. 26)

Height adjustment The height of the seat can be adjusted.

Raise the complete seat assembly to the desired height. It then locks in the corresponding detent.

Lower seat: Raise the seat completely. From the highest position, the seat can then be lowered again to the lowest position.

298 672.0 - BA DO 208 / 204 MEGA

6.2.21

Prior to operation Seat angle adjustment The longitudinal angle of the seat cushion can be adjusted individually.

To adjust the angle, lift the left-hand button (4).

Simultaneously load or relieve the seat cushion to angle it in the desired direction.

(Fig. 26)

Seat depth adjustment The seat depth can be individually adjusted.

To adjust the seat depth, lift the right-hand button (3).

The desired position can be achieved by simultaneously pushing the seat cushion forwards or backwards.

(Fig. 26)

Lumbar support Turning the handwheel (8) to the left or right allows both the height and the degree of support in the backrest cushion to be individually adjusted.

(Fig. 27)

Armrest angle The longitudinal angle of the armrests can be adjusted by turning handwheels (1).

(Fig. 26)

Adjusting the driver's seat horizontally Actuating the locking lever (2) upwards releases the longitudinal adjustment.

DANGER! The locking lever (2) must engage in the desired position. After locking, shifting the driver's seat to another position must not be possible any more.

(Fig. 26)

6.2.22

BA DO 208 / 204 MEGA - 298 672.0

Prior to operation Access ladders

2

Front ladder DANGER! Move the ladder only when the combine is at standstill!

The ladder must be in the front position before starting to drive the combine.

28

(Fig. 28) When climbing onto or off the combine, the ladder must be in the side position.

(Fig. 29)

1

29 Adjusting the ladder: When adjusting from the ground, release lever (1) on the operating rod and move the ladder to the front or to the side.

When adjusting from the operator's platform, release lever (2) and turn the ladder at the operating rod.

(Fig. 28, 29)

DANGER! The ladder must always correctly lock in the selected position.

298 672.0 - BA DO 208 / 204 MEGA

6.2.23

Prior to operation Access and ladder extension If the combine is extra-wide due to its tyres (see table), the access and ladder on the left-hand side of the combine must be altered as shown in the table.

E

Fig. 32 = Fig. 33, 34, 35 =

Access without extension Access with overwide tyres

To fit certain tyres sizes, the rear catch for the ladder lock (E) must be replaced by a new catch (R).

This catch will extend the swing travel of the ladder.

30

The catch is fastened at the factory to the access ladder.

(Fig. 30, 31) The ladder must be removed in order to install the catch.

R 31

6.2.24

BA DO 208 / 204 MEGA - 298 672.0

Prior to operation NOTE: Railing measured at the bottom from tube centre to tube centre.

Front railing A1 = 825 mm A2 = 624 mm B = 338 mm L = mounting plate Rear railing C = bar D = 618 mm Extensions F1 = 103 mm F2 = 206 mm G = 515 mm

Tyres

Figure

Railing, front

Bar

Extensions

Railing rear

23.1 R 30 (620 / 75 R30

32

A2

C

–

–

30.5 L - 32R2

33

A2

C

F1

–

24.5 - 32

34

A2

C

F2

–

24.5 R32

34

A1

C

F2

–

(650 / 75R32)

34

A1

C

F2

–

30.5 R 32

35

A1

C

F1 + F2

–

73 x 44 - 32 (1050 / 50R32)

36

A1 + B Mounting plate L

–

G + F1

D

298 672.0 - BA DO 208 / 204 MEGA

6.2.25

Prior to operation

C

A2

32 C

A2

F1

33

6.2.26

BA DO 208 / 204 MEGA - 298 672.0

Prior to operation

C

A2

F2

34

C

A1

F1

F2

35

298 672.0 - BA DO 208 / 204 MEGA

6.2.27

Prior to operation

D B

A1

G F1

L

36 Rear ladder 4 DANGER! R

Switch off combine engine and remove the ignition key before climbing onto combine to carry out service work or refuelling.

Before using the ladder, ensure that it is securely engaged at (4) and locked at (R).

37

(Fig. 37) Always raise the ladder before driving the combine.

DANGER!

4

Ensure that the ladder is securely engaged at (4) and locked at (R).

R (Fig. 38)

38

6.2.28

BA DO 208 / 204 MEGA - 298 672.0

Prior to operation

Prior to operation DRIVING THE COMBINE DANGER! For road travel with a raised front attachment, the control lever or the safety rocker switch must be disengaged or switched off and locked. This is essential to prevent lowering of the front attachment.

Before dismounting from the combine lower the front attachment to rest on the ground, stop the engine and withdraw the ignition key (main switch key).

No travel in 3rd gear is allowed on roads with a gradient exceeding 7%. Never uncouple the machine and let it freewheel.

Engine speed turn switch Function of turn switch (68): = Slow idle speed = Fast idle speed (Fig. 1, 2)

68

1 NOTE: When engaging the 3rd gear with the engine speed switch in position the engine speed is automatically reduced.

40238

298 672.0 - BA DO 208 / 204 MEGA

2

6.3.1

Prior to operation Starting the engine 45

Switch (45) for threshing mechanism engagement / disengagement must be switched off.

(Fig. 3)

3 Move ground speed control lever (F) to the «0»-position or there will be no contact to the starter (Fig. 4).

F A

0

Move turn switch (68) to the slow idle speed position (Fig. 1, 2).

B

4 Turn the ignition key until resistance is felt and hold for approx. 15 seconds in the heat position. Then press key in and turn further (heating only required with Perkins engines). When the engine has started, let it run at slow idling speed for a short time.

The engine must not be run at full speed as long as the oil pressure light is on and the beeper sounds.

When working, turn switch (68) must be in fast idle speed position .

(Fig. 1, 2)

Starting the engine from cold: During the cold season allow the engine to slow-idle for a few minutes after it has fired. Possibly use winter fuel.

6.3.2

BA DO 208 / 204 MEGA - 298 672.0

Prior to operation Adjusting stiffness of ground speed control lever In order that the ground speed control lever does not move independently when released, the stiffness of the ground speed control lever can be adjusted at clamping screw (K).

K

Clamping screw (K) is accessible after opening the central terminal compartment.

(Fig. 5) 5

Gear ranges S

3.

Lever (S) moved rearward and to the right 1st gear range = field operations Lever (S) moved forward and to the left 2nd gear range = field operations

1.

Lever (S) moved forward and to the right 3rd gear range = road travel

2.

(Fig. 6)

6 ATTENTION! Always bring the machine to a full stop before engaging a gear range or before changing to another gear range.

If gear range selection proves to be difficult, momentarily operate the ground speed control lever with the engine running.

The combine ground speed is varied with the ground speed control lever (F). To increase forward speed, move the control lever further forward (A). To increase the speed in reverse, move the control lever further backwards (B).

(Fig. 4)

ATTENTION! It is essential to run the engine while the ground speed control lever is being operated.

298 672.0 - BA DO 208 / 204 MEGA

6.3.3

Prior to operation Stopping the combine Reset the ground speed control lever (F) to neutral position (0).

(Fig. 4) DANGER! Before dismounting from the combine stop the engine, withdraw the ignition key (main switch key), set the handbrake and, if parking the machine on sloping ground, secure the machine additionally by chocking the wheels.

Driving behaviour DANGER! The driving behaviour of a combine is influenced by the ground conditions and by the front attachment, e.g. maize header.

Therefore always adapt your driving style and speed to the ground or road conditions.

Take particular care when working and turning on hillsides, particularly with a full grain tank.

Steering The hydrostatic steering enables easy steering of the combine with rear wheels.

DANGER! Drive carefully on public roads and when turning: Sharp turns make the combine swing wide!

The steering continues to function even with the engine stopped, but much greater steering effort is required.

6.3.4

BA DO 208 / 204 MEGA - 298 672.0

Prior to operation Brakes Foot brake DANGER! Always lock the brake pedals together before moving the machine on public roads and lanes and check brakes for equal effectiveness on both the drive wheels.

7

The foot brakes are designed to work independently when the pedal lock is removed to facilitate turning sharp corners. CAUTION: Use brakes carefully on hilly ground!

(Fig. 7)

The foot brake should grip when the brake pedal is depressed by about one third of its total travel.

A = 1/3 B = 2/3

A

(Fig. 8) B DANGER! Always make sure that the brakes function correctly and adequately stop the machine.

It is most important to inspect the brake linings periodically.

8

The brake system must be adjusted, serviced and repaired only by authorized workshops or authorized brake services.

Handbrake Brake-action of handbrake (B) is independent of foot brake action. The handbrake should be effective with the handle locked in the first 3 to 4 teeth in the segment. For reasons of safe operating conditions make sure that the ratchet securely locks in the segment after prolonged use of the combine.

B

A = Brake fluid reservoir A

(Fig. 9) 9

298 672.0 - BA DO 208 / 204 MEGA

6.3.5

Prior to operation Stopping the engine Move turn switch (68) to idle speed position .

Switch off threshing mechanism and then ignition.

(Fig. 10) ATTENTION! Before stopping a turbo-charged engine, always let it slow idle for a little while.

Failure to do so results in damage to the turbo charger compressor wheel.

68

10

CLAAS Autopilot Putting the CLAAS Autopilot into operation: The CLAAS Autopilot is only to be switched on when working between the rows in maize crops.

51 50

DANGER! It is imperative to switch off the CLAAS Autopilot by means of rocker switch (65) before travelling on public roads and lanes.

65 11

S

The security bracket (S) must be positioned over the foot switch before moving the combine harvester on the road.

Sit on the operator's seat and engage the threshing mechanism.

Release the lock and actuate rocker switch (51).

Swing back security bracket (S) and switch on foot switch (F).

(Fig. 11, 12)

F

12

6.3.6

BA DO 208 / 204 MEGA - 298 672.0

Prior to operation When entering the field, first steer the machine manually.

Once regular row conditions permit automatic operation, continue to drive for about 1 metre and then engage the Autopilot by depressing the foot switch (F, Fig. 12) to the stop and promptly releasing it again (the red indicator light in the vehicle information unit comes on).

Do not turn the steering wheel while switching to automatic operation and after the automatic control has been engaged.

The CLAAS Autopilot now guides the machine along the maize rows by way of the touch sensor arms.

The system keeps the machine also on course when there are short gaps within the rows.

For over-riding the CLAAS Autopilot system or to switch off the automatic control for headland turns or at the end of the field, turn the steering wheel quickly one quarter of a turn and then continue to steer manually as usual.

Where row spacings give trouble, better results may be obtained by passing the «contact row» not exactly midway between the sensor arms. The left touch sensor arm may be run somewhat closer to the row then the right one, or vice versa. To keep the machine automatically on the selected «off centre course», the centralizer switch (50) should be dislocated from the indicated centre position as required.

After field operations have been completed, immediately switch off the CLAAS Autopilot by operating rocker switch (51) and by lowering the security bracket (S) into lock position over the foot switch to prevent accidental engagement of the CLAAS Autopilot during road transport.

(Fig. 11, 12)

Safety shut-off system: The driver's seat is equipped with a safety shut-off system. As soon as the driver leaves the seat, the CLAAS Autopilot will be switched off.

298 672.0 - BA DO 208 / 204 MEGA

6.3.7

Prior to operation

6.3.8

BA DO 208 / 204 MEGA - 298 672.0

Prior to operation

Prior to operation REAR AXLE Setting the adjustable rear axle DANGER! No persons must ever be allowed on the combine when work is being carried out underneath it and the machine is raised.

R

A raised machine must always be supported by suitable stands or blocks.

1

– On the right-hand side, remove both clamping bolts (R) of the track rod.

– Remove mounting bracket (B) of the steering cylinder from the axle body.

S

– Remove mounting bolts (S), on both sides.

– Set the adjustable axle to any one of three track widths – 2395 mm, 2595 mm and 2795 mm (with 14.5/75 - 20 tyres). Install mounting bolts (S), but do not tighten them at this time.

– Tighten the mounting bolts (S).

B

– Mount bracket (B) to the respective tapped holes.

2

– Fit both the clamping bolts (R) to the corresponding notches of the track rod and securely tighten the bolts.

ATTENTION! With 500/60 - 22.5 tyres, the track width must only be adjusted to 2645 mm and 2845 mm, respectively. With 14.9 - 24 tyres, the track width must only be adjusted to 2740 mm.

S

S

The tyres will take damage if this is neglected.

3

298 672.0 - BA DO 208 / 204 MEGA

(Fig. 1, 2, 3)

6.4.1

Prior to operation Changing the rear axle from transport position to working position DANGER! No persons must ever be allowed on the combine when work is being carried out underneath it and the machine is raised.

A raised machine must always be supported by suitable stands or blocks.

Ensure that the lift capacity of the lifting device is adequate.

Combine with adjustable and rigid axle: For field operations the rear axle must be secured with middle axle bolt (M) in the bottom hole (A). Hole (T) is provided for rail transport.

(Fig. 4)

4 Secure middle axle bolt with plate (P).

Bolt on the plate with hexagon head bolts M 14 x 35, contact washers A 14 and hex. nuts M 14.

P

(Fig. 5)

M

5

6.4.2

BA DO 208 / 204 MEGA - 298 672.0

Prior to operation CLAAS-4-Trac-System During operation of the combine, the steering axle must be attached with middle axle bolt (M) in the upper hole (T).

E

Tighten castellated nut on middle axle bolt and secure with cotter pin.

N

E

Bolt on plate (N) of the middle axle bolt with 2 hexagon head bolts M 14 x 35, contact washers A 14 and hex. nuts M 14.

Remove steering axle pendulum limiters (E).

6

(Fig. 4, 6)

Lowering the stub axles:

A

Move the stub axles from position (A) to position (B).

B

Tighten hexagon head bolts (B and C) to the specified torque.

(Fig. 7)

C

C

7

Towing a combine with driven rear axle ATTENTION! If a combine with driven rear axle is to be towed more than approx. 500 metres, the driven rear axle must be disengaged at the final drives.

Disengaging the final drives: – Remove hexagon head bolts (2) on both sides.

(Fig. 8)

2

F

8

298 672.0 - BA DO 208 / 204 MEGA

6.4.3

Prior to operation – Turn flange (F) around.

Flange side (A) faces inwards.

(Fig. 9, 10)

F

9

F

F

E E

A

A

37908

10 – Bolt on flange (F) again.

(Fig. 11) 2

F

11 Engaging the final drives: Turn flange around so that flange side (E) is facing inwards.

(Fig. 8, 10)

6.4.4

BA DO 208 / 204 MEGA - 298 672.0

Prior to operation

Prior to operation CUTTERBAR CYLINDERS Hydraulic cylinders Attaching the cutterbar hydraulic cylinders NOTE!

F 1

The cutterbar floatation springs are set at the factory in bores (1) – see page 8.1.6, Adjusting the cutterbar floatation springs.

3

2

1

The bores (2) are provided for installation of the unloading device.

When using other cutterbar sizes and if the cutterbar cylinders are attached in the bores (3), the cutterbar floatation springs must be newly set.

(Fig. 1)

Attaching the right-hand cutterbar cylinder For cutterbar widths up to and including 5.10 m (17 ft), the right-hand cutterbar cylinder must be attached to bracket (M).

A

For cutterbar widths of 6.00 m (20 ft) and 6.60 m (22 ft), for all soybean cutterbars and for the folding cutterbar, the right-hand cutterbar cylinder must be attached to bracket (A).

M

(Fig. 2) 2

298 672.0 - BA DO 208 / 204 MEGA

6.5.1

Prior to operation Attaching a third cutterbar cylinder For cutterbar widths of 6.00 m (20 ft) and wider, and for 5-row and wider maize heads with stalk chopper, a third cutterbar cylinder must be fixed to the bracket (A), depending on the piston rod diameter.

Refer to the chart below.

(Fig. 3)

3

Piston rod

Third cutterbar cylinder

55 mm dia.

X

Maize head

Cutterbar 4.5 m folding

from 6.00 m

from 7.50 m

5-row with stalk chopper

6-row folding

6-row with stalk chopper

8-row

–

–

+

+

+

+

+

– not required / + required

6.5.2

BA DO 208 / 204 MEGA - 298 672.0

Prior to operation

Prior to operation TOWING AND SIDE WALK RAILING Towing the combine ATTENTION! Prior to towing, shift the gear into neutral.

Forward When towing the combine in forward direction, the chain or tow rope can be attached to the traction eyes (Z) on the front axle.

(Fig. 1)

Z

Z

1 Backward When towing the combine in backward direction, sling the chain around axle mount (A) right under the axle support tube. The chain or tow rope must not be attached to the clevis hitch or to the axle body.

(Fig. 2)

A

ATTENTION! Do not damage the steering hydraulic line (H) when attaching the chain or tow rope.

2

☞ Loosen clamp (N) and push up the N

hydraulic lines out of the way.

H

After towing secure the hydraulic lines again with clamp (N).

(Fig. 3)

3

298 672.0 - BA DO 208 / 204 MEGA

6.6.1

Prior to operation Side walk railing Tilting the side walk railing The railing (L) of the side walk can be tilted a little bit outwards after unlocking the linkage (G). This provides easier access to the grain tank.

L

(Fig. 4) G

4

6.6.2

BA DO 208 / 204 MEGA - 298 672.0

Prior to operation

Prior to operation CAB AND LIGHTING Cab

C

D

D B

Standard combine specifications include a cab with ventilation system / filters.

B

The following optional extras are available for this cab: a) Heating b) Compressor-type air conditioning or c) Heating and compressor-type air conditioning.

E

A

The use of these variations make combine operations much easier since the driver is protected from dust, heat and cold.

A 1

(Fig. 1)

Driving lights, worklights and mirrors A = Two worklights for driving lights B = Four lamps on the top of the cab to illuminate the front attachment C = Two lamps to illuminate the work area ahead D = Mirror E = Starting mirror (Fig. 1)

F = One light to the left of the engine compartment to illuminate the unloading auger and the transport vehicle when unloading the grain tank.

F

(Fig. 2)

2

298 672.0 - BA DO 208 / 204 MEGA

6.7.1

Prior to operation G = One light in the sieve pan area The light can be switched on and off with rocker switch (1).

G DANGER! The light (G) must be switched off during operation. If necessary, clean the area around the light.

1

(Fig. 3) 3 H = One light for inspecting the returns The light comes on automatically when the inspection door is opened.

(Fig. 4) H

4 J = Two lights on the back of the rear hood (Fig. 5)

J

J

5 K = One light in the grain tank The light is switched on when the ignition is switched on.

(Fig. 6) K

6

6.7.2

BA DO 208 / 204 MEGA - 298 672.0

7 Operation – cutterbar

Operation – cutterbar

Operation – cutterbar ATTACHING THE CUTTERBAR Adjusting the strippers DOMINATOR MEGA 204 When attaching a grain cutterbar, strippers (W) on the front of the feeder house must be bolted with their narrow sides to the feeder house.

(Fig. 1)

W

W 1 Machine with Auto Contour: Raise the strippers to the upper limit of their slots and secure them tightly.

Machine without Auto Contour: Adjust the strippers in their slots to line up with the strippers on the cutterbar back panel when the cutterbar is attached.

(Fig. 1)

Machine with CLAAS Auto Contour DANGER! Safety hazards exist when coupling a front attachment (cutterbar, maize picker head etc.) to the machine.

Drive the combine up to the cutterbar so that the coupling lugs (F) of the hydraulic cylinders on the feeder house are directly under the corresponding holes (G) of the upper cutterbar transverse plate. Lift the cutterbar by operating the hydraulic control lever.

G

(Fig. 2) F

2

298 672.0 - BA DO 208 / 204 MEGA

7.1.1

Operation – cutterbar Lock the cutterbar at the bottom on either side. Insert the locking pins (V) and secure with spring clips (S).

ATTENTION! U

When the cutterbar is raised, guide (U) must locate against lock pin (V).

V 2

If necessary, loosen bolts (2) and adjust the guide accordingly. After adjustment, retighten the bolts.

S

3

Turn the rubber cover (G) over onto the feeder house.

Secure the lugs (F) with the locking pins (R), on the cutterbar transverse plate, by turning them to the right.

At the same time pull out the safety lock (P).

G F

(Fig. 3)

R ATTENTION! P

Safety lock (P) must be secured and correctly engaged.

(Fig. 4) 4

7.1.2

BA DO 208 / 204 MEGA - 298 672.0

Operation – cutterbar Levelling the coupling lug cylinders A correction can be made, if both hydraulic cylinders do not have the same height in the middle setting: 1. Remove the cutterbar.

2. Open the valve (R).

To do this, set the lever (H) to position (A).

H R

3. Switch on safety rocker switch (65).

Z

Operate rocker switch (55) for manual levelling of the cutterbar so that both cylinders extend.

A

5

Operate until both cylinders are fully out.

4. Operate the opposite end of rocker switch (55).

The left-hand cylinder retracts.

Retract the cylinder to the full extent.

5. Shut the valve by turning the lever (H) to position (Z).

6. By operating the rocker switch, bring the hydraulic cylinders to the middle position and attach the cutterbar again.

(Fig. 5, 6)

55

65 6

Machine without Auto Contour DANGER! Safety hazards exist when coupling a front attachment (cutterbar, maize picker head etc.) to the machine.

Drive the combine as straight as possible up to the cutterbar so that the coupling lugs (F) of the feeder house are directly under the corresponding holes (G) of the upper cutterbar transverse plate. Lift the cutterbar by operating the hydraulic control unit lever.

G

(Fig. 7)

F

7

298 672.0 - BA DO 208 / 204 MEGA

7.1.3

Operation – cutterbar Lock the cutterbar at the bottom on either side. Insert the locking pins (V) and secure with spring clips (S).

V

Adjust the height of locking plates (H) and secure so that the locking pins engage easily.

H S

The locking plates (H) must be clearance-free up against locking pins (V).

(Fig. 8)

8 Levelling the cutterbar Before initially putting the combine to work check that the cutterbar is level with the ground and adjust the cutterbar to be horizontal if necessary.

F

Drive the combine with the cutterbar attached on a flat, even surface.

Lower the cutterbar onto the ground.

Loosen coupling lugs (F) and raise or lower the lugs so that on a flat surface the cutterbar is parallel with the ground.

9

(Fig. 9)

Adjust the stop plates (K) to the new cutterbar position by removing shims (S), located between the stop plates and the cutterbar frame, from the right-hand side and installing them on the left-hand side, or vice versa, so that the feeder house will fit without tension from either side between the stop plates.

S

K

(Fig. 10)

10

7.1.4

BA DO 208 / 204 MEGA - 298 672.0

Operation – cutterbar Connecting the universal drive shafts DOMINATOR 208 MEGA Set the guard (S) in the up position. Depress the plunger (1) and slide the universal drive shaft on to the shaft splines of the feeder housing. Ensure that the plunger engages correctly. Fold the guard (S) down again.

S 1

6.00 m – 9.00 m cutterbars: Connect the universal drive shafts on both sides and fold down the safety shields (S).

11

(Fig. 11, 12) DANGER! Never operate the universal drive shaft without guards and safety shields installed.

S 1

12

Connecting the universal drive shafts DOMINATOR 204 MEGA S

Left-hand side: Set the guard (S) in the up position. Depress the plunger (1) and slide the universal drive shaft on to the shaft splines of the feeder housing. Ensure that the plunger engages correctly. Fold the guard (S) down again.

(Fig. 13)

1 13

298 672.0 - BA DO 208 / 204 MEGA

7.1.5

Operation – cutterbar Right-hand side: (6.00 m – 9.00 m cutterbars)

F

Depress the plunger (1) and slide the universal drive shaft on to the shaft splines on the feeder housing.

Ensure that the plunger engages correctly.

1

S

Push guard (S) over the shaft. The guard must be right home and secured by wing bolt (F).

(Fig. 14) DANGER! 14

Never operate the universal drive shaft without guards and safety shields installed.

Connecting hydraulic hoses When hooking up the hydraulic quick-couplers, make sure to connect those couplers, that have equal coloured markings.

B E

F

B = without colour marks, reel up / down F = blue (reel forward) fore and aft reel adjustment E = red (reel backward) fore and aft reel adjustment (Fig. 15) 15 When attaching the cutterbar to the combine for the first time, loosen the union nuts and adjust the elbows of the quick couplers so that the high pressure hoses connect easily. Make sure that the high pressure hoses do not twist when they are being connected.

There must be no tension on the high pressure hoses from any side.

Connecting the cables Connect plug (A) for the reel speed adjustment and plug (C) for the CLAAS Auto Contour System.

The plugs are manufactured so that they cannot be mistaken.

A

(Fig. 16)

C 16

7.1.6

BA DO 208 / 204 MEGA - 298 672.0

Operation – cutterbar Installing the stands Cutterbars up to 5.10 m:

O

With the cutterbar attached to the machine, fit stand (E) to holes (O) on the right-hand side of the cutterbar and secure with spring (H).

(Fig. 17)

E

DANGER! H

Always make sure that the front attachment (cutterbar, maize picker head etc.) is securely supported when it is being detached from the machine and parked.

17

Attach stand (E) to the bearing shield (L) on the left-hand side of the cutterbar and secure with spring (H).

(Fig. 18) L E H 18 6.00 m – 9.00 m cutterbars: Attach stands (E) to bearing shields (L) and secure with springs (H).

(Fig. 19) E

H

L 19

298 672.0 - BA DO 208 / 204 MEGA

7.1.7

Operation – cutterbar Before removing the cutterbar from the machine, place stands (E) under the outer skids on both ends of the cutterbar and secure each stand with spring (H). The cutterbar can then easily be picked up with the feeder house for attachment to the machine.

(Fig. 20)

E H

20

7.1.8

BA DO 208 / 204 MEGA - 298 672.0

Operation – cutterbar

Operation – cutterbar ADJUSTMENTS AT THE CUTTERBAR DANGER! Knives, the cutterbar, mower bar, auger and reel etc. cannot be completely shielded by constructional measures due to their function.

☞ For this reason, an adequate safety distance must be maintained to these moving elements during operation!

☞ Safely support the attached cutterbar before working underneath it.

B

Dividers

A

The three-sectional divider consists of the divider (A), the adjustable short inner deflector (B) and the long outer deflector (C).

(Fig. 1) 6

The divider is attached to the cutterbar by a quick release device, and is available in a short version (for short strawed crops) and a long version.

5 C

1 Adjusting the crop dividers: R R

L

L

Loosen hexagon head bolts (2) and adjust divider centre plates (A) as close as possible to the reel.

Ensure that the reel does not collide with the crop dividers.

2

2

Position left-hand divider centre plate (A) in the middle of the slot.

22

37341

Push the right-hand divider centre plate (A) completely to the right-hand side.

2

L = Left-hand crop divider R = Right-hand crop divider (Fig. 1, 2)

298 672.0 - BA DO 208 / 204 MEGA

7.2.1

Operation – cutterbar Adjust inner deflectors (B) so that they do not collide and so that the reel shaft does not become wrapped with crop.

Loosen the toggle bolts (5) and turn locks (6) and adjust the outer deflectors (C) laterally and in the height so that the stalks are pressed into the standing crop.

3

S

3

Loosen bolts (3) and adjust the height of the crop dividers at the adjusting plates (S) so that the divider tips are not constantly scraping on the ground and do not dig into the ground when driving over uneven ground.

(Fig. 1, 3)

Grain lifters The number of grain lifters to be fitted depends on the condition of the crop.

In down and weedy crops fit a lifter on every fourth to sixth knife finger, and in short strawed standing crops with the heads hanging down, fit lifters closer together.

2

Slacken the nut (1). Slide the lifter between the washer and the upper nut, at the same time placing the lifter opening (2) over the finger tip, then retighten the nut securely.

1 4

Do not fit a lifter on the first three fingers from either end of the cutterbar.

(Fig. 4)

Transport bracket for crop lifters: Crop lifters can be housed in the bracket provided on the right-hand side of the cutterbar.

Secure the crop lifters on both sides with spring clips (F).

(Fig. 5)

F

5

7.2.2

BA DO 208 / 204 MEGA - 298 672.0

Operation – cutterbar Knife DANGER! Always wear gloves to prevent cuts when removing or installing the knife.

Be especially careful while removing the knife when the finger bar, knife and fingers are misaligned or covered with dirt.

6

(Fig. 6)

Removing the knife 6.00 m – 9.00 m cutterbars Position the knife so that it is at the extreme end of its left-hand stroke.

Loosen the socket head screws (N) and pull out of the knife.

M

(Fig. 7)

N

7 3.00 m – 5.10 m cutterbars Set the knife to the left-hand end of its stroke.

Undo the hex. bolts (N) and remove the knife.

(Fig. 8)

N

M 8 Installing the knife Slide the knife into the finger bar. Secure the knife with hex. bolts (N). To ensure the correct fitting of dowel (M), the recess must be perfectly clean.

(Fig. 7, 8)

298 672.0 - BA DO 208 / 204 MEGA

7.2.3

Operation – cutterbar Adjusting the height of the knife head 6.00 m – 9.00 m cutterbars After slackening clamping screw (K), adjust drive arm (G) so that a clearance of 0.5 to 1 mm is obtained between the first sections of the knife and the flats of the double fingers on which the sections run.

K

Securely tighten the clamping screw after the drive arm has been adjusted.

G

(Fig. 9) 9 3.00 m – 5.10 m cutterbars After slackening clamping screw (K), adjust drive arm (G) so that a clearance of 0.5 to 1 mm is obtained between the first sections of the knife and the flats of the double fingers on which the sections run.

Securely tighten the clamping screw after the drive arm has been adjusted.

G K

(Fig. 10)

10 Adjusting the knife clips Adjust the knife clips (M) by fitting or removing shims.

The clips should be adjusted so that the knife operates smoothly.

There should be about 1.5 mm play between the knife clip and knife section.

