Repair Manual For Claas Mega 202 218 Combine Harvester

REPAIR
MANUAL
CLAAS
DOMINATOR 218 MEGA
DOMINATOR 208 MEGA'
DOMINATOR 204 MEGA
DOMINATOR 203 MEGA
DOMINATOR 202 MEGA
188 056.0-DO 218-202 MEGA-GB -10.96-350 -V + H
CONVERSION FACTORS
Length
millimetres (mm) X 0.03937 = inches (in)
millimetres (mm) X 0.00328 = feet (ft)
centimetres (cm) X 0.3937 = inches (in)
metres (m) X 3.2808 = feet (ft)
kilometres (km) X 0.6214 = miles
Area
square metres (m2) X 1550 = square inches (sq in)
square metres (m2) X10.764 = square feet (sq ft)
hectare (ha) X 2.4710 = acres
Weight
kilogrammes (kg) X 2.2046 = pounds (lb)
Torque
metre kilopond (mkp) X 7.233 = foot pounds (ft lb)
newton metres (Nm) X 0.7376 = foot pounds (ft lb)
metre kilopond (mkp) X 9.81 = newton metre (Nm)
Pressure
bar X 14.504 = pounds per square inch (psi)
kg/sq cm (at) X 0.980665* = bar
kg/sq cm (at) X 14.223 = pounds per square inch (psi)
* Where feasible and for practical reasons, this factor is rounded to a whole unit to equal kg/sq cm (at) and bars.
Volume and capacities

cubic centimetres (cm3) x 0.06102 = cubic inches (cu in)
liters (I) x 0.2201 = Imperial gallons (Imp. gal)
liters (I) x 0.8798 = Imperial quarts (Imp. qt)
liters (I) x 0.2642 = U.S. gallons (U.S. gal)
liters (I) x 1.05668 = U.S. quarts (U.S. qt)
liters (I) x 0.0275 = Imp. bushels
liters (I) x 0.02838 = U.S. bushels
Velocity
kilometres/hour (km/h) x 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 x 27
+27 °C = = 48.6 + 32 = 80.6 °F
5
-24 °C = -11.2 °F
+ 2 °C = +35.6 °F
+ 1 °C = +33.8 °F
Whilst great care has been taken to ensure accuracy in the compilation of the conversion factors, CLAAS cannot be held
responsible for any errors or omissions.
FOREWORD This CLAAS REPAIR MANUAL has been prepared to assist
all personnel concerned with the maintenance and service
of CLAAS Forage Harvesters and to help preserve their
permanent working order.
The experience of our Service engineers has been compiled
in this CLAAS REPAIR MANUAL which explains the
procedure of repairs, the different adjustments to be made,
the use of CLAAS Special Tools etc. The illustrations
included in support to the explanations show the sequence
of major repairs so that minor repairs can easily be drawn
out.
The CLAAS REPAIR MANUAL is filed in a folder which
allows to insert supplementary pages as issued and to have
always an updated manual at hand for reference.
To be sure, always compare settings and filling capacities
with specifications stated in the Operator's Manual which
applies to the Forage Harvester.
CLAAS KGAa
Service Department
INTRODUCTION TO THE The present CLAAS REPAIR MANUAL is devided into main
CLAAS REPAIR MANUAL groups (see group index).
Pages and illustrations are numbered consecutively
throughout each main group. Page numbering starts always
with the number 1 in each group. The first figure at the
bottom if each page refers to the main group wheras the
second figure following the point indicates the numerical
order of the pages.
Where service operations apply to a specific Forage
Harvester model only, this is clearly indicated by reference
to that model. When a service procedure applies to all
machines covered by this book, the machine names are
not especially mentioned.
Supplementary sections are numbered by an additional
figure which is separated by a dash from the preceding
figures. Any supplements should be inserted at the back of
the relevant main group and the list of contents be changed
accordingly.
The symbols communicate brief messages when recurring
service procedures are described. Their meaning is
explained at the beginnig of this book.
The section »GENERAL REPAIR INSTRUCTIONS« at the
beginning of this book contains useful practical hints. Read
and follow these fundamental instructions. They are the
basis for reliable service and durability of parts after repairs
have been carried out.
The description of a particular service procedure can

easily be found by checking the list of contents of the
appropriate main group.
KEY TO SYMBOLS
In this CLAAS REPAIR MANUAL a limited number of symbols from the DIN 30600 have been used. which was prepared by
the German Standard Institution (DIN).
The meaning of the symbols will soon be learned by the user. The symbols help to quickly recognize recurring service
procedures and they also help to communicate information shown by the illustrations.
@]
Remove, Prevent damage
Grease
dismantle to material
� �
[I] Dismantle
�
Oil
[I] Special tool
[;] @
Drain,
Assemble Adjust, set
Drain outlet
�
i Install
Mount
�
Visually
check
�
Fill,
Filler opening
[BJ [I] @
Unlock. release
Mark Overflow
Secure
�
Balance
�
Lock Bound
Seal using adhesives
1�1 Bleed
Possibly Block up
reusable Support Hold
� �
[ij
Renew on each Note direction
assembly of installation
�
GENERAL RECOMMENDATION FOR REPAIR
1 . Locate the seat of the trouble, note all defective parts and take all precautions to prevent accidents.
2. Use genuine CLAAS spares and suitable CLAAS special service tools.
3. Always disconnect the negative battery cable (-) when working on the engine.
4. Drain off oil before removing the transmission cases. Use a plastic or soft metal hammer to separate parts tightly fitted
into each other.
5. Three-phase alternator
a)Never disconnect the cables between the alternator, voltage regulator and battery with the alternator running.
b) Do not connect the battery terminals in reverse polarity; this will destroy the alternator diodes.
c) Do not carry out work on live parts unless the engine is stopped and the battery cables are disconnected.
d) Do not flash connections to check current flow. This will damge the semiconductors.
e) Do not use an electric welder on machines unless all the alternator wires are disconnected!
f) The battery provides the current for the field excitation required to start the alternator action via the charge indicator
bulb. Burnt out bulbs must, therefore, be renewed to ensure positive field excitation.
6. Correct tension of steel roller chains
Find the center point in the slack span between sprockets. With the tight span slightly under load, push in the center point
of the slack span with the thumb. The tension of the chain is correct when its slack span deflects about 2 % of the center
distance between shafts. Tension of new chains should be checked at short intervals.
Example: If the distance between the centers of the shafts is 500 mm, the slack span of the chain should deflect about
1 0 mm.
7. Taper ring fasteners (locking cones)
Parts can be securely fastended by taper rings. even when high power is transmitted from the drive element to the shaft
and vice versa. However, the preload must be correct.
Installation:
When fitting the taper rings, it is important that the shaft, hub, parallel key and taper rings are thoroughly cleaned, that
semi-fluid lubricant NLGI grade 00 (e.g. Shell Retinax G or its equivalent) is applied and that the components are
tightened to the specified torque in the correct order of assembly.
IMPORTANT! No solid grease must be used when assembling the parts.

Removal:
After loosening the fixing components that clamp the taper rings axially in position, use a suitable hammer and
block-ended tube and apply a short, sharp blow to loosen the taper ring fasteners.
IMPORTANT! The inside diameter of the tube must be large enough to fit over the taper ring.
8. Self-locking bolts (with adhesive-filled micro capsules)
Renew self-locking bolts, e.g. Verbus-Plus/lmbus-Plus or similar bolts whenever they have been disturbed. In exceptional
cases, self-locking bolts may be reused up to three times. Always be sure to tighten the self-locking bolts to the specified
torque.
Self-locking bolts with adhesive-filled micro capsules must always be quickly tightened to the specified
torque. When removing these bolts. screw them quickly all the way out. These self-locking bolts with adhesive-filled micro
capsules must not come in contact with sealant or jointing compound (e.g. Epple 33
or similar products).
Instead of self-locking bolts, regular bolts with liquid locking compound may be used if need be. However, this must not
become common practice.
However, care must be taken to use bolts and liquid locking compound only in places where it is possible
to heat the fasteners to about 200 °C (392 °F) for removal. Ensure that the regular bolts conform to the specified grades
(8.8/1 0.9 or similar property classes).
Self-locking bolts with adhesive-filled micro capsules can only be used where the operating temperature will not exceed
+ 90 °C (1 94 °F).
After 24 hours of curing at +20 °C (68 °F) these fasteners can be subjected to full stress. To speed-up curing time, the
bonded parts can be heated. e.g. at + 70 °C (1 58 °F) total hardening time is reduced to 1 5 minutes.
9. Liquid locking compound (e.g. DELO-ML 1 87 / Loctite 242 or their equivalents)
Liquid locking compound must only be used at locations recommended by the manufacturer.
Correct application:
All metal surfaces where liquid locking compound is to be applied must be absolutely free from grease.
Use »AKTIVATOR« that comes with the workshop package for cleaning.
Allow the AKTIVATOR to dry off the metal surfaces before applying the liquid locking compound. Especially in the case of
holes that are not drilled all the way through care must be taken to ensure that no remains of AKTIVATOR (cleaning
agent) are left.
When fitting screw fasteners with liquid locking compound, try to apply the compound to the inside thread only (nuts) in
small amounts (drops). When using liquid locking compound in holes that are not drilled all the way through, only apply
the compound to the bottom end of the thread by wetting a length of thread that equals about the diameter of the bolt (1 x
the nominal diameter of the bolt). The same applies to any extra long female threads. Applying the locking compound to
the thread of the bolt or at the top end of a female thread, spreads the compound over the full lenght of thread when the
bolt is being screwed in. As a result, too much break-away torque is required to remove the bolt, should this be
necessary, and the bolt could break.
Fasteners fitted with liquid locking compound can easily be loosened after heating them to 200 °C (392 °F).
1 0. Correct installation of lock collar bearings
Lock collar bearings are tightened by pushing the eccentric locking collar over the extended inner ring of the bearing and
rotating the locking collar in direction of shaft rotation. This clamps the bearing to the shaft.
It is suggested to smear the inner ring and the shaft with semi-fluid lubricant NLGl-grade 00 (e.g. Shell Retinax G or its
equivalent) before mounting the bearings. This will make removal of bearings at a later time easier, should this be
necessary.
The locking collar is tightened by applying light hammer blows to a punch and tapping the collar in direction of shaft
rotation until a moderate lock is obtained. Then tighten the set screw. Loosen the bearing by tapping the eccentric collar
in the opposite direction of the rotation of the shaft.
1 1 . Correct installation of adapter sleeve bearings
Adapter sleeve bearings can be mounted to any drawn or turned shafts, the seatings have not to be especially finished.
This is of advantage because it allows the shaft to be axially moved as required so that the correct alignment is obtained.
When installing the adapter sleeve bearing, note the tapered inner ring. Clean the taper lock adapter sleeve and shaft
before installing the bearing and check that the lock nut runs easily along the thread in order to prevent the adapter
sleeve from turning when the nut is being tightened.
Tightening the bearing:

First tighten the lock nut to the point where play of the adapter sleeve is eliminated and slight preload exists. Then tighten
the nut about 90 degrees and continue to turn the nut until the nearest slot fits the tab. Secure the nut by properly bending
the tab into place.
Loosening the bearing:

Bend up the tab which secures the adapter sleeve lock nut. First back off the nut a few turns only (all of the nut's thread
must still grip the thread of the adapter sleeve). Then use a suitable pipe and loosen the taper sleeve by applying a short,
sharp blow.
1 2. Olive (ferrule) fittings on hydraulic lines
When assembling the unit on site or when installing a factory-assembled fitting: always make sure to liberally oil the inside
of the union, and to tighten the union nut until resistance is felt and then 1 /2-turn past that point.
Assembly on site:
a) Cut the tube at right angles. Do not use a cut-off wheel because this somehow slants the wall of the tube and causes
burrs, inside and out. Very carefully remove burrs both from the inside and outside of the tube end (but do not
chamfer). Clean all foreign matter from the tube. In case of a bent tube, make sure that the length of the straight end
of the tube up to the bend is at least two times the height of the union nut.
b) Slide the union nut and olive on to the tube.
c) Push the tube into the union until it bottoms and tighten the union nut until the olive cuts into the tube wall (the tube
must not rotate with the nut). You will notice when this happens because resistance is felt at this point.
d) Turn the union nut 1 /2-turn past the point of resistance.
e) Check cutting of olive into the tube wall: Some kind of a crest must be visible and provide snug fitting.
The olive may rotate but must not move axially.
Installation of factory-assembled unit:

Oil the union liberally. Insert the assembled tube. Tighten the union nut until resistance is felt and then 1 /2-turn past that
point.
Reinstallation of a used fitting:

Every time the olive fitting has been loosened, retighten the union nut only until snug. Do not overtighten the unit.
The olive (ferrule) fitting leaks:
When the fitting leaks, first loosen the union nut until some oil comes out. Then retighten the union nut correctly.
1 3. Progressive tube fittings on hydraulic tubes
For all pre-assembled as well as factory delivered pre-assembled profile ring tube fittings, the end assembly is completed
with the required connections being well oiled, and the nut tightened 1 /2 a turn over the point where the pressure is
distinctly felt.
Pre-assembly:
a) Cut the tube off square. Do not use a pipe cutter! The tube would be cut at an angle which would lead to a burr on the
inside and outside. De-burr the inside and outside of the tube ends lightly (do not chamfer!) and clean. The straight
end of a bent tube must be at least twice as long as the height of the nut, measured from the start of the radius.
b) Slide the union nut and the ferrule onto the tube.
c) Press the tube into the coupling up to the stop and tighten the union nut until the ferrule grips the tube (The tube must
not turn). This point is felt by the increasing force exerted.
d) Tighten the nut a further half turn over the pressure point.
e) Check for indentation of the sealing edge: A visible swelling must be formed in the area in front of the ferrule. The
ferrule may turn but must not have any axial movement.
Final assembly:
Fit the pre-assembled tube into the well oiled coupling, tighten the nut until resistance is felt, then tighten the nut another
half turn.
Important: Hold the body of the coupling with a spanner when tightening the nut!
Repeated assembly:
After loosening the profile ring connections, always tighten the nut until resistance is felt, then tighten a further half turn.
Important: Hold the body of the coupling with a spanner when tightening the nut!
Leakage at ferrule connections:
If a connection is leaking, loosen the nut so that a little oil runs out, then tighten again according to the instructions.
NOTEI Deviating methods of tightening reduce the nominal pressure performance and the durability of the connections.
Leakages and slipping out of the tubes are the results.
1 4. Taper fitting connections for hydraulic tubes

Assembly:
Oil the 0-ring on the taper fitting. Tighten the nut another 1 /3 of a turn after the pressure point has been felt.
NOTE! Deviating methods of tightening reduce the nominal pressure performance and the durability of the connections.
Leakages and slipping out of the tubes are the results.
1 5. Welding
IMPORTANT! When carrying out electric welding on the machine, proceed as follows:
a) Disconnect the cable from the negative (earth) terminal of the battery (on machines with two batteries remove the
negative (earth) cable from each battery).
b) Disconnect the main cable loom plug from the socket on the engine.
c) Remove the electronic plug-in modules from the central electrics compartment.
d) Remove the diode plate from the central electrics compartment.
e) Disconnect the cable connection to the fieldwork computer.
f) Disconnect the plug at the reversing gearbox.
g) Connect the earth clamp of the welder always in the near vicinity of the area where the welding is being carried out.
1 6. Some advice for speedy and correct repair:
a) Certain parts have to be marked before disassembly to ensure their correct left-to-right position and balance when
reassembled.
b) Fit roll (expansion) pins always with their gap pointing to the side of load. If fitted with a quarter of a turn from this
position, they will get loose, go astray or shear off.
c) Always renew cotter pins, split pins, locking wires, locking plates, tab washers and lock washers when carrying out
repairs.
d) Fit lubricated ball and sleeve bearings with high quality grease.
e) Care for sprockets and V-belt pulleys to be properly aligned.
f) Care for strict cleanliness when working on hydraulic systems.
g)Never mix different types/qualities of oil.
h) Run the machine or operate machine assemblies at low speed after any repair.
GROUP
INDEX
1 Specifications
2 Sectional view of machine
3 Drive schematic
4 Cutterbar
5 Threshing mechanism
6 Elevators and Crop Delivery
7 Engine and Drives
8 Transmission and Chassis
9 Hydraulic System
10 Steering and rear axle
11 Electrical System
12 Add-on equipment
1
Specifications
1 SPECIFICATIONS Settings and Capacities 1.
DOMINATOR 21 8 MEGA / 208 MEGA
Settings and Capacities 1. 4
DOMINATOR 204 MEGA / 203 MEGA
Settings and Capacities 1. 7
DOMINATOR 202 MEGA
Safety Devices 1. 10
DOMINATOR 21 8 MEGA- 202 MEGA
Basic Setting for Concave 1. 11
DOMINATOR 21 8 MEGA- 202 MEGA
Specifications
DOMINATOR 218 MEGA/ 208 MEGA
SETTINGS AND CAPACITIES
Hydraulic oil pressures

Pressure relief valve
Lift hydraulic system 1 80 bar

Hydrostatic steering system 1 20 bar + circuit flow pressure

Low pressure hydraulic system 20+2 bar
LINDE hydrostatic ground drive system

(BPV 1 00 SR / BMF 1 05 T)
High pressure relief valve setting 420 bar
Charge pressure 1 8+ 1 bar
Cold start valve 25+2-5 bar
Oil capacities
Hydraulic system
Work hydraulic system

Initial filling 8.5 litres of multi-grade hydraulic oil of viscosity classes
ISO-VG 32 or VG 46 to DIN 51 524 Part 3*
Oil change approx. 7 litres of multi-grade hydraulic oil of viscosity

classes ISO-VG 32 or VG 46 to DIN 51 524 Part 3*
LINDE hydrostatic ground drive system

(BPV 1 00 SR / BMF 1 05 T)
ISO-VG 32 or VG 46 to DIN 51 524 Part 3*

classes ISO-VG 32 or VG 46 to DIN 51 524 Part 3*
* The following guide values must be observed when selecting the hydraulic oil:
Pour point - lower than -25° C (DIN ISO 301 6)
Viscosity 0° c - < 600 cSt. (DIN 51 562)
Viscosity 40° C - max. 50.6 cSt. (DIN 51 562)
Viscosity index - > 1 70 (DIN ISO 2909)
The oil must have detergency properties.
DO 21 8 - 202 MEGA 1.1

Specifications

Oil capacities
Transmissions
ON MACHINE:
FINAL DRIVE GEARBOXES 4.5 litres each SAE 90, 85 W-90 (MIL-L-21 05 B)
API GL - 5 - 90 hypoid transmission oil
TRANSMISSION GEARBOX 5 litres SAE 90, 85 W-90 (MIL-L-21 05 B)

DRUM VARIABLE SPEED DRIVE

Two-step gearbox 1 . 0 litre SAE 1 40 (MIL-L-21 05)
API - GL - 4 - 1 40 transmission oil
CLAAS 4-TRAC HYDROSTATIC DRIVEN REAR AXLE

Planetary gearboxes 0.8 litres each SAE 90, 85 W-90 (MIL-L-21 05 B)
FRONT ATTACHMENTS:
CUTTERBAR KNIFE DRIVE
Wobble drive casing 0. 75 litres SAE 90 (MIL-L-21 05)
API - GL - 4 - 90 transmission oil
MAIZE PICKER HEAD SL

Picker head gearboxes 1 . 0 litre each SAE 90 (MIL-L-21 05)
6-ROW MULTIMASTER
Auxiliary gearbox 1 . 0 litre SAE 90 (MIL-L-21 05)
Picker head gearboxes 1 .25 litres each SAE 90 (MIL-L-21 05)

Engines, see engine operating manual and combine operating manual
Tyre sizes and tyre pressures

Minimum tyre pressures
Maize picker head Grain and rice cutterbar
Machine type Maximum
DO 218 / 208 MEGA tyre 8-row 6-row folding 6-row 5-row 30' 25'/7.50m 20'/6.00m 17'/5.10m
Tyre size pressures 6-row with 5-row 4-row - 95cm 9.00m 22'/6.60m 15'/4.50m 15'/4.50m
stalk with stalk 4-row with folding
chopper chopper stalk
chopper
24.5 - 32 12PR 2.1bar 2.1bar 2.0bar 2.0bar 2.0bar 2.0bar 2.0bar 2.0bar 1.9bar
24.5 - 32 16PR 2.6bar 2.6bar 2.3bar 2.0bar 2.0bar 2.3bar 2.0bar 2.0bar 1.9bar
24.5 R32 159A8 1.9bar - - 1.9bar 1.8bar - 1.9bar 1.8bar 1.8bar
30.5 R32 12PR 1.8bar 1.8bar 1.6bar 1.6bar 1.6bar 1.7bar 1.7bar 1.7bar 1.6bar
30.5 R32 166A8 1.9bar 1.7bar 1.4bar 1.2bar 1.2bar 1.4bar 1.2bar 1.2bar 1.1bar
14.9/80 - 24 10PR 2.9bar 2.4bar

500/60 - 22.5 8PR 2.0bar 1.5bar
16.9 - 24 8PR 2.2bar - - - - - - - 2.2bar
Torque settings of wheel bolts

Rear wheels wheel nuts with thrust piece H 22
DIN 74361 - 1 0= 860 Nm (86 mkp)
Front wheels wheel bolts M 1 8 x 1 .5= 325 Nm (32.5 mkp)
CLAAS 4-Trac rear wheel drive wheel bolts M 22 x 1 .5 - 8.8 and
spring washers C 22.5 DIN 74361 (Limes ring)= 520 Nm
1 .2 DO 21 8 - 202 MEGA
Specifications
Basic setting
Reel drive shaft perpendicular above knife bar,

reel tines perpendicular
Intake auger approx. 1 5 mm clearance between auger flights and bottom

plate of cutterbar trough
Brakes
Foot brake full braking effect after first third of pedal travel
Hand brake brake must hold after the first 3 to 4 teeth of the segment
Steering With steering cylinder piston fully extended, the adjustable

stop bolts must be contacting the steering arms
DO 21 8 - 202 MEGA 1 .3
Specifications



Hydrostatic steering system 20+2 bar
SAUER hydrostatic ground drive system

(90 R 075 / 90 M 075)
Purging pressure 1 8+ 1 -5 bar
Charge pressure 21 + 1 bar
Oil capacities
Hydraulic system
Work hydraulic system:

ISO-VG 32 or VG 46 to
DIN 51 524 Part 3*

classes ISO-VG 32 or VG 46 to
DIN 51 524 Part 3*

(90 R 075 / 90 M 075)
Initial filling 1 9 litres of multi-grade hydraulic oil of viscosity classes
DIN 51 524 Part 3*

DIN 51 524 Part 3*
Viscosity at 0° c - < 600 cSt. (DIN 51 562)
Viscosity at 40° C- max. 50.6 cSt. (DIN 51 562)
1 .4 DO 21 8 - 202 MEGA
Specifications

Oil capacities
Transmissions
ON MACHINE:
FINAL DRIVE GEARBOXES 3 litres each SAE 90, 85 W-90 (MIL-L-21 05 B)
TRANSMISSION GEARBOX 6.8 litres SAE 90, 85 W-90 (MIL-L-21 05 B)



API - GL - 5 - 90 hypoid transmission oil
FRONT ATTACHMENTS:

6-ROW MULTIMASTER
Picker head gearboxes 1 .25 litres each SAE 90 (MIL-L-21 05)

Minimum tyre pressu res

Maize picker head Grain pu tterbar
Machine type
Maximum
DO 204 MEGA 6-row 6-row 5-row 4-row 30' 25'/7.50m 20'/6.00m 17'/5.10m 13'
tyre
DO 203 MEGA folding 5-row 4-row95 cm 9.00m 22'/6.60m 15'/4.50m 15'/4.50m 3.90m
pressu res
Tyre size 6-row with stalk 4-row with folding 14'/4.20m
with stalk chopper stalk copper
chopper
23.1 -26 14PR 2.5bar - 2.3bar 2.1bar 2.0bar - 2.3bar 2.1bar 2.0bar 1.9bar
23.1 -30 14PR 2.5bar 2.0bar 1.8bar 1.7bar 1.5bar - 1.8bar 1.6bar 1.5bar 1.4bar
23.1 R30 155A8 1.9bar 1.8bar 1.6bar 1.5bar 1.3bar 1.8bar 1.6bar 1.4bar 1.3bar 1.2bar
23.1 R30 161AB 2.7bar 1.6bar 1.6bar 1.5bar 1.3bar 1.8bar 1.6bar 1.4bar 1.3bar 1.2bar
24.5 -32 16PR 2.6bar 1.6bar 1.4bar 1.3bar 1.1bar 1.6bar 1.4bar 1.2bar 1.1bar 1.0bar
24.5 R32 167AB 3.0bar 1.5bar 1.3bar 1.2bar 1.1bar 1.5bar 1.3bar 1.1bar 1.0bar 1.0bar
20.8 R38 153A8 1.9bar - 1.9bar 1.7bar 1.5bar - 1.8bar 1.6bar 1.5bar 1.4bar
14.5/75 -20 BPR 3.0bar 2.6bar

500/60 -22.5 BPR 2.0bar 1.0bar
14.9/80 -24 10PR 2.9bar 2.4bar
DO 218 - 202 MEGA 1 .5

Specifications

Front wheels wheel nuts with thrust piece H 22
DIN 74361 - 1 0= 860 Nm (86 mkp)
Rear wheels wheel bolts M 1 8 x 1 .5= 325 Nm (32.5 mkp)
Basic setting

Brakes

1 .6 DO 21 8 - 202 MEGA
Specifications
DOMINATOR 202 MEGA


Pressure relief valve 20+2 bar

Hydrostatic steering system

(90 R 075 / 90 M 075)
Purging pressure 1 8+ 1 -5 bar
Charge pressure 21 + 1 bar
Oil capacities
Hydraulic system
Work hydraulic system:

DIN 51 524 Part 3*

DIN 51 524 Part 3*

(90 R 075 / 90 M 075)
Initial filling 1 9 litres of multi-grade hydraulic oil of viscosity classes
DIN 51 524 Part 3*

DIN 51 524 Part 3*
Viscosity 0° c - < 600 cSt. (DIN 51 562)
Viscosity 40° C - max. 50.6 cSt. (DIN 51 562)
DO 21 8 - 202 MEGA 1 .7
Specifications
DOMINATOR 202 MEGA

Oil capacities
Transmissions
ON MACHINE:
FINAL DRIVE GEARBOXES 3 litres each SAE 90, 85 W-90 (MIL-L-21 05 B)
TRANSMISSION GEARBOX 6.8 litres SAE 90, 85 W-90 (MIL-L-21 05 B)



FRONT ATTACHMENTS:
API - GL - 4 -90 transmission oil
6-ROW MULTIMASTER
API - GL- 4 - 90 transmission oil
Picket head gearboxes 1 .25 litres each SAE 90 (MIL-L-21 05)

API - GL- 4 - 90 transmission oil

Minimum tyre pressu res
Machine type
Maximum Maize picker head Grain and rice cu tterbar
DO 202 MEGA
tyre
Tyre size 5-row 4-row 4-row 22' 20'/6.00m 17'/5.10m 13'/3.90m 15'/4.50m
pressu res
with stalk with stalk 5-row 6.60m 15'/4.50m 12'/3.60m folding
chopper chopper 14'/4.20m
23.1 -26 14PR 2.5bar 2.3bar 2.1bar 2.0bar 2.3bar 2.1bar 2.0bar 1.9bar -
28.1 -26 14PR 1.8bar 1.8bar 1.7bar 1.5bar 1.8bar 1.6bar 1.5bar 1.4bar -
23.1 -30 14PR 2.5bar 1.6bar 1.5bar 1.3bar 1.6bar 1.4bar 1.3bar 1.2bar 1.7bar
23.1 R30 161AB 2.7bar 1.5bar 1.3bar 1.3bar 1.4bar 1.3bar 1.3bar 1.1bar 1.5bar
24.5 -32 16PR 2.6bar 1.3bar 1.2bar 1.1bar 1.3bar 1.1bar 1.0bar 1.0bar 1.4bar
12.5/80 -18 10PR 4.0bar 2.2bar
14.5/75 -20 BPR 3.0bar 1.5bar
500/60 -22.5 BPR 2.0bar 0.8bar
14.9/80 -24 10PR 2.9bar 2.4bar
1 .8 DO 218 - 202 MEGA

Specifications
DOMINATOR 202 MEGA

Front wheels
wheel nuts with thrust piece H 22
DIN 74361 - 1 0= 860 Nm (86 mkp)
Rear wheels wheel bolts M 1 8 x 1 .5= 325 Nm (32.5 mkp)
Basic setting

Brakes

DO 21 8 - 202 MEGA 1 .9
Specifications
DOMINATOR 21 8 MEGA - 202 MEGA
Safety features
Slip clutches
Upper feed rake shaft 430 Nm - double spring
Reel:
Grain cutterbar up to 5. 1 0 m 300 Nm
Grain cutterbar above 6. 0 m 430 Nm
4.50 m folding grain cutterbar 200 Nm each
Rice cutterbar 300 Nm
Soybean cutterbar 300 Nm
Intake auger 300 Nm
Grain cutterbar up to 4.50 m 300 Nm

Grain cutterbar above 5. 1 0 m 700 Nm
Rice cutterbar up to 4.50 m 300 Nm
Rice cutterbar above 5. 1 0 m 700 Nm
Soybean cutterbar 3.90 m - 7.50 m 700 Nm
4-row maize picker head SL 250 ± 40 Nm

6-row maize picker head, folding 250 ± 40 Nm
(Multimaster)
Cam-type cut-out clutch
Picker-head gearboxes:
8-row maize picker head SL 2 x 650 ± 50 Nm
6-row maize picker head, folding 1 400 Nm
(Multimaster)
Shear bolt
Grain tank unloading Hexagon head bolt
MEGA 21 8 / 208
M1 0 x 50 MK (Vp) DIN 931 - 8.8
Self-locking nut VM 1 0
MEGA 204 / 202
M1 0 x 40 MK (Vp) DIN 931 - 8.8
Self-locking nut VM 1 0
1.10 DO 21 8 - 202 MEGA

Specifications
Basic setting for concave

Concave settings Dimensions in mm
HE HE HA
L ev er Grain preconcav e Maize Main concav e20 x42 Rice preconcav e S pike tooth concav e
preconcav e
position entrance entrance entrance exit entrance entrance exit
H VE VE HE HA VE HE HA
4 thbar 3 rdbar 3 rdbar 3 rd from lastbar 2 ndbar 1 st toothbar 3 rd last endbar
11 10 10 7 10 9 7
2 13 12 11 8 12 10 8
4 17 16 14 10 15 13 11
5 20 19 16 12 18 15 13
6 23 22 18 14 21 17 15
7 26 25 21 16 24 19 17
8 29 28 24 19 27 22 20
9 32 31 27 22 30 24 23
10 36 35 30 25 33 27 26
11 39 38 33 28 37 30 30
12 43 42 36 31 40 33 34
13 47 46 40 35 44 36 38
14 51 50 44 39 48 39 42
15 56 56 48 43 51 42 46
DO 2 1 8 - 202 M EGA 1.11

2
Sectional view of machine
2 SECTIONAL VIEW OF MACHINE Sectional view of machine 2. 1
Sectional view of machine
SECTIONAL VIEW OF MACHINE

1 Three-sectional divider 28 Cleaning fan
2 Reel 29 Primary wind duct with
3 Reel tines adjustable deflector (DO 21 8 - 204 MEGA)
4 Reel intermediate drive 30 Windboard, adjustable
5 Reel variable drive 31 Clean grain auger
6 Reel cylinder 32 Returns auger
7 Crop lifter 33 Deflector curtain, straw walker compartment
8 Main table auger 34 Horizontal unloading auger
9 Feeder house 35 Lateral augers
10 Feed rake 36 Grain elevator
11 Cutterbar cylinder 37 Grain tank filler auger
12 Stone trap 38 Grain tank
13 Pre-concave 39 Grain tank lid
14 Main concave 40 Returns elevator
15 Accelerator 41 Returns back-to-drum auger
16 Threshing drum 42 Operator's platform
17 Impeller 43 Cab
18 Deflector curtain, concave exit 44 Engine
19 Straw walkers 45 Air cleaner
20 Intensive separation system, cranks with tines 46 Final drive
21 Under-walker return pan 47 Transmission
22 Grain tank unloading tube 48 Traction wheels
23 Rear hood 49 Rear wheels
24 Preparation floor 50 Straw chopper
25 Straw sieve pan
26 Upper sieves
27 Lower sieves
DO 21 8 - 202 MEGA 2. 1
3
Drive Schematic
3 DRIVE SCHEMATIC V-belt and chain diagram 3. 2
DOMI NATOR 21 8 M EGA / 208 M EGA
V-belt and chain diagram 3. 4
DOMI NATOR 204 M EGA / 203 M EGA
V-belt and chain diagram 3. 6
DOMI NATOR 202 M EGA
Drive Schematic
3.2 DO 21 8 - 202 MEGA

Drive Schematic
V-belt and chain diagram

1 Hydraulic pump power band belt, ground drive

2 Hydraulic pump drive belt
(lift hydraulic system, steering system, low pressure
hydraulic system)
3 Compressor drive belt, air conditioner
4 Grain tank clutch power band belt
5 Threshing mechanism clutch power band belt
6 Intermediate cleaning fan drive belt
7 Intermediate sieve pan drive
8 Tine crankshaft drive belt
9 Reel drive chain (4.50 m - 5. 1 0 m cutterbars)
1 0 Intermediate reel drive chain
(4.50 m - 5. 1 0 m cutterbars)
1 1 Variable speed reel drive belt
1 2 Chain - intermediate variable speed reel drive
1 3 Power band belt for snapping units (maize picker head)
1 4 Chain - intake auger drive (maize picker head)
1 5 Chain - intermediate drive shaft (maize picker head)
1 6 V-belt - knife drive casing (6.00 m - 9. 00 m cutterbars)
1 7 Intake auger drive chain (6.00 m - 9. 00 m cutterbars)
1 8 V-belt - knife drive casing (4.50 m - 5. 1 0 m cutterbars)
1 9 Intake auger drive chain (4.50 m - 5. 1 0 m cutterbars)
20 Cutterbar drive belt (two)
21 Power band belt - accelerator
22 Wide-section belt - fan drive
23 Power band belt - sieve pan and auger drive
24 Straw walker drive belt
25 Straw spreader drive belt
26 Chain - grain tank filler auger drive
27 V-belt - straw chopper intermediate drive assembly
28 Drive chain - grain tank unloading auger
29 Chain - grain tank intermediate drive assembly
30 Rotary screen drive belt
31 Rotary screen intermediate drive belt
32 Chain - returns elevator
33 Straw chopper drive belt
34 Wide section belt - threshing drum variable speed drive
35 Threshing drum drive power band belt
36 Reel variable speed drive belt
(6. 00 m - 9. 00 m cutterbars)
37 Chain - reel intermediate drive assembly
38 Chain - reel intermediate variable speed drive
39 Reel drive chain (6.00 m - 9. 00 m cutterbars)
40 Cogged drive belt for maize picker head (stalk chopper)
41 Power band belt for stalk chopper intermediate drive
assembly
42 Suction blower drive V-belt
DO 21 8 - 202 MEGA 3.3

Drive Schematic
3.4 DO 21 8 - 202 MEGA

Drive Schematic
V-belt and chaiPl diagram

DOM I NATO R 204 M EGA / 203 M EGA

(lift hydraulic system, steering system,
low pressure hydraulic system)
8 Tine crank shaft drive belt
1 6 V-belt - knife drive casing (6.00 m - 7.50 m cutterbars)
1 7 Intake auger drive chain (6.00 m - 7.50 m cutterbars)
(6. 00 m - 7.50 m cutterbars)
39 Reel drive chain (6.00 m - 7.50 m cutterbars)
assembly
43 Set of rotary screen intermediate drive belts
DO 21 8 - 202 MEGA 3.5

Drive Schematic
3.6 DO 21 8 - 202 MEGA

Drive Schematic
V-belt and chain diagram

DOMI NATO R 202 M EGA

(lift hydraulic system, steering system, low pressure
hydraulic system)
8 Tine crank shaft drive belt
1 6 V-belt - knife drive casing (6.00 m - 6.60 m cutterbars)
1 7 Intake auger drive chain (6.00 m - 6.60 m cutterbars)
39 Reel drive chain (6.00 m - 6.60 m cutterbars)
assembly
43 Set of rotary screen intermediate drive belts
DO 21 8 - 202 MEGA 3. 7
4
Cutterbar
4 CUTTERBAR CUTTERBARS
Drives 4. 1
Removal of reel variable speed belt 4. 1
Removal of spring-loaded variable speed pulley 4. 2
Removal of reel lower variable speed pulley 4. 2
Reel speed control disassembled 4. 4
Assembly and installation of electric reel
speed controls 4. 5
Installation of reel lower variable speed pulley 4. 6
Removal of reel 4. 7
Removal of wobble drive unit for knife drive 4. 9
Disassembly of wobble drive unit 4. 11
Wobble drive unit disassembled 4. 13
Assembling and installing the wobble drive unit
for knife drive 4. 14
Removing the fingers of the intake auger 4. 15
Installing the fingers of the intake auger 4. 15
Removing the finger shaft from the intake auger 4. 15
Intake auger disassembled
4.50 m - 5. 1 0 m cutterbar
to machine no. 4. 1 7
6. 00 m - 9. 00 m cutterbar
to machine no. 4. 1 8
4.50 - 9. 00 m cutterbar
from machine no. 4. 19
Installing the finger shaft in the intake auger 4. 20
Removal of intake auger 4. 20
Setting the slip clutch of the intake auger 4. 24
FEEDER HOUSING
Removal of lower feed rake drum 4. 24
Lower feed rake drum disassembled
DO 21 8 - 208 MEGA 4. 25
DO 204 - 202 MEGA 4. 26
Assembly of lower feed rake drum 4. 26
Installation of lower feed rake drum 4. 26
Tensioning the feed chains 4. 27
Removal of feeder housing 4. 27
Removal of upper feed rake drum 4. 28
Upper feed rake shaft disassembled
DO 21 8 - 208 MEGA 4. 31
Upper feed rake shaft disassembled
DO 204 - 202 MEGA 4. 32
Installation of upper feed rake shaft 4. 33
Setting the feed rake drive slip clutch 4. 33
Removal of cutterbar intermediate drive shaft 4. 34
Installation of cutterbar intermediate drive shaft 4. 35
Cutterbar
CUTTER BARS
The service work was carried out on a 6. 00 m special
cutterbar but applies equally to all cutterbar sizes.
Where differences exist, this is specifically mentioned,
especially in the description of adjustment procedures.
Drives
Left-hand side:
1 Cutterbar intermediate shaft, UH

2 Drive shaft for intake auger
3 Knife drive
4 Steel roller chain - intake auger drive
5 Knife drive belt
(Fig. 1 )
Right-hand side:
(on cutterbars up to 5. 1 0 m these elements are installed
on the UH side too)
6 Cutterbar intermediate drive shaft R/H

7 Reel variable speed drive
8 Reel intermediate drive assembly
9 Reel sprocket with slip clutch
10 Steel roller chain for reel variable speed drive
11 Reel variable speed belt
12 Steel roller chain for reel intermediate drive assembly
13 Steel roller chain for reel drive
(Fig. 2)
2
Removal of variable speed belt

Be careful when removing the belt.
Never reach between spring-loaded
pulley halves.
1 . Start the engine. Engage the threshing mechanism,

and operate the reel speed variator so that the reel
runs at full speed. (Pulley A operated to the "open"
position, pulley "B" to the "closed" position).
(Fig. 3)
DO 21 8 - 202 MEGA 4. 1
Cutterbar
2. Stop the engine. Leave the ignition on and leave the

threshing mechanism and cutterbar engaged. Remove
the guard located in front of the variable speed pulleys.
Hold the switch for reel speed variation in the
"slow speed" position until the pulley (B) is fully spread.
Remove the variable speed belt.
(Fig. 3)
Removal of spring-loaded variable speed pulley

Remove variable speed belt.
Remove bolt (S) together with the retainer washer and
remove the variable speed pulley from the shaft.
If the variable speed pulley is not pushed off the shaft
through the pressure of the spring while the bolt (S) is being
turned out, leave the bolt (S) far enough in the shaft and
free the pulley by light hammer blows from a plastic mallet.
Bolt (S) should not be turned entirely out until the pulley is
free.
(Fig. 4)
Removal of reel lower variable speed pulley

Remove variable speed belt.
Undo the adjusting linkage for reel speed variation at (B)
using a second spanner to hold the adjusting nut stationary.
(Fig. 5)
Unscrew the grease nipple located behind the sprocket of

the lower variable speed pulley (N).
(Fig. 6)
4.2 DO 21 8 - 202 MEGA

Cutterbar
Remove the front pulley half.

(Fig. 7)
Slacken off steel roller chain (1 0) and remove.

(Fig. 8)
Loosen grub screw (G).

(Fig. 9)
Remove parallel key from the shaft and remove the

rear half (H) of the variable speed pulley.
(Fig. 1 0)
10
DO 21 8 - 202 MEGA 4.3

Cutterbar
@�
11
Reel speed control disassembled :
1 1 8 · 5 x 28 x 5 seal washe r (to machine no. ... )

2 Flange
3 M 6 x 1 6 DIN 91 2 socke t he ad cap scre w
4 Paralle l k e y
5 Coupling
6 M 6 hex. nut (to machine no. ... )
Contact washe r (to machine no. ... )
Quick faste ne r (from machine no. ... )
7 Flange
8 Axial washe r
Needle be arings
1� Adjusting nut
11 Bush
.
12 Clamping p e e
13 He x. bolts � � x 60 DIN 931 -8.8
A 6 DIN 1 28 lock washe r
14 Conne cting rod
15 Spac er tube
16 Hub
17 M 6 x 1 1 O DIN 91 2-8.8 socke t he ad cap scre w
A 6 DIN 1 28 lock washe r
he x. nut M 6 DIN 934 (to machine no. ... )
18 1 0 x 20 DIN 933 he x. bolt
� 1 0 contact washe r
19 Ge are d motor
(Fig. 1 1 )
4.4 DO 21 8 - 202 MEGA

Cutterbar
----tl1"i---- 19
..
2 3 578 9 10 11 12 13 14 15 18
12
Assem bly and installation of electric reel speed

controls
IMPORTANT! Prior to assembly apply K2K DIN 51 825

lithium-saponified multi-purpose grease
(e.g. Shell Alvania G2 or similar product) to all sliding faces,
to the seals, washers and bearings.
Up to machine no. ... install sealing ring (1 ).
Push flange (2) onto electric motor and secure with the
socket head cap screws (6). Torque the socket head cap
screws to 8 Nm.
Insert parallel key (4) into the grove of the output shaft and
fit coupler (5), paying attention to position. For machines
up to machine no. ... , fit contact washer (6). On machines
above no. ... , fit quick fastener instead of hex. nut and
contact washer.
Fit flange (7) and axial washers (8) with needle bearing (9)
and adjusting nut (1 0). Install bush (1 1 ) and secure
clamping piece (1 2) with the hex. bolts (1 3).
Use two cables and fit female connectors to one end of
each cable. At the other end of the cable, make one loop
each and attach one cable each to the (+) terminal post
and to the (-) terminal post of a 1 2 V battery. Connect the
cables to the terminal spades of the geared electric motor
to start the motor (change cables for correct direction of
rotation, if required).
DO 21 8 - 202 MEGA 4.5

Cutterbar
Smear the thread of the thrust piece (1 4, with connecting

rod) with K2K DIN 51 825 grease (e.g. Shell Alvania G2 or
similar). Hold the threaded thrust piece against the adjusting
nut (1 0) so that the holes are aligned with each other.
Install the spacer tube (1 5), feed the connecting rod through
the reel support tube and secure the geared motor with the
socket head cap screws (1 7). Torque screws to 1 0 Nm.
(Figs. 1 1 and 1 2)
Installation of reel lower variable speed pulley
1 . Install fixed variable speed pulley half.

2. Position variable speed pulley half. Turn the Bowden
cable by means of the crank or operate the electric
motor until the adjuster rod in the reel support tube
locates against the stop.
3. Screw on the adjusting nut in the outside end of the
variable speed pulley until a distance of approx. 1 mm
is obtained between the hub of the moveable pulley
half and the fixed pulley half when the pulleys are in
the "fast speed" position. Lock the adjusting nut.
❖ Relining the reel slip clutch

Remove pin (S). Pull on the reel drive chain (K) until the
hole (2) in the spring-loaded cylinder is accessible.
Insert pin (S) in that hole.
�
Remove the slackened chain from the sprocket (H).
�
.____. (Fig. 1 3)
13
Remove all nuts from the studs and remove the pressure
springs.
Remove thrust piece (D), the front clutch lining (B) and the
sprocket (H).
(Fig. 1 4)
4.6 DO 21 8 - 202 MEGA

Cutterbar
Remove the set collar located in front of the hub of the

clutch and withdraw hub (N).
(Fig. 1 5)
15
When relining the slip clutch, the pressure springs should be

replaced at the same time.
Evenly adjust all springs until the slip clutch reaches the
prescribed slip torque.
Refer to Specifications »Safety Features«
(Fig. 1 6)
Check by using the following tools:
1 Assembly pin - part no. 1 81 835. 1

2 Torque wrench
(Fig. 1 6)
Removal of reel
Remove pin (S). Pull on the reel drive chain (K) until the
hole (2) in the spring-loaded cylinder is accessible.
Insert pin (S) in that hole.
Remove the slackened chain from the reel sprocket (H).
(Fig. 1 7)
DO 21 8 - 202 MEGA 4. 7
Cutterbar
Loosen set collar ( R ) and remove the complete sprocket

and slip clutch assembly.
(Fig. 1 8)
18
Detach chain tensioning linkage (G) at (1 ) and hydraulic

cylinder (Z) at (2 and 3). To do this, remove the split pins
and pins.
(Fig. 1 9)
19
Undo the support (V) of the guard panelling.

(Fig. 20)
20
Detach the hydraulic cylinder at (4). To do this, remove the

split pin and pin. Undo self-locking nut (5).
Use suitable lifting tackle, hoist, front end loader or similar
equipment and lift the reel from its support arms.
(Fig. 21 )
4.8 DO 21 8 - 202 MEGA

Cutterbar
Remove the set collar ( R ) located in front of the reel tine

adjuster. Note shims.
(Fig. 22)
22
Pull spring-loaded pin (F) and remove bearing bracket (B).

(Fig. 23)
23
Damaged reel tines can be replaced once the bearings on

the tine tubes have been loosened.
(Fig. 24)
24
Removal of wobble drive unit for knife drive

Move the knife to its UH dead centre by turning the knife
drive components.
Unbolt knife head (F) from the rocker arm.
(Fig. 25)
DO 21 8 - 202 MEGA 4.9

Cutterbar
Loosen the clamping bolt on rocker arm (S) and remove the
rocker arm.
(Fig. 26)
26
Remove idler pulley ( R ) and belt (K) for knife drive.

(Fig. 27)
27
Slacken all bolts on pulley (V) and remove bolt (1 )

(Fig. 28)
28
Loosen clamping screw (2) and withdraw the pulley.

