CLAAS LEXION 480 REPAIR MANUAL – PDF DOWNLOAD

Description

CLAAS LEXION 480 REPAIR MANUAL – PDF DOWNLOAD

DESCRIPTION:

CLAAS LEXION 480 REPAIR MANUAL – PDF DOWNLOAD
TABLE OF CONTENTS:

CLAAS LEXION 480 REPAIR MANUAL – PDF DOWNLOADContents 3
General information 15
General 17
Introduction 17
Introduction to the CLAAS Repair Manual 18
Key to symbols 19
Safety Rules 21
Important notice 21
Identification of warning and danger signs 22
Correct use of the machine 22
General safety and accident prevention regulations 22
Leaving the machine 23
Compressor-type air conditioner 23
Maintenance 23
Basic rule 23
Pressure accumulator 23
General repair information 25
Reason of damage 25
Spare parts 25
Engine 25
Gearboxes 25
Alternator 25
Tensioning the steel roller chains 25
Taper ring fasteners 25
Self-locking bolts 25
Liquid locking compound 26
Correct installation of lock collar bearings 26
Correct installation of adapter sleeve bearings 26
Ferrule fittings on hydraulic lines 26
Progressive ring fittings on hydraulic lines 27
Taper fittings on hydraulic lines 27
Welding 28
Some advice for speedy and correct repair work: 28
Tightening torques 29
Bolts 29
Hydraulic fittings 30
Brake line screw joints 31
Wheel bolts 32
Safety features 32
Specifications 33
Lubricants chart 33
Hydraulic pressure values 34
Sectional view of machine 35
Drive diagram 39
Drive diagram, left-hand 39
Drive system diagram, right-hand side 40
Operator’s platform 41
Air conditioner 43
Important instructions regarding the compressor-type air conditioning system 43
Important instructions regarding the installation of parts in the compressor-type air conditioner 44
Air conditioning system – Topping up refrigerant 45
Checking / topping up the refrigerant oil level at the air conditioner compressor 46
Topping up refrigerant oil 47
Removing the condenser 47
Refitting the condenser 48
Removing the air conditioner compressor 49
Installing the air conditioner compressor 50
Removing the air conditioner compressor electro-magnetic clutch 50
Air conditioner compressor Sanden Sd 7h 15, disassembled 54
Installing the air conditioner compressor electro-magnetic clutch 55
Removing the air conditioner compressor cylinder head / cylinder head gasket 57
Installing the air conditioner compressor cylinder head / cylinder head gasket 58
Removing the air conditioner compressor shaft seal 59
Installing the air conditioner compressor shaft seal 61
Removing the expansion valve 62
Air conditioning system (cab side), disassembled 64
Installing the expansion valve 65
Removing the thermostat 65
Installing the thermostat 67
Removing the evaporator 68
Installing the evaporator 69
Removing the filter receiver drier 71
Filter receiver drier, disassembled 72
Installing the filter receiver drier 72
Steering 75
Scenes of failures on the Orbitrol steering unit 75
External leaks 75
Internal leaks 75
Removing the steering column 76
Disassembling the steering column 78
Steering column, disassembled: 81
Assembling the steering column 82
Installing the steering column 83
Removing the valve block from the Orbitrol 85
Installing the valve block on the Orbitrol 86
Removing the Orbitrol 88
Orbitrol, disassembled 88
Installing the Orbitrol 89
Parking brake 93
Removing the parking brake 93
Installing the parking brake 94
Foot brake 95
Removing the master brake cylinder 95
Master brake cylinder, disassembled 95
Assembling the master brake cylinder 95
Installing the master brake cylinder 96
Adjusting the master brake cylinder 96
Engine electric system 97
Alternator 97
Threshing mechanism 99
Feed rake conveyor 101
Removing the feed rake conveyor 101
Installing the feed rake conveyor 103
Removing the intercepting piece 104
Installing the intercepting piece 104
Removing the feed rake conveyor suction blower 105
Disassembling the feed rake conveyor suction blower 105
Feed rake conveyor suction blower, disassembled: 107
Assembling the feed rake conveyor suction blower 108
Installing the feed rake conveyor suction blower 109
Removing the top feed rake shaft 109
Feed rake top shaft, disassembled 114
Installing the feed rake top shaft 115
Removing the bottom feed rake roller 119
Bottom feed rake roller, disassembled 121
