CLAAS DOMINATOR 208 & 204 MEGA III Operation Manual PDF Download

Description

CLAAS DOMINATOR 208 MEGA III DOMINATOR 204 MEGA III Operator’s Manual – PDF DOWNLOAD

DESCRIPTION:

CLAAS DOMINATOR 208 MEGA III DOMINATOR 204 MEGA III Operator’s Manual – PDF DOWNLOAD

INTRODUCTION

• The present Operator’s Manual applies to the CLAAS combine-harvesters
• DOMINATOR 208 MEGA from serial no. 94503000
  DOMINATOR 204 MEGA from serial no. 93503000
• It is primarily intended to give the machine driver information on setting, using and operating the machine. Texts and pictures apply, in general, to all combine models covered by this book, and the information given applies equally, except where reference is made to a particular model in captions to the pictures or in the main text.
• Operation and maintenance of important ancillary equipment is also covered by this manual. Please read the instructions which apply to the appropriate ancillary equipment on your combine. Provided you follow the advice on the care and servicing of your machine you will be rewarded with reliable and long service from your Combine Harvester.
• We recommend that you allow your authorized CLAAS Dealer to carry out the regular maintenance. Omissions of parts of the maintenance schedule or incorrect operation lead to a drop in performance and cost valuable time.
• By correct servicing and operation you can make full use of our sound experience and of the latest technical knowledge in Combine Harvesting with which your combine has been designed and thereby insure reliability of your Combine Harvester. This Operator’s Manual can be ordered from your CLAAS Dealer as well as the manuals listed below:

General information
ROAD TRAFFIC REGULATIONS

IMPORTANT:

• Road traffic regulations may vary between countries. In case of discrepancies between the instructions provided by the manufacturer and the traffic regulations of the relevant countries, the traffic regulations of the countries concerned apply. In addition to his driving licence, the operator must always carry the copy of the vehicle type approval registration issued by the Kraftfahrt-Bundesamt (the Federal Motor Vehicle Executive).
• A warning triangle and, on machines over 4 t permissible total weight, at least one wheel chock must always be carried on the combine. When driving on public roads with the combine, comply with all the requirements stated under letter C in the copy of the vehicle type approval registration (§ 18 Section 5 StVZO) issued by the Kraftfahrt-Bundesamt (the Federal Motor Vehicle Executive).
• On machines with exceptional width (width over the tyres), a vehicle type approval registration for individual vehicles (single expert opinion) and an special approval in accordance with § 70, Section 1, clauses 1 and 2 of the StVZO must be carried instead of the machine’s General Operating Permit.
• Furthermore, all the requirements stated in the vehicle type approval registration for individual vehicles and in the special approval must be observed. The issue of a special approval differs from country to country. The excess width must be marked in accordance with the regulations for the marking of road vehicles with excess width (two marker boards at the front and back, protective bar, two amber flashing warning beacons).
• If any part(s) of the combine is/are subsequently modified whose condition is/are prescribed or the operation of which (after being modified) could represent a hazard to other road users, then the vehicle type approval registration shall no longer be valid and application must be made for a new vehicle type approval registration.
• In this case the machine must be presented to the motor vehicle safety inspection authority responsible (TÜV) in order to obtain an expert opinion certificate (§ 19 section 2 STVZO). If you are in any doubt as to whether this situation applies in your case, please contact us as manufacturers.
• If a transport vehicle for front end attachments is towed behind the combine then the cable for the lighting system must be connected and the good condition of the lighting system assured. If the combine is equipped with a maize picker head or folding cutterbar, the regulations and requirements of the machine’s General Operating Permit must be observed, in particular the requirements concerning ballast weights and tyres.