(Fig. 11) M

11 Spare knife 6.00 m – 9.00 m cutterbars A spare knife (E) can be placed in the support on the cutterbar.

E

Before the knife can be pulled out of the support, the knife drive belt (K) must be removed from the spring-loaded idler (S). Then loosen lock (R) and push it back.

R K

(Fig. 12) S 12

7.2.4

BA DO 208 / 204 MEGA - 298 672.0

Operation – cutterbar 3.00 m – 5.10 m cutterbars A spare knife (E) can be placed in the support on the cutterbar.

E

The spare knife is secured in position when the hinged side panel (O) is closed.

(Fig. 13) O

13

Cutterbar skids Cutterbar skids (V) are height-adjustable. Proper positioning of skids depends on the size of the tyres.

Lower skids as much as possible.

(Fig. 14) V

14

Reel Reel height is adjustable from the operator's platform by means of the hydraulic control unit: Lower the reel in downed crops and raise it in standing crops.

If, with the reel in deepest position, the reel tines come in touch with the cutterbar knife, readjust setting of eye bolts (B).

B

(Fig. 15)

15 After dismantling or disconnecting any parts of the reel hydraulic system, the system must be bled – see page 9.3.5, Bleeding the reel cylinders.

298 672.0 - BA DO 208 / 204 MEGA

7.2.5

Operation – cutterbar Reel tines A vertical setting of reel tines, or slightly forward of vertical, is best in most cases.

In badly lodged crops or very short-strawed crops the reel tines should be set backward to a grabbing position by relocating lever (B) in the perforated segment (C).

C

(Fig. 16) B

NOTE! 16

Adjusting the tines of the reel too much to the rear causes the reel to wrap.

Reel drive Changing speed ranges of reel: 6.00 m – 9.00 m cutterbars By means of double sprocket (D) two speed ranges can be obtained.

14 teeth sprocket = 12 – 47 rpm 17 teeth sprocket = 15 – 57 rpm

D

(Fig. 17) 17 Safety features: The reel is fitted with a slip clutch (R) which protects it from damage through overloading.

Never tighten the slip clutch to such an extent that it becomes blocked and thereby fails to function as a safety device.

R

(Fig. 18)

18

7.2.6

BA DO 208 / 204 MEGA - 298 672.0

Operation – cutterbar Fore and aft reel adjustment (mechanical)

N

To adjust the reel forward or backward remove the pins (N) and block the spring-loaded cylinder (E).

E

After the reel has been moved to the desired position, reinstall pins (N) and unlock the spring-loaded cylinder (E).

The reel drive chain (K) is automatically tensioned by spring-loaded cylinder (E).

K

(Fig. 19, 20) 19

N

20 Fore and aft reel adjustment (hydraulic) The reel can be adjusted forward and backward via the two horizontally fitted double-acting hydraulic cylinders (H) by pressing the push-buttons (5 and 6) on the multifunction handle.

H

(Fig. 21, 22)

21 Adjusting the reel: 5

5 = Reel forward 6 = Reel backward

6

(Fig. 22)

22

298 672.0 - BA DO 208 / 204 MEGA

7.2.7

Operation – cutterbar Reel variable speed drive Reel speed is infinitely variable from the operator’s platform by way of electric motor (M) and variable speed drive (V).

V

Operate the reel variator only when the cutterbar is running.

(Fig. 23) M

23 Adjusting the reel speed: Switch on master rocker switch (65) after releasing its lock.

The reel speed can be varied by pressing rocker switch (60).

(Fig. 24)

65

60

24

Main table auger F

S

Adjust clearance to cutterbar trough Basic setting of auger is with a gap of approx. 15 mm between auger flights (S) and bottom of cutterbar trough.

When thick swaths have to be picked up, the main table auger should be raised to avoid overloading the table auger. If the crop is bulky, raise the main table auger to reduce the amount of broken straw.

S F 25

The auger flights (S) move the material to the middle of the cutterbar where the retractable fingers (F) feed the crop under the auger to the feed rake.

Replace damaged fingers immediately.

The basic setting of the table auger can be adjusted at adjusting screws (C) on the left-hand and right-hand sides.

C

Loosen fixing bolts (4) on both sides before making the adjustment.

4

After adjusting the auger, retighten all screws and bolts securely.

4

(Fig. 25, 26)

3 B

7.2.8

26

BA DO 208 / 204 MEGA - 298 672.0

Operation – cutterbar Adjusting position of auger fingers The position of the auger fingers (F) is adjusted with lever (B) after removing bolt (3).

After adjusting the fingers, retighten the bolt securely.

(Fig. 25, 26) Cutterbar with Multi-finger auger: Position lever (B) in the 2nd hole from the bottom.

Cutterbar without Multi-finger auger: Position lever (B) in the 4th hole from the bottom.

(Fig. 25, 26)

Adjusting the stripper plates Adjust stripper plates (L) as close as possible to the auger, on both sides. Also adjust the stripper plates whenever the auger has been adjusted up or down.

(Fig. 27) L

27 Safety features: The main table auger is fitted with a slip clutch (R) which protects it from damage through overloading.

R

(Fig. 28) Never tighten the slip clutch to such an extent that it becomes blocked and thereby fails to function as a safety device.

For the slip clutch torque – see page 5.4.1, Safety features.

28

298 672.0 - BA DO 208 / 204 MEGA

7.2.9

Operation – cutterbar Replacing knife sections in the field DANGER! Switch off the engine and turn off the battery isolating switch!

Using special tool (S), the knife sections can be riveted on with the knives installed.

S

Proceed as follows: 29

– Remove the damaged sections.

– Clean the mounting surface.

– Mount the new section in the correct position.

– Position special tool (S) with the hooks over two knife fingers.

– Insert the rivets and hold them steady using the special tool.

– Rivet on the new knife sections.

The special tool (S) can be obtained from the CLAAS spare parts department.

(Fig. 29)

7.2.10

BA DO 208 / 204 MEGA - 298 672.0

8 Operation – basic machine

Operation – basic machine

Operation – basic machine FEEDER HOUSING DOMINATOR 208 MEGA

Chains Chains with serrated slats (E) move the crop to the threshing parts.

Stops in either side of the feeder housing limit the low position of the feed rake. Relocate the stops by engaging the expansion pin in the respective hole on each side of the feeder housing: hole (1) is for small grains and hole (2) is for maize.

Just loosen nut (S) to relocate the stop.

E

E

(Fig. 1, 2, 3) 1

DOMINATOR 204 MEGA

E

E

2

S 1 2

3 Safety feature: The feed rake is fitted with a slip clutch (R) which protects it from damage through overloading.

(Fig. 4) Never tighten the slip clutch to such an extent that it becomes blocked and thereby fails to function as a safety device.

R

Torque of the slip clutch – see page 5.4.1, Safety features.

4

298 672.0 - BA DO 208 / 204 MEGA

8.1.1

Operation – basic machine Cutterbar reverse drive By pressing rocker switch (63) the main table auger, reel and feed rake run in reverse. The cutterbar drive must be disengaged and safety rocker switch (65) turned on. The crop is ejected to the front in order to remove blockages.

E

Just operate the electric motor (E) briefly by means of rocker switch (63) and never any longer than 10 seconds.

5

The starter cable for the reverser motor is routed via relay and switch of cutterbar drive to the switch console.

This is to assure that the reverser can only be engaged with the engine running and cutterbar drive shut off.

ATTENTION! Before engaging the reverser unit, all movement of the feed rake and cutterbar drive mechanisms must have stopped.

63

65 6

Lower the reel to its deepest position. This prevents material building up at the main table auger.

(Fig. 5, 6) When the reel is adjusted all the way to the rear, lift the reel somewhat to prevent the reel tines from fouling the main table auger.

8.1.2

BA DO 208 / 204 MEGA - 298 672.0

Operation – basic machine

1

CLAAS Auto Contour Automatic cutting height control and lateral levelling system

2

How the system works:

7

Select the desired cutting height, up to approx.

150 mm, with potentiometer knob (53).

8

Pushing button (8) on the multi-function lever once engages the Auto Contour system.

7

The cutterbar automatically floats vertically (in the direction of travel) and tilts sideways to follow ground contours. If the value selected with potentiometer (53) is exceeded or not reached, sensors (S) on the left-hand end and on the right-hand end of the cutterbar will transmit the deviations to the electronic system. The electronic controls energize the appropriate solenoid valves. The hydraulic system then adjusts the cutterbar to the correct position.

When the sensors have reached the pre-set point, the electronic controls deenergize the solenoid valves.

Where cutting height exceeds approx. 150 mm, sensing bands (T) under the cutterbar do not have proper contact to the ground which results in less accurate controls.

L

8

S

Pressing push buttons (1, cutterbar up) or push button (2, cutterbar down) disengages the Auto Contour System.

T 9

C

40265

In laid crops the driver should adjust the control system to run the cutterbar with its skids on the ground.

The pressure exerted by the cutterbar on the ground can be pre-set and will then be controlled by the sensor on the right-hand cutterbar cylinder. The cutterbar's ground pressure can also be adjusted during operation with potentiometer (53). Ground pressure rate is indicated by gauge (22) on the operations display screen. The sensors on the ends of the cutterbar are only for lateral levelling of the cutterbar.

(Fig. 7, 8, 9, 10, 11)

D

52

298 672.0 - BA DO 208 / 204 MEGA

53

10

8.1.3

Operation – basic machine

NOTE! The figures 0 – 10 on the selector potentiometers (52 and 53) and indicators (21 and 22) do not stand for measurement units but are for reference when selecting the actual cutting height.

(Fig. 10, 11)

8.1.4

BA DO 208 / 204 MEGA - 298 672.0

Operation – basic machine

Operation – basic machine 23

21

20

22

S 24

24

29

30

31

32

25

26

27

28

33

34

Cutterbar automatic pre-set height (machines with Auto Contour) How the system works: Use potentiometer knob (52) to adjust for cutting heights above 150 mm.

Pushing button (7) on the multi-function lever once engages the cutterbar pre-set height controls. The electronics operate the solenoid valve until sensor (L) on the feeder housing signals that the pre-set cutterbar height has been reached. The pre-set cutterbar height control system stays on until push buttons (1 or 2) are pressed (cutterbar up / down). This disengages the cutterbar pre-set height system.

35

37

T 36

38

11 If both sensing bands are being operated, e.g. when passing ground undulations, the cutterbar is automatically raised. Pressing push button (7) lowers the cutterbar and returns it to the pre-set height position.

Once the cutterbar has reached the pre-set cutting height, the setting will be shown by indicator (21) on the operations display screen.

(Fig. 7, 8, 9, 10, 11)

When sensor bands (T) contact the ground, the cutterbar is levelled laterally with the slope by way of sensors (S).

298 672.0 - BA DO 208 / 204 MEGA

8.1.5

Operation – basic machine

Operation – basic machine Adjusting the cutterbar floatation springs NOTE! The cutterbar floatation springs have been set at the factory – see page 6.5.1, Attaching the cutterbar hydraulic cylinders.

W

E Attach the cutterbar.

12

Lower the cutterbar until the skids are approx. 100 mm above the ground. Check for a distance (Y) of 5 mm between the cylinder plates and the nuts.

Adjust the floatation springs (E) to the correct load, if necessary. To do this turn Allen screws (W) in or out as required until there is a distance (Y) of 5 mm between the cylinder plates and the nuts.

Adjusting screws (W): Turn the screws in to increase the clearance.

Turn the screws out to decrease the clearance.

(Fig. 12, 13)

Checking the cutterbar floatation springs and checking the feeder house suspension for smooth movement Lower the cutterbar with Auto-Contour or Contour system deactivated until the skids are approx. 100 mm from the ground. Distance (Y) between the cylinder plates and spacer tubes (D) should now be 5 mm.

W

If this clearance is not obtained, adjust floatation springs (E) to the correct load by turning Allen screws (W) in or out as required.

Y 13

Then raise the cutterbar as far as possible by hand and let it go again.

The cutterbar must settle at the previously adjusted height setting. If not, use lubricant to remove any frictional resistance that may exist at the mounting points of the feeder housing and cutterbar cylinders.

(Fig. 12, 13)

8.1.6

BA DO 208 / 204 MEGA - 298 672.0

Operation – basic machine Setting the cutting height indicator Sender (G) for the cutting height indicator is located on the right-hand side of the feeder housing.

B Q G

Lower the cutterbar until the skids are approx.

100 mm above the ground. Loosen mounting bolts (B) and adjust sender (G) to position the pointer of indicator (21) halfway between the 1st and 2nd graduation mark on the scale.

1

2

14

Test for correct setting: Lower the cutterbar until the cutterbar skids just contact the ground. The pointer of cutting height indicator (21) must now be positioned a breadth of the pointer above the «0». Retighten the mounting bolts after carrying out the adjustment.

(Fig. 11, 14)

For work with maize picker head: Set stop (Q) to position (2).

(Fig. 14)

For work with grain cutterbar: Set stop (Q) to position (1).

(Fig. 14)

Cutterbar spring pressure indicator Sensor (S) on the right-hand cutterbar cylinder cannot be adjusted.

When combining, lower the cutterbar with the hydraulics so that the pointer of indicator (22) indicates in the upper range of the scale at «9 – 10».

S

ATTENTION!

15

The more the pointer moves toward «0», the more ground pressure is exerted by the cutterbar.

High ground pressure causes excessive wear of cutterbar skids.

(Fig. 11, 15)

298 672.0 - BA DO 208 / 204 MEGA

8.1.7

Operation – basic machine Adjusting the cutterbar drop rate The rate of drop of the cutterbar can be adjusted at the drop rate restrictor at (V) on the 3/3 way solenoid control valve.

Adjust the drop rate restrictor so that the fully raised cutterbar drops to the ground in approx.

5 to 6 seconds. The hydraulic oil must be at operating temperature.

V

To carry out the adjustment loosen the lock nut.

16

Turn in the adjusting screw if the cutterbar is to drop slower.

Turn out the adjusting screw if the cutterbar is to drop faster.

Retighten the lock nut after the adjustment has been carried out.

(Fig. 16)

8.1.8

BA DO 208 / 204 MEGA - 298 672.0

Operation – basic machine Putting the CLAAS Auto Contour System into operation Start the engine, engage threshing mechanism and cutterbar. Switch on safety rocker switch (65) and rocker switch (54).

54

55

65 17

C C

If this is the initial operation, first raise the cutterbar to full height, leave it raised for 30 seconds and then lower the cutterbar so that it rests on the ground and leave in that position for 30 seconds. This makes the system register the extreme positions of the cutterbar and the CLAAS Auto Contour System is ready for operation.

Select the desired cutting height (max. 150 mm) by turning knob (53).

D D

Press push button (8) once. Indicator light (D) comes on. The cutterbar raises or lowers to the pre-set cutting height (the cutterbar goes up if it is below the pre-set height and drops if it is above the pre-set height).

Cutting height is indicated by indicator (21) on the operations display screen as soon the cutterbar has reached the pre-set height.

Cutting height can always be varied by adjusting potentiometer knob (53).

52 52

40265

53 53

18

(Fig. 11, 17, 18) Raising the cutterbar:

1

Press push button (1). The cutterbar lifts and, at the same time, Auto Contour is switched off.

2

Lowering the cutterbar and re-engaging Auto Contour:

7

Pressing push button (8) once re-engages the Auto Contour System and drops the cutterbar to the cutting height previously selected with potentiometer knob (53).

8

NOTE! 19

If required, the cutterbar can at any time be tilted sideways with the hand-controlled rocker switch (55).

DANGER! Always switch off safety rocker switch (65) before moving the combine on the road.

(Fig. 11, 17, 18, 19)

298 672.0 - BA DO 208 / 204 MEGA

8.1.9

Operation – basic machine Operation with maize picker head The CLAAS Auto Contour System must be switched off when operating the machine with a maize picker head.

Move the CLAAS Auto Contour ON / OFF rocker (54) to the off position.

(Fig. 20)

54

65 20 Programming the CLAAS Auto Contour System 1

NOTE!

2

The electronic system is programmed at the factory. The standard programme is realized with potentiometer (53) set to «5».

After replacement or repair of the electronic system, the unit needs not be reprogrammed.

21

C C

D D

However, it must «learn» the upper and lower limits of the cutterbar again. To do this proceed as follows: Start the engine. Switch on the safety rocker switch and the CLAAS Auto Contour master switch. The threshing mechanism and cutterbar switch stay in OFF position.

Raise the cutterbar to full height and wait for approx.

30 seconds. Then lower the cutterbar until the tension is relieved from the cutterbar float springs and wait for approx. 30 seconds too. There is no need to keep push buttons (1 and 2) pressed during that time.

40265

8.1.10

52 52

53 53

To obtain proper function, it is essential to adjust the cutterbar floatation springs and the cutterbar drop rate correctly.

22

(Fig. 21, 22)

BA DO 208 / 204 MEGA - 298 672.0

Operation – basic machine Programming the system with, for instance, potentiometer (53) set to «1» (modifying the standard programme) Set potentiometer (53) according to the chart.

Start engine and let it slow idle.

Switch on safety rocker switch (65) and rocker switch (54). Engage the threshing mechanism and cutterbar.

Press push button switches (1, cutterbar UP) and (2, cutterbar DOWN) both at the same time and for at least 3 seconds until both indicator lights (C and D) flash.

Operate push button (2) and lower the cutterbar until all load is removed from the cutterbar springs and wait for approx. 30 seconds.

Operate push button (1) and lift the cutterbar as far as it will go and wait for approx. 30 seconds.

When this sequence of operations has been programmed into the Auto Contour System the cutting height can be pre-selected up to a maximum height of 150 mm. After programming the system, cutterbar operation will be smoother.

(Fig. 21, 22, 23)

Setting chart for automatic cutting height control Application

Programming indicator (potentiometer 53)

Resultant tendencies on functions positive

LEDs showing

negative

Standard

5

blink at the same time

Standing grain

5 to 8.5

max. cutting height up to 150 mm

Oscillating up and down Sensitivity Ground pressure

blink at the same time

Laid grain crops

0 to 5

Sensitivity Ground pressure Oscillating up and down

max. cutting height below 150 mm

blink at the same time

Soybean cutterbar

8.5 to 10

More sensitive lateral levelling

blink alternately

The controls operate more steadily when the distance between the adjustable skids and the ground is not too great.

When the cutterbar bulldozes (especially when large tyres are fitted), set the adjustable skids lower down.

This provides for better control of ground pressure.

298 672.0 - BA DO 208 / 204 MEGA

8.1.11

Operation – basic machine Putting the cutterbar automatic pre-set height system into operation (machines with Auto Contour) Start the engine, engage threshing mechanism and cutterbar.

Switch on safety rocker switch (65) and rocker switch (54).

54

65 23

C C

D D

Use potentiometer knob (52) to adjust for cutting heights above 150 mm. Momentarily press button (7).

Indicator light (C) shows and the cutterbar is lowered or raised to the pre-set cutting height (the cutterbar goes up if it is below the pre-set height and drops if it is above the pre-set height).

Cutting height is shown by indicator (21) on the operations display screen, as soon the cutterbar has reached the pre-set height. Cutting height can always be varied by adjusting potentiometer knob (52).

(Fig. 11, 23, 24, 26)

40265

52 52

53 53

24

NOTE! With potentiometer knob (52) set to «0» and with cutterbar in lowest position, the cutting height should not be less than 150 mm.

If required, adjust sensor (L) on the feeder housing accordingly.

L (Fig. 24, 25) 25 Raising the cutterbar: Press push button (1). The cutterbar lifts and, at the same time, cutterbar pre-set height control is switched off.

(Fig. 21)

8.1.12

BA DO 208 / 204 MEGA - 298 672.0

Operation – basic machine Lowering the cutterbar and engaging the cutterbar pre-set height control: 1

Pressing push button (7) once engages the cutterbar pre-set height control and adjusts the cutterbar to pre-set height.

2 7

NOTE!

26

If either of buttons (1 and 2) is operated, the cutterbar preset height will always be switched off and can only be switched on again by momentarily pressing button (7).

(Fig. 26)

CLAAS Contour System (ground pressure control) How the systems works: The Contour System automatically adjusts the cutterbar up and down for optimum ground pressure of the cutterbar in undulating conditions.

This minimizes pick-up losses and drastically reduces wear on skids, crop lifters and finger bar.

Carry out and take notice of the following adjustments, described in the information for the Auto Contour System: 1. Setting the cutterbar floatation springs 2. Checking cutterbar floatation springs and checking feeder house suspension for smooth movement 3. Setting the cutting height indicator 4. Cutterbar spring pressure indicator 5. Adjusting the cutterbar drop rate

298 672.0 - BA DO 208 / 204 MEGA

8.1.13

Operation – basic machine Setting the cutterbar ground pressure S

M

This operation should be carried out with the machine in the field.

K

The weight exerted by the cutterbar on the ground can be adjusted by means of the cam track (S) on the control box of the Contour System to match ground conditions.

T

To adjust the basic setting, slacken the lock nut (K) and turn nut (M) in or out as required.

27

Clockwise = high ground pressure Anti-clockwise = low ground pressure Retighten the lock nut securely after adjusting the ground pressure setting.

ATTENTION! The cam track (S) must not touch the cutterbar floatation spring. If necessary, bend the control box (T) up a small distance to move it out of the way.

(Fig. 27)

Putting the CLAAS Contour System into operation Start the engine. Engage the threshing mechanism and cutterbar drive. Switch on the safety rocker switch (65) and master rocker switch (64). Press the push button (8) on the multifunction lever. The cutterbar will now lower automatically until it makes contact with the ground or it will go up, depending on its position.

54

64

The cutterbar glides at optimum ground pressure over the ground and adjusts automatically to changing ground contours.

65 28

The Contour System can be switched on or off in any cutterbar position. Changing from Contour to pre-set height control is also possible with the cutterbar in any position.

(Fig. 28)

8.1.14

BA DO 208 / 204 MEGA - 298 672.0

Operation – basic machine Raising the cutterbar: Press button (1). The cutterbar rises and the Contour System is switched off at the same time.

1 2

Lowering the cutterbar and re-engaging the Contour System:

7

Press button (8) once. The Contour System is re-engaged and the cutterbar drops automatically to the predetermined ground pressure setting.

8

NOTE! 29

If either of buttons (1 and 2) is operated, the Contour System will always be switched off and can only be re-engaged by pressing button (8).

(Fig. 29)

DANGER! Always switch off and lock safety rocker switch (65) before moving the machine on the road.

(Fig. 28)

DANGER!

C

Machines fitted with a maize picker head must have the Contour System switched off.

☞ To prevent unintended use of the Contour System, disconnect the cable (C) leading to the switch mounted on the left-hand cutterbar cylinder (Fig. 30). .

30

298 672.0 - BA DO 208 / 204 MEGA

8.1.15

Operation – basic machine CLAAS cutterbar pre-set height Putting the cutterbar pre-set height system into operation Switch on engine, safety rocker switch (65) and master rocker switch (64) for Contour system.

Engage threshing mechanism and cutterbar.

64

65 31

C C

Use potentiometer knob (52) to adjust for cutting heights above 150 mm. Momentarily press button (7).

Indicator light (C) shows and the cutterbar is lowered or raised to the pre-set cutting height (the cutterbar goes up if it is below the pre-set height and drops if it is above the pre-set height).

Cutting height is shown by indicator (21) on the operations display screen as soon as the cutterbar has reached the pre-set height. Cutting height can always be varied by adjusting potentiometer knob (52).

D D

(Fig. 11, 29, 31, 32)

NOTE! 52

52

40265

53 53

32

With potentiometer knob (52) set to «0», the cutting height should be not less than 150 mm when the cutterbar is fully lowered.

If required, adjust sensor (L) on the feeder housing accordingly.

(Fig. 25, 32)

Cutterbar adjusting range Cutting height adjustment range: The cutterbar can be hydraulically lowered below 0 (dimension A) and raised above 0 (dimension B) – see table.

B

(Fig. 33) A H 33

8.1.16

BA DO 208 / 204 MEGA - 298 672.0

Operation – basic machine Clearance height Clearance height (H) under the cutterbar skid with cutterbar fully raised – see table. *

Depending on the make of tyre, clearance height may be up to 50 mm less.

*

Dimensions may also be different with the various sizes of cutterbars.

(Fig. 33)

Cutterbar adjusting range without Auto Contour Front axle tyre sizes

Rear axle tyre sizes

Cutting height range with floatation springs in use

Cutting height range with floatation springs blocked

Dimension A mm

Dimension B mm

Dimension A mm

Dimension B mm

23.1 R 30 161 A8

500/60-22.5 8 PR

- 492*

+ 1203**

- 260*

+ 1435**

24.5-32

16 PR

500/60-22.5

- 430*

+ 1339**

- 275*

+ 1500**

24.5-32

12 PR

14.9/80-24 12 PR

- 471*

+ 1294**

- 306*

+ 1459**

24.5 R 32 167 A8

14.9/80-24 12 PR

- 471*

+ 1294**

- 306*

+ 1459**

30.5 R 32 167 A8

14.9/80-24 12 PR

- 471*

+ 1294**

- 306*

+ 1459**

* With Auto Contour -42 mm / **With Auto Contour +42 mm

Clearance height to underside of cutterbar skid Front axle tyre sizes

Rear axle tyre sizes

Clearance height to underside of cutterbar skid, dimension H*/mm with Auto Contour

Clearance height to underside of cutterbar skid, dimension H*/mm without Auto Contour

with cutterbar floatation springs in use

with cutterbar floatation springs blocked

with cutterbar floatation springs in use

with cutterbar floatation springs blocked

23.1 R 30 161 A8

500/60-22.5 8 PR

906

1138

864

1096

24.5-32

16 PR

500/60-22.5

1110

1175

996

1161

24.5-32

12 PR

14.9/80-24 12 PR

997

1162

955

1120

24.5 R 32 167 A8

14.9/80-24 12 PR

997

1162

955

1120

30.5 R 32 167 A8

14.9/80-24 12 PR

997

1162

955

1120

298 672.0 - BA DO 208 / 204 MEGA

8.1.17

Operation – basic machine Cutterbar clutch DANGER! Before working in or at the cutterbar unit, always disengage the cutterbar drive, stop the engine and withdraw the ignition key (main switch key).

Cutterbar Quick Stop: In the event that foreign matter enters the cutterbar, the cutterbar and all feed components can be instantly stopped.

Engaging and disengaging the cutterbar

46

Engaging the cutterbar: Switch on the safety rocker switch (65). Start the engine and engage the threshing mechanism. Run the engine at full idling speed.

Then engage the cutterbar by pressing push-button (46).

(Fig. 34)

65

34 Disengaging the cutterbar:

S

The cutterbar is thrown out by pressing the foot-operated switch (D).

The cutterbar can only be re-engaged by pressing push-button (46).

(Fig. 34, 35)

D 35

8.1.18

BA DO 208 / 204 MEGA - 298 672.0

Operation – basic machine

Operation – basic machine THRESHING MECHANISM DANGER! Repair, service and cleaning work and the elimination of malfunctions should only be performed with the drive disengaged and the engine switched off. Remove the ignition key (main switch key).

Stone trap DANGER! M The attached cutterbar must be supported securely before any work is undertaken beneath it.

A stone trap (M) at the front of the concave is a safeguard against stones and other foreign objects damaging the threshing parts.

1

Raise the cutterbar to maximum height, unlock cover (K) by twisting the locking pins (R) and take cover out to the front.

K R

Clean the stone trap daily. When working in fields which are stony and when threshing lodged grain, the stone trap should be cleaned at shorter intervals.

(Fig. 1, 2)

R

2

Engaging and disengaging the threshing mechanism The threshing drive power band is engaged by an idler pulley. Power is transmitted from the engine output pulley to the threshing mechanism.

ATTENTION! Engage and disengage the threshing mechanism with the engine slow idling.

298 672.0 - BA DO 208 / 204 MEGA

8.2.1

Operation – basic machine Engaging the threshing mechanism:

45

Start the engine and switch on safety rocker switch (65). Turn switch (45) clockwise to unlock and release it. The threshing mechanism is then engaged by means of a solenoid valve and the low-pressure hydraulic system.

(Fig. 3)

65 3 Disengaging the threshing mechanism: Disengage by depressing the switch (45).

45

(Fig. 4)

4

Concave adjustment Using the concave lever (H), the preconcave-toaccelerator and main concave-to-threshing drum clearances can be adjusted simultaneously.

H

Moving lever (H) down increases the concave clearance.

3.

Moving lever (H) up decreases the concave clearance.

(Fig. 5) 5 Basic setting:

HA

S

Let lever (H) catch in the third hole from the top.

Set the basic setting of preconcave and main concave on both sides at the turnbuckles (S).

VE HE

VE = Preconcave front HE = Main concave front HA = Main concave rear

S

6

8.2.2

BA DO 208 / 204 MEGA - 298 672.0

Operation – basic machine To adjust the lock nuts, loosen the turnbuckle nuts on both sides. Tighten the lock nuts when the adjustment is complete. For measuring bars of concaves and settings see «Concave settings».

(Fig. 5, 6) NOTE! Check the basic concave setting approx.

50 operating hours after initial operation and each time after installing the threshing concave, correct if necessary.

Concave settings

Basic setting is shown shaded

H

HA VE 3.

4.

