Technical Information · issue 40 of 2005
Service Notes
IssueTI 40/2005
Full text
Page 1 of 25
STIH)
Technical Information 40.2005
Service Notes for STIHL SP 200 Special Harvesters – Series 4233
Contents
1. General
1.1 Preparing the surfaces to be joined
1.2 Removing adhesive
2. General drawings
3. Control handle
3.1 Disassembling and assembling the control handle
4. Drive tube assembly
4.1 Drive tube, engine end
4.2 Swivel coupling
4.3 Drive tube, gearhead end
5. Gearhead
5.1 Changing the gear oil
5.2 Disassembling the gearbox
5.3 Dismantling the gearbox
5.4 Assembling the gearhead
5.5 Attaching and lining up the gearhead
6. Pushrod and hook
6.1 Disassembling the pushrod
6.2 Assembling the pushrod
6.3 Hook
7. Harness
7.1 Attaching the harness
7.2 Disassembling the eyes
7.3 Assembling the eyes
8. Special tools
8.1 Set of service tools
8.2 Illustrations of special tools
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)m~ge 2 Technical Information 40.2005
1. General . Remove any grease, oil, dust or other dirt from
the surfaces to be joined, using an appropriate
Three different adhesives and an activator are used solvent.
to secure screws and to join components on the
STIHL SP 200 special harvesters. . Apply activator 7649 to one of the surfaces (or
to both surfaces if the gap is large) and allow to
Part Name dry.
Loctite 243
. Apply adhesive evenly along a length
Threadlocker
corresponding to two-thirds of the overlapping
Loctite 326 surfaces. Cover the whole surface, starting at
Fast-curing adhesive the beginning of the part with the outward-facing
Loctite 638 surface to be joined. This ensures that the
Retaining compound adhesive is evenly distributed.
Loctite 7649
. Slowly join the two surfaces together until they
Activator for Loctite 326
are bearing on each other. Push and pull to
Some general instructions on the use of adhesives distribute the adhesive evenly.
are therefore given to start with. Caution!
The working time is less than 60 seconds.
1.1 Preparing the surfaces to be joined Disassembled parts:
1.1.1 Loctite 243 (threadlocker) . Use sandpaper or similar to remove adhesive
residues from the surfaces to be joined.
New parts:
. Then proceed as for new parts.
. Remove any grease, oil, dust or other dirt from
the inside and outside thread, using an
appropriate solvent. 1.1.3 Loctite 638 (retaining compound)
. Apply threadlocker evenly along a length Threaded joints
corresponding to half of the overlapping thread.
Cover the whole surface, starting at the New parts:
beginning of the outside thread. This ensures . Remove any grease, oil, dust or other dirt from
that the adhesive is evenly distributed. the inside and outside thread, using an
. Assemble the threaded joint and tighten. appropriate solvent.
Disassembled parts: . Apply adhesive evenly along a length
corresponding to half of the overlapping thread.
. Clean the thread with a wire brush or similar, Cover the whole surface, starting at the
taking care not to damage the flanks of the beginning of the outside thread. This ensures
thread. that the adhesive is evenly distributed.
. Then proceed as for new parts. . Assemble the threaded joint and tighten.
Disassembled parts:
1.1.2 Loctite 326 (adhesive) . Clean the thread with a wire brush or similar,
Activator 7649 is used to ensure even curing of the taking care not to damage the flanks of the
bond. Homogeneous adhesion can therefore be thread.
expected, even in the case of larger bonded joints. . Then proceed as for new parts.
New parts:
. The surfaces to be joined can be roughened
with fine sandpaper to improve adhesion.
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Technical Information 40.2005 Page 3
Plain bearings 2. General drawings
New parts: The drawings on the following pages can be copied
. Remove any grease, oil, dust or other dirt from for use at the workbench.
the surfaces to be joined, using an appropriate A Control handle
solvent.
B Drive tube assembly
. Apply adhesive to the whole of the outer ring of
the bearing. C Gearhead
. Insert bearing into bearing housing. D Pushrod and hook
. Remove surplus adhesive, using an appropriate
solvent.
Disassembled parts:
. Use sandpaper or similar to remove adhesive
residues from the surfaces to be joined.
. Then proceed as for new parts.
1.2 Removing adhesive
All the adhesives used can be removed by heat.
The use of an electric hot-air blower producing a hot
air jet at least 600 °C (1100 °F) is recommended for
releasing bonds. This allows the bond area to be
heated quickly, without damaging other parts. The
bond areas should be heated as evenly as possible.