Registration

As a self-propelled working machine with a maximum speed of up to 20 km/h, the combine is not subject to the normal registration regulations and is not required to bear a registration plate. The machine must, however, be clearly and indelibly marked on the left-hand side with the Christian name and surname of the owner and his address. The towing of trailers in the trailer hitch when driving on public roads is not permitted.
TABLE OF CONTENTS:

CLAAS DOMINATOR 208 MEGA III DOMINATOR 204 MEGA III Operator’s Manual – PDF DOWNLOAD

CONTENTS
1 Introduction
Introduction 111
2 Contents
Contents 211
3 General information
Road traffic regulations 311
Important 321
Identification plate / Serial number 331
Identification plate 332
Combine serial number 332
Engine serial number
MERCEDES OM 906 LA 332
Cutterbar identification plate 333
Identification plate of folding cutterbar 333
Maize picker head serial number 333
Multimaster 333
Serial number of maize head stalk chopper 334
Straw chopper 334
Cab serial number 334
4 Safety rules
Safety rules 411
Safety lock 414
Fire extinguisher 414
Battery isolating switch 415
Wheel chock
(Not for all countries) 415
Safety decals with pictorials 421
5 Specifications
Conversion factors 511
CLAAS DOMINATOR 208 MEGA 521
CLAAS DOMINATOR 204 MEGA 531
Safety features 541
Front attachments – weights, dimensions 551
Sectional view of combine 561
Description and function of the combine 562
Cutterbar 562
Threshing mechanism 563
Straw walkers 563
Cleaning 563
Disawning 563
Basic rules for combining 564
6 Prior to operation
Before initial operation 611
Operator’s platform 621
Cab 622
Cab with ventilating system 623
Cab with fan and compressor-type air conditioner 623
Cab with ventilating system and heating 625
Reheat System
(fogged windows) 625
Problem, cause and / or remedy –
Compressor-type air conditioner 626
Opening and closing the cabin roof 628
Opening the cabin roof 628
Closing the cabin roof 628
Steering column 629
Ignition switch 629
Vehicle information unit 6210
Function of vehicle information unit 6211
Operations display screen 6212
Function of operations display 6213
Switch console 6214
Multi-function lever 6215
Central terminal compartment 6215
Plug-in type module (P) CLAAS Autopilot 6216
Grain tank discharge tube – swinging out and in 6217
Grain tank discharge engagement
and disengagement 6218
Threshing mechanism engagement /
disengagement 6218
Engaging and disengaging the cutterbar drive 6219
Positioning the cutterbar / maize picker head
for road travel 6219
Adjusting the threshing drum speed 6220
Adjusting the steering column position 6220
Driver’s seat, mechanical 6221
Weight adjustment 6221
Height adjustment 6221
Seat angle adjustment 6222
Seat depth adjustment 6222
Lumbar support 6222
Armrest angle 6222
Adjusting the driver’s seat horizontally 6222
Access ladders 6223
Front ladder 6223
Access and ladder extension 6224
Rear ladder 6228
Driving the combine 631
Engine speed turn switch 631
Starting the engine 632
Adjusting stiffness of ground speed control lever 633
Gear ranges 633
Stopping the combine 634
Driving behaviour 634
Steering 634
Brakes 635
Foot brake 635
Handbrake 635
Stopping the engine 636
CLAAS Autopilot 636
Rear axle 641
Setting the adjustable rear axle 641
Changing the rear axle from transport position
to working position 642
CLAAS-4-Trac-System 643
Towing a combine with driven rear axle 643
Contents
212 BA DO 208 / 204 MEGA – 298 6720
Contents
Cutterbar cylinders 651
Hydraulic cylinders 651
Attaching the cutterbar hydraulic cylinders 651
Attaching the right-hand cutterbar cylinder 651
Attaching a third cutterbar cylinder 652
Towing and side walk railing 661
Towing the combine 661
Forward 661