HE

Position

Grain preconcave

Maize preconcave

Adjusting lever

Front

Front

Front

VE

HE

H

HE

VE

VE th

rd

Main concave 20 x 42 Rear

Rice preconcave

4 bar

3 bar

3rd bar

1

11

10

10

10

2

13

12

12

3

15

14

4

17

5

Front

VE 2

nd

bar

Rear

HE st

HA rd

1 spike tooth bar

3 last rear bar

10

9

7

11

12

10

8

14

12

13

11

9

16

16

14

15

13

11

20

19

19

16

18

15

13

6

23

22

22

18

21

17

15

7

26

25

25

21

24

19

17

8

29

28

28

24

27

22

20

9

32

31

31

27

30

24

23

10

36

35

35

30

33

27

26

11

39

38

38

33

37

30

30

12

43

42

42

36

40

33

34

13

47

46

46

40

44

36

38

14

51

50

50

44

48

39

42

15

56

56

56

48

51

42

46

298 672.0 - BA DO 208 / 204 MEGA

last bar

Spike tooth concave

Front

HA 3rd

HA

8.2.3

Operation – basic machine Threshing drum The drum can only work efficiently when the rasp bars are straight and not too worn.

The drum was balanced at the factory.

Therefore, when replacing the rasp bars, always fit bars of the same weight and have the drum rebalanced.

The rasp bars must fit tightly into the drum plates.

ATTENTION! Retighten the securing bolts after the first 10 hours of work.

Drum repairs should only be carried out by trained expert personnel.

Cleaning dirty threshing parts When working in green and damp crops the drum, the concave, the space behind the concave and the front of the preparation floor will quickly become clogged with dirt.

Then the separation through the concave is lessened, the straw walkers are overloaded, the drum gets unbalanced and the sieves are unevenly fed.

S

To ensure trouble-free operation of the combine, it is essential to check these parts regularly for dirt.

7

The rasp bars should be kept equally clean to prevent the drum becoming unbalanced.

Large inspection holes (S) facilitate checking and cleaning, once the doors have been removed.

(Fig. 7)

8.2.4

BA DO 208 / 204 MEGA - 298 672.0

Operation – basic machine Threshing drum speed On-the-go variation of drum speed combined with concave adjustments which can be carried out from the platform, allow quick changes of threshing operations in order to match crop conditions. Damp, long-strawed crops as well as crops difficult to thresh and disawn require faster drum speeds than dry and brittle crops.

Drive with intermediate drive: The threshing drum is driven by the impeller shaft via the hydraulically adjustable variable speed pulley (1), the wide-section V-belt (2), the spring-loaded variable speed pulley (3), the power band belt (4) and the V-belt pulley (5).

1 2

5

3

(Fig. 8) The threshing drum speed can be varied from 650 to 1500 rpm by means of the continuously adjustable variable-speed drive.

4 8

For special applications, a threshing drum variablespeed drive with a speed range of 500 to 1200 rpm may be used.

Drive without intermediate drive: The threshing drum is driven by the impeller via the hydraulically adjustable variable speed pulley (1), the wide-section V-belt (2) and the spring-loaded variable speed pulley (3).

1

(Fig. 9) The threshing drum speed can be varied from 650 to 1500 rpm by means of the continuously adjustable variable-speed drive.

2 3 9

For special applications, a threshing drum variablespeed drive with a speed range of 500 to 1200 rpm may be used.

The accelerator is driven by the threshing drum via V-belt pulley (6), power band belt (7) and V-belt pulley (8).

(Fig. 10) 1 6

8 7

10

298 672.0 - BA DO 208 / 204 MEGA

8.2.5

Operation – basic machine Adjusting the threshing drum speed Machines with hydrostatic ground drive:

B

Only adjust the threshing drum speed with threshing mechanism engaged and running.

Operate lever (H) in direction (A) to increase drum speed.

H

Operate lever (H) in direction (B) to reduce drum speed.

A

(Fig. 11) 11 Threshing drum speed display With engine running and threshing mechanism engaged, threshing drum speed is shown on display (20), when rocker switch (59) is in the OFF position and locked.

20

(Fig. 12)

59 12 Threshing drum two-step variable speed drive To thresh delicate crops it is possible, through the two step variable speed drive, to adjust drum speed in two separate ranges.

First step = 280 to 650 rpm Second step = 650 to1500 rpm

Speed range adjustment: B

First step: Bolt bridge piece (D) at (B) to support (S) by means of two tapered bolts.

A

Second step: Bolt bridge piece (D) to variable drive (A) with the two tapered bolts.

D A

S

(Fig. 13)

B

13

8.2.6

BA DO 208 / 204 MEGA - 298 672.0

Operation – basic machine Preconcave Removing the concave segments: DANGER! Shut down the engine and remove ignition key!

Unscrew the concave segment fastening screws (K).

Lift the segments at the front and remove.

NOTE! K

Always remove the centre segment first when removing segments.

After this, push the outer segments slightly towards the centre and remove.

14

The reverse order applies to installation.

Tighten the mounting bolts firmly.

(Fig. 14, 15)

T

15 The concave segments may also be removed and installed with the feed rake installed. To this end, remove the drum inspection cover (T).

(Fig. 15, 16)

16

298 672.0 - BA DO 208 / 204 MEGA

8.2.7

Operation – basic machine

S D

17

Disawning Disawner plates are provided under the preconcave which may be activated in two steps if needed to improve disawning results.

DANGER!

V

U

Actuate disawner plates with the engine shut down only!

1 2

V = Disawner plate deactivated U = Disawner plate activated First activate the front disawner plate using lever (1).

18

In case of insufficient disawning, the rear disawner plate may additionally be activated using lever (2).

(Fig. 17, 18)

8.2.8

BA DO 208 / 204 MEGA - 298 672.0

Operation – basic machine Threshing segment With crops which are difficult to thresh, a threshing segment (D) may be installed between the preconcave and the main concave.

With maize and various leguminous plants, the segment must be removed.

CAUTION! The hexagon bolts (S) must be bolted back into the threshing concave immediately after removing the segment. Otherwise the thread bores will plug.

(Fig. 17)

298 672.0 - BA DO 208 / 204 MEGA

8.2.9

Operation – basic machine Unslugging the threshing drum DANGER! Always switch off the engine and remove the ignition key and allow the mechanisms to stop before attempting to clear a wrapped-up threshing drum.

U

Unslug the threshing drum as follows: 19

– Shut down threshing mechanism.

– Switch off the engine and remove ignition key.

– Fully open the threshing concave.

– Remove guard (U) on the left-hand side.

M

– Fit the drum turning disc (E) in two holes of the Vbelt pulley (M). The lever position of the drum turning disc may be varied by re-locating the plug (S). See also figure 21.

E

– Using a suitable lever (flat bar, tube or the like), rotate the threshing drum opposite its direction of rotation via the perforated bar (L). The straw can be cleared through the open drum access door.

S L 20

DANGER! When removing the straw through the drum access door, care must be taken to prevent accidental rotation of the drum by any other person working on the machine – Beware of personal injury!

– Remove drum turning disc.

– Start the engine and let run at lower idle speed.

21

– Shut off cutterbar and engage threshing mechanism.

– Shut off threshing mechanism and stop the engine.

– Re-fit guard (U). Move threshing concave back to the desired position.

(Fig. 19, 20, 21)

8.2.10

BA DO 208 / 204 MEGA - 298 672.0

Operation – basic machine Impeller 1

The impeller (1) slows the movement of straw coming from the drum (2) and guides it over the transition plate (3) onto the front of the straw walkers. Thus the full length and width of straw walkers is used.

2

(Fig. 22) 3

22

Deflector curtain A deflector curtain (S) behind the impeller holds back any bouncing grains and deflects the kernels down onto the front of the straw walkers.

The curtain is vertically adjustable. If the curtain is worn or adjusted too high, the kernels are thrown onto the rear end of the straw walkers and cannot be separated before the straw falls to the ground.

S

After a long period of service check that the curtain is in good condition and replace it if necessary.

23

1 H

(Fig. 23)

On the right-hand side of the machine the deflector curtain can be vertically adjusted by means of lever (H), chain (K) and arrester bracket (1).

2

Raise the curtain in heavy, long-strawed crops and where a lot of green-stuff is encountered.

K

It is essential to lower the curtain again in shortstrawed light crops.

By means of arrester bracket (2) the deflector curtain can be locked so that it is rigid in one place and does not move backwards (e.g. for threshing maize).

24

298 672.0 - BA DO 208 / 204 MEGA

(Fig. 24)

8.2.11

Operation – basic machine

8.2.12

BA DO 208 / 204 MEGA - 298 672.0

Operation – basic machine

Operation – basic machine STRAW WALKERS AND CLEANING DANGER! Repair, service and cleaning work and the elimination of malfunctions should only be performed with the drives disengaged and the engine switched off. Remove the ignition key (main switch key)!

Straw walkers The straw walkers separate the remaining grain from the straw and convey the straw to the rear hood.

The under-walker troughs and return pan convey the grain separated by the walkers to the preparation floor.

T T

T

T

T

The under-walker pockets (T) can be cleaned through the raised back of the rear hood.

(Fig. 1)

1 Intensive separation system

Z

Z Z

Tines (Z) increase the agitation of straw on the straw walkers and speed up the travel of straw over the walkers. That way, the separating action of the straw walkers is greatly increased.

Z

The tine crankshafts are driven by way of V-belt (K).

The drive is taken from straw walker drive pulley (S).

Z

(Fig. 2, 3)

2

K

S 3

298 672.0 - BA DO 208 / 204 MEGA

8.3.1

Operation – basic machine Cleaning the straw walkers DANGER! Switch off the engine and remove the ignition key before working on the straw walkers.

Make sure that others cannot start the machine.

E

4

When working in damp and weedy crops, inspect the straw walkers frequently. Clean straw walkers if required.

The straw walker area is accessible via hatch (E) on the combine roof and in the grain tank via hatch (K).

(Fig. 4, 5)

K

5 Straw walker risers P

S

A = DOMINATOR 208 MEGA B = DOMINATOR 204 MEGA

F

D R P S N F

1.

2.

= = = = = =

Lateral riser Rice riser (also for grain) Parallel riser Top riser Top riser during straw walker lowering Direction of travel

1 – 4 = Straw walker steps (Fig. 6, 7)

D

R

3.

4.

B A

B A 6

8.3.2

BA DO 208 / 204 MEGA - 298 672.0

Operation – basic machine

D

R

R

D

R

R

S N

P 7

For a more intensive shaking effect, particularly with wet and heavy straw, risers can be installed on the straw walker racks.

The risers must be installed as shown in Fig. 6.

The risers can also be installed in combination to achieve an even better tumbling action.

If required, parallel risers (P) can be fitted to the follow-up steps of the straw walkers.

(Fig. 7) ATTENTION! Ensure that the agitator tines of the intensive separation system can move freely.

298 672.0 - BA DO 208 / 204 MEGA

8.3.3

Operation – basic machine Warning signal If for any reason whatever straw piles up on the straw walkers, flap (K) releases the warning signal on the operator's platform.

K

The «STOP» lamp in the combine operations display screen and the respective function lamp will come on at the same time.

Stop combine immediately to remedy the trouble.

(Fig. 8) 8 The same warning signal may be released by engine overheating, since it also controls the engine cooling system – see page 6.2.10, Vehicle information unit.

Sieve pan 1

1 2 3 4

1

2

(Fig. 9)

2

3

Preparation floor Wire rake on preparation floor Ventilated straw walker step Wire rake on ventilated straw walker step

3 4

4

9

5 6 7

5 Upper frogmouth sieve (grain pass-through area) 6 Upper frogmouth sieve (returns pass-through area) 7 Upper frogmouth sieve adjustment lever (grain pass-through area) 8 Upper frogmouth sieve adjustment lever (returns pass-through area) 9 Lower frogmouth sieve adjusting lever

5 6

8

9

7

8

(Fig. 10)

9 10

8.3.4

BA DO 208 / 204 MEGA - 298 672.0

Operation – basic machine Preparation floor Both the mixture of chaff-grain-broken straw from the concave and that from the straw walkers pour onto the preparation floor (1). The mixture is fluffed and evenly fed to the upper sieve through the shaking action of the preparation floor.

H H

S

Whenever the preparation floor becomes caked with dirt, uneven flow of the crop to the sieves results, which not only causes overloading of the sieves but also results in grain losses. Always keep preparation floor clean.

11

Remove the upper sieves, loosen the hooks (H) located underneath the preparation floor and pull the preparation floor sections out of the combine.

1

1

2

When reinstalling the preparation floor sections, be sure to clean the guide tracks and firmly secure the sections by means of the hooks.

2

3

3 4

To ease cleaning of the threshing concave and of the preparation floor, the sections (S) of the preparation floor can be taken out from the back.

4 12

The bulk of grain, when leaving the preparation floor, falls through the wire rake (2) onto the frogmouth sieve whereas coarse and heavier particles are retained somewhat longer.

Build-up of material on the wire rake is caused by bent tines which must be straightened.

3 = Ventilated straw walker step 4 = Wire rake on ventilated straw walker step (Fig. 11, 12)

Cleaning fan The cleaning fan blows all light particles out of the machine from below, and excessive «matting» of grain, chaff and broken straw on the upper sieve can be prevented by having sufficient volume of wind.

The wind blast also helps to fluff the material.

298 672.0 - BA DO 208 / 204 MEGA

8.3.5

Operation – basic machine Electrical fan speed adjustment Fan speed is infinitely variable from the driver's seat by way of electric motor (M).

(Fig. 13)

M

Fan speed must only be adjusted with the threshing mechanism running.

13 Adjusting the fan speed: Operate rocker switch (58) to adjust the fan speed. + = increase fan speed – = decrease fan speed 20

(Fig. 14)

58

59 14 Fan speed display With the engine running, threshing mechanism engaged and rocker switch (59) turned on – rocker switch unlocked – the fan speed is shown at (20) on the operations display screen.

(Fig. 14)

Setting the magnetic pick-up for the fan speed indicator: Set magnetic pick-up (J) to 1 ± 0.5 mm from cam wheel (Z).

NOTE! On combines with fieldwork computer, the gap must be 0.2 ± 0.1 mm.

Z J 15

8.3.6

(Fig. 15)

BA DO 208 / 204 MEGA - 298 672.0

Operation – basic machine Ventilated straw walker step The additional straw walker step (F) on the preparation floor allows a pre-cleaning of the grain/broken straw mixture.

The air blast which may be adjusted to the type of crop provides the pre-cleaning.

F

(Fig. 16, 18)

16 Adjusting the butterfly valve The butterfly valve (S) in the fan housing throat of the pre-cleaning unit is set to the 3rd hole in normal position for wheat, rye etc., using lever (H).

A

When harvesting heavy crops, set lever (H) in the 1st or 2nd hole. In case of lighter crops, set the lever (H) to the 4th to 7th hole, depending on the specific weight.

T F H

17

Any plugging in the fan housing throat (K) can be removed easily by moving lever (H) fully upwards to the stop (A). After this, swing lever (H) back to its initial position.

(Fig. 17, 18)

Adjusting the wind board

F

In its normal position, the wind board (L) in the fan housing throat is set to the 2nd hole from the bottom, using lever (T).

S

The clearance (X) between the fan housing throat floor plate and the wind board here is approx. 70 mm.

K L

Remove the hexagon bolt to carry out the adjustment.

Insert the hexagon bolt when the adjustment is complete.

X

(Fig. 17, 18) 18

298 672.0 - BA DO 208 / 204 MEGA

8.3.7

Operation – basic machine Sieves Adjusting the frogmouth sieves The frogmouth sieves can be adjusted with levers (5, 6 and 7) to suit all sizes of grain.

Lever (5) is used to adjust the upper frogmouth sieve over its full length, including the returns pass-through area (4).

3 4 5

5

7

7 6

6

19

Lever (6) is used to adjust only the returns pass-through area (4). Always adjust the returns pass-through area (4) wider than the grain pass-through area (3).

Lever (7) is used to adjust the lower frogmouth sieve openings.

The figures 1 to 9 on adjustment lever (7) are reference numbers only and do not indicate inch or metric measurements of the frogmouth sieve openings.

The setting is correct when the grain is screened out after passing over three quarters of the sieving area.

Adjust the returns pass-through area (4) for all crops to leave a gap wide enough to allow unthreshed material to drop through into the returns.

(Fig. 19)

Hillside riser plates (machines without 3-D cleaning system) Hillside riser plates (L) may be fitted to the divisions of the upper and lower sieves in case of major hillsides.

L

When harvesting on hillside fields, the hillside riser plates guarantee even and loose mat formation and therefore optimum use of the sieve area.

L

(Fig. 20, 21)

20 Lower sieves Flat sieves can be used instead of the lower frogmouth sieves (U) for combining special crops – see page 8.6.1, Sieve chart.

(Fig. 21) L

U

U

L

21

8.3.8

BA DO 208 / 204 MEGA - 298 672.0

Operation – basic machine Removing upper sieves Remove the side clamps (M and K) and clamp brackets (A) used to secure the sieves in axial direction on both sides. Remove the frogmouth sieves.

M

Installing upper sieves

M

M

K

K

A

After installing the frogmouth sieves, first tighten clamp brackets (A) used to hold the sieves in axial direction. Then secure the sieves with the side clamps (M and K).

K

A

A

(Fig. 22) 22 Removing lower sieves First remove the upper sieves. Loosen the sieve clamps (S) used to hold the sieves in axial direction.

Detach adjusting lever (7) and pull out the sieves.

Installing lower sieves S

S

After installing the sieves, secure with sieve clamp brackets (S) and reconnect adjusting lever (7).

Install the upper sieves.

S

(Fig. 23) 7

7

23 ATTENTION! When installing the sieves, ensure that all bolts and clamps are securely tightened!

Tightening torques of the axial bolts for the upper and lower sieves Upper sieves = 45 Nm (hex. nuts M 12) Lower sieves = 23 Nm (hexagon head bolts M 10)

298 672.0 - BA DO 208 / 204 MEGA

8.3.9

Operation – basic machine Dynamic sidehill levelling (3-D cleaning system) The 3-D-system moves the top sieve in three directions:

A

1. back and forth 2. up and down 3. sideways, «up the slope»

S B

Z 24

The 3-D design uses an additional pivot arm (A), which connects to the centre of the top sieve, on the right-hand side of the machine. As the degree of slope changes, control unit (S) sets pivot arm (A) at different angles to the top sieve by way of hydraulic cylinder (Z) and operating arm (B). As the slope gets steeper, the sideway thrust of the top sieve becomes stronger, moving the material «up the slope».

Divisions on sieves are no longer required.

(Fig. 24)

Position of machine: A = left-hand slope B = on flat level ground C = right-hand slope A

B

C

(Fig. 25)

25

Returns Coarse particles (e.g. unthreshed material) drop through the upper sieve and from the lower sieve and are then moved to the returns auger which moves the material to the returns elevator. The elevator carries the returns to the threshing drum for second threshing.

(Fig. 26)

26

8.3.10

BA DO 208 / 204 MEGA - 298 672.0

Operation – basic machine Excessive returns can have a number of reasons: 1. Incorrect setting of the threshing mechanism, concave, threshing drum speed (excessive cracked grain).

2. Sieves set too close or lower sieve holes too small.

3. Incorrect setting of the wind blast (too high or too low).

4. Ground travel speed too high.

Excessive returns cut down on efficiency and cause cracked grain and grain losses.

Inspecting the returns: DANGER! Do not reach into the returns inspection opening – Beware of personal injury!

K

Open inspection door (K). When opening the door, the light in the inspection hole comes on.

27

The amount and composition of the returns and thus the function of the cleaning system can be checked while the combine is in operation through the inspection doors.

(Fig. 27, 28) DANGER! At all times beware of sharp edges of augers.

Risk of injury!

K

28

298 672.0 - BA DO 208 / 204 MEGA

8.3.11

Operation – basic machine Combine performance monitor The electronic performance monitor allows the operator to make full use of the capacity of the combine.

As the instrument on the operator's platform indicates changes in threshing losses of grain, the operator can always drive at optimum working speed as long as grain losses do not exceed the acceptable level.

Straw walkers: Grain that is lost over the back of the combine with the straw falls through spouts (F) onto sensor (S).

(Fig. 29)

F

F

F

F

F F

S

C

29 Sieve pan: Grain losses over the sieve pan are registered by sensor (T, Fig. 30).

The impulses produced will be electronically amplified and shown by the light band in the meter.

T

The sensors extend over the full width of the machine, so that losses are also registered when the load is not evenly spread and when combining on slopes.

30

The number of lights illuminated in the meter light bands (1) for sieve pan and (2) for straw walkers depends on the number of kernels dropping on the sensors.

Straw and chaff produce only faint impulses which are sorted out by means of the amplifier and not shown by the meter light.

1

2

A

(Fig. 30, 31)

B

31

8.3.12

BA DO 208 / 204 MEGA - 298 672.0

Operation – basic machine Since the various kinds of grain have their specific properties (as shape of kernels, awns, amount of leaves on the straw etc.), a different number of grains strike the sensors although actual grain losses are the same. For this reason adjust the sensitivity of each sensor to grain type and crop conditions (damp straw, green material present etc.) with switch (A, sieve pan) and with switch (B, straw walkers). Use any of seven positions.

(Fig. 31)

While losses of grain over the straw walkers take place mostly when the combine is overloaded, sieve pan losses are mostly caused by faulty combine adjustments.

Adjusting monitor to crop type Adjust switches (A and B) for crop being harvested: Maize and beans Wheat and rye Barley Oats and light seeds

setting 1 to 2 setting about 3 setting about 6 setting about 6 setting 7

(Fig. 31)

Adjusting sensitivity of sensors Sensor sensitivity switches (C) behind the straw walkers and sieve pan have 3 positions: Position 1 = for lightweight grain Position 2 = for medium-weight grain Position 3 = for heavy grain

C

(Fig. 29, 30, 32)

1 2

3 32

298 672.0 - BA DO 208 / 204 MEGA

8.3.13

Operation – basic machine Putting the performance monitor into operation Start operation by driving at a forward speed which suits crop conditions. When after a sufficient time of operation the fourth to fifth bulb of the meter light bands (1 and 2) light up steadily, stop the combine.

Check the field losses in the swath.

– If loss is at an acceptable level, continue operation with selected setting.

– If the straw walker losses are too high, turn switch (B) to a higher position (about one half to one full setting higher).

Now adjust forward speed until the fourth or fifth bulb in the meter light bands light up again.

If the loss rate, indicated by the fourth or fifth bulb in the meter light bands is acceptable, the capacity of the combine is fully utilized at this forward speed.

The performance monitor should be adjusted as described to suit changing losses in the morning, when the crop is wet with dew, at noon, when the crop is absolutely dry and in the evening, when the crop gets gradually damp.

If the light band in the sieve pan meter indicates excessive losses of grain over the sieve pan, check the combine setting and check in particular whether any material «mats» on the sieves. Correct the problem.

When the right setting for the crop being harvested has been selected with switch (A) and when the cleaning units have been properly adjusted, one of the bulbs in the lower section of the meter will be on.

(Fig. 31)

8.3.14

BA DO 208 / 204 MEGA - 298 672.0

Operation – basic machine

Operation – basic machine GRAIN DELIVERY DANGER! Repair, service and cleaning work and the elimination of malfunctions should only be performed with the drives disengaged and the engine switched off. Remove the ignition key (main switch key)!

Augers and auger troughs Open the auger flaps (4) and clean the clean grain and returns auger when changing crops or when plugging occurs.

(Fig. 1) DANGER! At all times beware of sharp edges of augers.

Risk of injury!

4 1

Elevators Sweep elevators move up the material in the lower and, respectively, front half of the housings. Rubber paddles are used for elevating the material.

To check the chain tension, open the boot doors (A and B) of the clean grain and the returns elevators.

C

Where installed, guard (C) must be removed first.

In the event of plugging, open the auger flaps as well as the elevator boot doors (A and B).

2

Before clearing a blockage always stop the engine and wait until all mechanisms have stopped rotating. Then remove that part of grain that can be reached by hand. Thereafter allow the machine to clear all material by running the threshing mechanism.

Always ensure that the flaps and doors are correctly refitted and tightly closed.

(Fig. 2, 3)

B

DANGER!

A

At all times beware of sharp edges of augers.

Risk of injury!

3

298 672.0 - BA DO 208 / 204 MEGA

8.4.1

Operation – basic machine Grain tank DANGER! The augers located inside the grain tank cannot be shielded completely against accidental contact due to their function.

☞ Use a rod to clear blockages and a scoop or similar vessel to take grain samples – never use your hands or feet.

☞ Before entering the grain tank, be sure that the drive is disengaged and engine has been stopped. Ensure that no other person can restart the engine.

Filling the tank: The grain is carried up into the tank by way of the clean grain elevator and the centrally positioned filler auger (Z).

Z

(Fig. 4)

4 Grain tank covers Front grain tank cover: The front grain tank cover (D) can be opened with handle (S) from the steps.

D

(Fig. 5) ATTENTION! S The front grain tank cover (D) must be open during work.

5

When the grain tank is full the cover must not be closed and opened again. Otherwise the tank cover, and also the operating mechanism can become damaged.

If it is necessary to work with the tank cover closed, take care that the tank is not completely filled. If necessary set the 100% full sender to a lower position.

8.4.2

BA DO 208 / 204 MEGA - 298 672.0

Operation – basic machine Rear grain tank cover: The rear tank cover (R) can also be opened.

R

(Fig. 6) ATTENTION! Open the rear tank cover only when the front tank cover is closed.

Always close the rear grain tank cover before starting to work.

6

The front and rear grain tank covers must be closed when driving on public roads and lanes.

DOMINATOR 208 MEGA

Unloading the tank

S

The sloping bottom in the grain tank allows the grain to flow down to the horizontal cross auger (E).

On DOMINATOR 208 MEGA two additional lateral augers (S) feed the grain to the horizontal cross auger (E). The cross auger moves the grain to the left (as arrowed) and feeds it to the discharge tube auger, which then carries the grain to the transport vehicle.

B

E

S 7 DOMINATOR 204 MEGA

Plates (B) are tapered to provide a wider feed gap to the cross auger on the left-hand side than on the right-hand side. This keeps quickly flowing seeds from building up inside the discharge tube augers.

When combining poorly flowing seeds (e.g. grass seeds or similar crops) remove one or both the plates as necessary.

Z

(Fig. 7, 8)

B E

8

298 672.0 - BA DO 208 / 204 MEGA

8.4.3

Operation – basic machine Rear ladder with safety switch The rear ladder (G) is fitted with a safety switch.

When the main drive and / or the grain tank unloading drive are running and someone steps on the ladder, these drives will be switched off.

G

(Fig. 9) ATTENTION! Re-engage the drives only with the engine running at slow idling speed.

9

Grain tank discharge auger C

The discharge auger is swung in and out by hydraulic cylinder (A).

A

The valves inside the lock-up valve unit (C) prevent leak-back of oil from the hydraulic cylinder and hold the discharge tube auger in the required position.

(Fig. 10) DANGER! 10

The grain tank discharge tube swings wide!

Be sure everyone is clear of the tube while it is being moved.

The discharge tube must be swung in completely while the machine is being moved on roads and lanes.

8.4.4

BA DO 208 / 204 MEGA - 298 672.0

Operation – basic machine Swinging the grain tank discharge tube: Start the engine and turn on safety rocker switch (65).

E

A = Swinging the discharge chute out E = Swinging the discharge chute in A

61

Press the respective end of rocker switch (61). A time relay (25 seconds) swings the discharge chute into the respective end position.

65

Set rocker switch (61) to the middle position if movement of the discharge chute is to be interrupted.

11

(Fig. 11)

When the discharge tube is swung out a warning light (31), on the operations display screen illuminates.

(Fig. 12)

31 12 Grain tank discharge – engage and disengage Switch on safety rocker switch (65).

S

As soon as the warning light in the operation display screen is on, the discharge augers can be engaged by pressing down switch (F) with the foot. Switch (F) is a momentary switch so the discharge augers operate only while switch (F) is being pressed down.

F

Always engage security lock (S) before driving on public roads and lanes.

(Fig. 11, 13) 13

298 672.0 - BA DO 208 / 204 MEGA

8.4.5

Operation – basic machine Transport position: In transport position, the grain tank discharge auger rests on support (S) with bracket (H).

After loosening the bolts (2), align the height of support (S) so that the bracket (H) rests safely with the discharge auger swung in.

2

S

H

Tighten bolts (2) securely.

(Fig. 14)

14 Clean-out door on grain tank discharge tube Door (K) can be removed for cleaning the grain tank discharge tube, e.g. when changing to another certified crop.

DANGER! Before opening door (K) disengage the grain tank discharge augers, stop the engine and remove the ignition key (main switch key).

K

To avoid personal injury from rotating parts, it is essential to wait until the discharge augers and all movement have stopped before opening the clean-out-door.

15

Be especially careful when touching the discharge auger – sharp edges – danger of personal injury.

(Fig. 15)

Drive to grain tank discharge augers 1

V

DOMINATOR 208 MEGA The grain tank discharge augers are driven by way of intermediate drive shaft (V), drive shaft (A) and steel roller chains (1 and 2) positioned on the right-hand side of the machine.

2 A

(Fig. 16)

S 16

8.4.6

BA DO 208 / 204 MEGA - 298 672.0

Operation – basic machine DOMINATOR 204 MEGA V

1

The grain tank discharge augers are driven by way of intermediate drive shaft (V) and steel roller chain (1) positioned on the right-hand side of the machine.

(Fig. 17)

S

17 Shear bolt – grain tank discharge A shear bolt (S) in the sprocket driving the discharge augers protects the grain tank discharge augers from damage.

When replacing the shear bolt, assemble it from outside to inside.

(Fig. 16, 17) For specifications of shear bolt – see page 5.4.1, Safety features.

Lateral auger drive DOMINATOR 208 MEGA Power to the lateral augers (S) is taken from angle drive gearbox (W). Power to the gearbox is provided by the drive shaft.

W

(Fig. 18) S

18

298 672.0 - BA DO 208 / 204 MEGA

8.4.7

Operation – basic machine Grain tank fill indicator Two pressure switches in the grain tank operate warning lamps (34 and 37) in the operations display screen on the operator's platform, to give warning when the grain tank is full.