A slight crackling noise indicates that the bond is
loosening. Check frequently to see whether the
bond has loosened.
Caution! Contact with hot parts can cause burn
injuries.
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Technical Information 40.2005 Page 5
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)m~ge 6 Technical Information 40.2005
3. Control handle
See general drawing A.
Please refer to the general drawing for instructions
on disassembling and assembling the screwed
connections on the handle.
3.1 Disassembling and assembling the
control handle
. Unscrew the screws on the handle supports (1)
and remove tube (2) and control handle (3).
. Clamp the tube (2) and heat the adhesive on
one of the handle supports (1) – see 1.2 – before
removing the handle support.
. Slacken the control handle (3) attachment
screws and remove the control handle.
. Also disassemble the second handle support (1)
if necessary.
. Attach control handle (3) to tube (2).
. Apply Loctite 326 to tube (2) as described in
chapter 1.1.2 and press the handle support (1)
into place.
. Line up the handle support (1).
. Screw in and tighten the screws on the handle
supports (1).
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Technical Information 40.2005 Page 7
4. Drive tube assembly
See general drawing B.
. Slacken the union nut (12) using special tool
4233 893 1300 and remove the front part of the
drive tube from the machine. Use special tool
4233 893 1302 to steady the drive tube at the
gearhead end as you do so.
4.1 Drive tube, engine end
411TI078 KN
. Slacken attachment screw on clutch housing. 4
. Slacken attachment screws on handle support
retainers (general drawing A). . Use special tool 4233 890 2200 to steady the
drive shaft (4).
. Pull out the drive tube (1). The drive shaft (4) is
bolted to the clutch drum and therefore remains
attached to the engine.
. Pry out the plug (2) and dismantle the flexible
liner (3).
. To assemble, proceed in the reverse order.
4.1.1 Disassembling the drive shaft
. Disassemble tube from engine, see 4.1.
411TI079 KN
17 18
. Apply a high-temperature hot air jet to loosen
the adhesive from the screw (18), see 1.2. Use
a hexagon socket screw key (size 5 mm) to
17
unscrew the screw.
411TI077 KN
. Unscrew the screws (17) from the clutch
housing (28) and remove the clutch housing. 4
411TI080 KN
. Remove the drive shaft (4), using a plastic
hammer and punch to force it out if necessary.
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)m~ge 8 Technical Information 40.2005
4.1.2 Attaching the drive shaft
. Place drive shaft (4) in position.
. Apply Loctite 638 to the screw thread (18) as
described in chapter 1.1.3.
Take a hexagon socket screw key (size 5 mm),
steadying the drive shaft with special tool
8
4233 890 2200, and screw in and tighten the 10
screw (18).
. For further assembly operations, proceed in the
411TI069 KN
reverse order to disassembly.
4.2 Swivel coupling
. Steady the plug (8) using special tool
4233 893 1302 and use special tool
4.2.1 Disassembly
4233 893 1301 to slacken and unscrew the
union nut (10).
. Apply a high-temperature hot air jet to loosen
the adhesive from the plug (8), see 1.2.
Unscrew the plug, using special tool
4233 893 1302.
11
. For further swivel coupling disassembly
12 operations, please refer to the general drawing.
4.2.2 Assembly
411TI067 KN
. Use appropriate circlip pliers to remove the 9
circlip (11) and then remove the union nut (12).
411TI036 KN
11
. Place O-ring (9) in the plug (8).
411TI068 KN
. Use appropriate circlip pliers to remove the
second circlip (11).
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Technical Information 40.2005 Page 9
8
19 11
411TI037 KN
. Apply Loctite 243 to the plug thread (8) as
described in chapter 1.1.1 and use special tool 20
4233 893 1302 to screw in and tighten.
11
12
411TI039 KN
. Place ring (19, special tool 4233 893 7000) in
411TI038 KN
the groove in the cone.
. Place the white ring (11) in position with the
bevelled surface towards the union nut and
. Screw on and tighten the union nut (10) using press on with the sleeve (20, special tool
special tool 4133 893 1301. 4233 893 4902).
. Remove the ring (19, 4233 893 7000) from the
groove in the cone again.
. Place the ring (11) into the union nut (12) with
the bevelled surface towards the union nut and
press on with the sleeve (20, 4233 893 4902).
. To assemble, proceed in the reverse order to
disassembly.
4.3 Drive tube, gearhead end
. Slacken attachment screw on gearhead and
remove gearhead.
. Pry out the plug (2) and remove the flexible liner
(14) and the drive shaft (15).
. Remove the circlip (16) and pull the drive
shaft (15) out of the flexible liner (14).
