Name: Claas LEXION 480
Brand: Claas
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REPAIR MANUAL

LEXION 480

Table of Contents3
General Information15
General17
Introduction17
Introduction to the CLAAS Repair Manual18
Key to Symbols19
Safety Rules21
Important Notice21
Identification of Warning and Danger Signs22
Correct Use of the Machine22
General Safety and Accident Prevention Regulations22
Leaving the Machine23
Compressor-Type Air Conditioner23
Maintenance23
Basic Rule23
Pressure Accumulator23
General Repair Information25
Reason of Damage25
Spare Parts25
Engine25
Gearboxes25
Alternator25
Tensioning the Steel Roller Chains25
Taper Ring Fasteners25
Self-Locking Bolts25
Liquid Locking Compound26
Correct Installation of Lock Collar Bearings26
Correct Installation of Adapter Sleeve Bearings26
Ferrule Fittings on Hydraulic Lines26
Progressive Ring Fittings on Hydraulic Lines27
Taper Fittings on Hydraulic Lines27
Welding28
Some Advice for Speedy and Correct Repair Work28
Tightening Torques29
Bolts29
Hydraulic Fittings30
Brake Line Screw Joints31
Wheel Bolts32
Safety Features32
Specifications33
Lubricants Chart33
Hydraulic Pressure Values34
Sectional View of Machine35
Drive Diagram39
Drive Diagram, Left-Hand39
Drive System Diagram, Right-Hand Side40
Operator's Platform41
Air Conditioner43
Important Instructions Regarding the Compressor-Type Air Conditioning System43
Important Instructions Regarding the Installation of Parts in the Compressor-Type Air Conditioner44
Air Conditioning System - Topping up Refrigerant45
Checking / Topping up the Refrigerant Oil Level at the Air Conditioner Compressor46
Topping up Refrigerant Oil47
Removing the Condenser47
Refitting the Condenser48
Removing the Air Conditioner Compressor49
Installing the Air Conditioner Compressor50
Removing the Air Conditioner Compressor Electro-Magnetic Clutch50
Air Conditioner Compressor Sanden Sd 7H 15, Disassembled54
Installing the Air Conditioner Compressor Electro-Magnetic Clutch55
Removing the Air Conditioner Compressor Cylinder Head / Cylinder Head Gasket57
Installing the Air Conditioner Compressor Cylinder Head / Cylinder Head Gasket58
Removing the Air Conditioner Compressor Shaft Seal59
Installing the Air Conditioner Compressor Shaft Seal61
Removing the Expansion Valve62
Air Conditioning System (Cab Side), Disassembled64
Installing the Expansion Valve65
Removing the Thermostat65
Installing the Thermostat67
Removing the Evaporator68
Installing the Evaporator69
Removing the Filter Receiver Drier71
Filter Receiver Drier, Disassembled72
Installing the Filter Receiver Drier72
Steering75
Scenes of Failures on the Orbitrol Steering Unit75
External Leaks75
Internal Leaks75
Removing the Steering Column76
Disassembling the Steering Column78
Steering Column, Disassembled81
Assembling the Steering Column82
Installing the Steering Column83
Removing the Valve Block from the Orbitrol85
Installing the Valve Block on the Orbitrol86
Removing the Orbitrol88
Orbitrol, Disassembled88
Installing the Orbitrol89
Parking Brake93
Removing the Parking Brake93
Installing the Parking Brake94
Foot Brake95
Removing the Master Brake Cylinder95
Master Brake Cylinder, Disassembled95
Assembling the Master Brake Cylinder95
Installing the Master Brake Cylinder96
Adjusting the Master Brake Cylinder96
Engine Electric System97
Alternator97
Threshing Mechanism99
Feed Rake Conveyor101
Removing the Feed Rake Conveyor101
Installing the Feed Rake Conveyor103
Removing the Intercepting Piece104
Installing the Intercepting Piece104
Removing the Feed Rake Conveyor Suction Blower105
Disassembling the Feed Rake Conveyor Suction Blower105
Feed Rake Conveyor Suction Blower, Disassembled107
Assembling the Feed Rake Conveyor Suction Blower108
Installing the Feed Rake Conveyor Suction Blower109
Removing the Top Feed Rake Shaft109
Feed Rake Top Shaft, Disassembled114
Installing the Feed Rake Top Shaft115
Removing the Bottom Feed Rake Roller119
Bottom Feed Rake Roller, Disassembled121
Assembling the Bottom Feed Rake Roller121
Installing the Bottom Feed Rake Roller121
Replacing the Wooden Ledges122
Removing the Intermediate Floor123
Installing the Intermediate Floor125
Replacing the Runners125
Removing the Intermediate Drive Shaft126
Installing the Intermediate Drive Shaft131
Removing the Reverser Drive132
Installing the Reverser Drive135
Replacing the Feeder Chains135
Threshing Concave139
Removing the Stone Trap139
Installing the Stone Trap139
Removing the Preconcave140
Preconcave, Disassembled143
Installing the Preconcave144
Removing the Main Concave145
Main Concave, Disassembled148
Installing the Main Concave150
Basic Concave Setting154
Adjusting the Concave Potentiometer159