E L M

Pressure switch (M) lights the lamp (37) when the tank is filled to approx. 70%.

Pressure switch (E) lights the lamp (34) when the tank is filled to its true capacity.

19

Pressure switch (E) can be relocated in the bar (L) to adjust the «final warning level» (lamp 34 comes on) and by this the period of time that precedes unloading.

Which interval is chosen depends on operator preference.

Big windows also allow the grain level to be checked from the operator's platform.

(Fig. 19)

Acoustic grain tank fill indicator When the grain tank is 70% full, pressure switch (M) turns on indicator light (37) on the operations display screen and the buzzer sounds continuously.

47

Press push-button (47) to stop the buzzer.

Note: Shifting grain may cause the 70% full indicator to go off and then to come on again when operating on uneven ground.

(Fig. 19, 20) 20

8.4.8

BA DO 208 / 204 MEGA - 298 672.0

Operation – basic machine

Operation – basic machine STRAW CHOPPER / CHAFF SPREADER Straw chopper DANGER! DANGER: The guards of the straw chopper cover dangerous, rotating knives. Stay a safe distance away from the straw chopper during operation.

☞ Always disengage the threshing mechanism, stop the engine, withdraw the ignition key (main switch key) and wait for all mechanisms to stop before carrying out any work on the straw chopper.

(Danger: rotating knives).

☞ Before engaging the threshing drive, ensure that there are no persons in the danger area of the straw chopper.

☞ Note that the chopper knives run on after the machine drives have been disengaged.

When harvesting maize, convert the straw chopper by fitting the chopper maize kit and reduce chopper speed.

Before using the straw chopper, check 1. The knives for damage and the free-swinging knives for secure fit Check the condition of the knife retaining bolts 2. Tension of V-belts 3. That the belts run freely in their guards 4. That the fixed stationary knives are adjusted so that the desired length of cut is obtained 5. Setting of the cross knife

298 672.0 - BA DO 208 / 204 MEGA

8.5.1

Operation – basic machine

S

Putting the straw chopper into operation

K

1 P

1. Move back panel (S) to forward position and secure with turn locks (1), both sides.

2

2. Loosen turn lock (2). Swing the straw guide plate (E) with the lever (N) completely to the rear.

Lock (P) is moved off the drive pulley.

E 3

R

R

3. Pull on deflector rakes (R) to release the spring-loaded latches and fold the rakes onto the chopper. Loosen turn locks (3) on either side.

A V

N

B 1

Lift the left-hand adjuster (B) and swing up the spreading unit (V) until the notches of the adjusters (B) engage the pins at (A), both sides.

Tighten turn locks (3).

(Fig. 1)

4. Release the tension on drive belt (K) using lever (H). Move the drive belt from the outer idling pulley to the inner drive pulley. Tension the belt, using lever (H).

G

NOTE: Make sure that the V-belt is in the inner groove (G) of the intermediate drive pulley.

Groove (M) is for use in maize.

M

Close the guard. The straw chopper is ready for work.

(Fig. 1, 2, 3) 2

H 3

8.5.2

BA DO 208 / 204 MEGA - 298 672.0

Operation – basic machine Adjusting spreading width The spreading width of the straw chopper can be adapted to the cutterbar width by adjusting the deflectors (L) with lever (O).

To adjust the width, loosen turn lock (4) and move lever (O) to the left or right, depending on the desired spreading width.

4 O

Lever to left = Wide spreading pattern Lever to right = Narrow spreading pattern L

4

After adjusting the deflectors, retighten the turn lock knob.

(Fig. 4)

Electric deflector adjustment Using the electric deflector adjustment it is possible to alter the chopped straw discharge to the left or right.

This is particularly advantageous when combining on a hillside or with a strong sidewind as it helps to prevent the chopped straw being discharged into the still standing crop.

Adjusting the deflectors When centralizing switch (62) is activated, the deflectors (L) are adjusted by motor (M).

The direction in which the centralizing switch is turned is also the direction in which the deflectors are adjusted.

(Fig. 5, 6) 62 5

M

L 6

298 672.0 - BA DO 208 / 204 MEGA

8.5.3

Operation – basic machine Adjusting the length of cut The length of cut can be altered by turning the knife carrier. Loosen hexagon head bolts (5 and 6) on both sides of the straw chopper and turn the knife carrier using a spanner.

Direction A = shorter cut Direction B = longer cut

6

5

After adjustment, tighten hexagon head bolts (5 and 6) again on both sides of the straw chopper.

(Fig. 7, 8) 7 For operation in rape it is recommended to adjust the fixed, stationary knives all the way down.

Adjusting cross knife

Y U

DANGER!

Q

Caution – Risk of personal injury – Wear gloves.

A

To adjust the cross blade, loosen securing bolts (U) in the slots.

B 8

Adjust the cross knife (Q) so that the distance (Y) with the knives fully extended is 5 mm.

After adjustment, retighten all securing bolts (U) tightly.

(Fig. 8)

8.5.4

BA DO 208 / 204 MEGA - 298 672.0

Operation – basic machine Putting the straw chopper out of operation and changing over to windrowing straw 1. Release tension on drive belt (K) by using lever (H). Move the drive belt from the inner drive pulley to the outer idling pulley. Retension the belt.

2. Move back panel (S) to rearward position. Secure the back panel with turn lock (1) in the rear tapped holes.

H 9 S

4. Loosen turn locks (2) and swing guide plate (E) all the way to the front, using lever (N). Retighten the turn locks. A cam operates lock (P) so that the V-belt cannot be fitted.

K

1 2

E N

P

5. Pull on finger rakes (R) to release the spring-loaded latches, then swing the rakes up and lock them in position. Close and secure the guard. The chopper is now in the out-of-work position, the combine delivers a full swath of straw.

3 B

R

3. Loosen the turn locks (3) on each side of the machine. Lift the left-hand adjuster (B). Swing spreader unit (V) all the way down. Tighten the turn locks, on each side, to secure the adjusters in notches (T).

T V 10

NOTE! If straw walkers are in an awkward position, straw guide plate (E) might hit the spouts of the straw walkers. If this is the case, turn the straw walkers a little bit by hand.

(Fig. 9, 10)

Switching off the function control for the straw chopper: When the straw guide plate is swung forward, it trips switch (S) which switches off the speed-loss monitor of the straw chopper.

S

(Fig. 11)

11

298 672.0 - BA DO 208 / 204 MEGA

8.5.5

Operation – basic machine Hitching the cutterbar trailer to the combine Swing the spreading unit (V) all the way up and secure it in the notches (W) of adjusters (B).

(Fig. 12)

V

B

W 12

Chaff spreader The chaff spreader spreads the chaff from the sieve pan across the full working width of the cutterbar.

Spreading width can be adjusted to match the working width of the cutterbar.

(Fig. 13)

13 Setting the chaff spreader L

Adjust the chaff spreader by means of lever (H) after loosening toggle nut (K).

F

Move lever (H) up to increase spreading width.

Move lever (H) down to decrease spreading width.

Tighten toggle nut (K) after carrying out the adjustment.

B

To climb ladder (L), safety frame (B) can be folded down. To do this pull out spring clip (F).

K H

14

Before starting to combine, fold up safety frame (B) again and secure with spring clip (F).

For maintenance work on the sieve pan, the chaff spreader can be positioned vertically.

(Fig. 14, 15)

15

8.5.6

BA DO 208 / 204 MEGA - 298 672.0

Operation – basic machine

Operation – basic machine SIEVE CHART AND SUGGESTED COMBINE ADJUSTMENTS Sieve chart Size of hole

Used for

Flat Sieves 5.6 mm

Rye, wheat, winter barley

12.0 mm

Wheat, millet, beet seed, turnip seed, barley, lupines, rye, field peas, spinach, durra, sorghum, milo, vetch

16.0 mm

Barley, wheat, field beans, dwarf beans, peas, peas with oats, oats, maize / am. corn, beet seed, rice, soybeans, sunflowers

2.5 mm

Clover, lucerne, poppy seed, sesame

4.5 mm

Clover, lucerne, poppy seed, flax / linseed, spinach, rape seed, sesame

7.0 mm

Rape seed, bird rape, caraway seed, flax / linseed, radish seed, mustard, seradella, spinach, lupines

Frogmouth Sieves Frogmouth sieve

With long lips

Upper sieve

Frogmouth sieve

With short lips

Lower sieve

Frogmouth sieve

With short lips, deep tooth

Upper sieve (maize)

Special Sieves 18 x 45 20

/

Diagonally slotted hole / round hole sieve depressed

32 mm

Graepel sieve

80/40 mm

Graepel sieve

18 mm

Depressed

20 mm

Depressed

If special sieves are used in the upper position, the appropriate sieve extension has to be installed together with the sieve.

Every harvesting condition, however, requires the selection of a sieve, which is best suited for that particular condition.

298 672.0 - BA DO 208 / 204 MEGA

8.6.1

Operation – basic machine Suggested combine adjustments Crops

Wheat

Rye

Winter barley

Spring barley

Oats

Method of combining

Direct

Direct

Direct

Direct

Direct

Front attachment

Grain cutterbar

Grain cutterbar

Grain cutterbar

Grain cutterbar

Grain cutterbar

Reel tine setting

Vertical

Vertical

Vertical

Vertical

Vertical

Clearance between auger flights and cutterbar bottom [mm]

12 – 15

12 – 15

12 – 15

12 – 15

12 – 15

Threshing segment installed / removed

possibly installed*

removed

installed*

possibly installed*

removed

Disawner ON / OFF

possibly ON*

OFF

ON*

possibly ON*

OFF

Clearance between threshing drum and concave Adjusting lever Position from top

3rd

4th

2nd

2nd

4th

Preconcave segments Perforation** = alternative

6.5 x 38 12 x 38**

6.5 x 38 12 x 38**

6.5 x 38 12 x 38**

6.5 x 38 12 x 38**

6.5 x 38 12 x 38**

Precleaning air saver baffle (hole from the bottom)

3rd

3rd

3rd

3rd

3rd

Threshing drum speed [rpm]

1000 –1300

1200 – 1400

1300 – 1500

1300 – 1500

1200 – 1300

Opening of frogmouth sieves Upper sieve [mm]

10 – 13

10 – 13

10 – 13

10 – 13

10 – 13

Opening of frogmouth sieves Extension [mm]

10 – 13

10 – 13

10 – 13

10 – 13

10 – 13

Opening of frogmouth sieves Lower sieve [mm]

5–8

5–8

5–8

5–8

5–8

Fan speed [rpm]

1200

1100

1100

1000

900

Unit

Remarks * See information after the suggested combine adjustments

8.6.2

BA DO 208 / 204 MEGA - 298 672.0

Operation – basic machine

Crops

Rice

Field beans

Dwarf beans

Broad beans

Peas

Method of combining

Direct

Direct / from swaths

Direct / from swaths

From stooks / direct

Direct / from racks / from swaths

Front attachment

Grain cutterbar

Grain cutterbar / pick-up

Grain cutterbar / pick-up

Grain cutterbar

Grain cutterbar / pick-up

Reel tine setting

«Grab»

Vertical

Vertical

«Grab»

Vertical

Clearance between auger flights and cutterbar bottom [mm]

12 – 15

15 – 20

15 – 20

15 – 20

15 – 15

Threshing segment installed / removed

removed

removed

removed

removed

removed

Disawner ON / OFF

–

OFF

OFF

OFF

OFF

Clearance between threshing drum and concave Adjusting lever Position from top

6th

8th

9th

8th

9th

Preconcave segments Perforation** = alternative

Rice preconcave

19 x 38

19 x 38

19 x 38

12 x 38

Precleaning air saver baffle (hole from the bottom)

3rd

3rd

3rd

3rd

3rd

Threshing drum speed [rpm]

800

650

400

650

650

Opening of frogmouth sieves Upper sieve [mm]

10 – 13

10 – 13

10 – 13

approx. 15

approx. 15

Opening of frogmouth sieves Extension [mm]

10 – 13

10 – 13

10 – 13

10 – 13

10 – 13

Opening of frogmouth sieves Lower sieve [mm]

8 – 10

10 – 12

12 – 12

–

8 – 10

Fan speed [rpm]

1100

1100

1100

1100

1100

Remarks * See information after the suggested combine adjustments

Rice threshing equipment, possibly use tracks

Maize concave

Maize concave, possibly reduced threshing drum speed

Maize concave, reduced threshing drum speed

Possibly maize concave, reduced threshing drum speed

Unit

298 672.0 - BA DO 208 / 204 MEGA

8.6.3

Operation – basic machine

Crops

Soybeans

Maize / am. Corn

Corn Cob Mix

Sunflowers

Rape seed / bird rape

Method of combining

Direct

Direct

Direct

Direct

Direct / from swaths

Front attachment

Soybean cutterbar

Maize head

Maize head

Sunflower cutterbar

Grain cutterbar / pick-up

Reel tine setting

Vertical

–

–

–

Vertical

Clearance between auger flights and cutterbar bottom [mm]

12 – 15

25

25

12 – 15

25 – 30

Threshing segment installed / removed

removed

removed

removed

removed

possibly installed*

Disawner ON / OFF

OFF

OFF

OFF

OFF

OFF

Clearance between threshing drum and concave Adjusting lever Position from top

4th

9th Watch threshing

9th

4th

6th

Preconcave segments Perforation** = alternative

12 x 38

19 x 38

19 x 38 Round bar

19 x 38

6.5 x 38

Precleaning air saver baffle (hole from the bottom)

3rd

3rd

3rd

3rd

3rd

Threshing drum speed [rpm]

650

650

approx. 700

650

750

Opening of frogmouth sieves Upper sieve [mm]

10 – 13

approx. 13

Graepel sieve 80/40

10 – 13

4–6

Opening of frogmouth sieves Extension [mm]

10 – 13

approx. 13

–

10 – 13

4–6

Opening of frogmouth sieves Lower sieve [mm]

8 – 10

–

–

8 – 10

3–5

Fan speed [rpm]

1100

1400

750

1100

750

Remarks * See information after the suggested combine adjustments

Possibly maize concave or rice threshing equipment

Maize threshing equipment, poss. use spec. sieve in upper pos., poss. reduced threshing drum speed

Consult special threshing instructions

Possibly maize threshing equipment

Unit

8.6.4

3rd – 4th for round bar concave

BA DO 208 / 204 MEGA - 298 672.0

Operation – basic machine

Crops

Millet

Durra / sorghum

Poppy seed

Lupines

Linseed / flax

Method of combining

Direct

Direct / stationary threshing

Direct

Direct / from swaths

Direct

Front attachment

Grain cutterbar

Grain cutterbar

Grain cutterbar

Grain cutterbar / pick-up

Grain cutterbar

Reel tine setting

Vertical

Vertical

Vertical

Vertical

Vertical

Clearance between auger flights and cutterbar bottom [mm]

12 – 15

12 – 15

12 – 15

12 – 15

12 – 15

Threshing segment installed / removed

possibly installed*

possibly installed*

removed

removed

possibly installed*

Disawner ON / OFF

OFF

OFF

OFF

OFF

possibly ON*

Clearance between threshing drum and concave Adjusting lever Position from top

6th

6th

7th

7th

4th

Preconcave segments Perforation** = alternative

6.5 x 38 12 x 38**

6.5 x 38 12 x 38**

6.5 x 38

6.5 x 38

6.5 x 38

Precleaning air saver baffle (hole from the bottom)

3rd

3rd

7th

5th

5th

Threshing drum speed [rpm]

650 – 800

650 – 800

800

650

1000

Opening of frogmouth sieves Upper sieve [mm]

10 – 13

10 – 13

2–4

8 – 10

8 – 10

Opening of frogmouth sieves Extension [mm]

10 – 13

10 – 13

2–4

8 – 10

8 – 10

Opening of frogmouth sieves Lower sieve [mm]

5–8

5–8

2–4

3–5

3–5

Fan speed [rpm]

1100

1100

750

1100

750

Possibly reduced threshing drum speed

Possibly use 2.5 o flat sieve

Unit

Remarks * See information after the suggested combine adjustments

298 672.0 - BA DO 208 / 204 MEGA

8.6.5

Operation – basic machine

Crops

Caraway seed / fennel

Mustard

Seradella

Sesame

Sugar beet / beetroot / fodder beet seed

Method of combining

From swaths

Direct / from swaths

From swaths

From stooks

From stooks / from racks

Front attachment

Pick-up

Grain cutterbar / pick-up

Pick-up

Grain cutterbar

Grain cutterbar

Reel tine setting

–

Vertical

–

–

–

Clearance between auger flights and cutterbar bottom [mm]

12 – 15

12 – 15

12 – 15

20

20

Threshing segment installed / removed

removed

removed

removed

removed

removed

Disawner ON / OFF

OFF

OFF

OFF

OFF

OFF

Clearance between threshing drum and concave Adjusting lever Position from top

4th

4th

4th

4th

5th

Preconcave segments Perforation** = alternative

6.5 x 38

6.5 x 38

6.5 x 38

6.5 x 38

6.5 x 38

Precleaning air saver baffle (hole from the bottom)

5th

5th

5th

7th

3rd

Threshing drum speed [rpm]

1000 – 1200

800 – 1000

1000 – 1200

650 – 800

1000

Opening of frogmouth sieves Upper sieve [mm]

8 – 10

8 – 10

8 – 10

8 – 10

10 – 13

Opening of frogmouth sieves Extension [mm]

8 – 10

8 – 10

8 – 10

8 – 10

10 – 13

Opening of frogmouth sieves Lower sieve [mm]

3–5

3–5

3–5

3–5

5–8

Fan speed [rpm]

750

750

750

700

700

Possibly use fan shutters

Consult company for which seed is grown before combining

Unit

Remarks * See information after the suggested combine adjustments

8.6.6

BA DO 208 / 204 MEGA - 298 672.0

Operation – basic machine

Crops

Clover / lucerne

Grass seed, easy to thresh varieties

Grass seed, difficult to thresh varieties

Spelt

Triticale

Method of combining

Direct / from racks / from swaths

Direct / from swaths

Direct / from swaths

Direct

Direct

Front attachment

Grain cutterbar / pick-up

Grain cutterbar / pick-up

Grain cutterbar / pick-up

Grain cutterbar

Grain cutterbar

Reel tine setting

Vertical

«Grab»

«Grab»

Vertical

Vertical

Clearance between auger flights and cutterbar bottom [mm]

12 – 15

12 – 15

12 – 15

12 – 15

12 – 15

Threshing segment installed / removed

removed

removed

installed*

possibly installed*

possibly installed*

Disawner ON / OFF

ON*

possibly ON*

possibly ON*

possibly ON*

possibly ON*

Clearance between threshing drum and concave Adjusting lever Position from top

2nd

3rd

2nd

3rd

3rd

Preconcave segments Perforation** = alternative

6.5 x 38

6.5 x 38

6.5 x 38

6.5 x 38 12 x 38**

6.5 x 38 12 x 38**

Precleaning air saver baffle (hole from the bottom)

7th

7th

7th

3rd

3rd

Threshing drum speed [rpm]

1200

800 – 1000

1000 – 1200

1200

1350

Opening of frogmouth sieves Upper sieve [mm]

8 – 10

8 – 10

8 – 10

14

13

Opening of frogmouth sieves Extension [mm]

8 – 10

8 – 10

8 – 10

14

13

Opening of frogmouth sieves Lower sieve [mm]

3–5

3–5

3–5

10

8

Fan speed [rpm]

700

700

700

1200

1100

Remarks * See information after the suggested combine adjustments

Clover threshing equipment, (see CLAAS publication on threshing special crops)

Fan shutters, (see CLAAS publication on threshing special crops)

Fan shutters, (see CLAAS publication on threshing special crops)

Unit

298 672.0 - BA DO 208 / 204 MEGA

8.6.7

Operation – basic machine

Operation – basic machine Disawner plates In some cases, it is necessary to avoid the separation of single grains which have not been decorticated or disawned by the preconcave and to use these concave areas for rubbing out. Disawner plates may be engaged for this purpose.

Optimum preparation of the crop in the preconcave stage guarantees early separation in the main concave.

Threshing segment In addition to the measure above, the transition between preconcave and main concave may be altered in order to intensify the threshing action.

To this end, a threshing segment may be installed which radially adapts the main concave entrance.

This allows reducing the threshing drum speed.

Improved disawning and/or threshing ensures optimum grain quality.

Effects on function positive ____________ negative

8.6.8

Disawner plates

Decortication, disawning, preparation for early separation

Unnecessary mechanical load in case of easily threshable crops

Threshing segment

Threshing Return

Straw structure, residual separation, Cleaning yield

BA DO 208 / 204 MEGA - 298 672.0

Operation – basic machine

Operation – basic machine PROBLEM, CAUSE AND / OR REMEDY – BASIC MACHINE Problem

Possible cause and / or remedy

Cutterbar Poor cutting action

1.

2.

3.

4.

5.

Sudden knife blockage

1. Remove foreign objects.

2. Replace misaligned cutterbar fingers.

3. Adjust tension of knife drive belt.

Lodged crops not properly picked-up

1.

2.

3.

4.

5.

Dirt and material build-up on divider points

1. Set dividers to higher position using the slide.

2. Use special dividers.

3. Renew cutterbar skids if necessary.

Cutterbar lifts too slowly or will not lift

1. Adjust tension of hydraulic pump belt.

2. Have hydraulic oil pressure checked.

3. Check 3/3 directional control valve or electrical system.

Reel tending to stop

1. Check adjustment of slip clutch, possibly readjust a little bit.

2. Lubricate sliding faces of reel variable speed pulleys, but do not over-lubricate (the V-belt must be kept free of grease).

Feed rake and cutterbar tending to stop

1. Have slip clutch of upper feed rake shaft reset to correct tension.

2. Set clearance between sender and gear wheel at between 1 ± 0.5 mm 3. Tighten cutterbar drive belt according to instructions given in group «Maintenance».

4. Have KONAX clutch readjusted.

5. Have low pressure hydraulic system checked.

(Function monitor: red indicator light for feed rake goes on during field operations)

298 672.0 - BA DO 208 / 204 MEGA

Reset knife clips.

Sharpen knife.

Straighten finger bar.

Replace damaged knife sections.

Remove build-up of foreign material from cutterbar.

Check spacing of grain lifters.

Set reel fingers to «grabbing» position.

Cut crop from other direction.

Adjust setting of cutterbar float springs.

Adjust the reel further forward.

8.7.1

Operation – basic machine

Problem

Possible cause and / or remedy

Cutterbar dips at one end (machine without Auto Contour)

1. Adjust cutterbar mountings to level cutterbar.

2. Check pressure of tyres.

Cutterbar clutch will not disengage

1. Have KONAX clutch readjusted.

Uneven crop feed

1. Adjust main table auger height to suit crop conditions.

2. Adjust reel finger position and reel speed.

3. Adjust reel horizontally to match crop conditions.

4. Adjust tension of feed rake chains.

5. Adjust stop in feeder house to correct position.

Main table auger tending to stop or gets blocked

1. Reverse main table auger and remove foreign matter.

2. Have slip clutch reset to correct torque.

Crop wrapping round the reel shaft ends

1. Adjust inner deflectors closer to cutterbar centre and possibly higher.

Crop wrapping round the reel finger tubes

1. Raise the reel.

2. Set reel fingers more inclined to the front.

3. Adjust reel speed to match ground speed.

Reel fingers fouling knife in lowest position

1. Raise reel position by means of reel cylinder eyebolts.

Reel dips at one end when lifted

1. Check for equal adjustment of reel cylinders' eye bolts.

2. Bleed hydraulic reel cylinders.

3. Raise reel to maximum height, check if hydraulic cylinders are leaking and have them repaired if necessary.

Too many stones being picked-up

1. Reduce number of grain lifters.

2. Do not cut unnecessarily low (lodged crops should be lifted with grain lifters).

8.7.2

BA DO 208 / 204 MEGA - 298 672.0

Operation – basic machine

Problem

Possible cause and / or remedy

Threshing equipment

Dirty threshing parts cause unbalance and grain losses and worn threshing parts reduce combine throughput and leave unthreshed grain heads.

Slugging of drum

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

Reduce drum-to-concave clearance.

Increase drum speed in damp crops.

Adjust basic settings of concave.

Care for even feeding of crop to feed rake.

Adjust main table auger further down.

Lubricate sliding faces of drum variable speed pulleys (if necessary clean the sliding faces before applying grease to avoid belt slippage).

Check and have speed of straw walker shaft adjusted to 225 ± 5 rpm if necessary.

Reduce ground speed as moisture level increases.

Have slip clutches of cutterbar reset to correct torque.

Have low pressure hydraulic system checked and check threshing drive tensioning cylinder and jockey pulley for smooth operation.

Insufficient disawning

1.

2.

3.

4.

5.

Stones and other foreign matter causing damage to threshing parts

1. Clean stone trap regularly.

2. Do not cut unnecessarily low on stony ground.

Irregular speed variations of machine

1. Correct the setting of the idler pulley and spring-loaded cylinder that control the tension of the power band belt.

2. Have threshing mechanism engagement cylinder checked for leakages.

3. Have low pressure hydraulic system checked.

4. Check engine – see page 10.7.1, Engine problems, cause and / or remedy.

298 672.0 - BA DO 208 / 204 MEGA

Increase drum speed.

Adjust concave to drum clearance closer.

Install concave filler rasp bars.

Wait for crop to be fully ripened.

Check basic adjustment of concave and correct if necessary.

8.7.3

Operation – basic machine

Problem

Possible cause and / or remedy

Excessive belt wear

1. Clean and remove rust from V-belt pulleys, especially from variable speed pulleys.

2. Clean and grease sliding faces of variable speed pulleys.

3. Clean oiled up belts with soapy solution.

4. Engage combine drives with engine at slow idling speed, and then bring the engine to full speed.

5. Adjust belt tensioners.

Poor threshing action

1.

2.

3.

4.

Unbalance

1.

2.

3.

4.

Grain cracking

1. Decrease drum speed.

2. Increase drum-to-concave clearance.

3. Decrease drum speed for delicate crops by use of extra equipment. (Threshing drum 2-step variable speed drive.)

4. Remove concave filler rasp bars.

5. Adjust frogmouth sieves wider open or use sieves of wider hole size.

6. Adjust tension of elevator chains.

Adjust concave closer to drum.

Increase drum speed.

Adjust basic setting of concave.

Have worn or damaged threshing equipment replaced.

5. Install threshing segment, if necessary.

Clean dirty threshing drum.

Remove dust accumulations from belt pulleys.

Have damaged threshing drum repaired.

Check knives of straw chopper (where fitted).

Straw walkers Plugging of straw walkers (Function monitor: speed-loss indicator light ON)

8.7.4

1. Have speed of straw walker shaft adjusted to 225 ± 5 rpm. a) Adjust tension of belt driving the tine shafts of the intensive separation system. b) Adjust tension of straw walker drive belt.

2. Clean out straw walkers (build-up of awns etc.).

BA DO 208 / 204 MEGA - 298 672.0

Operation – basic machine

Problem

Possible cause and / or remedy

Cleaning Uneven feed to sieves

1. Clean preparation floor.

2. Straighten bent tines of preparation floor wire rake.

Knocking sieve pan

1. Remove dirt accumulations from above cleaning fan housing.

2. Retighten all bolts that secure the sieve pan.

3. Tighten the components securing the sieves.

4. Have sieve pan bearings replaced.

Excessive build up of material on frogmouth sieves

1. Reduce drum speed.

2. Increase drum-to-concave clearance.

3. Adjust frogmouth sieves to somewhat closer gaps.

4. Increase wind blast.

5. Adjust windboards to correct position.

Dirty grain sample

1.

2.

3.

4.

Increase wind blast.

Set windboards to correct position.

Decrease frogmouth sieves opening.

Use flat sieves of smaller hole size or decrease lower frogmouth sieve opening, respectively.

5. Have straw walker speed of machine checked and corrected if necessary (belt tension).

Dynamic sidehill levelling (3-D cleaning unit) Jerky motion of operating arm as combine angles over when combining across slopes

1. Ease pendulum in control unit. The pendulum must operate smoothly.

Uneven spread of material on the top sieve when combine tilts to the right or to the left

1. Adjust operating arm so that the hydraulic cylinder travels an equal distance to either side when the machine is on flat level ground.

298 672.0 - BA DO 208 / 204 MEGA

8.7.5

Operation – basic machine

Problem

Possible cause and / or remedy

Returns Excessive amount of chaff and short straw in the returns

1. Increase wind blast.

2. Adjust frogmouth sieves to somewhat closer gaps.

3. Reduce drum speed.

4. Possibly change concave clearance at the rear.

5. Have straw walker speed of machine checked and corrected if necessary.

Excessive amount of grain in the returns

1. Adjust frogmouth sieves wider.

2. Clean flat sieves or use sieves of bigger hole size.

Excessive amount of green in the returns

1. Lift cutterbar to highest possible position, the grain lifters should lift the crop out of the greenstuff.

2. Adjust rear end of frogmouth sieve to somewhat closer gaps.

Elevators Elevator obstructed (functions monitor: speed loss indicator light for clean or returns elevator shows)

1. Open elevator bottom flap to remove obstructing material. Open auger trough. Run combine with open flap until elevator and auger are clear. Tightly close elevator bottom flap and auger trough.

2. Possibly improvement by retensioning elevator chain.

3. Avoid material build-up and excessive returns.

4. Adjust tension of the belt driving the elevators.

Grain tank Grain tank discharge not functioning

8.7.6

1. Have low pressure hydraulic system checked and have jockey pulley and hydraulic cylinder for engagement of discharge augers checked for smooth operation.

2. Readjust the drive and belt guides for the grain tank discharge augers.

3. Replace shear bolt in sprocket driving the grain tank discharge auger.

4. Bend misaligned auger flights to correct position.

BA DO 208 / 204 MEGA - 298 672.0

Operation – basic machine

Problem

Possible cause and / or remedy

Grain losses

Losses of grain may have different reasons. Therefore, always determine first where the losses occur.