Assembling the bottom feed rake roller 121
Installing the bottom feed rake roller 121
Replacing the wooden ledges 122
Removing the intermediate floor 123
Installing the intermediate floor 125
Replacing the runners 125
Removing the intermediate drive shaft 126
Intermediate drive shaft, disassembled 130
Installing the intermediate drive shaft 131
Removing the reverser drive 132
Reverser drive, disassembled 134
Installing the reverser drive 135
Replacing the feeder chains 135
Threshing concave 139
Removing the stone trap 139
Installing the stone trap 139
Removing the preconcave 140
Preconcave, disassembled 143
Installing the preconcave 144
Removing the main concave 145
Main concave, disassembled 148
Installing the main concave 150
Basic concave setting 154
Adjusting the concave potentiometer 159
Learning the limit stops 159
Learning the limit stops 160
Accelerator 161
Removing the bearing assembly and the shaft on the right-hand side 161
Disassembling the right-hand bearing assembly 163
Assembling the right-hand bearing 163
Installing the right-hand bearing assembly and shaft 165
Removing the bearing assembly on the left-hand side 168
Disassembling the left-hand bearing assembly 170
Assembling the left-hand bearing assembly 171
Installing the left-hand bearing assembly 172
Replacing the accelerator caps 173
Removing the accelerator 174
Accelerator, disassembled 177
Installing the accelerator 178
Threshing drum 183
Removing the right-hand drum bearing assembly 183
Disassembling the right-hand drum bearing 185
Right-hand drum bearing, disassembled: 186
Installing the right-hand drum bearing 187
Removing the left-hand drum bearing assembly 188
Disassembling the left-hand drum bearing 190
Left-hand drum bearing assembly, disassembled: 190
Installing the left-hand drum bearing assembly 191
Removing the threshing drum 192
Threshing drum, disassembled 194
Renewing the beater bars 195
Removing the threshing drum shaft 196
Installing the threshing drum shaft 198
Installing the threshing drum 199
Impeller 201
Removing the right-hand impeller bearing 201
Installing the right-hand impeller bearing 203
Removing the left-hand impeller bearing 203
Installing the left-hand impeller bearing 205
Removing the impeller 206
Installing the impeller 208
Removing the flanged shaft (from serial no ) 209
Impeller disassembled (from serial no ) 210
Installing the flanged shaft 211
Removing the impeller shaft (up to serial no ) 212
Impeller disassembled (up to serial no ) 213
Installing the impeller shaft (up to serial no ) 214
Axial rotors 215
Removing the separation grates 215
Installing the separation grates 217
Removing the separating jacket 217
Installing the separating jacket 220
Removing the axial rotor supporting arm 221
Disassembling the axial rotor supporting arm 222
Supporting arm, disassembled: 223
Installing the axial rotor supporting arm 223
Removing the axial rotor 225
Installing the axial rotor 227
Removing the hybrid unit completely 228
Installing the hybrid unit 236
Cleaning unit 239
Return pan 241
Lowering the return pan (from serial no ) 241
Raising and installing the return pan (from serial no ) 242
Removing the return pan 243
Rear rocker arm, disassembled 245
Installing the return pan 245
Sieve pan 247
Removing and installing the sieves 247
Removing the upper sieves (from serial no ) 247
Removing the lower sieves (from serial no ) 249
Installing the sieves (from serial no ) 250
Tightening torques of axial mountings for the upper and lower sieves (from serial no ) 250
Sieves – Basic setting (electric sieve adjustment – from serial no ) 251
Removing the upper sieves (up to serial no ) 251
Removing the lower sieves (up to serial no ) 253
Installing the sieves (up to serial no ) 254
Tightening torques of axial mountings for the upper and lower sieves (up to serial no ) 255
Sieves – Basic setting (electric sieve adjustment – up to serial no ) 255
Removing the 3-D upper sieve frame 256
3-D upper sieve frame, disassembled 261
Installing the 3-D upper sieve frame 262
Removing the sieve pan 263
Sieve pan, disassembled 266
Installing the sieve pan 267
Checking and adjusting the alignment of preparation floor and sieve pan 270