Learning the Limit Stops159
Accelerator161
Removing the Bearing Assembly and the Shaft on the Right-Hand Side161
Disassembling the Right-Hand Bearing Assembly163
Assembling the Right-Hand Bearing163
Installing the Right-Hand Bearing Assembly and Shaft165
Removing the Bearing Assembly on the Left-Hand Side168
Disassembling the Left-Hand Bearing Assembly170
Assembling the Left-Hand Bearing Assembly171
Installing the Left-Hand Bearing Assembly172
Replacing the Accelerator Caps173
Removing the Accelerator174
Accelerator, Disassembled177
Installing the Accelerator178
Threshing Drum183
Removing the Right-Hand Drum Bearing Assembly183
Disassembling the Right-Hand Drum Bearing185
Right-Hand Drum Bearing, Disassembled186
Installing the Right-Hand Drum Bearing187
Removing the Left-Hand Drum Bearing Assembly188
Disassembling the Left-Hand Drum Bearing190
Left-Hand Drum Bearing Assembly, Disassembled190
Installing the Left-Hand Drum Bearing Assembly191
Removing the Threshing Drum192
Threshing Drum, Disassembled194
Renewing the Beater Bars195
Removing the Threshing Drum Shaft196
Installing the Threshing Drum Shaft198
Installing the Threshing Drum199
Impeller201
Removing the Right-Hand Impeller Bearing201
Installing the Right-Hand Impeller Bearing203
Removing the Left-Hand Impeller Bearing203
Installing the Left-Hand Impeller Bearing205
Removing the Impeller206
Installing the Impeller208
Removing the Flanged Shaft (from Serial no209
Impeller Disassembled210
Installing the Flanged Shaft211
Removing the Impeller Shaft (up to Serial no212
Impeller Disassembled213
Installing the Impeller Shaft214
(Up to Serial no215
Axial Rotors215
Removing the Separation Grates215
Installing the Separation Grates217
Removing the Separating Jacket217
Installing the Separating Jacket220
Removing the Axial Rotor Supporting Arm221
Disassembling the Axial Rotor Supporting Arm222
Supporting Arm, Disassembled223
Installing the Axial Rotor Supporting Arm223
Removing the Axial Rotor225
Installing the Axial Rotor227
Removing the Hybrid Unit Completely228
Installing the Hybrid Unit236
Cleaning Unit239
Return Pan241
Lowering the Return Pan (from Serial no241
Raising and Installing the Return Pan (from Serial no242
Removing the Return Pan243
Rear Rocker Arm, Disassembled245
Installing the Return Pan245
Sieve Pan247
Removing and Installing the Sieves247
Removing the Upper Sieves (from Serial no247
Removing the Lower Sieves (from Serial no249
Installing the Sieves (from Serial no250
Tightening Torques of Axial Mountings for the Upper and Lower Sieves (from Serial no250
Sieves - Basic Setting (Electric Sieve Adjustment - from Serial no251
Removing the Upper Sieves (up to Serial no251
Removing the Lower Sieves (up to Serial no253
Installing the Sieves (up to Serial no254
Tightening Torques of Axial Mountings for the Upper and Lower Sieves (up to Serial no255
Sieves - Basic Setting (Electric Sieve Adjustment - up to Serial no255
Removing the 3-D Upper Sieve Frame256
Installing the 3-D Upper Sieve Frame262
Removing the Sieve Pan263
Installing the Sieve Pan267
Checking and Adjusting the Alignment of Preparation Floor and Sieve Pan270
Preparation Floor271
Removing the Preparation Floor271
Preparation Floor, Disassembled273
Installing the Preparation Floor274
3-D Sieve Pan Control System275
Adjusting the 3-D Sieve Pan Control System275
Adjusting Pivot Arm (A) with the "3-D Gauge276
Rocker Arm Drive277
Removing the Intermediate Drive Shaft for the Rocker Arm Drive277
Intermediate Drive Shaft for Rocker Arm Drive, Disassembled278
Installing the Intermediate Drive Shaft for the Rocker Arm Drive279
Cleaning Fan281
Removing the Bearings of the Cleaning Fan281
Cleaning Fan Bearing, Disassembled284
Installing the Cleaning Fan Bearing284
Removing the Cleaning Fan Shaft285
Removing the Centre Cleaning Fan Bearing289
Centre Cleaning Fan Bearing, Disassembled289
Installing the Cleaning Fan Shaft290
Removing the Cleaning Fan Rotors291
Installing the Cleaning Fan Rotors291
Removing the Cleaning Fan Housing292
Installing the Cleaning Fan Housing294
Grain Delivery295
Returns Elevator297
Removing the Returns Elevator Chain297
Installing the Returns Elevator Chain299
Removing the Top Returns Auger299
Installing the Top Returns Auger301
Removing the Returns Elevator302
Disassembling the Returns Elevator303
Assembling the Returns Elevator305
Installing the Returns Elevator305
Removing the Returns Elevator Boot306
Installing the Returns Elevator Boot307
Removing the Lower Returns Auger307
Installing the Lower Returns Auger309
Grain Elevator311
Removing the Clean Grain Elevator Chain311
Installing the Clean Grain Elevator Chain312
Removing the Clean Grain Elevator Head313