Check combine for leakage losses. Check whether grain is lost where working parts join, especially check auger troughs, elevators etc. Extra care should be taken to check the working parts for good fitting when combining small seeds. Repair all leaks as necessary.

Losses that are caused by overripe crops or poor weather conditions must not be taken for combine losses.

Grain losses that are due to combining usually have four main causes: – Losses of grain over the cutterbar and cutting losses – Losses of grain caused by insufficient threshing – Losses of grain over the straw walkers – Losses of grain over the sieve pan

– Losses of grain over the cutterbar and cutting losses

1. Adjust reel tine angling to suit crop conditions.

2. Adjust reel speed to match ground speed.

3. Adjust the reel horizontally to match crop conditions.

4. In crops with hanging grain heads fit a grain lifter to every second cutterbar finger.

5. Adjust main table auger position to match crop conditions.

– Losses of grain caused by insufficient threshing

1. Have damaged or worn threshing drum repaired.

2. Adjust drum speed to crop conditions.

3. Adjust concave-to-drum clearance to crop conditions.

4. Correct basic adjustment of concave.

5. Adjust cutterbar to ensure even crop feed.

6. Have slip clutches on cutterbar checked for correct torque settings and adjusted as necessary.

298 672.0 - BA DO 208 / 204 MEGA

8.7.7

Operation – basic machine

Problem – Losses of grain over the straw walkers

– Losses of grain over sieve pan

Possible cause and / or remedy 1. Check and have speed of straw walker shaft adjusted to 225 ± 5 rpm if necessary.

2. Adjust tension of belt driving the crankshaft of the intensive separation system.

3. Adjust tension of the belt driving the straw walkers.

4. Provide for even crop feed to the threshing parts.

5. Clean concave and space behind it.

6. Avoid excessive returns by correct adjustment of cleaning unit.

7. Clean straw walkers and under-walker return floor.

8. Reduce drum speed and adjust concave-to-drum clearance closer.

9. Reduce ground speed.

10. Adjust deflector curtain over straw walkers to correct position.

11. Fit new deflector curtain over straw walkers.

12. Try to pick up less greenstuff.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

8.7.8

Avoid heavy build-up of material.

Increase air blast to meet crop conditions.

Adjust windboards to correct position.

Set cutterbar high enough to minimize greenstuff entering the combine.

Decrease drum speed when short straw overloads the sieve pan.

Check fan variable speed pulleys for smooth operation.

Adjust tension of sieve pan drive belt.

Check and have speed of straw walker shaft adjusted to 225 ± 5 rpm if necessary.

Adjust rear end of upper frogmouth sieve wider open.

Adjust frogmouth sieve gaps wider open and increase wind blast.

Avoid excessive returns.

Clean upper and lower sieves and preparation floor.

Reduce ground speed.

BA DO 208 / 204 MEGA - 298 672.0

9 Maintenance – basic machine, cutterbar

Maintenance – basic machine, cutterbar

Maintenance – basic machine, cutterbar IMPORTANT MAINTENANCE INSTRUCTIONS Important maintenance instructions and safety rules DANGER! Repair, service and cleaning work and the elimination of malfunctions should only be performed with the drive and engine switched off. Remove the ignition key (main switch key)!

Repairs to energy storage components (springs, any pressurized accumulators etc.) require expert knowledge and the correct tools and must only be carried out by specialist service shops.

Cutterbar DANGER! Before working on or in the cutterbar disengage the threshing mechanism and switch off the engine and wait until all parts have stopped moving.

Before working under the cutterbar support the cutterbar securely and fold down the safety lock, respectively. Make sure that the safety lock is correctly engaged.

Correct tension of steel roller chains

Find the centre point on the slack side of the chain between sprockets. With the tight side of the chain slightly under load, push in the centre point of the slack side with the thumb. The tension of the chain is correct when its slack side deflects about 2% of the centre distance between shafts. When new chains are fitted the tension should be checked at shorter intervals.

If a chain has excessively lengthened, shorten the chain by removing one double link.

Belts

All V-belts should always be kept under proper tension. Oiled belts can be cleaned with a soapy solution; never use gasoline or similar products for belt cleaning.

Check the tension of new belts after the first 2 to 3 hours of operation and retension, if necessary.

298 672.0 - BA DO 208 / 204 MEGA

9.1.1

Maintenance – basic machine, cutterbar Variable speed pulleys

Whenever the variable speed pulleys have been greased, operate the pulleys to ensure even spreading of grease on sliding parts.

Remove any accumulations of dust from between the variable speed pulley halves to make sure the pulleys can be run through their full speed range.

Bolts

Check bolts for tight fit and retighten them as necessary. Give particular attention to all nuts and bolts on the chassis, wheels and steering mechanism.

Lubrication

The oil in the engine, hydraulic systems and transmissions must be changed at the specified intervals.

Use only the recommended types of oil. Lubricate the machine with good quality grease only, e.g. multi-purpose grease Shell Retinax A EP 2.

Clean dirt from the grease nipples before greasing.

Lubricate the machine at regular intervals in accordance with the Lubrication Chart.

ENVIRONMENT! Lubricants and fuels must be stored in suitable containers and disposed of in a way that is harmless to the environment and in accordance with existing anti-pollution regulations.

DANGER! Be careful when draining hot oil – beware of burns!

9.1.2

BA DO 208 / 204 MEGA - 298 672.0

Maintenance – basic machine, cutterbar Brakes DANGER! The brakes must be thoroughly inspected at regular intervals!

Adjustment and repair work on the brake system are only to be carried out by specialist workshops or recognized brake service specialists!

Before driving on the road, apply the locking strap between brake pedals so that both front wheel brakes will be applied simultaneously.

Check the level of the brake fluid at regular intervals. Only use the recommended type of brake fluid and change the brake fluid as specified!

Take care when handling brake fluid (it is toxic and causes severe burns).

ENVIRONMENT! Be extra careful not to spill any brake fluid!

Dispose of brake fluid in a way that is harmless to the environment and in accordance with existing antipollution regulations!

298 672.0 - BA DO 208 / 204 MEGA

9.1.3

Maintenance – basic machine, cutterbar Wheels / tyres DANGER! Repair work on tyres must only be carried out by professionals and with suitable tools!

If tyre pressures exceed the specified values the tyres may explode!

☞ The tyres must be kept at the specified pressures, see page 5.2.4 or 5.3.4.

☞ Never stand in the vicinity of the tyre while it is being inflated.

☞ Regularly check the air pressure of the tyres.

Before carrying out any work on the wheels, care must be taken to ensure that the combine is correctly parked and stable and that its wheels are properly chocked to prevent the machine from rolling away (wheel chocks).

No persons must ever be allowed on the combine when work is being carried out underneath it and the machine is raised.

A raised machine must always be supported by suitable stands or blocks.

Ensure that the lift capacity of the lifting device is adequate.

Every time a wheel has been mounted, the wheel nuts or bolts must be retightened after the first 10 hours of operation, thereafter check the nuts or bolts every 50 hours of operation for tight fit. See page 5.2.5 or 5.3.5 for torque settings.

Retighten the track adjustment elements in accordance with the manufacturer's instructions.

The tyres must only be ballasted to the extent that the specified tyre pressures can be maintained.

9.1.4

BA DO 208 / 204 MEGA - 298 672.0

Maintenance – basic machine, cutterbar Hydraulic system DANGER! Before working on the hydraulic system it is essential to release all hydraulic pressure and to lower the front attachment, if fitted, to rest on the ground.

High pressure exists in the hydraulic system!

Escaping fluid (fuel or hydraulic oil) under high pressure can penetrate the skin and cause serious injury. If any fluid is injected into the skin, consult a doctor immediately as otherwise serious infections may result.

☞ Checking for leaks is hazardous. Use the correct equipment to search / check for possible leaks. NEVER use your hands to detect pressure leaks. Beware of personal injury.

☞ When working on the hydraulic system always stop the engine, withdraw the ignition key and secure the machine by applying the parking brake and using the wheel chock to prevent the combine from rolling away.

☞ Inspect hydraulic hoses regularly and replace damaged and deteriorated hoses by new ones! Replacement hoses must meet the technical requirements specified by the manufacturer!

Repair work on the hydraulic system must only be carried out by authorized CLAAS workshops.

298 672.0 - BA DO 208 / 204 MEGA

9.1.5

Maintenance – basic machine, cutterbar Electrical system DANGER! Always disconnect the ground strap from the (–) negative terminal of the battery before working on the electrical system.

Ensure that the battery straps and cables are connected correctly, connect the power cable to the (+) terminal first and then connect the ground strap to the (–) negative terminal.

Be extra careful with battery gases, battery gases are highly explosive.

Avoid sparks and naked flames in the vicinity of a battery.

Remove the covers (vent caps) when recharging the battery to prevent the accumulation of highly explosive gases.

Be extra careful when handling battery acids, beware of acid burns!

Always disconnect the cables from the alternator and battery before using an electric arc welder on the combine and front attachment.

ATTENTION! Only use original fuses. Fuses with a higher rating will damage the electric system.

ENVIRONMENT! The old battery must be disposed of in a way that is harmless to the environment and in accordance with existing environmental regulations!

9.1.6

BA DO 208 / 204 MEGA - 298 672.0

Maintenance – basic machine, cutterbar Air conditioning system DANGER! Avoid any contact with refrigerant liquid!

In case any refrigerant splashes into your eyes, consult a doctor immediately!

Maintenance and repair work must only be carried out by qualified personnel!

Do not weld on any components of the refrigerant circuit and in the immediate vicinity of any parts of the refrigerant circuit.

– Danger of poisoning!

Air conditioning systems must only be installed, repaired and maintained and serviced by qualified persons who have been especially trained for this type of work!

ATTENTION! Check the evaporator in the cab roof and the condenser in front of the water cooler regularly for dirt, debris and trash and clean as required.

NOTE! Refrigerants must not be exposed to ambient temperatures exceeding 80 °C!

ENVIRONMENT! Refrigerants pollute the environment if vented to the atmosphere. Please take the appropriate precautions when working on the compressor-type air conditioning system.

The refrigerant must be discharged by use of the correct recovery equipment before carrying out any repairs. It is essential to prevent refrigerant escaping into the atmosphere.

298 672.0 - BA DO 208 / 204 MEGA

9.1.7

Maintenance – basic machine, cutterbar Safety guards / spare parts DANGER! After carrying out the maintenance work, refit the safety guards so that they will give the intended protection.

Safety guards and shields that are subject to wear have to be regularly inspected and replaced in good time by new ones. Spare parts must at least comply with the technical standards required by the manufacturer of the implement. Original spare parts, for instance, are manufactured to meet these standards!

Unbalance ATTENTION! Erratic running of combine results in fatigue of material and breakage.

☞ Check revolving machine parts, particularly the threshing drum, regularly for dust accumulations and clean thoroughly.

Welding ATTENTION! When working on the machine with an electric arc welder, observe the following points: 1. Turn off the battery isolating switch!

2. Unplug the electric connectors between the engine and the main wiring loom.

3. Remove the electronic plug-in type modules located in the central electrics compartment.

4. Remove the diode plate from the central terminal compartment.

5. Disconnect the wiring connections to the fieldwork computer.

6. Always fit the earth cable of the electric arc welder close to the area being welded.

7. On combines with electronic motors, remove the plug at the motor electronics. It is not sufficient to simply turn off the battery isolator switch.

9.1.8

BA DO 208 / 204 MEGA - 298 672.0

Maintenance – basic machine, cutterbar

Maintenance – basic machine, cutterbar MAINTENANCE SCHEDULES AND LUBRICANTS CHARTS Maintenance schedules

100

Working hours

Every 50

100 Working hours

200

After the harvest

Daily

10

As required

After the first

Annually = every 500 working hrs.

Service intervals Before the Harvest

Maintenance Operations

HYDRAULIC SYSTEM Hydrostatic ground drive and work hydraulics – Check oil level – Change hydraulic oil – Change hydraulic oil filter – Adjust hydrostatic pump – Bleed reel cylinders – Bleed hydraulic cylinders for cutterbar lateral levelling (combines with Auto-Contour) – Replace return sieve in hydraulic oil tank FOOT BRAKE / BRAKE FLUID – Check brake fluid level, top up if necessary – Replace brake fluid and have system bled

every 2 years

TRANSMISSIONS – Adjust linkage for transmission shift Transmission gearbox – Check oil level – Oil change Final drives – Check oil level – Oil change Rear wheel drive planetary gears – Check oil level – Oil change Knife drive casing – Check oil level – Oil change Threshing drum reduction gearbox – Check oil level – Oil change FEEDER HOUSING – Tension feeder chains ELEVATOR CHAINS – Tension grain elevator chain – Tension returns elevator chain

298 672.0 - BA DO 208 / 204 MEGA

9.2.1

Maintenance – basic machine, cutterbar

100

Working hours

Every 50

100 Working hours

250

After the harvest

Daily

10

As required

After the first

Annually = every 500 working hrs.

Service intervals Before the Harvest

Maintenance Operations

DRIVES Check and / or adjust V-belt drives with spring-loaded belt tensioners – Cutterbar drive (1) – Hydrostatic ground drive (3) – Chaff spreader drive (16) – Straw chopper drive (20) – Straw chopper intermediate drive (21) – Threshing drum drive (24) – Radiator screen drive (26) – Radiator screen intermediate drive (27) – Knife drive (40) Check and / or adjust V-belt drives with non-spring-loaded belt tensioners – Compressor drive (2) – Work hydraulics pump drive (4) – Sieve pan / fan intermediate drive (7) – Sieve pan intermediate drive (9) – Sieve pan drive (10) – Straw walker drive (11) – Intensive separation system drive (12) – Chaff spreader drive (15) – Suction blower drive (22) – Alternator / fan drive (28)

(see Maintenance – engine)

Check and / or adjust chain drives – Filling auger drive (30) – Grain tank unloading intermediate drive (31) – Grain tank unloading intermediate drive (32) – Returns auger drive (33) – Main table auger drive (41) – Reel drive (42) – Reel drive (44) – Reel drive (45)

9.2.2

BA DO 208 / 204 MEGA - 298 672.0

Maintenance – basic machine, cutterbar

100

Working hours

Every 50

100 Working hours

250

After the harvest

Daily

10

As required

After the first

Annually = every 500 working hrs.

Service intervals Before the Harvest

Maintenance Operations

AIR CONDITIONING SYSTEM – Clean condenser – Replace filter-receiver drier

As soon as the indicator ball (blue ball) has turned pink

CAB – Clean or replace filters SPEED MONITOR – Adjust magnetic pick-ups FIRE EXTINGUISHER – Have fire extinguisher checked for serviceable condition

every 2 years

STRAW CHOPPER – Replace swinging knives – Replace fixed stationary knives WHEEL BOLTS AND NUTS – Tighten – see page 5.2.5 or page 5.3.5 REMOVE DIRT ACCUMULATIONS – Under-walker return floor, sieve pan, combine performance monitor sensors – Auger troughs, space above cleaning fan, preparation floor, threshing concave, sieves – Engine area, exhaust system, transmission / gearbox areas, brakes, hydrostatic ground drive system

298 672.0 - BA DO 208 / 204 MEGA

9.2.3

Maintenance – basic machine, cutterbar Lubricants charts Component

Type of Lubricant

Capacity

Viscosity

Change Intervals

Check

90

See Maintenance schedules

See Maintenance schedules

Gearboxes DOMINATOR 208 MEGA Transmission gearbox Final drives

DOMINATOR 204 MEGA Transmission gearbox

CLAAS hypoid transmission oil SAE 85W-90 API-GL-5 Multi purpose transmission oil conforming to (MIL-L-2105 B) API-GL-5-90 Specifications

Final drives

Cutterbar knife drive casing Rear wheel drive (CLAAS 4-Trac) planetary gears

Threshing drum reduction gearbox

6.0 litres 4.5 litres each

6.0 litres 4.5 litres each

CLAAS hypoid transmission oil SAE 85W-90 API-GL-5

0.85 litres

0.8 litres each

Multi purpose transmission oil conforming to (MIL-L-2105 B) API-GL-5-90 Specifications

CLAAS hypoid transmission oil SAE 85W-90 API-GL-4 Specifications

1.0 litre

Multi purpose transmission oil conforming to (MIL-L-2105) API-GL-4-90 Specifications

9.2.4

BA DO 208 / 204 MEGA - 298 672.0

Maintenance – basic machine, cutterbar Component

Type of Lubricant

Capacity

CLAAS hydraulic oil VD-Plus HVLPD 46

approx.

20 litres

Viscosity

Change Intervals

Check

See Maintenance schedules

See Maintenance schedules

Every 2 years

See Maintenance schedules

Hydraulic system Working hydraulics and hydrostatic ground travel drive

Multi-grade hydraulic oil, viscosity class ISO-VG 46 as per DIN 51 524, part 3 **

Foot brake

ATE brake fluid

Reservoir must always be full

Sanden oil SP 20 PAG

As required (approx.

310 cm3 refill capacity)

SAE Specifications DOT 4

Air conditioning system Sanden compressor SD 7 H 15

When replacing filter receiver drier or if refrigerant has been extracted

** When selecting hydraulic oil, observe the following guidelines: Pourpoint Viscosity 0 °C Viscosity40 °C Viscosity index

< -25 °C (DIN ISO 3016) < 600 cSt. (DIN 51 562) max. 50.6 cSt. (DIN 51 562) > 170 (DIN ISO 2909)

The oil must have detergent properties!

298 672.0 - BA DO 208 / 204 MEGA

9.2.5

Maintenance – basic machine, cutterbar

9.2.6

BA DO 208 / 204 MEGA - 298 672.0

Maintenance – basic machine, cutterbar

Maintenance – basic machine, cutterbar HYDRAULIC SYSTEM DANGER! Before performing any work on the hydraulic system, always shut off the engine, remove the ignition key (main switch key) and ensure that the combine cannot roll away (apply handbrake, place wheel chock in front or behind wheel). Engage gear.

NOTE! For oil change and oil level check intervals – see page 9.2.1, Maintenance schedules.

Hydraulic accumulators DANGER!

S

Take particular care when working on hydraulic accumulators!

K

Hydraulic accumulators are under high pressure!

1

In the case of valve-controlled accumulators such as e.g. for the Autopilot, the short-circuit screw has to be loosened before starting repair work on the accumulator so that the hydraulic pressure is relieved.

Proceed as follows: Loosen lock nut (K) and back off screw (S) slightly until the pressure has been relieved.

Then tighten screw (S) again up to the stop and tighten lock nut (K).

(Fig. 1)

298 672.0 - BA DO 208 / 204 MEGA

9.3.1

Maintenance – basic machine, cutterbar Checking the oil level M

(Hydrostatic ground speed drive and working hydraulics) NOTE!

H Before checking the oil level, lower the cutterbar and reel completely to the ground and swing in the grain tank unloading tube.

2

The hydraulic oil must be up to the mark on dipstick (M).

H = Hydraulic oil tank (Fig. 2)

Changing hydraulic oil (Hydrostatic ground speed drive and working hydraulics) Linde HPV 75 and HMF 105 DANGER! Take care when draining hot oil to avoid the danger of burning!

ENVIRONMENT! Dispose drained oil so that no harm is done to the environment and in accordance with existing environmental regulations!

9.3.2

BA DO 208 / 204 MEGA - 298 672.0

Maintenance – basic machine, cutterbar Connect a suitable hose (S) to drain fitting (H). Loosen nut (R) slightly and drain the old oil into a sufficiently large container.

H R

M

Remove drain plug (A) at the hydrostatic motor.

Drain the old oil into a sufficiently large container (capacity: 20 litres min.).

S

After draining the hydraulic oil, screw in drain plug (A) on the hydrostatic motor again tightly.

Tighten nut (R) on the oil drain fitting again firmly.

Remove hose (S).

3

H = Hydraulic oil drain fitting M = Engine oil drain fitting (Fig. 3, 4)

A

4 Changing the hydraulic oil filter Replace the hydraulic oil filter (F) by a new one whenever the hydraulic oil is changed.

ATTENTION! F

Use only genuine filters that are designed to take the pressure created by the variable displacement swash plate pump.

Always install new seals whenever the filter is changed.

5 (Fig. 5) NOTE! Oil type – see page 9.2.4, Lubricants charts.

298 672.0 - BA DO 208 / 204 MEGA

9.3.3

Maintenance – basic machine, cutterbar Refilling the system after hydraulic oil change M

1. Fill hydraulic reservoir (H) with hydraulic oil through filler cap (M) using a screen filter.

(– see page 9.2.4, Lubricants charts for the recommended oils)

H

Pour in hydraulic oil slowly to allow air to escape from the pump housing through the connecting lines and from reservoir (H).

6

2. Shift gear shift lever to neutral and allow the engine to run at slow idle speed for approx.

10 seconds. Top up oil level in hydraulic reservoir.

Repeat this procedure until a constant level of oil is being obtained in the reservoir.

3. Always add oil as necessary to bring oil up to the proper level in the reservoir.

4. Bleed and flush (scavenge) the hydrostatic transmission: With gear shift lever in neutral, set engine speed to slow idle. Move hydrostatic drive control lever from neutral halfway forward and let hydrostatic transmission rotate for approximately two minutes.

Then move lever halfway out of neutral in reverse direction and let hydrostatic transmission rotate for approximately two minutes.

5. With hydrostatic drive control lever in neutral, stop the Diesel engine. Add hydraulic oil up to the indicator mark on the dipstick, if required.

6. Carry out a test run.

(Fig. 6)

Hydrostatic pump adjustment If an absolute stop of the machine is not obtained with ground speed control lever in neutral position, the hydrostatic pump must be readjusted in the slots of the retarder for Bowden cable (C).

C

NOTE! Always ensure that the threaded end of Bowden cable engages in the clevis by at least 6 mm.

7 (Fig. 7)

9.3.4

BA DO 208 / 204 MEGA - 298 672.0

Maintenance – basic machine, cutterbar Bleeding the reel cylinders The reel cylinders must be bled each time the hydraulic cylinders and / or the feed lines have been repaired or disconnected.

1. Operate the hydraulic control unit to fully raise the reel and push the reel by hand, if necessary, to the maximum height position.

A

2. Loosen bleed screw (A) on cylinder without removing it.

8

3. Move the control unit lever in the «raise reel» position and hold it there. When bubble-free oil flows out, tighten bleed screw (A). Then raise and lower the reel several times.

4. Check reel cylinders for synchronized operation which is obtained by repeating the bleeding operation.

(Fig. 8) When the reel cylinders are fully drained, carry out the initial bleeding procedure with the reel removed from the machine. Failure to do so could result in damage to the reel.

298 672.0 - BA DO 208 / 204 MEGA

9.3.5

Maintenance – basic machine, cutterbar Bleeding the hydraulic cylinders for cutterbar lateral levelling (Machines with Auto Contour System) This must be done after the hydraulic system has been repaired.

V

1. Move lever (H) to (A) in order to open shut-off tap (R).

Loosen hex. screw plugs (V) on both the coupling lugs.

K 9

On the right-hand side loosen hex. head Allen screw (K) at the cylinder head.

2. Switch on safety rocker switch (65). Press the right-hand end of rocker switch (55) for manual operation so that both pistons extend.

Tighten screws (V and K) when bubble-free oil emerges.

V

3. Both cylinders should now be fully extended.

Loosen hex. head Allen screw (L) at the left-hand cylinder.

4. Press the left-hand end of rocker switch (55).

L 10

Tighten the screw (L) when bubble-free oil is issued.

The left-hand cylinder is now retracted.

(Fig. 9, 10, 11, 12)

H R Z

A

11

55

65 12

9.3.6

BA DO 208 / 204 MEGA - 298 672.0

Maintenance – basic machine, cutterbar Foot brake / brake fluid DANGER! Regularly check the level of the brake fluid in the reservoir and top up as necessary.

Use only the recommended brake fluid.

Adjustments, repairs and service work on the brake system must be performed only by specialist workshops.

A

Renew the brake fluid every 2 years and have the brake system bled.

13

A = Brake fluid reservoir (Fig. 13)

298 672.0 - BA DO 208 / 204 MEGA

9.3.7

Maintenance – basic machine, cutterbar

9.3.8

BA DO 208 / 204 MEGA - 298 672.0

Maintenance – basic machine, cutterbar

Maintenance – basic machine, cutterbar TRANSMISSION AND GEARBOXES ENVIRONMENT! Dispose of the oil in a way that is harmless to the environment and in accordance with existing environmental regulations.

Gear shift control adjustment Adjust shift rods (C and D) next to the operator's platform at ball joints (K), so that the gears are fully in mesh and the detent balls lock properly in the shift rails.

K

(Fig. 1) D

C

1

Change-speed transmission gearbox Checking oil level K = Oil level check plug (Fig. 2) K

A 2 Oil change A = Oil drain plug with magnet E = Oil filler plug with gearbox breather Clean the magnet of the oil drain plug on every oil change.

E

(Fig. 2, 3)

3

298 672.0 - BA DO 208 / 204 MEGA

9.4.1

Maintenance – basic machine, cutterbar Final drives DOMINATOR 208 MEGA K

Checking oil level K = Oil level check plug Oil change A = Oil drain plug E = Oil filler plug L = Gearbox breather

A 4

Clean the magnet of the oil drain plug on every oil change.

(Fig. 4, 5)

E

L 5

Final drives DOMINATOR 204 MEGA E

Checking oil level K = Oil level check plug Oil change A = Oil drain plug E = Oil filler plug with gearbox breather Clean the magnet of the oil drain plug on every oil change.

6

(Fig. 6, 7)

K A

7

9.4.2

BA DO 208 / 204 MEGA - 298 672.0

Maintenance – basic machine, cutterbar Rear wheel drive planetary gears CLAAS 4-Trac System Check oil level

K

When checking the oil level, ensure that the wheels of the rear axle are in contact with the ground and that oil level check plug (K) is in the horizontal plane (H).

H

The oil must be up to the level of check plug (K).

Oil change A 8

To drain the oil from the final drives, position the rear wheels so that drain plug (A) is at the bottom and screw (K) is in the horizontal plane.

To drain the oil, also remove screw (K).

After filling the final drives with oil, screw in both screws again tightly.

(Fig. 8)

Knife drive casing E

Checking the oil level / oil change Check the oil level in the casing at the oil level check plug (K).

A = Oil drain plug E = Oil filler plug K = Oil level check plug

A

K

NOTE! 9

When checking the oil level and when draining the transmission oil, set the cutterbar to such an elevation that the transmission is in a horizontal position.

(Fig. 9)

298 672.0 - BA DO 208 / 204 MEGA

9.4.3

Maintenance – basic machine, cutterbar Threshing drum reduction gearbox Located behind one of the holes (2) is a threaded plug, which can be used for filling and draining oil, and to check oil level.

2

Checking oil level X

Turn the threshing drum reduction gearbox so that the bore (2) in front of the sealing plug is 27° = dimension (X) under the horizontal plane (H). The oil level can be checked in this position.

2

Oil change 10

To drain the oil, turn the reduction gearbox so that the sealing plug is at the bottom.

To fill with oil the plug must be at the top.

(Fig. 10)

Grain tank Angle drive on grain tank discharge auger Unscrew lid (D), check grease filling in angle drive once a year and fill in grease as required. Ensure tight fit when bolting down the lid.

(Fig. 11)

D 11 Angle drive on grain tank (DOMINATOR 208 MEGA) Check the grease filling in the angle drives (W) once a year and fill in grease as required. To do this, open lids (E). When filling is complete, close lids (E) tightly.

E

(Fig. 12) W

12

9.4.4

BA DO 208 / 204 MEGA - 298 672.0

Maintenance – basic machine, cutterbar

Maintenance – basic machine, cutterbar FEEDER HOUSING DOMINATOR 208 MEGA

Tension feeder chains P

After loosening clamping bolts (A) and lock nuts (C), feeder chains (E) can be tensioned with the tensioning nuts (B). Tension the chains equally on both sides and only to the extent that the feed bars just touch the slide rails (G).

The chain tension can be checked with cutterbar installed through the inspection flaps (P) on the feeder housing.

E

(Fig. 1, 2, 3)

E

G

G

1 DOMINATOR 204 MEGA

P

E

E

G

2

C

B

A

3

298 672.0 - BA DO 208 / 204 MEGA

9.5.1

Maintenance – basic machine, cutterbar

9.5.2

BA DO 208 / 204 MEGA - 298 672.0

Maintenance – basic machine, cutterbar

Maintenance – basic machine, cutterbar ELEVATOR CHAINS Tension grain elevator chain To tension the grain elevator chain, open the elevator flap (B) on the elevator boot.

Loosen counter-nut (G).

Tension the grain elevator chain with nut (M).

B

Tension the grain elevator chain so that the conveyor plates do not scrape on the elevator housing.

A

At the bottom sprocket, it must still be possible to push the conveyor chain to the side by hand.

1 DOMINATOR 208 MEGA

Tighten counter-nut (G) again and close the flap on the elevator boot again tightly.

The drive chain for the filling auger is automatically held taut by the spring-loaded tensioner.

M

(Fig. 1, 2, 3)

G

S

K

2 DOMINATOR 204 MEGA

M

G

3

298 672.0 - BA DO 208 / 204 MEGA

9.6.1

Maintenance – basic machine, cutterbar Tension returns elevator chain To tension the returns elevator chain, open elevator flap (A) on the elevator boot.

G

Loosen clamping bolts (G) on both sides.

M

Relieve the drive chain for the levelling auger drive by loosening block tensioner (S).

S

Tension the returns elevator chain with nut (M) so that the conveyor plates do not scrape on the elevator housing.