(Fig. 29)
29
4. 1 0 DO 21 8 - 202 MEGA
Cutterbar
Unscrew base ot wobble drive case and remove the

complete wobble d rive assembly.
Remove d rain plug (A) and d rain the oil from the wobble
d rive case. Catch the oil in a container of adequate size.
Dispose of the oil so as not to harm the environment.
(Fig. 30)
Disassembly of wobble drive unit

Remove the wobble drive mount.
Unscrew cover (D) .
32
Remove the screws secu ring the housing (L) .
33
DO 218 - 202 MEGA 4.11

Cutterbar
Remove the wobble bearing assembly and wobble shaft as

a complete unit.
(Fig. 34)
34
Unlock slotted nut (N) (up to machine no. ... ) or (from

machine no. ... ) applying a torque of 1 00 Nm and remove.
(Fig. 35)
35
Drive the wobble shaft and wobble bearing out of the

wobble bearing housing (G).
(Fig. 36)
36
Slacken the set screws at (2) and remove the small axles by
driving them from the outside inwards.
(Fig. 37)
Use a suitable shaft end (approx. 26 mm in diameter) to

drive the bearing bushes out of the wobble yoke.
37
4. 1 2 DO 21 8 - 202 MEGA
Cutterbar
@--0
@)
38
Wobble drive unit disassembled:
1 Wobble yoke 21 Magnetic plug M 24 x 1 .5

2 Bearing bushes (oil drain plug)
3 Wobble housing 22 Screw plug M 1 0 x 1 DIN 906
4 Axles (oil level check plug)
5 Set screw M 8 x 1 6 DIN 91 5-45 H 23 Hex. bolt M 8 x 20 DIN 933-1 0.9
(lock with liquid locking compound, Lock washer 8 DIN 1 28
e.g. Casco ML 1 1 8 or equal) (Fig. 38)
6 Tapered roller bearing 3201 1 x DIN 720
7 Wobble shaft
8 Supporting ring as from cutterbar no. ...
Tab washer up to cutterbar no. ...
9 Slotted nut M 55 x 1 .5
10 Bearing housing
11 Needle sleeve 45 dia. x 52 dia. x 20, full-needle
12 O-ring 71 x 4 DIN 3770 NB 70
13 Socket head cap screw M 8 x 1 6 DIN 7984-8.8
Lock washer 8 DIN 7980
14 Shaft seal AS 45 x 62 x 8 DIN 3760-NB
15 Case
16 Needle bearing 25 dia. x 32 dia. x 26
17 Cover
18 Needle sleeve 35 dia. x 42 dia. x 20 DIN 61 8
19 Shaft seal 35 x 52 x 9
20 Screw plug with breather M 24 x 1 .5
DO 21 8 - 202 MEGA 4. 1 3
Cutterbar
Assembling and installing the wobble drive unit for

Up to machine no.... knife drive
1 . Assembly wobble yoke (1 ), bearing bushes (2) and
wobble housing (3).
2. NOTE! Set screws (5) are locked with liquid
locking compound (CASCO ML 1 1 8 or equal).
3. When installing the tapered roller bearings (6) make
sure to mount the bearings the right way round.
4. 1 Up to cutterbar no. ... : Tighten slotted nut (9) until
1-----1
tapered roller bearing is absolutely free of play or slightly
pre-loaded - to about 1 Nm bearing friction torque.
4.2 From cutterbar no. ... : Pre-load slotted nut (9) to 250 Nm
.....__.....
torque. Loosen the slotted nut (9). Turn tapered roller
bearing several times in alternate directions. Tighten the
slotted nut to 1 50 ± 20 Nm. Check the torque at the
wobble shaft without shaft seal (2.5 to 5 Nm).
Stake slotted nut without cracking it
(release torque 1 00.20 Nm).
5. Fit needle sleeves (1 1 ) to bearing housing (1 0).
Make sure a distance of 1 2 mm is obtained between the
end of the needle sleeve and the end of the bearing
housing.
6. Fit complete wobble shaft to the case. Install needle
bearing (1 6) and bearing housing (1 0).
39
7. Mount the bearing sleeve in cover (1 7). Smear face (Y)

From machine no. all the way around with sealing compound and screw
the cover in position.
8. Pack the cavities of shaft seals (1 4 and 1 9) all the way
round with rolling-bearing grease and install the seals.
9. After the wobble drive unit has been fully assembled,
fill the case with oil.
0. 75 litres of transmission oil SAE 90 (MIL-L-21 05)
API-GL-4-90.
1 0. When bolting the wobble drive case to the base,
torque the four M 1 8 x 45 DIN 91 2-1 0.9 socket
screws to 420 Nm .
(Figs. 39 and 40)
40
4. 1 4 DO 21 8 - 202 MEGA
Cutterbar
Removing the fingers of the intake auger

Undo the appropriate inspection door. Loosen lock nut (M)
and remove finger (F).
(Fig. 41 )
Installing the fingers of the intake auger
1 . Run the nut right down to the end of the thread.

$
2. Screw the finger (F) into finger bearing (L) until the finger 1-----1
locates on the shaft. Then ease back the finger, approx.
1 mm and lock it with the lock nut.
IMPORTANT! The finger (F) must be threaded as far as

possible into the bearing. But make sure that the finger will
not drag on the shaft.
(Fig. 41 )
Removing the finger shaft from the intake auger

With the service doors open, remove the clamping bolts of
arms (H). Remove the fingers (F) of the appropriate shaft.
(Fig. 42)
DO 21 8 - 202 MEGA 4. 1 5
Cutterbar
On the opposite side, unscrew clamping bolt (5) securing

the arm of the adjacent control shaft.
Unscrew the bolts that secure the flange ball bearing (K) to
the support inside the intake auger.
(Fig. 43)
43
Remove the complete finger shaft with finger bearings

attached through the service door.
(Fig. 44)
4. 1 6 DO 21 8 - 202 MEGA
Cutterbar
45
. •
Intake auger d1sassembled 21 Self-locking nut VM 6
.
4.50 m - 5. 1 0 m cutterbar to machine no. ... 22 Finger guide
23 Finger
1 Intake auger assembly 24 Hex. nut M 1 6 x 1 .5
2 Flange ball b a ing Pea 206 .
25 Finger bearing
3 Set screw M : ; 1 0 DIN 91 6 26 Finger shaft D 25 x 937
4 Lock collar 27 Cover
5 Flange Bfs 28 Finger shaft D 25 x 480 (for 4. 50 m cutterbar)
6 Lock collar �!aring Pea 206 Finger shaft D 25 x 788 (for 5. 1 0 m cutterbar)
7 Adjusting shaft D 30 x 1 75 29 Arm, UH.
s
8 Parallel key A X 7 X 32 DIN 6885 30 Shaft piec
9 Arm, R/H. 31 Flange ba� bearing Pea 205
10 Slotted mus m head screw 32 Set screw M 6 x 6 DIN 91 6
M 1 0 x 2 x � ��IN 603 33 Lock collar
�
Hex. nut 1 0 DIN 934 34 Bf 52
Contact washer A 1 0 35 Lock co II ar bearing Pea 205
11 Hex. bolt 1 55 DIN 931 36 Slotted mushroom head screw M 8 x 1 6 x 1 0 DIN 603
Hex. nut : 1 g �IN 934 37 Hub
Contact w her A 1 0 38 Hex. bolt M 1 0 x 25 RS
12 Finger sha� D 25 x 630 (for 4.5 m cutterbar) 39 Hex. hut M 1 0 DIN 934
Finger shaft 25 x 937 (for 5. 1 � m cutterbar)
13 Finger sha g 25 x 1 65
4o Intake auger
Hex bolt M 8 x 20 DIN 933
14
15
Finger sha� D 25 x 937
Bush
:!
43
Contact wash
Counters ��! �ut M 8 / 1 1 x 1 9
16 Bush 44 Hex. bolt � � x 1 6 DIN 933
17 Set screw M 1 0 x B DIN 91 6 Hex. nut M 8 DIN 934
18 Set collar 45 Feed assister
19 Hex. bolt M 6 X 1 6 DIN 933
20 Washer s. 4 DIN 9021 (Fig. 45)
DO 21 8 - 202 MEGA 4. 1 7
Cutterbar
46
Intake auger disassembled 26 Hex. bolt M 8 DIN 934

6. 00 m -9.00 m cutterbar to machine no. ... (for 7.5 and 9. 0 m cutterbar)
27 Contact washer A 8 (for 7.5 and 9. 0 m cutterbar)
1 Intake auger 28 Tensioner (for 7.5 m and 9. 0 m cutterbar)
2 Adjusting shaft D 30 x 1 70 (for 6. 0 and 6.6 m cutterbar) 29 Hub (for 6. 0 m and 6.6 m cutterbar)
Adjusting shaft D 30 x 365 (for 7.5 and 9. 0 m cutterbar) 30 Hex. bolt M 1 0 x 25 RS
3 Flange ball bearing Pea 206 (for 6. 0 and 6.6 m cutterbar)
4 Set screw M 8 x 1 0 Hex. bolt M 1 2 x 55 DIN 931
5 Lock collar (for 7.5 and 9. 0 m cutterbar)
6 Flange Bfs 62 Contact washer A 1 2
7 Lock collar bearing Pea 206 31 Hex. nut M 1 0 DIN 934 (for 6. 0 and 6.6 m cutterbar)
8 Arm, R/H. Hex. nut M 1 2 DIN 934 (for 7.5 and 9. 0 m cutterbar)
32 Cover
9 Hex. nut M 1 0 x 60 DIN 931
33 Hex. bolt M 8 x 20
1 0 Hex. nut M 1 0 DIN 934 34 Contact washer B 8
1 1 Bush 35 Countersunk rivet nut M 8 / 1 1 x 1 9
1 2 Bush
1 3 Set screw M 1 0 x 8 For 7.5 and 9. 0 m cutterbar
1 4 Set collar 36 Hub
37 Hex. bolt M 1 2 x 25 DIN 933
1 5 Intake auger
Hex. nut M 1 2 DIN 934
1 6 Cover Contact washer A 1 2
1 7 Hex. bolt M 6 x 1 6 DIN 933
1 8 Washer 6.4 DIN 9021 For 6. 0 and 6.6 m cutterbar
1 9 Self-locking nut VM 6 40 Hex. bolt M 8 x 1 6 DIN 933
Hex. nut M 8 DIN 934
20 Finger guide
Contact washer A 8
21 Finger 41 Intake auger feed assister
22 Hex. nut M 8 DIN 934 42 Auger flight extension
23 Finger bearing 43 Auger flight extension
24 Slotted mushroom head screw M 1 0 x 20 x 1 2 DIN 603 44 Slotted mushroom head screw M 1 0 x 20
Hex. nut M 1 0 DIN 934 Hex. nut M 1 0 DIN 934
Contact washer A 1 0 Contact washer A 1 0
25 Cover (for 7.5 and 9. 0 m cutterbar) (Fig. 46)
4. 1 8 DO 21 8 - 202 MEGA
Cutterbar
47
Intake auger disassembled: 24 Slotted mushroom head screw M 1 0 x 20 x 1 2 DIN 603

4.50 m - 9. 00 m cutterbar to machine no. ... Hex. nut M 10 DIN 934
Contact washer A 1 0
1 Intake auger assembly 25 Cover
2 Adjusting shaft 26 Hex. nut M 8 DIN 934
3 Flange ball bearing Pea 206 27 Contact washer A 8
4 Set screw M 8 x 1 0 28 Tensioner
5 Lock collar 29 Cover
6 Flange Bfs 62 30 Hex. bolt M 6 x 1 2
7 Lock collar bearing Pea 206 Hex. nut M 6
8 Arm Contact washer
9 Hex bolt M 1 0 x 60 x 1 0 DIN 931 31 Cover plate
10 Hex. nut M 1 0 DIN 934 32 Hex. bolt M 8 x 20
11 Contact washer A 1 0 33 Contact washer
12 Bush 34 Countersunk rivet nut
13 Set screw M 1 0 x 8 35 End of auger flight
14 Set collar 36 Slotted mushroom head screw M 1 0 x 20
15 End of auger flight 37 Hub
16 Intake auger 38 Hex. bolt M 1 2 x 55 DIN 931
17 Hex. bolt M 6 x 1 6 DIN 933 Hex. nut M 1 2 DIN 934
18 Washer 6.4 DIN 9021 Contact washer
19 Self-locking nut VM 6 39 Hex. bolt M 1 2 x 25 DIN 933
20 Finger guide Hex. nut M 1 2 DIN 934
21 Finger Contact washer A 1 2
22 Hex. nut M 1 6 x 1 .5 DIN 934
23 Finger bearing (Fig. 47)
DO 21 8 - 202 MEGA 4. 1 9
Cutterbar
Installing the finger shaft in the intake auger
1 . Assemble the finger shaft, finger bearing, set collars

and flange ball bearings. Do not tighten the set collars
and flange ball bearings at this time.
2. Install arm. Make sure that the drillings for the hex.
bolts in the arm and in the shaft line up correctly.
3. Secure the arm of the next shaft, bolt the flange ball
bearing to the support inside the intake auger and
tighten the lock collar.
4. Align arms and tighten with hex. bolts.
5. Bolt on all plastic guides, install fingers and lock the
fingers with lock nuts. See section »Installing the
fingers of the intake auger«.
6. Rotate the intake auger several times so that the finger
bearings can align themselves on the shaft. Then
tighten the set collars.
IMPORTANT! The fingers must be free to move in their

plastic guides.
(Figs. 45, 46 and 47)
Removal of intake auger

Remove the reel.
Remove the belt for the knife drive.
Unscrew hex. screw (S), remove the washers and reinstall
screw (S) to prevent damage to the thread by the puller.
.____. (Fig. 48)
48
Remove idler pulley (L) using a suitable puller. Note the

number and thickness of shims between V-belt pulley and
sprocket.
(Fig. 49)
49
4.20 DO 21 8 - 202 MEGA

Cutterbar
Slacken off and remove steel roller chain (K).

(Fig. 50)
50
Remove the key that attaches sprocket ( R ) together with

the slip clutch to the shaft and withdraw the assembly using
a suitable puller.
(Fig. 51 )
51
Remove the set collar and loosen the lock collar of the
flange ball bearing (F). /
v¢:
(Fig. 52) . tt-. . ·
52
Unscrew bearing plate (L) at (1 and 2) and withdraw the

assembly complete with bearing. Note the number and
thickness of shims between bearing and hub.
(Fig. 53)
53
DO 21 8 - 202 MEGA 4.21

Cutterbar
Loosen two clamping bolts located in the hub at (N).

(Fig. 54)
54
Pull the drive shaft out of the hub.

Special tool:
Hex. bolt M 1 2 x 1 40 DIN 933-8.8
replacement part no. 233 01 1 . 0
2 Hex. nut M 1 2 DIN 934-8
replacement part no. 236 1 72. 0
3 Washer 1 3 x 30 x 3, replacement part no. 236 844.0
4 Guide bushing, replacement part no. 1 81 807. 1
5 Tube, replacement part no. 1 81 878. 0
(Fig. 55)
On the right-hand cutterbar side unscrew clamping bolt (1 )

and hex bolt (2). Remove adjusting lever (H).
(Fig. 56)
56
Unscrew bearing plate (B) at (3 and 4).

(Fig. 57)
57
4.22 DO 21 8 - 202 MEGA

Cutterbar
If necessary, remove bearing plate (B) with a puller. Remove

the spacer located between the bearing plate and the flange
ball bearing.
(Fig. 58)
58
Loosen the lock collar of flange ball bearing (F).

(Fig. 59)
59
Unscrew the inspection door on the right end of the intake

auger and remove clamping bolt (S) from the control arm.
(Fig. 60)
60
Withdraw adjusting shaft (W).

The complete intake auger assembly can now be removed
from the front by pulling one end out first.
(Fig. 61 )
61
DO 21 8 - 202 MEGA 4.23

Cutterbar
Setting the slip clutch of the intake auger

When relining the slip clutch, the pressure springs should be
replaced at the same time.
Evenly adjust all springs until the slip clutch ( R ) is adjusted
to the prescribed torque
For torque levels, see »Safety Devices« in Group 1
Specifications.
(Fig. 62)
Check by using the following tools:

1 Assembly pin - part no. 1 81 835. 1
2 Torque wrench
Feed Rake
Removal of lower feed rake drum

Remove dust shield (W) and turn the feed rake chains so
that the chain connecting links are at the bottom.
(Fig. 63)
Loosen self-locking nuts (1 4) on either side and slacken the

feed rake chains at adjusting screws (1 3). Separate the feed
rake chains at the chain connecting links.
Remove self-locking nuts (1 4) on both sides of the feeder
housing and remove the flanged pins from the inside of the
housing.
On the right-hand side, self-locking nut (1 4) is accessible
through the opening in the guard of the reverser gear and
through a bore in the gear wheel.
(Fig. 64)
64
4.24 DO 21 8 - 202 MEGA

Cutterbar
Pull pins (1 1 ) on both sides up out of the support arm and

secure with a self-grip wrench.
(Fig. 65)
65
Remove the lower feed rake drum to the front.

(Fig. 66)
66

1 Support arm, UH
Support arm, R/H
¢
2
3
4
Deep grooved ball bearing 6306 2RS DIN 625
Felt strip
Drum
¢
5 Circlip 30 x 1 .5 DIN 471
6 Dust cap
7 Circlip 72 x 2.5 DIN 472
8 Split pin 3.2 x 1 8 DIN 94
9 Washer
10 Pressure spring 67
11 Stud
12 Stud
13 Chain tensioner
14 Self-locking nut Vm 1 6
15 Hex. nut M 20 DIN 934
(Fig. 67)
DO 21 8 - 202 MEGA 4.25

Cutterbar
DOMINATOR 204 MEGA / 203 MEGA / 202 MEGA

Support arm, UH
Support arm, R/H
2 Deep grooved ball bearing 6306 2RS DIN 625
3 Felt strip
4 Drum
5 Circlip 30 x 1 .5 DIN 471
6 Dust cap
8 Split pin 3.2 x 1 8 DIN 94
9 Washer
68 10 Pressure spring
11 Stud
12 Stud
13 Chain tensioner
14 Self-locking nut Vm 1 6
(Fig. 68)
Assembly of lower feed rake drum
1 . Press deep grooved ball bearing (2) into support

arm (1 ).
2. Replace felt strip (3) upon each reassembly and push
preassembled support arm onto the feed rake shaft.
3. Fit circlip (5). Fit dust cap (6) with circlip (7).
(Fig. 67 and 68)
Installation of lower feed rake drum

During installation of the lower feed rake drum, ensure that
the stud engages in the guide sleeve of the support arm.
Install stud (1 2) and chain tensioner (1 3) with self-locking
nut (1 4) and hex. nuts (1 5).
(Figs. 67, 68 and 69)
69
4.26 DO 21 8 - 202 MEGA

Cutterbar
21 8 MEGA / 208 MEGA
Fit the feed chains so that the feed rake slats are offset.
(Figs. 70 and 71 )
70
204 MEGA / 202 MEGA

Tensioning the feed chains
After loosening clamping screw (A) and lock nut (C), the
feed rake chains can be tensioned with adjusting nuts (B).
Tension the chains on both sides uniformly and only so
much that the feed rake slats just touch the slide rails (G).
The chain tension can also be checked with the cutterbar
installed through inspection flaps (P) on the feeder housing.
Insert the dowel pin of the stops on the left and right for
limiting the lower position of the feed rake in bore (1 ) when
harvesting grain, in bore (2) when harvesting maize.
To move the stops, simply loosen screw (S).
(Figs. 70, 71 and 72) 71
72
♦
Removal of feed rake
Raise the feed rake to its highest position and support
securely.
Unhook the feed plate from the feeder housing to the stone
trap under the feed rake by loosening the locking screws on
both sides and then pushing retaining rod to the left before
pulling out to the right.
(Fig. 73)
73
DO 21 8 - 202 MEGA 4.27

Cutterbar
Disconnect the cable for the starter motor of the reversing

unit at the battery terminals.
Disconnect the hydraulic lines for the cutterbar lateral
positioning system. Loosen the rubber cover on the starter
motor of the reversing unit and disconnect the cables.
Unscrew the cable from the magnetic pick-up.
(Fig. 74)
74
Remove the V-belts for the cutterbar drive.

Lower the feed rake until the hydraulic rams are fully
retracted.
Securely support the feed rake at front and back.
Disconnect the hydraulic cylinders under the feed rake.
When these pictures were taken, a mobile height-adjustable
stand (M) was used for removal of the feed rake. You can
manufacture such a stand yourself.
Remove the pins in the cutterbar yokes.
Push the combine back.
(Fig. 75)
Removal of upper feed rake shaft

Remove the feed rake.
Unbolt and remove the wear plate.
Unbolt the slip clutch of the upper feed rake shaft and pull
off the cutterbar drive pulley.
(Fig. 76)
4.28 DO 21 8 - 202 MEGA

Cutterbar
Turn the feed rake until the chain connecting links are at the
top, then separate the feed rake chains.
Unscrew and remove the anti-wrapping guards.
Remove circlip on (DO 21 8 - 208 MEGA) or gib head key
on (DO 204 - 202 MEGA) of the outer left-hand chain
sprocket.
(Fig. 77)
77
Remove parallel key and pull off clamping hub. Unscrew the
bearing unit on the left-hand side.
(Fig. 78)
78
Disconnect and remove the cam for the function control.

Loosen the clamping ring of the right-hand flanged bearing
and drive off in the opposite direction to the direction of
rotation.
(Fig. 79)
79
Press the shaft out of the bearing assembly to the left using
the special tool.
(Fig. 80)
DO 21 8 - 202 MEGA 4.29

Cutterbar
Special tool:
1 Puller bridge - part no. 1 81 800. 0

2 Threaded spindle - part no. 1 81 801 . 1
3 Adapter with ball - part no. 1 81 849. 0
4 Hex. bolt M 1 2 x 220 DIN 933-8.8 - part no. 244 422.0
5 Washer - part no. 236 844. 0
6 Hex. nut M 1 2 DIN 934-8 - part no. 236 1 72.0
(Fig. 81 )
81
Pull left-hand bearing housing assembly from the shaft.

Remove the shaft.
(Fig. 82)
82
4.30 DO 21 8 - 202 MEGA

Cutterbar
vi
®--f�
0--.:0 ,, ;,Of;
, 0
®_)Ill' ,..� .,,, ,,,
,,,,,_ .,,.
/
,,,,,..,,,,,,,..
0
83

Upper feed rake shaft disassembled:
1 Bearing assembly
2 Feed rake shaft
3 Sprocket 9 teeth 38.4 x 1 9
4 Circlip 60 x 2 DIN 471
5 Lock collar
6 Grub screw M 1 0 x 8 DIN 91 6
7 Cam bear
8 Grub screw M 8 x 1 0 DIN 91 6
9 Magnetic pick-up
Hex. nut Bm 1 8 x 1 .5
10 Countersunk head screw M 1 2 x 65 DIN 7991
11 Feed rake assembly
12 Spacer
13 Anti-wrap guard, middle
14 Anti-wrap guard
15 Anti-wrap guard, left
16 Anti-wrap guard, right
17 Mushroom head screw M 8 x 75 DIN 603-4.6
Contact washer A 8
18 Protective tube
19 Roll pin 8 x 1 4 DIN 1 481
(Fig. 83)
DO 21 8 - 202 MEGA 4.31

Cutterbar
(D ®
®� j l
0-� @I,,_, _
®_!!
84

Upper feed rake shaft disassembled:
1 Bearing assembly
2 Feed rake shaft
3 Sprocket 9 teeth 38.4 x 1 9
4 Gib-head key 1 4 x 9 x 63 DIN 6887
5 Lock collar
6 Grub screw M 1 0 x 8 DIN 91 6
7 Cam bear
8 Grub screw M 8 x 1 0 DIN 91 6
9 Magnetic pick-up
Hex. nut Bm 1 8 x 1 .5
10 Countersunk head screw M 1 2 x 65 DIN 7991
11 Feed rake assembly
12 Spacer
13 Anti-wrap guard
14 Anti-wrap guard, left
15 Anti-wrap guard, right
16 Mushroom head screw M 8 x 75 DIN 603-4.6
Contact washer A 8
17 Protective tube
18 Roll pin DIN 1 481
(Fig. 84)
4.32 DO 21 8 - 202 MEGA

Cutterbar
Installation of upper feed rake shaft

The lock collar bearings can be turned in the housings.
The outer eccentric shoulder of the inner ring must face
outwards.
Each bearing is exactly matched by the manufacturer so
that the complete bearing assembly must always be
replaced together.
1 . Install the right-hand bearing assembly for the upper
feed rake on the feeder housing.
2. First slide in the shaft on the left until it can be pushed
into the right-hand bearing.
3. Pull the left-hand bearing assembly onto the shaft with
the special tool and bolt down.
4. Secure the right-hand bearing with the lock collar.
5. Install the cam gear for the function control. Fit the
bearing cups on the left and right.
6. Adjust the sprockets so that the teeth align and secure
with circlip (DO 21 8 - 208 MEGA) or with gib-head key
(DO 204 - 202 MEGA).
7. Install the anti-wrap guards and cover plates.
8. Install the cutterbar drive pulley with mounted and
adjusted slip clutch on the left-hand side and bolt
down.
9. Fit the feed rake chains so that the feed rake slats are
offset.
1 0. Tension the feed rake chain again to the specified
tension. Install the feed rake.
(Figs. 83, 84, 85 and 86)
86
Special tool:
1 Threaded pin - part no. 1 81 899.0

2 Pipe - part no. 1 81 878.0
3 Guide bushing - part no. 1 81 807. 1
4 Axial grooved ball bearing - part no. 1 77 899. 0
5 Hex. bolt M 1 6 x 300 DIN 933-8.8 (with point) -
part no. 237 375. 1
6 Hex. nut M 1 6 DIN 934 - 8 - part no. 236 1 73. 0
(Fig. 87)
87
Adjustment of the feed rake drive slip clutch

The slip clutch is adjusted to 430 Nm.
Assembly pin - part no. 1 81 835. 1 (special tool)
Torque wrench
After repair or maintenance work on the slip clutch, the
spring bolts must be secured again with the locking wire.
(Fig. 88)
DO 21 8 - 202 MEGA 4.33

Cutterbar
Removal of cutterbar intermediate drive shaft

Remove the guard of the cutterbar reversing drive. Unbolt
the sprocket from the reversing unit.
(Fig. 89)
Loosen clamping hub (DO 21 8 - 208 MEGA) or hub with gib

head key (DO 204 - 202 MEGA) and pull off.
Loosen the lock collar of the flanged bearing and drive off in
the opposite direction to the direction of rotation.
(Fig. 90)
90
Remove guard on left-hand side and remove the V-belt.

Loosen clamping hub (DO 21 8 - 208 MEGA) or hub with gib
head key (DO 204 - 202 MEGA) and pull off belt pulley.
(Fig. 91 )
91
Loosen flanged bearing on the left and pull out the

intermediate shaft to the left.
(Fig. 92)
92
4.34 DO 21 8 - 202 MEGA

Cutterbar
Installation of cutterbar intermediate shaft

Push in the shaft from the left and install the flanged
bearings on the left and right. Align the shaft axially
so that dimension (X)
for DO 21 8 / 208 MEGA = 270 mm
for DO 204 I 203 I 202 MEGA = 400 mm.
(Fig. 93)
93
Push on and align the V-belt pulley. Secure clamping

hub (DO 21 8 - 208 MEGA) or hub with gib head key
(DO 204 - 202 MEGA).
(Fig. 94)
94
Fit the lock collar for the flanged bearing on the right. Push
on the sprocket of the reversing unit and secure with the
clamping hub (DO 21 8 - 208 MEGA) or hub with gib head
key (204 - 202 MEGA).
Fit the guard of the reversing unit.
Fit and tension the V-belt.
(Fig. 95)
95
DO 21 8 - 202 MEGA 4.35

5
Threshing mechanism
5 THRESHING MECHANISM Removal of stone trap 5. 1
Installation of stone trap 5. 1
Removal of preconcave 5. 2
Preconcave disassembled 5. 4
Installation of preconcave 5. 5
Removal of main concave 5. 5
Main concave disassembled 5. 8
Installation of main concave 5. 9
Adjustment of preconcave and main concave 5. 9
Basic adjustment of concave 5. 10
ACCELERATOR
Removal of accelerator 5. 1 1
Accelerator dismantled 5. 1 3
Installation of accelerator 5. 1 4
THRESHING DRUM
Removal of threshing drum 5. 17
Threshing drum dismantled 5. 19
Installation of threshing drum 5. 20
Renewing the rasp bars of the threshing drum 5. 20
Renewing the threshing drum shaft 5. 21
Removal of left-hand threshing drum bearing 5. 22
Installation of left-hand threshing drum bearing 5. 23
Removal of right-hand threshing drum bearing 5. 23
Installation of right-hand threshing drum bearing 5. 24
IMPELLER
Removal of impeller 5. 25
mpeller dismantled 5. 28
Assembly of impeller 5. 29
Installation of impeller 5. 29
Adjusting the deflector plate 5. 31
STRAW WALKERS
Removal of under-walker return pan 5. 31
Installation of under-walker return pan 5. 32
Removal of straw walkers 5. 33
Installation of straw walkers 5. 33
Removal of front straw walker shaft 5. 34
Installation of front straw walker shaft 5. 34
Removal of rear straw walker shaft 5. 35
Installation of rear straw walker shaft 5. 36
Removal of rear tine crankshaft 5. 36
Removal of front tine crankshaft 5. 37
Installation of tine crankshafts 5. 38
SIEVE PAN 5. 39
Removal of preparation floor 5. 40
Rocker arm drive disassembled 5. 42
Installation of preparation floor 5. 43
Installation of rocker arms for sieve pan drive 3 - D 5. 44
Removal of sieve pan 5. 45
Installation of sieve pan 5. 49
Removal of 3 - D sieve frame 5. 50
3 - D sieve frame suspension and drive
disassembled 5. 53
Installation of 3 - D sieve frame 5. 54
Installation of 3 - D sieve pan controller 5. 56
Adjusting pivot arms with 3 - D gauge 5. 56
Installing new seal strips 5. 57
Removal of intermediate drive shaft for
rocker arms 5. 57
Intermediate drive shaft for rocker arms
disassembled 5. 59
Installation of intermediate drive shaft for
rocker arms 5. 60
CLEANING FAN
Removal of UH and R/H bearing from
cleaning fan 5. 60
Installation of UH and R/H bearing to
cleaning fan 5. 63
Removal of middle bearing from cleaning fan 5. 64
DO 21 8 MEGA / 208 MEGA / 204 MEGA
Installation of middle bearing to cleaning fan 5. 66
Removal of fan rotors 5. 66
Removal of fan housing 5. 67
Fan housing disassembled 5. 70
Installing fan housing 5. 71
Adjusting air deflector 5. 71
Fan blast reduction kit disassembled 5. 72
Installation of fan blast reduction kit 5. 73
Adjusting fan blast reduction kit 5. 74
Removal of windboard 5. 75
Installation of windboard 5. 76
Adjustment of windboard 5. 76
Removal of cleaning fan 5. 77
DO 203 MEGA / 202 MEGA
Fan blades 5. 77
Fan shaft 5. 77
Fan spiders and fan rotor 5. 79
Fan disassembled 5. 81
Installation of fan housing 5. 82
Adjusting windboards 5. 83
Installing fan blast reduction kit 5. 84
Threshing mechanism
Removal of stone trap

Remove feed rake (see Group 4).
Undo 6 hex. bolts M 1 0 x 35 DIN 933 and remove the
preconcave bars.
Remove the concave segments. Remove the centre
segment first, followed by the outer concave segments.
Unbolt the seal retaining strip from the stone trap
(6 hex. bolts M 8 x 20 with self-locking nut).
(Fig. 1 )
Undo the M 1 0 x 25 bolts that secure the stone trap to the

combine housing.
The stone trap can now be lifted from the combine housing.
(Fig. 2)
Installation of stone trap

Lift stone trap into the combine from the front and attach to
the combine housing using the M 1 0 x 25 hex. bolts.
Secure the seal with retaining strip and M 8 x 20 hex. bolts
to the stone trap.
Install the two outer concave segments first, then the centre
one.
Install the preconcave bars and secure segments with the
M 1 0 x 35 hex. bolts.
(Figs. 1 , 2 and 9)
DO 21 8 - 202 MEGA 5. 1
Threshing mechanism
Removal of preconcave
Remove feed rake.
Remove stone trap.
U nscrew from the preconcave the bolts that lock the
th readed pins on either side of the machine.
(Fig. 3)
Set down the preconcave and main concave, for example,

using a piece of square timber.
(Fig. 4)
U nbolt the protective cover (S) on the left-hand side of the

mach ine.
(Fig. 5)
U ndo the two threaded pins at (A and B) .

Remove the seal plate and washer.
(Fig. 6)
5. 2 DO 218 - 202 MEGA

Threshing mechanism
Remove the protective device on the right-hand side of the

mach ine.
U ndo the two threaded pins at (A and B) .
Remove the seal plate and the washer.
(Fig. 7)
Lift preconcave out the front.

(Fig. 8)
DO 218 - 202 MEGA 5.3

Threshing mechanism
[J]
Preconcave disassembled:
1 Preconcave
2 Washer
3 Threaded pin
4 Belleville springs
6 Tab washer (from machine no. ... )
7 Contact washer A 8 (from machine no. ... )
8 H ex. bolt M 8 x 1 2 D I N 933
(from machine no. ... )
9 Seal plate
10 Slider
11 Threaded pin
12 H ex. bolt M 8 x 45 D I N 933
H ex. nut M 8 D I N 934
13 Stone trap
14 H ex. bolt M 1 0 x 25 D I N 933
H ex. bolt M 1 0 D I N 934
15 Retaining bar
16 Hex. bolt M 8 x 20 DIN 933
Self-locking nut VM 8
17 Seal
18 Preconcave segment
19 Preconcave bar
20 Hex. bolt
21 Intermediate bar (option)
(Fig. 9)
5.4 DO 21 8 - 202 MEGA

Threshing mechanism
Installation of preconcave
Lift preconcave (1 ) into the machine.
Fit the threaded pins (3 and 1 1 ) with washer (2) and the seal
plate (9) to either side of the machine. Lock the threaded
pins with hex. bolts (1 2).
Install stone trap (1 3).
Adjust main concave and preconcave.
Install protective guard to concave adjustment mechanism.
(Figs. 3 to 9)
Removal of main concave

Remove feed rake.
Remove stone trap.
Remove preconcave.
Rest main concave, for example, on pieces of square
timbers.
Unbolt cover from drum housing.
(Fig. 1 0)
Loosen M 8 x 25 securing bolt with M 8 nut at (A) .

Remove bolt (S) from the main concave.
Remove slider and washer.
(Fig. 1 1 )
11
DO 21 8 - 202 MEGA 5.5

Threshing mechanism
Unbolt the front rocker arm from the preparation floor.

(Fig. 1 2)
12
Unbolt cover from drum housing on right-hand side of the

machine.
Slacken the accelerator drive belt and unbolt the idler
pulley (S).
(Fig. 1 3)
13
Undo M 8 x 25 bolt with M 8 nut at (A) .

Remove bolt (S) from main concave.
Remove slider and washer.
(Fig. 1 4)
14
Unbolt front rocker arm from preparation floor.

(Fig. 1 5)
15
5.6 DO 21 8 - 202 MEGA

Threshing mechanism
Remove rake behind concave or transition plate and

deflector curtain.
(Fig. 1 6)
16
Lift concave out the front of the machine body.
IMPORTANT! Fold in lateral seals to avoid damaging them.
DO 21 8 - 202 MEGA 5. 7
Threshing mechanism
17
Main concave dismantled:
1 Main concave
2 Hex. bolt M 1 2 x 25 DIN 933
Contact washer
3 Rake behind concave
4 Blind rivet A 4.8 x 1 2 DIN 7337
5 Retaining bar
6 Deflector curtain
7 Washer
8 Slider
9 Belleville spring
1 0 Bolt
1 1 Hex. bolt M 8 x 25 RS DIN 933
(Fig. 1 7)
5.8 DO 21 8 - 202 MEGA

Threshing mechanism
Installation of main concave

Lift the main concave into front of the machine.
Secure rake behind concave or transition plate (3) and
deflector curtain with hex. bolts (1 ).
Tighten bolt (1 0) with washer (7), slider (8) and Belleville
springs (9) so as to exert slight tension on Belleville springs.
Lock bolt (1 0) with hex. bolt (1 1 ).
Raise preparation floor and secure the front rocker arms on
the left and right.
Bolt covers to the drum housing.
Install idler pulley for the accelerator drive and adjust the
V-belt to the specified tension.
(Figs. 1 O to 1 7)
Install preconcave.
Install stone trap.
Adjustment of preconcave and main concave

Lock the concave adjusting lever (H) in the 3rd hole from
the top. On both sides of the machine adjust the
preconcave and the main concave to their basic settings
by means of the turnbuckle nuts or hex. nuts.
VE= preconcave - entrance
HE= main concave - entrance
HA= main concave - exit
Loosen the lock nuts on both ends of the turnbuckle to
make adjustment. Retighten the lock nuts after the
adjustment has been made. See »Concave settings« for bar
clearances and settings.
(Figs. 1 8 and 1 9)
IMPORTANT! Check and if necessary correct the basic

setting of the concave approx. 50 working hours after
putting the machine initially into operation or after installing a
concave.
19
DO 21 8 - 202 MEGA 5.9

Threshing mechanism
Basic adjustment of concave

Concave settings Dimensions in mm
HE HE HA
L ev er Grain preconcav e Maize Main concav e20 x42 Rice preconcav e S pike tooth concav e
preconcav e
position entrance entrance entrance exit entrance entrance exit
H VE VE HE HA VE HE HA
4 thbar 3 rdbar 3 rdbar 3 rd from lastbar 2 ndbar 1 st toothbar 3 rd last endbar
11 10 10 7 10 9 7
2 13 12 11 8 12 10 8
4 17 16 14 10 15 13 11
5 20 19 16 12 18 15 13
6 23 22 18 14 21 17 15
7 26 25 21 16 24 19 17
8 29 28 24 19 27 22 20
9 32 31 27 22 30 24 23
10 36 35 30 25 33 27 26
11 39 38 33 28 37 30 30
12 43 42 36 31 40 33 34
13 47 46 40 35 44 36 38
14 51 50 44 39 48 39 42
15 56 56 48 43 51 42 46
5. 1 0 DO 21 8 - 202 MEGA
Threshing mechanism
ACCELERATOR
Removal of accelerator
Remove feed rake.
Unbolt the protective guard from the right and left-hand side
of the machine.
Unscrew the lubricating line (S) on the right-hand side of the
machine.
Remove the circlip and washer (D).
(Fig. 20)
Set down the accelerator so that it is secure.

Undo the M 1 2 x 30 hex. bolt from the end of the shaft.
Undo the three M 1 2 x 35 hex. screws that hold the bearing
in place.
Screw two M 1 0 x 70 DIN 933 hex. bolts into the threaded
pins of the flanged bearing. Press the bearing unit from the
shaft by alternately tightening the bolts.
(Fig. 21 )
Undo the three M 8 x 1 8 hex. bolts that secure the

anti-wrapping guard.
(Fig. 22)
22
On the left-hand side of the machine slacken accelerator

drive belt tension and remove the belt.
(Fig. 23)
23
DO 21 8 - 202 MEGA 5. 1 1
Threshing mechanism
Unbolt the V-belt pulley from the clamping hub.

(Fig. 24)
24
Unscrew and remove the clamping hub.

Withdraw parallel key from shaft and pull spacer ring off the
shaft.
(Fig. 25)
25
Disconnect lubricating line from the bearing.

Undo the three hex. socket head cap screws that secure the
bearing.
Pull bearing unit assembly off the shaft using a puller.
(Fig. 26)
26
Lift accelerator with anti-wrapping guard out the front of the

machine.
(Fig. 27)
27
5. 1 2 DO 21 8 - 202 MEGA
Threshing mechanism
28
[J]
Accelerator dismantled: 15 Bearing cover
16 Self-aligning roller bearing
1 Accelerator drum 17 Bearing half
2 Hex. bolt M 6 x 20 DIN 933 18 Male connector Ll4M DIN 3900
Contact washer A 6 19 Felt ring
3 Countersunk rivet nut 20 Spacer ring
4 Cover 21 Hex. socket head cap screw M 1 2 x 35
5 Square neck coach bolt M 1 0 x 25 Fl 4Kt Spring washer A 1 2 DIN 1 28
Self-locking nut Vm 1 0 22 Male connector Ll4M DIN 3900
Contact washer A 1 0 23 Circlip 75 x 2.5 DIN 472
6 Cap 24 Washer
7 Parallel key A 1 4 x 9 x 40 DIN 6885 25 Hex. bolt M 1 2 x 30 DIN 933
8 Shaft Contact washer A 1 2
9 Hex. bolt M 1 2 x 65 DIN 931 26 Washer
Hex. bolt M 1 2 DIN 934 27 Circlip 75 x 2.5 DIN 472
Contact washer A 1 2 28 Self-aligning roller bearing DIN 630
1 0 Hex. bolt M 8 x 20 DIN 931 29 Bearing housing
Contact washer A 8 30 Felt ring
1 1 Cover 31 Hex. bolt M 1 2 x 35 DIN 933
1 2 Anti-wrapping guard Contact washer A 1 2
1 3 Hex. bolt M 8 x 1 8 DIN 933
Contact washer A 8 (Fig. 28)
1 4 Felt ring
DO 21 8 - 202 MEGA 5. 1 3
Threshing mechanism
29
Installation of accelerator
Lift accelerator with anti-wrapping guard into the front
right-hand side of the machine.
(Fig. 30)
Secure rest accelerator on a piece of square timber or

similar object.
(Fig. 31 )
5. 1 4 DO 21 8 - 202 MEGA
Threshing mechanism
On the right-hand side of the machine, pre-assemble

bearing housing (29) with felt ring (30) and self-aligning
roller bearing (28) and circlip (27).
Pull pre-assembled bearing housing onto shaft using
special tool.
(Fig. 32)
Special tool:
1 Hex. bolt M 1 2 x 300 - part no. 237 375. 1
2 Hex. nut M 1 2
4 Tube 45 dia. x 32 dia. x 1 50 long, self-manufactured
(Fig. 33)
33
Bolt down the bearing housing with hex. bolts (31 )

Screw in hex. bolt (25) with washer (26) to tighten the
accelerator axially.
(Fig. 34)
34
On the left-hand side of the machine, place bearing cover

(1 5) with felt ring (1 4), self-aligning roller bearing (1 6) and
bearing half (1 7) with felt ring (1 9) onto the shaft.
Pull bearing unit onto the shaft using special tool.
(Fig. 35)
DO 21 8 - 202 MEGA 5. 1 5
Threshing mechanism
Special tool:
1 Hex. bolt M 1 2 x 300 - part no. 237 375. 1
2 Hex. nut M 1 2
4 Tube 50 dia. x 42 dia. x 1 50 long, self-manufactured
(Fig. 36)
36
Secure bearing unit to sidewall of machine using the hex.

socket head cap screws (21 ). Screw on lubricating line (S).
Distance (Y) must be 1 1 1 .5 mm.
(Figs. 29 and 37)
37
Push spacer ring (20) onto shaft. Insert A 1 2 x 8 x 50

parallel key into shaft.
Push clamping hub (K) onto shaft as far as shoulder. Torque
the clamping bolt to 45 Nm.
(Fig. 38)
38
Secure V-belt pulley to hub using the M 1 0 x 25 DIN 933

hex. bolts.
Check that distance (X) is 67.5 mm.
Install V-belt and adjust tension (see Group 7 »Drives«).
(Figs. 29 and 39)
39
5. 1 6 DO 21 8 - 202 MEGA
Threshing mechanism
On the right hand side of the machine fit washer (24) with
circlip (23).
Screw on lubricating line and lubricate both bearing points.
(Fig. 40)
40
Check basic adjustment of concaves and correct as

necessary.
(See Adjustment of main concave and preconcave)
Install both covers on drum housing.
Secure the guard.
Install feed rake.
THRESHING DRUM
Removal of threshing drum

Remove feed rake.
Remove accelerator.
On the left-hand side of the machine, remove anti-wrapping
guard from the accelerator. Do this by removing the three
M 8 x 1 8 hex. bolts.
(Fig. 41 )
Unbolt two opposing drum cover plates (A).

(Fig. 42)
42
DO 21 8 - 202 MEGA 5. 1 7
Threshing mechanism
On the left-hand side of the machine unbolt the V-belt pulley

from the drum shaft.
Disconnect the lubricating line from the bearing unit.
Secure drum with square timbers to prevent it from slipping
or jamming.
Remove the hex. socket head cap screws that secure the
bearing.
(Fig. 43)
43
On the right-hand side of the machine, slacken the power

band belt that drives the drum.
(Fig. 44)
44
Remove the bolts which secure the drum to the flanges of

the stub shaft, both sides.
(Fig. 45)
45
Lift drum out the front of the machine by means of fork-lift or

similar equipment.
In doing so, turn the mounting flanges so that the chamfered
edges can be passed out between the rasp bars.
(Fig. 46)
46
5. 1 8 DO 21 8 - 202 MEGA
Threshing mechanism
!@ll�I Il 0 ,�
ct®�
47
Threshing drum dismantled: 26 Self-locking nut Vm 1 2

27 Rasp bars
1 Male connector Ll4M DIN 3900 28 Drum disc
2 Locking ring Vskz 8 29 Gib head key 1 4 x 9 x 56 DIN 6887
3 Hex. socket head cap screw M 8 x 20 DIN 91 2 30 Drum disc
4 Felt ring 31 Drum shaft
5 Slotted round nut 32 Drum disc
6 Tab washer 33 Hex. bolt M 1 4 x 50 DIN 931
7 Felt strip Hex. nut M 1 4 DIN 934
8 Bearing half Circlip 1 4
9 Spherical roller bearing 34 R/H trunnion
10 Adapter sleeve 35 Hex. bolt M 1 2 x 20 DIN 933
11 Bearing half Hex. nut M 1 2 DIN 934
12 Contact washer S 1 2 Contact washer A 1 2
13 Hex. bolt M 1 2 x 25 DIN 933 36 Drum cover plate
14 Felt strip 37 UH trunnion
15 Locating shell 38 Hex. bolt M 1 4 x 45 DIN 933
16 Adapter sleeve Hex. nut M 1 4 DIN 934
17 Spherical roller bearing Circlip 1 4
18 Bearing half
19 Tab washer For 2-step variable speed drive
20 Slotted round nut 40 Hex. bolt M 1 4 x 50 DIN 931
21 Locking ring Hex. nut M 1 4 DIN 934
22 Hex. socket head cap screw M 1 2 x 35 Contact washer A 1 4
23 Threshing drum 41 Flanged shaft
24 Hex. bolt M 1 2 x 30 DIN 933 (Fig. 47)
25 Square washer
DO 21 8 - 202 MEGA 5. 1 9
Threshing mechanism
Installation of threshing drum
1 . Lift threshing drum into the front of the machine body.