Dismantling the Clean Grain Elevator Head314
Clean Grain Elevator Head, Disassembled316
Assembling and Installing the Clean Grain Elevator Head317
Removing the Clean Grain Elevator Shaft317
Installing the Grain Elevator Shaft318
Removing the Clean Grain Elevator Boot319
Installing the Clean Grain Elevator Boot320
Removing the Clean Grain Auger320
Installing the Clean Grain Auger323
Removing the Grain Tank Filler Auger324
Removing the Grain Tank Filler Auger Angle Drive325
Disassembling the Grain Tank Filler Auger Angle Drive326
Grain Tank Filler Auger, Disassembled327
Installing the Grain Tank Filler Auger328
Grain Tank Unloading331
Removing the Grain Tank Cross Auger331
Grain Tank Cross Augers, Disassembled334
Installing the Grain Tank Cross Auger335
Removing the Vertical Grain Tank Unloading Auger337
Installing the Vertical Grain Tank Unloading Auger340
Removing the Horizontal Grain Tank Unloading Auger341
Installing the Horizontal Grain Tank Unloading Auger343
Removing the Lower Grain Tank Unloading Angle Drive (from Serial no343
Disassembling the Lower Grain Tank Unloading Angle Drive (from Serial no345
Lower Grain Tank Unloading Angle Drive, Disassembled (from Serial no348
Assembling the Lower Grain Tank Unloading Angle Drive (from Serial no349
Installing the Lower Grain Tank Unloading Angle Drive (from Serial no352
Removing the Lower Grain Tank Unloading Angle Drive (up to Serial no353
(Up to Serial no354
Installing the Lower Grain Tank Unloading Angle Drive (up to Serial no361
Removing the Upper Grain Tank Unloading Angle Drive362
Disassembling the Upper Grain Tank Unloading Angle Drive363
Assembling the Upper Grain Tank Unloading Angle Drive365
Installing the Upper Grain Tank Unloading Angle Drive368
Removing the Grain Tank Unloading Tube369
Refitting the Unloading Auger Tube370
Removing the Grain Tank Unloading Tube Elbow370
Installing the Grain Tank Unloading Tube Elbow371
Removing the Vertical Unloading Auger Tube371
Installing the Vertical Unloading Auger Tube372
Straw Discharge373
Straw Chopper375
Removing the Right-Hand Straw Chopper Bearing375
Right-Hand Straw Chopper Bearing Assembly, Disassembled377
Installing the Right-Hand Straw Chopper Bearing377
Removing the Left-Hand Straw Chopper Bearing379
Left-Hand Straw Chopper Bearing Assembly, Disassembled380
Installing the Left-Hand Straw Chopper Bearing380
Removing the Cutting Cylinder381
Cutting Cylinder, Disassembled385
Installing the Cutting Cylinder386
Replacing the Free-Swinging Knives387
Uni-Spreader391
Removing the Fan Blade Bearings391
Assembling and Installing the Fan Blade Bearing398
Drives403
Drive Belts405
General Information405
Drive Diagram406
Drive Diagram, Left-Hand406
Drive System Diagram, Right-Hand Side407
Left-Hand Drive Belts409
Removing the Cutterbar Drive Belt (1) (Cutterbar Drive Without Variable-Speed Drive)409
Installing and Adjusting the Cutterbar Drive Belt (1) (Cutterbar Drive Without Variable-Speed Drive)410
Removing the Cutterbar Drive Belt (2) (Cutterbar Drive with Variable-Speed Drive)411
Installing and Adjusting the Cutterbar Drive Belt (2) (Cutterbar Drive with Variable-Speed Drive)412
Removing the Cutterbar Variable-Speed Drive Belt (3)413
Installing and Adjusting the Cutterbar Variable-Speed Drive Belt (3)414
Removing the Impeller Drive Belt (4)415
Installing and Adjusting the Impeller Drive Belt (4)416
Removing the Cutterbar Intermediate Drive Belt (5)417
Installing and Adjusting the Cutterbar Intermediate Drive Belt (5)418
Removing the Uni-Spreader Hydraulic Pump Drive Belt (6)419
Installing and Adjusting the Uni-Spreader Hydraulic Pump Drive Belt (6)419
Removing the Main Intermediate Drive Belt (7)420
Installing and Adjusting the Main Intermediate Drive Belt (7)422
Removing the Grain Tank Unloading Intermediate Drive Belt (8)424
Installing and Adjusting the Grain Tank Unloading Intermediate Drive Belt (8)425
Removing the Straw Chopper Intermediate Drive Belt (9)426
Installing and Adjusting the Straw Chopper Intermediate Drive Belt (9)427
Removing the Straw Chopper Drive Belts (10 and 11)428
Installing and Adjusting the Straw Chopper Drive Belts (10 and 11)430
Removing the Uni-Spreader Intermediate Drive Belt (12)431
Installing and Adjusting the Uni-Spreader Intermediate Drive Belt (12)432
Removing the Sieve Pan Intermediate Drive Belt (13)433
Installing and Adjusting the Sieve Pan Intermediate Drive Belt (13)434
Removing the Sieve Pan Intermediate Drive Belt (14)435
Installing and Adjusting the Sieve Pan Intermediate Drive Belt (14)436
Removing the Sieve Pan Drive Belt (15)437
Installing and Adjusting the Sieve Pan Drive Belt (15)439
Removing the Uni-Spreader Drive Belt (16)440
Installing and Adjusting the Uni-Spreader441