Preparation floor 271
Removing the preparation floor 271
Preparation floor, disassembled 273
Installing the preparation floor 274
3-D sieve pan control system 275
Adjusting the 3-D sieve pan control system 275
Adjusting pivot arm (A) with the “3-D gauge” 276
Rocker arm drive 277
Removing the intermediate drive shaft for the rocker arm drive 277
Intermediate drive shaft for rocker arm drive, disassembled 278
Installing the intermediate drive shaft for the rocker arm drive 279
Cleaning fan 281
Removing the bearings of the cleaning fan 281
Cleaning fan bearing, disassembled 284
Installing the cleaning fan bearing 284
Removing the cleaning fan shaft 285
Removing the centre cleaning fan bearing 289
Centre cleaning fan bearing, disassembled 289
Installing the cleaning fan shaft 290
Removing the cleaning fan rotors 291
Installing the cleaning fan rotors 291
Removing the cleaning fan housing 292
Installing the cleaning fan housing 294
Grain delivery 295
Returns elevator 297
Removing the returns elevator chain 297
Installing the returns elevator chain 299
Removing the top returns auger 299
Installing the top returns auger 301
Removing the returns elevator 302
Disassembling the returns elevator 303
Assembling the returns elevator 305
Installing the returns elevator 305
Removing the returns elevator boot 306
Installing the returns elevator boot 307
Removing the lower returns auger 307
Installing the lower returns auger 309
Grain elevator 311
Removing the clean grain elevator chain 311
Installing the clean grain elevator chain 312
Removing the clean grain elevator head 313
Dismantling the clean grain elevator head 314
Clean grain elevator head, disassembled: 316
Assembling and installing the clean grain elevator head 317
Removing the clean grain elevator shaft 317
Installing the grain elevator shaft 318
Removing the clean grain elevator boot 319
Installing the clean grain elevator boot 320
Removing the clean grain auger 320
Installing the clean grain auger 323
Removing the grain tank filler auger 324
Removing the grain tank filler auger angle drive 325
Disassembling the grain tank filler auger angle drive 326
Grain tank filler auger, disassembled: 327
Installing the grain tank filler auger 328
Grain tank unloading 331
Removing the grain tank cross auger 331
Grain tank cross augers, disassembled 334
Installing the grain tank cross auger 335
Removing the vertical grain tank unloading auger 337
Installing the vertical grain tank unloading auger 340
Removing the horizontal grain tank unloading auger 341
Installing the horizontal grain tank unloading auger 343
Removing the lower grain tank unloading angle drive (from serial no ) 343
Disassembling the lower grain tank unloading angle drive (from serial no ) 345
Lower grain tank unloading angle drive, disassembled: (from serial no …) 348
Assembling the lower grain tank unloading angle drive (from serial no ) 349
Installing the lower grain tank unloading angle drive (from serial no ) 352
Removing the lower grain tank unloading angle drive (up to serial no ) 353
Disassembling the lower grain tank unloading angle drive (up to serial no ) 354
Lower grain tank unloading angle drive, disassembled: (up to serial no …) 357
Assembling the lower grain tank unloading angle drive (up to serial no ) 358
Installing the lower grain tank unloading angle drive (up to serial no ) 361
Removing the upper grain tank unloading angle drive 362
Disassembling the upper grain tank unloading angle drive 363
Upper grain tank unloading angle drive, disassembled: 364
Assembling the upper grain tank unloading angle drive 365
Installing the upper grain tank unloading angle drive 368
Removing the grain tank unloading tube 369
Refitting the unloading auger tube 370
Removing the grain tank unloading tube elbow 370
Installing the grain tank unloading tube elbow 371
Removing the vertical unloading auger tube 371
Installing the vertical unloading auger tube 372
Straw discharge 373
Straw chopper 375
Removing the right-hand straw chopper bearing 375
Right-hand straw chopper bearing assembly, disassembled 377
Installing the right-hand straw chopper bearing 377
Removing the left-hand straw chopper bearing 379