Pay attention to direction of drum rotation.
2. Bolt the flanged shafts to the drum and torque the bolts
to 1 30 Nm.
3. Fit the drum plates.
4. On the left-hand side of the machine, fit bearing unit
with the hex-socket head cap screws (22) so that it is
free of tension. The drum must turn easily when moved
by hand. Connect the lubricating line.
5. Bolt the V-belt pulley to the clamping hub.
6. On the right-hand side of the machine install the power
band belt and adjust to tension. (See Group 7 Drives.)
Install accelerator.
Check basic adjustment of concaves, correcting if
necessary. (See Adjustment of main concave and
preconcave.)
Install feed rake.
Renew rasp bars of the threshing drum.
(Figs. 41 to 47)
Renewing the rasp bars of the threshing drum

Damaged or worn rasp bars should be replaced with the
drum removed from the machine.
Drawing A= Worn rasp bar with pointed ribs.
Drawing B= Rasp bars with ribs in perfect condition.
(Fig. 48)
48
5.20 DO 21 8 - 202 MEGA

Threshing mechanism
Besides being bolted on, the rasp bars are also welded to
the drum discs.
Remove the bolts. Tip the rasp bars towards the weld runs.
The weld will break and the rasp bars can be removed.
Grind off what is left of the welds on the drum discs. Install
the new rasp bars and tighten the bolts to the recommended
torque.
Torque setting= 86 Nm
Securing bolts = hex. bolts
M 1 2 x 30 DIN 933-8.8 with self-locking nut Vm 1 2 and
square washer.
Also weld on the new rasp bars.
49
(Figs. 49 and 50)
Important
1 . When welding the bar to the drum disc, be sure not
to weld over the full width of the drum disc. Stop
the weld run approx. 5 mm from either end of the
disc.
2. Balance the drum after each repair.
3. If the drum is not running true and variations of
roundness exceed 1 .5 mm, turn the outside of the
drum in a lathe.
4. If the damage is extensive, e.g. if the drum discs or
shaft are damaged, a new drum should be
installed.
5. When the drum has been repaired, retighten the
bolts that secure the rasp bars to the drum after the 50
first 1 0 hours of work.
Renewing the threshing drum shaft

Remove the drum.
Extract the gib head keys. Clean the full length of the drum
shaft thoroughly. Pull the shaft out of the drum.
During assembly of the new shaft, great accuracy should be
exercised to obtain precise fit of the gib head keys. They
must be fitted to evenly contact their keyways over the
entire length.
Position the shaft so that it extends an equal distance on
both sides. Drive the gib head key firmly home.
Install the threshing drum.
(Fig. 51 )
51
DO 21 8 - 202 MEGA 5.21

Threshing mechanism
Removal of left-hand threshing drum bearing

Left-hand side of the machine
Slacken accelerator drive V-belt and remove.
(Fig. 52)
Unbolt V-belt pulley.

Unbolt clamping hub and extract the parallel keys from the
shaft.
(Fig. 53)
53
[I] Unlock and remove the slotted round nut.

Use a suitable block-ended tube and loosen the adapter
sleeve by applying a short, sharp blow.
Pull bearing off the shaft.
(Fig. 54)
Left-hand threshing drum bearing disassembled:

1 Flanged shaft
2 Felt strip
3 Locating shell
4 Adapter sleeve
5 Spherical roller bearing
6 Bearing half
7 Tab washer
8 Slotted round nut
9 Hex. socket head cap screw M 1 2 x 35
I
®
Locking ring
(Fig. 54)
54
5.22 DO 21 8 - 202 MEGA

Threshing mechanism
Installation of left-hand threshing drum bearing
1 . Bearing location, adapter sleeve and shaft seat must be

free of grease.
2. Slide bearing assembly onto shaft and secure to
machine sidewall by means of the hex. socket head cap
screws (9).
3. Connect lubricating line.
4. Pre-torque M 50 x 1 .5 slotted round nut to 30 Nm and
continue turning the nut until the tab of the tap washer
coincides with a slot of the nut. Turn the slotted nut
through a further 68 ° and then lock the nut by means of
the tab washer.
5. Fit the parallel key to the shaft and push on the clamping
hub. Torque the clamping screw to 78 Nm.
6. Bold the V-belt pulley to the clamping hub.
7. Install and tension the V-belt for the accelerator drive
(see Group 7 Drives).
(Figs. 52 to 54)
Removal of right-hand threshing drum bearing
Right-hand side of machine

Slacken and remove the power band belt that drives the
threshing drum.
(Fig. 55)
Unbolt guard.
Pull the gib head key from V-belt pulley.
Pull off V-belt pulley by means of puller.
Remove two-step speed drive from machines equipped with
this facility. (See Group 7 Drives).
(Fig. 56)
56
DO 21 8 - 202 MEGA 5.23

Threshing mechanism
Unlock and remove the slotted round nut.

sleeve by applying a short, sharp blow.
Pull bearing off the shaft.
(Fig. 57)
Right-hand threshing drum bearing disassembled:
1 Flanged shaft
2 Felt strip
3 Locating shell
4 Adapter sleeve
5 Spherical roller bearing
6 Bearing half
7 Felt ring
8 Tab washer
9 Slotted round nut
10 Hex. socket head cap screw M 8 x 20
Locking ring
57 1 1 Hex. bolt M 1 2 x 25 DIN 933
Contact washer S 1 2
(Fig. 57)
Installation of right-hand threshing drum bearing

free of grease.
2. Slide bearing assembly onto shaft and secure to
machine sidewall by means of the hex. socket head cap
_
screws (1 0). Torque hex. bolts (1 1 ) to 79 Nm.
3. Connect lubricating line.
.__ _.
4. Pre-torque M 55 x 2 slotted round nut to 35 Nm and
continue turning until the lug of tab washer is located on
groove of slotted round nut. Turn groove nut through a
further 60 ° and lock with tab washer.
5. Push on V-belt pulley and secure with gib head key.
Install two-step speed drive on machines with this
facility. (See Group 7 Drives).
6. Install and tension power band belt for driving the
threshing drum (see Group 7 Drives)
7. Install guard.
(Figs. 55 and 57)
5.24 DO 21 8 - 202 MEGA

Threshing mechanism
IMPELLER
Removal of impeller
On right-hand side of machine, remove the variable speed
drive for the threshing drum. (See Group 7.)
Disconnect lubricating line from bearing unit.
Unbolt bearing unit from the machine body.
(Fig. 58)
Pull bearing unit off shaft using special tool.

(Fig. 59)
Special tool:

2 Spindle - part no. 1 81 801 . 1
4 Hex. bolt M 1 6 x 1 40 - part no. 242 795. 0
5 Washer - part no. 235 1 27.2
6 Threaded pin - part no. 1 81 889. 0
(Fig. 60)
60
Remove guard on left-hand side of the machine.

(Fig. 61 )
61
DO 21 8 - 202 MEGA 5.25

Threshing mechanism
Slacken V-belt that drives the sieve pan and remove belt.
Slacken V-belt that drives the cutterbar and remove belt.
Remove cutterbar clutch (See Group 7 Drives.)
(Fig. 62)
62
Disconnect lubricating line from bearing.

Unbolt cover from sidewall.
(Fig. 63)
63
Remove two opposing M 1 2 x 20 hex. bolts from the bearing

unit.
Using special tool, pull bearing unit with cover off the shaft.
(Fig. 64)
Special tool:

2 Spindle - part no. 1 81 801 . 1
4 Hex. bolt M 1 6 x 260 - part no. 235 81 6. 0
5 Washer - part no. 235 1 27.2
6 Threaded pin - part no. 1 81 889. 0
7 Bolt with centering head M 1 6 x 60
part 603 038. 0
(Fig. 65)
65
5.26 DO 21 8 - 202 MEGA

Threshing mechanism
Pull impeller out the left-hand side of the machine.

(Fig. 66)
66
Before removi ng the impeller discs, it is recommended to

measu re the distance between the shaft and the outermost
discs.
Once installed, it is extremely difficult to align the impeller
relative to the machine wal l .
DO 218 - 202 MEGA 5. 27

Threshing mechanism
® ®
-· -
L L_
JD ®
· --
®�-@
67
[J]
Impeller dismantled:
1 Shaft
2 Impeller disc
3 Impeller disc
4 Parallel key
5 Hex. bolt M 1 0 x 30 RS
6 Cover plate
9 Bearing unit
10 Male connector
11 Bearing unit
12 Male connector
13 Screw plug M 8 x 1 DIN 906
14 Shim
15 Cover
16 Hex. bolt M 1 2 x 20 DIN 933
17 Washer 1 0.5 DIN 1 25
18 Contact washer A 1 0
19 Hex. nut M 1 0 DIN 934
(Fig. 67)
5.28 DO 21 8 - 202 MEGA

Threshing mechanism
Assembly of impeller
Push drum discs with parallel keys onto shaft (1 ). Bolt on
cover plates (4).
X
Align drum discs and cover plates with the shaft so that
distance
X= 29.5 mm on right-hand side of the machine
Y = 39.5 mm on left-hand side of the machine.
Axially secure drum disc (3) using hex. bolt with cut point
(5). Lock hex. bolt with hex. nut.
(Figs. 68 and 69)
68
69
Assembly of bearing unit

The bearings are lubricated by way of grease nipple, offset
annular grease passage in the housing and offset grease
drilling (1 ) in the outer race of the bearing.
During assembly, be sure that grease drilling (1 ) lines
up with the grease passage in the housing.
(Fig. 70)
70
Installation of impeller
Install the bearing on right-hand side to the sidewall. Lift
impeller into the machine from the left-hand side and push
to the right up to shoulder of the shaft using the special tool.
(Fig. 71 )
DO 21 8 - 202 MEGA 5.29

rn
Threshing mechanism
On the left-hand side, pull the bearing onto the shaft up to

the shoulder using the special tool.
(Fig. 72)
72
Special tool:
1 Tube 52 dia. x 200 (self-manufactured)
rrr
2 Hex. bolt M 1 6 x 300 DIN 933 - 8.8 -
· �
part no. 237 375. 0
3 Hex. nut M 1 6 DIN 934 - 8 - part no. 236 1 73. 0
5 Puller shoe - part no. 1 81 836. 0
(Fig. 73)
4 ® ®
73
Fit cover and bolt down. Measure distance (X) between

bearing and cover. The number and thickness (Y) of shims
is calculated from
Y = 1 8 mm - X.
Remove the cover again and make up clearance (Y) using
0. 75 mm and 2. 0 mm shims.
(Figs. 74 and 75)
74
75
5.30 DO 21 8 - 202 MEGA

Threshing mechanism
Bolt the cover to the sidewall and UH bearing.

Connect lubricating line to the UH and R/H bearings and
lubricate.
(Fig. 76)
Install cutterbar clutch (See Group 7 Drives).

Install and tension the V-belt that drives the sieve pan and
cutterbar (see Group 7 Drives).
Install the threshing drum variable speed drive on the
right-hand side of the machine (see Group 7 Drives).
76
Adjusting the deflector plate

Adjust stop bolts (A), one on each side, in the slots so that
the impeller passes the deflector plate (L) as close as
possible. Maximum clearance is 1 mm.
(Fig. 77)
STRAW WALKERS
Removal of under-walker return pan

Remove the bolts that secure the under-walker return pan to
the front rocker arms.
(Fig. 78)
DO 21 8 - 202 MEGA 5. 31
Threshing mechanism
Remove the bolts that attach the rear rocker arms to

combine sidewalls.
(Fig. 79)
79
Rear rocker arm dismantled:
1 Rocker arm
2 Washer
3 Housing
4 Rubber bush
5 Split pin 4 x 22 DIN 94
Contact washer A 8
(Fig. 80)
80
Installation of under-walker return pan

When installing new rubber bushes (4), make sure that the
bushes are not under torsion when the under-walker return
pan is in the middle of its travel. This way, the bushes are
equally twisted in both directions when the under-walker
return pan oscillates and premature wear is prevented.
Make sure that the rubber strips on both sides of the

under-walker return pan are not twisted down when the
return pan is being installed.
5. 32 DO 21 8 - 202 MEGA
Threshing mechanism
Removal of straw walkers

Remove the under-walker return floor. Remove all sieves.
Remove the sensor tray from behind the straw walkers.
Unscrew the straw walker bearings and remove the lower
bearing half. Note the number of shims installed (Z).
Refit the shims and lower bearing half (straw walker lifted
clear of the crankshaft) and only start the nuts on the
threads.
(Fig. 81 )
81
With the back adjusted to rearward position, remove the

straw walkers from the rear of the combine.
(Fig. 82)
82
Installation of straw walkers

Bearings must be shimmed so that their play is reduced to a
minimum but care must be taken to avoid binding of the
bearings on the straw walkers crankshaft.
The bearings must move easily sideways, but tipping the
walkers to either side should not be possible.
Spacer tubes have been pressed into the holes of the
bearing halves, through which the bolts are inserted. This is
to avoid distortion of the bearings when the bolts are
tightened.
Install all straw walkers, but only tighten the bearings by
hand at this time.
Tighten all the rear straw walker bearings first. Before
tightening the front bearing of each straw walker, completely
turn the crankshaft several times.
Replace the self-locking nuts (and if required the carriage
bolts), when their locking effect decreases and the nuts fit
loosely on the threads of the bolts. The self-locking nuts
should not be used more than twice at the most.
The bolts of the straw walker bearings should be tightened
to a torque of 26 Nm.
(Fig. 83)
DO 21 8 - 202 MEGA 5.33

Threshing mechanism
Removal of front straw walker shaft

Remove the under-walker return pan. Remove all straw
walkers.
Loosen the lock collar of the flange ball bearing on the
left-hand side of the machine. Unbolt the mounting flanges
at the side panel and, from the inside, drive the bearing off
the straw walker shaft.
(Fig. 84)
On the right-hand side of the machine, remove the bolts that

attach the flange ball bearing of the front straw walker shaft
to the side panel.
Take the straw walker shaft out of the right-hand side of the
machine.
(Fig. 85)
85
Installation of front straw walker shaft

Install the straw walker shaft from the right-hand side of the
machine.
Fix the flange ball bearings to the shaft so that there is equal
spacing (X) on both sides between the outer guide ring of
the shaft and the combine sidewall.
(Fig. 86)
Install the straw walkers and the under-walker return pan.

Install the sensor tray and the sieves.
5.34 DO 21 8 - 202 MEGA

Threshing mechanism
Removal of rear straw walker shaft

Remove the under-walker return pan.
Undo all wood bearings of the rear straw walker shaft,
loosely refitting the lower bearings halves and the shims to
the straw walkers during this operation. Also refer to Section
»Straw walker removal«.
Place a tube or a beam or something similar (A) under the
straw walkers. Use wire or rope and tie up the straw walkers
through the access door on top of the combine housing.
(Fig. 87)
Open the guard. Remove the two belts which drive the
straw walker shaft and the intensive separation system.
Pull off the pulley (C).
(Fig. 88)
88
Loosen the lock collars of the flange ball bearings on both

sides of the machine and remove the bolts that secure the
bearings to the combine side panels.
(Fig. 89)
89
Drive both straw walker shaft bearings from the shaft.

(Fig. 90)
Remove the straw walker shaft from inside the combine.
90
DO 21 8 - 202 MEGA 5.35

Threshing mechanism
Installation of rear straw walker shaft

Centre the shaft between the sidewalls of the machine so as
to obtain equal distances on both sides between the outer
guide rings of the shaft and the combine sidewalls (also see
Section "Installation of front straw walker shaft").
Before securing the rear straw walker bearings, loosen the
front straw walker bearings. Refer to "Installation of straw
walkers" for information regarding bearing adjustment.
Removal of rear tine cran kshaft

Open the hinged guard on the left-hand side of the machine.
Slip the V-belt for intensive separation system drive off
pulley (D) and, where fitted, slip the levelling auger drive belt
off pulley (D). Withdraw the V-belt pulley from the tine
crankshaft.
(Fig. 91 )
Loosen the lock collars of the flange ball bearings on either

side of the combine and undo the bolts that secure the
bearings in the combine side panels.
(Fig. 92)
92
Detach all tine control arms (A) from the tines.

(Fig. 93)
93
5.36 DO 21 8 - 202 MEGA

Threshing mechanism
Remove the bolts that attach the control shaft (W) to the
side panels and remove the complete shaft assembly
towards the top.
(Fig. 94)
94
Drive both flange ball bearings off the tine crankshaft, from
inside the combine outward. Incline and remove the
complete tine crankshaft assembly.
(Fig. 95)
95
Removal of front tine cran kshaft

Swing out the unloading auger and remove the guard
located in front of the intensive separation unit drive.
Remove the V-belt and remove pulley (K) from the hub.
(Fig. 96)
Pull out the gib-head key and withdraw the complete pulley
assembly (K).
(Fig. 97)
97
DO 21 8 - 202 MEGA 5.37

Threshing mechanism
On both sides, loosen the lock collars of the flange ball

bearings (F) and remove the bolts that secure the bearings
to the combine side panels.
(Fig. 98)
98
Open the service door in the grain tank floor for access to
the front tine crankshafts.
Detach all control arms from the tines. Move the arms to
one side of the control shaft. Drive both flange ball bearings
off the tine crankshaft, from inside the combine outward.
Incline the complete tine crankshaft assembly upward and
remove through the grain tank service door.
(Fig. 99)
99
Properly assembled tine crankshaft.

(Fig. 1 00)
1 00
Installation of tine cran kshafts

1 . Install the completely assembled tine crankshaft in the
combine so that the deflectors (A) point toward the rear,
as seen in direction of travel.
2. Install the flange ball bearings, on both sides of the
machine.
3. Adjust the crankshaft sideways so that there are equal
distances on both sides between the outer cranks and
the combine side panels. The tines must centre in the
slots of stripper plate (B). Lock the flange ball bearings.
5.38 DO 21 8 - 202 MEGA

Threshing mechanism
4. Install scrapers (1 ) and set them as close as possible to

the crankshafts with no interference. .
5. Fit control arms (S) to the tines using flange pins,
contact washers and self-locking nuts.
(Figs. 1 01 and 1 02)
1 02
SIEVE PAN
To remove and install the sieve pan assembly, the

preparation floor assembly and the preparation floor drive, it
is suggested to take out the sieves, under-walker return pan
and also the sections of the preparation floor pan.
Remove the preparation floor sections. Remove the hook

bolts (H) located under the preparation floor.
(Fig. 1 03)
1 03
Remove the upper sieve, the sections of the preparation

floor can the be easily pulled out from the back with a wire
hook (D) or similar item.
Remove the under-walker return pan (R).
(Fig. 1 04)
1 04
DO 21 8 - 202 MEGA 5.39

Threshing mechanism
Removal of preparation floor

Refer to »SIEVE PAN « .
Unbolt and detach the pitmans on both sides of machine.
(Fig. 1 05)
Unbolt the bracket (H) on the left and right-hand side of the
machine.
Unbolt the tool box on the 3-D version.
Disconnect the connecting rod of the rocker arm at (A).
(Fig. 1 06)
1 06
Pull off the rocker arm gradually using two pullers.

Screw in a hexagon head bolt here to prevent damage to
the thread.
IMPORTANT! The rocker arms are not symmetrical,
therefore note and mark fitting location.
(Fig. 1 07)
Pull the seal and washer off the trunnion.

Unbolt seal plate and remove.
(Fig. 1 08)
1 08
5.40 DO 21 8 - 202 MEGA

Threshing mechanism
Unbolt the trunnion from the preparation floor on the left and
right-hand side of the machine. Note and mark trunnion
position.
(Fig. 1 09)
Remove rocker arms from the front of preparation floor, both

sides. To do this, undo the M 1 2 hex. nuts and pull off rocker
arms.
(Fig. 1 1 0)
110
Remove the bolts that secure the double rockers and

remove the rocker assembly.
(Fig. 1 1 1 )
111
The preparation floor can now be lifted out of the rear of the
machine.
(Fig. 1 1 2)
112
DO 21 8 - 202 MEGA 5. 41
Threshing mechanism
0)
'® ®
JI
·(b __ _ --- --- ----
cb @ l --
cp�,
®@ @
113
[J]
Rocker arm drive disassembled: 1 3 Bearing support (for 3-D)
1 4 Hex. bolt M 1 0 x 75 DIN 931
1 Trunnion Hex. nut M 1 0 DIN 934
2 Hex. bolt M 1 2 x 30 DIN 933 Contact washer A 1 0
Contact washer A 1 2 1 5 Washer
3 Washer 1 6 Stud
4 Sealing plate 1 7 Sealing washer
5 Hex. bolt M 8 x 20 DIN 933 1 8 Washer
Contact washer A 8 1 9 Hex. bolt M 1 2 x 35 DIN 933
6 Seal Contact washer A 1 2
7 Washer 20 Metal rubber bearing
8 Rocker arm 21 Hex. bolt M 1 6 x 45 DIN 933
9 Metal rubber bearing Contact washer A 1 6
1 0 Bearing support 22 Metal rubber bearing
1 1 Hex. bolt M 1 0 x 20 DIN 933 23 Pitman
1 2 Hex. nut M 1 2 DIN 934 (for 3-D) (Fig. 1 1 3)
Contact washer A 1 2 (for 3-D)
5.42 DO 21 8 - 202 MEGA

Threshing mechanism
Installation of preparation floor

1 . Lift the preparation floor into the combine from the rear,
making sure that the rubber sealing strips on the sides
are not bent down.
2. Bolt on the double rocker arms and the front rocker arms
with the metal rubber bearings, but do not tighten at this
stage.
3. Bolt the trunnion (1 ) to the preparation floor on the left
and right-hand side of the machine, paying attention to
position.
4. Install sealing plate (4). Push seal (6) and washer (7)
onto the trunnion.
5. Install rocker arms (8) for the sieve pan drive, paying
attention to position. Do not yet tighten the bolts
securing the metal rubber bearings (see "Installation of
rocker arms for sieve pan drive").
6. Install the pitmans (23).
IMPORTANT! The bearing units are located in the same
position on the left and right-hand side. However, the
preparation floor is not moved to the centre of the
machine body.
7. Install left and right-hand brackets.
Move the sieve pan and preparation floor to the middle
position and tighten metal rubber bearing of the double
rocker arms, front rocker arms and rocker arms for the
sieve pan drive to the prescribed torques.
Tightening torques:
M 10 46 Nm
M 12 80 Nm
M 16 1 95 Nm
This installation sequence must be followed to ensure

that the rubber elements of the metal rubber bearings
are subjected to equal twisting loads on both sides
during the shaking movements of the sieve pan and the
under-walker return floor. If this is not observed, the
rubber bearings will be subject to premature wear.
8. Install the sections into the preparation floor frame and
check for tight, firm fit.
9. Install sieves and return pan.
(Figs. 1 05 to 1 1 3)
DO 21 8 - 202 MEGA 5.43

Threshing mechanism
Installation of rocker arms for sieve pan

drive 3 - D
1 . Insert M 1 0 x 90 bolt (S) and pull the rocker arm onto
the shaft using the special tool.
2. Install connecting rod with washer.
3. Install bracket (H) and pitman (23)
Note that the bearing units are located in the same
position on the left and right-hand side. However, the
preparation floor is not moved to the centre of the
machine body.
4. Fit and tension the drive belt.
114 5. Position the sieve pan and preparation floor in exactly
the middle position of the oscillation range and tighten
the metal rubber bearing of the double rocker arms,
front rocker arms and rocker arms for the sieve pan
drive to the prescribed torques.
Tightening torques:
M 10 46 N m
M 12 80 N m
M 16 1 95 Nm

that the rubber elements of the metal rubber bearings
during the shaking movements of the sieve pan and
the under-walker return floor. If this is not observed, the
115
6. Bolt on the tool box.
(Figs. 1 05 to 1 1 5)
Special tool:
Hex. bolt M 1 6 x 300 DIN 931 -8.8

part no. 237 375. 0
2 Hex. nut M 1 6 DIN 934 - 8
part no. 236 1 73. 0
3 Axial-contact deep-grooved ball bearing -
part no. 1 77 899. 0
·�
(Fig. 1 1 6)
® G)
116
5.44 DO 21 8 - 202 MEGA

Threshing mechanism
Removal of sieve pan

Remove upper and lower sieve.
Remove under-walker return pan.
Unbolt and detach pitmans on both sides of the machine.
(Fig. 1 1 7)
117
Unbolt the bracket (H) on the left and right-hand side

of the machine.
Unbolt tool box on 3-D version.
Loosen connecting rod at rocker arm (A).
(Fig. 1 1 8)
118
Pull off the rocker arm gradually using two pullers.

Screw in a hexagon head bolt here to prevent damage to
the thread.
IMPORTANT! The rocker arms are not symmetrical,
therefore note and mark fitting location.
(Fig. 1 1 9)
Without 3-D
Undo and remove the M 1 0 x 75 DIN 931 -8.8 hex. bolts
on both sides.
Pull off bearing shaft using the special tool.
(Figs. 1 20 and 1 21 )
DO 21 8 - 202 MEGA 5.45

Threshing mechanism
1 21
Special tool:
ffi·�
1 Tube 52 dia. x 200 (self-manufactured)
2 Hex. bolt M 1 6 x 300 DIN 933-8.8
part no. 237 375. 0
3 Hex. nut M 1 6 DIN 934 - 8
part no. 236 1 73. 0
® ®
4 Axial-contact deep-grooved ball bearing -
part no. 1 77 899. 0
4
(Fig. 1 22
1 22
With 3-D
Unbolt the bearing supports on both sides in the sieve pan
and drive inwards with a light alloy punch.
(Figs. 1 23 and 1 24)
1 23
1 24
5.46 DO 21 8 - 202 MEGA

Threshing mechanism
Unbolt the inner sieve pan rocker arm assemblies.

Lift the sieve pan out the combine from the rear.
(Fig. 1 25)
1 25
Inner rocker arms disassembled:
1 Trunnion
2 Metal rubber trunnion
®
I
G)
3 Rocker arm, left and right
4 Bearing support for sieve pan
5 Bearing support for under-walker return floor
6
7
8
Washer 1 2.5 x 32 x 9
Contact washer
Hex. bolt M 1 0 x 30 DIN 933 - 8.8
�
v
(Fig. 1 26)
1 26
DO 21 8 - 202 MEGA 5.47

Threshing mechanism
I I
'e��====='i e:=::==:==�g
I i
X X
n----x-----81
Uu:,ood'.r
I I
I I
1 27
5.48 DO 21 8 - 202 MEGA

Threshing mechanism
Installation of sieve pan

1 . Install sieve pan and under-walker return floor.
2. Press the metal rubber bearing into the rocker arm and
sieve pitman. The outer metal ring of the bearing must
be flush with the housing.
3. Bolt on the trunnion.
4. Install the rocker arms and sieve pitman, taking care
not to lose the shims.
5. Bolt on bracket (H).
6. Loosely screw in all hex. bolts (X) with washers
(6, 8 and 9) and contact washers for axially preloading
the metal rubber bearings.
7. Position the sieve pan exactly in the middle position of
the oscillation range. In this position, secure the metal
rubber bearings axially by tightening the hex. bolts (X)
to the prescribed torque.
Tightening torques:
M 10 46 Nm
M 12 80 Nm
M 16 1 95 Nm
I LI
that the ,ubbe, elements of the metaJ ,ubbe, beari ngs
I
c�
n
during the shaking movements of the sieve pan and
the under-walker return floor. If this is not observed, the
8. Install 3 - D sieve frame.
(Figs. 1 26 and 1 27)
DO 21 8 - 202 MEGA 5.49

Threshing mechanism
Removal of the 3-D sieve frame

Completely unbolt the tool box on the left-hand side.
Remove the upper frogmouth sieves.
Unbolt the front rocker arms and connecting rods for the
upper sieve frame on both sides and remove the frame.
(See Installation of sieve pan).
(Fig. 1 28)
Unbolt and remove the rear rocker arms for the upper sieve
frame.
(Fig. 1 29)
1 29
Unbolt bearing (L) of the control arm.

(Fig. 1 30)
1 30
Unbolt and remove transverse connecting tube ( R ) from

the side and middle sieve panels.
(Fig. 1 31 )
1 31
5.50 DO 21 8 - 202 MEGA

Threshing mechanism
Unbolt the left-hand panel from the transverse profile and

remove to the rear.
Lift out the middle and right-hand panel together with the
transverse profile to the rear.
(Fig. 1 32)
1 32
Unbolt control rod (S) at (1 and 2).

Unbolt the pivot arm at (3). The transverse profile can now
be disassembled for the replacement of parts.
(Fig. 1 33)
1 33
DO 21 8 - 202 MEGA 5.51

Threshing mechanism
1 34
5.52 DO 21 8 - 202 MEGA

Threshing mechanism
3-D sieve frame - suspension and drive - disassembled:
1 Bracket
2 Pivot arm
3 Flanged ball bearing Bfa 20
4 Hex. bolt M 8 x 25 DIN 933 - 8.8
5 Control arm
6 Middle bearing
7 Outer bearing
8 Metal rubber bearing for outside
9 Metal rubber bearing for middle
10 Stud
11 Hex. bolt M 1 0 x 70 DIN 931 - 8.8
13 Metal rubber bearing
14 Sleeve
15 Hex. bolt M 1 2 x 1 00 DIN 931 - 8.8
17 Hex nut. M 1 2 DIN 934 - 8
18 Hex. bolt M 8 x 60 DIN 931 - 8.8
19 Slotted mushroom head screw M 1 0 x 30 DIN 603 - 8.8
20 Support
21 Hex. bolt M 1 0 x 30 DIN 933 - 8.8
22 Connecting rod, right
24 Washer 1 7 x 26 x 3
25 Control arm
27 Washer 1 1 x 26 x 4
29 Hex. bolt M 1 0 x 20 DIN 933 - 8.8
30 Washer 1 1 x 26 x 5
31 Hex. bolt M 1 0 x 90 DIN 931 - 8.8
33 Hex. nut M 1 0 DIN 934 - 8
34 Bracket
35 Hex. bolt M 8 x 45 DIN 931 - 8.8
36 Washer 8.5 x 30 x 2
37 Bracket
38 Hex. bolt M 1 0 x 35 DIN 933 - 8.8
39 Connecting rod, left
A= Right-hand side of combine
B= Left-hand side of combine
(Fig. 1 34)
DO 21 8 - 202 MEGA 5.53

Threshing mechanism
34 H 34
X
G
I
- ,� -- r
r..:..7J
-- _ _ __;_ti :j'J
i·I--l 1I i
I
1 - ·-·
!iU
1 35
Installation of 3-D sieve frame

V= Drive connecting rods and suspension of the sieve
frame for front upper sieve
H=Suspension of the sieve frame for rear upper sieve
1 . Preassemble middle and right-hand panel on the
transverse profile and lift in to the combine from the rear.
Bolt in the left-hand panel and the transverse tube.
NOTE! The sealing rubber must lap over the panel.
2. Press the metal rubber bearing into the control arm and
connecting rods. The outer metal ring of the bearing
must be flush with the housing.
3. Bolt on the trunnion, ensuring the length (G) of bracket
(34) is facing upwards
4. Before installing the sieve pan main rocker arms, be
sure to install hex. bolts (31 ) with washers (30).
5. Fit connecting rods (22 and 39) and washers (24).
6. Install front control arm (25) with the long side (L) facing
upwards and the rear control arm with the long side (L)
facing downwards.
Fit washers (27) and loosely screw in all bolts (X) for
axially preloading the metal rubber bearings with contact
washers. Screw on the nuts of the hex. bolts with
contact washers loosely.
5.54 DO 21 8 - 202 MEGA

Threshing mechanism
I LI
7. Pos,;o, the s;eve pao exactly ;, the m;ddle pos,;o, of
I
its oscillation range. In this position, secure the metal
c�
n
rubber bearings axially by tightening the hex. bolts or
nuts (X) to the prescribed torque.
Tightening torques:
M 10 46 Nm
M 12 80 Nm
M 16 1 95 Nm
This installation sequence must be followed to ensure that
the rubber elements of the metal rubber bearings are
subjected to equal twisting loads on both sides during the
shaking movements of the sieve pan. If this is not observed,
the rubber bearings will be subject to premature wear.
(Figs. 1 35 and 1 36)
I \
I \
C
I
I \
\
I \
I
C:
\
\
.I \
I H
�1.
.
2 �1, 2 �
0 0\
1 36
DO 21 8 - 202 MEGA 5.55

Threshing mechanism
1. Installation of 3-D sieve pan controller

\ I
Install the oscillation housing (P) and hydraulic cylinder (Z)
\P I
I to the right-hand side of the machine. Fit all hydraulic lines.
.,._,I Park the combine so that it is level and position the sieve
pan exactly in the middle.
Measure and note the distance (Q) from the machine wall to
pivot point (B).
Disconnect cylinder (Z) at pivot point (B) and control rod (C)
at bracket (H).
Start the engine and with the engine running, push
oscillation housing (P) outwards in the direction of the arrow
1 37 until the hydraulic piston is completely retracted.
IMPORTANT! Hold the oscillation housing in

this position until the engine has been
switched off and is stationary. (A second
person is required for this!)
Now connect the oscillation housing again at (B). Distance

(Q) must now have been reduced by 70 mm, otherwise
distance (Q) must be adjusted at yoke end (G) with lock nut
(2) loosened.
After adjustment, reconnect control rod (C) and hydraulic
cylinder (Z).
(Figs. 1 37 and 1 38)
1 38
Adjusting pivot arm {A) with »3-D gauge«

Park the combine so that it is level and position the sieve
pan exactly in the middle.
Position the »3-D gauge«, part no. 1 81 993.0, so that points
(3 and 4) are against the rear panel and blocks
(7 and 8) are against the lower edge (S) of the bracket.
7 Then push the »3 - D gauge« parallel towards the side
panel until point (5) is against the pivot arm.
Point (6) must now be up against or aligned with the pivot
arm. Otherwise adjust pivot arm (A) with control rod (C) at
ball joint (K) with lock nut (1 ) loosened.
Adjust oscillation housing (P) and hydraulic cylinder (Z).
(Figs. 1 36 to 1 39)
A D
1 39
5.56 DO 21 8 - 202 MEGA

Threshing mechanism
Installing new seal strips

With sieve pan removed, drill off the rivet heads and drive
out the rivets.
(Fig. 1 40)
1 40
Attach new seal strips using blind rivets.

(Fig. 1 41 )
1 41
Removal of intermediate drive shaft for

rocker arms
On both sides of the machine remove the pitmans.
Remove the belt that drives the sieve pan.
Loosen the lock collar of lock collar bearing (F) and remove
from crank pin.
(Fig. 1 42)
Remove the bolts that secure V-belt pulley (K).

(Fig. 1 43)
1 43
DO 21 8 - 202 MEGA 5.57

Threshing mechanism
Slacken the clamping screw of eccentric hub (E) and, if

required, remove the eccentric hub with a two-arm puller.
(Fig. 1 44)
1 44
Loosen the lock collar of the UH bearing unit (L) and

remove the bolts that secure the bearing in the sidewall.
(Fig. 1 45)
1 45
Pull the bearing unit off the shaft.

(Fig. 1 46)
1 46
Undo the bolts that secure the lock collar bearing to the R/H
sidewall and pull the intermediate drive shaft (W) out of the
combine from the R/H side of the machine.
(Fig. 1 47)
1 47
5.58 DO 21 8 - 202 MEGA

Threshing mechanism
1 48
Intermediate drive shaft for rocker arms disassembled:
1 Shaft
3 Bearing unit
4 Lock collar
5 Parallel key A 1 0 x 8 x 45 DIN 6885
6 Eccentric hub
8 V-belt pulley
1 0 Bearing unit
1 1 Lock collar
1 2 Pitman
1 3 Hex. bolt M 1 0 x 20 DIN 933
(Fig. 1 48)
DO 21 8 - 202 MEGA 5.59

Threshing mechanism
Installation of intermediate drive shaft for

rocker arms
1 . Push shaft (1 ) into the machine from the right.
2. Secure the lock collar bearing (3) to the right-hand
sidewall with hex-bolts (2).
3. On the left-hand side of the machine, pull bearing unit
onto shaft. Bolt the bearing unit to the sidewall and
secure with lock collar.
4. Insert parallel key, fit clamping hub and secure with
hex. bolt (7).
5. Bolt on V-belt pulley.
6. Push bearing unit (1 0) onto eccentric hub and secure
with lock collar (1 1 ).
7. Bolt on pitman.
8. Install and tension V-belt for sieve pan drive.
(Figs. 1 42 to 1 48)
CLEANING FAN
Removal of UH and R/H bearing

from cleaning fan
Remove fan belt.
Operate the cleaning fan to maximum speed.
Disengage the threshing mechanism, stop
the engine and remove the ignition key.
Screw one BM 1 2 x 80 DIN 564-8.8 hex. bolt (S, part no.

236 301 . 0) into a tapped hole in the front fixed pulley half
1 49 until the rear moveable pulley is blocked open.
With the engine switched off, turn on the ignition and
engage the threshing mechanism. Then operate the fan
variable speed drive to the slow speed position by actuating
the appropriate rocker switch.
Remove the variable speed belt from the pulleys.
On the left-hand side of the machine, lower the hinged
bottom plate. To do this, release the plug. Unbolt the side
guard.
(Fig. 1 49)
5.60 DO 21 8 - 202 MEGA

Threshing mechanism
Undo the two M 1 0 x 8 set screws on the variable speed

pulley.
Pull the variable speed pulley assembly off the shaft and
remove the parallel key.
(Fig. 1 50)
1 50
[I]
Unlock slotted round nut and loosen with a hook spanner.
(Fig. 1 51 )
1 51

sleeve of the bearing by applying a short, sharp blow.
Block-ended tube: 50 dia. x 4 x 500 (self-manufactured)
(Fig. 1 52)
1 52
Unscrew the hex. bolts that secure the bearing plate and
pull the bearing unit off the shaft.
(Fig. 1 53)
1 53
DO 21 8 - 202 MEGA 5. 61
Threshing mechanism
On the right-hand side of the machine, lower the hinged

bottom plate. To do this, release the plug.
Disconnect the cable plugs from the magnetic pick-up.
Undo the M 8 x 1 2 set screw and pull the cam wheel off the
shaft.
(Fig. 1 54)
1 54
[I]
Unlock slotted round nut and loosen with a hook spanner.
(Fig. 1 55)
1 55

sleeve of the bearing by applying a short, sharp blow.
Block-ended tube: 50 dia. x 4 x 500 (self-manufactured)
(Fig. 1 56)
1 56
Unscrew the hex. bolts that secure the bearing plate and
pull the bearing unit off the shaft.
(Fig. 1 57)
1 57
5.62 DO 21 8 - 202 MEGA

Threshing mechanism
Self-aligning ball bearing disassembled:
1 Bearing plate
2 Adapter sleeve
3 Bearing half
Felt strip
4 Self-aligning ball bearing
5 Bearing half
Felt strip
6 Circlip
7 Slotted round nut
8 Slotted mushroom head screw M 8 x 20 DIN 603
Slotted mushroom head screw M 8 x 30 DIN 603
Hex. nut M 8 DIN 934 1 58
Contact washer A 8
(Fig. 1 58)
tallatlon of L/H and R/H bearing ID cleaning 1m1

1+f
��

dry and free from grease.
2. Preassemble bearing unit, push onto shaft and bolt to
bearing plate.
[I]
3. Pre-torque M 35 x 1 .5 slotted round nut to 1 5 Nm and
continue turning until the lug of tab washer is located on
groove of slotted round nut. Turn slotted round nut
through a further 62 ° and lock with tab washer.
4. On the right-hand side of the machine push on cam
wheel and secure with set screw. Using gauge, adjust
the magnetic pick-up to achieve a spacing of 0.2 ± 0. 1
mm.
5. On the left-hand side of the machine insert parallel key,
push the variable speed pulley assembly onto the shaft
and secure axially with two M 1 0 x 8 set screws.
6. Install fan belt and unscrew the hex. bolt to lock the
variable speed pulley assembly.
(Figs. 1 49 to 1 58)
DO 21 8 - 202 MEGA 5.63

Threshing mechanism
Removal of middle bearing from cleaning fan

Remove bearing unit assembly from the right-hand side of
the machine.
On the left-hand side of the machine remove the two
M 1 0 x 30 hex. bolts that secure the bearing plate.
(Fig. 1 59)
Unbolt lower fan guard. To do this, unscrew fourteen

M 1 0 x 20 hex. bolts and four M 8 x 20 hex. bolts.
Remove the bolts securing the cover on the fan housing.
(Fig. 1 60)
1 60
[I]
Unlock slotted round nut of the middle adapter sleeve
bearing and loosen with a hook spanner.
(Fig. 1 61 )
1 61
Loosen the adapter sleeve bearing. To do this, knock the

shaft towards the right by applying a short, sharp blow with
a soft metal punch from the left-hand side of the machine. At
the same time, hold a heavy object (hammer or other
suitable item) against the middle bearing plate.
(Fig. 1 62)
1 62
5.64 DO 21 8 - 202 MEGA

Threshing mechanism
Loosen hub of fan rotors and ease open a small distance

using a chisel.
(Fig. 1 63)
1 63
Thoroughly clean the shaft and pull out to the left-hand side
of the machine.
NOTE: On machines without fan blast reduction kit, the
rotors will need supporting to prevent them from falling out.
(Fig. 1 64)
1 64
Remove bolts securing plate flanges for the middle bearing.

(Fig. 1 65)
1 65
Middle fan bearing disassembled:
1 Bearing plate
2 Steel flange
3 Adapter sleeve
4 Adapter sleeve bearing
5 Circlip
6 Slotted round nut
(Fig. 1 66)
1 66
DO 21 8 - 202 MEGA 5.65

Threshing mechanism
Installation of middle bearing to cleaning fan

1 . Secure preassembled steel flange bearing to bearing
plate. Loosen bearing plate at the two hex. bolts so
that plate moves in slots.
2. Bearing location, adapter sleeve and shaft seat must
be dry and free of grease.
3. Push the shaft into machine from left. Fit rotors onto
shaft, paying attention to the direction of rotation.
4. On the left-hand side of the machine, bolt the bearing
plate with bearing to the support.
5. Install bearing on the right-hand side of the machine.
(See Installation of UH and R/H bearing.)
6. Align the middle bearing plate in the slots so that the
shaft runs freely in the bearings.
7. Pre-torque slotted round nut to 1 5 Nm and continue
turning until the lug of tab washer is located on groove
of slotted round nut. Turn slotted round nut through a
8. Align rotors at the side and secure by means of
[I]
clamping hub.
9. Bolt covers to housings and install fan guard.
1 0. Install fan belt and unscrew the hex. bolt to lock the
variable speed pulley assembly.
(Figs. 1 59 to 1 66)
Removal of fan rotors

Remove fan shaft. (See Removal of middle bearing).
On machines with fan blast reduction kit, connecting rods
have to be removed that are used for adjusting the fan blast
reduction kit.
On the left-hand side of the machine, loosen and remove
the two set collars.
(Fig. 1 67)
5.66 DO 21 8 - 202 MEGA

Threshing mechanism
Loosen the clamping screws in the plate halves of the fan

blast reduction kit.
Pull the lower connecting rods out the right-hand side of the
machine while a second person removes the rotors.
(Figs. 1 68 and 1 69)
1 68
1 69
Removal of fan housing

Remove fan rotors.
Unscrew the self-locking nuts at (A) and remove the air
deflectors out the bottom of both fan housings.
(Fig. 1 70)
1 70
Undo set collars on the air deflector adjustment shaft and

pull out shaft to the left.
(Figs. 1 71 and 1 72)
1 71
DO 21 8 - 202 MEGA 5. 67
Threshing mechanism
1 72
On the left-hand side of machines with fan blast reduction

kit, loosen and remove the set collars that lock the upper
connecting rods.
Undo the clamping screws in the plate halves.
(Fig. 1 73)
1 73
Unbolt bearing bracket from machine body on the right-hand

side of the machine. Remove connecting rods, complete
with bearing bracket, out of machine to the right.
(Fig. 1 74)
1 74
Remove the fan blast reduction kit plates out the machine
from below.
(Fig. 1 75)
1 75
5 . 68 DO 21 8 - 202 MEGA
Threshing mechanism
Unbolt fan housing from air outlet duct and lower air tunnel.
(Fig. 1 76)
1 76
Undo the hex. bolts at the front cross plate.

(Fig. 1 77)
1 77
Lower the fan housing.

(Fig. 1 78)
1 78
DO 21 8 - 202 MEGA 5.69

Threshing mechanism
1 79
Fan housing disassembled: 10 Set collar

DO 21 8 MEGA / 208 MEGA / 204 MEGA 11 Shaft
12 Air deflector
1 Blast housing 13 Self-locking nut Vm 6
2 Hex. bolt M 6 x 1 2 DIN 933 Contact washer A 6
Hex. nut M 6 DIN 934 14 Expansion pin
Contact washer A 6 15 Bearing plate
3 Wind tunnel 16 Hex. bolt M 8 x 20 DIN 933
4 Hex. bolt M 1 0 x 25 DIN 933 Hex. nut M 8 DIN 934
Hex. bolt M 1 0 x 20 DIN 933 Contact washer A 8
Hex. nut M 1 0 DIN 934 17 Connecting link
Contact washer A 1 0 18 Lever
5 Fan housing 19 Bolt
6 Partition 20 Pressure spring
7 Cover 21 Hex. nut M 8 DIN 934
8 Cross plate 22 Ball knob
9 Hex. bolt M 6 x 1 6 DIN 933
Hex. nut M 6 DIN 934 (Fig. 1 79)
Contact washer A 6
5. 70 DO 21 8 - 202 MEGA
Threshing mechanism
Installing fan housing

1 . Lift fan housing (5) from below into the machine and bolt
to cross plate (8), wind tunnel (3) and blast duct (1 ).
2. Pull set collar (1 0) onto the shaft (1 1 ) and push shaft
from the left-hand side through the drilling in the fan
housing.
3. Bolt air deflectors (1 2) with self-locking nuts (1 3) to the
shaft.
4. Centre the shaft (1 1 ) in the housing so that the air
deflectors are easy to adjust.
5. Axially secure the shaft with the set collars.
(Fig. 1 79)
Adjusting air deflector

Air deflector (S) in primary air duct (K) for pre-separation, is
set in the 3rd hole from the bottom by means of lever (H) for
the normal setting in wheat, rye, etc.
For heavy seeds, set lever (H) in the 2nd or 1 st hole. For
light seeds, set lever (H) in any of the 4th to 7th hole
according to the specific weight of the seed.
(Figs. 1 80 and 1 81 )
1 81
DO 21 8 - 202 MEGA 5. 71
Threshing mechanism
1 82
Fan blast reduction kit disassembled:

1 Ball knob
2 Hex. nut M 1 0
3 Bearing bracket
5 Hex. bolt M 8 x 25 RS DIN 933
6 Plate half
7 Ball knob
8 Bearing bracket
9 Bearing
10 Hex. bolt M 6 x 1 6 DIN 933
Contact washer A 6
11 Plate half
12 Connecting rod 1 0H9 dia. x 1 700 mm
15 Set collar
(Fig. 1 82)
5. 72 DO 21 8 - 202 MEGA
Threshing mechanism
Installation of fan blast reduction kit

1 . Insert connecting rods (1 3) and (1 4). Push the left-hand
plate onto connecting rod (1 3) (short offset) and
right-hand plate onto connecting rod (1 4) (long offset).
2. Fit bearing bracket (3) and at this stage loosely bolt to
the frame at (0). Now loosely screw a hex. bolt (5) into
the arms (A) of plates and into the bearings (L).
(Fig. 1 83)
3. Position bearing bracket (8) onto the two connecting

rods (9) and push the connecting rods through the
drillings down through the fan housing and at the same
time through the arms (A) of the plates.
NOTE: The rotors must be installed.
4. Loosely screw one hex. bolt (5) into the arms (A) and
into the bearings at (U).
(Fig. 1 84)
1 84
5. Screw ball heads (1 ) onto the connecting rods

(1 3 and 1 4) and lock with M 1 0 hex. nuts.
6. If necessary, fit washers at the fixture points for bearing
brackets (3) so that the connecting rods can move
without restraint.
(Fig. 1 85)
1 85
7. Screw ball heads (7) onto connecting rods (1 2). If

necessary, fit washers at the fixture points for bearing
brackets (8) so that the connecting rods can move
without restraint.
(Fig. 1 86)
1 86
DO 21 8 - 202 MEGA 5. 73
Threshing mechanism
8. On the left-hand side, fit set collars (1 5) onto the end of

connecting rods at (C and D) and secure with set
screws.
(Figs. 1 87 and 1 88)
1 87
1 88
Adjusting fan blast reduction kit:

Push all plates right up to the fan intake opening by hand
(closed position).
Almost fully insert connecting rod for right-hand plate.
Almost fully insert connecting rod for left-hand plate.
Now secure the plates to the connecting rods by tightening
the hex. bolts (5) in arms (A) . Be sure that the connecting
rods are easy to move.
(Fig. 1 89)
Adjusting fan blast reduction kit

Depending on the type of crop being harvested, the fan
intakes can be opened or closed at the connecting rods by
varying degrees. This adjusts the wind flow rate to suit crop
conditions in addition to fan speed regulation.
Always adjust the left and right-hand side by the equal
amounts.
After each adjustment, secure connecting rods in the
bearing brackets by means of the hex. bolts.
(Fig. 1 89)
1 89
5. 74 DO 21 8 - 202 MEGA
Threshing mechanism
Removal of windboard
The windboard can either be removed through the sieve
pan after removing the sieves or from below through the
grain auger trough.
To remove the windboard through the grain auger trough,
unbolt the fan guard.
Open the auger trough latches and lower the trough.
(Fig. 1 90)
Unbolt the cross plate (Q) and lift out of the machine from
below.
(Fig. 1 91 )
1 91
Unbolt the windboard from the bearing strap on the

right-hand side.
On the left-hand side unbolt the windboard from the lever.
(Fig. 1 92)
1 92
Lift the windboard out of the machine from below.