Removing the Grain Tank Unloading Drive Chain (17)442
Installing and Adjusting the Grain Tank Unloading Drive Chain (17)443
Right-Hand Drive Belts445
Adjusting the Axial Rotor Step Drive (18)445
Adjusting the Axial Rotor Intermediate Drive (19)446
Removing the Fan Intermediate Drive Belt (20)447
Installing and Adjusting the Fan Intermediate Drive Belt (20)448
Removing the Fan Drive Belt (21)449
Installing and Adjusting the Fan Drive Belt (21)449
Removing the Threshing Mechanism Variable-Speed Drive Belt (22)450
Installing and Adjusting the Threshing Mechanism Variable-Speed Drive Belt (22)451
Removing the Threshing Drum Drive Belt (23)452
Installing and Adjusting the Threshing Drum Drive Belt (23)453
Removing the Accelerator Drive Belt (24)454
Installing and Adjusting the Accelerator Drive Belt (24)455
Removing the Radiator Chaff Screen Intermediate Drive Belt (25)456
Installing and Adjusting the Rotary Chaff Screen Intermediate Drive Belt (25)457
Removing the Radiator Chaff Screen Drive Belt (26)458
Installing and Adjusting the Rotary Chaff Screen Drive Belt (26)458
Removing the Fan Drive Belt (27)459
Installing and Adjusting the Fan Drive Belt (27)460
Removing the Suction Blower Drive Belt (28)461
Installing and Adjusting the Suction Blower Drive Belt (28)462
Drive Belt (29)462
Installing and Adjusting the Air Conditioner Compressor Drive Belt (29)464
Removing the Compressed-Air Compressor Drive Belt (30)465
Installing and Adjusting the Compressed-Air Compressor Drive Belt (30)466
Removing the Alternator Drive Belt (31)467
Installing and Adjusting the Alternator Drive Belt (31)468
Removing the Feed Rake Conveyor Suction Blower Drive Belt (34)470
Installing and Adjusting the Feed Rake Conveyor Suction Blower Drive Belt (34)471
Removing the Straw Spreader Drive Belt (36)472
Installing and Adjusting the Straw Spreader Drive Belt (36)473
Cutterbar Drive477
Removing the Front Pulley of Cutterbar Drive (1)477
Installing the Front Pulley of Cutterbar Drive (1)478
Removing the Deflection Pulley of Cutterbar Drive (1)478
Deflection Pulley of Cutterbar Drive (1), Disassembled479
Installing the Deflection Pulley of Cutterbar Drive (1)479
Removing the Slip Clutch of Cutterbar Drive (1)479
Installing the Slip Clutch of Cutterbar Drive (1)480
Replacing the Slip Clutch Linings of Cutterbar Drive (1)481
Slip Clutch of Cutterbar Drive (1), Dismantled481
Removing the Jockey Pulley of Cutterbar Drive (1)483
Jockey Pulley of Cutterbar Drive (1), Disassembled483
Removing the Rear Pulley of Cutterbar Drive (1) (up to Serial no483
Dismantling the Rear Pulley of Cutterbar Drive486
Rear Pulley of Cutterbar Drive (1), Disassembled488
(Up to Serial no489
Assembling the Rear Pulley of Cutterbar Drive (1) (up to Serial no489
Installing the Rear Pulley of Cutterbar Drive491
Removing the Rear Pulley of Cutterbar Drive (1) (from Serial no493
Dismantling the Rear Pulley of Cutterbar Drive (1) (from Serial no496
Rear Pulley of Cutterbar Drive (1), Disassembled498
Assembling the Rear Pulley of Cutterbar Drive (1) (from Serial no499
Installing the Rear Pulley of Cutterbar Drive (1) (from Serial no500
Removing the Cutterbar Variable-Speed Pulley Assembly (Spring-Loaded)502
Disassembling the Cutterbar Variable-Speed Pulley Assembly (Spring-Loaded)503
Cutterbar Variable-Speed Pulley Assembly (Spring-Loaded), Disassembled506
Assembling the Cutterbar Variable-Speed Pulley Assembly (Spring-Loaded)507
Installing the Cutterbar Variable-Speed Pulley Assembly (Spring-Loaded)511
Removing the Cutterbar Drive V-Belt Pulley When a Cutterbar Variable-Speed Drive Is Fitted513
Disassembling the Cutterbar Drive V-Belt Pulley513
When a Cutterbar Variable-Speed Drive Is Fitted513
Cutterbar Drive V-Belt Pulley with a Cutterbar Variable-Speed Drive Fitted, Disassembled515
Assembling the Cutterbar Drive V-Belt Pulley with a Cutterbar Variable-Speed Drive Fitted516
Installing the Cutterbar Drive V-Belt Pulley with a Cutterbar Variable-Speed Drive Fitted518
Removing and Disassembling the Cutterbar Drive Deflection Pulley (2) with a Cutterbar Variable-Speed Drive Fitted518
Assembling and Installing the Cutterbar Drive Deflection Pulley (2) with a Cutterbar Variable-Speed Drive Fitted519
Removing the Cutterbar Variable-Speed Pulley Assembly (Hydraulic)519
Disassembling the Cutterbar Variable-Speed Pulley Assembly (Hydraulic)522
Cutterbar Variable-Speed Pulley Assembly (Hydraulic), Disassembled524
Assembling the Cutterbar Variable-Speed Pulley Assembly (Hydraulic)526
Installing the Cutterbar Variable-Speed Pulley Assembly (Hydraulic)527
Removing the Cutterbar Clutch528
Cutterbar Clutch, Disassembled535
Installing the Cutterbar Clutch536