. To assemble, proceed in the reverse order to
disassembly. Line up the gearhead, see 5.5.
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)m~ge 10 Technical Information 40.2005
5. Gearhead 5.3 Dismantling the gearbox
See general drawing C. . Disassemble the gearbox, see 5.2.
. Drain the gear oil, see 5.1.
5.1 Changing the gear oil
The first oil change should be carried out after 5.3.1 Opening the gear housing
20 – 25 hours’ operation and regularly as required
thereafter.
3
2
411TI050 KN
411TI047 KN
. Use a suitable tool to prise off the plug (8).
. Turn the drive tube so that the screw plug (2)
faces downwards. Place a suitable container
underneath to catch the oil.
. Unscrew the screw plug (2) and remove it
together with the sealing ring (3).
. Drain the gearbox completely. The gearbox may
be warmed slightly with a hot air blower to
liquefy the gear oil.
411TI016 KN
. Pour in approx. 110 ml (3.7 oz.) gear oil
(0781 313 7002, Klüber Synthetic oil GH 6)
through the drain hole.
. Steady the gearhead with special tool
. Fit a new sealing ring (3) – part number 4233 890 2200.
4233 649 0200
. Place sealing ring (3) over the screw plug (2),
screw in and tighten. 9
Note:
Alternatively, the oil change can be carried out with
the gearbox disassembled.
5.2 Disassembling the gearbox
. Slacken the screw (7) and pull the gearbox off
411TI076 KN
the drive tube.
. Apply a high-temperature hot air jet to loosen
the adhesive on the screw (9), see 1.2.
Use a hexagon socket screw key (size 6 mm) to
unscrew the screw.
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Technical Information 40.2005 Page 11
411TI051 KN
411TI046 KN
25 . Remove the spur bevel gear (14).
. Unscrew the screws (26).
. Remove the gearbox cover (25).
5.3.2 Disassembling the connecting rod, spur
bevel gear and bearing
9
1
411TI052 KN
22 14
. Apply heat to the gear housing in the bearing
21 area.
23
21
411TI048 KN
24 1
. Remove the circlips (24) and the washers (21).
13 27
22 10
411TI053 KN
11
12
. Remove the grooved ball bearing (13) using a
standard internal puller (27).
411TI049 KN
. Remove the circlip (12).
. Remove the spacer ring (11) and the grooved
ball bearing (10).
. Pry off the connecting rod (22) evenly, using two
suitable tools.
. Remove the needle bearings (23) and
washers (21).
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)m~ge 12 Technical Information 40.2005
5.3.3 Disassembling the pushrod housing
411TI056 KN
1
411TI026 KN
. Tilt and separate the pushrod housing from the
. Clamp the gear housing (1), using special tools gear housing (1).
4233 893 5200 and 4233 893 8700.
5.3.4 Disassembling the drive pinion
20 15
19
18
16
411TI054 KN
411TI010 KN
16
. Apply a high-temperature hot air jet to loosen General view of drive pinion
the adhesive on the pushrod housing, see 1.2.
1
411TI055 KN
2
411TI014 KN
. Take special tool 4233 893 1303 and unscrew
the pushrod housing.
. Unscrew the plug (20) using special tool
4233 893 2800.
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Technical Information 40.2005 Page 13
5.3.5 Disassembling the thrust plates
1
5
1
6
411TI057 KN
411TI060 KN
4
. Insert special tool 4233 890 4400 into the drive 5
tube clamp of the gear housing (1). General view of thrust plates
5
411TI058 KN
411TI061 KN
. Use a size 10 mm wrench to screw in the screw
of the special tool 4233 890 4400 into the thread
in the drive pinion. . Apply a high-temperature hot air jet to loosen
the adhesive on the nuts (5), see 1.2.
5
4
411TI059 KN
411TI062 KN
. Use a size 13 mm wrench to turn the nut of the
special tool 4233 890 4400 and thus pull out the . Steady the screws (4) with hexagon socket
drive pinion. screw key 4233 893 0900 (size 2.5 mm) and
. For further steps in dismantling the drive pinion, unscrew the nuts (5).
please refer to the general drawing. . For further steps in dismantling, please refer to
the general drawing.
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)m~ge 14 Technical Information 40.2005
5.4 Assembling the gearhead
5.4.1 Installing the thrust plates
1
1
5
411TI012 KN
6
. Use special tool 4233 893 1500 to push the
411TI060 KN
4 drive pinion into the gear housing (1).
5
. Place the thrust plates (6) in position.