(Fig. 1 93)
1 93
DO 21 8 - 202 MEGA 5. 75
1hreshing mechanism
Windboard disassembled:
1 Windboard
2 Bearing strap
Contact washer A 8
4 Profile
5 Lever
(Fig. 1 94)
1 94
Installation of windboard
1 . Lift windboard into the machine from below.
Bolt to lever (5) and bearing strap (2) (paying attention to
fitting position).
2. Install cross place and bolt into position.
3. Close grain auger trough. Bolt on lower fan guard.
(Figs. 1 90 to 1 94)
Adjustment of windboard
Basic setting of windboard (L) in the fan housing throat is
with lever (T) engaged in the 2nd hole from the bottom. This
provides a clearance (X) of approx. 70 mm from the
windboard to the bottom of the fan housing. To adjust, take
out the hex. bolt.
(Figs. 1 95 and 1 96)
1 96
5 ..76 DO 21 8 - 202 MEGA

Threshing mechanism
Removal of cleaning fan

Remove fan belt.
Operate tJ,e cleaning fan to maximum speed.
Disenga9!e the threshing mechanism, stop the
engine arid remove the ignition key.
Screw one BM 1 2 x 8� DIN 564-8.8 hex. bolt (S, part no.
236 301 . 0) into a tapp9d hole in the front fixed pulley half
until the rear moveablfi pulley is blocked open.
With the engine switch,!8d off, turn on the ignition and
engage the threshing mechanism. Then operate the fan
variable speed drive td the slow speed position by actuating
the appropriate rocker:Switch.
Remove the variable speed belt from the pulleys.
On the left-hand side qf the machine, lower the hinged
bottom plate. To do thi@!, release the plug. Unbolt the side
guard.
Undo the two M 1 0 x � set screws of the variable speed
pulley. Pull the variabl£J speed pulley assembly off the shaft
and withdraw the parallel key.
(Fig. 1 97)
Fan blades
DO 203 MEGA / 202 pJjEGA
I
Fan blades and / or strtys can now be replaced by new
I
ones as necessary.
The fan assembly is 1:,a1anced. Mark the fan blades and
spiders and note bal@ncing weights (which could be
bolts) where fitted, b@fore disassembly.
(Fig. 1 98)
1 98
Fan shaft
DO 203 MEGA / 202 l\�EGA
Right-hand side:
Unlock the castellated nut of the adapter sleeve bearing and
back off the nut a few rurns.
(Fig. 1 99)
1 99
DO 21 8 - 202 MEGA 5. 77
Threshing mechanism
Knock loose the adapter sleeve by using a suitable tube

and applying a sharp, short blow.
(Fig. 200)
200
Unscrew and pull the complete bearing off the shaft.

(Fig. 201 )
201
Left-hand side:
Unscrew the adapter sleeve bearing from the support.
Loosen the set screws of all fan spiders.
(Fig. 202)
202
Clean the entire length of the fan shaft from paint and dirt
and pull it out the left-hand side of the machine.
(Fig. 203)
203
5. 78 DO 21 8 - 202 MEGA
Threshing mechanism
Fan spiders and fan rotor

Remove support (L), left-hand side.
(Fig. 204)
Fan spiders can now easily be replaced by new ones.

Remove the fan assembly by taking it out the left-hand side.
To do this, cover (T) has to be removed.
(Fig. 205)
205
Remove the clean grain auger trough.

Remove the four bolts (1 ), on both sides, that secure the
cross plate.
(Fig. 206)
206
Unscrew the fan housing from the combine side panels,

each side.
On the left-hand side of the machine, remove the left-hand
section of the preparation floor to provide better access to
the upper bolt.
(Fig. 207)
207
DO 21 8 - 202 MEGA 5. 79
Threshing mechanism
Unscrew the front rocker arms of the preparation floor from

the fan housing. The fan housing can now be removed to
the side from the combine.
(Fig. 208)
208
5.80 DO 21 8 - 202 MEGA

Threshing mechanism
209
[J]
Fan disassembled: 1 2 Hex. bolt M 1 2 x 45 DIN 933
DO 203 MEGA / 202 MEGA Self-locking nut Vm 1 2
1 Fan housing 1 3 Bearing half
2 Hex. bolt M 1 0 x 25 DIN 933 Felt strip
Hex. nut M 1 0 DIN 934 1 4 Adapter sleeve
Contact washer A 1 0 1 5 Self-aligning ball bearing 1 207 K/C3 DIN 630
3 Fan spider 1 6 Tab washer
4 Hex. bolt M 1 0 x 30 RS 1 7 Slotted round nut M 35 x 1 .5
Hex. nut M 1 0 DIN 934 1 8 Bearing half
5 Stay Felt strip
6 Shaft 1 9 Slotted mushroom head screw M 8 x 20 x 1 3 DIN 603
7 Fan blade Hex. nut M 8 DIN 934
8 Hex. bolt M 6 x 20 DIN 933 Contact washer A 8
Hex. nut M 6 DIN 934 20 Hex. bolt M6 x 1 6 DIN 933
Contact washer A 6 Hex. nut M 6 DIN 934
9 Support Contact washer A 6
1 0 Hex. bolt M 1 2 x 35 DIN 933 21 Side section
Self-locking nut Vm 1 2 (Fig. 209)
1 1 Hex. bolt M 1 0 x 25 DIN 933
Self-locking nut Vm 1 0
DO 21 8 - 202 MEGA 5.81

Threshing mechanism
Installation of fan housing

� 1 . Lift fan housing into the machine from below and bolt on
the front rocker arms of the preparation floor.
2. Bolt fan housing to the sidewalls of the machine, both
sides.
3. Secure the cross plate and install grain trough.
4. Preassemble fan rotor with shaft (6), fan spider (3) and
fan blade (7). Fit the hex. bolts (4) but do not tighten at
this stage.
5. Lift preassembled rotor from the left into machine.
6. Secure support, left.
7. Bearing location, adapter sleeve and shaft seat must be
dry and free of grease.
Push UH and R/H bearings onto shaft and bolt to
support.
8. Align the shaft so that the distance (X) between bearing
support and end of shaft on the left-hand side of the
machine is 263.5 mm. Align the fan spiders to the centre
of the housing. Secure and lock spiders with the hex.
bolts (4).
21 0
[I] 9. Pre-torque slotted round nut to 1 5 Nm and continue

turning until the lug of tab washer is located on groove of
slotted round nut. Turn slotted round nut through a
1 0. Fit variable speed pulley assembly and secure with the
two set screws. Install fan belt and fit all guards.
(Figs. 1 97 to 21 0)
5.82 DO 21 8 - 202 MEGA

Threshing mechanism
Removal of windboards
With the sieve removed, unscrew the bolts that secure the
lever and bearing strap to the windboards.
The windboards can be removed through the fan and to the
side out of the machine.
(Fig. 21 1 )
Windboard disassembled:
1 Bearing strap
2 Windboard
3 Lever
Contact washer A 8
(Fig. 21 2)
21 2
Adjusting windboards
The windboards in the fan housing throat can be adjusted to
four positions each by the levers (H) after removing the hex.
bolts (S).
Normal position:
Lower lever (H) = 2nd hole from the bottom
X= approx. 82 mm
Upper lever (H) = 3rd hole from the top
X= approx. 56 mm
Set the windboards steeper for heavy crops and less steep
for lighter crops. 21 3
After adjustment of the windboards, insert and tighten hex.
bolts (S).
(Figs. 21 3 and 21 4)
21 4
DO 21 8 - 202 MEGA 5.83

Threshing mechanism
Installing wind blast reduction kit

DO 203 M EGA / 202 M EGA
First install one upper segment of the fan opening and
engage two hook bolts at (A) behind the rim of the cleaning
fan.
Tighten hook bolts and lock with lock nuts.
Now insert the lower segment and also secure with two
hook bolts behind the rim of the cleaning fan at (B).
For specific crops, the wind flow rate passing through the
open section (0) from the cleaning fan can, in addition to
fan speed, be regulated by turning the lower segment after
21 5 loosening the hook bolts. After each adjustment, re-tighten
the hook bolts and lock with lock nuts.
(Fig. 21 5)
5.84 DO 21 8 - 202 MEGA

6
Elevators and
Crop Delivery
6 ELEVATORS AND CROP DELIVERY RETURNS ELEVATOR
Removal of upper returns elevator shaft 6. 1
Installation of upper returns elevator shaft 6. 2
Removal of returns delivery auger 6. 3
Returns delivery head, disassembled 6. 5
Installation of returns delivery auger 6. 6
Removal of returns elevator assembly 6. 6
Removal of returns auger 6. 7
Installation of returns auger 6. 10
GRAIN ELEVATOR
Removal of grain elevator chain 6. 10
Installation of grain elevator chain 6. 11
Removal of grain tank filler auger 6. 11
Grain tank filler auger, disassembled 6. 13
Installation of grain tank filler auger 6. 14
Removal of grain elevator 6. 15
Removal of upper grain elevator shaft 6. 16
Grain elevator head, disassembled 6. 18
Installation of upper grain elevator shaft,
installation of grain elevator 6. 1 9
Removal of grain elevator housing 6. 1 9
Installation of grain auger 6. 22
GRAIN TAN K
Removal of grain tank unloading auger 6. 23
Installation of grain tank unloading auger 6. 24
Removal of grain tank unloading tube auger 6. 25
Installation of grain tank unloading tube auger 6. 26
Removal of unloading auger angle drive gearbox 6. 26
Installation of unloading auger angle drive gearbox 6. 27
Removal of grain tank unloading tube 6. 28
Installation of grain tank unloading tube 6. 28
Removal of lateral augers 6. 29
Installation of lateral augers 6. 31
Removal of grain tank intermediate drive shaft 6. 31
Elevators and Crop Delivery
RETURNS ELEVATOR
Removal of upper returns elevator shaft

Open the elevator boot door, turn the elevator chain until
chain connecting link (U) is at the bottom. Relieve the
tension in the elevator chain and remove the connecting
link.
(Fig. 1 )
Remove the cover of the elevator head and take out the
elevator chain through the top of the elevator housing.
(Fig. 2)
Slacken and remove drive chain (A) of the returns delivery

auger.
(Fig. 3)
Drive the expansion pin out of the hub of sprocket (K) and
remove the sprocket.
(Fig. 4)
DO 21 8 - 202 MEGA 6. 1
Pull the cable from magnetic pick-up (J).

Loosen the grub screw in cam collar (N). The cam collar is
at the same time the lock collar for the flange ball bearing.
Loosen the cam collar= bearing lock collar by driving in the
opposite direction to the direction of shaft rotation.
Unbolt and pull off the flange bearing. Unscrew magnetic
pick-up (J).
(Fig. 5)
Loosen the lock collar of front flange ball bearing (L) and
unbolt the complete bearing assembly.
(Fig. 6)
Loosen the set collars on both sides of the inner sprocket

and push the collars to the side. Drive the sprocket off the
parallel key and remove the shaft with sprocket.
(Fig. 7)
.iiiillll 7
Installation of the upper returns elevator shaft

1 . Install the shaft with sprocket, parallel key and set
collars in the elevator housing. Centre the sprocket on
the parallel key and secure with the set collars.
2. Pull the flange ball bearing onto the shaft and bolt to
the elevator housing. Position the shaft so that the
sprocket is in the centre of the elevator housing.
Secure the shaft with the lock collar and cam collar.
6.2 DO 21 8 - 202 MEGA

3. Bolt on the magnetic pick-up and adjust so that the gap

between pick-up and cam collar is 1 ± 0.5 mm.
4. Fit the sprocket and secure with the expansion pin. Fit
and tension the drive chain.
5. Fit and tension the elevator drive chain, then close the
housing cover.
(Figs. 1 to 7 and 1 3)
Removal of returns delivery auger

Remove the auger drive chain and drive the expansion pin
out of sprocket (R). Remove the sprocket.
(Fig. 8)
Loosen the lock collar of the flange ball bearing. Unbolt and
pull off the bearing.
(Fig. 9)
Remove sealing washer (C) from the service slot.

(Fig. 1 0)
10
DO 21 8 - 202 MEGA 6.3

Loosen the lock collar of inner bearing (F) of the returns

delivery auger.
(Fig. 1 1 )
11
Turn delivery auger (V) out through service slot (S).

(Fig. 1 2)
12
6.4 DO 21 8 - 202 MEGA

13
Returns delivery head, disassembled: 17 Sprocket

1 Chain tensioner 18 Parallel key A 8 x 7 x 30 DIN 6885
2 Cam collar 19 Flange ball bearing
Grub screw M 6 x 6 20 Expansion pin 6 x 40 DIN EN 28752
3 Sheet metal flange 21 Sprocket
4 Lock collar bearing Pea 205 22 Elevator head
5 Magnetic pick-up 23 Self-locking nut Vm 1 2
6 Hex. nut BM 1 8 x 1 .5 24 Sheet metal flange
7 Retainer 25 Lock collar bearing Pea 205
8 Plug 26 Lock collar
9 Retaining washer 27 Slotted mushroom-head screw M 1 0 x 35 DIN 603
1 0 Cover Hex. nut M 1 0 DIN 934
1 1 Chain tensioner Contact washer A 1 0
1 2 Hexagon head bolt M 1 2 x 25 DIN 933 28 Washer
Contact washer A 1 2 29 Tensioner block
1 3 Self-locking nut Vm 1 2 30 Washer
1 4 Chain tensioner 31 Roller chain
1 5 Shaft (Fig. 1 3)
1 6 Set collar
DO 21 8 - 202 MEGA 6.5

Installation of returns delivery auger

1 . Twist in the delivery auger from the right through the
service slot.
2. Install tensioner block (29) with slotted
mushroom-head screw (27) and washers (28 and 29)
in the service slot.
3. Pull the lock collar bearing over the threshing drum
until it is up against the auger and bolt to the unloading
auger tube. Lock the bearing on the auger with the lock
collar and secure.
4. Pull the bearing onto the elevator head and bolt down.
Lock the lock collar in the direction of rotation and
secure.
5. Push sprocket (21 ) onto the auger and secure with
expansion pin (20). Fit and tension the chain.
(Figs. 8 to 1 3)
Removal of returns elevator assembly

link.
(Fig. 1 4)
Loosen lock collar (S) of the flange ball bearing on the

elevator boot. Unbolt the safety guard with frame on the
right-hand side of the machine.
(Fig. 1 5)
15
6.6 DO 21 8 - 202 MEGA

Unbolt the lower end of the returns elevator at the bottom

from bracket (T).
(Fig. 1 6)
16
Remove the three hexagon head bolts M 6 x 20 on the

returns inspection door. Unbolt the elevator head from
bracket (H).
(Fig. 1 7)
17
Remove the complete returns elevator assembly together

with the delivery tube. The bottom sprocket must be turned
so that one gap between the teeth is facing towards the
elevator wall.
(Fig. 1 8)
18
Removal of returns auger

Turn the elevator chain so that the connecting link is at the
bottom and split the chain. Loosen outer set collar (R) in
front of the sprocket.
(Fig. 1 9)
DO 21 8 - 202 MEGA 6.7

Loosen lock collar (S) of the flange ball bearing in the

elevator boot.
(Fig. 20)
20
On the left-hand side, unbolt tool box (W) together with

guards (A).
(Fig. 21 )
21
Remove the elevator drive belt and pull the gib-head key out
of pulley (K).
(Fig. 22)
22
Pull off pulley (K) using a puller, if necessary.

(Fig. 23)
23
6.8 DO 21 8 - 202 MEGA

Loosen the lock collar of flange ball bearing (F). Unbolt and
pull off the flange ball bearing assembly.
(Fig. 24)
24
Loosen and remove sealing washer (V) in the service slot.

(Fig. 25)
25
To ease handling, loosely install V-belt pulley (K).

Turn the returns auger out to the left through the service
slot. At the same time, drive the sprocket in the elevator
boot off the auger shaft on the right-hand side.
(Fig. 26)
26
DO 21 8 - 202 MEGA 6.9

Installation of returns auger

1 . Turn in the returns auger through the service slot. At
the same time, slide the sprocket and set collar over
the auger shaft in the elevator boot.
2. Left-hand side of machine:
3. Install the sealing washer in the service slot. Fit the
flange ball bearing and secure with the lock collar.
4. Fit V-belt pulley (K), align and secure with the gib-head
key.
5. Position the sprocket exactly in the centre of the
elevator boot and secure with the set collars. Connect
the returns elevator chain and adjust to the correct
tension.
(Figs. 1 9 to 26)
GRAIN ELEVATOR
Removal of grain elevator chain

link.
(Fig. 27)
Remove steel roller chain (B) at the elevator head. Remove

the elevator head cover.
(Fig. 28)
28
6. 1 0 DO 21 8 - 202 MEGA
Evenly pull out both strands of the grain elevator chain

through the top of the housing.
(Fig. 29)
29
Installation of grain elevator chain

Feed in the elevator chain from the top, ensuring that both
chain strands hang down the same length. The delivery side
is to the front.
Tension the elevator chain:
Loosen counter-nut (G) on the elevator head and tension
the elevator chain with nut (M).
Tension the elevator chain so that the delivery plates do not
scrape on the elevator housing. It must still be possible to
push the chain to the side by hand at the bottom sprocket.
Tighten the counter-nut again and close the elevator boot
cover tightly. Drive chain (K) for the filler auger is
automatically tensioned by spring-loaded tensioner (S).
(Figs. 27 to 30)
Removal of grain tan k filler auger

Unbolt grain tank filler auger (F) at the grain tank wall.
(Fig. 31 )
DO 21 8 - 202 MEGA 6. 1 1
Remove steel roller chain (B) at the elevator head.

(Fig. 32)
32
Unbolt angle drive gearbox housing (W).

(Fig. 33)
33
Remove the hexagon head bolt from the end of the filler
auger.
Press the filler auger out of the bevel gear using a puller.
Take the filler auger out of the grain tank.
(Fig. 34)
34
6. 1 2 DO 21 8 - 202 MEGA
-�
@'5--@)
35
Grain tank filler auger, disassembled: 1 4 Slotted mushroom-head screw M 1 0 x 40 DIN 603
1 Grease nipple As 6 x 1 DIN 71 41 2 Contact washer A 1 0
2 Sheet metal flange 1 5 Felt ring
3 Adjusting bearing 16 -
4 Sheet metal flange 1 7 Flange
5 Slotted mushroom-head screw M 8 x 1 6 x 1 0 DIN 603 1 8 Housing
Hex. nut M 8 1 9 Circlip 47 x 1 .75 DIN 472
Contact washer A 8 20 Deep-groove ball bearing 6005-2RS DIN 625
6 Filler auger 21 Shaft
7 Deep-groove ball bearing 6208-2RS DIN 625 22 Elbow union Ll4M DIN 3903
8 Circlip 23 Washer
9 Parallel key A 8 x 7 x 30 DIN 6885 24 Hexagon head bolt M 1 0 x 25 DIN 933
10 Bevel gear 25 Lubrication line
11 Circlip
12 Filler tube (Fig. 35)
13 Hexagon head bolt M 8 x 1 6 DIN 933
Hex. nut M 8 x 1 6 DIN 933
Contact washer
DO 21 8 - 202 MEGA 6. 1 3
21
11-
20
- ====
====:::lf2i::f��it...
19
7
10 11 24 10 8 7 15 8
36
Installation of grain tan k filler auger

$ 1 . Lower the filler auger into the grain tank from above.
1-----1 2. Push flange (1 7) with felt ring (1 5) onto the filler auger.
Pack area (F) of the flange with 90 g of multigrade
grease and install deep-groove ball bearing (7) with
circlip (8). Insert parallel key (9) and fit bevel gear (1 0)
with hexagon head bolt (24).
3. Place circlip (1 9) into flange (1 8). Preassemble shaft
(21 ) with circlip (1 1 ), parallel key (9) and bevel gear (1 0).
Pull bearing (7) onto the bevel gear and insert the shaft
into the flange. Pull bearing (20) onto the shaft and
secure with circlip (1 1 ).
4. Bolt on preassembled flange (1 8) with slotted
mushroom-head screws (1 4).
5. Bolt on grain tank filler auger (1 2) and bolt down the up
per bearing.
6. Grease the angle drive gearbox.
7. Fit the steel roller chain for the filler auger drive.
(Figs. 31 to 36)
6. 1 4 DO 21 8 - 202 MEGA
Removal of grain elevator

Remove the grain tank filler auger and grain elevator chain.
Remove the complete returns elevator assembly.
Unbolt returns tube (U) at bracket (1 ) and pull off the tube.
Unbolt support tube (H) from the side panel and from the
grain elevator boot at (2).
(Fig. 37)
On the left-hand side of the machine, remove bolt (S)

securing the support tube.
(Fig. 38)
38
Pull out support tube (H) to the right-hand side.

(Fig. 39)
39
Loosen the lock collar of flange ball bearing (F) at the grain
elevator boot. Unbolt and pull off the bearing together with
the bearing plate.
(Fig. 40)
40
DO 21 8 - 202 MEGA 6. 1 5
Remove the bolts securing centre plate (T) inside and

outside the elevator boot at (4) and remove the centre plate
from below.
(Fig. 41 )
41
Remove the complete grain elevator assembly.

(Fig. 42)
42
Removal of upper grain elevator shaft

Remove the grain elevator.
Drive the expansion pin out of sprocket (K) and pull off the
sprocket.
(Fig. 43)
Loosen the clamping screw of cam wheel (N) and unlock

the cam wheel by tapping in the opposite direction of shaft
rotation.
NOTE: The cam wheel also serves as a lock collar for the
flange ball bearing.
Unscrew magnetic pick-up (J).

(Fig. 44)
44
6.16 DO 21 8 - 202 MEGA

Thoroughly clean the shaft. Loosen the set collars on both

sides of sprocket (R) and push the collars along the shaft
away from the sprocket. If necessary, smooth any marks
made by the cup point set screws on the shaft with a file.
(Fig. 45)
45
Loosen the lock collar of the rear bearing and remove the
complete bearing assembly.
(Fig. 46)
46
Pull out upper elevator shaft (W) to the rear and at the same
time lift out sprocket (R) and the set collars from above.
(Fig. 47)
47
DO 21 8 - 202 MEGA 6. 1 7
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48
Grain elevator head, disassembled: 25 Hexagon head bolt M 1 0 x 30 DIN 933

1 Lock collar Self-locking nut Vm 1 O
2 Sheet metal flange 26 Pressure spring
3 Lock collar bearing Pea 205 27 Stud
4 Shaft 28 Tube
5 Sealing plate 29 Cotter pin 4 x 22 DIN 94
6 Set collar 30 Slotted mushroom-head screw M 8 x 20 DIN 603
7 Sprocket Hex. nut M 8 DIN 934
8 Parallel key A 8 x 7 x 30 DIN 6885 Contact washer B 8
9 Sheet metal flange 31 Plate
10 Lock collar bearing Pea 205 32 Bushing
11 Cam wheel 33 Bracket
12 Hexagon head bolt M 1 6 x 1 90 DIN 931 34 Washer
13 Cover 35 Circlip 20 x 1 .2 DIN 471
14 Hexagon head bolt M 8 x 20 DIN 933 36 Hex. nut M H1 2 DIN 934
Hex. nut M 8 DIN 934 37 Contact washer A 1 2
Contact washer B 8 38 Stud
15 Hex. nut M1 6 39 Circlip 47 x 1 .75 DIN 472
16 Washer 40 Deep-groove ball bearing 6204 Z DIN 625
17 Tensioner 41 Circlip 20 x 1 .2 DIN 471
18 Tensioner plate, left 42 Chain pinion
19 Elevator head 43 Bracket
20 Slotted mushroom-head screw M 6 x 1 6 x 1 0 DIN 603 44 Hex. nut Bm 1 8 x 1 .5
Hex. nut M 6 DIN 934 45 Magnetic pick-up
Contact washer A 6 46 Expansion pin 5 x 40 DIN 1 481
21 Tensioner plate, right 47 Expansion pin 8 x 40 DIN 1 481
22 Washer 48 Sprocket
23 Contact washer A 8 49 Sprocket
24 Hex. nut M 8 DIN 934 (Fig. 48)
6. 1 8 DO 21 8 - 202 MEGA
Installation of upper grain elevator shaft,

installation of grain elevator
First install the upper grain elevator shaft with sprocket, set
collars and flange ball bearings, but do not tighten the
lock collars of the bearings and the inner sprocket at
this stage.
Secure sprocket (K) with the expansion pin and bolt on
angle drive gearbox (W) without filler auger. Now check the
alignment of sprocket (K) with the sprocket of the angle
drive gearbox using a straight edge (L) and lock the upper
shaft in position with the lock collars of the bearings.
Position the inner sprocket exactly in the centre of the
elevator head and secure with set collars. Bolt on angle
drive gearbox (W) again.
Install the grain elevator and grain tank filler auger, ensuring
that the grease nipple in the elevator head is in the correct
position and pack the angle drive gearbox with 90 g of
multi-grade grease. (See »Installation of grain tank filler
auger«.)
Fit the grain elevator chain and install the returns elevator.
(Figs. 48 and 49)
Removal of grain elevator housing

Remove the grain elevator chain.
(Fig. 50)
Remove guard (S) . On the drive side, disconnect the cable

for the speed-loss monitor at the magnetic pick-up and at
the elevator head.
(Fig. 51 )
51
DO 21 8 - 202 MEGA 6. 1 9
Unbolt the elevator head from the elevator housing and

remove the complete elevator head assembly.
(Fig. 52)
52
Disconnect plug (V) of the magnetic pick-up cable.

Unbolt the elevator housing from the bottom of the grain
tank from under the bottom plate.
(Fig. 53)
53
Remove all bolts (F) around the grain elevator boot.

(Fig. 54)
54
Push up grain elevator housing (S) using a lever (H), if

necessary.
(Fig. 55)
55
6.20 DO 21 8 - 202 MEGA

Remove grain elevator housing (S) through the top of the

grain tank.
(Fig. 56)
56
Removal of grain auger

Open the elevator boot door, turn the elevator chain until the
chain connecting link is at the bottom, relieve the tension in
the elevator chain and remove the connecting link.
Remove the elevator cover. Evenly pull out both strands of
the grain elevator chain slightly and support the chain on the
elevator head using a suitable length of timber (K) or similar
block.
Loosen set collars (1 ) holding sprocket (2) in the elevator
boot and loosen the lock collar of flange ball bearing (F).
Thoroughly clean the shaft of the grain auger in the elevator
boot.
(Figs. 57 and 58)
58
On the left-hand side of the machine, remove the auger

drive belt and pull off grain auger drive pulley (B).
(Fig. 59)
59
DO 21 8 - 202 MEGA 6.21

e,;wu;s:m,.,.. . .. .... . --:;:�:
----- · · - Loosen the lock collar of left-hand flange ball bearing (F),
unbolt the flange ball bearing from the side panel and pull
,.,,, ....
the bearing off the auger shaft. Loosen and remove sealing
washer (V) from the service slot.
(Fig. 60)
60
Turn the grain auger out to the left-hand side through the
service slot, at the same time driving the sprocket and set
collars off the shaft on the right-hand side in the elevator
boot.
Pulley (B) can be installed more easily if it is set in place
with the key.
(Fig. 61 )
61
Installation of grain auger

1 . Turn in the grain auger through the service slot, at the
same time pushing the sprocket and set collars onto the
shaft in the elevator boot.
� 2. Left-hand side of machine:
Fit the sealing washer in the service slot. Fit the flange
ball bearing and secure with the lock collar. Key the
V-belt pulley in position and fit the V-belt.
3. Install the flange ball bearing in the elevator boot.
Position the sprocket exactly in the centre of the elevator
housing and secure with the lock collars to prevent any
lateral movement.
4. Fit the grain elevator chain.
(Figs. 57 to 61 )
6.22 DO 21 8 - 202 MEGA

GRAIN TANK
Removal of grain tan k unloading auger

Unbolt conical cover (A) over the grain tank unloading
auger.
(Fig. 62)
Remove steel roller chain (K) on the right-hand side.

(Fig. 63)
63
Drive out the gib-head key and pull off sprocket (R).
(Fig. 64)
64
Loosen the lock collar of the bearing, unbolt the bearing and
pull the bearing off the auger shaft.
(Fig. 65)
65
DO 21 8 - 202 MEGA 6.23

Unbolt and remove bearing plate (B) from the grain tank
side panel.
(Fig. 66)
66
Push grain tank unloading auger (E) slightly to the right with
the splined shaft profile out of the angle drive gearbox.
(Fig. 67)
67
Turn grain tank unloading auger (E) to the right out of the
service slot.
(Fig. 68)
68
.W.
Installation of grain tank unloading auger
7+f 1 . Turn in the grain tank unloading auger to the left through
the service slot.
LJ
2. Before pushing the splined shaft profile into the angle
�
drive gearbox, coat the splines generously with grease.
�-� 3. Bolt the bearing plate to the grain tank side panel.
4. Fit and tighten the lock collar bearing, ensuring that the
shoulder of the auger is firmly up against the bearing
inner race.
6.24 DO 21 8 - 202 MEGA

5. Pull on and align the sprocket then secure in position

with the gib-head key. Fit and tension the steel roller
chain.
(Figs. 62 to 69)
Removal of grain tan k unloading tube auger

Slide open cover (R) in the grain tank unloading tube and
remove securing bolt (1 ).
(Fig. 70)
Unbolt spout (T).

(Fig. 71 )
71
Unbolt bearing cover (L) from the end of the unloading tube
and pull out the grain tank unloading tube auger.
(Fig. 72)
72
DO 21 8 - 202 MEGA 6.25

Installation of grain tan k unloading tube auger

A special M 1 2 x 95 x 77 bolt, DIN grade 1 0.9, must be used
to secure the auger to the stub shaft of the angle drive
gearbox.
If necessary, this special bolt can be manufactured from a
normal hexagon head bolt to DIN 931 -1 0.9 with a shank
length of 77 mm.
Removal of unloading auger angle drive gearbox

Unbolt the grain tank unloading tube auger at the angle
drive gearbox and on the outside at the unloading tube (see
also »Removal of grain tank unloading tube auger«) and
pull back slightly.
Unbolt the lower angle drive gearbox from the outside ...
... and in the grain tank unloading tube.

(Figs. 73 and 74)
74
Remove the lower bolt from the auger flight. Remove the
lower angle drive gearbox assembly.
(Fig. 75)
75
6.26 DO 21 8 - 202 MEGA

Pull out the auger flight from above.

(Fig. 76)
76
Unbolt the stud and remove the three bolts (2) securing the
upper angle drive gearbox.
Watch for spacer washers (A) which may be installed
between the mounting flanges.
Lift out the upper angle drive gearbox from above.
NOTE: If the upper angle drive gearbox is defective, it has

to be replaced as a complete unit; individual parts cannot
be serviced.
(Fig. 77)
77
Installation of unloading auger angle drive

gearbox
1 . Push on the upper angle drive gearbox of the grain tank
unloading auger. Do not tighten the gearbox mounting
bolts at this stage.
2. Install auger flight (F) and lower angle drive gearbox.
Tighten the mounting bolts of the lower angle drive
gearbox.
3. Secure the auger flight at (2 and 3) with necked-down
bolt (Part No. 603 532.2) and flat collar nut M 1 2 x 1 .5.
Install the lower bolt strain-free.
(Figs. 78 and 79)
79
DO 21 8 - 202 MEGA 6.27

Removal of grain tan k unloading tube

Remove the grain tank unloading auger.
Remove the lower unloading auger angle drive gearbox and
lift out the agitator flight shaft.
Remove connecting pin (V) of the unloader swing cylinder.
(Fig. 80)
Unbolt the upper flange half (B) of the turning ring. The
unloading tube is now held in the lower flange half of the
turning ring.
(Fig. 81 )
81
The grain tank unloading tube can now be lifted out of the
flange half and to the side by two persons if a suitable hoist,
crane, front loader, etc. is not available.
(Fig. 82)
82
Installation of grain tan k unloading tube

1 . Coat the turning ring generously with grease before
installing.
2. Bolt on the unloader swing cylinder.
3. Install the grain tank unloading tube auger.
4. Install the unloading auger angle drive gearbox.
6.28 DO 21 8 - 202 MEGA

Removal of lateral augers

Loosen and drive off the lock collar of the rear flange ball
bearing.
(Fig. 83)
Unbolt the rear flange ball bearing and pull the bearing off
the auger shaft.
(Fig. 84)
84
Unbolt cover (D) of the angle drive gearbox in the grain

tank.
(Fig. 85)
85
Remove the circlip in front of the bevel gear at (1 ).

(Fig. 86)
86
DO 21 8 - 202 MEGA 6.29

Unbolt bearing flange (E).

In order to remove the right-hand lateral auger, cover (A) of
the unloading auger must also be removed.
(Fig. 87)
87
If necessary, press the auger shaft out of bevel gear (K)

using a special tool.
Hexagon head bolt (1 ) BM 1 2 x 80 (Part No. 236.301 . 0) and
Reducer (2) M 1 6 to M 1 2 (Part No. 1 81 933.0)
(Fig. 88)
Push the lateral auger slightly to the rear through the service
slot. Pull bearing (L) from the auger shaft using a puller.
(Fig. 89)
89
Turn out the lateral auger to the rear through the service
slot.
(Fig. 90)
90
6.30 DO 21 8 - 202 MEGA

Installation of lateral augers

1 . Install the lateral auger together with the bearings and at
the same time install the bevel gear in the angle drive
gearbox.
2. Bolt the rear bearing to the rear panel of the grain tank.
Bolt the bearing flange of the front bearing to the angle
drive gearbox.
Install the circlip in front of the bevel gear.
3. Push the auger backwards or forwards so that the bevel
gears have a slight backlash. Next secure first the front
bearing, then the rear bearing with the lock collars.
4. Pack the angle drive gearbox with 250 g of roller bearing
grease and fit the gearbox cover.
Removal of grain tan k intermediate drive shaft

Remove steel roller chains (1 and 2)
(Fig. 91 )
Remove sprocket (3) and bearing (4) from the intermediate

drive shaft.
(Fig. 92)
92
DO 21 8 - 202 MEGA 6. 31
Loosen the bolts securing belt guide (B) and remove power
band belt (V).
(Fig. 93)
93
Pull out gib-head key (5) securing V-belt pulley (R).

(Fig. 94)
94
In the grain tank, loosen lock collar (S) of the flange ball
bearing.
(Fig. 95)
95
Push back intermediate drive shaft (W) using a lever (H) or

similar tool, if necessary, until the V-belt pulley can be
removed.
(Fig. 96)
96
6. 32 DO 21 8 - 202 MEGA
Take out V-belt pulley (R). Intermediate drive shaft (W) c;:an
be pulled out to the right.
(Fig. 97)
97
DO 21 8 - 202 MEGA 6.33

7
Engine and Drives
7 ENGINE AND DRIVES ENGINE
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7. 1
Removing engine output shaft . . . . . . . . . . . . . . . . . . . . . 7. 1
Installing engine output shaft . . . . . . . . . . . . . . . . . . . . . . 7. 6
Engine output shaft dismantled, Mercedes OM 441 A . 7. 7
Engine output shaft dismantled, Mercedes OM 366 LA
(208 MEGA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7. 1 0
Engine output shaft dismantled,
Mercedes OM 366 LA / OM 366 A . . . . . . . . . . . . . . . . . 7. 12
Engine output shaft dismantled, Perkins 1 006.6 T . . . . 7. 14
Adjusting hydraulic pump . . . . . . . . . . . . . . . . . . . . . . . . . 7. 17
Removing radiator rotary screen drive . . . . . . . . . . . . . . 7. 17
Drive for radiator rotary screen dismantled . . . . . . . . . . 7. 20
Installing radiator rotary screen drive . . . . . . . . . . . . . . . 7. 21
Removing radiator rotary screen . . . . . . . . . . . . . . . . . . . 7. 21
Radiator rotary screen dismantled . . . . . . . . . . . . . . . . . 7. 23
Installing radiator rotary screen . . . . . . . . . . . . . . . . . . . . 7. 24
Removing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7. 24
Installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7. 27
Removing oil cooler for hydrostatic ground
drive system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7. 28
CUTTERBAR AND THRESHING MECHANISM DRIVE

Removing hydraulic cutterbar clutch . . . . . . . . . . . . . . . 7. 29
Cutterbar clutch cylinder dismantled . . . . . . . . . . . . . . . 7. 32
Assembling hydraulic cutterbar clutch . . . . . . . . . . . . . . 7. 33
Removing threshing mechanism drive pulley . . . . . . . . 7. 34
Installing threshing mechanism drive pulley . . . . . . . . . 7. 35
Adjusting threshing mechanism drive . . . . . . . . . . . . . . . 7. 36
Adjusting threshing drum drive . . . . . . . . . . . . . . . . . . . . 7. 37
Adjusting accelerator drive . . . . . . . . . . . . . . . . . . . . . . . . 7. 38
Adjusting cutterbar drive . . . . . . . . . . . . . . . . . . . . . . . . . . 7. 39
Adjusting grain tank unloading auger
drive belt clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7. 40
Adjusting hydrostatic ground drive system . . . . . . . . . . 7. 41
THRESHING DRUM VARIABLE SPEED DRIVE

Removing and fitting threshing drum
variable speed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7. 42
Removing spring-loaded variable
speed pulley assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 7. 43
Dismantling spring-loaded variable
Spring-loaded variable speed
pulley assembly dismantled . . . . . . . . . . . . . . . . . . . . . . . 7. 44
Assembling spring-loaded variable
Installing spring-loaded variable
Removing hydraulic variable speed pulley assembly . 7. 48
Hydraulic variable speed pulley assembly dismantled
(with intermediate drive) . . . . . . . . . . . . . . . . . . . . . . . . . . 7. 50
Hydraulic variable speed pulley assembly dismantled
(without intermediate drive) . . . . . . . . . . . . . . . . . . . . . . . 7. 50
Installing hydraulic variable speed pulley assembly . . . 7. 51
Removing variable speed pulley intermediate drive . . . 7. 51
Variable speed pulley intermediate drive dismantled . . 7. 52
Installing variable speed pulley intermediate drive . . . . 7. 52
Removing planetary gear unit . . . . . . . . .. . . ... . ... . . 7. 53
Dismantling planetary gear unit . . . . . . . .. . . ... . ... . . 7. 54
Planetary gear unit dismantled . . . . . . . .. . . ... . ... . . 7. 55
Assembling planetary gear unit . . . . . . . .. . . ... . ... . . 7. 56
Installing planetary gear unit . . . . . . . . . .. . . ... . ... . . 7. 58
FAN VARIABLE SPEED MECHANISM

Removing and fitting fan speed control belt . . . . . . . . . 7. 59
Removing upper variable speed pulley
(electrically adjustable) . . . . . . . . . . . . . . . . . . . . . . . . . . . 7. 60
Upper variable speed pulley and intermediate
drive shaft dismantled . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7. 61
Electric fan speed control assembly dismantled . . . . . . 7. 62
Installing fan variable speed pulleys . . . . . . . . . . . . . . . . 7. 63
Assembling and installing electric fan speed control . . 7. 65
Removing lower variable speed pulley . . . . . . . . . . . . . . 7. 66
Removing drive belt for suction blower . . . . . . . . . . . . . 7. 67
Engine and Drives
ENGINE
Alternator
Always observe the following points before performing any
work on the engine:
a) Never disconnect the cables connecting the
alternator and battery whilst the alternator is
running.
b) Pay attention to the correct polarity when
connecting the battery. Reversing the polarity will
burn out the alternator diodes.
c) Carry out work on current-carrying components only 1
with the engine shut off and the battery cables
disconnected.
d) The normal method of testing for current flow in
cables by shorting to earth must not be used with
alternators. This would damage the
semi-conductors.
e) Before carrying out electrical welding work on the
combine, disconnect the cables from the alternator!
f) The combine battery provides the current for the
field excitation required to start the alternator
operation via the charge indicator light. Burned out
bulbs must therefore be replaced to ensure proper
field excitation.
(Fig. 1 )
Removing engine output shaft

Unbolt the guards.
On combines with compressor-type air conditioning system,
loosen and remove the adjusting ring.
Never disconnect the refrigerant hoses. Place
the compressor to one side and support so that
the refrigerant hoses are not kinked and the
compressor is not in the way of the further
maintenance work.
(Fig. 2)
Block the spring-loaded cylinder.

(Fig. 3)
DO 21 8 - 202 MEGA 7. 1
Engine and Drives
Ease back the hydraulic pump and loosen the three

hexagon head bolts (S).
Back off the adjusting screws and push back the hydraulic
pump.
(Fig. 4)
Remove the drive belt from the hydraulic pump.

(Fig. 5)
Remove drive belt (2) and disconnect spring-loaded cylinder

(Z).
(Fig. 6)
Pull the idler pulley complete with shaft out of the clutch bell
housing.
(Fig. 7)
7.2 DO 21 8 - 202 MEGA

Engine and Drives
Push back belt guides (R and P).