Left-Hand Threshing Mechanism Drive543
Removing the Threshing Mechanism Drive Pulley Assembly543
Threshing Mechanism Drive Pulley Assembly, Disassembled549
Installing the Threshing Mechanism Drive Pulley Assembly550
Right-Hand Threshing Mechanism Drive557
Removing the Threshing Drum Variable-Speed Pulley Assembly (Hydraulic)557
Disassembling the Threshing Drum Variable-Speed Pulley Assembly (Hydraulic)558
Threshing Drum Variable-Speed Pulley Assembly (Hydraulic), Disassembled560
Assembling the Threshing Drum Variable-Speed Pulley Assembly (Hydraulic)562
Installing the Threshing Drum Variable-Speed Pulley Assembly (Hydraulic)562
Removing the Threshing Drum Variable-Speed Pulley Assembly (Spring-Loaded)563
Disassembling the Threshing Drum Variable-Speed Pulley Assembly (Spring-Loaded)564
Threshing Drum Variable-Speed Pulley Assembly (Spring-Loaded), Disassembled567
Assembling the Threshing Drum Variable-Speed Pulley Assembly (Spring-Loaded)568
Installing the Threshing Drum Variable-Speed Pulley Assembly (Spring-Loaded)572
Removing the Threshing Mechanism Drive Pulley574
Disassembling the Threshing Mechanism Drive Pulley574
Threshing Mechanism Drive Pulley, Disassembled576
Assembling the Threshing Mechanism Drive Pulley577
Installing the Threshing Mechanism Drive Pulley579
Threshing Drum Reduction Gearbox581
Removing the Threshing Drum Reduction Gearbox581
Disassembling the Threshing Drum Reduction Gearbox582
Threshing Drum Reduction Gearbox, Disassembled586
Assembling the Threshing Drum Reduction Gearbox588
Installing the Threshing Drum Reduction Gearbox591
Threshing Mechanism Intermediate Drive595
Removing the Right-Hand Intermediate Drive Shaft Bearing595
Installing the Right-Hand Intermediate Drive Shaft Bearing596
Removing the Left-Hand Intermediate Drive Shaft Bearing596
Installing the Left-Hand Intermediate Drive Shaft Bearing597
Removing the Intermediate Drive Shaft598
Installing the Intermediate Drive Shaft598
Grain Tank Unloading Drive599
Removing the Grain Tank Unloading Drive Pulley599
Installing the Grain Tank Unloading Drive Pulley601
Chopper Drive603
Removing the Stage 1 Chopper Drive V-Belt Pulley603
Stage 1 Chopper Drive V-Belt Pulley, Disassembled605
Assembling and Installing the Stage 1 Chopper Drive V-Belt Pulley606
Removing the Stage 2 Chopper Drive V-Belt Pulley608
Stage 2 Chopper Drive V-Belt Pulley, Disassembled610
Assembling and Installing the Stage 2 Chopper Drive V-Belt Pulley611
Removing the Jockey Pulley of Straw Chopper Drive (10)613
Jockey Pulley of Straw Chopper Drive (10), Disassembled613
Assembling and Installing the Jockey Pulley of Straw Chopper Drive (10)613
Removing the Jockey Pulley of Straw Chopper Drive (11)614
Jockey Pulley of Straw Chopper Drive (11), Disassembled614
Assembling and Installing the Jockey Pulley of Straw Chopper Drive (11)615
Removing the Stage 3 Chopper Drive V-Belt Pulley615
Disassembling the Stage 3 Chopper Drive V-Belt Pulley617
Stage 3 Chopper Drive V-Belt Pulley, Dismantled619
Assembling and Installing the Stage 3 Chopper Drive V-Belt Pulley620
Straw Spreader Drive623
Removing the Straw Spreader Bearing Housing623
Disassembling the Straw Spreader Bearing Housing624
Straw Spreader Bearing Housing, Disassembled627
Assembling the Straw Spreader Bearing Housing629
Installing the Straw Spreader Bearing Housing631
Uni-Spreader Drive635
Removing the Uni-Spreader Drive Angle Drive635
Mounting the Uni-Spreader Drive Angle Drive636
Sieve Pan Drive637
Removing the Sieve Pan Drive V-Belt Pulley637
Sieve Pan Drive V-Belt Pulley, Disassembled638
Installing the Sieve Pan Drive V-Belt Pulley639
Removing the Front Sieve Pan Drive Deflection Pulley640
Front Sieve Pan Drive Deflection Pulley, Disassembled640
Assembling the Front Sieve Pan Drive Deflection Pulley641
Installing the Front Sieve Pan Drive Deflection Pulley641
Removing the Rear Sieve Pan Drive Deflection Pulley641
Rear Sieve Pan Drive Deflection Pulley, Disassembled642
Assembling the Rear Sieve Pan Drive Deflection Pulley643
Installing the Rear Sieve Pan Drive Deflection Pulley643
Fan Drive645
Removing the Stage 1 Fan Drive V-Belt Pulley645
Stage 1 Fan Drive V-Belt Pulley, Disassembled645
Installing the Stage 1 Fan Drive V-Belt Pulley645
Fan Adjustment (Electric)646
Fan Adjustment (Electric) Version647
Up to Serial no650
From Serial no650
Removing the Fan Adjustment (Electric) (Version 1)650
Disassembling the Fan Adjustment (Electric) (Version 1)651
Fan Adjustment (Electric), Disassembled (Version 1)653
Assembling the Fan Adjustment (Electric) (Version 1)654
Installing the Fan Adjustment (Electric) (Version 1)656
Removing the Fan Adjustment (Electric)658
(Version 1, Version 3)658