Left-hand straw chopper bearing assembly, disassembled 380
Installing the left-hand straw chopper bearing 380
Removing the cutting cylinder 381
Cutting cylinder, disassembled 385
Installing the cutting cylinder 386
Replacing the free-swinging knives 387
Uni-spreader 391
Removing the fan blade bearings 391
Assembling and installing the fan blade bearing 398
Drives 403
Drive belts 405
General Information 405
Drive diagram 406
Drive diagram, left-hand 406
Drive system diagram, right-hand side 407
Left-hand drive belts 409
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-spreader drive belt (16) 441
Removing the grain tank unloading drive chain (17) 442
Installing and adjusting the grain tank unloading drive chain (17) 443
Right-hand drive belts 445
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
Removing the air conditioner compressor drive belt (29) 463
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 drive 477
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), disassembled 479
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), dismantled 481
Removing the jockey pulley of cutterbar drive (1) 483
Jockey pulley of cutterbar drive (1), disassembled 483
Removing the rear pulley of cutterbar drive (1) (up to serial no ) 483
Dismantling the rear pulley of cutterbar drive (1) (up to serial no ) 486
Rear pulley of cutterbar drive (1), disassembled: (up to serial no ) 488
Assembling the rear pulley of cutterbar drive (1) (up to serial no ) 489
Installing the rear pulley of cutterbar drive (1) (up to serial no ) 491
Removing the rear pulley of cutterbar drive (1) (from serial no ) 493
Dismantling the rear pulley of cutterbar drive (1) (from serial no ) 496
Rear pulley of cutterbar drive (1), disassembled: (from serial no ) 498
Assembling the rear pulley of cutterbar drive (1) (from serial no ) 499
Installing the rear pulley of cutterbar drive (1) (from serial no ) 500
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), disassembled: 506
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 fitted 513
Disassembling the cutterbar drive V-belt pulley when a cutterbar variable-speed drive is fitted 513
Cutterbar drive V-belt pulley with a cutterbar variable-speed drive fitted, disassembled: 515
Assembling the cutterbar drive V-belt pulley with a cutterbar variable-speed drive fitted 516
Installing the cutterbar drive V-belt pulley with a cutterbar variable-speed drive fitted 518
Removing and disassembling the cutterbar drive deflection pulley (2) with a cutterbar variable-sp 518
Assembling and installing the cutterbar drive deflection pulley (2) with a cutterbar variable-spe 519
Removing the cutterbar variable-speed pulley assembly (hydraulic) 519
Disassembling the cutterbar variable-speed pulley assembly (hydraulic) 522
Cutterbar variable-speed pulley assembly (hydraulic), disassembled: 524
Assembling the cutterbar variable-speed pulley assembly (hydraulic) 526
Installing the cutterbar variable-speed pulley assembly (hydraulic) 527
Removing the cutterbar clutch 528
Cutterbar clutch, disassembled 535
Installing the cutterbar clutch 536
Left-hand threshing mechanism drive 543
Removing the threshing mechanism drive pulley assembly 543
Threshing mechanism drive pulley assembly, disassembled 549
Installing the threshing mechanism drive pulley assembly 550
Right-hand threshing mechanism drive 557
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), disassembled: 560
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), disassembled: 567
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 pulley 574
Disassembling the threshing mechanism drive pulley 574
Threshing mechanism drive pulley, disassembled: 576
Assembling the threshing mechanism drive pulley 577
Installing the threshing mechanism drive pulley 579
Threshing drum reduction gearbox 581
Removing the threshing drum reduction gearbox 581
Disassembling the threshing drum reduction gearbox 582
Threshing drum reduction gearbox, disassembled: 586
Assembling the threshing drum reduction gearbox 588
Installing the threshing drum reduction gearbox 591
Threshing mechanism intermediate drive 595
Removing the right-hand intermediate drive shaft bearing 595
