Claas Lexion 480 Operating instructions

REPAIR MANUAL

LEXION 480

Readandfollowsafetyinstructions!

188 678.1 - RHB LEXION 480 0.1.1

Contents

CONTENTS

1. General information

General .................................................................................. 1.1.1

Introduction ...................................................................... 1.1.1

Introduction to the CLAAS Repair Manual ....................... 1.1.2

Key to symbols ................................................................ 1.1.3

Safety Rules .......................................................................... 1.2.1

Important notice ............................................................... 1.2.1

Identification of warning and danger signs ...................... 1.2.2

Correct use of the machine ............................................. 1.2.2

General safety and accident prevention regulations ....... 1.2.2

Leaving the machine ....................................................... 1.2.3

Compressor-type air conditioner ...................................... 1.2.3

Maintenance .................................................................... 1.2.3

Basic rule ......................................................................... 1.2.3

Pressure accumulator ...................................................... 1.2.3

General repair information ..................................................... 1.3.1

Reason of damage .......................................................... 1.3.1

Spare parts ...................................................................... 1.3.1

Engine ............................................................................. 1.3.1

Gearboxes ....................................................................... 1.3.1

Alternator ......................................................................... 1.3.1

Tensioning the steel roller chains .................................... 1.3.1

Taper ring fasteners ........................................................ 1.3.1

Self-locking bolts ............................................................. 1.3.1

Liquid locking compound ................................................. 1.3.2

Correct installation of lock collar bearings ....................... 1.3.2

Correct installation of adapter sleeve bearings ................ 1.3.2

Ferrule fittings on hydraulic lines ..................................... 1.3.2

Progressive ring fittings on hydraulic lines ....................... 1.3.3

Taper fittings on hydraulic lines ....................................... 1.3.3

Welding ............................................................................ 1.3.4

Some advice for speedy and correct repair work ............ 1.3.4

Tightening torques ................................................................. 1.4.1

Bolts ................................................................................. 1.4.1

Hydraulic fittings .............................................................. 1.4.2

Brake line screw joints ..................................................... 1.4.3

Wheel bolts ...................................................................... 1.4.4

Safety features ................................................................ 1.4.4

Specifications ......................................................................... 1.5.1

Lubricants chart ............................................................... 1.5.1

Hydraulic pressure values ............................................... 1.5.2

Sectional view of machine ..................................................... 1.6.1

Drive diagram ......................................................................... 1.7.1

Drive diagram, left-hand .................................................. 1.7.1

Drive system diagram, right-hand side ............................ 1.7.2

2. Operator's platform

Air conditioner ........................................................................ 2.1.1

Important instructions regarding

the compressor-type air conditioning system .................. 2.1.1

Important instructions regarding the installation

of parts in the compressor-type air conditioner ................ 2.1.2

Air conditioning system – Topping up refrigerant ............ 2.1.3

Checking / topping up the refrigerant oil level

at the air conditioner compressor .................................... 2.1.4

Topping up refrigerant oil ................................................. 2.1.5

Removing the condenser ................................................ 2.1.5

Refitting the condenser ................................................... 2.1.6

Removing the air conditioner compressor ....................... 2.1.7

Installing the air conditioner compressor ......................... 2.1.8

Removing the air conditioner compressor

electro-magnetic clutch ................................................... 2.1.8

Air conditioner compressor Sanden Sd 7h 15,

disassembled ................................................................ 2.1.12

Installing the air conditioner compressor

electro-magnetic clutch ................................................. 2.1.13

Removing the air conditioner compressor

cylinder head / cylinder head gasket ............................. 2.1.15

Installing the air conditioner compressor

cylinder head / cylinder head gasket ............................. 2.1.16

Removing the air conditioner

compressor shaft seal ................................................... 2.1.17

Installing the air conditioner

compressor shaft seal ................................................... 2.1.19

Removing the expansion valve ..................................... 2.1.20

Air conditioning system (cab side),

disassembled ................................................................ 2.1.22

Installing the expansion valve ....................................... 2.1.23

Removing the thermostat .............................................. 2.1.23

Installing the thermostat ................................................ 2.1.25

Removing the evaporator .............................................. 2.1.26

Installing the evaporator ................................................ 2.1.27

Removing the filter receiver drier .................................. 2.1.29

Filter receiver drier, disassembled ................................ 2.1.30

Installing the filter receiver drier .................................... 2.1.30

Steering ................................................................................. 2.2.1

Scenes of failures on the Orbitrol steering unit ............... 2.2.1

External leaks .................................................................. 2.2.1

Internal leaks ................................................................... 2.2.1

Removing the steering column ........................................ 2.2.2

Disassembling the steering column ................................ 2.2.4

Steering column, disassembled ...................................... 2.2.7

Assembling the steering column ..................................... 2.2.8

Installing the steering column .......................................... 2.2.9

Removing the valve block from the Orbitrol .................. 2.2.11

Installing the valve block on the Orbitrol ....................... 2.2.12

Removing the Orbitrol ................................................... 2.2.14

Orbitrol, disassembled .................................................. 2.2.14

Installing the Orbitrol ..................................................... 2.2.15

Parking brake ........................................................................ 2.3.1

Removing the parking brake ........................................... 2.3.1

Installing the parking brake ............................................. 2.3.2

Foot brake ............................................................................. 2.4.1

Removing the master brake cylinder ............................... 2.4.1

Master brake cylinder, disassembled .............................. 2.4.1

Assembling the master brake cylinder ............................ 2.4.1

Installing the master brake cylinder ................................. 2.4.2

Adjusting the master brake cylinder ................................ 2.4.2

Engine electric system .......................................................... 2.5.1

Alternator ......................................................................... 2.5.1

Contents

0.1.2 RHB LEXION 480 - 188 678.1

Contents

3. Threshing mechanism

Feed rake conveyor ............................................................... 3.1.1

Removing the feed rake conveyor ................................... 3.1.1

Installing the feed rake conveyor ..................................... 3.1.3

Removing the intercepting piece ..................................... 3.1.4

Installing the intercepting piece ....................................... 3.1.4

Removing the feed rake conveyor

suction blower .................................................................. 3.1.5

Disassembling the feed rake conveyor

suction blower .................................................................. 3.1.5

Feed rake conveyor suction blower,

disassembled ................................................................... 3.1.7

Assembling the feed rake conveyor

suction blower .................................................................. 3.1.8

Installing the feed rake conveyor

suction blower .................................................................. 3.1.9

Removing the top feed rake shaft .................................... 3.1.9

Feed rake top shaft, disassembled ................................ 3.1.14

Installing the feed rake top shaft .................................... 3.1.15

Removing the bottom feed rake roller ............................ 3.1.19

Bottom feed rake roller, disassembled .......................... 3.1.21

Assembling the bottom feed rake roller ......................... 3.1.21

Installing the bottom feed rake roller .............................. 3.1.21

Replacing the wooden ledges ........................................ 3.1.22

Removing the intermediate floor .................................... 3.1.23

Installing the intermediate floor ...................................... 3.1.25

Replacing the runners .................................................... 3.1.25

Removing the intermediate drive shaft .......................... 3.1.26

Intermediate drive shaft, disassembled ......................... 3.1.30

Installing the intermediate drive shaft ............................ 3.1.31

Removing the reverser drive .......................................... 3.1.32

Reverser drive, disassembled ....................................... 3.1.34

Installing the reverser drive ............................................ 3.1.35

Replacing the feeder chains .......................................... 3.1.35

Threshing concave ................................................................. 3.2.1

Removing the stone trap .................................................. 3.2.1

Installing the stone trap .................................................... 3.2.1

Removing the preconcave ............................................... 3.2.2

Preconcave, disassembled .............................................. 3.2.5

Installing the preconcave ................................................. 3.2.6