. Apply Loctite 638 to the thread of the screws (4)
as described in chapter 1.1.3. Steady the
nuts (5) and screw in and tighten the screws (4).
5.4.2 Assembling the drive pinion 19
411TI013 KN
. Use special tool 4233 893 1501 to push the oil
20 15 seal (19) into the plug (20).
19
18 . Insert plug (20) into gear housing (1).
16
17
411TI010 KN
16 20
1
. Reassemble the disassembled drive pinion in
accordance with the general drawing.
1
411TI014 KN
. Use special tool 4233 893 2800 to screw in and
tighten the plug (20).
411TI011 KN
. Insert the drive pinion into the gear housing (1).
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Technical Information 40.2005 Page 15
5.4.3 Assembling the pushrod housing
411TI029 KN
411TI026 KN
. Take special tool 4233 893 1303 and screw in
. Clamp the gear housing (1), using special tools and tighten the pushrod housing.
4233 893 5200 and 4233 893 8700.
5.4.4 Assembling the bearings, spur bevel
gear and connecting rod
18
411TI027 KN
411TI006 KN
. Tilt the pushrod housing (18) and insert into the
gear housing (1).
. Insert special centering tool 4233 893 5400 into
. Apply Loctite 243 to the thread of the pushrod the gear housing (1).
housing (18) as described in chapter 1.1.1.
10
411TI007 KN
1
411TI028 KN
18
. Use special tool 4233 893 1500 to press in the
. Insert the pushrod housing into the gear grooved ball bearing (10).
housing (1).
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)m~ge 16 Technical Information 40.2005
12
1
21
23
21
411TI031 KN
411TI008 KN
24
. Insert the circlip (12). . Fit the washers (21) and needle bearing (23).
. Mount the connecting rod (22).
. Fit the washers (21) and mount the circlips (24).
5.4.5 Closing the gear housing
13
11
1
411TI009 KN
. Insert the spacer ring (11) and the grooved ball 26
bearing (13) and press in using special tool
4233 893 1500.
411TI046 KN
25
14 . Apply Dirko HT red sealant – part number
0783 830 2000 – to the edge of the gear
housing (1).
. Put the gearbox cover (25) in place.
. Screw in and tighten the screws (26).
411TI015 KN
. Insert the spur bevel gear (14).
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Technical Information 40.2005 Page 17
5.5 Attaching and lining up the gearhead
. Pour in 120 ml (4.1 oz.) gear oil (0781 313 7002,
Klüber Synthetic oil GH 6) through the drain
hole.
. Fit a new sealing ring –
part number 4233 649 0200
. Place sealing ring over the screw plug, screw in
and tighten.
411TI016 KN
. Push gearhead on to drive tube.
. Steady the gearhead with special tool
4233 890 2200.
9 270°
411TI017 KN
411TI040 KN
. Apply Loctite 638 to the screw thread (9) as
described in chapter 1.1.3. Screw in and tighten
the screw (9).
. Turn the drive tube swivel coupling to the centre
position 135° (total swivel angle approx. 270°).
. Position gearhead vertically with the hook
pointing downwards and tighten the screw (7).
8
411TI030 KN
. Use special tool 4233 893 1500 to push in the
plug (8).
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)m~ge 18 Technical Information 40.2005
6. Pushrod and hook
See general drawing D.
6.1 Disassembling the pushrod
. Proceed as described in chapter 5., paras. 5.2
to 5.3.3.
. Unscrew the hook (13)
411TI081 KN
. Clamp the forkhead and special tools.
411TI063KN
. Pry off the hand guard (10), or cut it off with a
sharp knife and remove it.
411TI065 KN
9 1
7
8
7 . Apply a high-temperature hot air jet to loosen
the adhesive on the pushrod (1), see 1.2.
411TI025 KN
. Remove the snap ring (9), the washers (7) and
the needle bearing (8).
411TI066 KN
12
. Fit the appropriate open-end wrench over the
carrier (12) and unscrew the carrier.
411TI021 KN
. Attach special tools 4233 893 4600 and
4233 893 4601 to the appropriate ends of the
pin (6).
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Technical Information 40.2005 Page 19
6.2 Assembling the pushrod
1
3
411TI070 KN
1
411TI019 KN
. Pull off the pushrod housing over the free end of
the pushrod. . Insert pushrod (1) into housing (2).
. Remove the special tools from the forkhead. . Fit oil seal (3).
. Clamp the free end of the pushrod (1) with
clamping jaws 5910 893 2700.
. Apply a high-temperature hot air jet to loosen
the adhesive on the pushrod (1), see 1.2.