4

At the bottom sprocket, it must still be possible to push the conveyor chain to the side by hand.

Tension the drive chain with block tensioner (S) again.

Tighten clamping bolts (G) again and close the flap on the elevator boot again tightly.

(Fig. 1, 3)

9.6.2

BA DO 208 / 204 MEGA - 298 672.0

Maintenance – basic machine, cutterbar

Maintenance – basic machine, cutterbar DRIVE BELTS / DRIVE CHAINS – BASIC MACHINE General notes Figures (1 and 2) show the overview of the belt and chain drives.

ATTENTION! When the belts are removed and during prolonged standstills of the machine, protect the grooves and running surfaces of the drive belts in the pulleys against corrosion.

Before fitting the belts again, clean the grooves and running surfaces in the pulleys.

DANGER! Caution when carrying out installation work on the variable-speed pulleys. Never put your hands between the pulley halves – Danger of accidents!

NOTE! Use special tools for fitting and removing the variable speed drive belts.

For variable-speed pulleys which move easily, the pulley halves can be pressed apart or blocked using a special bolt BM 12 x 180 DIN 564-8.8 (Part No. 236 302.0).

This special bolt is referred to in the following text as (B).

If the pulley halves are difficult to move, use two bolts.

If possible, always open the variable-speed pulleys with the drives still running and then switch off the engine and drives.

298 672.0 - BA DO 208 / 204 MEGA

9.7.1

Maintenance – basic machine, cutterbar

1

Drive diagram left 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Cutterbar drive Compressor drive Hydrostatic ground drive Working hydraulics – pump drive Threshing mechanism drive Grain tank unloading drive Sieve pan / fan intermediate drive Fan drive Sieve pan intermediate drive Sieve pan drive Straw walker drive Intensive separation system drive Free Straw spreader drive Chaff spreader drive Chaff spreader drive Accelerator drive

(Fig. 1)

9.7.2

BA DO 208 / 204 MEGA - 298 672.0

Maintenance – basic machine, cutterbar

2

Drive diagram right 20 21 22 23 24 25 26 27 28 29 30 31 32

Straw chopper drive Straw chopper intermediate drive Suction blower drive Threshing drum variable speed drive Threshing drum drive Free Radiator screen drive Radiator screen intermediate drive Alternator / fan drive Free Filling auger drive Grain tank unloading intermediate drive Grain tank unloading intermediate drive (DOMINATOR 208 MEGA) 33 Returns drive (Fig. 2)

298 672.0 - BA DO 208 / 204 MEGA

9.7.3

Maintenance – basic machine, cutterbar

F

K

R

X

1

A

3

Drive belts / drive chains Removing cutterbar drive belt (1) Remove drive belt (7).

Relieve cutterbar drive belt (1): DANGER! Take particular care when unscrewing cylinder barrel (R).

Do not unscrew the cylinder barrel too far – Danger of accidents!

9.7.4

BA DO 208 / 204 MEGA - 298 672.0

Maintenance – basic machine, cutterbar Proceed as follows: 1. Determine dimension (X).

2. Loosen lock nut (K).

R

F

H

3. Back off cylinder barrel (R) up to dimension (X).

At the same time, tighten nut (K) until washer (S) is up against bracket (H).

S K

Pin (B) must then be under no strain; if necessary, retighten cylinder barrel (R) and nut (K) again slightly.

X

4

4. Remove the cotter pin from pin (B) and remove the pin.

5. Remove belt (1).

(Fig. 3, 4, 5)

R

H

S

K

B

5 Fitting and tensioning cutterbar drive belt (1) 1. Bolt on idler pulley (A).

DOMINATOR 208 MEGA = 2nd hole from bottom DOMINATOR 204 MEGA = 5th hole from bottom The tightening torque for the M 16 mounting bolt is 130 Nm. 2. Fit belt (1).

3. Insert pin (B) and secure.

4. Adjust spring-loaded cylinder (F) at cylinder barrel (R) with lock nut (K) loosened so that dimension (X) with lock nut tightened is 75 mm.

Carry out a test run and check the belt tension again.

(Fig. 3, 4, 5)

298 672.0 - BA DO 208 / 204 MEGA

9.7.5

Maintenance – basic machine, cutterbar Tensioning compressor drive belt (2) Loosen clamping bolt (3), push the compressor in the direction of the arrow and tighten the clamping bolt again. Always keep the drive belt well tensioned.

2

ATTENTION! K 3

The hoses (K) of the air conditioning system must not be kinked.

K

6

Carry out a test run and check the belt tension again.

(Fig. 6)

9.7.6

BA DO 208 / 204 MEGA - 298 672.0

Maintenance – basic machine, cutterbar

K

M

H R

T

Y

N 3

S

N

7 Tensioning hydrostatic ground drive belt (3) DANGER! Carry out the adjustment only with the engine switched off and the ignition key removed.

Note the adjustment of the spring-loaded cylinder and the tensioning of drive belt (3) at the same time!

298 672.0 - BA DO 208 / 204 MEGA

9.7.7

Maintenance – basic machine, cutterbar Tension power band belt: Tension power band belt (3) with nuts (N) loosened using clamping rails (S) so that jockey pulley (T) deflects the power band belt by 25 – 30 mm at (Y).

The V-belt can be tensioned at clamping rails (S) with the different hole spacing by inserting two key pullers or similar tools.

After adjustment, tighten nuts (N) again.

(Fig. 7, 8)

S 8

Adjust the spring-loaded cylinder: Loosen lock nut (K) and adjust cylinder barrel (R) so the tube (M) just contacts bracket (H). Tighten lock nut (K) again.

(Fig. 7) Carry out a test run and check the belt tension again.

Tensioning working hydraulics pump drive belt (4) Tension the V-belt with tensioner rod (T).

P

To tension the belt, loosen lock nut (K) and tension V-belt (4) with nut (M). After tensioning, lock nut (K) again.

T 4

K

P = Hydraulic pump (Fig. 9)

M

Carry out a test run and check the belt tension again.

9

9.7.8

BA DO 208 / 204 MEGA - 298 672.0

Maintenance – basic machine, cutterbar Removing and installing the power band belt (3) Remove compressor drive V-belt (2).

U

K

Manufacture U-piece (U) according to specified dimensions and place it on the cylinder tube (R). Secure U-piece with a spring clip.

R

Turn back the lock nut (K) and turn in the cylinder tube (R).

(Fig. 10)

10 Dimensions of U-piece (self-manufactured)

D

B

C

A B C D E F

A F E

= = = = = =

46 mm 30 mm 38 mm approx. 30 mm 7 mm ∅ 4 mm

(Fig. 11)

38739

11 Loosen the four nuts (N) enough that the hydraulic pump can be moved.

N

Push hydraulic pump upwards a little bit.

Remove power band belt (3).

(Fig. 12) N

12 Install and tension power band belt (3) – see page 9.7.8, Tension power band belt: Tension the compressor drive V-belt (2) – see page 9.7.6, Tensioning compressor drive belt (2).

298 672.0 - BA DO 208 / 204 MEGA

9.7.9

Maintenance – basic machine, cutterbar

Maintenance – basic machine, cutterbar

E

Z R

K S

D C

5 A B

Y 39957

13 Threshing mechanism drive belt (5) DANGER! Carry out the adjustment only with the engine switched off and the ignition key removed.

When the engine is running, a hydraulic pressure of 20 bar is exerted on the ring surface, port (R), of the low-pressure hydraulic cylinder. As a result, the threshing mechanism drive is switched off via jockey pulley (S).

Adjust belt guides: Secure the belt guides at points (A, B, C and D) so that with the belt tensioned, the distances (Y) between the back of the belt and the guides are 5 to 7 mm at all points.

Adjust the belt guide at (E) so that with the belt tensioned, distance (Z) between the back of the belt and the guide is 6 ± 1 mm.

After every adjustment, carry out a test run, check the dimensions and correct, if necessary.

(Fig. 13)

When the threshing mechanism drive is switched on, the piston surface, port (K), is also pressurised to 20 bar. As a result, the larger piston surface causes the piston rod to extend and to tension the drive belt (5) with jockey pulley (S).

9.7.10

BA DO 208 / 204 MEGA - 298 672.0

Maintenance – basic machine, cutterbar

Maintenance – basic machine, cutterbar Removing and installing the threshing mechanism drive belt (5) Remove V-belts (7, 1, 2, 3, 4 and 6).

C

K

On the DOMINATOR 204 MEGA, the drive belt (6) is located behind drive belt (5).

D

(Fig. 14)

14 Remove hydraulic cylinder (H). To do this, unscrew hexagon bolt (E) and remove cotter pin (F).

(Fig. 15)

F H

E

15 Set back guide plate (G).

(Fig. 16) G

16 Unscrew the bottom belt guide (R).

(Fig. 17) R

17

298 672.0 - BA DO 208 / 204 MEGA

9.7.11

Maintenance – basic machine, cutterbar Unscrew the belt guide (T).

Remove the threshing mechanism drive belt (5).

(Fig. 18) T

18 Install threshing mechanism drive belt (5).

Bolt down belt guides (R and T).

(Fig. 17, 18)

Adjust belt guides – see page 9.7.10, Adjust belt guides: Install drive belts (6, 4, 3, 2, 1 and 7).

Drive belt (6) is provided on DOMINATOR 208 MEGA only.

Re-fit and attach hydraulic cylinder for grain tank unloading.

9.7.12

BA DO 208 / 204 MEGA - 298 672.0

Maintenance – basic machine, cutterbar

Maintenance – basic machine, cutterbar

2 1

X

Y Y

A

B

S

6

C

3 4

R K

41338

19 Grain tank unloading drive belt (6) DANGER! Carry out the adjustment only with the engine switched off and the ignition key removed.

When the engine is running, a hydraulic pressure of 20 bar is exerted on the ring surface, port (R), of the low-pressure hydraulic cylinder. As a result, grain tank unloading is switched off via jockey pulley (S).

Adjust belt guides: Secure the belt guides (A and B) at points (1, 2 and 3) so that with the belt tensioned, the distances (Y) between the back of the belt and the guides are 5 – 7 mm at all points.

Adjust belt guide (C) at point (4) so that distance (X) is 6 ± 1 mm.

After every adjustment, carry out a test run, check the dimensions and correct, if necessary.

(Fig. 19)

When grain tank unloading is switched on, the piston surface, port (K), is also pressurised to 20 bar. As a result, the larger piston surface causes the piston rod to extend and to tension the drive belt (6) with jockey pulley (S).

298 672.0 - BA DO 208 / 204 MEGA

9.7.13

Maintenance – basic machine, cutterbar

Maintenance – basic machine, cutterbar Removing the grain tank unloading drive belt (6): Remove drive belts (7, 1, 2, 3 and 4).

Loosen hexagon bolt (S) and rotate belt guide (C) downwards.

C

Remove drive belt (6).

S

(Fig. 20)

20 Installing the drive belt (6) and adjusting the belt guide: Install drive belt (6).

Adjust belt guide (C) – see page 9.7.10, Adjust belt guides: Install the drive belts (4, 3, 2, 1 and 7).

Removing and installing the sieve pan drive belt (7) Open cover (K) and remove guard (C).

K

(Fig. 21)

C 21 Unscrew hydraulic hose (H) from the hydraulic cylinder.

H

(Fig. 22)

22

9.7.14

BA DO 208 / 204 MEGA - 298 672.0

Maintenance – basic machine, cutterbar Remove speed control belt (8).

Relieve the tension of drive belt (7). To do this, turn back nut (M) on the spring-loaded bar (S).

Now remove the drive belt between the electric motor (E) and the cover.

7

(Fig. 23) S

M

E

K 23 Tensioning the drive belt (7): Install drive belt (7) and tension by means of nut (M).

Now lock the spring-loaded bar with lock nut (K).

Install speed control belt (8).

Connect hydraulic hose (H) to the hydraulic cylinder.

(Fig. 22, 23)

Removing and fitting fan variable-speed belt (8) ATTENTION! With the combine engine running, set the fan to the lowest speed. Switch off the threshing mechanism, switch off the engine and remove the ignition key.

L

Remove cable plug (L) from the DC motor.

24

Tension belt (8) by hand until the spring-loaded variable-speed pulley is completely open.

Remove the belt from both pulleys.

Before fitting the variable-speed belt again, clean the pulley running surfaces.

Place the belt into the spring-loaded variable-speed pulley from the bottom.

Pull the belt into the variable-speed pulley assembly until the pulley is completely open. Fit the belt at the top. Fit cable plug (L).

8

Carry out a test run.

(Fig. 24, 25) 25

298 672.0 - BA DO 208 / 204 MEGA

9.7.15

Maintenance – basic machine, cutterbar Removing and installing the sieve pan drive belt (9) Remove speed control belt (8).

Loosen the jockey pulley (S).

Remove the drive belt (9).

S

9

(Fig. 26)

26 Installing and tensioning the drive belt (9): Install drive belt (9).

Tension drive belt by pressing down the jockey pulley (S) while at the same time tensioning the jockey pulley.

Install speed control belt (8).

(Fig. 26)

M

Removing and installing the sieve pan drive belt (10)

K

Loosen the lock nut (K) and turn back nut (M).

Loosen the clamping bolt (R).

Remove the drive belt (10).

(Fig. 27)

R 10

27 Installing and tensioning the sieve pan drive belt (10): Install drive belt (10) and tension by means of nut (M).

Tighten clamping bolt (R) and lock nut (K).

(Fig. 27)

9.7.16

BA DO 208 / 204 MEGA - 298 672.0

Maintenance – basic machine, cutterbar Removing and installing the straw walker drive belt (11) Remove sieve pan drive belt (9).

Loosen lock nut (K) and turn back nut (M).

Loosen clamping bolt (B).

B

Remove drive belt (11).

M

(Fig. 28)

K

11 28 Installing and tensioning the straw walker drive belt (11): Install drive belt (11) and tension it using the nut (M).

Tighten clamping bolt (B) and lock nut (K).

Install drive belt (9).

(Fig. 28)

Removing and installing the intensive separation system drive belt (12) Remove straw walker drive belt (11) at the rear.

M

K

Loosen lock nut (K) and turn back nut (M).

R

Loosen the clamping bolt (R).

Remove drive belt (12).

X

(Fig. 29)

12 29 Installing and tensioning the intensive separation system drive belt (12): Install drive belt (12) and tension it using nut (M).

After tensioning, lock nut (K).

Tighten clamping bolt (R).

The spring length (X) must be 73-3 mm with the clamping bolt (R) loosened.

(Fig. 29)

298 672.0 - BA DO 208 / 204 MEGA

9.7.17

Maintenance – basic machine, cutterbar Removing and installing the chaff spreader drive belt (15)

S

Remove straw walker drive belt (11) at the rear.

Remove intensive separation system drive belt (12).

Loosen the jockey pulley (S).

Remove drive belt (15).

15

(Fig. 30)

30 Installing the chaff spreader drive belt (15): Install drive belt (15).

Tension drive belt by pressing down the jockey pulley (S) and at the same time tighten the clamping bolt.

Install straw walker drive belt (11).

Install intensive separation system drive belt (12).

(Fig. 30)

Chaff spreader drive belt (16) This belt (16) is tensioned via spring (F).

Retensioning is not possible.

(Fig. 31)

16

F

31

9.7.18

BA DO 208 / 204 MEGA - 298 672.0

Maintenance – basic machine, cutterbar

21

K M

N

22 2 1

X

F

39961

32 Straw chopper intermediate drive belt (21) Loosen lock nut (1) and adjust cylinder barrel (2) so that the distance (X) with the lock nut tightened is 30+5 mm.

Carry out a test run and check the belt tension again.

(Fig. 32)

Removing the V-belt (21): Loosen lock nut (K) and turn in the hexagon bolt (E).

(Fig. 33)

E

K 33

298 672.0 - BA DO 208 / 204 MEGA

9.7.19

Maintenance – basic machine, cutterbar Manufacture a U-piece (U) according to specified dimensions and place it on the cylinder tube (2).

Secure U-piece with a spring clip.

Turn back the hexagon nut (M) and turn in the cylinder tube (2).

M

(Fig. 34) 2 U

34 Dimensions of U-piece (self-manufactured)

D

B

C

A B C D E F

A F E

= = = = = =

46 mm 30 mm 38 mm approx. 30 mm 7 mm dia. 4 mm

(Fig. 35)

38739

35 Unscrew the three hexagon bolts (S).

(DOMINATOR 208 MEGA) Loosen hexagon bolt (B) at the jockey pulley and remove the V-belt.

(Fig. 36)

S B

36 Rotate the V-belt pulley (K) and push it into the recess (DOMINATOR 208 MEGA).

(Fig. 37) K

37

9.7.20

BA DO 208 / 204 MEGA - 298 672.0

Maintenance – basic machine, cutterbar Pull V-belt (21) through between grain elevator and V-belt pulley.

21

(Fig. 38)

38 Remove guard (T).

(Fig. 39)

T

39 – Unscrew hydraulic hose (H) from the hydraulic cylinder.

– Remove V-belts (22 and 21) from the variable speed pulley.

H

(Fig. 40) 22

21 40

298 672.0 - BA DO 208 / 204 MEGA

9.7.21

Maintenance – basic machine, cutterbar Installing and tensioning the V-belt (21): – Install V-belt (21) on V-belt pulley (K) and jockey pulley (L).

K

S

– Fit the V-belt pulley (K) to the intermediate drive using the 3 hexagon bolts (S).

B

– Tighten the hexagon bolts (S) to 195 Nm. – Tighten hexagon bolt (B) to 130 Nm. – Install V-belts (21 and 22) at the drum variable speed drive.

L 41

– Remove U-piece (U).

– Turn out the hexagon bolt (E) again up to the jockey pulley arm and lock it.

– Re-fit hydraulic hose. Re-fit guard (T).

– Tension V-belt – see page 9.7.19, Straw chopper intermediate drive belt (21).

(Fig. 33, 34, 39, 40, 41)

Tensioning suction blower drive belt (22) Loosen clamping bolt (K) slightly.

With nut (N) loosened, tension belt (22) with nut (M).

Tighten nut (N) and clamping bolt (K) again.

K

Carry out a test run and check the belt tension again.

N

M

(Fig. 32, 42)

42 Removing and fitting threshing drum variable speed drive belt (23) DANGER!

T

Caution when carrying out installation work on the variable-speed drives. Never put your hands between the pulley halves – Danger of accidents!

Block the variable-speed pulleys with a special tool – see following text.

43 Shut down the engine and remove the ignition key.

Remove guard (T).

(Fig. 43)

9.7.22

BA DO 208 / 204 MEGA - 298 672.0

Maintenance – basic machine, cutterbar Remove guard (C).

(Fig. 44) C

44 Unscrew hydraulic hose (H) from the hydraulic cylinder.

H

Relieve tension of V-belts (21 and 22) and remove.

(Fig. 45)

22

21 45 Screw two hexagon head bolts (S) BM 12 x 180 DIN 564-8.8 (Part No. 236 302.0) through the tapped bores in the front pulley half until they contact the rear pulley half. This locks the variable-speed pulley in the open position.

Remove V-belt (23) from both pulleys.

S

(Fig. 46)

46

ATTENTION! Before fitting the variable-speed drive belt again, clean the pulley running surfaces.

After fitting the belt, pull it taut between the pulley halves and unscrew the hexagon head bolts from the tapped bores. Connect the hydraulic hose and fit guards (C and T).

Carry out a test run.

(Fig. 43, 44, 45, 46)

298 672.0 - BA DO 208 / 204 MEGA

9.7.23

Maintenance – basic machine, cutterbar Removing and filtting the threshing drum drive belt (24) DANGER! Shut down the engine and remove ignition key before commencing work!

D

– Remove guards (C and T).

– Remove threshing drum speed control belt (23).

47

– Unscrew bridge (D) if necessary. (machine with step control drive) (Fig. 43, 44, 47)

– Relieving the tension of threshing drum drive belt (24): Remove blind cover (P).

Loosen the lock nut (1).

Fully turn back the cylinder tube (2).

(Fig. 48) 1 2 P 48 – Remove threshing drum drive belt (24).

(Fig. 49)

49

9.7.24

BA DO 208 / 204 MEGA - 298 672.0

Maintenance – basic machine, cutterbar Installing and tensioning the threshing drum drive belt (24): – Install drive belt (24).

– Screw in cylinder tube (2).

1

D

– Adjust cylinder tube (2) until the end of the graduated scale (D) is flush with washer (S).

Tighten lock nut (1).

S 2

– Insert blind cover (P).

P

– Install threshing drum speed control belt (23).

50

(Fig. 50)

Tensioning radiator screen intermediate drive belt (27) Loosen lock nut (K) and tension V-belt (27) with nut (M).

M

Spring length (X) must be 35 mm.

K

After tensioning, lock nut (K) again.

X

(Fig. 2, 51)

39962

51 Tensioning the grain tank unloading intermediate drive chain (31) (DOMINATOR 208 MEGA) K

31

To tension the chain, loosen tensioner block (K).

Tension the chain with tensioner block (K) and retighten the tensioner block.

(Fig. 52)

52 Tensioning the grain tank unloading intermediate drive chain (32) (DOMINATOR 208 MEGA)

K

To tension the chain, loosen jockey sprocket (K).

32

Hold the chain under tension with jockey sprocket (K) and tighten the jockey sprocket again.

(Fig. 53)

53

298 672.0 - BA DO 208 / 204 MEGA

9.7.25

Maintenance – basic machine, cutterbar Tensioning the grain tank unloading intermediate drive chain (31) (DOMINATOR 204 MEGA) K

To tension the chain, loosen tensioner block (K).

31

Tension the chain with tensioner block (K) and retighten the tensioner block.

(Fig. 54)

54 Tensioning returns drive chain (33) To tension the chain, loosen tensioner block (K).

Tension the chain with tensioner block (K) and retighten the tensioner block.

33

(Fig. 55)

K

55

9.7.26

BA DO 208 / 204 MEGA - 298 672.0

Maintenance – basic machine, cutterbar

2

X

F

1

56 Removing and installing the accelerator drive belt (17) Removing the drive belt (17):

K

Open door (K) and remove guard (C).

(Fig. 57)

C 57 Manufacture U-piece (U) according to specified dimensions and place it on the cylinder tube (2).

Secure U-piece with spring clip.

2 U

Turn back the lock nut (1) and turn in the cylinder tube (2).

1

Remove drive belt (17).

(Fig. 58) 17 58

298 672.0 - BA DO 208 / 204 MEGA

9.7.27

Maintenance – basic machine, cutterbar Dimensions for U-piece (self-manufactured)

D

B

C

A B C D E F

A F E 38739

= = = = = =

46 mm 30 mm 38 mm approx. 30 mm 7 mm dia. 4 mm

(Fig. 59)

59 Installing and tensioning the drive belt (17): Adjust cylinder tube (2) so that the dimension (X) is 135 mm with the lock nut (1) tightened.

(Fig. 56)

9.7.28

BA DO 208 / 204 MEGA - 298 672.0

Maintenance – basic machine, cutterbar

Maintenance – basic machine, cutterbar

60

Straw chopper drive belt (20)

Chopper drive in maize:

Adjust spring-loaded cylinder (C):

Replace the rear V-belt with the shorter belt.

Carry out adjustment at cylinder barrel (2) with lever (H) released and lock nut (1) loosened.

Adjust jockey pulley (B) so that the distance (A) is as large as possible, but not more than 145 ± 10 mm.

1. Adjust jockey pulley (B) so that the distance (A) is as large as possible, but not more than 130 ± 10 mm.

(Fig. 60)

2. Adjust spring-loaded cylinder (C) so that dimension (X) is 30+5 mm when lever (H) is locked.

After adjustment, tighten lock nut again.

Adjust spring-loaded cylinder (F): Loosen lock nut (1) and adjust cylinder barrel (2) so that the distance (X) with the lock nut tightened is 30+5 mm.

298 672.0 - BA DO 208 / 204 MEGA

9.7.29

Maintenance – basic machine, cutterbar

9.7.30

BA DO 208 / 204 MEGA - 298 672.0

Maintenance – basic machine, cutterbar

Maintenance – basic machine, cutterbar DRIVE BELTS / DRIVE CHAINS – CUTTERBAR General notes Figure 1 shows the overview of the belt and chain drives.

ATTENTION! When the belts are removed and during prolonged standstills of the machine, protect the grooves and running surfaces of the drive belts in the pulleys against corrosion.

Before fitting the belts again, clean the grooves and running surfaces in the pulleys.

DANGER! Caution when carrying out installation work on the variable-speed pulleys. Never put your hands between the pulley halves – Danger of accidents!

298 672.0 - BA DO 208 / 204 MEGA

9.8.1

Maintenance – basic machine, cutterbar

44 45

43 42

40

41

40

41

44 45

43 42

1

Drive diagram cutterbar 40 41 42 43 44 45

Knife drive belt Main table auger drive chain Reel drive chain Reel drive belt Reel drive chain Reel drive chain

(Fig. 1)

9.8.2

BA DO 208 / 204 MEGA - 298 672.0

Maintenance – basic machine, cutterbar Cutterbar up to 5.10 m

Tensioning knife drive belt (40) Adjust spring-loaded cylinder: Loosen lock nut (3) and adjust cylinder barrel (4) so that the spring length (X) with the lock nut tightened is 100 mm.

X 4

3

(Fig. 2, 3)

40 2 Cutterbar over 6.00 m

40 X

3

4

40

3 Tensioning main table auger drive chain (41) Loosen jockey sprocket (S) slightly.

Tension chain (41) by pressing jockey sprocket (S) down. Tighten the jockey sprocket.

Carry out a test run and check the chain tension again.

S

(Fig. 4)

41 4

298 672.0 - BA DO 208 / 204 MEGA

9.8.3

Maintenance – basic machine, cutterbar Cutterbar up to 5.10 m

Tensioning reel drive chain (42) Loosen jockey sprocket (S) slightly.

Tension chain (42) by moving jockey sprocket (S).

Tighten the jockey sprocket.

S 42

Carry out a test run and check the chain tension again.

(Fig. 5, 6)

5 Cutterbar over 6.00 m

S 42 6 Removing and fitting reel drive belt (43) DANGER! Caution when carrying out installation work on the variable-speed drives. Never put your hands between the pulley halves – Danger of accidents!

Start the diesel engine with the cutterbar attached.

Switch on the main drive, threshing mechanism and cutterbar drive. Adjust the reel to the slowest speed.

DANGER! Switch off the engine and remove the ignition key.

9.8.4

BA DO 208 / 204 MEGA - 298 672.0

Maintenance – basic machine, cutterbar Cutterbar up to 5.10 m

Unbolt guard (A).

(Fig. 7, 8) A

7 Cutterbar over 6.00 m

A

8 Cutterbar up to 5.10 m

Unscrew hexagon head bolt M 10 x 140 (K) until belt (43) can be pulled into the spring-loaded variable speed pulley assembly.

K DANGER! Do not unscrew hexagon head bolt (K) completely – Danger of accidents!

43

Remove belt (43).

9

(Fig. 9, 10)

Cutterbar over 6.00 m

K

43

10

298 672.0 - BA DO 208 / 204 MEGA

9.8.5

Maintenance – basic machine, cutterbar Before fitting the power band belt again, clean the pulley running surfaces.

Fit belt (43) first to the spring-loaded variable speed pulley and then to the lower variable speed pulley.

Screw in hexagon head bolt (K) again.

NOTE! Note that the parallel key engages in the groove of the pulley half.

Bolt on guard (A).

Carry out a test run.

(Fig. 7, 8, 9, 10)

Tensioning reel drive chain (44) Tension the chain with tensioner rod (S).

K

Loosen hexagon head bolt (A) slightly. Loosen lock nut (K). Tension chain (44) with nut (M). After tensioning the chain, lock nut (K) again.

M

Tighten hexagon head bolt (A).

Carry out a test run and check the chain tension again.

S

(Fig. 1, 11)

A 11

Tensioning reel drive chain (45) Z

B

The reel drive chain (45) is constantly held under tension by spring cylinder (E).

E

Adjusting the spring cylinder:

K

Loosen lock nut (K) and turn cylinder barrel (Z) until the stop washer in cylinder barrel (Z) is visible in the middle of bore (W). Tension lock nut (K) again.

W 45

NOTE! 12

Note that the stud (B) is inserted in the rear hole.

Carry out a test run and check the chain tension again.

(Fig. 12)

9.8.6

BA DO 208 / 204 MEGA - 298 672.0

Maintenance – basic machine, cutterbar

Maintenance – basic machine, cutterbar CAB / COMPRESSOR-TYPE AIR CONDITIONER Cab

K

Cleaning the filters

D

Swing the cab roof (D) up, release retainer frame (K) and remove the filters (F). Clean the air ducts in the cab roof.

K F F

If the filters are just clogged up with dust on the outside faces, clean them by tapping or using a vacuum cleaner or compressed air.

It is imperative that damaged filters and sealing strips be replaced.

1

(Fig. 1) When installing the filters, make sure that the sealing strips are seated properly to prevent dust entering the cab.

Compressor-type air conditioner Cleaning the condenser The condenser (N) is located behind the rotary radiator screen.

N

Inspect the condenser for dirt during the usual daily cleaning of the water cooler (radiator). If necessary, blow out the condenser with compressed air, air pressure must not exceed 5 bar.

ATTENTION! 2

It is most important to avoid damaging the fins – see page 10.4.3, Cleaning the radiator chaff screen.

(Fig. 2)

DANGER! Maintenance work on any part of the refrigerant circuit (e.g. changing the filter receiver-drier) must be carried out only by qualified, expert personnel.

298 672.0 - BA DO 208 / 204 MEGA

9.9.1

Maintenance – basic machine, cutterbar Checking refrigerant level The refrigerant level can be checked at the sight glass (G) of the filter receiver drier.

A white float ball and a blue indicator ball can be seen in the sight glass.