Backward 661
Side walk railing 662
Tilting the side walk railing 662
Cab and lighting 671
Cab 671
Driving lights, worklights and mirrors 671
7 Operation – cutterbar
Attaching the cutterbar 711
Adjusting the strippers
DOMINATOR MEGA 204 711
Machine with CLAAS Auto Contour 711
Levelling the coupling lug cylinders 713
Machine without Auto Contour 713
Levelling the cutterbar 714
Connecting the universal drive shafts
DOMINATOR 208 MEGA 715
Connecting the universal drive shafts
DOMINATOR 204 MEGA 715
Connecting hydraulic hoses 716
Connecting the cables 716
Installing the stands 717
Adjustments at the cutterbar 721
Dividers 721
Grain lifters 722
Knife 723
Removing the knife 723
Installing the knife 723
Adjusting the height of the knife head 724
Adjusting the knife clips 724
Spare knife 724
Cutterbar skids 725
Reel 725
Reel tines 726
Reel drive 726
Fore and aft reel adjustment
(mechanical) 727
Fore and aft reel adjustment
(hydraulic) 727
Reel variable speed drive 728
Main table auger 728
Adjust clearance to cutterbar trough 728
Adjusting position of auger fingers 729
Adjusting the stripper plates 729
Replacing knife sections in the field 7210
8 Operation – basic machine
Feeder housing 811
Chains 811
Cutterbar reverse drive 812
CLAAS Auto Contour
Automatic cutting height control
and lateral levelling system 813
Cutterbar automatic pre-set height
(machines with Auto Contour) 815
Adjusting the cutterbar floatation springs 816
Checking the cutterbar floatation springs
and checking the feeder house suspension
for smooth movement 816
Setting the cutting height indicator 817
Cutterbar spring pressure indicator 817
Adjusting the cutterbar drop rate 818
Putting the CLAAS Auto Contour System
into operation 819
Operation with maize picker head 8110
Programming the CLAAS Auto Contour System 8110
Setting chart for automatic cutting height control 8111
Putting the cutterbar automatic pre-set
height system into operation
(machines with Auto Contour) 8112
CLAAS Contour System
(ground pressure control) 8113
Setting the cutterbar ground pressure 8114
Putting the CLAAS Contour System into operation 8114
CLAAS cutterbar pre-set height 8116
Putting the cutterbar pre-set height system
into operation 8116
Cutterbar adjusting range 8116
Clearance height 8117
Cutterbar adjusting range without Auto Contour 8117
Clearance height to underside of cutterbar skid 8117
Cutterbar clutch 8118
Engaging and disengaging the cutterbar 8118
Threshing mechanism 821
Stone trap 821
Engaging and disengaging the threshing mechanism 821
Concave adjustment 822
Concave settings 823
Threshing drum 824
Cleaning dirty threshing parts 824
Threshing drum speed 825
Adjusting the threshing drum speed 826
Threshing drum speed display 826
Threshing drum two-step variable speed drive 826
Preconcave 827
Disawning 828
Threshing segment 829
Unslugging the threshing drum 8210
Impeller 8211
Deflector curtain 8211
Straw walkers and cleaning 831
Straw walkers 831
Intensive separation system 831
Cleaning the straw walkers 832
Straw walker risers 832
Warning signal 834
Sieve pan 834
Preparation floor 835
298 6720 – BA DO 208 / 204 MEGA 213
Contents
Cleaning fan 835
Electrical fan speed adjustment 836
Fan speed display 836
Ventilated straw walker step 837
Adjusting the butterfly valve 837
Adjusting the wind board 837
Sieves 838
Adjusting the frogmouth sieves 838
Hillside riser plates
(machines without 3-D cleaning system) 838
Lower sieves 838
Removing upper sieves 839
Installing upper sieves 839
Removing lower sieves 839
Installing lower sieves 839
Tightening torques of the axial bolts
for the upper and lower sieves 839
Dynamic sidehill levelling
(3-D cleaning system) 8310
Returns 8310
Combine performance monitor 8312