Removing the main concave ........................................... 3.2.7

Main concave, disassembled ......................................... 3.2.10

Installing the main concave ........................................... 3.2.12

Basic concave setting .................................................... 3.2.16

Adjusting the concave potentiometer ............................. 3.2.21

Learning the limit stops .................................................. 3.2.21

Learning the limit stops .................................................. 3.2.22

Accelerator ............................................................................. 3.3.1

Removing the bearing assembly and

the shaft on the right-hand side ....................................... 3.3.1

Disassembling the right-hand bearing assembly ............. 3.3.3

Assembling the right-hand bearing .................................. 3.3.3

Installing the right-hand bearing assembly

and shaft .......................................................................... 3.3.5

Removing the bearing assembly

on the left-hand side ........................................................ 3.3.8

Disassembling the left-hand bearing assembly ............. 3.3.10

Assembling the left-hand bearing assembly .................. 3.3.11

Installing the left-hand bearing assembly ...................... 3.3.12

Replacing the accelerator caps ..................................... 3.3.13

Removing the accelerator ............................................. 3.3.14

Accelerator, disassembled ............................................ 3.3.17

Installing the accelerator ............................................... 3.3.18

Threshing drum ..................................................................... 3.4.1

Removing the right-hand drum bearing assembly ........... 3.4.1

Disassembling the right-hand drum bearing .................... 3.4.3

Right-hand drum bearing, disassembled ......................... 3.4.4

Installing the right-hand drum bearing ............................. 3.4.5

Removing the left-hand drum bearing assembly ............. 3.4.6

Disassembling the left-hand drum bearing ...................... 3.4.8

Left-hand drum bearing assembly,

disassembled .................................................................. 3.4.8

Installing the left-hand drum bearing assembly ............... 3.4.9

Removing the threshing drum ....................................... 3.4.10

Threshing drum, disassembled ..................................... 3.4.12

Renewing the beater bars ............................................. 3.4.13

Removing the threshing drum shaft .............................. 3.4.14

Installing the threshing drum shaft ................................ 3.4.16

Installing the threshing drum ......................................... 3.4.17

Impeller .................................................................................. 3.5.1

Removing the right-hand impeller bearing ...................... 3.5.1

Installing the right-hand impeller bearing ........................ 3.5.3

Removing the left-hand impeller bearing ......................... 3.5.3

Installing the left-hand impeller bearing ........................... 3.5.5

Removing the impeller ..................................................... 3.5.6

Installing the impeller ....................................................... 3.5.8

Removing the flanged shaft

(from serial no. ...) ........................................................... 3.5.9

Impeller disassembled

(from serial no. ...) ......................................................... 3.5.10

Installing the flanged shaft ............................................. 3.5.11

Removing the impeller shaft

(up to serial no. ...) ........................................................ 3.5.12

Impeller disassembled

(up to serial no. ...) ........................................................ 3.5.13

Installing the impeller shaft

(up to serial no. ...) ........................................................ 3.5.14

Axial rotors ............................................................................. 3.6.1

Removing the separation grates ..................................... 3.6.1

Installing the separation grates ....................................... 3.6.3

Removing the separating jacket ...................................... 3.6.3

Installing the separating jacket ........................................ 3.6.6

Removing the axial rotor supporting arm ........................ 3.6.7

Disassembling the axial rotor supporting arm ................. 3.6.8

Supporting arm, disassembled ........................................ 3.6.9

Installing the axial rotor supporting arm .......................... 3.6.9

Removing the axial rotor ............................................... 3.6.11

Installing the axial rotor ................................................. 3.6.13

Removing the hybrid unit completely ............................ 3.6.14

Installing the hybrid unit ................................................. 3.6.22

4. Cleaning unit

Return pan ............................................................................. 4.1.1

Lowering the return pan

(from serial no. ...) ........................................................... 4.1.1

Raising and installing the return pan

(from serial no. ...) ........................................................... 4.1.2

188 678.1 - RHB LEXION 480 0.1.3

Contents

Removing the return pan ................................................. 4.1.3

Rear rocker arm, disassembled ....................................... 4.1.5

Installing the return pan ................................................... 4.1.5

Sieve pan ............................................................................... 4.2.1

Removing and installing the sieves ................................. 4.2.1

Removing the upper sieves

(from serial no. ...) ........................................................... 4.2.1

Removing the lower sieves

(from serial no. ...) ........................................................... 4.2.3

Installing the sieves

(from serial no. ...) ........................................................... 4.2.4

Tightening torques of axial mountings

for the upper and lower sieves

(from serial no. ...) ........................................................... 4.2.4

Sieves – Basic setting

(electric sieve adjustment – from serial no. ...) ................ 4.2.5

Removing the upper sieves

(up to serial no. ...) ........................................................... 4.2.5

Removing the lower sieves

(up to serial no. ...) ........................................................... 4.2.7

Installing the sieves

(up to serial no. ...) ........................................................... 4.2.8

Tightening torques of axial mountings

for the upper and lower sieves

(up to serial no. ...) ........................................................... 4.2.9

Sieves – Basic setting

(electric sieve adjustment – up to serial no. ...) ............... 4.2.9

Removing the 3-D upper sieve frame ............................ 4.2.10

3-D upper sieve frame, disassembled ........................... 4.2.15

Installing the 3-D upper sieve frame .............................. 4.2.16

Removing the sieve pan ................................................ 4.2.17

Sieve pan, disassembled ............................................... 4.2.20

Installing the sieve pan .................................................. 4.2.21

Checking and adjusting the alignment

of preparation floor and sieve pan ................................. 4.2.24

Preparation floor .................................................................... 4.3.1

Removing the preparation floor ....................................... 4.3.1

Preparation floor, disassembled ...................................... 4.3.3

Installing the preparation floor ......................................... 4.3.4

3-D sieve pan control system ................................................. 4.4.1

Adjusting the 3-D sieve pan control system ..................... 4.4.1

Adjusting pivot arm (A) with the “3-D gauge” ................... 4.4.2

Rocker arm drive .................................................................... 4.5.1

Removing the intermediate drive shaft

for the rocker arm drive ................................................... 4.5.1

Intermediate drive shaft for rocker arm drive,

disassembled ................................................................... 4.5.2

Installing the intermediate drive shaft

for the rocker arm drive ................................................... 4.5.3

Cleaning fan ........................................................................... 4.6.1

Removing the bearings of the cleaning fan ..................... 4.6.1

Cleaning fan bearing, disassembled ............................... 4.6.4

Installing the cleaning fan bearing ................................... 4.6.4

Removing the cleaning fan shaft ..................................... 4.6.5

Removing the centre cleaning fan bearing ...................... 4.6.9

Centre cleaning fan bearing, disassembled .................... 4.6.9

Installing the cleaning fan shaft ..................................... 4.6.10

Removing the cleaning fan rotors .................................. 4.6.11

Installing the cleaning fan rotors ................................... 4.6.11

Removing the cleaning fan housing .............................. 4.6.12

Installing the cleaning fan housing ................................ 4.6.14

5. Grain delivery

Returns elevator .................................................................... 5.1.1

Removing the returns elevator chain .............................. 5.1.1

Installing the returns elevator chain ................................ 5.1.3

Removing the top returns auger ...................................... 5.1.3

Installing the top returns auger ........................................ 5.1.5

Removing the returns elevator ........................................ 5.1.6

Disassembling the returns elevator ................................. 5.1.7

Assembling the returns elevator ...................................... 5.1.9

Installing the returns elevator .......................................... 5.1.9

Removing the returns elevator boot .............................. 5.1.10

Installing the returns elevator boot ................................ 5.1.11

Removing the lower returns auger ................................ 5.1.11

Installing the lower returns auger .................................. 5.1.13

Grain elevator ........................................................................ 5.2.1