Disassembling the Fan Adjustment (Electric) (Version 1, Version 3)659
Fan Adjustment (Electric), Disassembled (Version 1, Version 3)661
Assembling the Fan Adjustment (Electric) (Version 1, Version 3)662
Installing the Fan Adjustment (Electric) (Version 1, Version 3)664
Removing the Fan Adjustment (Electric) (Version 2)666
Disassembling the Fan Adjustment (Electric) (Version 2)667
Fan Adjustment (Electric), Disassembled (Version 2)669
Assembling the Fan Adjustment (Electric) (Version 2)670
Installing the Fan Adjustment (Electric) (Version 2)673
Removing the Fan Variable-Speed Drive (Electric)675
Electric Fan Variable-Speed Pulley Assembly, Disassembled676
Assembling and Installing the Electric Fan Variable-Speed Pulley Assembly677
Removing the Fan Drive Jockey Pulley (20)680
Fan Drive Jockey Pulley (20), Disassembled680
Installing the Fan Drive Jockey Pulley (20)681
Removing the Fan Variable-Speed Pulley Assembly (Spring-Loaded)681
Disassembling the Fan Drive Variable-Speed Pulley Assembly (Spring-Loaded)682
Fan Variable-Speed Pulley Assembly (Spring-Loaded), Disassembled684
Assembling the Fan Variable-Speed Pulley Assembly (Spring-Loaded)685
Installing and Adjusting the Fan Variable-Speed Pulley Assembly (Spring-Loaded)686
Axial Rotor Drive687
Removing the Axial Rotor Intermediate Drive V-Belt Pulley687
Axial Rotor Intermediate Drive V-Belt Pulley, Disassembled689
Assembling and Installing the Axial Rotor Intermediate Drive V-Belt Pulley690
Removing the Axial Rotors Drive Jockey Pulley (18)692
Axial Rotor Drive Jockey Pulley (18), Disassembled692
Installing the Axial Rotors Drive Jockey Pulley (18)693
Removing the Bearings of Axial Rotors Drive (18)693
Bearing of Axial Rotors Drive (18), Disassembled695
Installing the Bearings of Axial Rotors696
Drive (18)696
Removing the Axial Rotors Drive697
Disassembling the Axial Rotor Gearbox698
Axial Rotor Gearbox, Disassembled701
Assembling the Axial Rotor Gearbox702
Installing the Axial Rotor Gearbox706
Engine Output709
Removing the Engine Output Pulley709
Installing the Engine Output Pulley709
Removing the Transfer Gearbox710
Disassembling the Transfer Gearbox715
Transfer Gearbox, Disassembled719
Assembling the Transfer Gearbox720
Installing the Transfer Gearbox727
Rotary Screen Drive731
Removing the Rotary Screen Drive731
Disassembling the Rotary Screen Drive731
Rotary Screen Drive, Disassembled733
Assembling and Installing the Rotary Screen Drive734
Removing the Fan Drive735
Installing the Fan Drive735
Final Drives737
Removing the Final Drive Gearbox737
Disassembling the Final Drive Gearbox737
Removing the Wheel Drive Shaft737
Removing the Intermediate Shaft739
Removing the Drive Shaft741
Assembling the Final Drive Gearbox743
Installing the Drive Shaft743
Installing the Intermediate Shaft744
Installing the Wheel Drive Shaft747
Disassembling the Planetary Final Drive Gearbox751
Planetary Final Drive Gearbox, Disassembled758
Assembling the Planetary Final Drive Gearbox759
Installing the Final Drive Gearbox763
Manual Gearbox767
Removing the Manual Gearbox767
Disassembling the Manual Gearbox769
Removing the Shifter Rails769
Removing the Drive Shaft771
Removing the Main Shaft772
Removing the Differential774
Disassembling the Differential775
Differential, Disassembled777
Assembling the Differential777
Installing the Differential779
Manual Gearbox, Disassembled781
Assembling the Manual Gearbox782
Installing the Main Shaft783
Installing the Drive Shaft784
Installing the Shifter Rails785
Installing the Manual Gearbox788
Servo Gearshift791
Removing the Shifter Pistons791
Servo Gearshift, Disassembled793
Installing the Shifter Pistons793
Bleeding the Shifter Piston794
Brake795
Parking Brake - Replacing the Brake Linings795
Bleeding the Brake System796
Disc Brake - Changing the Brake Pads796
Removing a Brake Calliper797
Installing a Brake Calliper798
Steering Axle799
Removing the Wheel Bearing799
Wheel Bearing, Disassembled802
Installing the Wheel Bearing803
Removing the Stub Axle805
Stub Axle, Disassembled808
Installing the Stub Axle808
Setting the Track Width811
Adjusting the Steering Axle End Stops813
Removing the Steering Axle814
Steering Axle Bearing, Disassembled816
Installing the Steering Axle817
Machine Body819
Rotary Screen821
Removing the Rotary Screen821
Disassembling the Rotary Screen821
Rotary Screen, Disassembled823
Assembling and Installing the Rotary Screen824
Trough and Lateral Panel, Disassembled826
Adjusting the Trough and the Lateral Panel827
(If Suction Blower with Drive Is Fitted)827
Removing the Fan Drive828
Installing the Fan Drive828
Removing the Rotary Screen Suction Blower829
Disassembling the Rotary Screen Suction Blower829
Rotary Screen Suction Blower, Disassembled831