Adjusting monitor to crop type 8313
Adjusting sensitivity of sensors 8313
Grain delivery 841
Augers and auger troughs 841
Elevators 841
Grain tank 842
Grain tank covers 842
Unloading the tank 843
Rear ladder with safety switch 844
Grain tank discharge auger 844
Grain tank discharge – engage and disengage 845
Clean-out door on grain tank discharge tube 846
Drive to grain tank discharge augers 846
Shear bolt – grain tank discharge 847
Lateral auger drive 847
Grain tank fill indicator 848
Acoustic grain tank fill indicator 848
Straw chopper / Chaff spreader 851
Straw chopper 851
Before using the straw chopper, check 851
Putting the straw chopper into operation 852
Adjusting spreading width 853
Electric deflector adjustment 853
Adjusting the deflectors 853
Adjusting the length of cut 854
Adjusting cross knife 854
Putting the straw chopper out of operation
and changing over to windrowing straw 855
Hitching the cutterbar trailer to the combine 856
Chaff spreader 856
Setting the chaff spreader 856
Sieve chart and suggested combine adjustments 861
Sieve chart 861
Suggested combine adjustments 862
Disawner plates 868
Threshing segment 868
Problem, cause and / or remedy – Basic machine 871
9 Maintenance – basic machine, cutterbar
Important maintenance instructions 911
Important maintenance instructions and safety rules 911
Maintenance schedules and lubricants charts 921
Maintenance schedules 921
Lubricants charts 924
Hydraulic system 931
Hydraulic accumulators 931
Checking the oil level
(Hydrostatic ground speed drive
and working hydraulics) 932
Changing hydraulic oil
(Hydrostatic ground speed drive
and working hydraulics)
Linde HPV 75 and HMF 105 932
Changing the hydraulic oil filter 933
Refilling the system after hydraulic oil change 934
Hydrostatic pump adjustment 934
Bleeding the reel cylinders 935
Bleeding the hydraulic cylinders
for cutterbar lateral levelling
(Machines with Auto Contour System) 936
Foot brake / brake fluid 937
Transmission and gearboxes 941
Gear shift control adjustment 941
Change-speed transmission gearbox 941
Checking oil level 941
Oil change 941
Final drives
DOMINATOR 208 MEGA 942
Checking oil level 942
Oil change 942
Final drives
DOMINATOR 204 MEGA 942
Checking oil level 942
Oil change 942
Rear wheel drive planetary gears
CLAAS 4-Trac System 943
Check oil level 943
Oil change 943
Knife drive casing 943
Checking the oil level / oil change 943
Threshing drum reduction gearbox 944
Checking oil level 944
Oil change 944
Grain tank 944
Angle drive on grain tank discharge auger 944
Angle drive on grain tank
(DOMINATOR 208 MEGA) 944
Feeder housing 951
Tension feeder chains 951
Elevator chains 961
Tension grain elevator chain 961
Tension returns elevator chain 962
Drive belts / drive chains – basic machine 971
General notes 971
Drive diagram left 972
Drive diagram right 973
214 BA DO 208 / 204 MEGA – 298 6720
Contents
Drive belts / drive chains 974
Removing cutterbar drive belt (1) 974
Fitting and tensioning cutterbar drive belt (1) 975
Tensioning compressor drive belt (2) 976
Tensioning hydrostatic ground drive belt (3) 977
Tensioning working hydraulics pump drive belt (4) 978
Removing and installing the power band belt (3) 979
Threshing mechanism drive belt (5) 9710
Removing and installing the threshing mechanism
drive belt (5) 9711
Grain tank unloading drive belt (6) 9713
Removing and installing the sieve pan drive belt (7) 9714
Removing and fitting fan variable-speed belt (8) 9715
Removing and installing the sieve pan drive belt (9) 9716
Removing and installing the sieve pan
drive belt (10) 9716
Removing and installing the straw walker
drive belt (11) 9717
Removing and installing the intensive
separation system drive belt (12) 9717