G

(Fig. 3)

3 Function of the white float ball: The refrigerant level can be monitored by means of the white float ball.

To check, put the air conditioner system into operation.

If the white float ball is at the bottom – there is a refrigerant shortage. Contact the air conditioner repair service.

If the white float ball is at the top – the refrigerant quantity is ok.

Function of blue indicator ball: Moisture in the refrigerant circuit is absorbed by the filter receiver drier. The blue ball turns pink when the filter receiver drier is saturated with moisture.

Replacing the filter receiver drier Replace the filter receiver drier: 1. When the indicator ball (blue ball) has turned pink.

2. Whenever a repair is carried out which makes it necessary to open the refrigerant circuit (but only if the air conditioning system has been in service for a longer period of time).

Required refrigerant quantity – Refrigerant R 134 a The required filling quantity is 1.550 kg of refrigerant.

Type of oil in the compressor = SANDEN Oil – (PAG).

9.9.2

BA DO 208 / 204 MEGA - 298 672.0

Maintenance – basic machine, cutterbar Maintenance work before the harvest 1. Check the clutch, V-belt tension and the alignment of the belt pulleys.

2. Check that all the compressor mounting screws are in place and tight.

3. Check that all the clutch securing screws are in place and tight.

4. Check the hoses for wear and abrasions – particularly at bends and where clamps are fitted.

5. Check that the condenser and evaporator are clean. If necessary, clean them.

6. Check the colour of the moisture indicator (blue ball). If the ball has already turned pink, moisture saturation has been reached. In this case the filter receiver drier must be replaced.

ATTENTION! If the ball has turned pink, the filter receiver drier must be replaced immediately as otherwise the system will be damaged by the build-up of acid.

298 672.0 - BA DO 208 / 204 MEGA

9.9.3

Maintenance – basic machine, cutterbar

9.9.4

BA DO 208 / 204 MEGA - 298 672.0

Maintenance – basic machine, cutterbar

Maintenance – basic machine, cutterbar FIRE EXTINGUISHER Have fire extinguisher checked for serviceable condition The agent for the fire extinguisher manufacturer should check the extinguisher at least every two years.

The date of manufacture or the date last checked is shown on the extinguisher.

(Fig. 1)

1

298 672.0 - BA DO 208 / 204 MEGA

9.10.1

Maintenance – basic machine, cutterbar

9.10.2

BA DO 208 / 204 MEGA - 298 672.0

Maintenance – basic machine, cutterbar

Maintenance – basic machine, cutterbar SPEEDS Checking the speed of the straw walker shaft The straw walkers must operate at the correct speed of 225 ± 5 rpm if an efficient performance of the machine is to be obtained.

Check the speed with a hand tachometer at the straw walker shaft. It is essential that this speed is maintained.

Check the speed with the combine in the no-load condition and with engine running at maximum speed.

Setting the magnetic pick-ups Use a feeler gauge (V) and set all magnetic pick-ups to provide a clearance of 1 ± 0.5 mm. Then tighten the nuts (K) to lock the magnetic pick-ups to their brackets.

K

(Fig. 1) V

1 Machines equipped with fieldwork computer Set the magnetic pick-up which is located at the cleaning fan to provide a 0.2 ± 0.1 mm clearance.

Adjust the magnetic pick-up for the threshing drum to provide a clearance of 2 ± 0.5 mm.

(Fig. 1)

298 672.0 - BA DO 208 / 204 MEGA

9.11.1

Maintenance – basic machine, cutterbar

9.11.2

BA DO 208 / 204 MEGA - 298 672.0

Maintenance – basic machine, cutterbar

Maintenance – basic machine, cutterbar STRAW CHOPPER DANGER! Always disengage the threshing mechanism, stop the engine and remove the main switch key (ignition key) before carrying out any work on the straw chopper.

After disengaging the drives and stopping the engine – beware – the rotor of the straw chopper still turns!

Changing the free-swinging knives ATTENTION! AII knives on the rotor are nearly of the same weight. Therefore, blunt knives must not be resharpened.

When one cutting edge of the knives is worn, the knives can be turned end for end. When replacing free-swinging worn knives by new ones, the opposing free-swinging knives on the rotor must be replaced too. If this is ignored, the rotor may be thrown out of balance. This may result to further damage.

DANGER! Avoid personal injury! Wear gloves!

Block the rotor so that it cannot turn.

Removing knives Loosen hex. bolt (S) and remove knives (M) and bushings (1).

(Fig. 1)

H

V 2 1

M

1

S 1

298 672.0 - BA DO 208 / 204 MEGA

9.12.1

Maintenance – basic machine, cutterbar Installing knives Make sure bushings (2) are inserted on each side of bracket (H). Insert bushings (1) into knives and secure with hex. bolt (S) and self-locking nut (V).

(Fig. 1) ATTENTION! Only use bolts and nuts of the quality and grade specified by the manufacturer.

☞ Hex. bolt M 10 x 50 DIN 931-10.9 Self-locking nuts VM 10 DIN 980-10

☞ Tightening torque M 10 - 10.9 = 65 Nm

ATTENTION! For nuts and bolts with silvery / grey Dacromet coating, the tightening torque is reduced.

☞ Tightening torque for bolts with Dacromet coating M 10 - 10.9 = 55 Nm

Changing the fixed stationary knives Loosen hex. bolts (6) on either side of the chopper.

B

Remove hex. bolts at (5) on either side.

Remove the spring clip from rod (7) on the right-hand side of the machine.

7 5

6

Turn the knife carrier all the way down and pull out the rod (7) as far as this is necessary. The rod is pulled out through the hole (B) in the chopper sidewall.

In this position every knife can be exchanged.

2

9.12.2

(Fig. 2)

BA DO 208 / 204 MEGA - 298 672.0

Maintenance – basic machine, cutterbar

Maintenance – basic machine, cutterbar WINTER STORAGE INSTRUCTIONS FOR COMBINES Proper storage of the combine after the harvest is essential in order to obtain the optimum return on the investment capital in this machine. Thorough and conscientious maintenance and cleaning and the replacement of worn or damaged parts at this point will save time and money when the combine is required for operation again.

1. Clean the exterior of all bearings of dust and grease.

2. Clean the combine thoroughly inside and out, particularly the threshing drum, concave, the space behind the drum, the preparation floor, return floors, straw walkers and above the cleaning fan.

ATTENTION! If the combine is washed (which should be avoided, where possible), all the lubrication points must be lubricated after washing.

Then allow the combine to run for a few minutes and operate all the variable speed drives.

Hollow spaces such as cable lead-throughs should not be cleaned with water. In some cases the water can no longer be removed from the hollow spaces and can lead to rusting.

3. Using good quality grease, lubricate all grease points of the combine after the harvest, taking care not to miss any of those requiring only annual attention. Run the combine for a short period of time to distribute the grease evenly and until the grease has slightly protruded from the bearings to form a seal. With the combine still running, operate the variable speed drives to distribute the grease evenly between the sliding parts.

Seal off peripheries of slip clutches with paint to keep moisture out and to keep friction faces from rusting.

4. Open the elevator covers and auger troughs.

Remove the sieves.

5. Grease all polished parts such as knives and crop lifters.

6. Coat the inner flanks of the variable speed pulleys with corrosion inhibitor as far as possible.

7. Change the hydraulic and transmission oil – see page 9.2.1 or page 10.2.1.

8. After cleaning, inspect the combine and have any necessary repairs carried out immediately.

9. Park the combine in a dry place where it is protected from the weather and where no commercial fertilisers are stored!

10. Lower the cutterbar to the ground or remove in order to relieve the hydraulic system.

11. Jack up the combine so that the full weight is not resting on the wheels.

298 672.0 - BA DO 208 / 204 MEGA

9.13.1

Maintenance – basic machine, cutterbar

9.13.2

BA DO 208 / 204 MEGA - 298 672.0

10 Maintenance – engine

Maintenance – engine

Maintenance – engine IMPORTANT MAINTENANCE INSTRUCTIONS Important maintenance instructions and safety rules DANGER! Repair, maintenance and cleaning work and the elimination of malfunctions should only be performed with the drives switched off and the engine stopped. Remove the ignition key.

Always turn off the battery isolating switch when working on engine!

The efficiency of the combine depends essentially on the care given to the engine. Periodical checking, lubrication and cleaning of the engine are therefore of vital importance.

Cooling water and air intake hoses

Check condition and security of coolant and air intake hoses every 50 operating hours.

Replace coolant hoses and non-metallic parts of air intake system every 2 years.

Check engine, radiator and exhaust system daily for dirt and clean if necessary.

Coolant

The engine cooling system has been filled with a mixture of corrosion inhibiting anti-freeze and water at the factory.

The coolant consists of 50% corrosion inhibiting anti-freeze and 50% water.

This ensures frost protection down to approx. -37 °C. Also refer to the specifications of the engine manufacturer – DC sheet 325.0 and 325.2.

Belts

All V-belts must be kept properly tensioned at all times.

Check the tension of new belts after the first 2 or 3 hours of operation and retension, if necessary.

Cleaning the engine compartment and hazard areas

Thoroughly clean the engine area, and in particular the exhaust system and the area around the brakes, transmission, gearboxes etc. to prevent fire hazards.

If the material harvested is extremely dry and in heavy dust conditions, check the points and areas named more often and clean, if necessary.

298 672.0 - BA DO 208 / 204 MEGA

10.1.1

Maintenance – engine

10.1.2

BA DO 208 / 204 MEGA - 298 672.0

Maintenance – engine

Maintenance – engine MAINTENANCE SCHEDULES AND LUBRICANTS CHARTS Maintenance schedule

100

Every 50

Working hours

100

250

Working hours

After the harvest

Daily

10

As required

After the first

Annually = every 500 working hrs.

Service intervals Before the Harvest

Maintenance Operations

FUEL SYSTEM – Fuel tank - clean filler neck filter – Drain condensed water – Clean fuel prefilter – Clean fuel prefilter / water separator – Replace fuel filter elements – Bleed fuel system ENGINE OIL / OIL FILTER (See also Lubricants Chart) – Check engine oil level

* *

– Change engine oil – Replace oil filter – Top up engine oil COOLING SYSTEM – Replace all coolant hoses

every 2 years

– Replacing the cooling liquid

every 2 years

– Check coolant level / top up – Clean radiator screen and radiator DRY-TYPE AIR CLEANER – Replace all non-metal parts of air intake system and charge air cooler

every 2 years

– Retighten all clamps on the air intake hoses – Clean air intake screen – Clean main air filter cartridge

when warning device comes on

– Replace main air filter cartridge – Replace air filter safety cartridge (After servicing the main filter cartridge five times)

at least every two years

V-BELTS / VALVES – Tension alternator drive belt

refer to engine manufacturer's operating manual

– Have the valve timings on the engine adjusted

refer to engine manufacturer's operating manual

For further instructions regarding maintenance refer to engine manufacturer's operating manual

BATTERY – Check voltage, recharge if necessary – Check electrolyte level and concentration, correct if necessary

*

See «Lubricants Chart» on next page

298 672.0 - BA DO 208 / 204 MEGA

10.2.1

Maintenance – engine Lubricants chart Component

Type of Lubricant

Capacity

MERCEDES OM 906 LA

CLAAS Ultratec XXL SAE 10 W 40

approx.

28 litres

Viscosity

Change Intervals

Check

See Maintenance Schedule

See Maintenance Schedule

See Maintenance Schedule

See Maintenance Schedule

Engine oil as per DC sheet 228.5

Preservation of engine **

Cooling system

corrosion inhibiting anti-freeze

50% corrosion inhibiting anti-freeze and 50% water

every 2 years

see «Specifications» for filling capacities

*

If diesel fuels with a sulphur content exceeding 0.3% by weight are used, it is essential to change the engine oil at shorter intervals.

Running-in oil that allows extended initial operation interval is filled in at the factory. This oil is specified

by DC sheet 228.5. If engine oil must be topped up due to oil consumption, use engine oil specified in the Lubricants chart.

** Please refer to the Operator's Manual of the engine manufacturer.

10.2.2

BA DO 208 / 204 MEGA - 298 672.0

Maintenance – engine

Maintenance – engine MAINTENANCE – ENGINE Engine overview 3

MERCEDES OM 906 LA

2

1 2 3 4 5 6 7 8 9

7 1

1

Engine number Oil filler cap Fuel filter Starter motor Oil filter Alternator Oil dipstick Charge blower Charge blower

Also refer to the Operator's Manual of the engine manufacturer.

(Fig. 1, 2)

5

4

6 8

9

2

Fuel feed system DANGER! Only fill up the fuel tank with the engine stopped – DO NOT SMOKE!

ENVIRONMENT! Observe specified quality requirements of oils and fuel.

Store oils and fuel only in approved containers!

Dispose used filter elements in a way that is harmless to the environment and in accordance with existing environmental regulations.

298 672.0 - BA DO 208 / 204 MEGA

10.3.1

Maintenance – engine Fuel tank Please refer to «Specifications» for fuel tank capacities.

An electrical fuel gauge is located in the vehicle information unit on the operator's platform.

1

Use clean fuel only. Clean the sieve in the tank filler neck (1) from time to time with Diesel fuel. Renew the sieve if damaged.

Close the filler cap tightly after refuelling.

3

Fill the fuel tank immediately after finishing work, as this will reduce the condensation of water in the tank.

Drain off moisture and sediment which may have settled in the sump (V) of the tank by removing the drain plug (2).

(Fig. 3, 4)

V 2

4 Fuel shut-off tap Before opening the fuel filter or fuel lines, shut-off tap (P) must be closed as otherwise fuel will run out.

Before starting the engine, open shut-off tap (P) again.

(Fig. 5) P

5

10.3.2

BA DO 208 / 204 MEGA - 298 672.0

Maintenance – engine Water separator / fuel prefilter (extra equipment – small version) The fuel prefilter is accessible after opening the right-hand side flap.

Any water in the fuel collects in sight glass (5) which is below the filter.

3

Drain trapped water in good time by loosening drain plug (6) and collect in a container.

5 ENVIRONMENT!

6

6

Dispose of the collected water and diesel fuel in an environmentally safe manner.

Close the fuel shut-off tap (P) before changing filter cartridge (3).

Replace the seal rings at every filter change.

Ensure that seal ring (2) is installed in the correct position.

(Fig. 5, 6, 7)

Water separator / fuel prefilter disassembled:

1

1 2 3 4 5 6

2 3

Filter head Seal ring Filter cartridge O-ring Sight glass Drain plug

(Fig. 6, 7)

4 5

6

7 Fuel prefilter The fuel prefilter filters the fuel before it enters the fuel pump.

Replace the filter element, when necessary.

To change the filter element, unscrew filter housing (T). Before unscrewing the filter housing, close the fuel shut-off tap.

T

(Fig. 8)

8

298 672.0 - BA DO 208 / 204 MEGA

10.3.3

Maintenance – engine Water separator / fuel prefilter (extra equipment – large version)

1

If any water is present in the diesel fuel it will recollect in the lower glass sediment bowl (8).

Drain off any water by means of drain screw (10).

Dispose of the collected water and diesel fuel in an environmentally safe manner.

P

The fuel prefilter (5) can be removed from above by loosening toggle bolt (1).

9

ENVIRONMENT! Before loosening the toggle bolt (1) the fuel pipe (S) must be closed by the shut-off tap (P), to prevent fuel running out.

Before tightening up the filter housing, loosen shut-off tap (P) to allow the filter to fill with fuel. This will prevent too much air entering the fuel system.

Clean dirty prefilters. Replace damaged seals by new ones. Always take care that seals are correctly re-located.

(Fig. 9, 10)

Water separator / fuel prefilter disassembled:

1 2

1 2 3 4 5 6 7 8 9 10

3 4 5 6 7 8 9 10

10.3.4

10

Toggle bolt Ring Housing cover Sealing ring Fuel prefilter Housing O-ring Glass water trap O-ring Drain screw

(Fig. 10)

BA DO 208 / 204 MEGA - 298 672.0

Maintenance – engine Fuel filter The fuel filter retains even the smallest particles of dirt floating in the fuel.

X

Replace the filter element in filter housing (X) once a year = 500 operating hours.

Bleed the fuel system every time the fuel filter has been renewed.

See also engine manufacturer's operating manual.

(Fig. 11) 11 Bleeding the fuel system The fuel pump draws in the diesel fuel from the tank through fuel prefilter (V) and pumps it through the filter system to the injection pumps.

R

1. Loosen primer pump by turning the knurled nut (R) in anti-clockwise direction.

2. Actuate the primer pump until the resistance increases noticeably.

V

3. Secure the primer pump plunger with the knurled nut again.

12

(Fig. 12)

Checking engine oil level Check the oil level daily, approx. five minutes after the engine has been shut off.

At no time should the level of the oil be higher than the FULL mark (maximum) on the dipstick and fall below the SAFE mark (minimum).

Only use approved oils that conform to the specifications stated in the Lubricants Chart.

298 672.0 - BA DO 208 / 204 MEGA

10.3.5

Maintenance – engine Engine oil change DANGER! Be careful when draining hot oil – beware of burns!

ENVIRONMENT! Dispose of the drained oil and used oil filters in a way that is harmless to the environment and in accordance with existing environmental regulations.

NOTE! Refer to the Lubricants Chart for recommended oil qualities and oil change frequencies.

Engine oil should be drained off from a hot engine immediately after stopping the engine to flush dirt particles floating in the oil out of the sump.

Draining the old oil Fit a suitable hose (S) to engine oil drain fitting (M).

Loosen nut (R) slightly and collect the old oil in a sufficiently large container.

H M

After draining the engine oil, tighten nut (R) on the oil drain fitting again.

R

Remove hose (S).

S

H = Hydraulic oil drain fitting M = Engine oil drain fitting 13

10.3.6

(Fig. 13)

BA DO 208 / 204 MEGA - 298 672.0

Maintenance – engine Oil filter The oil filter (5) contains a paper element.

Replace the filter element each time the engine oil is changed. Thoroughly clean the filter bowl.

5

NOTE! Information regarding the replacement of the filter element is to be taken from the Operator's Manual of the engine manufacturer.

14 (Fig. 14)

Filling in engine oil Fill in engine oil up to the FULL mark (maximum) on the dipstick.

2

Refit and tighten the cap (2) to the oil filler neck.

Run the engine briefly at slow idling speed.

Stop the engine and examine it, including the oil filter, for leaks.

15

Wait approx. 5 minutes, then check the oil level in the engine. If necessary, top up with oil to the upper mark on the dipstick.

(Fig. 15)

Tensioning the alternator belt See engine manufacturer's operating manual.

298 672.0 - BA DO 208 / 204 MEGA

10.3.7

Maintenance – engine

10.3.8

BA DO 208 / 204 MEGA - 298 672.0

Maintenance – engine

Maintenance – engine COOLING SYSTEM Coolant ATTENTION! Engines must always be filled only with corrosion inhibitor / anti-freeze before operation.

Otherwise the engine will be damaged.

NOTE! Check the handbook of the engine manufacturer for instructions concerning the cooling system.

Anti-freeze is mixed with the engine cooling water at the factory. Always check the coolant for sufficient anti-freeze protection at the beginning of the cold season.

Renew all coolant hoses on the engine every 2 years.

Before the beginning of the cold season mix a sufficient amount of anti-freeze solution to the cooling water.

Water drain plugs on the engine block See engine manufacturer's operating manual.

Water cooler DANGER! Be careful when opening the hot radiator.

Only loosen the radiator cap up to the stop and allow the excess pressure to escape – Danger of scalding!

The drain tap is accessible after folding up the rotating radiator chaff screen.

If the combine is to be stored over the winter without anti-freeze, drain all the water at drain tap (A).

A

Before filling the radiator with coolant, close the drain tap tightly.

(Fig. 1)

1

298 672.0 - BA DO 208 / 204 MEGA

10.4.1

Maintenance – engine Filling the cooling system with coolant DANGER! Be careful when opening the hot radiator.

Only loosen the radiator cap up to the stop and allow the excess pressure to escape – Danger of scalding!

Fill coolant through filler neck (E) into the system.

Fill up to the brim.

K = Water level check glass

E 4

Run engine for a short time. Stop the engine. Check cooling water level once more and top up if necessary.

2 K

(Fig. 2)

2 Overpressure The diaphragm beneath the radiator cap (2) is compressed if there is an overpressure in the cooling system.

This allows the steam to escape through the over flow pipe (4).

(Fig. 2) Antifreeze / corrosion protection The cooling liquid consists of 50% anti-corrosion / antifreeze agent and 50% water.

Please refer also to the operating instructions of the engine manufacturer.

When topping up cooling liquid, anti-corrosion / antifreeze agent and water must be added at equal portions.

Any use of the machine without anti-corrosion agent is not allowed.

10.4.2

BA DO 208 / 204 MEGA - 298 672.0

Maintenance – engine Warning notice If the radiator is left empty during the inactive period, attach a warning notice showing the inscription «CAUTION! Radiator contains no water!» to the filler neck. Attach the same notice to the steering wheel.

Close the radiator filler cap tightly. Never put cold water into a hot engine. Take care the cooling water is clean, and does not contain too much lime and chlorine. Whatever containers are used for cooling water should be absolutely clean.

Cooling water temperature A temperature gauge shows the temperature of the cooling water.

Correct temperature is 80 to 95 °C (176 to 203 °F) with the combine operating.

Warning signal: See engine manufacturer's operating manual.

Radiator chaff screen Cleaning the radiator chaff screen The engine will overheat if the rotary radiator screen or the radiator are dirty.

With the engine stopped, check the rotary radiator screen regularly and clean as necessary.

Folding up radiator chaff screen Loosen clamp (L) and remove hose (S) from the suction blower.

(Fig. 3)

L

S

3

298 672.0 - BA DO 208 / 204 MEGA

10.4.3

Maintenance – engine Loosen quick connectors (T) and pull out the sealing plate (D).

(Fig. 4) T T D

4 Pull back jockey pulley (R) and engage the bracket at (A).

G

Remove V-belt (G).

A

(Fig. 5) R

5 Release the radiator chaff screen at quick connectors (S).

Lift the radiator chaff screen up to the mechanical stop of the gas pressure springs. Lower the chaff screen again slightly until the mechanical detent engages and the chaff screen is held in the open position.

S

(Fig. 6)

S

6 Swinging up the oil cooler Unlatch fastener (P) and fold up the oil cooler (O) and secure the cooler by attaching hook (H) to one of the spokes of the rotor.

H

The water cooler (W), the intercooler (L), the condenser (N, if cooling system is provided) and the oil cooler (O) are accessible for cleaning.

N P

Before stopping an overheated engine allow it to idle for short period of time.

O L

(Fig. 7)

W 7

10.4.4

BA DO 208 / 204 MEGA - 298 672.0

Maintenance – engine Clean water cooler and intercooler Blow out the radiator with compressed air (maximum 5 bar) from the outside inwards.

Take care not to damage the fins. Run the engine.

Then, with the engine shut down and, if possible, cold, clean the engine compartment by blowing out.

After completing the maintenance work, lower the oil cooler and lock again.

Closing the radiator chaff screen: Raise the radiator chaff screen slightly to disengage the mechanical detent. Then lower the radiator chaff screen to the closed position.

Lock the radiator chaff screen. Fit and tension the V-belt. Install and lock the sealing plate.

298 672.0 - BA DO 208 / 204 MEGA

10.4.5

Maintenance – engine

10.4.6

BA DO 208 / 204 MEGA - 298 672.0

Maintenance – engine

Maintenance – engine DRY-TYPE AIR CLEANER Warning device Contact switch (K) is operated by vacuum in the air intake pipe when the air cleaner cartridge is dirty.

The warning device is then activated. For further information – see page 6.2.10, Vehicle information unit.

K

(Fig. 1)

1

Cleaning the air cleaner intake screen Inspect the air intake screen (A) regularly, especially when operating in extreme dusty conditions. Always stop the engine and wait for all mechanisms to stop before cleaning the air intake screen.

A

(Fig. 2)

2

Cleaning the air cleaner As soon as the warning system comes on – warning light (4) shows, warning lights (8 and 10) blink and the buzzer sounds – stop the engine and clean the air cleaner – see page 6.2.10, Vehicle information unit.

ATTENTION! Always wait for the warning device to come on before cleaning the air cleaner.

298 672.0 - BA DO 208 / 204 MEGA

10.5.1

Maintenance – engine Cleaning the dry-type air cleaner with dust extractor unit Heavy particles of dirt and circulating, loose dust particles are sucked out of the air cleaner body by the dust extractor unit.

S

Flexible hose (S) is connected to the air cleaner cover (D) and to the silencer tail pipe (A).

Most of the dust is thus steadily extracted from the air cleaner body and discharged through the tail pipe of the silencer.

A 3

(Fig. 3, 4) ATTENTION! Always stop the engine and wait for all mechanisms to stop before opening the air cleaner body.

10.5.2

BA DO 208 / 204 MEGA - 298 672.0

Maintenance – engine Removing the main filter cartridge K

Remove cover (D) after loosening clamps (K).

(Fig. 4)

D K K 4 Carefully remove the air filter main cartridge, twisting the cartridge slightly.

Clean the main cartridge using compressed air. Air pressure must not exceed 5 bar. Blow air from the inside to the outside.

F

If the main cartridge has to be temporary cleaned in the field, this can be done by very gently tapping the end of the cartridge with the palm of the hand.

ATTENTION! 5

Never tap hard against the main cartridge or strain it in any way to prevent the cartridge from being stressed. If this is neglected the cartridge will not seal correctly at the filter seating.

(Fig. 5, 6)

F

G 6

298 672.0 - BA DO 208 / 204 MEGA

10.5.3

Maintenance – engine Installing the main filter cartridge Before installing the main cartridge check it for damage outside and inside.

If holes, cracks or dents are noted or if it is ruptured or stressed, the main cartridge must be replaced by a new one.

Check seating (G) of the filter. If damage is noted or if there are any spots where the filter will not seal properly, the main cartridge must be replaced by a new one.

Carefully install the main cartridge.

ATTENTION! Always install genuine main cartridges.

When installing the main cartridge care must be taken to ensure that it fits tightly.

Fit cover (D) and secure with clamps (K).

(Fig. 4, 5, 6)

Safety cartridge Remove and install safety cartridge: – Switch off the engine.

– Remove cover (D).

– Remove main cartridge (F).

S

– Remove safety cartridge (S).

If necessary, pull out the safety cartridge at ring (R).

– Clean the filter housing thoroughly.

7

– Insert a new safety cartridge.

– Install a cleaned or new main cartridge (F).

– Fit cover (D), ensuring that the clamps (K) are securely locked.

See also maintenance chart.

(Fig. 4, 5, 7, 8)

S R

ATTENTION!

8

10.5.4

Always use genuine safety cartridges.

When installing the cartridge make sure that it fits snugly.

BA DO 208 / 204 MEGA - 298 672.0

Maintenance – engine

Maintenance – engine ELECTRICAL EQUIPMENT Battery The battery is located on the left-hand side of the machine behind the side panels.

(Fig. 1) ATTENTION! Only run the engine when the battery is connected.

1 DANGER! Be careful with battery gases – they are highly explosive.

☞ Avoid sparks and naked flames in the vicinity of the battery.

☞ Remove the covers (vent caps) when recharging the battery to prevent the accumulation of highly explosive gas.

Be careful when handling battery acids – beware of acid burns.

ENVIRONMENT! Dispose of an old battery in a way that is harmless to the environment. Follow the existing environmental regulations.

The battery is filled and charged ready for use before the machine leaves the factory.

2

Fill new batteries with diluted sulphuric acid (specific gravity 1.285 in normal climates, 1.23 in tropical climates) and have them charged.

Check the electrolyte level, at least every two weeks, and top up with distilled water, if necessary. The level must be approx. 10 mm above the battery plates. Have the specific gravity of the electrolyte measured from time to time with a hydrometer (2) (Fig. 2).

2

298 672.0 - BA DO 208 / 204 MEGA

Before storing the combine for the winter, charge the battery and recharge it every six weeks or place it in the care of a battery service specialist.

10.6.1

Maintenance – engine Alternator ATTENTION! – Never turn off the battery isolating switch with the engine running.

– Never disconnect the cables connecting the alternator and battery with the alternator running.

– Do not connect battery terminals in reverse polarity. This will burn out the alternator diodes.

– Do not carry out any work on live parts unless the engine is stopped and the battery cables are disconnected.

– Do not flash connections to check current flow.

This will damage the semiconductors.

– Before doing any electric welding on the combine, be sure to disconnect the cables at the alternator terminals!

– The battery provides the current for the field excitation required to start the alternator action via the charge indicator bulb. Burned out bulbs must be, therefore, renewed.

10.6.2

BA DO 208 / 204 MEGA - 298 672.0

Maintenance – engine

Maintenance – engine ENGINE PROBLEMS, CAUSE AND / OR REMEDY Engine problems

Possible cause and / or remedy

Red indicator lamp (battery charge) lights up (with engine running)

1.

2.

3.

4.

Retension alternator belts.

Check wiring connections.

Have alternator repaired.

Increase engine speed (when engine is running at slow idle speed).

Water temperature gauge does not function or jumps straight to maximum

1. Clean and tighten all cable connections.

2. Fuse F 19 or F 52 defective. Replace fuse.

3. Replace temperature gauge sensor.

Oil pressure lamp lights up and buzzer sounds

1. Determine cause of low engine oil pressure.

2. Top up engine oil.

3. Have possible engine defect repaired.

Air-cleaner warning lamp lights up and the warning device comes on

1. Check radiator rotary screen for dirt and clean if necessary.

2. Clean air cleaner main cartridge or replace if necessary.

3. Replace air cleaner safety cartridge.

Engine starts with difficulty

1.

2.

3.

4.

5.

6.