Removing the clean grain elevator chain ........................ 5.2.1

Installing the clean grain elevator chain .......................... 5.2.2

Removing the clean grain elevator head ......................... 5.2.3

Dismantling the clean grain elevator head ...................... 5.2.4

Clean grain elevator head, disassembled ....................... 5.2.6

Assembling and installing the clean grain

elevator head .................................................................. 5.2.7

Removing the clean grain elevator shaft ......................... 5.2.7

Installing the grain elevator shaft .................................... 5.2.8

Removing the clean grain elevator boot .......................... 5.2.9

Installing the clean grain elevator boot .......................... 5.2.10

Removing the clean grain auger ................................... 5.2.10

Installing the clean grain auger ..................................... 5.2.13

Removing the grain tank filler auger ............................. 5.2.14

Removing the grain tank filler auger

angle drive ..................................................................... 5.2.15

Disassembling the grain tank filler auger

angle drive ..................................................................... 5.2.16

Grain tank filler auger, disassembled ............................ 5.2.17

Installing the grain tank filler auger ............................... 5.2.18

Grain tank unloading ............................................................. 5.3.1

Removing the grain tank cross auger ............................. 5.3.1

Grain tank cross augers, disassembled .......................... 5.3.4

Installing the grain tank cross auger ............................... 5.3.5

Removing the vertical grain tank

unloading auger .............................................................. 5.3.7

Installing the vertical grain tank

unloading auger ............................................................ 5.3.10

Removing the horizontal grain tank

unloading auger ............................................................ 5.3.11

Installing the horizontal grain tank

unloading auger ............................................................ 5.3.13

Removing the lower grain tank

unloading angle drive

(from serial no. ...) ......................................................... 5.3.13

Disassembling the lower grain tank

unloading angle drive

(from serial no. ...) ......................................................... 5.3.15

0.1.4 RHB LEXION 480 - 188 678.1

Contents

Lower grain tank unloading angle drive,

disassembled

(from serial no. …) ........................................................... 5.3.18

Assembling the lower grain tank

unloading angle drive

(from serial no. ...) .......................................................... 5.3.19

Installing the lower grain tank

unloading angle drive

(from serial no. ...) .......................................................... 5.3.22

Removing the lower grain tank

unloading angle drive

(up to serial no. ...) ......................................................... 5.3.23

Disassembling the lower grain tank

unloading angle drive

(up to serial no. ...) ......................................................... 5.3.24

Lower grain tank unloading angle drive,

disassembled

(up to serial no. …) ........................................................... 5.3.27

Assembling the lower grain tank

unloading angle drive

(up to serial no. ...) ......................................................... 5.3.28

Installing the lower grain tank

unloading angle drive

(up to serial no. ...) ......................................................... 5.3.31

Removing the upper grain tank

unloading angle drive ..................................................... 5.3.32

Disassembling the upper grain tank

unloading angle drive ..................................................... 5.3.33

Upper grain tank unloading angle drive,

disassembled ................................................................. 5.3.34

Assembling the upper grain tank

unloading angle drive ..................................................... 5.3.35

Installing the upper grain tank

unloading angle drive ..................................................... 5.3.38

Removing the grain tank unloading tube ....................... 5.3.39

Refitting the unloading auger tube ................................. 5.3.40

Removing the grain tank unloading tube elbow ............. 5.3.40

Installing the grain tank unloading tube elbow ............... 5.3.41

Removing the vertical unloading auger tube ................. 5.3.41

Installing the vertical unloading auger tube ................... 5.3.42

6. Straw discharge

Straw chopper ........................................................................ 6.1.1

Removing the right-hand straw chopper bearing ............. 6.1.1

Right-hand straw chopper bearing assembly,

disassembled ................................................................... 6.1.3

Installing the right-hand straw chopper bearing ............... 6.1.3

Removing the left-hand straw chopper bearing ............... 6.1.5

Left-hand straw chopper bearing assembly,

disassembled ................................................................... 6.1.6

Installing the left-hand straw chopper bearing ................. 6.1.6

Removing the cutting cylinder .......................................... 6.1.7

Cutting cylinder, disassembled ...................................... 6.1.11

Installing the cutting cylinder .......................................... 6.1.12

Replacing the free-swinging knives ............................... 6.1.13

Uni-spreader .......................................................................... 6.2.1

Removing the fan blade bearings .................................... 6.2.1

Assembling and installing the fan blade bearing ............. 6.2.8

7. Drives

Drive belts .............................................................................. 7.1.1

General Information ......................................................... 7.1.1

Drive diagram ........................................................................ 7.1.2

Drive diagram, left-hand .................................................. 7.1.2

Drive system diagram, right-hand side ............................ 7.1.3

Left-hand drive belts .............................................................. 7.2.1

Removing the cutterbar drive belt (1)

(Cutterbar drive without variable-speed drive) ................ 7.2.1

Installing and adjusting the cutterbar drive belt (1)

(Cutterbar drive without variable-speed drive) ................ 7.2.2

Removing the cutterbar drive belt (2)

(Cutterbar drive with variable-speed drive) ..................... 7.2.3

Installing and adjusting the cutterbar drive belt (2)

(Cutterbar drive with variable-speed drive) ..................... 7.2.4

Removing the cutterbar variable-speed

drive belt (3) .................................................................... 7.2.5

Installing and adjusting the cutterbar

variable-speed drive belt (3) ............................................ 7.2.6

Removing the impeller drive belt (4) ................................ 7.2.7

Installing and adjusting the impeller drive

belt (4) ............................................................................. 7.2.8

Removing the cutterbar intermediate drive belt (5) ......... 7.2.9

Installing and adjusting the cutterbar

intermediate drive belt (5) .............................................. 7.2.10

Removing the uni-spreader hydraulic pump

drive belt (6) .................................................................. 7.2.11

Installing and adjusting the uni-spreader

hydraulic pump drive belt (6) ......................................... 7.2.11

Removing the main intermediate drive belt (7) .............. 7.2.12

Installing and adjusting the main

intermediate drive belt (7) .............................................. 7.2.14

Removing the grain tank unloading

intermediate drive belt (8) .............................................. 7.2.16

Installing and adjusting the grain tank

unloading intermediate drive belt (8) ............................. 7.2.17

Removing the straw chopper

intermediate drive belt (9) .............................................. 7.2.18

Installing and adjusting the straw chopper

intermediate drive belt (9) .............................................. 7.2.19

Removing the straw chopper drive

belts (10 and 11) ........................................................... 7.2.20

Installing and adjusting the straw chopper

drive belts (10 and 11) ................................................... 7.2.22

Removing the uni-spreader

intermediate drive belt (12) ............................................ 7.2.23

Installing and adjusting the uni-spreader

intermediate drive belt (12) ............................................ 7.2.24

Removing the sieve pan intermediate

drive belt (13) ................................................................ 7.2.25

Installing and adjusting the sieve pan

intermediate drive belt (13) ............................................ 7.2.26

Removing the sieve pan intermediate

drive belt (14) ................................................................ 7.2.27

Installing and adjusting the sieve pan

intermediate drive belt (14) ............................................ 7.2.28

Removing the sieve pan drive belt (15) ......................... 7.2.29

188 678.1 - RHB LEXION 480 0.1.5

Contents

Installing and adjusting the sieve pan

drive belt (15) ................................................................. 7.2.31

Removing the uni-spreader drive belt (16) .................... 7.2.32

Installing and adjusting the uni-spreader

drive belt (16) ................................................................. 7.2.33

Removing the grain tank unloading

drive chain (17) .............................................................. 7.2.34