Installing the right-hand intermediate drive shaft bearing 596
Removing the left-hand intermediate drive shaft bearing 596
Installing the left-hand intermediate drive shaft bearing 597
Removing the intermediate drive shaft 598
Installing the intermediate drive shaft 598
Grain tank unloading drive 599
Removing the grain tank unloading drive pulley 599
Installing the grain tank unloading drive pulley 601
Chopper drive 603
Removing the stage 1 chopper drive V-belt pulley 603
Stage 1 chopper drive V-belt pulley, disassembled 605
Assembling and installing the stage 1 chopper drive V-belt pulley 606
Removing the stage 2 chopper drive V-belt pulley 608
Stage 2 chopper drive V-belt pulley, disassembled 610
Assembling and installing the stage 2 chopper drive V-belt pulley 611
Removing the jockey pulley of straw chopper drive (10) 613
Jockey pulley of straw chopper drive (10), disassembled 613
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), disassembled 614
Assembling and installing the jockey pulley of straw chopper drive (11) 615
Removing the stage 3 chopper drive V-belt pulley 615
Disassembling the stage 3 chopper drive V-belt pulley 617
Stage 3 chopper drive V-belt pulley, dismantled: 619
Assembling and installing the stage 3 chopper drive V-belt pulley 620
Straw spreader drive 623
Removing the straw spreader bearing housing 623
Disassembling the straw spreader bearing housing 624
Straw spreader bearing housing, disassembled: 627
Assembling the straw spreader bearing housing 629
Installing the straw spreader bearing housing 631
Uni-spreader drive 635
Removing the uni-spreader drive angle drive 635
Mounting the uni-spreader drive angle drive 636
Sieve pan drive 637
Removing the sieve pan drive V-belt pulley 637
Sieve pan drive V-belt pulley, disassembled 638
Installing the sieve pan drive V-belt pulley 639
Removing the front sieve pan drive deflection pulley 640
Front sieve pan drive deflection pulley, disassembled 640
Assembling the front sieve pan drive deflection pulley 641
Installing the front sieve pan drive deflection pulley 641
Removing the rear sieve pan drive deflection pulley 641
Rear sieve pan drive deflection pulley, disassembled 642
Assembling the rear sieve pan drive deflection pulley 643
Installing the rear sieve pan drive deflection pulley 643
Fan drive 645
Removing the stage 1 fan drive V-belt pulley 645
Stage 1 fan drive V-belt pulley, disassembled 645
Installing the stage 1 fan drive V-belt pulley 645
Fan adjustment (electric) 646
Fan adjustment (electric) Version 1 (up to serial no ) 647
Fan adjustment (electric) Version 2 (from serial no …, up to serial no …) 648
Fan adjustment (electric) Version 3 (from serial no ) 649
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) (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, disassembled 676
Assembling and installing the electric fan variable-speed pulley assembly 677
Removing the fan drive jockey pulley (20) 680
Fan drive jockey pulley (20), disassembled 680
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), disassembled: 684
Assembling the fan variable-speed pulley assembly (spring-loaded) 685
Installing and adjusting the fan variable-speed pulley assembly (spring-loaded) 686
Axial rotor drive 687
Removing the axial rotor intermediate drive V-belt pulley 687
Axial rotor intermediate drive V-belt pulley, disassembled 689
Assembling and installing the axial rotor intermediate drive V-belt pulley 690
Removing the axial rotors drive jockey pulley (18) 692
Axial rotor drive jockey pulley (18), disassembled 692
Installing the axial rotors drive jockey pulley (18) 693
Removing the bearings of axial rotors drive (18) 693
Bearing of axial rotors drive (18), disassembled 695
Installing the bearings of axial rotors drive (18) 696
Removing the axial rotors drive 697
Disassembling the axial rotor gearbox 698
Axial rotor gearbox, disassembled: 701
Assembling the axial rotor gearbox 702
Installing the axial rotor gearbox 706
Engine output 709
Removing the engine output pulley 709
Installing the engine output pulley 709
Removing the transfer gearbox 710
Disassembling the transfer gearbox 715
Transfer gearbox, disassembled: 719