(Fig. 8)
Remove the cotter pin securing the castellated nut and

unscrew the castellated nut.
Mount the puller (special tool kit) and pull off the engine
output pulley. If necessary, loosen the pulley with a short,
sharp blow.
Remove the cotter pin securing the castellated nut and

unscrew the castellated nut.
(Fig. 9)
Mount the puller (special tool kit) and pull off the engine
output pulley. If necessary, loosen the pulley with a short,
sharp blow.
(Fig. 1 0)
Special tool:
1 . Spindle - Part No. 1 81 801 . 1

2. Puller bridge - Part No. 1 81 800. 0
3. Hexagon head bolt M 1 6 x 75 DIN 933-8.8
Part No. 237 379. 0 with nuts and washers
4. Puller plate - Part No. 1 81 803. 1
5. Adapter with ball - Part No. 1 81 849. 0
6. Hex. nut M 1 6 DIN 934-8 - Part No. 236 1 76. 0
7. Washer 1 7 mm - Part No. 235 1 27.2
8. Extension pin - Part No. 1 81 81 0. 1
9. Hammer bolt - Part No. 1 81 895. 0
(Fig. 1 1 )
11
DO 21 8 - 202 MEGA 7.3

Engine and Drives
Unbolt the belt guides in the area of the engine output shaft
housing. Unbolt spring-loaded cylinder (Z).
(Fig. 1 2)
12
Tie up the hydraulic tank assembly and ensure that no

hydraulic oil escapes.
Remove the hexagon head bolts from the engine output
shaft housing.
(Fig. 1 3)
13
Pull off the engine output shaft housing using a special tool.
Attach the puller arms to the housing with hexagon head
bolts M 8 x 25.
(Fig. 1 4)
14
Special tool:
1 Spindle - Part No. 1 81 800. 1

2 Adapter with ball - Part No. 1 81 849. 0
3 Puller bridge - Part No. 1 81 800. 0
4 Hex. nut M 1 6 - Part No. 236 1 73. 0
5 Washer 1 7 mm - Part No. 235 1 27.2
6 Hexagon head bolt M 1 6 x 50 Part No. 235 586. 0
7 Puller arm - Part No. 1 81 808.0
8 Hexagon head bolt M 1 2 x 50 Part No. 237 573. 0
9 Hex. nut M 1 2 - Part No. 236 1 72. 0
10 Washer 1 3 mm - Part No. 235 1 24.2
(Fig. 1 5)
15
7.4 DO 21 8 - 202 MEGA

Engine and Drives
On OM 441 A
Unlock and remove the castellated nut from the face of the
adapter sleeve bearing.
Special tool:
Installation tool for engine output shaft bearing
Part No. 1 81 963. 0
1 Special socket spanner - Part No. 1 81 968.0

2 Tube - Part No. 1 81 964. 0
(Fig. 1 6)
Pull off the adapter sleeve bearing and multi-ring seal using
a 3-arm puller.
(Fig. 1 7)
17
On OM 366 LA / OM 366 A
Pull off the bearing assembly of the engine output shaft
using a special tool.
Special tool:
3 Threaded adapter - Part No. 1 81 967. 0
4 Tube - Part No. 1 81 964. 0
5 Hexagon head bolt Bm 1 2 x 1 80
DIN 564-8.8 - Part No. 236 302. 0
If the bolt length is not sufficient to pull off the bearing
completely, insert a shaft section between bolt and engine
output shaft.
(Fig. 1 8) 18
I �I
U n bolt tt,e engine oUlplrt shaft complete with d rlven d isc
from the engine flywheel.
(Fig. 1 9)
19
DO 21 8 - 202 MEGA 7.5

Engine and Drives
Unbolt the engine output shaft from the driven disc. The
bolts are very tight. Verbus-Plus self-locking bolts are used.
(Fig. 20)
20
Drive the plastic bushing out of the driven disc using a

suitable tube (R).
(Fig. 21 )
21
Installing engine output shaft

Install a new plastic bushing in the driven disc using a
special tool.
Special tool:
Hexagon head bolt M 1 6 x 300 SP -

Part No. 237 375. 1
2 Retainer plate (2 used) - Part No. 1 81 836. 1
3 Axial grooved ball bearing 51 1 03 - Part No. 1 77 899. 0
4 Hex. nut with collar M 1 6-1 0 - Part No. 244 059. 0
(Fig. 22)
22
7.6 DO 21 8 - 202 MEGA

Engine and Drives
--
23
Engine output shaft, dismantled: 16 Hexagon head bolt M 22 x 85 DIN 931 -8.8 VP
MERCEDES OM 441 A 17 Parallel key A 1 3 x 9 x 65
18 Driven disc
1 Engine output shaft housing 19 Contact washer A 1 0
2 Contact washer A 1 0 20 Hexagon head bolt M 1 0 x 35 DIN 933-8.8
3 Hexagon head bolt M 1 0 x 35 DIN 933-8.8 21 Bushing
4 Hexagon head bolt M 1 2 x 25 RS 22 Flexible coupling disc
5 Detent edged ring Vskz 8 23 Hexagon head bolt M 22 x 85 DIN 931 -8.8 VP
6 Hex. socket head cap screw M 8 x 20 DIN 91 2 24 Hex. nut M 22 DIN 934
7 Plug M 1 0 x 1 DIN 906 25 Output shaft
8 Circlip 1 00 x 3 DIN 472 26 Compound seal Z 21 1
9 Compound seal Z 31 0 27 Taper sleeve
10 Engine pulley 28 Self-aligning roller bearing 2221 1 Ek/C3 DIN 635
11 Cover plate 29 Tab washer
12 Spacer ring 30 Slotted nut M 55 x 2
13 Castellated nut M 36 x 1 .5 DIN 935 31 Washer
14 Cotter pin 6.3 x 56 DIN 94
15 Washer (Fig. 23)
DO 21 8 - 202 MEGA 7. 7
Engine and Drives
22 24 8 28 27 28 8 30 9
31
23 11
12
21
18 14
13
24
DOMINATOR 21 8 MEGA
MERCEDES OM 441 A
1 . Bolt flexible coupling disc (22) to the flange of engine
output shaft (25) using three self-locking hexagon head
bolts (23) M 22 x 85 DIN 931 VP (Verbus-Plus).
Tighten hexagon head bolts (23) to a torque of 330 Nm.
Screw on hex. nuts (24) and also tighten to 330 Nm.
CAUT ION! When tightening the hex. nuts, be sure to

counterhold the hexagon head bolts.
2. Position engine output shaft (25) against driven disc (1 8)

and insert the ball into bushing (21 ).
3. Bolt the output shaft with flexible coupling disc (22) to
driven disc (1 8) using three self-locking hexagon head
bolts (1 6) M 22 x 85 DIN 931 -8.8 VP (Verbus-Plus) and
washers (1 5). Tighten the hexagon head bolts to a
torque of 330 Nm.
4. Position engine output shaft housing (1 ) and bolt to the
engine all round.
5. Screw in three hex. socket head cap screws (6) with
detent edged ring (5).
7.8 DO 21 8 - 202 MEGA

Engine and Drives
6. Fill compund seal (26) Z 21 1 between the plate rings all

round with »Shell DARINA 2« high-temperature grease
and drive in with the special tool until they just contact
hex. socket head cap screws (6).
7. Fill space (A) with 35 g of »Shell DARINA 2«
high-temperature grease.
8. Pack self-aligning roller bearings (28) with »Shell
DARINA 2« high-temperature grease.
Clean the seat of taper sleeve (27) in the bearing and on
the shaft. Install bearing with taper sleeve to dimension
(X) 26.5+2-5 .
9. Oil thread and face of slotted nut (30) and the tab
washer and screw on. Tighten slotted nut first to a
torque of 40 Nm with the special tool, then tighten by a
further 1 00 ° to 1 30 ° . Secure the slotted nut with the tab
washer.
When securing the bearing, be sure to counterhold the
engine crankshaft.
1 0. Fit circlip (8).
A slight clearance must be left between the circlip and
the bearing outer race.
1 1 . Fill space (B) with 35 g of »Shell DARINA 2«
high-temperature grease.
1 2. Fill compound seal (9) Z 31 0 between the plate rings all
round with »Shell DARINA 2« high-temperature grease
and drive in with the special tool until they bottom.
»Shell DARINA 2« high-temperature grease can be
obtained from the CLAAS spare parts department, Part No.
1 77 507.0.
(Figs. 23 and 24 )
Special tool for bearing of engine output shaft:

1 1 Tube - Part No. 1 81 964.0
2 2 Adapter for driving in compound seal (26) Z 21 1 -
Part No. 1 81 966.0
3 Wrench for tightening the slotted nut -
Part No. 1 81 968.0
4 Adapter for driving in compound seal (9) Z 31 0 -
Part No. 1 81 965. 0
5 Threaded adapter - Part No. 1 81 967. 0
6 Hexagon head bolt BM 1 2 x 1 80 DIN 564-8.8 -
Part No. 236 302. 0
5 and 6= For pulling off the bearing during dismantling
(Fig. 25) 25
DO 21 8 - 202 MEGA 7.9

Engine and Drives
--.
26
Engine output shaft, dismantled:

MERCEDES OM 366 LA
DOMINATOR 208 MEGA
1 Flexible coupling disc

2 Hexagon head bolt M 1 8 x 65 DIN 931 VP
3 -
4 Output shaft
5 Parallel key A 1 3 x 9 x 65
6 Deep-groove ball bearing 631 1 -2RS/C4
7 Engine output shaft housing
9 Hexagon head bolt M 1 0 x 30 DIN 933
10 Circlip 1 20 x 4 DIN 472
11 Engine pulley
12 Cover plate
13 Washer 37 DIN 1 25
14 Castellated nut M 36 x 1 .5 DIN 935
16 Driven disc
17 Contact washer A 8
18 Hexagon head bolt M 8 x 30 DIN 933
19 Bushing
20 Drive belt pulley (combines with air conditioning only)
21 Detent edged ring Vskz 1 0
(combines with air conditioning only)
(Fig. 26)
7. 1 0 DO 21 8 - 202 MEGA
Engine and Drives
12
13
15
14
27
DOMINATOR 208 MEGA

MERCEDES OM 366 LA
1 . Ball bearing (6) must be heated before installation. rn

the bearing using a hot plate or similar heater to approx.
80 ° C and quickly push the bearing onto the bearing
seat until it is approx. 2.5 mm (dimension X) from the
4. Bolt the preassembled engine output shaft to the
flywheel with hexagon head bolts (1 8).
5. Push on engine output shaft housing (7) and bolt to the
engine all round. Fit circlip (1 0). A slight clearance must
be left between circlip and bearing outer race.
6. Insert parallel key (5) and push on engine pulley (1 1 ).
shaft shoulder. Install cover plate (1 2) and washer (1 3) on the shaft and
tighten castellated nut (1 4) to a torque of 550 Nm.
2. Bolt flexible coupling disc to the flange of engine output Tighten the nut until cotter pin (1 5) can be inserted.
shaft (4) using three self-locking hexagon head bolts (3)
M 1 8 x 65 DIN 931 VP (Verbus-Plus). 7. On combines with air conditioning, install belt pulley (20).
Tighten the hexagon head bolts to a torque of 330 Nm. (Figs. 26 and 27)
3. Position driven disc (1 6) with bushing (1 9) on the ball of
the engine output shaft and bolt the driven disc with
flexible coupling disc (1 ) to the engine output shaft using
three self-locking hexagon head bolts (3) M 1 8 x 65 DIN
931 VP (Verbus-Plus). Tighten the hexagon head bolts
DO 21 8 - 202 MEGA 7. 1 1
Engine and Drives
-----
-----
28
Engine output shaft, dismantled:

MERCEDES OM 366 LA / OM 366 A
1 Flexible coupling disc

2 Washer 1 8.5 x 37 x 4
3 Hexagon head bolt M 1 8 x 65 DIN 931 VP
4 Output shaft
5 Parallel key A 1 3 x 9 x 65
6 Deep-groove ball bearing 631 1 -2RS/C4
7 Engine output shaft housing
8 Contact washer S 1 0
9 Hexagon head bolt M 1 0 x 30 DIN 933
11 Engine pulley
12 Cover plate
13 Washer 37 DIN 1 25
14 Castellated nut M 36 x 1 .5 DIN 935
16 Driven disc
17 Contact washer S 8
19 Bushing
21 Drive belt pulley (combines with air conditioning only)
22 Spring lock washer
(Fig. 28)
7. 1 2 DO 21 8 - 202 MEGA
Engine and Drives
12
13
15
14
29
DOMINATOR 204 MEGA / 203 MEGA / 202 MEGA 4. Bolt the preassembled engine output shaft to the
MERCEDES OM 366 LA / OM 366 A flywheel with hexagon head bolts (1 8).
1 . Ball bearing (6) must be heated before installation. 5. Push on engine output shaft housing (7) and bolt to the
Heat the bearing using a hot plate or similar heater to engine all round. Fit circlip (1 0). A slight clearance
approx. 80 ° C and quickly push the bearing onto the must be left between circlip and bearing outer race.
[I]
bearing seat until it is approx. 2.5 mm (dimension X) 6. Insert parallel key (5) and push on engine pulley (1 1 ).
from the shaft shoulder. Install cover plate (1 2) and washer (1 3) on the shaft
2. Bolt flexible coupling disc to the flange of engine and tighten castellated nut (1 4) to a torque of 550 Nm.
output shaft (4) using three self-locking hexagon Tighten the nut until cotter pin (1 5) can be inserted.
head bolts (3) M 1 8 x 65 DIN 931 VP (Verbus-Plus). 7. On combines with air conditioning, install belt pulley
Tighten the hexagon head bolts to a torque of (20).
330 Nm. Screw on hex. nuts (20) and also tighten to
330 Nm. (Figs. 28 and 29 )
CAUT IONI When tightening the hex. nuts, be sure to

3. Position driven disc (1 6) with bushing (1 9) on the ball
of the engine output shaft and bolt the driven disc with
flexible coupling disc (1 ) to the engine output shaft
using three self-locking hexagon head bolts (3) M 1 8 x
65 DIN 931 VP (Verbus-Plus).
Tighten the hexagon head bolts to a torque of 330 Nm.
DO 21 8 - 202 MEGA 7. 1 3
Engine and Drives
30
Engine output shaft, dismantled: 1 3 Hex. nut M 1 6 DIN 934

1 4 Engine output shaft housing
PERKINS 1 006.6 T (1 25 kW) 1 5 Hex. socket head cap screw M 1 0 x 80 DIN 91 2-8.8
1 Flexible coupling disc Hex. nut M 1 0 DIN 934
2 Shim 1 7 DIN 933 Contact washer A 1 0
3 Hexagon head bolt M 1 6 x 55 DIN 931 -8.8 VP 1 6 Circlip 1 1 0 x 4 DIN 472
4 Output shaft 1 7 Engine pulley
5 Parallel key A 1 3 x 9 x 65 1 8 Cover plate
6 Deep-groove ball bearing 631 0-2RS/C4 DIN 625 1 9 Washer 37 DIN 1 25
7 Hex. socket head cap screw M 1 0 x 70 DIN 91 2-8.8 20 Castellated nut M 36 x 1 .5 DIN 935
Hex. nut M 1 0 x 70 DIN 934 21 Cotter pin 6.3 x 56 DIN 94
Contact washer A 1 0 22 Drive belt pulley (combines with air conditioning only)
8 Detent edged ring Vskz 1 0 23 Detent edged ring Vskz 1 0
9 Hex. socket head cap screw M 1 0 x 55 DIN 91 2-8.8 (combines with air conditioning only)
1 0 Hex. socket head cap screw M 1 0 x 90 DIN 91 2-8.8 24 Hex. socket head cap screw M 1 0 x 70
Hex. nut M 1 0 DIN 934 (combines with air conditioning only)
1 1 Spacer (Fig. 30)
1 2 Bushing
7. 1 4 DO 21 8 - 202 MEGA
Engine and Drives
6 16 5 17
18
11 19
12
21
20
22
31
[I]
DOMINATOR 203 MEGA 5 Insert parallel key (5) and push on engine pulley (1 7).
Install cover plate (1 8) and washer (1 9) on the shaft
PERKINS 1 006.6 T and tighten castellated nut (20) to a torque of 550 Nm.
1 Ball bearing (6) must be heated before installation. Tighten the nut until cotter pin (21 ) can be inserted.
Heat the bearing using a hot plate or similar 6 On combines with air conditioning, install belt pulley
heater to approx. 80 ° C and quickly push the (22).
bearing onto the bearing seat until it is approx.
2.5 mm (dimension X) from the shaft shoulder. (Figs. 30 and 31 )
2 Bolt flexible coupling disc to the flange of engine output
shaft (4) using three self-locking hexagon head bolts
(3) M 1 6 x 55 DIN 931 VP (Verbus-Plus).
Tighten the hexagon head bolts to a torque of 21 0 Nm.
Screw on hex. nuts (20) and also tighten to 21 0 Nm.
CAUT ION! When tightening the hex. nuts, be sure to

3 Position spacer (1 1 ) with bushing (1 2) on the ball of the
engine output shaft and bolt the spacer with flexible
coupling disc (1 ) to the engine output shaft using three
self-locking hexagon head bolts (3) M 1 6 x 55 DIN 931
VP (Verbus-Plus). Tighten the hexagon head bolts to a
torque of 21 0 Nm.
4 Push on engine output shaft housing (1 4) and bolt to
the engine all round. Fit circlip (1 6). A slight clearance
must be left between circlip and bearing outer race.
DO 21 8 - 202 MEGA 7. 1 5
Engine and Drives
Install the hydraulic tank assembly.

Install the idler pulley complete with shaft in the clutch bell
housing.
(Fig. 32)
32
Fit drive belt (2) and install spring-loaded cylinder (Z).

(Fig. 33)
33
Fit the drive belt for the hydraulic pump.

Tension the pump at the adjusting screws and secure with
three hexagon head bolts.
(Fig. 34)
34
On combines with compressor-type air conditioning system,

install the compressor and lock the adjusting ring.
Never disconnect the refrigerant hoses. Install
the compressor so that the refrigerant hoses are
not kinked.
Bolt on the guards.
(Fig. 35)
35
7. 1 6 DO 21 8 - 202 MEGA
Engine and Drives
Adjusting hydraulic pump

If the combine does not come to an absolute standstill when
the ground travel lever is in position 0, the hydraulic pump
must be adjusted at the slots in the retarder for Bowden
cable (C).
Ensure that the thread is still screwed at least 6 mm into the
yoke.
(Figs. 36 and 37)
Sauer-system
37
Removing radiator rotary screen drive

Remove the exhaust hose of the radiator chaff screen
cleaner.
(Fig. 38)
Unbolt the sealing plate with wiper under the radiator

screen.
(Fig. 39)
39
DO 21 8 - 202 MEGA 7. 1 7
Engine and Drives
Swing back the jockey pulley to relieve the drive belt tension
and remove the drive belt.
(Fig. 40)
� 40
Relieve the spring-loaded cylinder for the tension of the

inner drive belt and remove the drive belt.
(Fig. 41 )
41
Remove strap (23) from jockey pulley support (1 0).

Unbolt bracket (22) from the bearing tube.
Unscrew self-locking nut (4) from the shaft and remove the
pulley.
Pull drive belt pulley (6) from the shaft and remove the
woodruff key.
(Fig. 42)
42
7. 1 8 DO 21 8 - 202 MEGA
Engine and Drives
Remove the two inner screws M 1 0 x 25 SB securing the

bearing tube.
(Fig. 43)
43
Remove the two outer screws M 1 0 x 25 SB securing the

bearing tube.
Pull out the bearing tube with mounted shaft from under the
radiator.
(Fig. 44)
44
DO 21 8 - 202 MEGA 7. 1 9
Engine and Drives
/ --:::- .,;:::,,-- - "'

,,
- _...._
', \
� ---
/ /
I I /
I \
I \
/ / \ \
I \ \
I
I/ /T''i I I
I
\l 1 /
I I ~ ; /
I \ ; /
\ , _ _,,, I
\ I
\ I
- - 2: "'-,- - ,,/
I
I
I
I
45
Drive for radiator rotary screen dismantled: 22 Bracket

23 Strap
1 Sealing washer 24 Cotter pin 3.2 x 22 DIN 92
2 Bolt 1 2 G 6 x 30 x 50 DIN 1 445 25 Threaded yoke
3 Woodruff key 5 x 7.5 DIN 6888 26 Bushing
4 Self-locking nut Vm 1 6 x 1 .5 27 Washer
5 Washer 1 7 DIN 1 25 28 Pressure spring
6 Drive belt pulley D 1 43.6 29 Hex. nut M 1 0 DIN 934
7 Washer 1 7 x 26 x 3 30 Tension spring
8 Circlip 42 x 1 . 75 DIN 472 31 Detent plate
9 Angular contact ball bearing 3004 2 RS 32 Bolt
1O Jockey pulley support 33 Circlip 1 2 x 1 DIN 471
11 Bushing 34 Hex. nut M 1 2 DIN 934
12 Deep-groove ball bearing 6004 2 RS DIN 625 35 Contact washer A 1 0
13 Shaft 36 Jockey pulley assembly
14 Bearing tube Bolt
15 Contact washer S 1 0 Circlip 47 x 1 . 75 DIN 472
16 Hexagon head bolt M 1 0 x 25 DIN 933-8.8 SB Deep-groove ball bearing 6204 RS DIN 625
17 Jockey pulley support Circlip 20 x 1 .2 DIN 471
18 Drive belt pulley D 1 08.6 Jockey pulley
19 Jockey pulley assembly 37 Drive belt
Circlip 37 x 1 .5 DIN 472 38 Drive belt
Jockey pulley 39 Drive belt pulley
Deep-groove ball bearing 6301 2 RS DIN 625 40 Detent edged ring Vskz 1 O
20 Hex. nut M 1 0 DIN 934 41 Hex. socket head cap screw M 1 0 x 45 DIN 91 2
21 Contact washer A 1 0 (Fig. 45)
7.20 DO 21 8 - 202 MEGA

Engine and Drives
Installing radiator rotary screen drive
1 . Insert shaft (1 3) into bearing tube (1 4). Centre the shaft

and push on bearing (1 2). Push bushing (1 1 ) onto the
shaft.
2. Preassemble jockey pulley supports (1 0 and 1 7) with
bearings (9) and circlips (8). Push preassembled jockey
pulley supports onto the shaft.
3. Lift the bearing tube from the left under the radiator
screen into the combine and secure with hex. head bolts
(1 6).
4. Fit washer (7) on both sides of the combine. Insert
woodruff key (3) and push on drive belt pulleys (6 and
1 8). Screw on self-locking nut (4) with washer (5) and
tighten the nut to a torque of 65 Nm.
5. Fit jockey pulleys (1 9 and 36). Hook in tension spring
(30) on the right-hand side. Install spring-loaded cylinder
on the left-hand side. Fit the drive belt and adjust the
double springs with nuts (M) so that a distance (X) of 45
mm is obtained. After adjustment, lock the nuts.
6. Fit the drive belt on the right-hand side.
7. Install the sealing plate with wiper and exhaust hose.
(Figs. 38 to 46)
46
Removing radiator rotary screen

cleaner.
(Fig. 47)

screen.
(Fig. 48)
48
DO 21 8 - 202 MEGA 7.21

Engine and Drives
� 49
On combines with air conditioning, unbolt the bracket and

support for the mounting of the condenser. Pull down the
condenser.
The condenser is attached to the inlet hoses. Tie
these up with a rope so that they are not
damaged. The hoses must not be disconnected
as otherwise the refrigerant would escape.
DANGER OF ACCIDENTS!
50
Drive the roll pin out of the shaft.

(Fig. 50)
Pull the rotor with the shaft out of the bearings in the rear
panel.
(Fig. 51 )
7.22 DO 21 8 - 202 MEGA

Engine and Drives
52
Radiator rotary screen dismantled: 24 Grub screw M 8 x 20 DIN 933

25 Lock collar
1 Rear panel 26 Sheet metal flange
2 Contact washer A 6 � 27 Lock collar bearing Pea 206
3 Hexagon head bolt M 6 x 20 DIN 933 28 Retaining plate (for chaff screen cleaner)
4 Self-locking nut VM 8 29 Hexagon head bolt M 8 x 20 DIN 933
5 Sealing washer Hex. nut M 8 DIN 934
6 Slotted mushroom head screw M 8 x 35 Contact washer B 8
Hex. nut M 8 DIN 934 30 Deflector plate (for chaff screen cleaner)
Contact washer A 8
31 Slotted mushroom head screw M 8 x 1 6
7 Strut
8 Gas pressure spring Hex. nut M 8 DIN 934
9 Hexagon head bolt M 8 x 40 DIN 933 Contact washer A 8
10 Roll pin DIN 1 481 32 Cover plate (not with chaff screen cleaner)
11 Circlip 30 x 1 .5 DIN 471 33 Edge guard
12 Back-up washer S 30 x 42 DIN 988 34 Draftex profile
13 Hexagon head bolt M 8 x 40 DIN 933 35 Draftex profile
14 Contact washer B 8 36 Slotted mushroom head screw M 1 0 x 20 x 1 2 DIN 603
15 Hex. nut M 8 DIN 934 Hex. nut M 1 0 DIN 934
16 Hexagon head bolt M 8 x 25 DIN 933 Contact washer A 1 0
Contact washer A 8 37 Locking pin
Hex. nut M 8 38 Sealing profile
17 Clamp (for chaff screen cleaner) 39 Sealing plate
18 Sealing brush 40 Hinge
19 Rotor 41 Hexagon head bolt M 8 x 25 DIN 933
20 Lock washer Hex. nut M 8 DIN 934
21 Locking pin 42 Bracket (on OM 366 LA from Serial No. .... )
22 Shaft 43 Baffle plate (on OM 366 LA from Serial No. .... )
23 Flanged ball bearing assembly (Fig. 52)
DO 21 8 - 202 MEGA 7.23

Engine and Drives
1 . Push flanged ball bearing (23) onto the shaft.

Push on back-up washer (1 2) and fit circlip (1 1 ).
2. Push shaft with bearing into the rotor and bolt the sheet
metal flange of the bearing to the rotor.
3. Push the outer bearing with sheet metal flange onto the
shaft and bolt the sheet metal flange to the rotor.
4. Position the shaft so that back-up washer (1 2) is firmly
up against the inner bearing. Mount the lock collars in
the direction of rotation of the shaft and secure with the
grub screws.
[I]
On combines with radiator chaff screen cleaner, install
deflector and retaining plate on the shaft and align with
the wiper of the cleaner fan. Fasten the clamp on the
shaft.
� 6 Push the preassembled rotor into the rear panel and
secure the shaft with a roll pin. Bolt on the bracket with
the condenser again.
7. Install the sealing plate and connect the hose of the
[I]
cleaner fan.
(Figs. 47 to 53)
�
Removing radiator
cleaner.
(Fig. 53)

screen.
(Fig. 54)
54
7.24 DO 21 8 - 202 MEGA

Engine and Drives
(Fig. 55)
Remove the flap under the radiator rotary screen by

unbolting the struts on the left and right from the rear panel
of the radiator screen. Remove the bolts on the side and
take off the flap.
55
Remove the shock absorbers of the radiator screen rear

panel.
Remove radiator grille (B).
(Fig. 56)
56
Disconnect the hoses from the hydraulic oil cooler and

tightly plug the ends of the hoses and the connections on
the oil cooler with dust caps or plugs.
(Fig. 57)
57
On combines with air conditioning, the radiator screen can

be placed on top of the engine so that the air conditioning
system does not have to be evacuated.
Never disconnect the hoses of the air
•
conditioning system as otherwise the refrigerant
would escape. DANGER OF ACCIDENTS!
DO 21 8 - 202 MEGA 7.25

Engine and Drives
Remove the bolts at (A and B) and remove the radiator

grille.
(Figs. 58 and 59)
58
59
Disconnect the hoses (S) at the oil cooler for the hydrostatic
ground drive and collect the hydraulic oil (approx. 6 litres) in
a suitable container. Tightly plug the ends of the hoses and
the connections on the oil cooler with dust caps or plugs.
Remove the circlips at top left and right on the oil cooler
bracket.
Release the lock pins and pull out the oil cooler.
(Fig. 60)
Remove the bolts at (D) and take off the air cowl.
(Fig. 61 )
61
7.26 DO 21 8 - 202 MEGA

Engine and Drives
Drain the coolant and collect in a suitable container.

Unbolt upper strut (S).
Disconnect hose (A) for the expansion tank.
Disconnect radiator hoses (K).
(Fig. 62)
62
Disconnect the PVC hose from the water tap.

Unscrew the buffer under the radiator and remove the
radiator.
(Fig. 63)
63
Installing radiator
1 . When installing the radiator, inspect all coolant hoses
and replace, if necessary. The coolant and air intake
hoses must be replaced every 2 years.
2. Ensure that the frame, grilles and bellows are seated
securely.
3. Secure all connections tightly and carry out a test run to
check for leaks.
4. Top up the coolant and check the corrosion
inhibitor/antifreeze concentration (50% corrosion
inhibitor/antifreeze and 50% water).
Corrosion inhibitor (with or without antifreeze) should be �
�
0
added to the coolant even in warm countries where
there is no risk of frost. This helps to protect the engine.
CAUTIONI In hot countries, the percentage of corrosion

inhibitor/antifreeze should not exceed 50% as otherwise
the cooling efficiency will be impaired.
5. Top up hydraulic oil for the hydrostatic ground drive and
6
breathe the system.
\I/
_x_
DO 21 8 - 202 MEGA 7.27

Engine and Drives
Removing oil cooler for hydrostatic ground drive

system
Disconnect the hydraulic lines above the panelling at
connectors (A) and tightly plug the ends of the pipes and
hoses with dust caps or plugs.
(Fig. 64)
Swing the rotary screen upwards. Loosen lock (V) at the

bottom of the oil cooler.
Remove the two circlips at the top on both sides at (1 ) and
loosen one of the brackets slightly.
(Fig. 65)
65
Remove oil cooler (K) to one side.

(Fig. 66)
66
Installing oil cooler for hydrostatic ground drive

system
Securely tighten all hydraulic line connections and check
the connections for leaks during the test run.
If the hydraulic oil had been drained, refill with hydraulic oil
and breathe the ground drive system.
7.28 DO 21 8 - 202 MEGA

Engine and Drives
CUTTERBAR AND THRESHING MECHANISM

DRIVE
Removing hydraulic cutterbar clutch

Remove guard (S) on the left-hand side.
(Fig. 67)
Unbolt oil inlet assembly with hydraulic hose.

(Fig. 68)
68
Remove slotted nut using CLAAS special tool,

Part No. 1 81 809.0.
(Fig. 69)
Remove hollow cylinder together with the cylinder from the

hydraulic piston.
During removal, use centering adapter 1 81 909. 1 .
(Fig. 70)
70
DO 21 8 - 202 MEGA 7.29

Engine and Drives
Remove the Belleville springs from the shaft.

(Fig. 71 )
71
Remove the hex. socket head cap screws. Remove

mounting ring and hydraulic piston.
(Fig. 72)
72
Unbolt V-belt pulley and remove the moveable disc from the
clutch.
(Fig. 73)
73
Pull friction ring (R) only approx. halfway out of

clutch housing, then place adhesive tape around
the segments to hold them together. Finally
remove the friction ring as a complete unit.
If the segments of the friction ring are to be re-used, they
must not be mixed up. Mark each segment for identification
during removal. If a new friction ring is used, the segments
are numbered in the order in which they are to be
assembled.
Screw M 1 6 hexagon head bolt with retaining washer out of
the front end of the shaft.
(Fig. 74)
74
7.30 DO 21 8 - 202 MEGA

Engine and Drives
The clutch hub is clamped on the shaft with cones.

Select a tube with an inside diameter larger than the
locating collar on the clutch hub and loosen the cone with a
short sharp blow.
(Fig. 75)
75
Remove clutch hub with cones from the shaft.

Pull off the cutterbar drive pulley using a three-arm puller.
(Fig. 76)
76
DO 21 8 - 202 MEGA 7.31

Engine and Drives
®
@-
77
Cutterbar clutch cylinder dismantled: 24 Drive pulley

25 V-belt
1 Belleville springs 26 Back-up washer 40 x 50 x 2.5 DIN 988
2 Cylinder 27 Cone D 40
.
3 Back-up ring 28 Clutch assembly
4 O-ring 40.2 x 3 88 Nbr 1 56 29 Hub
5 O-ring Nbr 70 .
3o Friction ring
6 Wiper seal .
31 Pressure_ spring
7 Piston 32 Inner spring_
8 Back-up ring 33 Moveable disc
9 Slotted nut M 35 x 1 . 5 DIN 70852 34 Parallel key A 1 2 x 8 x 45 DIN 6885
10 Oil inlet assem 35 Washer
11 Circlip I 1 2 x 1 �rN 472 36 Circlip 1 6 DIN 1
12 Stepped washer 37 Hexagon head ::it M 1 6 x 40 - 38.8 DIN 933
13 Seal b It pulley D 274
14
15
Male adapter
Stop washer
;!
40
��r�ng washer 8 DIN 79
Hex. socket head cap s!�w M 8 x 25 DIN 91 2 - 8,8
16 Circlip A 1 0 x 1 DIN 471 41 Hydraulic �iston
.
17 Deep-groove ball bearing 6000 z DIN 625 42 Mounting ring
18 Spacer ring 43 Spring
· washer 8 DIN 7980
19 Circlip I 26 x 1 ·2 DIN 472 44 Hex. socket head cap screw M 8 x 35 DIN 91 2 - 1 0. 9
20 Oil inlet 45 V-belt
21 Spacer ring
22 Dee�-groove ball bearing 6208 RS DIN 625 (Fig. 77)
23 Circhp I 80 x 2. 5 DIN 472
7.32 DO 21 8 - 202 MEGA

Engine and Drives
37 44 36 34 38 33 32 30 22 2 1
6
6
3
4
7 ----__::::j��
10
9
8
3
4
1
2
40 27 3 1 26 23 24
78
Assem bling hydraulic cutterbar clutch

1 . Insert deep-groove ball bearing (22) into drive pulley
(24) and fit back-up washer (26) and circlip (23).
2. Drive spacer ring (21 ) and drive pulley assembly onto
the shaft up to the stop.
Apply semi-fluid gear lubricant G 00 DIN 51 502 (41 1
423.0) to all cones, the corresponding tapered seats
and the insides of the hubs before assembly.
DO 21 8 - 202 MEGA 7.33

Engine and Drives
3. Fit clutch hub (29) with cone (27) and parallel key (34),
screw in hexagon head bolt (37) with circlip (36) and
washer (35) and tighten to a torque of 1 80 Nm.
4. Place the segments of friction ring (30) in numerical
order around the inner spring and apply adhesive tape
around the segments to hold them together. Insert the
friction ring into the hub and remove the adhesive tape.
5. Insert all pressure springs (31 ) and fit moveable disc
(33). Bolt on V-belt pulley (38) with hex. socket head
cap screws (40). Screw on hydraulic piston (41 ) and
mounting ring (42) with hex. socket head cap screws
(44).
6. Install O-rings and back-up rings in cylinder (2) and
piston (7) as shown in the sketch. Install Belleville
springs (1 ), cylinder and piston.
CAUT IONI Ensure that all edges are smooth and

deburred to avoid the risk of damaging the O-rings.
7. Install slotted nuts (9) and oil inlet assembly (1 0).

8. Bolt on jockey pulley (R) and guard (S). Connect oil
supply line (0).
(Figs. 67 to 78)
Removing threshing mechanism drive pulley

Remove hydraulic cutterbar clutch.
Remove spacer ring and unbolt power band belt (8).
(Fig. 79)
7.34 DO 21 8 - 202 MEGA

Engine and Drives
Using a block-ended tube (S), loosen the cone in the

threshing mechanism drive pulley with a short, sharp blow.
The inside diameter of the tube must be larger than the
diameter of the cone to prevent the cone being damaged.
(Fig. 80)
80
Remove the cone and pull off the threshing mechanism

drive pulley.
(Fig. 81 )
81
Insta l l i n g threshing mechanism drive pul ley

Apply semi-fluid gear lubricant G 00 DIN 51 502
$
d
(41 1 423.0) to all cones, the corresponding tapered
seats and the insides of the hubs before assembly.
1 . Install threshing mechanism drive pulley (H) with cones s
(K) and parallel key (P).
2. Push on spacer ring (D) and spacer tube (R) 40.2 x
48.3 x 96 (629 1 76.0). Push on lock washer (C) and
tighten bolt (S) to a torque of 1 80 Nm.
3. Unscrew bolt (S) and remove tube (R). Push rear cone
for the hub of the hydraulic cutterbar clutch or cutterbar
drive pulley onto the shaft up to the spacer ring. Fit hub 82
or washer with front cone. Screw in hexagon head bolt
(S) with spring lock washer and lock washer and
tighten to a torque of 1 80 Nm.
4. Fit belt and install power band belt.
Adjust threshing mechanism drive and cutterbar drive
according to the adjustment instructions.
(Fig. 82)
�
DO 21 8 - 202 MEGA 7.35

Engine and Drives
83
ADJUSTING THRESHING MECHANISM DRIVE
Carry out adjustment only with the engine

stopped 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.
The threshing mechanism drive is thus disengaged via
jockey pulley (S).
When the threshing mechanism drive is engaged the piston
surface, port (K), is also pressurised with 20 bar. With the
pressure now on the larger piston surface, the piston rod is
extended and tensions the drive belt with jockey pulley (S).
Adjusting the belt guide:
Secure the belt guides at points (A, B, C and D) so that with
the belt tensioned, distance (Y) between the back of the belt
and the belt guides is 5 to 7 mm over the complete length.
Adjust the belt guide at (E) so that, with the belt tensioned,
the distance between the back of the belt and the guide
is 7 ± 2 mm.
(Fig. 83)
7.36 DO 21 8 - 202 MEGA

Engine and Drives
84
ADJUSTING THRESHING DRUM DRIVE

Threshing drum drive with intermediate drive

Adjust spring-loaded cylinder (F):
Loosen lock nut (1 ) and adjust cylinder tube (2) so that
distance (X) with the lock nut tightened is 30 mm.
(Fig. 84)
DO 21 8 - 202 MEGA 7.37

Engine and Drives
85
ADJUSTING ACCELERATOR DRIVE


Loosen lock nut (1 ) and adjust cylinder tube (2) so that
distance (X) with the lock nut tightened is 1 38 mm.
(Fig. 85)
7.38 DO 21 8 - 202 MEGA

Engine and Drives
86
ADJUSTING CUTTERBAR DRIVE
.Lil_
� Carry out adjustment only with the engine
1 . Adjust jockey pulley (A) so that the angle (Y) of jockey

pulley arm (H) is 0 ° to 1 0 ° .
2. Loosen lock nut (1 ) and adjust spring-loaded cylinder
(F) at cylinder tube (2) so that distance (X) with the lock
nut tightened is 75 mm.
(Fig. 86)
DO 21 8 - 202 MEGA 7.39

Engine and Drives
.-R
87
ADJUSTING GRAIN TANK UNLOADING AUGER

DRIVE BELT CLUTCH

When the engine is running, a hydraulic
pressure of 20 bar is exerted on the ring surface,
port (R), of low-pressure hydraulic cylinder (Z).
The grain tank unloading auger drive is thus disengaged via
jockey pulley (S).
When the grain tank unloading auger drive is engaged, the
piston surface, port (K), is also pressurised with 20 bar. With
the pressure now on the larger piston surface, the piston rod
is extended and tensions the drive belt with jockey pulley
(S).
Adjusting the belt guide:
Secure the belt guides (A, B, and C) at points (1 , 2, 3 and 4)
so that, with the belt tensioned, the distance (Y) between
the back of the belt and the belt guides is 5 to 7 mm over
the complete length.
After each adjustment, perform a test run, recheck all
dimensions and correct, if necessary.
(Fig. 87)
7.40 DO 21 8 - 202 MEGA

Engine and Drives
88
ADJUSTING HYDROSTATIC GROUND DRIVE
.Lil_
� Carry out adjustment only with the engine
Tension power band belt:

Loosen clamping screws (K) and tension power band belt
(V) at adjusting screw (S) so that jockey pulley (R) deflects
the power band belt at (Y) by 30 + 1 0 mm.
The hydraulic pump drive shaft can be aligned with the
motor output pulley with adjusting screws (E).
Loosen lock nut (1 ) and adjust cylinder tube (2) with a drifter
until distance (X) between stop washer (3) and slide ring (4)
with lock nut (1 ) tightened is 30 mm. Ensure that plastic
5
block (5) contacts stop (6) stress-free. Adjust the

-3
spring-loaded cylinder accordingly.

After tensioning the power band belt, ensure that the
hydraulic hoses are not strained and do not rub.
(Figs. 88 and 89)
DO 21 8 - 202 MEGA 7.41

Engine and Drives
THRESHING DRUM VARIABLE SPEED DRIVE
Removing and fitting threshing drum variable

speed belt
Threshing drum drive with intermediate drive:
With the engine running and threshing
mechanism switched on, run the variable speed
drive up to maximum revs. Switch off the
threshing mechanism, switch off the engine and
remove the ignition key.
Remove guards (S and T).
(Fig. 90)
Remove suction blower drive belt.

Remove straw chopper intermediate drive belt.
Screw two hexagon head bolts (3) BM 1 2 x 1 80
DIN 564-8.8, Part No. 236 302.0, through the tapped bores
of the front pulley halves until they contact the rear pulley
half to hold the variable speed drive pulley halves apart.
With the engine switched off, move the hydraulic drum
speed control lever to "slow" and at the same time press the
halves of the hydraulically adjustable variable speed pulley
apart. Finally remove belt (R) from both pulleys.
Disconnect the hydraulic hose from hydraulic cylinder (Z).
Remove the speed control belt.
91
After fitting the speed control belt again, pull the belt firmly
between the pulley halves and remove the hexagon head
bolts from the tapped bores. Reconnect the hydraulic hose
and install the guards again.
NOTE: During prolonged standstills, protect the surfaces of

the speed control pulleys against corrosion.
Before fitting the speed control belts, clean the surfaces of

the pulleys, then install guards (S and T) again.
(Figs. 90 and 91 )
7.42 DO 21 8 - 202 MEGA

Engine and Drives
Removing spring-loaded variable speed pulley

assembly
Remove the threshing d rum variable speed belt, unscrew
the hexagon head bolt for axial secu ri ng of the variable
speed pul ley assembly and remove the bolt together with
the retai ning ri ng and spring lock washer.
(Fig. 92)
I nsert a hexagon head bolt M 1 6 x 3 00 th rough the tapped

bore in the th rust plate, press the hub of the variable speed
pulley off the parallel key and remove the variable speed
pulley assembly.
For safety, a hexagon head bolt M 1 6 x 260 can be screwed
i nto the shaft so that the variable speed pul ley assembly
does not fall down .
(Fig. 93)
93
Dismantling spring-loaded variable speed pulley

assembly
Never remove the countersunk head screws
from the mounting flange before the pressure
spring has been blocked with the special
tool. - Danger of accidents!
With the pressu re spring blocked, remove all the
cou ntersunk head screws.
(Fig. 94)
Back off the lever nut to completely relieve the pressu re

spring. The variable speed pul ley assembly can now be
safely disassembled and any damaged parts replaced.
(Fig. 95)
95
DO 218 - 202 MEGA 7.43

Engine and Drives
Special tool:
1 Lever nut - Part No. 1 81 880.0
3 Axial grooved ball bearing 51 305 DIN 71 1 -
Part No. 235 983.0
4 Locator tool - Part No. 1 81 896. 0
5 Centering washer - Part No. 1 81 879. 0
6 Sleeve - Part No. 1 81 881 . 0
(Fig. 96)
96
xv
97
Spring-loaded threshing drum variable speed pulley Protective cap
L!J
assembly dismantled: Spring washer 6 DIN 1 28 (3 used)
Hexagon head bolt M 6 x 1 2 DIN 933 - 8.8 (3 used)
1 Thrust ring � ��
28 Retaining ring
2 Parallel key A 1 2 x 8 x 1 1 0 DIN 6885 29 Spring washer 1 6 DIN 1 28
3 Parallel key 30 Hexagon head bolt M 1 6 x 55 DIN 931 - 8.8
4 Hex. socket head cap screw M 6 x 1 3.8 - 8.8
5 Sliding bushing X Fixed pulley half
6 Sliding rail 1 .8 mm / 2.3 mm / 2.8 mm Y Moveable pulley half
7 Notched dowel 6 x 20 DIN 1 472 Z Pressure spring with welded thrust plate
8 Felt strip 5 x 7 mm X, Y and Z cannot be replaced individually
9 Thrust washer (2 used)
10 Bearing bushing (2 used) (Fig. 97)
11 Circlip SB 63 (2 used)
12 Roll pin 5 x 30 DIN 1 481
13 Sealing washer
14 Plug M 1 2 x 1 .5 DIN 906
15 Roll pin 6 x 1 6 DIN 1 481 (6 used)
16 Sliding shoe
17 Roll pin 6 x 80 DIN 7346 (3 used)
18 Cover
19 Roll pin 1 0 x 1 4 DIN 1 481
20 Grease nipple H 1 .6 x 1 (6 used)
21 Countersunk head screw M 1 0 x 30 (6 used)
22 Shim 56 x 72 x 0.3/0.5 DIN 988
23 Thrust plate
24 Hexagon head bolt M 8 x 20
DIN 933 - 8.8 Verbus Plus (9 used)
7.44 DO 21 8 - 202 MEGA

Engine and Drives
Assem bling spring-loaded variable speed pulley

assembly
In order to centre parallel key (3), first drive a roll pin
(F, 6 mm dia., approx. 30 mm long) through the parallel key
into the bore of the groove.
(Fig. 98)
Place a square bar, flattened shaft or similar tool (E) onto

parallel key (3). Screw a hexagon head bolt M 1 2 x 1 .5 with
full-shaft thread in at (S) until it contacts this assembly aid.
Now alternately tighten bolt (S) and hammer the assembly
aid at (E) until the parallel key is pressed completely into
the groove.
I
After installing the parallel key, drive out roll pin (F) towards
the ; ns;de. Coat paral lel key and notched dowel (7) and hex.
// I
socket head cap screws (4) with liquid locking compound
(Casco 1 1 8 / Loctite 75) and tighten the hex. socket head •
cap screws to a torque of 1 0 Nm.
(Figs. 97 and 99)
99
Determine backlash:
Thoroughly clean both variable speed pulleys.
Liberally oil sliding bushing (5) and sliding rail (6) , install and
assemble the variable speed pulley halves.
Make a mark opposite one another on each variable speed
pulley half, then turn the variable speed pulley halves in
opposite directions and measure the backlash at the outer
circumference of the pulleys (distance between the two
marks).
When the variable speed pulley halves move easily, the
backlash should be as small as possible. It must not exceed
1 mm.
1 00
If necessary, the next thicker sliding rail (6) must be used.
(Fig. 1 00)
DO 21 8 - 202 MEGA 7.45

Engine and Drives
Install roll pins (1 7) only in the lubrication bore of the grease

nipple marked (2).
NOTE: The slot of roll pins (1 7) must always face towards
the middle (M). This ensures that when greasing at grease
nipple (2), the grease can pass to the inner sliding surface.
See details C-D and G-H.
Drive in roll pin (1 9) for securing pressure spring plate (Z)

and cover (1 8).
Insert felt ring (8) in the moveable variable speed pulley half.
Liberally coat sliding bushing and sliding surface with a
good quality grease (e.g. Shell "Retinax A" or similar grade).
Completely pack the lubrication grooves and all grease
channels with grease.
Assemble variable speed pulley halves (X and Y), cover
(1 8) and pressure spring with pressure plate (Z) and turn so
that the corresponding bore is facing towards roll pin (1 9).
Screw in bolt (4) of the special tool to guide the pressure
plate.
(Figs. 97 and 1 02 )
Special tool:
1. Spindle - Part No. 1 81 877. 0

2. Lever nut - Part No. 1 81 880.0
3. Axial grooved ball bearing - Part No. 235 983. 0
4. Hexagon head bolt M 1 0 x 200 - Part No. 21 1 739. 0
5. Locator tool - Part No. 1 81 896.0
(Fig. 1 01 )
1 01
Now compress the pressure spring with the preloading

device (special tool). Bolt on pressure plate with
countersunk head screws (21 ) and tighten to a torque of
49 Nm.
(Figs. 97 and 1 01 )
7.46 DO 21 8 - 202 MEGA

Engine and Drives
X V
A- B
M 19
G-H E- F
1 02
DO 21 8 - 202 MEGA 7.47

Engine and Drives
Installing spring-loaded variable speed pulley

assembly
Mount a thrust washer (9) on the hub of pressure plate (23)
and push the pressure plate hub into the hub of the variable
speed pulley. Install the second thrust washer (9) and thrust
ring (1 ) on the rear side. Now measure the axial clearance
of the variable speed pulley on the thrust plate hub.
Permissible axial clearance: maximum= 0.6 mm
minimum = 0.2 mm
Compensate axial clearance of more than 0.6 mm by
inserting shims (22) at the front at (V).
Liberally coat pressure plate hub and variable speed pulley
hub with a good quality grease (e.g. Shell "Retinax A" or
similar grade). Assemble the variable speed pulley
assembly with pressure plate hub, the shims as required
and the bolted protective cap (25). Install parallel key (2) in
the threshing drum shaft. Push the complete variable speed
pulley assembly onto the threshing drum shaft, ensuring
that the rear thrust washer (9) does not slip off the hub and
become jammed. Secure the variable speed pulley
assembly with hexagon head bolt (30), spring washer (29)
and retaining ring (28).
NOTE: Install retaining ring with sharp edge facing towards

the collar.
Tightening torque for hexagon head bolt (30)= 1 80 Nm.

Fit the threshing drum variable speed control belt.
After complete assembly, grease the variable speed pulley
liberally at all the grease nipples, rotate a few times and
then grease again until all the grease channels are
completely filled with grease.
(Fig. 1 02)
Removing hydraulic variable speed pulley

assembly
Remove the threshing drum variable speed belt.
Unbolt hydraulic cylinder (H) and remove.
(Fig. 1 03)
7.48 DO 21 8 - 202 MEGA

Engine and Drives
Remove the hexagon head bolt securing the variable speed

pulley axially.
(Fig. 1 04)
1 04
Using a block-ended tube (S), loosen the cone in the

threshing mechanism drive pulley hub with a short, sharp
blow. The inside diameter of the tube must be larger than
the diameter of the cone to prevent the cone being
damaged and must have a slot in the area of the head of
the hex. socket head cap screw to secure the parallel key.
Remove the front cone.
(Fig. 1 05)
1 05
If the rear cone was not loosened during removal of the front
cone, the variable speed pulley assembly can be removed
using a puller (special tool).
Before installing the puller, screw locator bolt without
retaining ring into the shaft to prevent damage to the thread.
(Fig. 1 06)
1 06
Special tool:
1 Spindle - Part No. 1 81 801 . 1
2 Hex. nut M 1 6 DIN 934 - Part No. 236 1 73. 0
3 Washers 1 7 DIN 1 25 - Part No. 235 1 27.2
4 Puller bridge - Part No. 1 81 800. 0 8
5 Hexagon head bolt BM 1 2 x 1 80 ====I
DIN 564 - 8.8 - Part No. 236 302.0
6 Washer 1 3 x 30 x 3 - Part No. 236 844. 0 9 1'}
7 Puller plate - Part No. 1 81 803. 1
8 Hexagon head bolts M 1 6 x 75 T
DIN 933 - 8.8 - Part No. 237 379.0
9 Extension - Part No. 1 81 806. 0
1 0 Adapter with ball - Part No. 1 81 849. 0
(Fig. 1 07) 1 07
DO 21 8 - 202 MEGA 7.49

Engine and Drives
1 08
Hydraulic variable speed pulley assembly dismantled: 1 2 Countersunk head screw M 1 2 x 1 65

With intermediate drive 1 3 Cover
1 4 Contact washer A 8
1 Spacer ring 1 5 Hexagon head bolt M 8 x 20
2 Cone 1 6 Sealing washer
3 Parallel key A 1 4 x 9 x 90 DIN 6885 1 7 Lubrication line
4 Felt strip 1 8 Grease nipple As 6 x 1
5 Sliding bushing 1 9 Spacer
6 Hexagon head bolt M 6 x 1 2 DIN 933 20 Contact washer A 1 6
7 Contact washer A 6 21 Hexagon head bolt M 1 6 x 1 20
8 Cover 22 V-belt pulley
9 Grub screw M 8 x 1 2 23 Spring washer A 1 2 DIN 1 28
10 Bushing 24 Hexagon head bolt M 1 2 x 35 DIN 933
11 Shim (Fig. 1 08)
1 09
Hydraulic variable speed pulley assembly dismantled: 1 2 Bushing

Without intermediate drive 1 3 Cover
1 4 Shim 26 x 42 x 3
1 Spacer ring 1 5 Countersunk head cap screw M 1 2 x 1 65
2 Cone 1 6 Sealing washer
3 Parallel key A 1 4 x 9 x 90 DIN 6885 1 7 Lubrication line
4 Felt strip 1 8 Grease nipple H 1 .6 x 1
5 Sliding bushing 1 9 Contact washer A 8
6 Hexagon head bolt M 6 x 1 2 DIN 933 20 Hexagon head bolt M 8 x 1 6 DIN 933
7 Spring washer A 6 DIN 1 28 21 Cone
8 Cover 22 Washer
9 Cover disc 23 Contact washer A 1 6
10 Spring washer A 1 0 DIN 1 28 24 Head centering bolt M 1 6 x 60
11 Hexagon head bolt M 1 0 x 30 DIN 933 (Fig. 1 09)
7.50 DO 21 8 - 202 MEGA

Engine and Drives
Installing hydraulic threshing drum variable

speed pulley assembly
Apply semi-fluid gear lubricant G 00 DIN 51 502 (41 1
423.0) to all cones, the corresponding tapered seats
and the insides of the hubs before assembly.
Oil sliding bushing (5) and install in the variable speed
pulley.
Install cone (2) and parallel key (3) on the shaft.
Push the variable speed pulley assembly onto the shaft and
fit cone (2).
Bolt on spacer (1 9) or washer (22) with hexagon head bolt
M 1 6 x 1 20 or countersunk head cap screw (24) and tighten
to a torque of 1 80 Nm.
Fit the speed control belt and bolt on the guard.
(Figs. 1 08 and 1 09)
Removing threshing drum variable speed pulley

intermediate drive shaft
Remove the threshing drum variable speed belt.
Remove spring-loaded threshing drum variable speed
pulley.
Pull off the V-belt pulley using a three-arm puller.
(Fig. 1 1 0)
110
Unbolt the complete bearing unit with the shaft at the three
hexagon head bolts M 1 6 x 35.
(Fig. 1 1 1 )
111
DO 21 8 - 202 MEGA 7.51

Engine and Drives
112
1
Intermediate drive shaft dismantled: 13 Carrier
14 Grease nipple AM 8 x 1
1 Shaft 15 V-belt pulley
2 Bearing inner race 16 Hub
3 Bearing outer race 17 Parallel key A 1 2 x 8 1 50
4 Outer spacer ring
5 Circlip (Fig. 1 1 2)
6 Housing
7 Inner spacer ring
8 Bearing seal ring
9 Hexagon head bolt M 1 0 x 25 DIN 933-8.8 VP
10 Hexagon head bolt M 1 6 x 35 DIN 933-8.8
11 Plate
12 Spacer plate 2 x 1 90 x 220
Installing intermediate drive shaft

1 . Press one bearing inner race (2) onto the shaft.
2. Install circlip (5) in housing (6). Fit outer spacer ring (4)
and press both bearing outer races into the housing,
observing the correct installation position (detail E).
3. Push inner spacer ring (7) onto the shaft. Pull the
preassembled housing onto the shaft and pack space
(G) with multi-grade grease K2K, Part No. 41 1 056.0.
Press the second bearing inner race onto the shaft.
NOTE: The bearings may only be replaced complete with

outer race.
4. Completely pack space (F) with multi-grade grease K2K
to DIN 51 825, Part No. 41 1 056. 0 (approx. 1 80 g).
5. Coat surface (D) with sealing compound DELO-ML 5328
and screw on plate (1 1 ).
6. Pack space (H) with multi-grade grease K2K, Part No.
41 1 056.0, and fit bearing seal ring (8).
7. Bolt preassembled intermediate drive shaft to the
combine housing.
113
7.52 DO 21 8 - 202 MEGA

Engine and Drives
8. Preassemble hub (1 6) on V-belt pulley (1 5) with

hexagon head bolts (9) M 1 0 x 25 DIN 933-8.8 VP
(Verbus-Plus). Push preassembled V-belt pulley onto the
shaft.
9. Install spring-loaded threshing drum variable speed
pulley.
(Figs. 1 1 0 to 1 1 3)
Removing planetary gear unit

Unbolt guard (S) and strut (T).
(Fig. 1 1 4)
Remove the V-belt and unbolt strut (P).