Installing and adjusting the grain tank

unloading drive chain (17) ............................................. 7.2.35

Right-hand drive belts ............................................................ 7.3.1

Adjusting the axial rotor step drive (18) ........................... 7.3.1

Adjusting the axial rotor intermediate

drive (19) ......................................................................... 7.3.2

Removing the fan intermediate drive belt (20) ................. 7.3.3

Installing and adjusting the fan

intermediate drive belt (20) .............................................. 7.3.4

Removing the fan drive belt (21) ..................................... 7.3.5

Installing and adjusting the fan drive belt (21) ................. 7.3.5

Removing the threshing mechanism

variable-speed drive belt (22) .......................................... 7.3.6

Installing and adjusting the threshing

mechanism variable-speed drive belt (22) ....................... 7.3.7

Removing the threshing drum drive belt (23) ................... 7.3.8

Installing and adjusting the threshing

drum drive belt (23) ......................................................... 7.3.9

Removing the accelerator drive belt (24) ....................... 7.3.10

Installing and adjusting the accelerator

drive belt (24) ................................................................. 7.3.11

Removing the radiator chaff screen

intermediate drive belt (25) ............................................ 7.3.12

Installing and adjusting the rotary chaff screen

intermediate drive belt (25) ............................................ 7.3.13

Removing the radiator chaff screen drive

belt (26) ......................................................................... 7.3.14

Installing and adjusting the rotary chaff screen

drive belt (26) ................................................................. 7.3.14

Removing the fan drive belt (27) ................................... 7.3.15

Installing and adjusting the fan drive belt (27) ............... 7.3.16

Removing the suction blower drive belt (28) .................. 7.3.17

Installing and adjusting the suction blower

drive belt (28) ................................................................. 7.3.18

Removing the air conditioner compressor

drive belt (29) ................................................................. 7.3.19

Installing and adjusting the air conditioner

compressor drive belt (29) ............................................. 7.3.20

Removing the compressed-air compressor

drive belt (30) ................................................................. 7.3.21

Installing and adjusting the compressed-air

compressor drive belt (30) ............................................. 7.3.22

Removing the alternator drive belt (31) ......................... 7.3.23

Installing and adjusting the alternator

drive belt (31) ................................................................. 7.3.24

Removing the feed rake conveyor suction

blower drive belt (34) ..................................................... 7.3.26

Installing and adjusting the feed rake conveyor

suction blower drive belt (34) ......................................... 7.3.27

Removing the straw spreader drive belt (36) ................. 7.3.28

Installing and adjusting the straw spreader

drive belt (36) ................................................................ 7.3.29

Cutterbar drive ....................................................................... 7.4.1

Removing the front pulley of cutterbar

drive (1) ........................................................................... 7.4.1

Installing the front pulley of cutterbar drive (1) ................ 7.4.2

Removing the deflection pulley

of cutterbar drive (1) ........................................................ 7.4.2

Deflection pulley of cutterbar drive (1),

disassembled .................................................................. 7.4.3

Installing the deflection pulley

of cutterbar drive (1) ........................................................ 7.4.3

Removing the slip clutch of cutterbar drive (1) ................ 7.4.3

Installing the slip clutch of cutterbar drive (1) .................. 7.4.4

Replacing the slip clutch linings

of cutterbar drive (1) ........................................................ 7.4.5

Slip clutch of cutterbar drive (1), dismantled ................... 7.4.5

Removing the jockey pulley of cutterbar

drive (1) ........................................................................... 7.4.7

Jockey pulley of cutterbar drive (1),

disassembled .................................................................. 7.4.7

Removing the rear pulley of cutterbar drive (1)

(up to serial no. ...) .......................................................... 7.4.7

Dismantling the rear pulley of cutterbar drive (1)

(up to serial no. ...) ........................................................ 7.4.10

Rear pulley of cutterbar drive (1), disassembled

(up to serial no. ...) ........................................................ 7.4.12

Assembling the rear pulley of cutterbar drive (1)

(up to serial no. ...) ........................................................ 7.4.13

Installing the rear pulley of cutterbar drive (1)

(up to serial no. ...) ........................................................ 7.4.15

Removing the rear pulley of cutterbar drive (1)

(from serial no. ...) ......................................................... 7.4.17

Dismantling the rear pulley of cutterbar drive (1)

(from serial no. ...) ......................................................... 7.4.20

Rear pulley of cutterbar drive (1), disassembled

(from serial no. ...) ......................................................... 7.4.22

Assembling the rear pulley of cutterbar drive (1)

(from serial no. ...) ......................................................... 7.4.23

Installing the rear pulley of cutterbar drive (1)

(from serial no. ...) ......................................................... 7.4.24

Removing the cutterbar variable-speed

pulley assembly (spring-loaded) ................................... 7.4.26

Disassembling the cutterbar variable-speed

pulley assembly (spring-loaded) ................................... 7.4.27

Cutterbar variable-speed pulley assembly

(spring-loaded), disassembled ...................................... 7.4.30

Assembling the cutterbar variable-speed

pulley assembly (spring-loaded) ................................... 7.4.31

Installing the cutterbar variable-speed

pulley assembly (spring-loaded) ................................... 7.4.35

Removing the cutterbar drive V-belt pulley

when a cutterbar variable-speed drive is fitted .............. 7.4.37

Disassembling the cutterbar drive V-belt pulley

when a cutterbar variable-speed drive is fitted .............. 7.4.37

Cutterbar drive V-belt pulley with a cutterbar

variable-speed drive fitted, disassembled ..................... 7.4.39

0.1.6 RHB LEXION 480 - 188 678.1

Contents

Assembling the cutterbar drive V-belt pulley

with a cutterbar variable-speed drive fitted .................... 7.4.40

Installing the cutterbar drive V-belt pulley

with a cutterbar variable-speed drive fitted .................... 7.4.42

Removing and disassembling the cutterbar drive

deflection pulley (2) with a cutterbar

variable-speed drive fitted .............................................. 7.4.42

Assembling and installing the cutterbar drive

deflection pulley (2) with a cutterbar

variable-speed drive fitted .............................................. 7.4.43

Removing the cutterbar variable-speed

pulley assembly (hydraulic) ........................................... 7.4.43

Disassembling the cutterbar variable-speed

pulley assembly (hydraulic) ........................................... 7.4.46

Cutterbar variable-speed pulley assembly

(hydraulic), disassembled .............................................. 7.4.48

Assembling the cutterbar variable-speed

pulley assembly (hydraulic) ........................................... 7.4.50

Installing the cutterbar variable-speed

pulley assembly (hydraulic) ........................................... 7.4.51

Removing the cutterbar clutch ....................................... 7.4.52

Cutterbar clutch, disassembled ..................................... 7.4.59

Installing the cutterbar clutch ......................................... 7.4.60

Left-hand threshing mechanism drive .................................... 7.5.1

Removing the threshing mechanism drive

pulley assembly ............................................................... 7.5.1

Threshing mechanism drive pulley assembly,

disassembled ................................................................... 7.5.7

Installing the threshing mechanism drive

pulley assembly ............................................................... 7.5.8

Right-hand threshing mechanism drive ................................. 7.6.1

Removing the threshing drum variable-speed

pulley assembly (hydraulic) ............................................. 7.6.1

Disassembling the threshing drum

variable-speed pulley assembly (hydraulic) ..................... 7.6.2

Threshing drum variable-speed pulley assembly

(hydraulic), disassembled ................................................ 7.6.4

Assembling the threshing drum variable-speed

pulley assembly (hydraulic) ............................................. 7.6.6

Installing the threshing drum variable-speed

pulley assembly (hydraulic) ............................................. 7.6.6

Removing the threshing drum variable-speed

pulley assembly (spring-loaded) ...................................... 7.6.7

Disassembling the threshing drum

variable-speed pulley assembly (spring-loaded) ............. 7.6.8

Threshing drum variable-speed pulley assembly

(spring-loaded), disassembled ....................................... 7.6.11

Assembling the threshing drum variable-speed

pulley assembly (spring-loaded) .................................... 7.6.12

Installing the threshing drum variable-speed

pulley assembly (spring-loaded) .................................... 7.6.16

Removing the threshing mechanism

drive pulley ..................................................................... 7.6.18