Removing and installing the chaff spreader
drive belt (15) 9718
Chaff spreader drive belt (16) 9718
Straw chopper intermediate drive belt (21) 9719
Tensioning suction blower drive belt (22) 9722
Removing and fitting threshing drum
variable speed drive belt (23) 9722
Removing and filtting the threshing drum
drive belt (24) 9724
Tensioning radiator screen intermediate
drive belt (27) 9725
Tensioning the grain tank unloading
intermediate drive chain (31)
(DOMINATOR 208 MEGA) 9725
Tensioning the grain tank unloading
intermediate drive chain (32)
(DOMINATOR 208 MEGA) 9725
Tensioning the grain tank unloading
intermediate drive chain (31)
(DOMINATOR 204 MEGA) 9726
Tensioning returns drive chain (33) 9726
Removing and installing the accelerator
drive belt (17) 9727
Straw chopper drive belt (20) 9729
Drive belts / drive chains – cutterbar 981
General notes 981
Drive diagram cutterbar 982
Tensioning knife drive belt (40) 983
Tensioning main table auger drive chain (41) 983
Tensioning reel drive chain (42) 984
Removing and fitting reel drive belt (43) 984
Tensioning reel drive chain (44) 986
Tensioning reel drive chain (45) 986
Cab / Compressor-type air conditioner 991
Cab 991
Cleaning the filters 991
Compressor-type air conditioner 991
Cleaning the condenser 991
Checking refrigerant level 992
Replacing the filter receiver drier 992
Required refrigerant quantity – Refrigerant R 134 a 992
Maintenance work before the harvest 993
Fire extinguisher 9101
Have fire extinguisher checked
for serviceable condition 9101
Speeds 9111
Checking the speed of the straw walker shaft 9111
Setting the magnetic pick-ups 9111
Machines equipped with fieldwork computer 9111
Straw chopper 9121
Changing the free-swinging knives 9121
Removing knives 9121
Installing knives 9122
Changing the fixed stationary knives 9122
Winter storage instructions for combines 9131
10 Maintenance – engine
Important maintenance instructions 1011
Important maintenance instructions
and safety rules 1011
Maintenance schedules and lubricants charts 1021
Maintenance schedule 1021
Lubricants chart 1022
Maintenance – engine 1031
Engine overview 1031
Fuel feed system 1031
Fuel tank 1032
Fuel shut-off tap 1032
Water separator / fuel prefilter
(extra equipment – small version) 1033
Fuel prefilter 1033
Water separator / fuel prefilter
(extra equipment – large version) 1034
Fuel filter 1035
Bleeding the fuel system 1035
Checking engine oil level 1035
Engine oil change 1036
Draining the old oil 1036
Oil filter 1037
Filling in engine oil 1037
Tensioning the alternator belt 1037
Cooling system 1041
Coolant 1041
Water drain plugs on the engine block 1041
Water cooler 1041
Filling the cooling system with coolant 1042
Overpressure 1042
Antifreeze / corrosion protection 1042
Warning notice 1043
Cooling water temperature 1043
Radiator chaff screen 1043
Cleaning the radiator chaff screen 1043
Folding up radiator chaff screen 1043
Swinging up the oil cooler 1044
Clean water cooler and intercooler 1045
Dry-type air cleaner 1051
Warning device 1051
298 6720 – BA DO 208 / 204 MEGA 215
Contents
Cleaning the air cleaner intake screen 1051
Cleaning the air cleaner 1051
Cleaning the dry-type air cleaner
with dust extractor unit 1052
Removing the main filter cartridge 1053
Installing the main filter cartridge 1054
Safety cartridge 1054
Electrical equipment 1061
Battery 1061
Alternator 1062
Engine problems, cause and / or remedy 1071
Engine winter storage 1081
Engine preservation 1081
11 Lubrication chart
Lubricants and lubrication instructions 1111
12 Index
Index 1211
IMAGES PREVIEW OF THE MANUAL:

CLAAS DOMINATOR 208 MEGA III DOMINATOR 204 MEGA III OPERATOR’S MANUAL – PDF DOWNLOAD:

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