Unscrew the drain plug and drain the transmission oil (1
litre). After draining the oil, screw in the plug again and
tighten securely.
(Fig. 1 1 5)
Unbolt hexagon head bolt M 1 6 x 45 from the end of the

shaft.
(Fig. 1 1 6)
116
DO 21 8 - 202 MEGA 7.53

Engine and Drives
Pull off the planetary gear unit with the special tool.
(Fig. 1 1 7)
Special tool:
1 Spindle - Part No. 1 81 801 . 1

2 Hexagon head bolt M 1 6 x 50
DIN 933 - 8.8 - Part No. 235 586.0
3 Washer 1 7 - Part No. 235 1 27.2
5 Hexagon head bolt M 1 0 x 25
DIN 933 - 8.8 - Part No. 21 5 521 .0
6 Washer 1 0.5 - Part No. 236 91 3.2
7 Puller plate - Part No. 1 81 935.2
8 Adapter with ball - Part No. 1 81 849. 0
(Fig. 1 1 8)
118
Dismantling planetary gear unit

Before dismantling the planetary gear unit, observe the
marks on the gearbox halves or make alignment marks.
Remove hexagon head bolts M 8 x 25. Screw two hexagon
---
head bolts into the thread of the upper gearbox half and
gradually press the two halves apart.
(Fig. 1 1 9)
119
Remove the balancing weight with O-ring and planetary

gear stage.
(Fig. 1 20)
1 20
7.54 DO 21 8 - 202 MEGA

Engine and Drives
Remove the cone and press the sun gear out of the
gearbox halves using a puller.
(Fig. 1 21 )
When pressing the cylindrical roller bearings out of the

gearbox halves, count and note the number of shims.
1 21
6
t-·-
1 22
Planetary gear unit dismantled: 25 Plug M 1 6 x 1 .5

26 Washer
1 Gearbox housing 27 Hexagon head bolt M 1 6 x 45 DIN 933
2 Deep-groove ball bearing 1 601 6 C4 DIN 625 28 O-ring 45 x 1 .5 - N DIN 3771
3 Cylindrical roller bearing Nj 2207 Ecma / C3 29 Torque arm
4 O-ring 65 x 3 - N DIN 3771 30 Tapered bolt
5 Balancing weight 31 Hexagon head bolt M 1 0 x 25
6 Hex. socket head cap screw M 6 x 1 2
7 Sun gear (Fig. 1 22)
8 Cone
9 Cylindrical roller bearing
10 Stepped sleeve
11 Circlip
12 Needle bearing 28 x 45 x 1 7 / 20
13 Sun gear
14 Deep-groove ball bearing 1 601 6 C4 DIN 625
15 Planetary gear stage
16 Cylindrical roller bearing Nj 2207 Ecma / C3
17 Shim
18 Shaft seal As 80 x 1 00 x 1 0 DIN 3760
19 Threaded stud
20 Gasket
21 Gearbox housing
22 Roll pin D 1 0 x 28 DIN 7979
23 Contact washer S 8
DO 21 8 - 202 MEGA 7.55

Engine and Drives
1 3 15 21 16 17
9
13
10
11
12
28
+++'1-- 2 7
��""1�
26
31
14
29
4 5
1 23
Assembling planetary gear unit

1 . Install circlip (1 1 ) and stepped sleeve (1 0) in sun
gear (1 3).
2. Press bearing outer race (9) into sun gear (1 3) so that
the inner race can be inserted from the outside.
Observe the correct installation position!
3. Coat threaded stud (1 9) with CASCO 1 1 8 and insert
into gearbox half (21 ).
7.56 DO 21 8 - 202 MEGA

Engine and Drives
4. Install the number and thickness of shims (1 7) found

during dismantling in gearbox half (21 ). Shrink
cylindrical roller bearing (1 6) and deep-groove ball
bearing (1 4) by deep-cooling in liquid nitrogen and
press into gearbox half (21 ). Do not leave the bearings
in the liquid nitrogen for more than 1 hour.
Dry the bearings immediately after shrinking and then
coat with Anticorit 03W, Part No. 241 680.0, in the
spray/rotation process to protect against corrosion.
5. Press preassembled sun gear with the special tool into
ct?
the gearbox half.
Coat shaft seal (1 8) with grease before installing.
d
6. Shrink cylindrical roller bearing (3) and deep-groove
ball bearing (2) by deep-cooling in liquid nitrogen and
press into gearbox half (1 ). Do not leave the bearings
in the liquid nitrogen for more than 1 hour.
Dry the bearings immediately after shrinking and then
coat with Anticorit 03W, Part No. 241 680.0, in the
spray/rotation process to protect against corrosion.
7. Press sun gear (7) with the special tool into gearbox
ct?
half (1 ).
Coat shaft seal (1 8) with grease before installing.
d
8. Uniformly heat the bearing inner races of cylindrical
roller bearings (3 and 1 6) to approx. 80 ° C and press
on planetary gear stage (1 5). Observe the correct
installation position!
9. Insert O-ring (4) and install the balancing weight.
1 24
1 0. Install cone (8) in sun gear (7). Align the marks on the
gearbox halves and ensure that the roll pins are
correctly aligned. Tighten hexagon head bolts (24)
evenly and cross-wise to a torque of 23 Nm. �
(Figs. 1 1 9 to 1 26)
1 25
Special tool:

2 Axial grooved ball bearing - Part No. 235 983. 0
3 Centering washer - Part No. 1 81 879. 0
4 Tube - ID 82 x 65 mm long
(Fig. 1 26)
1 26
DO 21 8 - 202 MEGA 7.57

Engine and Drives
Installing planetary gear unit

Push the planetary gear unit onto the flanged shaft and
secure in place using the special tool.
(Fig. 1 27)
Special tool:
Hexagon head bolt M 1 6 x 300 - Part No. 237 375. 1

2 Hex. nut M 1 6 - Part No. 244 059. 0
3 Axial grooved ball bearing - Part No. 1 77 899. 0
(Fig. 1 28)
I
1 28
Screw hexagon head bolt M 1 6 x 45 Verbus-Plus (replace

every time the bolt is loosened) into the end of the shaft with
washer (26) and tighten to a torque of 1 20 Nm.
(Fig. 1 29)
1 29
Pack centering cover of the torque arm with multi-grade

grease K2K to DIN 51 525, Part No. 41 1 056.0.
Bolt on the torque arm with 6 hexagon head bolts M 1 0 x 25
DIN 933 - 1 0.9 Verbus-Plus (replace every time the bolt is
loosened).
Tightening torque= 69 Nm
(Fig. 1 30)
7.58 DO 21 8 - 202 MEGA

Engine and Drives
Turn planetary gear unit so that the plug is at the top. Pour
in 1 litre of multi-grade transmission oil API-GL-4-1 40, Part
No. 201 654.0, and screw in the plug again. �
0
�
Bolt on strut (T).
Depending on the gear ratio, bolt torque arm (29) with 2
tapered bolts M 1 6, Part No. 628 700.2, to the gearbox
housing (n= 650 - 1 500 rpm) or to strut (T)
(n = 280 - 650 rpm).
Tightening torque= 1 20 Nm
(Figs. 1 31 and 1 32)
1 31
1 32
FAN VARIABLE SPEED MECHANISM
Removing and fitting fan speed control belt

With the combine engine running, run the fan up
to its highest speed. Switch off the threshing
mechanism, switch off the engine and remove
the ignition key.
Screw a hexagon head bolt (S) BM 1 2 x 80 DIN 564-8.8
(Part No. 236 301 . 0) into a tapped bore in the front fixed
pulley half until the rear moveable pulley half is blocked in
the open position.
With the combine engine switched off, turn on the ignition
and threshing mechanism. Then actuate the corresponding
rocker switch to adjust the fan speed to "slow'' and remove
the speed control belt from the pulleys.
NOTE: During prolonged standstills, protect the surfaces of

the speed control pulleys against corrosion.
Before fitting the speed control belts, clean the surfaces of

the pulleys.
(Fig. 1 33)
DO 21 8 - 202 MEGA 7.59

Engine and Drives
Removing upper variable speed pulley

(electrically adjustable)
Slacken the fan speed control belt and slip it off the lower
variable speed pulley.
Disconnect plug (1 ) and remove three hexagon head
bolts M 6 x 1 1 0.
(Fig. 1 34)
Remove the complete electric geared motor (G). Loosen the

lock nut behind back-up washer (S) and unscrew back-up
washer and lock nut.
(Fig. 1 35)
1 35
Remove the variable speed pulley half.

(Fig. 1 36)
1 36
Slacken and remove the V-belt of the fan intermediate drive

shaft.
Remove the circlip and pull off the V-belt pulley using a
puller.
(Fig. 1 37)
1 37
7.60 DO 21 8 - 202 MEGA

Engine and Drives
@)
I
1 38
Upper variable speed pulley and intermediate 1 7 Hexagon head bolt M 1 0 x 25 DIN 933
drive shaft dismantled: Contact washer A 1 0
Washer 1 0.5 DIN 1 25
1 Bracket with bearing journal 1 8 Cotter pin 4 x 22 DIN 94
2 Shim 1 9 Eyebolt
3 Bushing 20 Hex. nut M 1 2 DIN 934
4 Jockey pulley arm 21 Hexagon head bolt M 1 0 x 20 DIN 933
5 Back-up washer S 25 x 35 DIN 988 Contact washer A 1 0
6 Deep-groove ball bearing 6205-2RS DIN 625 22 Angle bracket
7 Hexagon head bolt M 8 x 80 DIN 931 -8.8 23 Hex. nut M 1 6 DIN 934
Contact washer A 8 24 Contact washer A 1 6
Washer 8.4 DIN 1 25 25 Washer 1 6.5 x 33 x 3
8 V-belt pulley 26 Shim
9 Variable speed pulley 27 Deep-groove ball bearing 6203-2RS DIN 625
10 Deep-groove ball bearing 6204-2RS DIN 625 28 Circlip 40 x 1 . 75 DIN 472
11 Circlip 20 x 1 .2 DIN 471 29 Jockey pulley
12 Sliding bushing 30 Spacer bushing
13 Variable speed pulley 31 Stud
15 Deep-groove ball bearing 6304-2RS DIN 625 (Fig. 1 38)
16 Hex. nut M 1 6 x 1 DIN 934
DO 21 8 - 202 MEGA 7.61

Engine and Drives
1 39
Electric fan speed control assembly dismantled: Up to Combine Serial No. ...
32 Back-up washer S 20 x 28 DIN 988
Shim 20 x 28 x 0.5 DIN 988
49 Driver
33 Thrust sleeve
50 Parallel key A 2 x 2 x 1 0 DIN 6885
34 Hex. nut M 1 6 x 1 DIN 934
51 Flange
35 Bushing
52 Seal ring
36 Back-up washer
53 Motor
37 Hexagon head bolt M 6 x 1 20 DIN 931
54 Cap
55 Cable strap
38 Spacer tube
56 Cap
39 Thrust collar
40 Hexagon head bolt M 6 x 60 DIN 931 From Combine Serial No. ....
Spring washer A 6 DIN 1 28 57 Quick connector
41 Clamping ring 58 Driver
42 Bushing 59 Hex. socket head cap screw
43 Axial washer As 3552 Detent edged ring Vskz 6
44 Needle bearing Axk 3552 60 Flange
45 Adjusting nut 61 Seal ring
46 Ring 62 Motor
63 Protective cap
64 Cable strap
(Fig. 1 39)
7.62 DO 21 8 - 202 MEGA

Engine and Drives
A B 33
Q
L
1 40
Installing fan variable speed pulleys
Upper pulley assembly:

Use washers 8.4 DIN 1 25 when bolting together the pulley
assembly at (7). The washers hold the bearing in its seat.
Install the pulley assembly.
DO 21 8 - 202 MEGA 7.63

Engine and Drives
When bolting on the pulley, adjust the bracket in the slots so

that gap (Q) between the upper and lower variable speed
pulley assemblies is
for 21 8 / 208 / 204 MEGA (Q) = 652 mm and
for 203 I 202 MEGA (Q)= 686.5 mm.
Install circlip (1 4) and deep-groove ball bearing (1 5) in
moving variable speed pulley half (1 3).
Push variable speed pulley half onto the hub of pulley half
(9) and adjust until gap (H) is
For 21 8 / 208 / 204 MEGA (H) = 32 mm and
For 203 I 202 MEGA (H)= 31 .5 mm (high fan speed
position).
Insert shims (32) at (B) to obtain the required gap (H).
Thrust sleeve (33) must contact (A) and (B) without
clearance, see detail (Y).
(Figs. 1 38 to 1 40)
39 40 41 45 46
1 41
7.64 DO 21 8 - 202 MEGA

Engine and Drives
Lower variable speed pulley assembly:
$
Assembling and installing electric fan speed
control Place a straightedge (L) against the lower, spring-loaded
d
1 . NOTE! Before assembly, coat all sliding surfaces, variable speed pulley. Now move the lower variable speed
shims, sealing washer and bearings with grease K2K pulley on the shaft until the distance at the top between the
to DIN 51 825, lithium-saponified multi-grade grease free straightedge (which is the extension of the lower pulley)
(e.g. Shell Alvania G2 or equivalent product). and the upper fixed pulley half (inner edge) is
2. Push seal ring (61 ) onto motor (62). Insert hexagon (E)= 43.5 mm (21 8 / 208 / 204 MEGA) or
head bolts (37) into bores of flange (60) and push (E)= 41 .5 mm (203 / 202 MEGA) plus shim thickness (F).
flange onto the shaft. Bolt flange to motor with three Now secure the spring-loaded variable speed pulley
hex. socket head cap screws (59). Tighten the screws assembly on the shaft.
3. Push driver (58) onto the shaft stub and secure with (Figs. 1 38 to 1 41 )
quick connector (57).
4. Push on ring (46) with axial washer, needle bearings
(43, 44) and adjusting nut (45). Install bushing (42) and
clamping ring (41 ) and secure with hexagon head bolts
(40).
5. Adjust variable speed pulley half (1 3) to gap
(H)= 32 mm (21 8 / 208 / 204 MEGA) or
(H) = 31 .5 mm (203 / 202 MEGA)
(high fan speed position)
6. Now screw on hex. nut (34) to obtain a stroke
(K)= 22. 1 mm (21 8 / 208 / 204 MEGA) or
(K)= 20. 1 mm (203 / 202 MEGA)
7. Push on back-up washer (36) until it contacts the hex.
nut. Position the back-up washer as shown in detail
(W) with the hole pattern to dimension (P)= 45 ° + 1 0 ° to
the horizontal and secure with hex. nut (34).
8. Fit flat connectors to one end of two cables. Make a
loop in the other cable end and connect one to the (+)
terminal and one to the (-) terminal of a 1 2 V battery.
Operate the electric geared motor by touching the
cables to the terminals of the motor. Check the correct
direction of rotation of the geared motor and correct, if
necessary, by reversing the connections.
9. Coat the thread of thrust collar (39) with grease K2K to
DIN 51 825, lithium-saponified multi-grade grease (e.g.
Shell Alvania G2 or equivalent product) and hold
@]
against adjusting nut (45) so that the two thrust pins (J)
engage in the holes of back-up washer (36) when the
motor is tilted at an angle of (R)= 1 5 ° + 1 0 ° to the
horizontal (see detail (W). Screw in thrust collar
completely in this position.
1 0. Now push on spacer tube (38) and bolt the electric
geared motor complete with the hexagon head bolts
and nuts (37) to back-up washer (36). Ensure that the
motor is in the correct position as shown in detail (W).
Push on the flat connector housing.
DO 21 8 - 202 MEGA 7.65

Engine and Drives
y
A
Removing lower variable speed pulley
Slacken fan variable speed belt and slip belt off pulley.
'V
Remove guard and fan intake housing on the left-hand side.
Loosen the set screw in the variable speed pulley hub and
pull off the complete variable speed pulley using a puller
�
.....__..... (special tool).
(Fig. 1 42)
1 42
Special tool:
1 Spindle - Part No. 1 81 801 . 1

" gl 2 Hexagon head bolt M 1 6 x 50 DIN 933-8.8 -
Part No. 235 586.0
3 Washer 1 7 - Part No. 235 1 27.2
llllllalll 5 Adapter with ball - Part No. 1 81 849. 0
6 Threaded pin - Part No. 1 81 899. 0
(Fig. 1 43)
1 43
Disassemble variable speed pulley:

(with spring compressor from CLMS special tool kit)
Never remove the hex. socket head cap screws
holding the spring plate (T) before the pressure
spring has been blocked with the spring
compressor.
(Fig. 1 44)
1 44
Compress the spring slightly with the special tool, unscrew

the hex. socket head cap screws, then completely relieve
the spring by backing off the lever nut.
7.66 DO 21 8 - 202 MEGA

Engine and Drives
Special tool:

2 Hexagon head bolt M 1 6 x 1 40 DIN 931 -8.8 -
Part No. 242 795. 0
2 3 45
••
3 Puller plate for flanged bearing - Part No. 1 81 935.2
4 Guide bushing - Part No. 1 81 807. 1
C
1
5 Axial grooved ball bearing 51 305 - Part No. 235 983. 0
(Fig. 1 45)
2
1 45
Removing drive belt for suction blower

Unbolt bracket (H).
(Fig. 1 46)
Back off hex. nuts to slacken the suction blower drive and
remove the V-belt.
(Fig. 1 47)
1 47
DO 21 8 - 202 MEGA 7.67

8 TRANSMISSION AND CHASSIS FINAL DRIVE GEARBOX
Removal of final drive gearbox
DO 21 8 / 208 MEGA 8.
Disassembly of final drive gearbox
DO 21 8 / 208 MEGA 8.
Final drive gearbox dismantled
DO 21 8 / 208 MEGA 8. 5
Assembly of final drive gearbox
DO 21 8 / 208 MEGA 8. 6
DO 21 8 / 208 MEGA (rice) 8. 9
DO 21 8 / 208 MEGA (rice) 8. 1 0
Installing final drive gearbox
DO 21 8 / 208 MEGA 8. 1 2
DO 204 I 203 I 202 MEGA 8. 1 3
Disassembly of final drive gearbox
DO 204 I 203 I 202 MEGA 8. 1 4
DO 204 I 203 I 202 MEGA 8. 1 7
DO 204 I 203 I 202 MEGA 8. 1 8
DO 204 I 203 I 202 MEGA (rice) 8. 21
DO 204 I 203 I 202 MEGA (rice) 8. 22
DO 204 I 203 I 202 MEGA 8. 24
HYDROSTATIC GROUND DRIVE SYSTEM

Removal of hydraulic pump 8. 24
Installing hydraulic pump 8. 27
Filling instructions for refilling
hydrostatic ground drive systems 8. 27
Removal of hydrostatic motor 8. 29
Installing hydrostatic motor 8. 29
TRANSMISSION
Removal of main shaft and drive shaft
DO 21 8 / 208 MEGA 8. 30
Main shaft and drive shaft removed
DO 21 8 / 208 MEGA 8. 34
Installing main shaft and drive shaft
DO 21 8 / 208 MEGA 8. 35
Removal of complete transmission unit 8. 35
Disassembly of transmission DO 21 8 / 208 MEGA 8. 36
Removal of the differential DO 21 8 / 208 MEGA 8. 36
Disassembly of the differential 8. 41
Differential dismantled 8. 42
Assembly of the differential 8. 43
Assembling and installing transmission
DO 21 8 / 208 MEGA 8. 43
Removal of main shaft, drive shaft and intermediate shaft
DO 204 I 203 I 202 MEGA 8. 44
Transmission shafts and intermediate gear dismantled
DO 204 I 203 I 202 MEGA 8. 50
DO 204 I 203 I 202 MEGA 8. 51
Removal of the differential 8. 51
Adjusting the magnetic pick-up 8. 51
Adjusting the transmission 8. 52
8
Transmission
and Chassis
FRONT AXLE
Removal of the front axle assembly 8. 52
Installing the front axle assembly 8. 53
HYDRAULIC BRAKE SYSTEM

Adjustment of master brake cylinder 8. 54
Adjustment of the drum brake 8. 54
Bleeding the drum brake system 8. 55
Changing the brake pads of the disc brakes 8. 55
Removal of the disc brake caliper unit 8. 56
Disc brake caliper unit dismantled 8. 57
Assembly of the disc brake caliper unit 8. 57
Bleeding the disc brake system 8. 58
Transmission and Chassis
FINAL DRIVE GEARBOX

DO 21 8 / 208 MEGA
Support the combine securely under the axle body and
remove the drive wheel.
Drain the transmission oil and collect in a sufficiently large
container. Dispose of the old oil in accordance with the local
waste disposal regulations.
Unbolt the final drive gearbox from the axle flange.
(Fig. 1 )
Attach the final drive gearbox to a suitable hoist or other

lifting gear and then drive the final drive gearbox off the
dowel pins.
(Fig. 2)
Remove splined bushing (P) and washers (S) from the

intermediate drive shaft.
(Fig. 3)
Dismantling of final drive gearbox

DO 21 8 / 208 MEGA
Drive cap (K) off its seat. Hold the punch at an angle and
tap against the cap.
(Fig. 4)
DO 21 8 - 202 MEGA 8. 1
[I] Remove the roll pins from the castellated nut and unscrew
the nut.
(Fig. 5)
Drive the wheel shaft out of the gearbox using a light alloy
punch or hardwood block.
Unbolt the gearbox cover.

(Fig. 6)
Remove spacer ring (D).

(Fig. 7)
First remove large spur gear (G), then intermediate shaft (Z)
and pinion shaft (R).
(Fig. 8)
8.2 DO 21 8 - 202 MEGA

Transmission and Chassis Transmission and Chassis
19
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24
15
37
21 --
-TI-F��?ltr,�::.::��I
36
34
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''iii ' 45
29 --........_.-,........,
30 ---trrl��
� o oo·l @ ®
33 44
� OJI
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tJ
10 9
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Final drive gearbox dismantled: 23 Spur gear Assembly of final drive gearbox
DO 21 8 / 208 MEGA 24 Intermediate shaft
25 Taper roller bearing 3031 1 A DIN 720 (Standard version)
1 Circlip
2 Washers 26 Shim 1 00 x 1 20 x 0. 1 / 0.3 / 0.5 DIN 988 1 . Thoroughly clean all gearbox parts.
3 Splined bushing 27 O-ring
2. Wet taper roller bearings, sliding surfaces and sealing
4 Grease nipple 28 Cover
lips of the shaft seals with oil before installation.
5 Axle housing 29 Cap
30 Castellated nut M 42 x 1 .5 3. Install all gearbox shafts and spur gears, but do not
6 Axle housing �
31 Roll pin 5 x 60 DIN 1 481 install taper roller bearing (34) , castellated nut (30)
7 Screw plug
32 Roll pin 8 x 60 DIN 1 481 and the two covers (1 6 and 28) at this stage.
8 Gearbox breather M 1 0 x 1
9 Roll pin 33 Spacer ring 4. Apply a uniform, thin coat of sealing compound
34 Taper roller bearing 3231 1 B DIN 720 (DELO-ML 5328) to flange faces (F) of the gearbox
[£]
1 0 Socket head cap screw M 1 2 x 40 DIN 91 2-1 0.9
Detent edge ring Vskz 1 2 35 Shim 55 x 68 x 1 DIN 988 housing halves. Assemble the gearbox housing halves
1 1 Screw plug M 1 0 x 1 36 Back-up washer S 1 00 x 1 20 DIN 988 and bolt together. Tighten hex. socket head cap screws
1 2 Socket head cap screw M 1 6 x 50 DIN 91 2 37 Circlip 1 20 x 4 DIN 472 (1 2) to a torque of 1 95 Nm and hex. socket head cap
Spring washer 38 Spacer ring screw (1 0) to 1 1 0 Nm.
1 3 Magnetic filter plug 39 Spur gear
40 Circlip 1 80 x 4 DIN 472 5. Press intermediate shaft (24) and taper roller bearing
1 4 Shaft seal As 45 x 72 x 8 DIN 3760 (25) firmly into the bearing seat without any axial play.
1 5 Hexagon head bolt M 1 0 x 25 DIN 933 41 Back-up washer
42 Taper roller bearing 32220 DIN 720 Now select the thickness of the shims (26) at (X) so that
Spring washer an axial preload of 0.2 to 0.3 mm is created when
1 6 Cover 43 Spacer ring
44 Shaft seal B2 1 40 x 1 80 x 1 5 cover (28) is bolted on. Install O-ring (27) in cover (28).
1 7 Shim
[£]
45 Wheel shaft, preassembled Apply a uniform, thin coat of sealing compound (DELO-
1 8 Taper roller bearing 33209 DIN 720 ML 5328) to flange faces (E) of cover and housing and
1 9 Pinion shaft 46 Wheel bolts
bolt on the cover.
20 Taper roller bearing 33208 DIN 720 47 Thrust nut
21 Taper roller bearing 3031 0 DIN 720 (Fig. 1 0)
8.6 DO 21 8 - 202 MEGA

6. Press pinion shaft (1 9) and taper roller bearings

(1 8 and 20) firmly into their seats without any axial play.
Now select the thickness of the shims (1 7) at (Y) so that
an axial preload of 0.1 to 0.2 mm is created when
cover (1 6) is bolted on. Apply a uniform, thin coat of
sealing compound (DELO-ML 5328) to the flange faces
of the cover and housing and bolt on the cover.
7. Place the final drive gearbox on the wheel flange.
Ensure that wheel shaft (45) has no axial play in taper
roller bearing (42) as well as in spur gear (39) and
spacer ring (44).
Now measure distance (D) from the flange surface of the
housing cover to the spacer ring.
If distance (D) exceeds 63.25 mm, shim (35) must be
inserted.
8. Install circlip (37) and back-up washer (36). Now
measure control dimension (K) from the flange surface
of the housing cover to the spacer washer.
Maximum distance 64.64 mm
Minimum distance 64. 1 5 mm
If necessary, fit shim (37) and taper roller bearing (34).
Screw on castellated nut (30) and tighten the nut whilst
turning the bearing in both directions until there is no
measurable play. Now tighten the castellated nut to a
torque of approx. 250 to 600 Nm.
Now secure the castellated nut with roll pins (31 and 32)
and fit spacer ring (33). Coat the seat of cap (29) with
sealing compound (DELO-ML 5328) and press into
place.
When all the sealing lips of the shaft seals have been
thoroughly wetted with oil, the rolling torque at the pinion
shaft at (Z) should be 300 to 700 Ncm.
(Figs. 1 O and 9)
DO 21 8 - 202 MEGA 8. 7
l0 �0
' i.11 19
6 14
15
®---- 24
37
21 �----t��h��JI
11iii 36
34
cooo o·J
®
29 ---
30 ---:Gl�M��
55
33
53
_jl��>'777½¼��
54
l l @ @
@
. .
®
G
12 11
Final drive gearbox dismantled: 28 Cover
DO 21 8 / 208 MEGA (Rice version) 29 Cap Assembly of final drive gearbox
1 Circlip 30 Castellated nut M 42 x 1 .5
2 Washer 31 Roll pin 5 x 60 DIN 1 481 (Rice version)
3 Splined bushing 32 Roll pin 8 x 60 DIN 1 481 1 . Thoroughly clean all gearbox parts.
4 Grease nipple 33 Spacer ring
5 Axle housing 34 Taper roller bearing 3231 1 B DIN 720 2. Wet taper roller bearings, sliding surfaces and sealing
6 Axle housing 35 Shim 55 x 68 x 1 DIN 988 lips of the shaft seals with oil before installation.
7 Screw plug 36 Back-up washer S 1 00 x 1 20 DIN 988 3. Install outer race of taper roller bearing (42) with circlip
8 Gearbox breather M 1 0 x 1 37 Circlip 1 20 x 4 DIN 472 (40) and back-up washer (41 ) in the housing.
9 Roll pin 38 Spacer ring
4. Apply a uniform, thin coat of sealing compound
1 0 Socket head cap screw M 1 2 x 40 DIN 91 2-1 0.9 39 Spur gear
(DELO-ML 5328) to the flange faces at (G) and bolt on
I /71
Detent edge ring Vskz 1 2 40 Circlip 1 80 x 4 DIN 472
bearing race (49).
1 1 Screw plug M 1 0 x 1 41 Back-up washer �
1 2 Socket head cap screw M 1 6 x 50 DIN 91 2 42 Taper roller bearing 32220 DIN 720 5. Install the wheel shaft with bearing race (54) and secure
Spring washer 43 - with hex. socket head cap screw (51 ) and roll pins (52).
1 3 Magnetic filter plug 44 - Push taper roller bearing (42) onto the shaft.
1 4 Shaft seal As 45 x 72 x 8 DIN 3760 45 - 6. Coat the slip ring seals (53) and taper roller bearing (42)
1 5 Hexagon head bolt M 1 0 x 25 DIN 933 46 -
LJ
genero,sly with grease and lnsl0JI, obseMng the correct
Spring washer 47 - position of the slip ring seals.
1 6 Cover 48 Washer
1 7 Shim 49 Bearing race 7. Install all gearbox shafts and spur gears, but do not 1 � I
1 8 Taper roller bearing 33209 DIN 720 50 Hexagon head bolt M 8 x 25 DIN 933 install taper roller bearing (34) , castellated nut (30)
1 9 Pinion shaft Spring washer and the two covers (1 6 and 28) at this stage.
20 Taper roller bearing 33208 DIN 720 51 Hex. socket head cap screw M 8 x 20 DIN 7984
21 Taper roller bearing 3031 0 DIN 720 52 Roll pin
22 Circlip 67 x 2.5 DIN 471 53 Slip ring seal with O-ring
23 Spur gear 54 Bearing outer race
24 Intermediate shaft 55 Preassembled wheel shaft
25 Taper roller bearing 3031 1 A DIN 720 56 Wheel stud
26 Shim 1 00 x 1 20 x 0. 1 / 0.3 / 0.5 DIN 988 57 Flanged bushing
27 O-ring (Fig. 1 2)
8. 1 0 DO 21 8 - 202 MEGA
8. Apply a uniform, thin coat of sealing compound

(DELO-ML 5328) to flange faces (F) of the gearbox
housing halves. Assemble the gearbox housing halves
and bolt together. Tighten hex. socket head cap screws
(1 2) to a torque of 1 95 Nm and hex. socket head cap
screw (1 0) to 1 1 0 Nm.
9. Press intermediate shaft (24) and taper roller bearing
(25) firmly into the bearing seat without any axial play.
Now select the thickness of the shims (26) at (X) so that
an axial preload of 0.2 to 0.3 mm is created when
cover (28) is bolted on. Install O-ring (27) in cover (28).
Apply a uniform, thin coat of sealing compound
(DELO-ML 5328) to flange faces (E) of cover and
housing and bolt on the cover.
1 0. Press pinion shaft (1 9) and taper roller bearings (1 8 and
20) firmly into the seats without any axial play. Now
select the thickness of the shims (1 7) at (Y) so that an
axial preload of 0.1 to 0.2 mm is created when cover
(1 6) is bolted on. Apply a uniform, thin coat of sealing
compound (DELO-ML 5328) to the flange faces of the
cover and housing and bolt on the cover.
1 1 . Place the final drive gearbox on the wheel flange.
Ensure that wheel shaft (45) has no axial play in taper
roller bearing (42) and spur gear (39).
housing cover to the spacer ring.
inserted.
1 2. Install circlip (37) and back-up washer (36). Now
measure control dimension (K) from the flange surface
of the housing cover to the spacer washer.
Maximum distance 64.64 mm
Minimum distance 64. 1 5 mm
If necessary, fit shim (36) and taper roller bearing (34).
Screw on castellated nut (30) and tighten the nut whilst
turning the bearing in both directions until there is no
measurable play.
Now tighten the castellated nut to a torque of approx.
250 to 600 Nm. Secure the castellated nut with roll pins
(31 and 32) and fit spacer ring (33). Coat seat of cap (29)
with sealing compound (DELO-ML 5328) and press into
place.
thoroughly wetted with oil, the rolling torque at the pinion
shaft at (Z) should be 300 to 700 Nern .
(Figs. 1 1 and 1 2)
DO 21 8 - 202 MEGA 8. 1 1

DO 21 8 / 208 MEGA
With the final drive gearbox installed, check for correct end
play of splined bushing (P). Maximum end play 1 .5 mm,
minimum end play 0.8 mm. If necessary, fit a shim (S) 45 x
65 x 0. 75 between circlip and splined bushing.
(Fig. 1 3)
13
Lift the final drive gearbox in front of the axle flange using a
suitable hoist. Push the final drive gearbox onto the locating
ring. Ensure that the dowel pin fits into the corresponding
bore. Drive in the dowel pin and insert all the bolts.
Tighten hexagon head bolts M 20 x 50 DIN 933-8.8 and
hex. socket head cap screws M 20 x 50 DIN 91 2-8.8 (at the
front corners of the axle tube) to a torque of 370 Nm.
(Figs. 1 4 and 1 5)
14
15
Fill each of the final drive gearboxes with 4.5 litres of hypoid
transmission oil to (MIL-L-21 05 B) API-GL-5-90.
K = Oil level check plug
A = Oil drain plug
E = Oil filler plug
L = Gearbox breather
(Figs. 1 6 and 1 7)
8. 1 2 DO 21 8 - 202 MEGA
17
♦
DO 204 MEGA / 203 MEGA / 202 MEGA
Support the combine securely under the axle body and
remove the drive wheel.
Drain the transmission oil and collect in a sufficiently large
container. Dispose of the old oil in accordance with the local
9
waste disposal regulations.
Unbolt the final drive gearbox from the axle flange.
(Fig. 1 8)
18
Attach the final drive gearbox to a suitable hoist or other

lifting gear and then drive the final drive gearbox off the
dowel pins.
(Fig. 1 9)
19
Remove splined bushing (P) and washers (S) from the

intermediate drive shaft.
(Fig. 20)
20
DO 21 8 - 202 MEGA 8. 1 3
Dismantling of final drive gearbox

Drive cap (K) off its seat. Hold the punch at an angle and
tap against the cap.
(Fig. 21 )
[I] Remove the roll pins from the castellated nut and unscrew
the nut.
(Fig. 22)
22
Drive the wheel shaft out of the gearbox using a light alloy
punch or hardwood block.
(Fig. 23)
23
Unbolt the gearbox cover.

(Fig. 24)
24
8. 1 4 DO 21 8 - 202 MEGA
Remove the spur gear from the gearbox housing.

(Fig. 25)
25
Remove cone (8) and circlip in front of the bearing and drive
the taper roller bearing out of its seat.
(Fig. 26)
26
Unbolt the cover in front of the pinion shaft bearing at (A)

and drive out the pinion shaft together with its bearing
inwards
(Fig. 27)
27
DO 21 8 - 202 MEGA 8. 1 5
�'._ . J
@-�- / F
29 28

(Standard version)
Final drive gearbox dismantled: 16 Wheel shaft with wheel bolts
17 Circlip 80 x 4 DIN 471 1 . Thoroughly clean all gearbox parts.
(Standard version) 18 Spur gear 2. Wet all bearings, sliding surfaces and sealing lips of the
19 Spring washer 1 2 DIN 1 28 shaft seals with oil before installation.
1 Gearbox housing 20 Hexagon head bolt M 1 2 x 30 DIN 933-8.8
3. Press pinion shaft (3) with taper roller bearings (2) and
2 Taper roller bearing 3301 0 DIN 720 21 Cone
(4) firmly into the gearbox housing.
3 Pinion shaft 22 Shim 50 x 62 x 1 DIN 988
Also install spacer ring (5) and spur gear (1 8) in the
4 Taper roller bearing 32208 DIN 720 23 Circlip 1 1 0 x 4 DIN 472
gearbox housing.
5 Spacer ring 24 Taper roller bearing 3031 0 DIN 720
6 Shim 68 x 79.5 x 0.5 / 0.3 / 0. 1 25 Spacer ring 4. Install wheel shaft bearing (1 1 - 1 4) in gearbox cover
7 Cover 26 Castellated nut M 42 x 1 .5 DIN 937 (1 5) and push in wheel shaft (1 6).
8 Shaft seal AS 50 x 65 x 8 DIN 3760 27 Roll pin 8 x 60 DIN 1 481
9 Spring washer 1 0 DIN 1 28 Roll pin 5 x 60 DIN 1 481 CAUT ION! Coat taper roller bearing (1 3) with roller bear
10 Hexagon head bolt M 1 0 x 25 DIN 933-8.8 28 Cap ing grease before installation.
11 Shaft seal 1 1 0 x 1 1 5 x 1 5 29 Screw plug M 24 x 1 .5
12 Spacer ring 30 Magnetic filter plug M 24 x 1 .5 Ensure that shaft seal (1 1 ) is not damaged when
13 Taper roller bearing 33020 DIN 720 31 Gearbox breather installing the wheel shaft.
14 Circlip 1 50 x 4 DIN 472 (Fig. 29) 5. Install circlip (1 7). Apply a uniform, thin coat of sealing
15 Gearbox cover compound (DELO-ML 5328) to flange faces (F) of the
gearbox housing halves. Assemble the gearbox housing
halves and bolt together.
8. 1 8 DO 21 8 - 202 MEGA
6. Place the final drive gearbox on the wheel shaft flange.

Insert cone (21 ).
Ensure that the wheel shaft has no axial play in the bear
ing and spur gear.
housing to the cone.
inserted.
@]
7. Coat inner wheel shaft bearing (24) with roller bearing
grease. Install circlip (23) and spacer ring (25). Screw on
castellated nut (26) and tighten the nut whilst turning the
bearing in both directions until there is no measurable
[I]
play.
300 to 500 Nm and secure with roll pin (27).
8. Press pinion shaft (3) and taper roller bearings (4 and 2)
firmly into their seats without any axial play. Now select
the thickness of the shims (6) at (J) so that an axial pre
load of 0.1 to 0.2 mm is created when cover (7) is
bolted on. Install shaft seal (8) in cover (7). Apply a uni
form, thin coat of sealing compound (DELO-ML 5328) to
the flange faces of the cover and housing and bolt on the
cover.
9. Coat the seat of cap (28) with sealing compound
(DELO-ML 5328) and press into place.
thoroughly wetted with oil, the slip torque at the pinion shaft
at (Z) should be 2.5 to 5 Nm.
(Figs. 29 and 28)
DO 21 8 - 202 MEGA 8. 1 9
�'
i
�- - J
i
@-ill:,. __ j
31 30
Final drive gearbox dismantled: 19 Spring washer 1 2 DIN 1 28 Assembly of final drive gearbox
DO 204 MEGA / 203 MEGA / 202 MEGA 20 Hexagon head bolt M 1 2 x 30 DIN 933-8.8
21 Cone DO 204 MEGA / 203 MEGA / 202 MEGA
(Rice version) 22 Shim 50 x 62 x 1 DIN 988 (Rice version)
23 Circlip 1 1 0 x 4 DIN 472
1 Gearbox housing 24 Taper roller bearing 3031 0 DIN 720
2 Taper roller bearing 3301 0 DIN 720 1 . Thoroughly clean all gearbox parts.
25 Spacer ring
3 Pinion shaft 26 Castellated nut M 42 x 1 .5 DIN 937 2. Wet all bearlngs, sliding surtaces and seW lng lips of the
4 Taper roller bearing 32208 DIN 720 27 Roll pin 8 x 60 DIN 1 481 shaft seals with oil before installation.
5
6
Spacer ring
Shim 68 x 79.5 x 0.5 I 0.3 I 0. 1
Roll pin 5 x 60 DIN 1 481 3. Press pinion shaft (3) with taper roller bearings (2) and U
I /\ I
28 Cap
7 Cover (4) firmly into the gearbox housing.
29 Screw plug M 24 x 1 .5
8 Shaft seal AS 50 x 65 x 8 DIN 3760 30 Magnetic filter plug M 24 x 1 .5 Also install spacer ring (5) and spur gear ( 1 8) in the
9 Spring washer 1 0 DIN 1 28 31 Gearbox breather gearbox housing.
10 Hexagon head bolt M 1 0 x 25 DIN 933-8.8 32 Bearing ring 4. Coat circlip (1 4) and taper roller bearing (1 3) with roller
11 - 33 Slide ring seal with O-ring bearing grease and install in the gearbox housing,
12 - 34 Bearing ring
13 Taper roller bearing 33020 DIN 720 5. Apply a unllo"", thin coat of sealing compound
35 Spring washer A 8
14 Circlip 1 50 x 4 DIN 472 (DELO-ML 5328) to the flange faces at (G) and bolt on
36 Hexagon head bolt M 8 x 25 DIN 933-8.8 �
bearing race (32).
d
15 Gearbox cover 37 Cover I /7 I
16 Wheel shaft with wheel bolts 6. Push bearing ring (34) onto the wheel shaft and bolt on.
[£]
17 Circlip 80 x 4 DIN 471 (Fig. 31 )
Coat the slide ring seal all round with roller bearing
18 Spur gear grease and install together with the wheel shaft.
7. Install circlip (1 7). Apply a uniform, thin coat of sealing
I I
compound (DELO-ML 5328) to flange faces (F) of the
gearbox housing halves. Assemble the gearbox housing /)
halves and bolt together. �
8.22 DO 21 8 - 202 MEGA

8. Place the final drive gearbox on the wheel shaft flange.

Insert cone (21 ).
Ensure that the wheel shaft has no axial play in the
bearing and spur gear. Now measure distance (D) from
the flange surface of the housing to the cone.
inserted.
9. Coat inner wheel shaft bearing (24) with roller bearing
grease. Install circlip (23) and spacer ring (25). Screw on
castellated nut (26) and tighten the nut whilst turning the
bearing in both directions until there is no measurable
play.
300 to 500 Nm and secure with roll pin (27).
1 0. Press pinion shaft (3) and taper roller bearings (4 and 2)
[I]
firmly into their seats without any axial play. Now select
the thickness of the shims (6) at (J) so that an axial
preload of 0.1 to 0.2 mm is created when cover (7) is
bolted on. Install shaft seal (8) in cover (7). Apply a
uniform, thin coat of sealing compound (DELO-ML 5328)
to the flange faces of the cover and housing and bolt on
the cover.
1 1 . Coat the seat of cap (28) with sealing compound
(DELO-ML 5328) and press into place.
thoroughly wetted with oil, the slip torque at the pinion shaft
at (Z) should be 2.5 to 5 Nm.
(Figs. 31 and 30)
DO 21 8 - 202 MEGA 8.23


With the final drive gearbox installed, check for correct end
play of splined bushing (P). Maximum end play 1 .5 mm,
minimum end play 0.8 mm. If necessary, fit a shim (S)
45 x 65 x 0. 75 between circlip and splined bushing.
(Fig. 32)
@ Fill each of the final drive gearboxes with 3 litres of hypoid

transmission oil to (MIL-L-21 05 B) API-GL-4-90.
Bolt the final drive gearbox to the axle body and tighten the
bolts to the prescribed torque, see »Installing final drive
gearbox« DO 21 8 MEGA / 208 MEGA.
III
lYJ
HYDROSTATIC GROUND DRIVE SYSTEM
Removal of hydraulic pump

Block the spring-loaded cylinder of the power band belt
jockey pulley using a key extractor.
(Fig. 33)
33
Loosen the four hexagon head bolts of the adjusting

support. Loosen adjusting screw M 1 2 x 1 40 and so slacken
the power band belt. Take off the belt.
(Fig. 34)
34
8.24 DO 21 8 - 202 MEGA

Loosen screw plug (B) under the hydrostatic motor and

drain the hydraulic oil into a sufficiently large container.
@
Q
Caution when draining hot oil - danger of burns! '¥
Dispose of the drained oil in accordance with the
local waste disposal regulations.
After draining the hydraulic oil, insert screw plug (B) again
and screw tight.
(Fig. 35)
35
Loosen the flange connection of the high-pressure hoses at

the hydrostatic motor, drain the oil out of the hoses and
collect in the container.
Reconnect the hoses tightly to the motor.
(Fig. 36)
36
Disconnect the high-pressure and low-pressure hoses from

the hydraulic pump. Drain the remaining oil out of the hoses
and collect in the container.
Seal the ends of all lines and all ports tightly with plastic
caps or plugs.
(Fig. 37)
37
Push the lines away to one side.

Disconnect the bowden cable from the actuating lever and
unscrew the complete cable bracket.
DO 21 8 - 202 MEGA 8.25

Unbolt the pump flange from the adjustment support.

(Fig. 38)
38
Attach the hydraulic pump complete with oil tank to a

suitable hoist and lift off from the adjustment support.
(Fig. 39)
39
Unscrew the hose connection from the oil tank and pump.
Unbolt the oil tank complete with bracket from the pump
flange.
(Fig. 40)
40
Unbolt the V-belt pulley from the pump.