Disassembling the threshing mechanism

drive pulley ..................................................................... 7.6.18

Threshing mechanism drive pulley,

disassembled ................................................................. 7.6.20

Assembling the threshing mechanism

drive pulley .................................................................... 7.6.21

Installing the threshing mechanism

drive pulley .................................................................... 7.6.23

Threshing drum reduction gearbox ........................................ 7.7.1

Removing the threshing drum

reduction gearbox ............................................................ 7.7.1

Disassembling the threshing drum

reduction gearbox ............................................................ 7.7.2

Threshing drum reduction gearbox,

disassembled .................................................................. 7.7.6

Assembling the threshing drum

reduction gearbox ............................................................ 7.7.8

Installing the threshing drum

reduction gearbox .......................................................... 7.7.11

Threshing mechanism intermediate drive .............................. 7.8.1

Removing the right-hand intermediate

drive shaft bearing ........................................................... 7.8.1

Installing the right-hand intermediate

drive shaft bearing ........................................................... 7.8.2

Removing the left-hand intermediate

drive shaft bearing ........................................................... 7.8.2

Installing the left-hand intermediate

drive shaft bearing ........................................................... 7.8.3

Removing the intermediate drive shaft ............................ 7.8.4

Installing the intermediate drive shaft .............................. 7.8.4

Grain tank unloading drive ..................................................... 7.9.1

Removing the grain tank unloading

drive pulley ...................................................................... 7.9.1

Installing the grain tank unloading

drive pulley ...................................................................... 7.9.3

Chopper drive ...................................................................... 7.10.1

Removing the stage 1 chopper

drive V-belt pulley .......................................................... 7.10.1

Stage 1 chopper drive V-belt pulley,

disassembled ................................................................ 7.10.3

Assembling and installing the stage 1

chopper drive V-belt pulley ............................................ 7.10.4

Removing the stage 2 chopper

drive V-belt pulley .......................................................... 7.10.6

Stage 2 chopper drive V-belt pulley,

disassembled ................................................................ 7.10.8

Assembling and installing the stage 2 chopper

drive V-belt pulley .......................................................... 7.10.9

Removing the jockey pulley of

straw chopper drive (10) .............................................. 7.10.11

Jockey pulley of straw chopper drive (10),

disassembled .............................................................. 7.10.11

Assembling and installing the jockey pulley

of straw chopper drive (10) .......................................... 7.10.11

Removing the jockey pulley of

straw chopper drive (11) .............................................. 7.10.12

Jockey pulley of straw chopper drive (11),

disassembled .............................................................. 7.10.12

Assembling and installing the jockey pulley

of straw chopper drive (11) .......................................... 7.10.13

Removing the stage 3 chopper

drive V-belt pulley ........................................................ 7.10.13

188 678.1 - RHB LEXION 480 0.1.7

Contents

Disassembling the stage 3 chopper

drive V-belt pulley ........................................................ 7.10.15

Stage 3 chopper drive V-belt pulley,

dismantled ................................................................... 7.10.17

Assembling and installing the stage 3 chopper

drive V-belt pulley ........................................................ 7.10.18

Straw spreader drive ............................................................ 7.11.1

Removing the straw spreader bearing housing ............. 7.11.1

Disassembling the straw spreader bearing housing ...... 7.11.2

Straw spreader bearing housing, disassembled ............ 7.11.5

Assembling the straw spreader bearing housing ........... 7.11.7

Installing the straw spreader bearing housing ............... 7.11.9

Uni-spreader drive ............................................................... 7.12.1

Removing the uni-spreader drive angle drive ................ 7.12.1

Mounting the uni-spreader drive angle drive ................. 7.12.2

Sieve pan drive .................................................................... 7.13.1

Removing the sieve pan drive V-belt pulley ................... 7.13.1

Sieve pan drive V-belt pulley, disassembled ................. 7.13.2

Installing the sieve pan drive V-belt pulley .................... 7.13.3

Removing the front sieve pan drive

deflection pulley ............................................................. 7.13.4

Front sieve pan drive deflection pulley,

disassembled ................................................................. 7.13.4

Assembling the front sieve pan drive

deflection pulley ............................................................. 7.13.5

Installing the front sieve pan drive

deflection pulley ............................................................. 7.13.5

Removing the rear sieve pan drive

deflection pulley ............................................................. 7.13.5

Rear sieve pan drive deflection pulley,

disassembled ................................................................. 7.13.6

Assembling the rear sieve pan drive

deflection pulley ............................................................. 7.13.7

Installing the rear sieve pan drive

deflection pulley ............................................................. 7.13.7

Fan drive .............................................................................. 7.14.1

Removing the stage 1 fan drive V-belt pulley ................ 7.14.1

Stage 1 fan drive V-belt pulley, disassembled ............... 7.14.1

Installing the stage 1 fan drive V-belt pulley .................. 7.14.1

Fan adjustment (electric) ............................................... 7.14.2

Fan adjustment (electric)

Version 1

(up to serial no. ...) ......................................................... 7.14.3

Fan adjustment (electric)

Version 2

(from serial no. …, up to serial no. …) ............................... 7.14.4

Fan adjustment (electric)

Version 3

(from serial no. ...) ......................................................... 7.14.5

Removing the fan adjustment (electric)

(Version 1) ..................................................................... 7.14.6

Disassembling the fan adjustment (electric)

(Version 1) ..................................................................... 7.14.7

Fan adjustment (electric), disassembled

(Version 1) ..................................................................... 7.14.9

Assembling the fan adjustment (electric)

(Version 1) ................................................................... 7.14.10

Installing the fan adjustment (electric)

(Version 1) ................................................................... 7.14.12

Removing the fan adjustment (electric)

(Version 1, version 3) .................................................. 7.14.14

Disassembling the fan adjustment (electric)

(Version 1, version 3) .................................................. 7.14.15

Fan adjustment (electric), disassembled

(Version 1, version 3) .................................................. 7.14.17

Assembling the fan adjustment (electric)

(Version 1, version 3) .................................................. 7.14.18

Installing the fan adjustment (electric)

(Version 1, version 3) .................................................. 7.14.20

Removing the fan adjustment (electric)

(Version 2) ................................................................... 7.14.22

Disassembling the fan adjustment (electric)

(Version 2) ................................................................... 7.14.23

Fan adjustment (electric), disassembled

(Version 2) ................................................................... 7.14.25

Assembling the fan adjustment (electric)

(Version 2) ................................................................... 7.14.26

Installing the fan adjustment (electric)

(Version 2) ................................................................... 7.14.29

Removing the fan variable-speed drive

(electric) ...................................................................... 7.14.31

Electric fan variable-speed pulley assembly,

disassembled .............................................................. 7.14.32

Assembling and installing the electric fan

variable-speed pulley assembly .................................. 7.14.33

Removing the fan drive jockey pulley (20) .................. 7.14.36

Fan drive jockey pulley (20), disassembled ................ 7.14.36

Installing the fan drive jockey pulley (20) .................... 7.14.37

Removing the fan variable-speed

pulley assembly (spring-loaded) ................................. 7.14.37

Disassembling the fan drive variable-speed

pulley assembly (spring-loaded) ................................. 7.14.38

Fan variable-speed pulley assembly

(spring-loaded), disassembled .................................... 7.14.40

Assembling the fan variable-speed

pulley assembly (spring-loaded) ................................. 7.14.41

Installing and adjusting the fan variable-speed

pulley assembly (spring-loaded) ................................. 7.14.42

Axial rotor drive ................................................................... 7.15.1