Engine temperature too high, the warning device comes on

1. Check radiator rotary screen for dirt and clean if necessary.

2. Check radiator for dirt.

3. Check coolant level and top up if necessary.

4. Replace thermostat insert.

5. Replace coolant hoses.

6. Replace radiator cab.

Engine stops

1. Refuel.

2. Clean screen in fuel pre-cleaner.

3. Check breather in fuel tank filler cap and clean if necessary.

4. Check screw fittings of fuel system and tighten if necessary.

Loose battery terminal clamps – tighten.

Recharge battery.

Bleed fuel system.

Clean fuel prefilter.

Replace fuel filter.

Tighten screw fittings of fuel system.

Also see the Operator's Manual of engine manufacturer.

298 672.0 - BA DO 208 / 204 MEGA

10.7.1

Maintenance – engine

Engine problems

Possible cause and / or remedy

Battery Terminals corroded

1. Keep terminals clean (do not scrape terminals to be hollow).

Terminal clamps corroded

1. Remove battery. Clean terminal clamps with ammonia, rinse off and dry.

Electrolyte boils over

1. Check electrolyte level.

2. Check operation of voltage regulator and replace if necessary.

3. Have battery checked.

Battery dirty

1. Remove battery. Clean terminals and surface with brush and water.

ATTENTION! Laying metal objects on the battery will cause self-discharging of the battery and present a serious FIRE HAZARD!

10.7.2

BA DO 208 / 204 MEGA - 298 672.0

Maintenance – engine

Maintenance – engine ENGINE WINTER STORAGE Engine preservation 1. Clean exterior surfaces of engine thoroughly.

2. Preserve engine (see Operator's Instruction Book of the engine manufacturer).

3. Replace coolant hoses and hoses on charge-air cooling system every 2 years.

Check coolant for frost resistance and add anti-freeze if necessary.

4. Replace all non-metallic parts on air intake system every 2 years by new ones.

5. Replace air cleaner main cartridge by a new one.

6. Fill up the fuel tank with fuel.

Do not leave the machine standing out of doors, as this would cause condensation in the fuel tank.

7. Place the battery in the care of a battery service specialist or put it to some other use.

ATTENTION! Antifreeze (50%) should be added to the coolant even in warm countries where there is no risk of frost. This helps to protect the engine.

In hot countries, the concentration of corrosion inhibitor / antifreeze should not exceed 50%, as otherwise the efficiency of the coolant is decreased.

The engine must not be operated without anti-freeze.

For further information, refer to the engine manufacturer's operating manual.

298 672.0 - BA DO 208 / 204 MEGA

10.8.1

Maintenance – engine

10.8.2

BA DO 208 / 204 MEGA - 298 672.0

11 Lubrication chart

Lubrication chart

Lubrication chart

LUBRICANTS AND LUBRICATION INSTRUCTIONS

Brand name grease

Optional extra

Examples: Manufacturer Designation FINA ARAL FUCHS SHELL DEA AVIA FAG SKF

«Marson EPL 2» «Aralub HLP 2» «Renolit TEP 2» «Retinax EP 2» or «Alvania G3» «Glisando EP2» «Avilup Special Grease EP» «Arcanol L 135 V» «LGEP2»

Where 3 grease nipples are installed, only one grease nipple needs to be greased

Where 3 pairs of grease nipples are installed, only one pair needs to be greased

Wipe up any escaped grease

Move part in direction of arrow to spread grease

Every 10 working hours

Every 100 working hours

Every 50 working hours

Once a year (500 working hours)

298 672.0 - BA DO 208 / 204 MEGA

11.1.1

Lubrication chart

Lubrication chart

2

1

3

50878

1

2

3

11.1.2

BA DO 208 / 204 MEGA - 298 672.0

Lubrication chart

5

4

50879 6.00 - 9. 00 m

4

298 672.0 - BA DO 208 / 204 MEGA

5

11.1.3

Lubrication chart

1 2

3

4

5

6

50880 6.00 m - 9.00 m

11.1.4

1

2

3

4

5

6

BA DO 208 / 204 MEGA - 298 672.0

Lubrication chart

7

8

9

10

11

50881

7

8

9

10

11

298 672.0 - BA DO 208 / 204 MEGA

11.1.5

Lubrication chart

11.1.6

12

13

14

15

16

17

18

19

BA DO 208 / 204 MEGA - 298 672.0

Lubrication chart

1 2

3 4 5 6

7

8

50883 3.00 - 5.10 m

6.00 m - 9.00 m

1 3.00 - 5.10 m

298 672.0 - BA DO 208 / 204 MEGA

2 3.00 m - 5.10 m

6.00 - 9.00 m

3

4

5

6

7

8

11.1.7

Lubrication chart

11.1.8

9

10

11

12

13

14

BA DO 208 / 204 MEGA - 298 672.0

Lubrication chart

298 672.0 - BA DO 208 / 204 MEGA

15

16

17

18

11.1.9

Lubrication chart

19 20

23

21 22

50886 DO 208 MEGA

DO 204 MEGA

19

20

21

22

23

11.1.10

BA DO 208 / 204 MEGA - 298 672.0

Lubrication chart

6.00 m - 9.00 m

6.00 m - 9.00 m

24 6.00 m - 9.00 m

26

298 672.0 - BA DO 208 / 204 MEGA

25 6.00 m - 9.00 m

6.00 m - 9.00 m

27

28

11.1.11

Lubrication chart

1

11.1.12

BA DO 208 / 204 MEGA - 298 672.0

Lubrication chart

2

4

3

5

50889

298 672.0 - BA DO 208 / 204 MEGA

2

3

4

5

11.1.13

Lubrication chart

11.1.14

BA DO 208 / 204 MEGA - 298 672.0

12 Index

Index

Index INDEX A Access and ladder extension ............................................... 6.2.24 Access ladders ..................................................................... 6.2.23 Acoustic grain tank fill indicator .............................................. 8.4.8 Adjust clearance to cutterbar trough ...................................... 7.2.8 Adjusting cross knife .............................................................. 8.5.4 Adjusting monitor to crop type ............................................. 8.3.13 Adjusting position of auger fingers ......................................... 7.2.9 Adjusting sensitivity of sensors ............................................ 8.3.13 Adjusting spreading width ...................................................... 8.5.3 Adjusting stiffness of ground speed control lever .................. 6.3.3 Adjusting the butterfly valve ................................................... 8.3.7 Adjusting the cutterbar drop rate ............................................ 8.1.8 Adjusting the cutterbar floatation springs ............................... 8.1.6 Adjusting the deflectors .......................................................... 8.5.3 Adjusting the driver's seat horizontally ................................. 6.2.22 Adjusting the frogmouth sieves .............................................. 8.3.8 Adjusting the height of the knife head .................................... 7.2.4 Adjusting the knife clips ......................................................... 7.2.4 Adjusting the length of cut ..................................................... 8.5.4 Adjusting the steering column position ................................ 6.2.20 Adjusting the stripper plates ................................................... 7.2.9 Adjusting the strippers DOMINATOR MEGA 204 ...................................................... 7.1.1 Adjusting the threshing drum speed .................................... 6.2.20 Adjusting the threshing drum speed ...................................... 8.2.6 Adjusting the wind board ........................................................ 8.3.7 Adjustments at the cutterbar .................................................. 7.2.1 Alternator ............................................................................. 10.6.2 Angle drive on grain tank (DOMINATOR 208 MEGA) .................................................... 9.4.4 Angle drive on grain tank discharge auger ............................ 9.4.4 Antifreeze / corrosion protection .......................................... 10.4.2 Armrest angle ....................................................................... 6.2.22 Attaching a third cutterbar cylinder ........................................ 6.5.2 Attaching the cutterbar ........................................................... 7.1.1 Attaching the cutterbar hydraulic cylinders ............................ 6.5.1 Attaching the right-hand cutterbar cylinder ............................ 6.5.1 Augers and auger troughs ..................................................... 8.4.1 B Backward ............................................................................... 6.6.1 Basic rules for combining ....................................................... 5.6.4 Battery ................................................................................. 10.6.1 Battery isolating switch .......................................................... 4.1.5 Before initial operation ........................................................... 6.1.1 Before using the straw chopper, check .................................. 8.5.1 Bleeding the fuel system ...................................................... 10.3.5 Bleeding the hydraulic cylinders for cutterbar lateral levelling (Machines with Auto Contour System) ................................... 9.3.6 Bleeding the reel cylinders ..................................................... 9.3.5 Brakes .................................................................................... 6.3.5 C Cab ........................................................................................ 6.2.2 Cab ........................................................................................ 6.7.1

298 672.0 - BA DO 208 / 204 MEGA

Cab ........................................................................................ 9.9.1 Cab / Compressor-type air conditioner .................................. 9.9.1 Cab and lighting .................................................................... 6.7.1 Cab serial number ................................................................. 3.3.4 Cab with fan and compressor-type air conditioner ................ 6.2.3 Cab with ventilating system ................................................... 6.2.3 Cab with ventilating system and heating ............................... 6.2.5 Central terminal compartment ............................................. 6.2.15 Chaff spreader ....................................................................... 8.5.6 Chaff spreader drive belt (16) .............................................. 9.7.18 Chains ................................................................................... 8.1.1 Change-speed transmission gearbox .................................... 9.4.1 Changing hydraulic oil (Hydrostatic ground speed drive and working hydraulics) Linde HPV 75 and HMF 105 ................................................. 9.3.2 Changing the fixed stationary knives ................................... 9.12.2 Changing the free-swinging knives ..................................... 9.12.1 Changing the hydraulic oil filter ............................................. 9.3.3 Changing the rear axle from transport position to working position ................................................................. 6.4.2 Check oil level ....................................................................... 9.4.3 Checking engine oil level ..................................................... 10.3.5 Checking oil level .................................................................. 9.4.1 Checking oil level .................................................................. 9.4.2 Checking oil level .................................................................. 9.4.2 Checking oil level .................................................................. 9.4.4 Checking refrigerant level ...................................................... 9.9.2 Checking the cutterbar floatation springs and checking the feeder house suspension for smooth movement ............................................................ 8.1.6 Checking the oil level (Hydrostatic ground speed drive and working hydraulics) ......................................................... 9.3.2 Checking the oil level / oil change ......................................... 9.4.3 Checking the speed of the straw walker shaft ..................... 9.11.1 CLAAS Auto Contour Automatic cutting height control and lateral levelling system ................................................... 8.1.3 CLAAS Contour System (ground pressure control) .................................................... 8.1.13 CLAAS cutterbar pre-set height .......................................... 8.1.16 CLAAS DOMINATOR 204 MEGA ......................................... 5.3.1 CLAAS DOMINATOR 208 MEGA ......................................... 5.2.1 CLAAS Autopilot .................................................................... 6.3.6 CLAAS-4-Trac-System .......................................................... 6.4.3 Clean water cooler and intercooler ...................................... 10.4.5 Cleaning ................................................................................ 5.6.3 Cleaning dirty threshing parts ................................................ 8.2.4 Cleaning fan .......................................................................... 8.3.5 Cleaning the air cleaner ...................................................... 10.5.1 Cleaning the air cleaner intake screen ................................ 10.5.1 Cleaning the condenser ........................................................ 9.9.1 Cleaning the dry-type air cleaner with dust extractor unit ... 10.5.2 Cleaning the filters ................................................................. 9.9.1 Cleaning the radiator chaff screen ...................................... 10.4.3 Cleaning the straw walkers ................................................... 8.3.2

12.1.1

Index Clean-out door on grain tank discharge tube ......................... 8.4.6 Clearance height .................................................................. 8.1.17 Clearance height to underside of cutterbar skid .................. 8.1.17 Closing the cabin roof ............................................................ 6.2.8 Combine performance monitor ............................................ 8.3.12 Combine serial number .......................................................... 3.3.2 Compressor-type air conditioner ............................................ 9.9.1 Concave adjustment .............................................................. 8.2.2 Concave settings ................................................................... 8.2.3 Connecting hydraulic hoses ................................................... 7.1.6 Connecting the cables ........................................................... 7.1.6 Connecting the universal drive shafts DOMINATOR 204 MEGA ...................................................... 7.1.5 Connecting the universal drive shafts DOMINATOR 208 MEGA ...................................................... 7.1.5 Conversion factors ................................................................. 5.1.1 Coolant ................................................................................. 10.4.1 Cooling system .................................................................... 10.4.1 Cooling water temperature ................................................... 10.4.3 Cutterbar ................................................................................ 5.6.2 Cutterbar adjusting range .................................................... 8.1.16 Cutterbar adjusting range without Auto Contour .................. 8.1.17 Cutterbar automatic pre-set height (machines with Auto Contour) ................................................ 8.1.5 Cutterbar clutch .................................................................... 8.1.18 Cutterbar cylinders ................................................................. 6.5.1 Cutterbar identification plate .................................................. 3.3.3 Cutterbar reverse drive .......................................................... 8.1.2 Cutterbar skids ....................................................................... 7.2.5 Cutterbar spring pressure indicator ........................................ 8.1.7 D Deflector curtain ................................................................... 8.2.11 Description and function of the combine ................................ 5.6.2 Disawner plates ..................................................................... 8.6.8 Disawning .............................................................................. 5.6.3 Disawning .............................................................................. 8.2.8 Dividers .................................................................................. 7.2.1 Draining the old oil ............................................................... 10.3.6 Drive belts / drive chains – basic machine ............................. 9.7.1 Drive belts / drive chains – cutterbar ...................................... 9.8.1 Drive belts / drive chains ........................................................ 9.7.4 Drive diagram cutterbar ......................................................... 9.8.2 Drive diagram left ................................................................... 9.7.2 Drive diagram right ................................................................. 9.7.3 Drive to grain tank discharge augers ..................................... 8.4.6 Driver's seat, mechanical ..................................................... 6.2.21 Driving behaviour ................................................................... 6.3.4 Driving lights, worklights and mirrors ..................................... 6.7.1 Driving the combine ............................................................... 6.3.1 Dry-type air cleaner .............................................................. 10.5.1 Dynamic sidehill levelling (3-D cleaning system) .......................................................... 8.3.10 E Electric deflector adjustment .................................................. 8.5.3 Electrical equipment ............................................................. 10.6.1 Electrical fan speed adjustment ............................................. 8.3.6 Elevator chains ...................................................................... 9.6.1

12.1.2

Elevators ................................................................................ 8.4.1 Engaging and disengaging the cutterbar ............................. 8.1.18 Engaging and disengaging the cutterbar drive .................... 6.2.19 Engaging and disengaging the threshing mechanism ........... 8.2.1 Engine oil change ................................................................ 10.3.6 Engine overview .................................................................. 10.3.1 Engine preservation ............................................................. 10.8.1 Engine serial number MERCEDES OM 906 LA ....................................................... 3.3.2 Engine speed turn switch ...................................................... 6.3.1 Engine winter storage .......................................................... 10.8.1 Engine problems, cause and / or remedy ............................ 10.7.1 F Fan speed display ................................................................. 8.3.6 Feeder housing ...................................................................... 8.1.1 Feeder housing ...................................................................... 9.5.1 Filling in engine oil ............................................................... 10.3.7 Filling the cooling system with coolant ................................ 10.4.2 Final drives DOMINATOR 204 MEGA ...................................................... 9.4.2 Final drives DOMINATOR 208 MEGA ...................................................... 9.4.2 Fire extinguisher .................................................................... 4.1.4 Fire extinguisher .................................................................. 9.10.1 Fitting and tensioning cutterbar drive belt (1) ........................ 9.7.5 Folding up radiator chaff screen .......................................... 10.4.3 Foot brake ............................................................................. 6.3.5 Foot brake / brake fluid .......................................................... 9.3.7 Fore and aft reel adjustment (hydraulic) .............................................................................. 7.2.7 Fore and aft reel adjustment (mechanical) .......................................................................... 7.2.7 Forward ................................................................................. 6.6.1 Front attachments – weights, dimensions ............................. 5.5.1 Front ladder ......................................................................... 6.2.23 Fuel feed system ................................................................. 10.3.1 Fuel filter .............................................................................. 10.3.5 Fuel prefilter ......................................................................... 10.3.3 Fuel shut-off tap ................................................................... 10.3.2 Fuel tank .............................................................................. 10.3.2 Function of operations display ............................................. 6.2.13 Function of vehicle information unit ..................................... 6.2.11 G Gear ranges ........................................................................... 6.3.3 Gear shift control adjustment ................................................. 9.4.1 General notes ........................................................................ 9.7.1 General notes ........................................................................ 9.8.1 Grain delivery ........................................................................ 8.4.1 Grain lifters ............................................................................ 7.2.2 Grain tank .............................................................................. 8.4.2 Grain tank .............................................................................. 9.4.4 Grain tank covers .................................................................. 8.4.2 Grain tank discharge – engage and disengage ..................... 8.4.5 Grain tank discharge auger ................................................... 8.4.4 Grain tank discharge engagement and disengagement ...... 6.2.18 Grain tank discharge tube – swinging out and in ................. 6.2.17 Grain tank fill indicator ........................................................... 8.4.8

BA DO 208 / 204 MEGA - 298 672.0

Index Grain tank unloading drive belt (6) ....................................... 9.7.13 H Handbrake ............................................................................. 6.3.5 Have fire extinguisher checked for serviceable condition ...................................................... 9.10.1 Height adjustment ................................................................ 6.2.21 Hillside riser plates (machines without 3-D cleaning system) ............................... 8.3.8 Hitching the cutterbar trailer to the combine .......................... 8.5.6 Hydraulic accumulators .......................................................... 9.3.1 Hydraulic cylinders ................................................................. 6.5.1 Hydraulic system .................................................................... 9.3.1 Hydrostatic pump adjustment ................................................ 9.3.4 I Identification plate .................................................................. 3.3.2 Identification plate / Serial number ......................................... 3.3.1 Identification plate of folding cutterbar ................................... 3.3.3 Ignition switch ........................................................................ 6.2.9 Impeller ................................................................................ 8.2.11 Important ................................................................................ 3.2.1 Important maintenance instructions ..................................... 10.1.1 Important maintenance instructions ....................................... 9.1.1 Important maintenance instructions and safety rules ........... 10.1.1 Important maintenance instructions and safety rules ............. 9.1.1 Installing knives .................................................................... 9.12.2 Installing lower sieves ............................................................ 8.3.9 Installing the knife .................................................................. 7.2.3 Installing the main filter cartridge ......................................... 10.5.4 Installing the stands ............................................................... 7.1.7 Installing upper sieves ........................................................... 8.3.9 Intensive separation system .................................................. 8.3.1 Introduction ............................................................................ 1.1.1 K Knife ....................................................................................... 7.2.3 Knife drive casing ................................................................... 9.4.3 L Lateral auger drive ................................................................. 8.4.7 Levelling the coupling lug cylinders ....................................... 7.1.3 Levelling the cutterbar ............................................................ 7.1.4 Lower sieves .......................................................................... 8.3.8 Lubricants and lubrication instructions ................................. 11.1.1 Lubricants chart ................................................................... 10.2.2 Lubricants charts .................................................................... 9.2.4 Lumbar support .................................................................... 6.2.22 M Machine with CLAAS Auto Contour ....................................... 7.1.1 Machine without Auto Contour ............................................... 7.1.3 Machines equipped with fieldwork computer ....................... 9.11.1 Main table auger .................................................................... 7.2.8 Maintenance – engine ......................................................... 10.3.1 Maintenance schedule ......................................................... 10.2.1 Maintenance schedules ......................................................... 9.2.1 Maintenance schedules and lubricants charts ..................... 10.2.1 Maintenance schedules and lubricants charts ....................... 9.2.1 Maintenance work before the harvest .................................... 9.9.3 Maize picker head serial number ........................................... 3.3.3

298 672.0 - BA DO 208 / 204 MEGA

Multi-function lever .............................................................. 6.2.15 Multimaster ............................................................................ 3.3.3 O Oil change ............................................................................. 9.4.1 Oil change ............................................................................. 9.4.2 Oil change ............................................................................. 9.4.2 Oil change ............................................................................. 9.4.3 Oil change ............................................................................. 9.4.4 Oil filter ................................................................................ 10.3.7 Opening and closing the cabin roof ....................................... 6.2.8 Opening the cabin roof .......................................................... 6.2.8 Operation with maize picker head ....................................... 8.1.10 Operations display screen ................................................... 6.2.12 Operator's platform ................................................................ 6.2.1 Overpressure ....................................................................... 10.4.2 P Plug-in type module (P) CLAAS Autopilot ........................... 6.2.16 Positioning the cutterbar / maize picker head for road travel ...................................................................... 6.2.19 Preconcave ........................................................................... 8.2.7 Preparation floor .................................................................... 8.3.5 Problem, cause and / or remedy – Basic machine ................ 8.7.1 Problem, cause and / or remedy – Compressor-type air conditioner ....................................... 6.2.6 Programming the CLAAS Auto Contour System ................. 8.1.10 Putting the CLAAS Auto Contour System into operation ...... 8.1.9 Putting the CLAAS Contour System into operation ............. 8.1.14 Putting the cutterbar automatic pre-set height system into operation (machines with Auto Contour) ............................................. 8.1.12 Putting the cutterbar pre-set height system into operation ....................................................................... 8.1.16 Putting the straw chopper into operation ............................... 8.5.2 Putting the straw chopper out of operation and changing over to windrowing straw ................................ 8.5.5 R Radiator chaff screen .......................................................... 10.4.3 Rear axle ............................................................................... 6.4.1 Rear ladder .......................................................................... 6.2.28 Rear ladder with safety switch ............................................... 8.4.4 Rear wheel drive planetary gears CLAAS 4-Trac System .......................................................... 9.4.3 Reel ....................................................................................... 7.2.5 Reel drive .............................................................................. 7.2.6 Reel tines .............................................................................. 7.2.6 Reel variable speed drive ...................................................... 7.2.8 Refilling the system after hydraulic oil change ...................... 9.3.4 Reheat System (fogged windows) .................................................................. 6.2.5 Removing and filtting the threshing drum drive belt (24) ..... 9.7.24 Removing and fitting fan variable-speed belt (8) ................. 9.7.15 Removing and fitting reel drive belt (43) ................................ 9.8.4 Removing and fitting threshing drum variable speed drive belt (23) ............................................................ 9.7.22 Removing and installing the accelerator drive belt (17) ...... 9.7.27 Removing and installing the chaff spreader drive belt (15) ...................................................................... 9.7.18

12.1.3

Index Removing and installing the intensive separation system drive belt (12) ......................................... 9.7.17 Removing and installing the power band belt (3) ................... 9.7.9 Removing and installing the sieve pan drive belt (10) ......... 9.7.16 Removing and installing the sieve pan drive belt (7) ........... 9.7.14 Removing and installing the sieve pan drive belt (9) ........... 9.7.16 Removing and installing the straw walker drive belt (11) ..... 9.7.17 Removing and installing the threshing mechanism drive belt (5) ......................................................................... 9.7.11 Removing cutterbar drive belt (1) ........................................... 9.7.4 Removing knives .................................................................. 9.12.1 Removing lower sieves .......................................................... 8.3.9 Removing the knife ................................................................ 7.2.3 Removing the main filter cartridge ....................................... 10.5.3 Removing upper sieves ......................................................... 8.3.9 Replacing knife sections in the field ..................................... 7.2.10 Replacing the filter receiver drier ........................................... 9.9.2 Required refrigerant quantity – Refrigerant R 134 a .............. 9.9.2 Returns ................................................................................ 8.3.10 Road traffic regulations .......................................................... 3.1.1 S Safety cartridge .................................................................... 10.5.4 Safety decals with pictorials ................................................... 4.2.1 Safety lock ............................................................................. 4.1.4 Safety rules ............................................................................ 4.1.1 Safety features ....................................................................... 5.4.1 Seat angle adjustment ......................................................... 6.2.22 Seat depth adjustment ......................................................... 6.2.22 Sectional view of combine ..................................................... 5.6.1 Serial number of maize head stalk chopper ........................... 3.3.4 Setting chart for automatic cutting height control ................. 8.1.11 Setting the adjustable rear axle ............................................. 6.4.1 Setting the chaff spreader ...................................................... 8.5.6 Setting the cutterbar ground pressure ................................. 8.1.14 Setting the cutting height indicator ......................................... 8.1.7 Setting the magnetic pick-ups .............................................. 9.11.1 Shear bolt – grain tank discharge .......................................... 8.4.7 Side walk railing ..................................................................... 6.6.2 Sieve chart ............................................................................. 8.6.1 Sieve chart and suggested combine adjustments ................. 8.6.1 Sieve pan ............................................................................... 8.3.4 Sieves .................................................................................... 8.3.8 Spare knife ............................................................................. 7.2.4 Speeds ................................................................................. 9.11.1 Starting the engine ................................................................. 6.3.2 Steering .................................................................................. 6.3.4 Steering column ..................................................................... 6.2.9 Stone trap .............................................................................. 8.2.1 Stopping the combine ............................................................ 6.3.4 Stopping the engine ............................................................... 6.3.6 Straw chopper ........................................................................ 3.3.4 Straw chopper ........................................................................ 8.5.1 Straw chopper ...................................................................... 9.12.1 Straw chopper / Chaff spreader ............................................. 8.5.1 Straw chopper drive belt (20) ............................................... 9.7.29 Straw chopper intermediate drive belt (21) .......................... 9.7.19 Straw walker risers ................................................................. 8.3.2 Straw walkers ......................................................................... 5.6.3

12.1.4

Straw walkers ........................................................................ 8.3.1 Straw walkers and cleaning ................................................... 8.3.1 Suggested combine adjustments .......................................... 8.6.2 Swinging up the oil cooler .................................................... 10.4.4 Switch console ..................................................................... 6.2.14 T Tension feeder chains ........................................................... 9.5.1 Tension grain elevator chain ................................................. 9.6.1 Tension returns elevator chain .............................................. 9.6.2 Tensioning compressor drive belt (2) .................................... 9.7.6 Tensioning hydrostatic ground drive belt (3) ......................... 9.7.7 Tensioning knife drive belt (40) ............................................. 9.8.3 Tensioning main table auger drive chain (41) ....................... 9.8.3 Tensioning radiator screen intermediate drive belt (27) ...... 9.7.25 Tensioning reel drive chain (42) ............................................ 9.8.4 Tensioning reel drive chain (44) ............................................ 9.8.6 Tensioning reel drive chain (45) ............................................ 9.8.6 Tensioning returns drive chain (33) ..................................... 9.7.26 Tensioning suction blower drive belt (22) ............................ 9.7.22 Tensioning the alternator belt .............................................. 10.3.7 Tensioning the grain tank unloading intermediate drive chain (31) (DOMINATOR 204 MEGA) .................................................. 9.7.26 Tensioning the grain tank unloading intermediate drive chain (31) (DOMINATOR 208 MEGA) .................................................. 9.7.25 Tensioning the grain tank unloading intermediate drive chain (32) (DOMINATOR 208 MEGA) .................................................. 9.7.25 Tensioning working hydraulics pump drive belt (4) ............... 9.7.8 Threshing drum ..................................................................... 8.2.4 Threshing drum reduction gearbox ........................................ 9.4.4 Threshing drum speed ........................................................... 8.2.5 Threshing drum speed display .............................................. 8.2.6 Threshing drum two-step variable speed drive ...................... 8.2.6 Threshing mechanism ........................................................... 5.6.3 Threshing mechanism ........................................................... 8.2.1 Threshing mechanism drive belt (5) .................................... 9.7.10 Threshing mechanism engagement / disengagement ......... 6.2.18 Threshing segment ................................................................ 8.2.9 Threshing segment ................................................................ 8.6.8 Tightening torques of the axial bolts for the upper and lower sieves .................................................... 8.3.9 Tilting the side walk railing ..................................................... 6.6.2 Towing a combine with driven rear axle ................................ 6.4.3 Towing and side walk railing .................................................. 6.6.1 Towing the combine .............................................................. 6.6.1 Transmission and gearboxes ................................................ 9.4.1 U Unloading the tank ................................................................. 8.4.3 Unslugging the threshing drum ............................................ 8.2.10 Vehicle information unit ....................................................... 6.2.10 Ventilated straw walker step .................................................. 8.3.7 W Warning device .................................................................... 10.5.1 Warning notice ..................................................................... 10.4.3 Warning signal ....................................................................... 8.3.4

BA DO 208 / 204 MEGA - 298 672.0

Index Water cooler ......................................................................... 10.4.1 Water drain plugs on the engine block ................................. 10.4.1 Water separator / fuel prefilter disassembled ...................... 10.3.4 Water separator / fuel prefilter (extra equipment – large version) ........................................ 10.3.4 Water separator / fuel prefilter (extra equipment – small version) ........................................ 10.3.3 Weight adjustment ............................................................... 6.2.21 Wheel chock (Not for all countries) .............................................................. 4.1.5 Winter storage instructions for combines ............................. 9.13.1

298 672.0 - BA DO 208 / 204 MEGA

12.1.5

Index

12.1.6

BA DO 208 / 204 MEGA - 298 672.0

Following the policy of the CLAAS KGaA mbH to improve their products as technical developments continue, CLAAS reserve the right to make alterations which must not necessarily correspond to text and illustrations contained in this publication, and without incurring obligation to alter any machines previously delivered.

Technical data, dimensions and weights are given as an indication only. Responsibility for errors or omissions not accepted.

Reproduction or translation of this publication, in whole or part, is not permitted without the written consent of the CLAAS KGaA mbH. All rights under the provision of the Copyright Act are reserved.

CLAAS KGaA mbH 33426 HARSEWINKEL Germany

Our contribution to the environment: CLAAS have printed this manual on 100% chlorine free paper.

CLAAS KGaA mbH 33426 HARSEWINKEL Germany

298 672.0 BA DO 208 / 204 MEGA GB - 06.02 - 25 - BEV Printed in Germany