Assembling and Installing the Rotary Screen Suction Blower832
Drive Axle833
Removing the Drive Axle833
Installing the Drive Axle836
Hydraulic System839
Oil Cooler841
Removing the Oil Cooler841
Installing the Oil Cooler844
Maintenance845
Hydraulic System845
Checking the Oil Level845
Changing the Hydraulic Oil846
Filling Instructions When Changing the Hydraulic Oil847
Hydraulic Pumps849
Removing the Uni-Spreader Hydraulic Pump849
Disassembling the Uni-Spreader Hydraulic Pump850
Uni-Spreader Hydraulic Pump, Disassembled851
Assembling the Uni-Spreader Hydraulic Pump851
Installing the Uni-Spreader Hydraulic Pump852
Removing the Ground Drive Hydraulic Pump852
Installing the Ground Drive Hydraulic Pump855
Removing the Hydraulic Double Pump856
Installing the Hydraulic Double Pump856
Hydrostatic Fixed Displacement Motors857
Removing the Ground Drive Hydrostatic Fixed Displacement Motor857
Installing the Ground Drive Hydrostatic Fixed Displacement Motor859
Removing the Reverser Drive Hydrostatic Fixed Displacement Motor861
Reverser Drive Hydrostatic Fixed Displacement Motor, Disassembled864
Installing the Reverser Drive Hydrostatic Fixed Displacement Motor865
Hydraulic Cylinders - High-Pressure Hydraulic Circuit867
Removing the Cutterbar Cross Levelling Hydraulic Cylinders867
Disassembling the Cutterbar Cross Levelling Hydraulic Cylinders867
Cutterbar Cross Levelling Hydraulic Cylinder, Disassembled869
Assembling the Cutterbar Cross Levelling Hydraulic Cylinders870
Installing the Cutterbar Cross Levelling Hydraulic Cylinders870
Bleeding the Cutterbar Cross Levelling Hydraulic Cylinders872
Removing the Cutterbar Hydraulic Cylinders873
Cutterbar Hydraulic Cylinders - Replacing the Seals873
Disassembling the Cutterbar Hydraulic Cylinders874
Assembling the Cutterbar Hydraulic Cylinder877
Installing the Cutterbar Hydraulic Cylinders878
Adjusting the Cutterbar Hydraulic Cylinders878
Removing the Cutterbar Variable-Speed Drive Hydraulic Cylinder879
Installing the Cutterbar Variable-Speed Drive Hydraulic Cylinder880
Disassembling the Rotary Coupling880
Rotary Coupling, Disassembled882
Assembling the Rotary Coupling883
Removing the Concave Adjustment Hydraulic Cylinder884
Disassembling the Concave Adjustment Hydraulic Cylinder885
Concave Adjustment Hydraulic Cylinder, Disassembled887
Assembling the Concave Adjustment Hydraulic Cylinder888
Installing the Concave Adjustment Hydraulic Cylinder889
Removing the Grain Tank Unloading Tube Swing Hydraulic Cylinder889
Disassembling the Grain Tank Unloading Tube Swing Hydraulic Cylinder889
Grain Tank Unloading Tube Swing Hydraulic Cylinder, Disassembled891
Assembling the Grain Tank Unloading Tube Swing Hydraulic Cylinder892
Installing the Grain Tank Unloading Tube Swing Hydraulic Cylinder893
Removing the Straw Chopper Drive Hydraulic Cylinder893
Disassembling the Straw Chopper Drive Hydraulic Cylinder894
Straw Chopper Drive Hydraulic Cylinder, Disassembled895
Assembling the Straw Chopper Drive Hydraulic Cylinder895
Installing the Straw Chopper Drive Hydraulic Cylinder896
Removing the Threshing Drum Variable-Speed Drive Hydraulic Cylinder896
Installing the Threshing Drum Variable-Speed Drive Hydraulic Cylinder897
Removing the Reverser Drive Hydraulic Cylinder898
Disassembling the Reverser Drive Hydraulic Cylinder898
Reverser Drive Hydraulic Cylinder, Disassembled899
Assembling the Reverser Drive Hydraulic Cylinder900
Installing the Reverser Drive Hydraulic Cylinder900
Hydraulic Cylinders for Low-Pressure Hydraulics903
Removing the Threshing Mechanism Engagement Hydraulic Cylinder903
Disassembling the Threshing Mechanism Engagement Hydraulic Cylinder904
Threshing Mechanism Engagement Hydraulic Cylinder, Disassembled904
Assembling the Threshing Mechanism Engagement Hydraulic Cylinder905
Installing the Threshing Mechanism Engagement Hydraulic Cylinder906
Removing the Grain Tank Unloading Engagement Hydraulic Cylinder906
Disassembling the Grain Tank Unloading Engagement Hydraulic Cylinder907
Grain Tank Unloading Engagement Hydraulic Cylinder, Disassembled908
Assembling the Grain Tank Unloading Engagement Hydraulic Cylinder909
Installing the Grain Tank Unloading Engagement Hydraulic Cylinder910
Removing the Engine Speed Control Hydraulic Cylinder (from Serial no911
Disassembling the Engine Speed Control Hydraulic Cylinder (from Serial no911
Engine Speed Control Hydraulic Cylinder, Disassembled (from Serial no913
Assembling the Engine Speed Control Hydraulic Cylinder (from Serial no914
Pre-Setting the Engine Speed Control Hydraulic Cylinder (from Serial no916
Installing the Engine Speed Control Hydraulic Cylinder (from Serial no916
Setting the Engine Speed Control Hydraulic Cylinder (from Serial no917