Removing the axial rotor intermediate

drive V-belt pulley .......................................................... 7.15.1

Axial rotor intermediate drive V-belt pulley,

disassembled ................................................................ 7.15.3

Assembling and installing the axial rotor

intermediate drive V-belt pulley ..................................... 7.15.4

Removing the axial rotors drive jockey

pulley (18) ..................................................................... 7.15.6

Axial rotor drive jockey pulley (18),

disassembled ................................................................ 7.15.6

Installing the axial rotors drive jockey

pulley (18) ..................................................................... 7.15.7

Removing the bearings of axial rotors

drive (18) ....................................................................... 7.15.7

Bearing of axial rotors drive (18),

disassembled ................................................................ 7.15.9

0.1.8 RHB LEXION 480 - 188 678.1

Contents

Installing the bearings of axial rotors

drive (18) ...................................................................... 7.15.10

Removing the axial rotors drive ................................... 7.15.11

Disassembling the axial rotor gearbox ......................... 7.15.12

Axial rotor gearbox, disassembled ............................... 7.15.15

Assembling the axial rotor gearbox ............................. 7.15.16

Installing the axial rotor gearbox .................................. 7.15.20

Engine output ....................................................................... 7.16.1

Removing the engine output pulley ............................... 7.16.1

Installing the engine output pulley ................................. 7.16.1

Removing the transfer gearbox ..................................... 7.16.2

Disassembling the transfer gearbox .............................. 7.16.7

Transfer gearbox, disassembled ................................. 7.16.11

Assembling the transfer gearbox ................................. 7.16.12

Installing the transfer gearbox ..................................... 7.16.19

Rotary screen drive .............................................................. 7.17.1

Removing the rotary screen drive .................................. 7.17.1

Disassembling the rotary screen drive ........................... 7.17.1

Rotary screen drive, disassembled ................................ 7.17.3

Assembling and installing the rotary screen drive ......... 7.17.4

Removing the fan drive .................................................. 7.17.5

Installing the fan drive .................................................... 7.17.5

Final drives ........................................................................... 7.18.1

Removing the final drive gearbox .................................. 7.18.1

Disassembling the final drive gearbox ........................... 7.18.1

Removing the wheel drive shaft ..................................... 7.18.1

Removing the intermediate shaft ................................... 7.18.3

Removing the drive shaft ............................................... 7.18.5

Final drive gearbox, disassembled ................................ 7.18.6

Assembling the final drive gearbox ................................ 7.18.7

Installing the drive shaft ................................................. 7.18.7

Installing the intermediate shaft ..................................... 7.18.8

Installing the wheel drive shaft ..................................... 7.18.11

Disassembling the planetary

final drive gearbox ....................................................... 7.18.15

Planetary final drive gearbox,

disassembled ............................................................... 7.18.22

Assembling the planetary

final drive gearbox ....................................................... 7.18.23

Installing the final drive gearbox .................................. 7.18.27

Manual gearbox ................................................................... 7.19.1

Removing the manual gearbox ...................................... 7.19.1

Disassembling the manual gearbox ............................... 7.19.3

Removing the shifter rails .............................................. 7.19.3

Removing the drive shaft ............................................... 7.19.5

Removing the main shaft ............................................... 7.19.6

Removing the differential ............................................... 7.19.8

Disassembling the differential ........................................ 7.19.9

Differential, disassembled ............................................ 7.19.11

Assembling the differential ........................................... 7.19.11

Installing the differential ............................................... 7.19.13

Manual gearbox, disassembled ................................... 7.19.15

Assembling the manual gearbox ................................. 7.19.16

Installing the main shaft ............................................... 7.19.17

Installing the drive shaft ............................................... 7.19.18

Installing the shifter rails .............................................. 7.19.19

Installing the manual gearbox ...................................... 7.19.22

Servo gearshift ............................................................. 7.19.25

Removing the shifter pistons ....................................... 7.19.25

Servo gearshift, disassembled .................................... 7.19.27

Installing the shifter pistons ......................................... 7.19.27

Bleeding the shifter piston ........................................... 7.19.28

Brake ................................................................................... 7.20.1

Parking brake – Replacing the brake linings ................. 7.20.1

Bleeding the brake system ............................................ 7.20.2

Disc brake – Changing the brake pads ......................... 7.20.2

Removing a brake calliper ............................................. 7.20.3

Installing a brake calliper ............................................... 7.20.4

Steering axle ........................................................................ 7.21.1

Removing the wheel bearing ......................................... 7.21.1

Wheel bearing, disassembled ....................................... 7.21.4

Installing the wheel bearing ........................................... 7.21.5

Removing the stub axle ................................................. 7.21.7

Stub axle, disassembled ............................................. 7.21.10

Installing the stub axle ................................................. 7.21.10

Setting the track width ................................................. 7.21.13

Adjusting the steering axle end stops .......................... 7.21.15

Removing the steering axle ......................................... 7.21.16

Steering axle bearing, disassembled .......................... 7.21.18

Installing the steering axle ........................................... 7.21.19

8. Machine body

Rotary screen ........................................................................ 8.1.1

Removing the rotary screen ............................................ 8.1.1

Disassembling the rotary screen ..................................... 8.1.1

Rotary screen, disassembled .......................................... 8.1.3

Assembling and installing the rotary screen .................... 8.1.4

Trough and lateral panel, disassembled ......................... 8.1.6

Adjusting the trough and the lateral panel

(if suction blower with drive is fitted) ................................ 8.1.7

Removing the fan drive ................................................... 8.1.8

Installing the fan drive ..................................................... 8.1.8

Removing the rotary screen suction blower .................... 8.1.9

Disassembling the rotary screen suction blower ............. 8.1.9

Rotary screen suction blower, disassembled ................ 8.1.11

Assembling and installing the rotary screen

suction blower ............................................................... 8.1.12

Drive axle ............................................................................... 8.2.1

Removing the drive axle .................................................. 8.2.1

Installing the drive axle .................................................... 8.2.4

9. Hydraulic system

Oil cooler ............................................................................... 9.1.1

Removing the oil cooler ................................................... 9.1.1

Installing the oil cooler ..................................................... 9.1.4

Maintenance .......................................................................... 9.2.1

Hydraulic system ............................................................. 9.2.1

Checking the oil level ...................................................... 9.2.1

Changing the hydraulic oil ............................................... 9.2.2

Filling instructions when changing the hydraulic oil ......... 9.2.3

Hydraulic pumps .................................................................... 9.3.1

Removing the uni-spreader hydraulic pump .................... 9.3.1

Disassembling the uni-spreader hydraulic pump ............ 9.3.2

Uni-spreader hydraulic pump, disassembled .................. 9.3.3

Assembling the uni-spreader hydraulic pump ................. 9.3.3

Installing the uni-spreader hydraulic pump ...................... 9.3.4

Removing the ground drive hydraulic pump .................... 9.3.4

188 678.1 - RHB LEXION 480 0.1.9

Contents

Installing the ground drive hydraulic pump ...................... 9.3.7

Removing the hydraulic double pump ............................. 9.3.8

Installing the hydraulic double pump ............................... 9.3.8

Hydrostatic fixed displacement motors .................................. 9.4.1

Removing the ground drive hydrostatic fixed

displacement motor ......................................................... 9.4.1

Installing the ground drive hydrostatic fixed

displacement motor ......................................................... 9.4.3