Assembling the transfer gearbox 720
Installing the transfer gearbox 727
Rotary screen drive 731
Removing the rotary screen drive 731
Disassembling the rotary screen drive 731
Rotary screen drive, disassembled: 733
Assembling and installing the rotary screen drive 734
Removing the fan drive 735
Installing the fan drive 735
Final drives 737
Removing the final drive gearbox 737
Disassembling the final drive gearbox 737
Removing the wheel drive shaft 737
Removing the intermediate shaft 739
Removing the drive shaft 741
Final drive gearbox, disassembled: 742
Assembling the final drive gearbox 743
Installing the drive shaft 743
Installing the intermediate shaft 744
Installing the wheel drive shaft 747
Disassembling the planetary final drive gearbox 751
Planetary final drive gearbox, disassembled: 758
Assembling the planetary final drive gearbox 759
Installing the final drive gearbox 763
Manual gearbox 767
Removing the manual gearbox 767
Disassembling the manual gearbox 769
Removing the shifter rails 769
Removing the drive shaft 771
Removing the main shaft 772
Removing the differential 774
Disassembling the differential 775
Differential, disassembled: 777
Assembling the differential 777
Installing the differential 779
Manual gearbox, disassembled 781
Assembling the manual gearbox 782
Installing the main shaft 783
Installing the drive shaft 784
Installing the shifter rails 785
Installing the manual gearbox 788
Servo gearshift 791
Removing the shifter pistons 791
Servo gearshift, disassembled: 793
Installing the shifter pistons 793
Bleeding the shifter piston 794
Brake 795
Parking brake – Replacing the brake linings 795
Bleeding the brake system 796
Disc brake – Changing the brake pads 796
Removing a brake calliper 797
Installing a brake calliper 798
Steering axle 799
Removing the wheel bearing 799
Wheel bearing, disassembled 802
Installing the wheel bearing 803
Removing the stub axle 805
Stub axle, disassembled 808
Installing the stub axle 808
Setting the track width 811
Adjusting the steering axle end stops 813
Removing the steering axle 814
Steering axle bearing, disassembled 816
Installing the steering axle 817
Machine body 819
Rotary screen 821
Removing the rotary screen 821
Disassembling the rotary screen 821
Rotary screen, disassembled: 823
Assembling and installing the rotary screen 824
Trough and lateral panel, disassembled 826
Adjusting the trough and the lateral panel (if suction blower with drive is fitted) 827
Removing the fan drive 828
Installing the fan drive 828
Removing the rotary screen suction blower 829
Disassembling the rotary screen suction blower 829
Rotary screen suction blower, disassembled: 831
Assembling and installing the rotary screen suction blower 832
Drive axle 833
Removing the drive axle 833
Installing the drive axle 836
Hydraulic system 839
Oil cooler 841
Removing the oil cooler 841
Installing the oil cooler 844
Maintenance 845
Hydraulic system 845
Checking the oil level 845
Changing the hydraulic oil 846
Filling instructions when changing the hydraulic oil 847
Hydraulic pumps 849
Removing the uni-spreader hydraulic pump 849
Disassembling the uni-spreader hydraulic pump 850
Uni-spreader hydraulic pump, disassembled: 851
Assembling the uni-spreader hydraulic pump 851
Installing the uni-spreader hydraulic pump 852
Removing the ground drive hydraulic pump 852
Installing the ground drive hydraulic pump 855
Removing the hydraulic double pump 856
Installing the hydraulic double pump 856
Hydrostatic fixed displacement motors 857
Removing the ground drive hydrostatic fixed displacement motor 857
Installing the ground drive hydrostatic fixed displacement motor 859
Removing the reverser drive hydrostatic fixed displacement motor 861
Reverser drive hydrostatic fixed displacement motor, disassembled 864
Installing the reverser drive hydrostatic fixed displacement motor 865
Hydraulic cylinders – High-pressure hydraulic circuit 867
Removing the cutterbar cross levelling hydraulic cylinders 867
Disassembling the cutterbar cross levelling hydraulic cylinders 867
Cutterbar cross levelling hydraulic cylinder, disassembled: 869
Assembling the cutterbar cross levelling hydraulic cylinders 870