(Fig. 41 )
Unbolt the pump from the pump flange.
41
8.26 DO 21 8 - 202 MEGA

Installing hydraulic pump
NOTE: When replacing a damaged hydraulic pump, always

replace the hydrostatic motor at the same time. Flush out �
the oil cooler and hydraulic lines.
1 . Bolt the hydraulic pump to the pump flange.

2. Bolt the V-belt pulley to the pump.
3. Install the hydraulic tank with bracket on the pump
flange.
4. Place the preassembled pump flange on the
adjustment support and bolt the flange to the bracket.
Do not tighten the bolts completely at this stage!
5. Align the hydraulic pump drive to the motor output shaft
using the two eyebolts. Lock the eyebolts.
6. Now tighten the bolts of the pump flange at the
adjustment support.
7. Fit the power band belt and tension with adjusting
screw M 1 2 x 1 40 DIN 933.
8. Install the bowden cable with bracket.
9. Pull out the key extractor to release the spring-loaded
cylinder.
1 0. Adjust the hydrostatic ground drive system. See Group
7 »Adjusting hydrostatic ground drive system«.
1 1 . Connect all high-pressure and low-pressure hoses to
the pump.
1 2. Fill the system with hydraulic oil, observing the filling
instructions.
(Figs. 33 to 41 ) �
Filling instructions for refilling hydrostatic

ground drive systems
I ['.'+'j
1 . Swing up oil cooler (0) so that it is horizontal.
2. Eogage a gea, and apply the handbrake. o, oombl oes 1
I
with CLMS 4-Trac system, switch off the system.
3. Connect a pressure gauge (0-600 bar) to the
measuring ports at (S).
42
DO 21 8 - 202 MEGA 8.27

4. Fill oil expansion tank (B) up to the "MAX." mark with

hydraulic oil at oil filler neck (E).
Pour in the hydraulic oil slowly so that the air can

escape from the pump housing via connecting lines (L)
and oil expansion tank (8).
5. Start the diesel engine (at slow idle speed) and switch
off again immediately.
Check the oil level and top up, if necessary.
Repeat this procedure until an increase in pressure of

at least 1 5 bar is seen on the pressure gauge and the
oil level in the tank is constant.
43
6. Start the diesel engine and run at slow idle speed.
If the pressure increases, load the hydraulic system in

both directions as follows:
a) Move the ground travel lever to forward travel until a
high pressure of 50-1 50 bar is reached. Hold this pres
sure for about 1 minute.
b) Move the ground travel lever to reverse travel until a
high pressure of 50-1 50 bar is reached. Hold this pres
sure for about 1 minute.
44
7. Check the oil level in the tank and top up, if necessary.
8. Shift the transmission to neutral and adjust the diesel
engine to slow idle speed. Move the hydrostatic ground
drive control lever to the forward travel position for
about 2 minutes, then move to the reverse travel
position for about 2 minutes.
NOTE: If the hydrostatic motor or hydraulic pump have
been replaced, the purging pressure must be checked and
corrected, if necessary. See high pressure/purging pressure
measurement in the Hydraulics/Electrics manual.
Com bines with CLAAS 4-Trac system

9. The 4-Trac system must remain switched off until all
the above points have been checked. Support the rear
axle securely on both sides.
1 0. Engage 3rd gear and apply the handbrake. Run the
diesel engine at slow idle speed.
1 1 . Switch on the CLAAS 4-Trac system.
Move the hydrostatic ground drive control lever to the
forward travel position for about 1 minute, then move to
the reverse travel position for about 1 minute.
Both rear wheels must rotate. The maximum pressure
must not exceed 1 50 bar.
1 2. Check the oil level and top up, if necessary.
(Figs. 42, 43 and 44)
8.28 DO 21 8 - 202 MEGA

+
HYDROSTATIC MOTOR
Removal of hydrostatic motor

Loosen screw plug (B) under the hydrostatic motor and
drain the hydraulic oil into a sufficiently large container.
Caution when draining hot oil - danger of burns!
9
After draining the hydraulic oil, insert screw plug (B) again
and screw tight.
(Fig. 45)
45
Loosen the flange connection of the high-pressure hoses at

the hydrostatic motor, drain the oil out of the hoses and
collect in the container.
Now disconnect the leak-off oil line and drain the remaining
oil.
Seal the ends of all lines and all ports tightly with plastic
caps or plugs.
(Fig. 46)
46
Unbolt the hydrostatic motor at the flange housing. Pull the

motor straight out of the splined bushing and remove the
gasket.
(Fig. 47)
47
Installing hydrostatic motor
NOTE: When replacing a damaged hydrostatic motor,

always replace the hydraulic pump at the same time. Flush
out the oil cooler and hydraulic lines.
1 . Thoroughly clean all parts and flange surfaces.

2. Drive a roll pin or two roll pins (on Sauer systems) into
the splined bushing so that the roll pins are centered in
the splined bushing. Coat the splined bushing with
roller bearing grease and bolt to the constant
displacement motor.
DO 21 8 - 202 MEGA 8.29

3. NOTE! When bolting to the flange of the Sauer system,

always fit spring washers to the bolts.
Failure to observe this point will result in damage to the
hydrostatic motor.
4. Bolt on the hydrostatic motor and connect all lines.
NOTE! When tightening the lines, always counter-hold
the fittings using a second spanner.
5. Fill the system. Observe the »Filling instructions for
refilling hydrostatic ground drive systems«.
6. Carry out a test run and check the system for leaks.
7. Adjust the magnetic pick-up.
(Figs. 45 to 47)
TRANSMISSION
Removal of main shaft and drive shaft

DO 21 8 / 208 MEGA
The main shaft and drive shaft can be replaced without
removing the transmission from the combine.
Unbolt the hydrostatic motor at the flange housing.
(Fig. 48)
Unscrew clamp (L) for the hydraulic hoses, pull off the
hydrostatic motor in a straight line, push to the side and
tie up.
The hydraulic oil does not have to be drained.
(Fig. 49)
49
8.30 DO 21 8 - 202 MEGA

Drain the oil from the transmission.

A = Oil drain plug
Clean the magnet in the oil drain plug at each oil
change. Screw the oil drain plug in tightly after
draining the oil.
(Fig. 50)
Remove yoke (G) of the handbrake linkage from lever (H) of

the handbrake drum.
(Fig. 51 )
51
Remove gear shift linkage (S1 and S2).

(Fig. 52)
52
Remove the key securing right-hand foot brake drum (T)

and push the drum along the intermediate shaft.
.&
Unbolt the brake plate, push to the right and place in the
brake drum.
NOTE , Take ca,e not to bend the brake line
(Fig. 53)
53
DO 21 8 - 202 MEGA 8. 31
Remove the key securing handbrake drum (C) and remove

the complete handbrake assembly.
Loosen the hook bolts of the preparation floor and remove
the preparation floor sections for easier access to the
transmission.
(Fig. 54)
54
Unbolt right-hand transmission case cover (R). Note that the

bolt at (P) is a precision-fit bolt.
(Fig. 55)
55
Unbolt flange housing (F) on the left-hand side.

(Fig. 56)
56
Unbolt the transmission case cover.

NOTE: When removing the cover, ensure that the shifter rail
locking springs at (2) do not fall into the transmission case.
Remove the detent balls using a magnet (M).
(Fig. 57)
57
8. 32 DO 21 8 - 202 MEGA
Remove two circlips from their grooves on the main

shaft at (X).
(Fig. 58)
58
On the left-hand side, pull off the inner race of the cylindrical
roller bearing.
(Fig. 59)
59
Remove back-up washer (2) together with the bearing inner

race.
(Fig. 60)
60
Pull main shaft (H) out to the right, at the same time taking
out spur gears (R) and the circlips through the top of the
transmission case.
There are two back-up washers in front of the right-hand
bearing inner race.
(Fig. 61 )
61
DO 21 8 - 202 MEGA 8.33

Push the drive shaft slightly to the right and pull off the
deep-groove ball bearing on the right-hand side.
(Fig. 62)
62
Pull out drive shaft (A) to the left and at the same time, lift
out double spur gear (D) through the top of the transmission
case.
(Fig. 63)
63
Main shaft and drive shaft dismantled:

DO 21 8 MEGA / 208 MEGA
1 Cylindrical roller bearing NJ 308 DIN 541 2

2 Back-up washer S 40 x 50 x 2.5 DIN 988
3 Shifter gear
4 Circlip 45 x 1 . 75 DIN 471
5 Main shaft
6 Double gear
7 Pinion
8 Back-up washer S 40 x 50 x 2.5 DIN 988
9 Cylindrical roller bearing NJ 2308 DIN 541 2
10 Deep-groove ball bearing 6308 DIN 625
64 11 Double shifter gear
13 Drive shaft
14 Cylindrical roller bearing NJ 208 E DIN 541 2
(Fig. 64)
8.34 DO 21 8 - 202 MEGA

$
DO 21 8 / 208 MEGA
1 . Thoroughly clean all transmission parts and oil before
0
installation.
2. On the main shaft, install back-up washers (2 and 8)
between spur gear and each cylindrical roller bearing
(left end one, right end two).
3. When bolting on the transmission cover, insert a
precision-fit bolt 1 2h 1 1 M 1 0 x 1 1 x 25 DIN 1 438 into the
corresponding hole on the right.
4. Apply sealing compound (DELO-ML 5349) to all the
J7
bolts before screwing into the through-bores in the
transmission case. �
5. Adjust the gear shift linkage so that the shifter gears
engage fully in all the gear ranges. The detent balls
must engage correctly.
6. Fill the transmission with 5 litres of hypoid transmission
6
oil SAE 90 (MIL-L-21 05 B) API-GL-5-90.
7. Install the hydrostatic motor. �
Removal of complete transmission unit

Remove the cutterbar including feeder housing.
Support the combine securely and remove the left-hand
front wheel.
Remove the left-hand final drive gearbox.
(Fig. 65)

(Fig. 66)
66
DO 21 8 - 202 MEGA 8.35

hydrostatic motor in a straight line, push to the side and tie
up.
(Fig. 67)
67
@ Drain the oil from the transmission.

A = Oil drain plug
draining the oil.
(Fig. 68)
68

the handbrake drum.
(Fig. 69)
69

(Fig. 70)
70
8.36 DO 21 8 - 202 MEGA

Pull intermediate shaft (V) together with the brake drum out
of the transmission in a straight line and take away from
below.
(Fig. 71 )
71
Unscrew the brake lines from the foot brakes on both sides.
Unbolt the left-hand brake plate (B) and remove completely.
(Fig. 72)
72
Securely support the transmission with a trolley jack. Use a

bracket or similar retainer to secure the transmission on the
jack.
Unbolt the support plates on the axle and drive out the
centering roll pins.
(Fig. 73)
Unbolt support plate (H) on the left-hand side of the

transmission.
(Fig. 74)
74
DO 21 8 - 202 MEGA 8. 37
Push the transmission to the left in a straight line until the

right-hand intermediate shaft is completely free of the
splined bushing. Now lower the transmission and pull out
from under the combine. Pull out right-hand intermediate
shaft (V) and unbolt the right-hand brake plate.
(Fig. 75)
75
Example of a secure mounting of the transmission on a

trolley jack.
1 . Support plate
2. Eyebolt to hold the transmission
(Fig. 76)
76
Disassembly of the transmission

DO 21 8 / 208 MEGA
Remove and install the main shaft and drive shaft. See
removal and disassembly operations with the transmission
installed in the combine.
Removal of the differential

DO 21 8 / 208 MEGA
Remove gearbox cover (D).
NOTE: When removing the cover, ensure that shifter rail
locking springs (F) do not fall into the transmission case.
(Fig. 77)
8.38 DO 21 8 - 202 MEGA

Remove the detent balls (K) using a magnet.

(Fig. 78)
78
Unbolt flange housing (L) for the mounting of the hydrostatic

motor.
(Fig. 79)
79
Remove the shift fork and shifter rail (1 ) for the main shaft
shifter gear.
(Fig. 80)
80
Remove circlip (S) from the groove on the main shaft.

(Fig. 81 )
81
DO 21 8 - 202 MEGA 8.39

Drive out main shaft (H) to the left by tapping gently with a
plastic-headed hammer.
NOTE: Ensure that the circlips are moved with the shaft and
do not jam in their grooves.
(Fig. 82)
82
Shims (A) are located between the bearings and the outer
gear wheels. Note the number and thickness of these
shims.
(Fig. 83)
83
Take out the gear wheels and circlips through the top of the
differential housing.
(Fig. 84)
84
Unbolt brake plate flange (B) on the left of the differential

housing.
(Fig. 85)
85
8.40 DO 21 8 - 202 MEGA

Press off the left-hand brake plate flange with

special tool (X).
Place a short shaft (35 mm dia. x 240 mm long,
self-manufactured) into the hub of the differential so that the
puller device is supported against the differential shaft.
(Fig. 86)
86
Special tool:
1 Puller - Part No. 1 81 81 6.3

2 Hexagon head bolt BM 1 2 x 60 DIN 564-8.8 -
Part No. 236 300.0
3 Hexagon head bolt BM 1 2 x 1 80 DIN 564-8.8 -
Part No. 236 302. 0
4 Washer 1 3 x 30 x 3 - Part No. 236 844. 0
5 Hex. nut M 1 2 DIN 934-8 - Part No. 236 1 72. 0
6 Short shaft 35 mm dia. x 240 long (self-manufactured)
(Fig. 87)
87
Press the differential off the right-hand bearing and lift out
through the top of the differential housing.
(Fig. 88)
88
Disassembly of the differential

Pull off deep-groove ball bearing (R).
Puller:
1 Two-arm puller
2 Hexagon head bolt M 1 6 x 50 DIN 933-8.8 -
Part No. 235 586. 0
3 Puller plate - Part No. 1 81 885. 0
4 Locator tool - Part No. 1 81 896. 0
Parts 2, 3 and 4 are parts of the CLMS special tool kit.
(Fig. 89)
89
DO 21 8 - 202 MEGA 8. 41
Remove all the connecting bolts.

(Fig. 90)
90
Drive the roll pin out of the differential pinion shaft.

(Fig. 91 )
91
Drive the differential pinion shaft out of the differential

housing.
(Fig. 92)
92
Differential dismantled:
�\�l1j,,J o�- b
1 Deep-groove ball bearing 601 8 DIN 625
2 Flange
3 4 3 Differential bevel gears
1 1 _ /{ ,,
4 Circlip 42 x 1 . 75 DIN 472
5 Differential pinions
'•• • 6 Bearing bushing

-
��
7�
5_:e . � .
,t�-J
7 Spacer tube
8 Differential pinion shaft
9 Roll pin 1 0 x 50 DIN 1 481
,
I
l� 14 15
10 Roll pin 6 x 50 DIN 1 481
93
8. 42 DO 21 8 - 202 MEGA
1 1 Differential housing
1 2 Roll pin 1 3 x 30 DIN 1 481
Roll pin 8 x 30 DIN 1 481
1 3 Ring gear
1 4 Self-locking nut VM 1 2 DIN 980-1 0
1 5 Hexagon head bolt M 1 2 x 1 60 DIN 931 -1 0.9
1 6 Deep-groove ball bearing 621 7 DIN 625
(on 21 8 MEGA / 208 MEGA / 204 MEGA / 203 MEGA)
Deep-groove ball bearing 621 8 DIN 625
(on 202 MEGA)
(Fig. 94)
Assem bly of the differential

Thoroughly clean all parts and oil before installation.
Apply a uniform, thin coat of Molykote paste G (CLMS Part
No. 41 1 294.0) to the contact surfaces at (A).
Install all parts of the differential housing. Centre ring gear
(1 3) on the differential housing with roll pins (1 2) and insert
hexagon head bolts (1 5).
Tightening torque:
Hexagon head bolt M 1 2 x 1 60= 1 00 Nm
(Figs. 94 and 95)
94
95
Assem bling and installing transmission

DO 21 8 / 208 MEGA
Install the differential. Install main shaft and drive shaft,
ensuring that the back-up rings between housing wall and
the gear wheels are in place.
Install the transmission. Take care not to damage the radial
seal rings during installation of the intermediate shafts.
Install the final drive gearbox. Install the hydrostatic motor.
Adjust the gear shift linkage and the brakes.
DO 21 8 - 202 MEGA 8.43

Removal of main shaft, drive shaft and

intermediate shaft
DO 204 / 203 / 202 MEGA
The main shaft, drive shaft and intermediate shaft can be
replaced without removing the transmission from the
combine.
(Fig. 96)
hydrostatic motor in a straight line, push to the side and tie
up.
(Fig. 97)
97
@ Drain the oil from the transmission.

A = Oil drain plug
draining the oil.
(Fig. 98)
98

the handbrake drum.
(Fig. 99)
99
8.44 DO 21 8 - 202 MEGA


(Fig. 1 00)
1 00
On DO 202 MEGA
Remove the key securing right-hand foot brake drum (T)
and push the drum along the intermediate shaft.
.&
Unbolt the brake plate, push to the right and place in the
brake drum.
NOTE! Take care not to bend the brake r;ne
(Fig. 1 01 )
1 01
Remove the key securing handbrake drum (C) and remove

the complete handbrake assembly.
Loosen the hook bolts of the preparation floor and remove
the preparation floor sections for easier access to the
transmission.
(Fig. 1 02)
1 02
Unbolt transmission case cover (R). The cover is centered

at (X) with precision-fit bolts.
(Fig. 1 03)
1 03
DO 21 8 - 202 MEGA 8.45

When removing the transmission case cover, note the

number and thickness of the shims at (P).
(Fig. 1 04)
1 04
Remove the upper transmission case cover.
NOTE: When removing the cover, ensure that the pressure

springs (F) do not fall into the transmission case.
Remove pressure springs (F).
(Fig. 1 05)
1 05
Remove the detent balls using magnet

(M, special tool, Part No. 1 81 842.0).
(Fig. 1 06)
Remove the main shaft:

Drive the roll pin out of shift fork (G). Drive shifter rail out of
the transmission case and take out the shift fork.
(Fig. 1 07)
1 07
8.46 DO 21 8 - 202 MEGA

Remove circlip (S) from the groove and push towards

double gear (D).
(Fig. 1 08)
1 08
Drive main shaft to the right and remove the bearing outer
race of cylindrical roller bearing (L).
(Fig. 1 09)
1 09
Remove the main shaft complete with double gear and

shifter gear out of the transmission case.
(Fig. 1 1 0)
110
Remove circlip from the double gear and drive double gear
from the main shaft.
(Fig. 1 1 1 )
111
DO 21 8 - 202 MEGA 8. 47
Pull bearing inner race of the cylindrical roller bearing from

the main shaft.
(Fig. 1 1 2)
112
Remove drive shaft:

Remove circlip (C) from the groove and push to the left.
(Fig. 1 1 3)
113
Drive the drive shaft to the right and remove bearing outer
race of the cylindrical roller bearing.
(Fig. 1 1 4)
114
Pull drive shaft out of the left-hand bearing and tilt

downwards. Turn shift fork (E) to the side.
(Fig. 1 1 5)
115
8.48 DO 21 8 - 202 MEGA

Remove drive shaft complete with double shifter gear from

the transmission case.
(Fig. 1 1 6)
116
Pull deep-groove ball bearing from the drive shaft.

(Fig. 1 1 7)
117
Remove intermediate gear:

The intermediate gear can be removed after removing the
main shaft.
Pull intermediate shaft out to the left using a special tool.
There is an M 1 0 thread in the end of the intermediate shaft
for this purpose.
Remove the intermediate shaft to the left and take out the
intermediate gear through the top of the transmission case.
(Figs. 1 1 8 and 1 1 9)
Special tool:
1 Puller bracket - Part No. 1 81 81 6.3
2 Threaded bolt - Part No. 1 81 889.0
3 Hexagon head bolt M 1 0 x 200 DIN 933-8.8 -
Part No. 21 1 739. 0
4 Hex. nut M 1 0 DIN 934-8 - Part No. 236 1 71 . 0
5 Washer 1 0.5 DIN 1 25 - Part No. 236 91 3.2
6 Washer 1 7 DIN 1 25 - Part No. 235 1 27.2
(Figs. 1 1 8 and 1 1 9)
119
DO 21 8 - 202 MEGA 8.49

@®
I �..,t,--®
r-®
A- @
Ii
@�
,@ @)
@ @) @
[J]
1 20
Transmission shafts and intermediate gear dismantled: 13 Double gear
'f
DO 204 MEGA / 203 MEGA / 202 MEGA 14 Circlip 45 x 1 . 75 DIN 471
15 Shifter gear
1 Bushing (on 204 MEGA / 203 MEGA) 16 Cylindrical roller bearing NJ 307 E DIN 541 2
2 Intermediate gear 17 Shaft seal 81 35 x 62 x 1 0
3 Cylindrical roller bearing NJ 2207 E DIN 541 2 18 Seal
(on 204 MEGA / 203 MEGA) 19 Transmission case cover
Cylindrical roller bearing NJ 207 E DIN 541 2 20 Hexagon head bolt M 1 0 x 25 DIN 933-8.8
(on 202 MEGA) Spring washer 1 O DIN 1 28
4 Circlip 72 x 2.5 DIN 472 21 Precision-fit bolt 1 2 h 1 1 M 1 O x 1 1 x 25
5 Intermediate shaft 22 Shaft seal As 20 x 30 x 7 DIN 3760
6 Drive shaft 23 Shifter rail
7 Cylindrical roller bearing 24 Shift fork
8 Double shifter gear 25 Roll pin 6 x 36 DIN 1 481
9 Circlip 50 x 2 DIN 471 (on 204 MEGA / 203 MEGA) 26 Roll pin 3.5 x 36 DIN 1 481
Circlip 42 x 1 . 75 DIN 471 (on 202 MEGA) 27 Shifter rail
1 0 Deep-groove ball bearing 6207 DIN 625 28 Shift fork
1 1 Main shaft (Fig. 1 20)
1 2 Cylindrical roller bearing NJ 2308 E DIN 541 2
(on 204 MEGA / 203 MEGA)
Cylindrical roller bearing NJ 2208 E DIN 541 2
(on 202 MEGA)
8.50 DO 21 8 - 202 MEGA

/
/
1 . Thoroughly clean all transmission parts and oil before
installation.
2. When bolting on the transmission cover, insert
precision-fit bolts 1 2h1 1 M 1 0 x 1 1 x 25 DIN 1 438 (P)
into the corresponding holes on the right.
3. Apply sealing compound (DELO-ML 5349) to all the
bolts before screwing into the through-bores in the
transmission case.
4. Adjust the gear shift linkage so that the shifter gears
engage fully in all the gear ranges. The detent balls 1 21
must engage correctly.
5. Fill transmission with 6.8 litres of hypoid transmission
oil SAE 90 (MIL-L-21 05 B) API-GL-5-90.
6. Install the hydrostatic motor.
(Fig. 1 21 )
Removal and disassembly of the differential

See »Removal and disassembly of the differentialcc DO 21 8
MEGA / 208 MEGA.
Adjusting the magnetic pick-up

Coat magnetic pick-up (J) with sealing compound and
screw in until it contacts the splined bushing, then back off
by 1 /2 turn so that a gap of 0.5 - 1 mm remains.
(Fig. 1 22)
DO 21 8 - 202 MEGA 8. 51
Adjusting the transmission

Adjust shifter rails (C and D) alongside the operator's
platform at ball joints (K) so that the shifter gears engage
fully and the detent balls of the shifter shafts lock.
(Fig. 1 23)
❖ FRONT AXLE
Removal of the front axle assembly

Remove the cutterbar including feeder housing.
Support the combine securely on both sides under the side
.....__..... panels.
Use supporting material (shaft stands or similar supports)
with a working load of at least 8 t.
(Fig. 1 24)
1 24
Unscrew pipe clamps at the left-hand combine side panel.

Unbolt hydrostatic motor (M) from the flange housing, push
to the side and tie up.
(Fig. 1 25)
1 25
Remove gear shift linkage (S1 and S2) at the shifter rails.
Pull off handbrake cable (H). Disconnect handbrake cable
(H) at the brake lever and at retarder (W).
(Fig. 1 26)
1 26
8. 52 DO 21 8 - 202 MEGA
Unscrew the hydraulic lines at the cutterbar cylinders and

collect the hydraulic oil.
Disconnect the cutterbar cylinder at the axle.
Unscrew brake lines (B) at the foot brake slave cylinders.
Loosen the clamp bands for handbrake cable (H).
(Fig. 1 27)
1 27
Remove axle mounting bolts (C, E and D) on both sides and

pull out the complete axle together with the final drive
gearboxes to the front.
(Fig. 1 28)
1 28
Installing the front axle assembly

Mounting bolts D:
Hexagon head bolts M 20 x 1 .5 x 1 40 DIN 960-8.8
Self-locking nuts VM 20 x 1 .5 DIN 980-8
Mounting bolts E:
Hexagon head bolts M 20 x 1 .5 x 50 DIN 960-8.8
Mounting bolts C:
Hexagon head bolts M 20 x 1 .5 x 1 00 DIN 960-8.8
(Fig. 1 28)
DO 21 8 - 202 MEGA 8.53

\I/
Adjust the shift linkage again. Bleed the foot brakes.
Connect the hydraulic lines to the cutterbar cylinders. Top
_x_ up with hydraulic oil and bleed.
6
Install hydrostatic motor.
HYDRAULIC BRAKE SYSTEM

(Foot brake)
Adjustment of master brake cylinder

With the brake pedals in rest position (not depressed), pins
(A) connecting the brake pedals to the adjustable
connecting rods (8) of the master brake cylinders must fit
freely through the holes in the yokes. Maximum clearance is
0. 5 mm.
(Fig. 1 29)
Adjustment of the drum brake

Support the combine securely with suitable stands or
blocks.
Adjust nuts (A) on the left-hand and right-hand brake plate
so that the brakes come on hard when the pedals are
depressed one-third of their total travel (check by turning the
drive wheels).
Both brakes must provide equal braking when their pedals
are positioned at the same height. If necessary, correct the
pedal position with adjusting nuts (A) at the brake plates.
Adjust the two brakes exactly during a test run.
(Fig. 1 30)
8.54 DO 21 8 - 202 MEGA

Bleeding the drum brake system

Top up the brake fluid reservoir on the operator's platform.
Remove pedal plates from the brake pedal arms.
Connect a bleed hose to bleed screw (D) and place the
other end of the hose into a suitable container (S). Loosen
bleed screw (D). Pull the foot brake pedal completely down
(until the piston of the master brake cylinder bottoms) by
hand several times from under the operator's platform. Hold
the brake pedal down and tighten bleed screw (D) again.
Release the brake pedal.
Repeat this procedure until the brake fluid comes out of the
bleed hose bubble-free.
NOTE: Ensure that there is sufficient brake fluid in the brake

fluid reservoir and in container (S).
(Fig. 1 31 )
After completing the bleeding process, install the pedal

plates on the brake pedal arms again.
Changing the brake pads of the disc brakes

Remove cover. Drive out pins (S) holding the brake pads on
the disc brake caliper.
(Fig. 1 32)
Push back the brake cylinders by forcing the brake pads

apart. Remove the brake pads (B) from above.
(Fig. 1 33)
1 33
DO 21 8 - 202 MEGA 8.55

Removal of the brake caliper unit

Disconnect the brake line at the bottom of the disc brake
caliper unit and plug the line.
Unbolt disc brake caliper (F) at the flange and remove the
complete assembly.
NOTE: The hexagon head bolts (1 ) are Verbus-Plus

self-locking bolts and have a very tight fit.
(Fig. 1 34)
Disassemble disc brake caliper (F) by removing connecting

bolts (2).
(Fig. 1 35)
1 35
The brake pistons can be easily pressed out of the calipers

with compressed air if one of the brake fluid bores is
blocked off.
(Fig. 1 36)
1 36
The seal rings can now be replaced.

(Fig. 1 37)
1 37
8.56 DO 21 8 - 202 MEGA

Disc brake caliper unit dismantled:
1 Inner housing half

2 Outer housing half
12 11
3
4
5
Quadring
Lip seal
Brake piston
■i ]0 6 2
=7
6 O-ring (seal for the brake fluid bores) o3 o
4 •s• o
4 o.
3 ·j =
•8 ■9 ■ a8
7 Hexagon head bolt M 1 0 x 75 - 1 0.9
(connecting bolts for the housing halves)
8 Plate behind the brake pads
(note the correct direction of installation)
9 Brake pad
1O Locking pins 1 38
11 Spring plate
12 Cover
13 Bleed nipple
(Fig. 1 38)
Assembly of the disc brake caliper unit

Place quadrings (3), lip seals (4) and brake piston (5) into
the housing halves.
Make sure that all parts are absolutely clean and lightly
oiled.
Install O-rings (6) and bolt the brake calipers together with
hexagon head bolts (7).
Tightening torque= 39 Nm
(Fig. 1 39)
1 39
�CJ:
NOTE: The plates (8) behind the brake pads must be
installed so that the scythe-shaped recesses (H) face in the
opposite direction to the direction of rotation (X) - arrow - of
the brake disc. �
(Fig. 1 40)
1 40
DO 21 8 - 202 MEGA 8.57

Do not insert the key to lock the brake disc at this stage.
Install the disc brake caliper and connect brake line (L).
Bolt the disc brake caliper to the flange using Verbus-Plus
hexagon head bolt M 1 6 x 1 .5 x 45 DIN 961 -1 0.9 and lock
washers at (1 ).
Use Verbus-Plus precision-fit bolt M 1 6 x 1 .5 x 4 2 DIN
61 0-1 0.9 at (2).
Tightening torque at (1 and 2)= 21 0 Nm
After complete assembly of the disc brake caliper, adjust the
brake disc on the intermediate drive shaft so that it is exactly
in the middle of the caliper, allowing for the axial clearance
of the intermediate shaft.
1 41
Insert the locking key into the brake disc.
(Fig. 1 41 )
Bleeding the disc brake system

Top up the brake fluid reservoir on the operator's platform.
Remove pedal plates from the brake pedal arms.
Connect a bleed hose to bleed screw (D) and place the
other end of the hose into a suitable container (S). Loosen
bleed screw (D). Pull the foot brake pedal completely down
(until the piston of the master brake cylinder bottoms) by
hand several times from under the operator's platform. Hold
the brake pedal down and tighten bleed screw (D) again.
Release the brake pedal.
Repeat this procedure until the brake fluid comes out of the
bleed hose bubble-free.
NOTE: Ensure that there is sufficient brake fluid in the brake
fluid reservoir and in container (S).
(Fig. 1 42)
After completing the bleeding process, install the pedal

plates on the brake pedal arms again.
8.58 DO 21 8 - 202 MEGA

9
Hydraulic System
9 HYDRAULIC SYSTEM HYDRAULIC PUMP
Removal of hydraulic oil reservoir complete with
hydraulic pump of lift hydraulic system 9. 1
Removal of hydraulic pump and hydraulic oil filter 9. 2
Hydraulic pump disassembled 9. 5
Assembling the hydraulic pump 9. 6
Damper 9. 7
HYDRAULIC CYLINDERSLOW-PRESSURE
HYDRAULIC SYSTEM
Removing hydraulic cylinder of threshing mechanism 9. 7
Disassembling hydraulic cylinder 9. 7
Assembling hydraulic cylinder 9. 8
Removing hydraulic cylinder of unloading auger 9. 9
Hydraulic cylinder disassembled 9. 10
Assembling hydraulic cylinder 9. 10
HYDRAULIC CYLINDERSHIGH-PRESSURE
HYDRAULIC SYSTEM
Removing Auto Contour System hydraulic cylinder 9. 1 1
Auto-contour hydraulic cylinder disassembled 9. 1 2
Installing Auto Contour System hydraulic cylinder 9. 1 2
Bleeding hydraulic cylinder for cutterbar
lateral levelling 9. 1 3
Reel hydraulic cylinder (raising and lowering) 9. 1 4

Disassembling reel hydraulic cylinders
(raising and lowering) 9. 1 4
Reel hydraulic cylinders (raising and lowering)
disassembled 9. 1 5
Bleeding reel cylinder (raising and lowering) 9. 1 6
Cutterbar hydraulic cylinder, replacing seals 9. 1 7
Disassembling cutterbar hydraulic cylinder 9. 1 7

Assembling and adjusting cutterbar
hydraulic cylinder 9. 1 9
Disassembling the rotary connector 9. 1 9

Rotary connector disassembled 9. 20
Assembling the rotary connector 9. 20
Disassembling the steering cylinder 9. 21

Steering cylinder disassembled 9. 22
Disassembling swing cylinder for grain tank

unloading auger 9. 23
Swing cylinder disassembled 9. 23
Assembling the swing cylinder 9. 24
Lock-up valve unit for swing cylinder 9. 25
Lock-up valve unit disassembled 9. 25
Hydraulic System
Cleanliness is imperative when servicing the hydraulic

system if the system is to function properly.
During disassembly of a hydraulic unit, always lay parts
removed out on a sheet of paper or cardboard.
Storing hydraulic components

If hydraulic components are to be stored after removal,
care should be taken to seal the connections with
plastic caps or something similar to prevent foreign
material from entering the component.
♦
HYDRAULIC PUMP
Removal of hydraulic oil reservoir complete with

hydraulic pump of lift hydraulic system
With all the hydraulic rams retracted, drain the hydraulic oil
from the system.
Relieve the tension on hydraulic pump drive belt at
9
tensioning bolt (S) and remove drive belt.
(Fig. 1 )
Disconnect hydraulic lines (L) at the hydraulic pump and the

return lines at the filters. Seal all lines and connections
using plastic caps or something similar.
(Fig. 2)
DO 21 8 - 202 MEGA 9. 1
Hydraulic System
Remove front shaft collar in front of jockey pulley arm (A) for
the ground drive pulley and pull the jockey pulley arm
forward.
Unscrew hex. nut of hydraulic pump mounting bolt and
remove the hydraulic pump together with the oil reservoir.
(Fig. 3)
Removal of hydraulic pump and hydraulic oil

filter
Loosen the clamping screw and remove pulley (K) from the
pump shaft.
(Fig. 4)
Remove hydraulic oil filter (F) from the hydraulic oil

reservoir.
During installation of the oil filter, ensure that recesses (B)
face upwards towards the filler neck. If the filter is not
installed in this way, oil will escape through the breather
screen when the cutterbar is lowered, particularly when
three cutterbar cylinders are installed.
(Fig. 5)
Unbolt support (C) at hydraulic pump and oil reservoir.

(Fig. 6)
9. 2 DO 21 8 - 202 MEGA
Hydraulic System
Going through the openings for the filters, unscrew hydraulic

pump (P) from the hydraulic oil reservoir.
(Fig. 7)
A damaged radial seal (D) can be replaced without

disassembling the pump. Use a screwdriver or similarly
suitable tool to lever out the damaged seal, taking care not
to damage its seat in the housing or the shaft.
During installation of the new radial seal, take care to
ensure that the lips of the seal are not damaged by the
keyway or at the shaft shoulder. Use a suitable tube to drive
in the seal.
(Fig. 8)
The hydraulic pump is secured in the oil reservoir by four M

8 x 25 DIN 933-8.8 Verbus Plus bolts.
Always use new Verbus Plus bolts if the hydraulic unit has
been disassembled. If genuine bolts are not available,
normal hex. bolts meeting the specifications of DIN 933-8.8
may be used. Coat these bolts with locking compound
(DELO-ML-5349) before inserting.
Take care to ensure that no locking compound gets into the
hydraulic pump.
DO 21 8 - 202 MEGA 9.3

Hydraulic System
Disassembling and assembling the hydraulic pump:
NOTE: Before disassembling the hydraulic pump, mark all

plates to ensure that they are installed in the same position.
1----1
All pump parts are matched and must not be installed in a

different position or mixed up during assembly.
�-� When removing the gear set of the low-pressure pump, take
care that driver ball (K) is not lost.
During pump assembly, ball (K) must fit into groove (N) of
the gear wheel to drive the gear set.
Pressure relief valve (D) of the low-pressure hydraulic
system is accessible after removing the pump or end plate
9 (E).
The setting pressure for the pressure relief valve is 21 +1 bar
at an oil temperature of 50 C.
The setting pressure can be adjusted at M 1 4 x 1 .5 DIN 906
plug (S). Do not adjust plug more than 1 /4 turn. If necessary,
use shims.
(Figs. 9 and 1 0)
Is
10
9.4 DO 21 8 - 202 MEGA

Hydraulic System
11
Hydraulic pump disassembled: 17 O-ring 25 x 3 Nb 70

18 O-ring 9.3 x 2.4 Nb 70
1 Breather air filter 19 O-ring 1 9.2 x 3 Nbr 872
2 O-ring 1 9 x 3.5 Nb 70 20 Triple hydraulic pump
3 Hydraulic oil reservoir 21 Screw connector
4 Hex. bolt M 8 x 25 DIN 933-8.8 22 Pipe union L 1 5 M DIN 3901
Seal A 8 x 1 4 Cu DIN 7603 23 Pipe union L 1 0 M DIN 3901
5 Filter head 24 Shaft seal 1 8 x 30 x 7 DIN 3760
6 Felt ring 25 x 36 x 3 25 Woodruff key 3 x 6.5 DIN 6888
7 Filter element 26 Spring washer A 1 2 DIN 1 28
8 Filter element 27 Hex. nut M 1 2 x 1 .5 6 22 H DIN 936
9 Felt ring 1 2 x 22 x 5 28 Hex. bolt M 8 x 25 Vp DIN 933.-8.8
10 Washer 1 3 DIN 433 Hex. bolt M 8 x 35 DIN 933.-8.8
11 Pressure spring 29 Seal
12 Lock washer 1 0 DIN 6799 30 Back-up plate
13 Seal 31 Glide plate
14 Seal A 22 x 27 Cu DIN 7603
15 Magnetic plug M 22 x 1 .5 (Fig. 1 1 )
16 Screw plug
DO 21 8 - 202 MEGA 9.5

Hydraulic System
Assembling the hydraulic pump

If necessary, glide plates (G), back-up plates (H) and/or
seals of the high-pressure pumps (steering/lift hydraulic
system) can be replaced while the hydraulic pump is
removed. The other parts of the pump cannot be replaced
individually.
When installing glide plates (G), ensure that the coated side
faced towards the pump gear wheels.
(Fig. 1 2)
Reassemble pump parts, observing the marks made during

disassembly. Insert attaching bolts (V) and initially tighten
crosswise fingertight. Finally tighten all bolts crosswise to
35 Nm.
(Fig. 1 3)
Cleaning the hydraulic oil filter

Clean the filter at each oil change.
Remove the filter from the reservoir. Remove securing
washer (9) and then pull filter element (4) out of filter top (2).
Since the return oil flows through the filter from the inside to
the outside, metallic particles or other foreign matter are
collected on the inside of the filter screen. Wash out filter
and blow through from the outside. Replace heavily soiled
filters.
Spring (8) and spring retainer (5) hold the filter tightly
against the base of the filter top. The filter is sealed by the
felt rings (3 and 6).
If the filter element becomes so heavily blocked that the
return oil cannot pass through fast enough, the filter element
will be unseated (pressure relief mechanism) and the oil
flows back unfiltered to the reservoir.
(Fig. 1 4)
9.6 DO 21 8 - 202 MEGA

Hydraulic System
Damper
{up to machine no . ........ )
Damper (D) is installed in the pressure line of the lift
hydraulic system and is located in the engine compartment
behind the platform back panel.
The damper stabilises the hydraulic oil flow and thus
reduces noise in the hydraulic system.
+-
(Fig. 1 5)
15
Direction of arrow= Direction of oil flow

A= Short pipe fitting, inlet
E= Long pipe fitting, outlet
(Fig. 1 5)
HYDRAULIC CYLINDERS
- LOW-PRESSURE HYDRAULIC SYSTEM -
Removing hydraulic cylinder of threshing

mechanism
Remove hydraulic cylinder (D).
Seal all hydraulic hoses and connections using plastic caps.
(Fig. 1 6)
Disassembling hydraulic cylinder

Turn cylinder head of removed cylinder so that locking wire
(S) is turned out of the groove in the cylinder barrel.
All seals can now be replaced.
(Fig. 1 7)
DO 21 8 - 202 MEGA 9. 7
Hydraulic System
Pull ram complete with cylinder head (K) out of the cylinder
barrel.
Clean ram and pull cylinder head from the ram.
(Fig. 1 8)
18
Hydraulic cylinder disassembled:

1 Cylinder barrel
2 Piston seal L26 - 40
3 Piston
4 Ram
5 O-ring 34.2 x 3 88 NBR 1 56
6 Back-up ring
7 Locking wire
8 Cylinder head
9 Seal
1 O Wiper seal
1 1 Screw plug
(Fig. 1 9)
19
Assembling hydraulic cylinder

1 . Piston (3) is secured on ram (4) with locking compound
(e.g. DELO - ML 5349).
2. Heat piston seal (2) in hot water before fitting. If
necessary, remove burrs on piston before assembly.
3. Oil all seals well and insert cylinder head into cylinder
�□:
barrel.
(Fig. 20)
0
20
Turn the cylinder head until hole in groove of cylinder head

is positioned under slot of cylinder barrel. Fit the hook of
locking wire (7) into hole in groove of cylinder head and turn
cylinder head. The locking wire is drawn into the groove.
Use a new locking wire whenever cylinder is disassembled.
(Fig. 21 )
9. 8 DO 21 8 - 202 MEGA
Hydraulic System
Removing hydraulic cylinder of unloading auger

Remove hydraulic cylinder (K).
Seal all hydraulic hoses and connections using plastic caps.
(Fig. 22)
Disassembling hydraulic cylinder

Clamp cylinder barrel in a vice and turn cylinder head so
that locking wire (1 1 ) is turned out of groove in cylinder
barrel.
(Fig. 23)
23
Pull cylinder head with ram out of the cylinder barrel.

Clean ram and pull cylinder head from the ram.
(Fig. 24)
24
Unscrew hydraulic piston (7) from ram (6).

(Fig. 25)
NOTE: Cap screw was locked with locking compound

before installation and is therefore very tight.
25
DO 21 8 - 202 MEGA 9.9

Hydraulic System
Hydraulic cylinder disassembled:
1 Cylinder barrel
2 Cylinder head
3 Seal
4 Wiper seal 22 x 30 x 7
5 O-ring 26.2 x 3 NB 70
6 Ram
7 Hydraulic piston
8 Piston seal
10 Hex. bolt MB x 20 DIN 933-8.8
11 Locking wire
26 12 Pipe union L 8 M DIN 3901
(Fig. 26)
Assembling hydraulic cylinder

1 . 1 . When installing hydraulic piston (7), apply compound
(e.g. DELO-ML 5349) to hex. bolt (1 0).
2. 2. Heat piston seal (8) in hot water before fitting.
3. 3. Coat O-ring (5) lightly with oil. Insert cylinder head (2)
into cylinder barrel (1 ) and turn until the hole in groove
of cylinder head is positioned under the slot in the
cylinder barrel. Fit the hook of locking wire (1 1 ) into
hole in groove of cylinder head and turn cylinder head.
The locking wire is drawn into the groove.
Use a new locking wire whenever cylinder is
disassembled.
(Fig. 27)
9. 1 0 DO 21 8 - 202 MEGA
Hydraulic System
Removing Auto Contour System hydraulic

cylinder
Seal the hydraulic hoses and connections using plastic
caps.
Disconnect couplings.
(Fig. 28)
28
Unscrew hydraulic cylinder barrel and remove from piston.

(Fig. 29)
29
Unscrew piston from ram.

(Fig. 30)
30
DO 21 8 - 202 MEGA 9. 1 1
Hydraulic System
CLAAS AUTO CONTOUR hydraulic cylinder disassembled:
1 Ram
2 Seal
3 Piston
4 Screw plug
5 Seal
i __ ® 6 Seal
Sealing washer (edge type)
7 Hex. socket head cap screw M 6 x 1 2 DIN 91 2
t(f;§slj1f...,----_@)
8 Wiper seal
9 Seal
CD @) 1O Cylinder head
'-@ 11
12
Non-return valve
Restrictor plate
13 Snap ring B 7 DIN 7993
14 Back-up ring
®-§ @--a 15 O-ring 58 x 3 - N DIN 3771
16 Hydraulic cylinder
®-� @-o 17 Pipe union L 8 B-M DIN 3901
18 Hex. bolt M 1 6 x 1 40 DIN 931
®-§ Hex. nut M 1 6 DIN 934
(Fig. 31 )
0- ®
@---@
31
Installing Auto Contour System hydraulic

cylinder
Install hydraulic cylinder and bleed hydraulic system.
Operate the system in a test run to check for leakage.
(Fig. 32)
32
9. 1 2 DO 21 8 - 202 MEGA
Hydraulic System
Bleeding hydraulic cylinder for cutterbar lateral

levelling
(Machines with Auto Contour System)
This must be done after the hydraulic system has been
repaired.
1 . Move lever (H) to (A) in order to open shut-off tap (R).
Loosen hex. screw plugs (V) on both the coupling lugs.
On the right-hand side loosen hex. head Allen screw
(K) at the cylinder head.
2. Switch on safety rocker switch (62). Press the R/H end
of the rocker switch (51 ) for manual operation so that
both pistons extend. Tighten screws (V and K) when 33
bubble-free oil emerges.
3. Both cylinders should now be full extended. Loosen
hex. head Allen screw (L) at the UH cylinder.
4. Press the UH end of the rocker switch (51 ). Tighten the
screw (L) when bubble-free oil is issued. The UH
cylinder is now retracted.
(Figs. 33 to 36)
34
35
36
DO 21 8 - 202 MEGA 9. 1 3
Hydraulic System
Reel hydraulic cylinder (raising and lowering)

Function of the synchronised reel cylinders:
The reel is raised and lowered by synchronised cylinders.
z When the lever of the hydraulic control unit is moved to the

»raise reel« position, oil is fed into the cylinder (1 ) at (Z).
During the upward stroke of the piston, the oil above the
piston is pushed into the cylinder (2) through connecting
pipeline (V), thus pushing up the piston at the same time.
(Fig. 37)
Absolute equal pressure in both cylinders:

37 In the highest and lowest reel positions by means of valves
(1 6).
Proper functioning of the synchronised cylinders is only
assured if the cylinders are bled properly.
(Figs. 37 and 39)
Disassembling reel hydraulic cylinders (raising

and lowering)
Turn head of removed reel hydraulic cylinder so that locking
wire (S) is turned out of the groove in the cylinder barrel.
Pull the cylinder head out of the cylinder barrel.
All seals can now be replaced.
(Fig. 38)
38
9. 1 4 DO 21 8 - 202 MEGA
Hydraulic System
I r
36
- - - - -�
( a �
39
Reel hydraulic cylinders (raising and lowering)

disassembled:
1 Reel cylinder assembly 20 Piston

2 Reel cylinder assembly 21 Piston seal
3 Eye bolt 22 Guide ring
4 Hex. bolt Bm 1 6 DIN 439 23 Hydraulic cylinder
5 Wiper seal 24 Eye bolt
6 Seal 25 Hex. nut Bm 1 6 DIN 439
7 Cylinder head 26 Wiper seal
8 Pipe union L 8 B-M DIN 3901 27 Seal
9 Locking wire 28 Cylinder head
10 Back-up ring 29 Screw plug
11 0-ring 30 Seal
12 Ram 31 Locking wire
13 Expansion pin 5 x 30 DIN 1 481 32 Back-up ring
14 Expansion pin 3 x 30 DIN 1 481 33 0-ring
15 Shaft collar 34 Ram
16 Valve 35 Circlip A 24 DIN 7993
17 Pressure spring 36 Hydraulic cylinder
18 Spacer tube 37 Pipe union L 8 B-M DIN 3901
19 0-ring (Fig. 39)
DO 21 8 - 202 MEGA 9. 1 5
Hydraulic System
a) Bleeding the reel cylinder

The reel cylinders have to be bled after any assembly work
on the cylinders and their pipelines.
1 . Raise the reel to the upper stops. If necessary, push up
the stops by hand.
2. Loosen (do not remove!) the bleed plug on the cylinder.
3. Hold the lever of the hydraulic control unit in the »raise
reel« position. When the oil runs out free of bubbles,
retighten the bleed plug. Finally raise and lower the
reel fully several times.
4. The reel cylinders must operate simultaneously,
otherwise repeat the bleeding procedure.
If the oil is completely drained from the reel hydraulic
cylinders, the following bleeding procedure must be
performedI
b) Bleeding the reel cylinders

Bleeding completely drained cylinders with reel
removed.
Move lever of hydraulic control unit to the "raise reel"
position. The left-hand cylinder is extended first. The valve
in the cylinder opens only when the cylinder is fully
extended, allowing the oil to flow to the right-hand cylinder.
When the oil runs out of the right-hand cylinder free of
bubbles, tightly close the bleed screw. Move lever of
hydraulic control unit to the "lower reel" position and push in
the right-hand cylinder by hand. The left-hand cylinder will
be retracted at the same time.
Fit the reel and raise to its highest position. Hold the lever of
the hydraulic control unit in the "raise reel" position and
loosen (do not remove!) the bleed plug on the right-hand
cylinder again. Close the bleed plug again when the oil runs
out free of bubbles.
9. 1 6 DO 21 8 - 202 MEGA
Hydraulic System
Cutterbar hydraulic cylinder, replacing seals
Removing the cylinder head:

Turn cylinder head of removed cutterbar hydraulic cylinder
so that locking wire (1 8) is turned out of the groove in the
cylinder barrel. Pull the cylinder head out of the cylinder
barrel. All seals can now be replaced.
Installing the cylinder head:

Push cylinder head fully into cylinder barrel and turn until
hole in groove of cylinder head is positioned under slot of
cylinder barrel. Fit hook of locking wire (1 8) into hole in
groove of cylinder head and turn cylinder head. The locking
wire is drawn into the groove. 40
Use a new locking wire whenever cylinder is disassembled.
(Fig. 40)
Disassembling cutterbar hydraulic cylinder

Evenly unscrew the three M 1 2 x 380 hex. socket head cap
screws (1 ). Tension is now fully relieved from the pressure
spring (6).
Remove spring and spring retainer.
(Fig. 41 )
41
Remove circlip (4) and spring guide (5) from cylinder.