Changing the Road Travel Engine Speed (Country Variants 20 Km/H And/Or 25 Km/H) by Converting the Cylinder918
Conversion of Cylinder to Another Country Variant (20 Km/H And/Or 25 Km/H)918
Removing the Engine Speed Control Hydraulic Cylinder (up to Serial no921
Disassembling the Engine Speed Control Hydraulic Cylinder (up to Serial no922
Engine Speed Control Hydraulic Cylinder, Disassembled (up to Serial no925
Assembling the Engine Speed Control Hydraulic Cylinder (up to Serial no926
Pre-Setting the Engine Speed Control Hydraulic Cylinder (up to Serial no927
Installing the Engine Speed Control Hydraulic Cylinder (up to Serial no927
Setting the Engine Speed Control Hydraulic Cylinder (up to Serial no928
Removing the 3-D Sieve Pan Hydraulic Cylinder930
Disassembling the 3-D Sieve Pan Hydraulic Cylinder930
3-D Sieve Pan Hydraulic Cylinder, Disassembled931
Assembling the 3-D Sieve Pan Hydraulic Cylinder932
Installing the 3-D Sieve Pan Hydraulic Cylinder933
Removing the Pendulum Control Unit of the 3-D Sieve Pan933
Disassembling the 3-D Sieve Pan Pendulum Control Unit933
Pendulum Control Unit of 3-D Sieve Pan, Disassembled935
Assembling the Pendulum Control Unit for 3-D Sieve Pan936
Installing the 3-D Sieve Pan Pendulum Control Unit936
Removing the Yield Meter Moisture Sensor Hydraulic Cylinder937
Disassembling the Yield Meter Moisture Sensor Hydraulic Cylinder938
Yield Meter Moisture Sensor Hydraulic Cylinder, Disassembled939
Assembling the Yield Meter Moisture Sensor Hydraulic Cylinder939
Installing the Yield Meter Moisture Sensor Hydraulic Cylinder940
Checking and Adjusting the Yield Meter Hydraulic Cylinder940
Yield Meter Hydraulic Cylinder, Disassembled942
Hydraulic Cylinders - Steering Hydraulics943
Removing the Steering Cylinder943
Disassembling the Steering Cylinder943
Steering Cylinder, Disassembled945
Assembling the Steering Cylinder946
Installing the Steering Cylinder947
Removing the Autopilot Steering Cylinder947
Disassembling the Autopilot Steering Cylinder948
Autopilot Steering Cylinder, Disassembled951
Assembling the Autopilot Steering Cylinder952
Installing the Autopilot Steering Cylinder953
Valve Combinations955
Removing the Feeder Reversing 3/2-Way Valve955
Feeder Reversing 3/2-Way Valve, Disassembled955
Removing the Cutterbar Cross Levelling 4/3-Way Valve956
Cutterbar Cross Levelling 4/3-Way Valve, Disassembled957
Removing the Concave Adjustment Pressure Relief Valve958
Concave Adjustment Pressure Relief Valve, Disassembled958
Assembling the Concave Adjustment Pressure Relief Valve958
Removing the Cutterbar and Threshing Drum Variable-Speed Drive 3/3-Way Valves958
Disassembled958
Variable-Speed Drive 3/3-Way Valves958
Removing the Threshing Drum Variable-Speed Drive 3/3-Way Valve961
Threshing Drum Variable-Speed Drive 3/3-Way Valve, Disassembled962
Removing the Concave, Grain Tank Unloading Tube and Straw Chopper 4/3-Way Valves963
Concave, Grain Tank Unloading Tube and Straw Chopper 4/3-Way Valve, Disassembled964
Assembling the Concave, Grain Tank Unloading Tube and Straw Chopper 4/3-Way Valves965
Installing the Concave, Grain Tank Unloading Tube and Straw Chopper 4/3-Way Valves965
Removing the Concave and Grain Tank Unloading Tube 4/3 Way Valves965
Concave and Grain Tank Unloading Tube 4/3-Way Valve, Disassembled967
Assembling the Concave and Grain Tank Unloading Tube 4/3-Way Valves968
Installing the Concave and Grain Tank Unloading Tube 4/3-Way Valves968
Removing the Main Valve968
Main Valve, Disassembled970
Assembling the Main Valve971
Installing the Main Valve971
Removing the CLAAS Autopilot Solenoid Valve972
CLAAS Autopilot Solenoid Valve, Disassembled973
Assembling the CLAAS Autopilot Solenoid Valve974
Installing the CLAAS Autopilot Solenoid Valve974
Removing the Low-Pressure Solenoid Valve Block974
Low-Pressure Solenoid Valve Block, Disassembled976
Assembling the Low-Pressure Solenoid Valve Block977
Installing the Low-Pressure Solenoid Valve Block977
Removing the Low-Pressure Solenoid Valve (Yield Meter)977
Yield Meter 3/2-Way Solenoid Valve, Disassembled979
Installing the Low-Pressure Solenoid Valve (Yield Meter)980
Engine981
Cooling System983
Removing the Intercooler983
Installing the Intercooler985
Removing the Radiator985
Installing the Radiator988
Fuel System989
Removing the Fuel Tank989
Installing the Fuel Tank990
Installing the Additional Fuel Tank990
Engine993
Removing the Engine993
Installing the Engine999
Index1003

Brand	Claas
Model	LEXION 480
Category	Farm Equipment
Language	English

Claas LEXION 480 User Manual

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Claas LEXION 480 Specifications

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