Installing the cutterbar cross levelling hydraulic cylinders 870
Bleeding the cutterbar cross levelling hydraulic cylinders 872
Removing the cutterbar hydraulic cylinders 873
Cutterbar hydraulic cylinders – Replacing the seals 873
Disassembling the cutterbar hydraulic cylinders 874
Cutterbar hydraulic cylinder, disassembled: 876
Assembling the cutterbar hydraulic cylinder 877
Installing the cutterbar hydraulic cylinders 878
Adjusting the cutterbar hydraulic cylinders 878
Removing the cutterbar variable-speed drive hydraulic cylinder 879
Installing the cutterbar variable-speed drive hydraulic cylinder 880
Disassembling the rotary coupling 880
Rotary coupling, disassembled 882
Assembling the rotary coupling 883
Removing the concave adjustment hydraulic cylinder 884
Disassembling the concave adjustment hydraulic cylinder 885
Concave adjustment hydraulic cylinder, disassembled: 887
Assembling the concave adjustment hydraulic cylinder 888
Installing the concave adjustment hydraulic cylinder 889
Removing the grain tank unloading tube swing hydraulic cylinder 889
Disassembling the grain tank unloading tube swing hydraulic cylinder 889
Grain tank unloading tube swing hydraulic cylinder, disassembled: 891
Assembling the grain tank unloading tube swing hydraulic cylinder 892
Installing the grain tank unloading tube swing hydraulic cylinder 893
Removing the straw chopper drive hydraulic cylinder 893
Disassembling the straw chopper drive hydraulic cylinder 894
Straw chopper drive hydraulic cylinder, disassembled: 895
Assembling the straw chopper drive hydraulic cylinder 895
Installing the straw chopper drive hydraulic cylinder 896
Removing the threshing drum variable-speed drive hydraulic cylinder 896
Installing the threshing drum variable-speed drive hydraulic cylinder 897
Removing the reverser drive hydraulic cylinder 898
Disassembling the reverser drive hydraulic cylinder 898
Reverser drive hydraulic cylinder, disassembled: 899
Assembling the reverser drive hydraulic cylinder 900
Installing the reverser drive hydraulic cylinder 900
Hydraulic cylinders for low-pressure hydraulics 903
Removing the threshing mechanism engagement hydraulic cylinder 903
Disassembling the threshing mechanism engagement hydraulic cylinder 904
Threshing mechanism engagement hydraulic cylinder, disassembled: 904
Assembling the threshing mechanism engagement hydraulic cylinder 905
Installing the threshing mechanism engagement hydraulic cylinder 906
Removing the grain tank unloading engagement hydraulic cylinder 906
Disassembling the grain tank unloading engagement hydraulic cylinder 907
Grain tank unloading engagement hydraulic cylinder, disassembled: 908
Assembling the grain tank unloading engagement hydraulic cylinder 909
Installing the grain tank unloading engagement hydraulic cylinder 910
Removing the engine speed control hydraulic cylinder (from serial no ) 911
Disassembling the engine speed control hydraulic cylinder (from serial no ) 911
Engine speed control hydraulic cylinder, disassembled: (from serial no ) 913
Assembling the engine speed control hydraulic cylinder (from serial no ) 914
Pre-setting the engine speed control hydraulic cylinder (from serial no ) 916
Installing the engine speed control hydraulic cylinder (from serial no ) 916
Setting the engine speed control hydraulic cylinder (from serial no ) 917
Changing the road travel engine speed (country variants 20 km/h and/or 25 km/h) by converting the 918
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 no ) 921
Disassembling the engine speed control hydraulic cylinder (up to serial no ) 922
Engine speed control hydraulic cylinder, disassembled: (up to serial no …) 925
Assembling the engine speed control hydraulic cylinder (up to serial no ) 926
Pre-setting the engine speed control hydraulic cylinder (up to serial no ) 927
Installing the engine speed control hydraulic cylinder (up to serial no ) 927
Setting the engine speed control hydraulic cylinder (up to serial no ) 928
Removing the 3-D sieve pan hydraulic cylinder 930
Disassembling the 3-D sieve pan hydraulic cylinder 930
3-D sieve pan hydraulic cylinder, disassembled: 931
Assembling the 3-D sieve pan hydraulic cylinder 932