(Fig. 42)
42
DO 21 8 - 202 MEGA 9. 1 7
Hydraulic System
G) ® ® © ®
I I
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43
Cutterbar hydraulic cylinder disassembled:
1 Hex. socket head cap screw M 1 2 x 380 x 360

DIN 91 2-8.8 (3 used)
2 Washer 1 3 x 22 x 1 .5
3 Spring retainer, front
4 Snap ring A 80 DIN 7993
5 Spring guide
6 Pressure spring
7 Spring retainer, rear
8 Washer 1 6.5 x 33 x 5
(4 used, two for each guide rod)
9 Self-locking nut VM 1 6 x 1 .5 DIN 980-1 0
10 Collar bushing (2 used)
11 Hex. bolt M 1 6 x 45 DIN 933-8.8
»Verbus Plus« (2 used)
12 Pipe union L 1 0 M DIN 3901
13 Guide bushing
14 Hydraulic cylinder
15 Snap ring A 55 DIN 7993
16 Hydraulic ram
17 O-ring 58 x 3 NB 72
18 Back-up ring
19 Locking wire 4 x 202
20 Cylinder head
21 Seal
22 Wiper seal P 6-55, 55 x 65 x 7
(Fig. 43)
9. 1 8 DO 21 8 - 202 MEGA
Hydraulic System
Assem bling and adjusting cutterbar hydraulic

cylinder
1 . Secure fit snap ring (1 5) in the groove of the hydraulic
ram (1 6)
2. Coat back-up ring (1 8), O-ring (1 7), seal (21 ) and wiper
seal (22) with oil and install.
3. Before inserting cylinder head, ensure that there are no
burrs on the cylinder barrel.
4. Use a new locking wire (1 9) whenever cylinder is
disassembled.
When the cutterbar trough is installed, adjust pressure
springs (6) of cutterbar cylinders.
Lower the cutterbar so that the skids are approx. 1 00 mm 44
above the ground. With the hex. socket head cap screws
(1 ), adjust the pretension of the pressure springs so that
there is a clearance (approx. 1 mm) between the flanges (F)
of the hydraulic cylinders (1 4) and the self-locking nuts (9)
or washers (8) on the bolts (8). The pointer on the floatation
indicator gauge is now positioned at the end of the scale.
Ensure that both pressure springs are adjusted evenly.
(Figs. 43, 44 and 45)
45
Disassembling the rotary connector

Remove the circlip (1 ) and stepped washer (2) from the
connector.
(Fig. 46)
Clamp the hex. flats of the connector in a vice (not too

tightly!) and remove circlip (1 0) from the groove.
(Fig. 47)
47
DO 21 8 - 202 MEGA 9. 1 9
Hydraulic System
Using a tapered key drift (K) and screwdriver (S), evenly

drive the oil inlet stem together with the ball bearings out of
the connector. Press the back-up ring and seal out of the
connector.
(Fig. 48)
48
Rotary connector disassembled:

2 Stepped washer
3 Seal
4 Back-up ring
5 Connector
6 Stop washer
8 Deep groove ball bearing 6000 Z DIN 625
(2 used)
9 Spacer
10 Circlip 26 x 1 .2 DIN 472
49 11 Oil inlet stem
12 Sealing washer (edge-type)
13 Restrictor pin assembly
14 Restrictor pin
15 Circlip B 7 DIN 7993
(Fig. 49)
Assembling the rotary connector

13 Place circlip (1 0) loosely on the oil inlet stem and drive the
��-15 first ball bearing (8) into position. Fit spacer (9), drive
!+,>,,,--'14 second ball bearing (8) into position and secure with circlip
(7). Fit back-up ring (4), seal (3), stepped washer (2) and
circlip (1 ) into connector (5) from the threaded side.
12
50
9.20 DO 21 8 - 202 MEGA

Hydraulic System
NOTE: The inner diameter of back-up ring (4) is slightly

larger on one side. The side with the smaller inner diameter �
must face in the direction of the arrow towards the seal. Fit
seal (3) with its open side in the direction of the arrow
�Q
=
towards the oil pressure side. Fit stepped washer (2) with its
shoulder towards the seal and fit circlip (1 ). Place stop
washer (6) into connector (5) so that its hollow side faces
towards the ball bearing. Insert the oil inlet stem into the
connector and secure with circlip (1 0).
(Fig. 50)
Disassembling the steering cylinder

Turn cylinder head (8) so that the locking wire (9) is turned
out of the groove in the cylinder barrel (1 7). Pull the cylinder
head together with the ram and piston out of the cylinder
barrel.
(Fig. 51 )
DO 21 8 - 202 MEGA 9.21

Hydraulic System
0
I
�
52
.
Steering cyhnder disassembled:
.
1 Split pm 5 x 45 DIN 94
2 Castellated nut M 24 x 1 .5
3 sealing cap
4 Ball joint
5 Wiper seal
6 Seal
.
(2 used)
8 Cylinder h�ad
9 Locking �ire 4 X 202
10 Back-up rm
�
11 O-ring 58 x NB 72
12 Ram
13 Spacer 65 x 7
14 Seal
15 Piston
16 Piston n_ut
17 Hydraulic cyl'nder
I
(Fig. 52)
9.22 DO 21 8 - 202 MEGA

Hydraulic System
Disassembling swing cylinder for grain tan k

unloading auger
The swing cylinder for the unloading auger is disassembled
in the same manner as the steering cylinder (see above).
53
Swing cylinder disassembled: 12 Hex. nut BM 1 8 x 1 .5 DIN 439

13 Yoke
1 Cylinder barrel 14 Pipe union L 1 0 M DIN 3901
2 Seal (2 used) 15 Angle union L 1 0 M
3 Piston
(Fig. 53)
4 Bush
5 Ram
6 O-ring 46.2 x 3 NB 72
7 Back-up ring
8 Locking wire
9 Cylinder head
10 Seal
11 Wiper seal
DO 21 8 - 202 MEGA 9.23

Hydraulic System
13 12 11 10 9 8 7 6 1 2
54
Assembling the swing cylinder

The functional cross-section applies also to the steering
cylinder:
Install hydraulic piston (3) and bush (4) on ram (5) coated
with locking compound (e.g. Casco 1 1 8/Loctite 75 or
similar).
Fit new seals on the hydraulic piston from both ends. The
seals must not be pushed over the centre land of the piston.
Always install the seals with the open sides facing outwards
(i.e. away from one another).
Install back-up ring (7) in front of O-ring (6) (i.e. facing
outwards) in the same groove of cylinder head (9). Install
.____. seal (1 0) with the open side facing towards the oil pressure
side and then fit wiper seal (1 1 ). Oil the seal and O-ring well
before installing.
Push cylinder head (9) up to the stop in cylinder barrel (1 ).
Turn cylinder head until hole in groove of cylinder head is
positioned under slot of cylinder barrel. Fit hook of locking
wire (8) into hole in groove of cylinder head and turn
cylinder head. The locking wire is drawn into the groove.
Use a new locking wire whenever the cylinder is
disassembled.
(Fig. 52, 53 and 54 )
9.24 DO 21 8 - 202 MEGA

Hydraulic System
Lock-up valve unit for swing cylinder

Lock-up valve (S) is located on the left-hand side of the front
wall in the engine compartment.
Non-return valves (4a and 4b) hold the unloading auger
stationary in the extended or retracted position.
If the unloading auger does not hold its preset position,
clean the respective valve or valve seating. Replace valve
or valve seating if damaged:
A = Connection and pressure line for swinging in the
grain tank unloading auger
B = Connection and pressure line for swinging out the
grain tank unloading auger 55
The larger surface area of control piston (2) ensures that the
non-return valve on the return side opens before the
non-return valve on the pressure side.
Restrictor plates (8) prevent the unloading auger swinging in
or out too fast. They are inserted between the hydraulic
A B
pipelines and the pipe unions (7).
(Figs. 55, 56 and 57)
A B
4a 2 4b
56
l
r: 57
Lock-up valve unit disassembled:
1 Valve body
2 Piston 1 5 x 1 5 DIN 5402
3 Threaded inserts
4 Poppet valve
5 Pressure spring
6 Spring guide
8 Restrictor plate D 1 0 / 1 . 1 mm
9 Pipe union L 8 M DIN 3901
(Fig. 57)
DO 21 8 - 202 MEGA 9.25

10
Steering and rear axle
10 STEERING AND REAR AXLE STEERING
Orbital steering unit problems 1 0. 1
Removal of steering column 1 0. 2
Installation of steering column 1 0. 2
Removal of valve block 1 0. 2
Installation of valve block 1 0. 3
Removal of steering unit 1 0. 3
Installation of steering unit 1 0. 4
Checking the hydraulic pressure of
steering system 1 0. 5
Bleeding the steering system 1 0. 5
REAR AXLE
Rear axle suspension 1 0. 6
Removal of wheel bearings 1 0. 7
Removal of stub axle 1 0. 8
Installation of stub axle 1 0. 12
Adjustment of the toe-in 1 0. 15
Adjustment of the steering stops 1 0. 15
Removal of the wheel hub unit 1 0. 16
Removal of the stub axle frame 1 0. 17
Assembling the stub axle 1 0. 19
STEERING
Orbital steering unit problems
External leaks:
External leaks are visible by oil leaking a t the flanges of the
valve block and of the steering block, and oil leaking from
the pressure relief valve and from the shock valve.
Cause:
1 . O-rings on the flange do not seal properly.
2. O-rings on the adjustment screw of the relief valve do
not seal properly.
3. O-rings on the shock valve plug do not seal properly.
Internal leaks:
Internal leaks might be the reason when the rear wheels do
not respond immediately to steering on soft ground, or no
firm resistance can be felt on the steering wheel when the
rear wheels are turned all the way to the left or right.
Cause:
The internal O-rings of the shock valve do not seal properly.
Remedy:
1 . If oil is leaking from the flanges of the valve block and
steering block, fit new O-rings.
2. If oil is leaking from the relief valve and shock valve and
if there are internal leaks, replace the complete valve
unit and fit a new one.
DO 21 8 - 202 MEGA 1 0. 1
Removal of steering column

Remove the steering wheel. Unbolt the steering column on
the operator's platform and remove it as a complete unit.
The shaft can be removed from the steering column tube by
pulling the shaft from the bottom end out of the tube.
(Fig. 1 )
T
Installation of steering column
A Adjust the starlock washer (E) on the steering column shaft
1-----1 (L) so that the shaft is free to move 1 to 1 .5 mm upward,
with steering column adjusted to any of the different
positions. Next, properly locate set collar (S) in order to fix
the starlock washer in position and to keep if from moving
1-----1 upward.
w ( F;g . 2 )
Removal of valve block

Disconnect the hydraulic lines from the valve block of the
steering unit. Plug the hydraulic lines and fittings with dust
caps.
(Fig. 3)
Remove the two socket head cap screws that secure the
valve block to the steering motor and remove the valve
block.
Note dowel pin.
(Fig. 4)
� 4
1 0.2 DO 21 8 - 202 MEGA

Valve block removed:

1 . O-rings OR 23.47 x 2.62 N DIN 3771
2. Valve block assembly
3. Socket head cap screw M 1 0 x 1 x 45 DIN 91 2-1 0.9
(Fig. 5)
Installation of valve block

1 . Thoroughly clean the flange faces of the valve block and
steering motor.
2. Make sure that the dowel pin is in position. The dowel
pin prevents the valve block from being mounted in
offset position.
3. Place seals (1 ) into recesses, position the valve block.
Make sure that the dowel fits in the corresponding hole
of the steering motor and that the seals are properly
seated.
4. Screw in socket head cap screws (3) and tighten the
screws to 65 Nm.
5. Connect hydraulic lines; always remember that absolute
cleanliness is essential.
(Fig. 5)
Removal of steering unit

Unbolt steering column on operator's platform.
Unbolt steering unit at operator's platform.
(Fig. 6)
DO 21 8 - 202 MEGA 1 0.3

Disconnect all hydraulic lines from the valve block and

remove the steering unit. Plug hydraulic lines and fittings
with dust caps.
(Fig. 7)
Replace O-rings (1 ) or renew the complete valve block (2),

see »Installation of valve block«.
1 O-rings OR 23.47 x 2.62 N DIN 377 H 1 (4 each)

2 Valve block assembly
3 Socket head cap screw M 1 0 x 1 x 45 DIN 91 2
(2 each)
4 Steering motor
5 Flange tube
(Fig. 8)
Installation of steering unit

When working on the steering unit, absolute cleanliness is
essential.
Screw the steering unit in place and connect hydraulic lines.
Install the steering column.
Check valves for emergency steering:

A = in the line from the steering valve block to the
hydraulic oil reservoir 1 .0 bar
B = in the line from the hydraulic oil reservoir to the
steering valve block 0.2 bar
Direction of arrow= flow direction
(Fig. 9)
1 0.4 DO 21 8 - 202 MEGA

Checking the hydraulic pressure of steering

system
The gauge connection (M) is located in the pressure line to
the steering unit.
Assembly mini gauge connecting hose (S) 1 81 951 . 0; mini
gauge coupling L 1 0-series 683.656.0; gauge connector
238 921 . 0 and oil pressure gauge (0 to 600 bar) 1 81 922. 0
and then connect the complete testing kit to the gauge
connection (M) (See also special tool catalogue).
I
With the engine nmnlng at fast Idle and with hydraulic oll at
...Q--,1
operating temperature, turn the steering wheel to the full
lock and hold it in this position. Now the gauge shows the
hydraulic pressure setting.
Proper hydraulic pressure of steering unit is 1 20 bar
(Fig. 1 0)
\I/
Bleeding the steering system
Each time the hydraulic steering column and its lines have
been serviced, the hydraulic lines must be bled with the __x_
engine stopped and ignition key removed (two persons are
required to carry out this job):
1 . Jack up under the centre of the steering axle to take the
weight off the rear wheels. Put a clean container under
the hydraulic steering cylinder to catch the hydraulic oil.
2. Turn the steering wheel to the left-hand lock. Disconnect
hydraulic hose (R) at the steering cylinder. Turn the
steering wheel to the right until bubble-free oil comes out
of the hydraulic hose. Reconnect the hydraulic hose.
Turn the steering wheel further to the right-hand lock. 11
3. Disconnect hydraulic hose (L) at the steering cylinder.

Turn the steering wheel to the left until bubble-free oil
comes out of the hydraulic hose. Reconnect the
hydraulic hose.
(Fig. 1 1 )
IMPORTANT! Check the level of the oil in the hydraulic

tank during the bleeding process and top up as
required.
DO 21 8 - 202 MEGA 1 0.5

REAR AXLE
If the rear axle and/or the rear axle suspension has to be

removed from the machine, securely support the machine
under the square tube.
(Fig. 1 2)
Position the stands or blocking material under the extreme

ends of the square tube. If required, insert a shaft (W),
40 mm diameter, into the square tube for supporting the
machine on the stands.
(Figs. 1 2 and 1 3)
13
Rear axle suspension

The rear axle suspension (A) is connected with the thresher
house and cleaning unit on both sides of the machines.
Hex. bolts M 1 4 x 1 30 DIN 931 -8.8 are used at connections
(H). Hex. bolts M 1 4 x 40 DIN 933-8.8 are used at
connections (C).
Torque on the bolts= 1 22 Nm
The rear axle suspension is also supported by two tube
braces from underneath.
Hex. bolts 1 1 6 x 40 DIN 933-8.8
Self-locking nut VM 1 6 and at each bolt two contact
14 washers A 1 6.
(Fig. 1 4)
1 0.6 DO 21 8 - 202 MEGA

Removal of wheel bearings

(2. 05 m rear axle)
Support the combine securely with suitable stands or blocks
under the rear axle and remove the wheels. Remove screw
cap (K). This is best done by inserting a wheel bolt and
securing the hub with a suitable lever (F) to prevent it from
turning.
(Fig. 1 5)
[I]
Unlock and remove the castle nut.
(Fig. 1 6)
16
Remove the wheel hubs (N) with a puller.

(Fig. 1 7)
17
Remove the front taper roller bearing and remove the outer
races of the bearings, if required, by using a punch.
(Fig. 1 8)
18
DO 21 8 - 202 MEGA 1 0. 7
Drive the rear taper roller bearing off the stub axle end by
using a dull chisel or similar tool. Then remove the bearing
completely with a puller. Be careful not to damage the seal.
(Fig. 1 9)
Removal of stub axle

(2. 05 m rear axle)
Remove the wheels and wheel bearings. Unlock and
remove the castle nut of the steering cylinder and of the
track rod.
Loosen the ball joints on the steering arm:

Tap with one hammer against the cone-shaped eye while
keeping the steering arm steady with a second hammer.
(Fig. 20)
Unscrew the bolt from the axle spindle and pull out the stub
axle assembly to the bottom.
(Fig. 21 )
21
Drive out the worn bearing bushings (B) and press in new
ones.
The new bearing bushings are precisely matched, and it
may be necessary to use flat iron straps and a screw clamp
bolt to press the bearing bushings into position.
(Fig. 22)
1 0.8 DO 21 8 - 202 MEGA

®-�
@-\ g----- 0
rl:
@--@9
i
@------o
@
ii @
23
Rear axle disassembled: 22 Ball joint

(2. 05 m rear axle) 23 Sealing cap
24 Self-locking nut V m 1 4 x 1 ,5
1 Bearing bushing 25 Hex. bolt M 1 2 x 55 DIN 933
2 Rear axle Hex. nut M 1 2 DIN 936
3 Stub axle, right
4 Hex. bolt M 1 2 x 20 DIN 933 (Fig. 23)
5 Cover washer
6 Bearing bushing
7 Bearing bushing
8 Axial thrust washer 45 x 65 x 3
9 Stub axle, left
10 Multi-ring seal
11 Thrust washer
12 Taper roller bearing 3021 0 DIN 720
13 Wheel hub
14 Taper roller bearing 30206 DIN 720
15 Washer
16 Caste nut M 24 x 2 DIN 937
17 Roll pin 5 x 36 DIN 1 481
18 Cap
19 Hex. bolt M 1 8 x 1 .5 x 30 DIN 961
Spring washer
20 Track rod
21 Hex. nut M 28 x 1 .5 DIN 936
DO 21 8 - 202 MEGA 1 0.9

5 4
9 ----l...
24
Installation of stub axle

(2.05 m rear axle)
4. Fit thrust washers (8) onto the stub axle so that the
polished faces point towards each other.
5. Press bearing bushings (7 and 8) into the rear axle.
Grease and fit the stub axle and secure with washer (5)
and hex. bolt (4).
6. Push multi-ring seals (1 0) with thrust washer (1 1 ) onto
stub axle. Press on taper roller bearing (1 2). Fill area (F)
in hub (1 3) with grease and fit wheel hub.
7. Grease and press in taper roller bearing (1 4). Adjust the
bearings with castle nut (1 6) so that there is not
measurable play when turning the bearing constantly in
either direction. Torque must not exceed 2.5 Nm.
8. Lock castle nut with roll pin and fit greased cap (1 8).
(Figs. 23 and 24)
1 0. 1 0 DO 21 8 - 202 MEGA
\l\j'---©
-- 0
O- @
S'-®
25
Rear axle disassembled: 23 Hex. bolt M 20 x 50 DIN 933-8.8

(2.30 m - 2. 70 m rear axle) Circlip 20
24 Hex. bolt M 1 6 x 45 DIN 933-8.8
1 Rear axle Hex. nut M 1 6 DIN 934-8
2 Bearing bushing 25 Stub axle, right
3 Adjustable element, right 26 Self-locking nut Vm 20 x 1 .5
4 Hex. bolt M 1 2 x 20 DIN 933-8.8 27 Bellow-type seal
Spring washer 1 2 DIN 1 28 28 Ball joint
5 Cover washer 29 Clamp
6 Bearing bushing 30 Track rod
7 Adjustable element, left 31 Hex. nut M 30 x 1 .5
8 Bearing bushing 32 Ball joint
9 Thrust washer
10 Stub axle, left (Fig. 25)
11 Multi-ring seal
12 Thrust washer
14 Wheel hub
16 Washer
17 Caste nut M 33 x 1 .5 DIN 937
18 Roll pin 6 x 45 DIN 1 481
19 Screw cap
20 Hex. bolt M 1 8 x 1 .5 x 35 DIN 961
Spring washer
21 Hex. bolt M 1 6 x 40 DIN 933-8.8
22 Cylinder holder
DO 21 8 - 202 MEGA 1 0. 1 1
5 4
19
18
17
26
Installation of stub axle

(2.30 m - 2.70 m rear axle)
1 . Fit thrust washers (9) onto the stub axle so that the
polished faces point towards each other.
2. Press bearing bushings (6 and 8) into the rear axle.
Grease and fit stub axle and secure with washer (5) and
hex. bolt (4).
3. Push multi-ring seals (1 1 ) with thrust washer (1 2) onto
stub axle. Press on taper roller bearing (1 3). Fill area (F)
in hub (1 4) with grease and fit wheel hub.
4. Grease and press in taper roller bearing (1 5). Adjust the
bearings with castle nut (1 7) so that there is not
measurable play when turning the bearing constantly in
either direction.
Torque must not exceed 2.5 Nm.
5. Lock castle nut with roll pin and fit cap with sealing
compound DELO-ML 5349.
(Figs. 25 and 26)
1 0. 1 2 DO 21 8 - 202 MEGA
27
Rear axle disassembled: 23 Hex. bolt M 1 6 x 40 DIN 933-8.8

(2.30 m - 2. 70 m rear axle Contact washer A 1 6
rice version) 24 Cylinder holder
25 Hex. bolt M 20 x 50 DIN 933-8.8
1 Rear axle Circlip 20
2 Bearing bushing 26 Hex. bolt M 1 6 x 45 DIN 933-8.8
3 Adjustable element, right Hex. nut M 1 6 DIN 934-8
4 Hex. bolt M 1 2 x 20 DIN 933-8.8 27 Stub axle, right
Spring washer 1 2 DIN 1 28 28 Self-locking nut Vm 20 x 1 .5
5 Cover washer 29 Bellow-type seal
6 Bearing bushing 30 Ball joint
7 Adjustable element, left 31 Clamp
8 Bearing bushing 32 Track rod
9 Thrust washer 33 Hex. nut M 30 x 1 .5
10 Stub axle, left 34 Ball joint
11 Axial face seal (Fig. 27)
12 O-ring
13 Hex. socket head cap screw M 8 x 20 DIN 91 2-8.8
Spring washer 8 DIN 7980
14 Bearing ring, inner
16 Wheel hub
18 Washer
19 Caste nut M 33 x 1 .5 DIN 937
20 Roll pin 6 x 45 DIN 1 481
21 Screw cap
22 Hex. bolt M 1 8 x 1 .5 x 35 DIN 961
Spring washer
DO 21 8 - 202 MEGA 1 0. 1 3
21
20
19
28
Installation of stub axle 6. Grease and press in taper roller bearing (1 7) and
(2.30 m - 2. 70 m rear axle rice version) grease. Adjust the bearings with castle nut (1 9) so that
1 . Fit thrust washers (9) onto the stub axle so that the there is not measurable play when turning the bearing
polished faces point towards each other. constantly in either direction.
2. Press bearing bushings (6 and 8) into the rear axle. Torque must not exceed 2.5 Nm.
Grease and fit stub axle and secure with washer (5) and 7. Lock castle nut with roll pin and fit cap with sealing
hex. bolt (4). compound DELO-ML 5349.
3. Push greased axial face seal (1 1 and 1 2) onto stub axle. (Figs. 27 and 28)
Push bearing ring (1 4) onto the stub shaft.
4. Press on taper roller bearing (1 5). Fill area (F) in hub
(1 6) with grease and fit wheel hub.
5. Apply an even, thin coat of sealing compound
(DELO-ML 5328) to the wheel hub.
Fit hex. socket head cap screws (1 3)
1 0. 1 4 DO 21 8 - 202 MEGA
Adjustment of the toe-in
To do this, adjust the track rod (S) as follows:

Loosen lock nut (1 ) and turn ball joint (2) in or out as
required.
(Fig. 29)
The rear wheels should have a toe-in of 0 to 1 5 mm

maximum. Toe-in is measured at the rim flanges where the
beading of the tyre rests.
(Fig. 30)
30
Adjustment of the steering stops
The steering stop bolts (A) have to be adjusted after any

adjustment of rear wheel toe-in:
1 . Position a jack under the centre of the rear axle and
raise the machine.
31
2. Screw stop bolts (A) all the way in.
3. Turn the steering wheel all the way to one lock.
4. Adjust the steering stop bolt so that the stop head lightly
touches the steering arm.
Now screw out the stop bolt one additional revolution so
that the hydraulic ram in the cylinder will have about 2.5
mm free play before it will lock. Perform the same
adjustment on opposite side. Lock both stop bolts into
place with the lock nuts.
(Fig. 31 )
DO 21 8 - 202 MEGA 1 0. 1 5
❖ Removal of the wheel hub unit

Support the rear axle securely.
1-----1 Take off the wheel and disconnect the hydraulic steering
cylinder on the left side, as seen in the direction of travel.
(Fig. 32)
32
Disconnect the hydraulic hoses and close the ends tight

with plastic caps.
(Fig. 33)
33
Unscrew the 90-degree elbow swivels.

(Fig. 34)
34
Unscrew the M 1 6 x 40 hexagon socket head cap screws

from the wheel hub unit.
(Fig. 35)
35
1 0. 1 6 DO 21 8 - 202 MEGA
Secure the wheel hub unit with a suitable lifting device.

Pull the wheel hub unit out of the stub axle frame while
turning it.
(Fig. 36)
36
Removal of the stub axle frame

Remove the wheel hub unit.
Remove the rear wheel position indicator completely.
(Fig. 37)
Unscrew the nut and loosen the bolt for the track rod.
Remove the slotted nuts from the pivot pins.
Remove the pivot pins.
Take off the stub axle frame.
(Fig. 38)
38
Press the bearing out of the frame with a special tool.

(Fig. 39)
DO 21 8 - 202 MEGA 1 0. 1 7
Special tools:
1 Hex. bolt M 1 6 x 300, replacement part no. 237 375. 1

2 Hex. nut M 1 6, replacement part no. 244 059. 0
3 Axial grooved ball bearing, replacement
part no. 1 77 899. 0
4 Puller cross bar, replacement part no. 1 81 836. 0
5 Pipe outer diameter 0 74 x 5 x 1 1 0 mm
6 Pipe inner diameter 0 82 x 3.5 x 60 mm
(Fig. 40)
40
�@ ®
e-
o-@
8-@
Cl!:M--®
,, ®'
0 22
--- � -- -- --- -- --
.
- - rlJ
11 1----��
@--
®
41
[I]
Stub axle assembly disassembled: 14 Stub axle frame
1 Frame 15 Hex. bolt M 1 6 x 60 DIN 931 -8.8
2 Hex. bolt M 20 x 60 DIN 933-8.8 16 Hex. nut M 1 6 DIN 934-8
3 Washer 20 17 Pivot bracket
4 Hex. bolt M 1 6 x 55 DIN 931 -8.8 18 Washer 1 6
5 Washer 1 6 19 Hex. bolt M 1 6 x 1 .5 x 45 DIN 961 -1 0.9
6 Hex. bolt M 8 x 25 DIN 933-8.8 20 Washer 1 6
7 Contact washer A 8 21 Hex. socket head cap screw M 1 6 x 40 DIN 91 2-8.8
8 Angle bracket 22 Wheel hub unit
9 Pivot pin 23 Pivot bracket
1 0 Spherical bearing 24 Screw plug M 20 x 1 .5
1 1 Slotted nut 25 Seal A 20 x 24 Cu DIN 7603
1 2 Locating ring 26 Adapter plate
1 3 Axial washers
1 0. 1 8 DO 21 8 - 202 MEGA
27 Hex. socket head cap screw M 1 0 x 30 DIN 91 2-8.8

Spring washer 1 0
28 O-ring 25 x 3.5 Nb 90 DIN 3771
29 Spring washer C 22.5 DIN 74361
30 Hex. bolt M 22 x 1 .5 x 45 DIN 961 -8.8
(Fig. 41 )
Assem bling the stub axle

1 . Press the bearings (1 0) into the frame with the aid of
the special tool.
2. When assembling the stub axle frame, ensure that the
locating ring (1 2) and the axial washer (1 3) are placed
correctly at the top between the frame and the stub
axle frame.
3. Screw in the pivot pins (9) and turn them tight to a
torque of 300 Nm.
4. Screw on the slotted nuts (1 1 ) and turn tight to a torque
of 200 Nm.
5. Place the wheel hub unit into the stub axle frame with
the leakage oil connector facing forward. Screw in the
hex. socket cap screws (21 ) M 1 6 x 40 and tighten 42
them down to a torque of 1 95 Nm.
6. Screw in the swivel-type elbow union and reconnect
the hydraulic hoses.
I' /
7. Mount the track rod and the hydraulic steering cylinder
and screw down tight.
8. Measure the toe-in at the inside edge where the
beading of the tyre rests. The toe-in should have a
value of O to max. 1 5 mm. After correcting the toe-in,
check the steering stops.
9. Adjust the steering stops.
1 0. Bleed the hydraulic steering system.
(Figs. 41 , 1 1 , 1 2 and 44)
43
DO 21 8 - 202 MEGA 1 0. 1 9
12 ADD-ON EQUIPMENT Taking off the straw chopper 1 2. 1
Straw chopper disassembled 1 2. 4
Assembling the straw chopper 1 2. 5
Adjusting the shear bar 1 2. 7
Taking off tensioning device for
straw chopper drive 1 2. 7
Tensioning device for straw chopper drive
disassembled 1 2. 8
Mounting the tensioning device for
straw chopper drive 1 2. 9
Taking out the straw chopper intermediate drive 1 2. 9
Intermediate drive for the straw chopper
disassembled 1 2. 1 0
Assembling straw chopper intermediate drive 1 2. 1 1
Adjusting spring cylinder on intermediate drive 1 2. 1 1
44
Special tools:
1 Hex. bolt M 1 6 x 300, replacement part no. 237 375. 1
2 Hex. nut M 1 6, replacement part no. 244 059. 0
3 Axial grooved ball bearing, replacement
part no. 1 77 899. 0
4 Puller cross bar, replacement part no. 1 81 836. 0
5 Pipe outer diameter 0 74 x 5 x 1 1 0 mm
(Fig. 45)
0
45
Adjusting the steering stops:

The stop bolts (S) have to be screwed in all the way on
either side. Turn the steering wheel all the way to one side
to a lock of the hydraulic cylinder. Adjust the appropriate
stop bolt so that it lightly touches the steering arm.
Then screw out the stop bolt one additional revolution so
that the hydraulic ram in the cylinder will have about 2.5 mm
free play before it will lock.
Perform the same adjustment on opposite side. Lock both
stop bolts into place with the lock nuts.
(Fig. 46)
1 0.20 DO 21 8 - 202 MEGA

Check the clearance of the tyres on the rear axle:

Lift the mach ine at the rear end. Lift the d riven rear axle on
either side up to the axle stop (X) and turn the steeri ng all
the way to either side.
Check the clearance of the tyres. If the tyres touch any
portion of the machine, the steeri ng stops have to be
screwed out appropriately.
(Fig. 47)
47
Check the oil level on the planetary d rives:

NOTE: When checki ng the oil leve l, the wheels m ust be on
level g round and the filling and oil level plug (K) must be in
line with horizontal line (H) .
K = oil level check plug
Oil type:
Hypoid transmission oil SAE 90
(MI L-L-21 05 B)
API -GL-5-90
Fi l l i ng capacity:
The filling capacity for each planetary d rive is 0.8 l itres of oil.
48
NOTE: When filling oil, unscrew plug (E) slightly.
(Fig. 48)
DO 218 - 202 MEGA 1 0.21

11
Electrical System
12
Add-on equipment
Add-on equipment
STRAW CHOPPER
Dangerous sharp knives are rotating under the
shields of the straw chopper, therefore stay clear
of the unit at any time with sufficient distances
when the chopper is in operation.
While working on the straw chopper always switch off the
threshing unit, stop the engine and remove the key from the
ignition.
(Caution, rotating knives)
Before starting the engine, make sure that there is no
person in the danger zone of the straw chopper.
When stopping the machine - note that the knife rotor
will continue to turn for a few seconds longer!
Taking off the straw chopper

On the right-hand side of the machine loosen the hex. bolt
which pretensions the pulley axially. Take off the belt.
Take off the deflector plate (B).
(Fig. 1 )
Pull off the loose pulley with a three-arm puller.

(Fig. 2)
Using a block-ended tube (S), loosen the cone by applying

a short, sharp blow onto the hub. The inside diameter of the
tube must be larger than the diameter of the cone. Remove
the outer cone and then the pulley.
(Fig. 3)
DO 21 8 - 202 MEGA 1 2. 1
Add-on equipment
[I]
Loosen the tab washer and unscrew the slotted nut with a
hook spanner.
(Fig. 4)
Loosen the taper lock adapter sleeve with an appropriate

block-ended tube.
Unscrew the hex. bolts (1 5) and take off the bearing.
(Fig. 5)
On the left-hand side of the machine unplug the cable for

the magnetic pick-up sensor. Take off the shield.
(Fig. 6)
Take off the sensor.

Loosen both hexagon socket set screws and take off the
cam wheel.
Cam wheel with four cams for maize and cam wheel with
two cams for small grains.
Loosen the taper lock adapter sleeve with an appropriate
block-ended tube.
Unscrew the hex. bolts (1 5) and take off the bearing.
(Fig. 7)
1 2.2 DO 21 8 - 202 MEGA

Add-on equipment
Unscrew the three M 1 0 x 25 hex. bolts (S) out of the cross

blade.
(Fig. 8)
Unscrew the six M 8 x 20 hex. bolts (B) out of the cross

blade from the inside.
(Fig. 9)
Take out the cross blade to the back. Take off the side lights
as complete units.
(Fig. 1 0)
10
Support the straw chopper securely under the spreading

unit.
(Fig. 1 1 )
DO 21 8 - 202 MEGA 1 2.3

��" ri <:
-----------� �•"'lr>ve
Remove lhe filler plates above the shaft e n ds o n ·the left a n d
' ---------
right s1 de..
U n screw the chopper from the frame member a ad lowe, '1
dow n .
(Fig. 1 2)
12
CAUT ION• Danger of injury -

· tive gloves.
wear protec
Take o Ut the k n ife rotor to the top through the slots.

(Fig. 1 3)
13
Straw chopper disassembled:

1 Kn ife rotor '
2 Free-swi n gi n n f
3 Hex. bolt M 1 i � �; DIN 931 for s a l g ai n s
Hexago n socket head cap screw � � o � 40 DIN 91 2
for maize
4 Bushi n g
5 Bushi n g
6 Self-locki n g n u Vm 1 0
�
7 Parallel key A 0 x 8 x 30 DIN 6885
8 Cover
9 Beari n g half
Felt ri n g
1 0 Taper lock adapter sleeve
1 2.4 DO 21 8 - 202 MEGA

Add-on equipment
11 Self-aligning ball bearing 1 309 K/C3 DIN 630

12 Circlip 45
13 Slotted nut M 45 x 1 .5
14 Bearing half
Felt ring
15 Hex. bolt M 1 2 x 60 DIN 931
16 Cam wheel
17 Socket head set screw
18 Knife carrier
19 Cross blade
20 Rod
21 Spring clip
22 Hex. bolt M 1 6 x 30 DIN 933
Contact washer
23 Cone
24 Pulley
25 Back-up ring
26 Pulley
28 Deep-groove ball bearing 6207 2RS DIN 625
29 Bushing
30 Hex. bolt M 1 6 x 45 DIN 933-8.8
(Fig. 1 4)
Assembling the straw chopper

CAUT ION! Danger of injury
•
wear protective gloves
Lift the knife rotor from the back into the machine.
Screw on the filler plates (F) above the shaft ends on either
side.
Swing up the straw chopper and screw onto the frame
member.
(Fig. 1 5)
Mount the cross blade from the back into the machine and
screw on the hex. bolts (B) from the inside.
Screw on the hex. bolts (S) into the cross blade.
Mount the side lights.
(Fig. 1 6 and 1 7)
16
DO 21 8 - 202 MEGA 1 2.5

Add-on equipment
17
Preassemble the bearings on the left and the right side on

the shaft ends.
(Fig. 1 8)
18
CAUT ION! Danger of injury
•
wear protective gloves
Align the knife rotor with respect to the fixed knives and
screw on the bearings with the three hex. bolts (1 5) on
either side.
(Figs. 1 4 and 1 9)
19
[I]
Screw on the slotted nut (1 3) to a torque of 70 Nm.
Secure the slotted nut with the circlip (1 2).
(Figs. 1 4 and 20)
20
1 2.6 DO 21 8 - 202 MEGA

Add-on equipment
Mount the cam wheel (1 6), four cams for maize and two
cams for small grains, onto the shaft end and fix the wheel
in position with the socket head set screws (1 7).
Mount the bracket for the magnetic pick-up sensor. Install
the sensor in the bracket so that the clearance between the
sensor tip and the cam is between 1 ± 0.5 mm. Fix the
sensor in that position with the nut and lock nut.
Plug the green/black power lead and the brown earth lead
into the sensor.
Plug the cable lead (green/white/black) and the cable lead
(brown) into the switch. Reinstall the shield.
(Fig. 21 )
21
On the drive side reassemble the cones, pulley and back-up

ring (23, 24, 25) according to (Fig. 1 4) using some »Shell
Alvania« grease. Preassemble the pulley (26) with the
circlips (27) and the deep grooved ball bearing (28) and
push it onto the shaft.
Install the bushing (29) with the hex. bolt (30) and tighten
the assembly down to a torque of 1 80 Nm .
Adjusting the cross blade

Caution - Danger of personal injury -
•
wear protective gloves.
For the adjustment of the cross blade loosen the hold-down

screws (U) in the slotted holes. Adjust the shear bar (Q) in
such a manner that the distance (Y) with the knives in their
swung-out position is 5 mm.
After the adjustment retighten all the hold-down screws (U).
(Fig. 23)
23
Taking off tensioning device for straw chopper

drive
Remove the belt (K) and take off the lower jockey pulley.
Unscrew the upper idler pulley and pull it off with a puller.
(Fig. 24)
24
DO 21 8 - 202 MEGA 1 2. 7
Add-on equipment
. @ 18
--- ----
25
Tensioning device for straw chopper drive disassembled: 19 Hex. nut M 1 6 DIN 934
1 Idler pulley 21 Jockey pulley bracket
2 Deep grooved ball bearing 6205-2RS / C3 DIN 625 22 Spacer washer
3 Circlip 52 x 2 DIN 472 23 Connecting rod
4 Spacer ring 24 Angle bracket
5 Washer 25 Bushing
6 Contact washer A 1 2 26 Roll pin 8 x 30 DIN 1 481
7 Hex. bolt M 1 2 x 25 DIN 933 27 Hex. nut M 1 2 DIN 934
8 Jockey pulley 28 Washer 1 3 x 40 x 6
9 Deep grooved ball bearing 6303-2RS DIN 625 29 Ball knob
10 Circlip 47 x 1 .75 DIN 472 30 Lever
11 Spacer ring 31 Hub
12 Lock collar 32 Spring guide
13 Hex. bolt M 1 6 x 85 DIN 7968 33 Compression spring
14 Hex. bolt M 1 2 x 25 DIN 933 34 Bushing
Contact washer B 1 2 35 Washer
15 Bracket 36 Hex. bolt M 1 2 x 20 DIN 933
16 Bushing 37 Contact washer A 1 2
17 Bolt B 1 0 A 1 2 x 38
Split pin 4 x 22 DIN 94 (Fig. 25)
18 Shim
1 2.8 DO 21 8 - 202 MEGA

Add-on equipment
Mounting the tensioning device for

straw chopper drive
Bolt the lever (9) onto the angle bracket (8) with the hex. bolt
(1 0). Mount the connecting rod (1 1 ), the spring guide (1 2)
and the compression spring on the lever assembly (9).
(Fig. 26)
26
Adjusting spring cylinder of tensioning device

Loosen the lock nut (K). Adjust the spring guide (32) to a
distance (X), when the lever (9) is in the tensioned position
and the lock nut (K) is retightened.
DO 202 - 204 = 1 00 mm
DO 208 - 21 8 = 1 38 mm (stronger spring)
(Fig. 27)
27
Taking out the straw chopper intermediate drive

Remove the belt and slacken the compression spring.
Take off the tensioning device for the intermediate drive.
(Fig. 28)
28
Unbolt the intermediate drive from the side frame.

(Fig. 29)
29
DO 21 8 - 202 MEGA 1 2.9

Add-on equipment
30
Intermediate drive for the straw chopper disassembled:

1 Jockey pulley
2 Deep grooved ball bearing
3 Circlip 40 x 1 .75 DIN 472
4 Spacer
5 Bolt
6 Spacer washer
8 Hexagon nut 1 6 DIN 934
9 Jockey pulley bracket
10 Bushing
11 Lever
13 Hex. nut M 1 0 x 25 DIN 933
14 Spring guide
15 Bracket
16 Bolt B 1 0 A 1 1 x 20 DIN 1 444
Split pin 3.2 x 22 DIN 94
17 Bushing
18 Compression spring
19 Washer 1 3 x 40 x 6
21 Bolt B 1 0 A 1 2 x 28
Split pin 4 x 22 DIN 94
22 Yoke
23 Hex. bolt M 1 2 x 35 DIN 933
25 Washer 1 2.5 x 44 x 1 0
27 Deep grooved ball bearing
6206-2RS I C3 DIN 625 chopper no. 1 0001 and up
6206-2RS DIN 625 up to chopper no. 1 0000
28 Sleeve
29 Pulley
30 Spacer ring
31 Round plate
32 Bracket
33 Hex. bolt M 1 0 x 25 DIN 933
(Fig. 30)
1 2. 1 0 DO 21 8 - 202 MEGA
Add-on equipment
Assembling straw chopper intermediate drive

Mount the intermediate drive (2) with the hex. bolts on the
side frame.
(Fig. 31 )
31
Place the belt (4) on the intermediate drive (2).

(Fig. 32)
32
Place the belt (1 ) on the intermediate drive (2) and install the
jockey pulley (5).
(Fig. 33)
33
Adjusting spring-loaded cylinder on intermediate

drive
Loosen lock nut (K). Adjust the spring guide ( R ) in such a
manner that the distance (X) between the washer (T) and
the guide bracket (N) will be 40 mm when the lock nut is
retightened.
(Fig. 34)
34
DO 21 8 - 202 MEGA 1 2. 1 1
CLAAS KGaA
D-33426 HARSEWI N KE L
G E RMANY P rinted in Germany

Repair Manual For Claas Mega 202 218 Combine Harvester

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Repair Manual For Claas Mega 202 218 Combine Harvester

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REPAIR

Volume and capacities

The description of a particular service procedure can

[I] Special tool

6. Correct tension of steel roller chains

7. Taper ring fasteners (locking cones)

IMPORTANT! No solid grease must be used when assembling the parts.

8. Self-locking bolts (with adhesive-filled micro capsules)

9. Liquid locking compound (e.g. DELO-ML 1 87 / Loctite 242 or their equivalents)

1 0. Correct installation of lock collar bearings

1 1 . Correct installation of adapter sleeve bearings

Tightening the bearing:

Loosening the bearing:

b) Slide the union nut and olive on to the tube.

d) Turn the union nut 1 /2-turn past the point of resistance.

Installation of factory-assembled unit:

Reinstallation of a used fitting:

1 3. Progressive tube fittings on hydraulic tubes

1 4. Taper fitting connections for hydraulic tubes

d) Remove the diode plate from the central electrics compartment.

e) Disconnect the cable connection to the fieldwork computer.

f) Disconnect the plug at the reversing gearbox.

1 6. Some advice for speedy and correct repair:

e) Care for sprockets and V-belt pulleys to be properly aligned.

f) Care for strict cleanliness when working on hydraulic systems.

g)Never mix different types/qualities of oil.

DOMINATOR 218 MEGA/ 208 MEGA

SETTINGS AND CAPACITIES

Hydraulic oil pressures

Pressure relief valve

Pressure relief valve

LINDE hydrostatic ground drive system

Work hydraulic system

Oil change approx. 7 litres of multi-grade hydraulic oil of viscosity

LINDE hydrostatic ground drive system

Oil change approx. 8 litres of multi-grade hydraulic oil of viscosity

DO 21 8 - 202 MEGA 1.1

DOMINATOR 218 MEGA/ 208 MEGA

TRANSMISSION GEARBOX 5 litres SAE 90, 85 W-90 (MIL-L-21 05 B)

DRUM VARIABLE SPEED DRIVE

CLAAS 4-TRAC HYDROSTATIC DRIVEN REAR AXLE

MAIZE PICKER HEAD SL

Picker head gearboxes 1 .25 litres each SAE 90 (MIL-L-21 05)

Tyre sizes and tyre pressures

14.9/80 - 24 10PR 2.9bar 2.4bar

Torque settings of wheel bolts

DOMINATOR 218 MEGA/ 208 MEGA

Reel drive shaft perpendicular above knife bar,

Intake auger approx. 1 5 mm clearance between auger flights and bottom

Steering With steering cylinder piston fully extended, the adjustable

DOMINATOR 204 MEGA/ 203 MEGA

SETTINGS AND CAPACITIES

Hydraulic oil pressures

Pressure relief valve

Pressure relief valve

Pressure relief valve

SAUER hydrostatic ground drive system

Work hydraulic system:

Oil change approx. 7 litres of multi-grade hydraulic oil of viscosity