Removing the reverser drive hydrostatic fixed

displacement motor ......................................................... 9.4.5

Reverser drive hydrostatic fixed

displacement motor, disassembled ................................. 9.4.8

Installing the reverser drive hydrostatic fixed

displacement motor ......................................................... 9.4.9

Hydraulic cylinders – High-pressure hydraulic circuit ............ 9.5.1

Removing the cutterbar cross levelling

hydraulic cylinders ........................................................... 9.5.1

Disassembling the cutterbar cross levelling

hydraulic cylinders ........................................................... 9.5.1

Cutterbar cross levelling hydraulic cylinder,

disassembled ................................................................... 9.5.3

Assembling the cutterbar cross levelling

hydraulic cylinders ........................................................... 9.5.4

Installing the cutterbar cross levelling

hydraulic cylinders ........................................................... 9.5.4

Bleeding the cutterbar cross levelling

hydraulic cylinders ........................................................... 9.5.6

Removing the cutterbar hydraulic cylinders ..................... 9.5.7

Cutterbar hydraulic cylinders –

Replacing the seals ......................................................... 9.5.7

Disassembling the cutterbar hydraulic cylinders .............. 9.5.8

Cutterbar hydraulic cylinder, disassembled ................... 9.5.10

Assembling the cutterbar hydraulic cylinder .................. 9.5.11

Installing the cutterbar hydraulic cylinders ..................... 9.5.12

Adjusting the cutterbar hydraulic cylinders .................... 9.5.12

Removing the cutterbar variable-speed drive

hydraulic cylinder ........................................................... 9.5.13

Installing the cutterbar variable-speed drive

hydraulic cylinder ........................................................... 9.5.14

Disassembling the rotary coupling ................................. 9.5.14

Rotary coupling, disassembled ...................................... 9.5.16

Assembling the rotary coupling ..................................... 9.5.17

Removing the concave adjustment

hydraulic cylinder ........................................................... 9.5.18

Disassembling the concave adjustment

hydraulic cylinder ........................................................... 9.5.19

Concave adjustment hydraulic cylinder,

disassembled ................................................................. 9.5.21

Assembling the concave adjustment

hydraulic cylinder ........................................................... 9.5.22

Installing the concave adjustment

hydraulic cylinder ........................................................... 9.5.23

Removing the grain tank unloading tube swing

hydraulic cylinder ........................................................... 9.5.23

Disassembling the grain tank unloading

tube swing hydraulic cylinder ......................................... 9.5.23

Grain tank unloading tube swing

hydraulic cylinder, disassembled ................................... 9.5.25

Assembling the grain tank unloading

tube swing hydraulic cylinder ........................................ 9.5.26

Installing the grain tank unloading tube swing

hydraulic cylinder .......................................................... 9.5.27

Removing the straw chopper drive

hydraulic cylinder .......................................................... 9.5.27

Disassembling the straw chopper drive

hydraulic cylinder .......................................................... 9.5.28

Straw chopper drive hydraulic cylinder,

disassembled ................................................................ 9.5.29

Assembling the straw chopper drive

hydraulic cylinder .......................................................... 9.5.29

Installing the straw chopper drive

hydraulic cylinder .......................................................... 9.5.30

Removing the threshing drum variable-speed

drive hydraulic cylinder .................................................. 9.5.30

Installing the threshing drum variable-speed

drive hydraulic cylinder .................................................. 9.5.31

Removing the reverser drive

hydraulic cylinder .......................................................... 9.5.32

Disassembling the reverser drive

hydraulic cylinder .......................................................... 9.5.32

Reverser drive hydraulic cylinder,

disassembled ................................................................ 9.5.33

Assembling the reverser drive

hydraulic cylinder .......................................................... 9.5.34

Installing the reverser drive

hydraulic cylinder .......................................................... 9.5.34

Hydraulic cylinders for low-pressure hydraulics .................... 9.6.1

Removing the threshing mechanism

engagement hydraulic cylinder ....................................... 9.6.1

Disassembling the threshing mechanism

engagement hydraulic cylinder ....................................... 9.6.2

Threshing mechanism engagement

hydraulic cylinder, disassembled .................................... 9.6.2

Assembling the threshing mechanism

engagement hydraulic cylinder ....................................... 9.6.3

Installing the threshing mechanism

engagement hydraulic cylinder ....................................... 9.6.4

Removing the grain tank unloading

engagement hydraulic cylinder ....................................... 9.6.4

Disassembling the grain tank unloading

engagement hydraulic cylinder ....................................... 9.6.5

Grain tank unloading engagement

hydraulic cylinder, disassembled .................................... 9.6.6

Assembling the grain tank unloading

engagement hydraulic cylinder ....................................... 9.6.7

Installing the grain tank unloading

engagement hydraulic cylinder ....................................... 9.6.8

Removing the engine speed control

hydraulic cylinder

(from serial no. ...) ........................................................... 9.6.9

Disassembling the engine speed control

hydraulic cylinder

(from serial no. ...) ........................................................... 9.6.9

Engine speed control hydraulic cylinder,

disassembled (from serial no. ...) .................................. 9.6.11

0.1.10 RHB LEXION 480 - 188 678.1

Contents

Assembling the engine speed control

hydraulic cylinder

(from serial no. ...) .......................................................... 9.6.12

Pre-setting the engine speed control

hydraulic cylinder

(from serial no. ...) .......................................................... 9.6.14

Installing the engine speed control

hydraulic cylinder

(from serial no. ...) .......................................................... 9.6.14

Setting the engine speed control

hydraulic cylinder

(from serial no. ...) .......................................................... 9.6.15

Changing the road travel engine speed

(country variants 20 km/h and/or 25 km/h)

by converting the cylinder .............................................. 9.6.16

Conversion of cylinder to another country

variant (20 km/h and/or 25 km/h) ................................... 9.6.16

Removing the engine speed control

hydraulic cylinder

(up to serial no. ...) ......................................................... 9.6.19

Disassembling the engine speed control

hydraulic cylinder

(up to serial no. ...) ......................................................... 9.6.20

Engine speed control hydraulic cylinder,

disassembled

(up to serial no. …) ........................................................... 9.6.23

Assembling the engine speed control

hydraulic cylinder

(up to serial no. ...) ......................................................... 9.6.24

Pre-setting the engine speed control

hydraulic cylinder

(up to serial no. ...) ......................................................... 9.6.25

Installing the engine speed control

hydraulic cylinder

(up to serial no. ...) ......................................................... 9.6.25

Setting the engine speed control

hydraulic cylinder

(up to serial no. ...) ......................................................... 9.6.26

Removing the 3-D sieve pan

hydraulic cylinder ........................................................... 9.6.28

Disassembling the 3-D sieve pan

hydraulic cylinder ........................................................... 9.6.28

3-D sieve pan hydraulic cylinder,

disassembled ................................................................. 9.6.29

Assembling the 3-D sieve pan

hydraulic cylinder ........................................................... 9.6.30

Installing the 3-D sieve pan

hydraulic cylinder ........................................................... 9.6.31

Removing the pendulum control unit

of the 3-D sieve pan ....................................................... 9.6.31

Disassembling the 3-D sieve pan

pendulum control unit .................................................... 9.6.31

Pendulum control unit of 3-D sieve pan,

disassembled ................................................................. 9.6.33

Assembling the pendulum control unit

for 3-D sieve pan ........................................................... 9.6.34

Installing the 3-D sieve pan pendulum

control unit ..................................................................... 9.6.34

Removing the yield meter moisture sensor

hydraulic cylinder ........................................................... 9.6.35

Disassembling the yield meter moisture

sensor hydraulic cylinder ............................................... 9.6.36

Yield meter moisture sensor hydraulic cylinder,

disassembled ................................................................ 9.6.37