Installing the 3-D sieve pan hydraulic cylinder 933
Removing the pendulum control unit of the 3-D sieve pan 933
Disassembling the 3-D sieve pan pendulum control unit 933
Pendulum control unit of 3-D sieve pan, disassembled: 935
Assembling the pendulum control unit for 3-D sieve pan 936
Installing the 3-D sieve pan pendulum control unit 936
Removing the yield meter moisture sensor hydraulic cylinder 937
Disassembling the yield meter moisture sensor hydraulic cylinder 938
Yield meter moisture sensor hydraulic cylinder, disassembled: 939
Assembling the yield meter moisture sensor hydraulic cylinder 939
Installing the yield meter moisture sensor hydraulic cylinder 940
Checking and adjusting the yield meter hydraulic cylinder 940
Yield meter hydraulic cylinder, disassembled 942
Hydraulic cylinders – Steering hydraulics 943
Removing the steering cylinder 943
Disassembling the steering cylinder 943
Steering cylinder, disassembled: 945
Assembling the steering cylinder 946
Installing the steering cylinder 947
Removing the Autopilot steering cylinder 947
Disassembling the Autopilot steering cylinder 948
Autopilot steering cylinder, disassembled: 951
Assembling the Autopilot steering cylinder 952
Installing the Autopilot steering cylinder 953
Valve combinations 955
Removing the feeder reversing 3/2-way valve 955
Feeder reversing 3/2-way valve, disassembled 955
Removing the cutterbar cross levelling 4/ 3-way valve 956
Cutterbar cross levelling 4/3-way valve, disassembled 957
Removing the concave adjustment pressure relief valve 958
Concave adjustment pressure relief valve, disassembled 958
Assembling the concave adjustment pressure relief valve 958
Removing the cutterbar and threshing drum variable-speed drive 3/3-way valves 958
Cutterbar and threshing drum variable-speed drive 3/3-way valve, disassembled 960
Installing the cutterbar and threshing drum variable-speed drive 3/3-way valves 961
Removing the threshing drum variable-speed drive 3/3-way valve 961
Threshing drum variable-speed drive 3/3-way valve, disassembled 962
Removing the concave, grain tank unloading tube and straw chopper 4/3-way valves 963
Concave, grain tank unloading tube and straw chopper 4/3-way valve, disassembled 964
Assembling the concave, grain tank unloading tube and straw chopper 4/3-way valves 965
Installing the concave, grain tank unloading tube and straw chopper 4/3-way valves 965
Removing the concave and grain tank unloading tube 4/3 way valves 965
Concave and grain tank unloading tube 4/3-way valve, disassembled 967
Assembling the concave and grain tank unloading tube 4/3-way valves 968
Installing the concave and grain tank unloading tube 4/3-way valves 968
Removing the main valve 968
Main valve, disassembled 970
Assembling the main valve 971
Installing the main valve 971
Removing the CLAAS Autopilot solenoid valve 972
CLAAS Autopilot solenoid valve, disassembled 973
Assembling the CLAAS Autopilot solenoid valve 974
Installing the CLAAS Autopilot solenoid valve 974
Removing the low-pressure solenoid valve block 974
Low-pressure solenoid valve block, disassembled 976
Assembling the low-pressure solenoid valve block 977
Installing the low-pressure solenoid valve block 977
Removing the low-pressure solenoid valve (yield meter) 977
Yield meter 3/2-way solenoid valve, disassembled 979
Installing the low-pressure solenoid valve (yield meter) 980
Engine 981
Cooling system 983
Removing the intercooler 983
Installing the intercooler 985
Removing the radiator 985
Installing the radiator 988
Fuel system 989
Removing the fuel tank 989
Installing the fuel tank 990
Installing the additional fuel tank 990
Installing the additional fuel tank 992
Engine 993
Removing the engine 993
Installing the engine 999
Index1003
Index1005
Numerical1005
A1005
B1006
C1006
D1007
E1007
F1008
G1008
H1008
I1008
J1011
K1011
L1011
M1011
O1011
P1011
R1011
S1014
T1014
U1015
V1015
W1015
Y1015

IMAGES PREVIEW OF THE MANUAL:

CLAAS LEXION 480 REPAIR MANUAL – PDF DOWNLOAD:

PLEASE NOTE:

• This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
• This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
• Require some other service manual or have any queries: please WRITE to us at [email protected]

S.M