411TI020 KN
. Use special tool 4233 893 4900 to press in the
oil seal (3).
411TI071 KN
5 . Fit the circlip (4).
. Fit the appropriate open-end wrench over the
forkhead (5) and unscrew the forkhead.
. For further housing component disassembly
operations, please refer to the general drawing. 411TI032 KN
. Attach special tools 4233 893 4600 and
4233 893 4601 to the appropriate ends of the
pin (6).
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)m~ge 20 Technical Information 40.2005
9
7
8
7
411TI022 KN
411TI025 KN
. Clamp the forkhead and special tools. . Fit the washers (7), needle bearing (8) and snap
ring (9).
. Proceed as described in chapter 5., paras. 5.4.3
to 5.5.
5
1
411TI023 KN
. Apply Loctite 638 to the forkhead thread (5) as
411TI034 KN
described in chapter 1.1.3. Screw in the
pushrod (5) by hand.
. Attach the pushrod housing over the free end of . Fit special tool 4233 894 7700 over the
the pushrod. carrier (12).
411TI024 KN
10
411TI035KN
. Place washer (11) on carrier. . Press on the hand guard (10), using special tool
4233 893 4901.
. Apply Loctite 638 to the carrier thread (12) as
described in chapter 1.1.3. Insert the carrier (12) . Screw on the hook.
by hand and tighten using the appropriate
wrench.
TI_40_2005_30_01_01.fm
)qechnic~l=fnform~tion=QMKOMMR========================================m~ge=ON
6.3 Hook
. Unscrew the hook.
6.3.1 Rubber insert
. Pry the rubber insert (14) out of the hook. Fit a
new rubber insert.
. Screw on the hook and line it up.
6.3.2 Cone connector
18
17
16
16
15
411TI064 KN
Special tool 4234 890 5200 is required for assembly.
This comprises a ring (17) and a sleeve (18).
. Place ring (17) in the groove in the cone.
. Place the white ring (16) in position with the
bevelled surface towards the union nut and
press on with the sleeve (18).
. Remove the ring (17) from the groove in the
cone again.
. Place the ring (16) into the union nut (15) with
the bevelled surface towards the union nut and
press on with the sleeve (18).
. Screw on the hook and line it up.
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)m~ge 22 Technical Information 40.2005
7. Harness 7.3 Assembling the eyes
7.1 Attaching the harness
411TI044 KN
411TI041 KN
1 3 1 . Fasten the short end.
Caution
. Attach the harness (2) to the drive tube (3) by Take care not to trap the throttle cable under the
the two eyes (1). belt!
7.2 Disassembling the eyes
411TI045 KN
411TI042 KN
. Fasten the long end.
. Undo the long end.
411TI043 KN
. Undo the short end.
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Technical Information 40.2005 Page 23
8. Special tools
8.1 Set of service tools
The special tools illustrated in chapter 8.2 are
included in the set of service tools 4233 007 2200.
8.2 Illustrations of special tools
1 4
47 mm
411TI088 KN
411TI085 KN
4233 890 2200 4233 893 1300
2 5
55 mm
411TI089 KN
411TI100 KN
4233 890 4400 4233 893 1301
3 6
2,5 mm
38 mm
14 mm
411TI033 KN
411TI102 KN
4233 893 0900 4233 893 1302
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)m~ge 24 Technical Information 40.2005
7 11
36 mm
411TI099 KN
411TI087 KN
4233 893 1303 4233 893 2800
8 411TI086 KN 12
411TI082 KN
4233 893 1500 4233 893 4600
9 13
411TI095 KN
4233 893 1501 411TI083 KN
4233 893 4601
10 14
411TI098 KN
411TI093 KN
4233 893 1502 4233 893 4900
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Technical Information 40.2005 Page 25
15 19
411TI091 KN
411TI094 KN
4233 893 4901 4233 893 7000
16 20
411TI092 KN
411TI097 KN
4233 893 4902 4233 893 8700
17 21
411TI096 KN
411TI090 KN
4233 894 7700
4233 893 5200
18 22
411TI101 KN
411TI084 KN
4233 893 5400 4234 890 5200
© Andreas Stihl AG & Co. KG, 2005 Technical Documentation
D1/MTK-na
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Extracted from the manufacturer's 2012 service catalogue. Most of these PDFs embed fonts with a shifted character map, so the text above was recovered rather than copied — read it as a faithful but imperfect transcription, and treat the page image above each block as the authority where the two disagree — the figures exist only there, because they are vector drawings that text extraction cannot keep.