Assembling the yield meter moisture

sensor hydraulic cylinder ............................................... 9.6.37

Installing the yield meter moisture

sensor hydraulic cylinder ............................................... 9.6.38

Checking and adjusting the yield meter

hydraulic cylinder ........................................................... 9.6.38

Yield meter hydraulic cylinder,

disassembled ................................................................ 9.6.40

Hydraulic cylinders – Steering hydraulics .............................. 9.7.1

Removing the steering cylinder ....................................... 9.7.1

Disassembling the steering cylinder ................................ 9.7.1

Steering cylinder, disassembled ...................................... 9.7.3

Assembling the steering cylinder ..................................... 9.7.4

Installing the steering cylinder ......................................... 9.7.5

Removing the Autopilot steering cylinder ........................ 9.7.5

Disassembling the Autopilot steering cylinder ................. 9.7.6

Autopilot steering cylinder, disassembled ....................... 9.7.9

Assembling the Autopilot steering cylinder .................... 9.7.10

Installing the Autopilot steering cylinder ........................ 9.7.11

Valve combinations ............................................................... 9.8.1

Removing the feeder reversing 3/2-way valve ................ 9.8.1

Feeder reversing 3/2-way valve,

disassembled .................................................................. 9.8.1

Removing the cutterbar cross levelling

4/3-way valve .................................................................. 9.8.2

Cutterbar cross levelling 4/3-way valve,

disassembled .................................................................. 9.8.3

Removing the concave adjustment

pressure relief valve ........................................................ 9.8.4

Concave adjustment pressure relief valve,

disassembled .................................................................. 9.8.4

Assembling the concave adjustment

pressure relief valve ........................................................ 9.8.4

Removing the cutterbar and threshing drum

variable-speed drive 3/3-way valves ............................... 9.8.4

Cutterbar and threshing drum

variable-speed drive 3/3-way valve,

disassembled .................................................................. 9.8.6

Installing the cutterbar and threshing drum

variable-speed drive 3/3-way valves ............................... 9.8.7

Removing the threshing drum variable-speed

drive 3/3-way valve .......................................................... 9.8.7

Threshing drum variable-speed

drive 3/3-way valve, disassembled .................................. 9.8.8

Removing the concave, grain tank unloading

tube and straw chopper 4/3-way valves .......................... 9.8.9

Concave, grain tank unloading tube and

straw chopper 4/3-way valve, disassembled ................. 9.8.10

Assembling the concave, grain tank unloading

tube and straw chopper 4/3-way valves ........................ 9.8.11

Installing the concave, grain tank unloading

tube and straw chopper 4/3-way valves ........................ 9.8.11

188 678.1 - RHB LEXION 480 0.1.11

Contents

Removing the concave and grain tank

unloading tube 4/3 way valves ...................................... 9.8.11

Concave and grain tank unloading tube

4/3-way valve, disassembled ......................................... 9.8.13

Assembling the concave and grain tank

unloading tube 4/3-way valves ...................................... 9.8.14

Installing the concave and grain tank

unloading tube 4/3-way valves ...................................... 9.8.14

Removing the main valve .............................................. 9.8.14

Main valve, disassembled ............................................. 9.8.16

Assembling the main valve ............................................ 9.8.17

Installing the main valve ................................................ 9.8.17

Removing the CLAAS Autopilot

solenoid valve ................................................................ 9.8.18

CLAAS Autopilot solenoid valve,

disassembled ................................................................. 9.8.19

Assembling the CLAAS Autopilot

solenoid valve ................................................................ 9.8.20

Installing the CLAAS Autopilot

solenoid valve ................................................................ 9.8.20

Removing the low-pressure

solenoid valve block ...................................................... 9.8.20

Low-pressure solenoid valve block,

disassembled ................................................................. 9.8.22

Assembling the low-pressure

solenoid valve block ...................................................... 9.8.23

Installing the low-pressure

solenoid valve block ...................................................... 9.8.23

Removing the low-pressure solenoid valve

(yield meter) ................................................................... 9.8.23

Yield meter 3/2-way solenoid valve,

disassembled ................................................................. 9.8.25

Installing the low-pressure solenoid valve

(yield meter) ................................................................... 9.8.26

10. Engine

Cooling system .................................................................... 10.1.1

Removing the intercooler ............................................... 10.1.1

Installing the intercooler ................................................. 10.1.3

Removing the radiator ................................................... 10.1.3

Installing the radiator ..................................................... 10.1.6

Fuel system .......................................................................... 10.2.1

Removing the fuel tank .................................................. 10.2.1

Installing the fuel tank .................................................... 10.2.2

Installing the additional fuel tank ................................... 10.2.2

Installing the additional fuel tank ................................... 10.2.4

Engine .................................................................................. 10.3.1

Removing the engine ..................................................... 10.3.1

Installing the engine ....................................................... 10.3.7

11. Index

Index .................................................................................... 11.1.1

0.1.12 RHB LEXION 480 - 188 678.1

Contents

General information

188 678.1 - RHB LEXION 480 1.1.1

General

GENERAL Introduction

This CLAAS REPAIR MANUAL is to assist in pre-

serving the permanent working order and therefore

the high value of your CLAAS combine-harvester by

careful maintenance and service.

Experience gathered by both our service engineers

and factory staff has been compiled in this REPAIR

MANUAL.

The figures explain the procedure of repairs and the

text describes the different adjustments to be made,

the use of CLAAS special tools etc.

The illustrations included in support to the expla-

nations show the sequence of major repairs so that

minor repairs can easily be followed.

The CLAAS REPAIR MANUAL is filled in a folder

which allows to insert supplementary pages as issued

following technical developments and to always have

an updated manual at hand for reference.

To be sure, always compare settings and filling

capacities with specifications stated in the current

Operator’s Manual which applies to the combine-

harvester.

CLAAS KGaA mbH

Service Department

General

1.1.2 RHB LEXION 480 - 188 678.1

General

Introduction to the CLAAS Repair Manual The CLAAS REPAIR MANUAL is divided into main

groups and subgroups.

The first figure at the bottom of each page refers to

the main group whereas the second figure following

the point indicates the subgroup; the figure behind

the second point indicates the page number. In each

subgroup, the figures and pages are numbered

consecutively, starting at 1.

Where differences between the machine types must

be observed, this is indicated in headings. Where a

service procedure applies to all machines covered by

this book, the machine names are not specifically

given.

When supplements are to be added, the subgroups

are supplemented or exchanged. Any possible

supplements are filed in the respective main group /

subgroup and the table of contents is updated and

replaced.

The symbols communicate brief messages when

recurring service procedures are described. Their

meaning is explained at the beginning of this manual.

The section “GENERAL REPAIR INSTRUCTIONS” at

the beginning of this manual 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 table of

contents of the appropriate main group /

subgroup.

188 678.1 - RHB LEXION 480 1.1.3

General

Key to symbols

This CLAAS REPAIR MANUAL uses some symbols as

defined in the “DIN 30600 Symbol summary” by the

German Standardisation Institute.

The meaning of these symbols will be easily

recognised and remembered by the user. These

symbols are to help to quickly recognise recurring

service procedures and they also help to communicate

information shown on the illustrations.

Dismantle,

remove Grease Prevent damage

to materials

Disassemble Oil Use special tool

Assemble Adjust / set Drain,

outlet

Install,

mount on Check visually Fill,

filler opening

Mark Unlock, release,

secure Overflow

Balance

Lock by means of

liquids,

glue, seal

Bleed

Possibly reusable

Underprop,

support

Renew on each

assembly

Observe direction

of installation

General

1.1.4 RHB LEXION 480 - 188 678.1

General

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