CLAAS LEXION 560 / 550 LEXION 540 / 540 C LEXION 530 / 520 / 510 Operator’s Manual – PDF DOWNLOAD

Description

CLAAS LEXION 560 / 550 LEXION 540 / 540 C LEXION 530 / 520 / 510 Operator’s Manual – PDF DOWNLOAD

DESCRIPTION:

CLAAS LEXION 560 / 550 LEXION 540 / 540 C LEXION 530 / 520 / 510 Operator’s Manual – PDF DOWNLOAD

Introduction
1.1 General Information
1.1.1 How to use this manual

• This operator’s manual is the original operator’s manual. In the following texts, it will be referred to simply as the operator’s manual. This operator’s manual is intended for all users and provides information on the use, operation, adjustment, maintenance, cleaning and transportation of the machine.
• Provided all instructions regarding proper maintenance and operation of your machine are followed, you can count on many years of reliable service. Failure to perform maintenance or incorrect operation lead to an increased safety risk, premature wear, a reduction in performance, loss of earnings and time. Have the post harvest check / annual check
• performed regularly by your CLAAS dealer. A combination of the prescribed maintenance work with the post harvest check is recommended. If you use the latest expertise and experience that went into this machine, it will render you consistently excellent service. There is a separate operator’s manual for front attachments and hitched devices.

General Information
2.1 Road traffic

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

TABLE OF CONTENTS:

CLAAS LEXION 560 / 550 LEXION 540 / 540 C LEXION 530 / 520 / 510 Operator’s Manual – PDF DOWNLOAD

Contents
1 Introduction
11 General Information 22
111 How to use this manual 22
112 Validity of instructions 24
2 General Information
21 Road traffic 25
22 Important notice 27
23 Identification plate / Serial number 28
231 Identification plate / Serial number 28
232 Identification plate 29
233 Machine serial number 29
234 Engine serial number 29
235 Straw chopper identification plate 31
236 Cab serial number 31
24 Attachment parts / machine body 32
241 Access to the workplace and maintenance areas 32
3 Safety Rules
31 Safety rules 35
311 General information 35
312 Identification of warning and danger signs 35
313 Intended use 36
314 Reasonable foreseeable misuse 37
315 General safety and accident prevention regulations 37
316 Transporting passengers, instructor, operating personnel 38
317 Driving operations 38
318 Leaving the combine harvester 39
319 Front attachments (cutterbar etc) and other components 39
3110 Air conditioner 40
3111 Maintenance 40
3112 Basic rule 40
3113 Accumulators 40
3114 Decommissioning and disposal 41
3115 Cylinder safety lock 41
3116 Fire extinguisher 42
3117 Battery isolating switch 43
3118 Wheel chocks 43
3119 Jack up the machine 44
3120 Loading and tying down the machine 45
3121 Hydraulic system 46
3122 Danger of injury due to escaping hydraulic liquid 46
32 Safety decals with pictorials 47
321 General information on safety decals 47
322 Safety decals 48
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4 Specifications
41 CLAAS LEXION 560 / 550 / 540 / 540 C 72
411 Cab / Operator’s platform 72
412 Cutterbar 72
413 Threshing mechanism 73
414 Separation 73
415 Cleaning (Standard cleaning system) 74
416 Grain delivery 74
417 Engine 75
418 Chassis 77
419 Tyres and tyre pressures 78
4110 Torque settings of wheel bolts 80
4111 Track width 81
4112 Transport position / Working position 84
4113 Weights 87
4114 Safety features 87
42 CLAAS LEXION 530 / 520 88
421 Cab / Operator’s platform 88
422 Cutterbar 88
423 Threshing mechanism 89
424 Separation 89
425 Cleaning (Standard cleaning system) 90
426 Grain delivery 90
427 Engine 91
428 Chassis 92
429 Tyres and tyre pressures 93
4210 Torque settings of wheel bolts 94
4211 Track width 95
4212 Transport position / Working position 99
4213 Weights 102
4214 Safety features 102
43 CLAAS LEXION 510 103
431 Cab / Operator’s platform 103
432 Cutterbar 103
433 Threshing mechanism 104
434 Separation 105
435 Cleaning (Standard cleaning system) 105
436 Grain delivery 105
437 Engine 106
438 Chassis 107
439 Tyres and tyre pressures 108
4310 Torque settings of wheel bolts 108
4311 Track width 109
4312 Transport position / Working position 113
4313 Weights 116
4314 Safety features 116
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5 Prior to operation
51 General Information 117
511 Initial operation check list 117
512 Loading and tying down the machine 118
52 Cab 120
521 Cab with automatic air conditioner 120
522 Automatic air conditioner 122
523 Putting the automatic air conditioner into operation 123
524 Setting the cab temperature 124
525 Manually setting the evaporator blower speed 124
526 Activating ECON operating mode 125
527 Deactivating ECON operating mode 125
528 REHEAT operation (Dehumidify cab windows) 126
529 Displaying the outside temperature 127
5210 Changing the temperature display to °Fahrenheit 127
5211 Floor heating 127
5212 Display of malfunction – Error in thermometer F0 (cab, blue) 128
5213 Display of malfunction – Error in thermometer F1 (exhaust, yellow) 128
5214 Display of malfunction – Error in thermometer F2 (outside, red) 128
5215 Cab with air conditioner (Standard version) 129
5216 Putting the air conditioning system into operation 131
5217 Heater 132
5218 Floor heating 133
5219 REHEAT operation (Dehumidify cab windows) 133
5220 Problem, possible cause or remedy – air conditioner system 134
5221 Cooling box 136
5222 Cooling unit (option) 136
5223 Cooling bag (option) 136
5224 Ice bucket (option) 137
5225 Windscreen washer 137
5226 Crop inspection 137
5227 Opening and closing the cab roof 138
5228 Cab emergency exit 138
5229 Operator’s platform overview 139
5230 Control console 141
5231 Screen (vehicle information display) 144
5232 Screen (harvest display) 146
5233 Keys C / Rotary switch D 148
5234 Ignition switch 149
5235 Multifunction switch 150
5236 Vehicle information unit 151
5237 Multifunction handle 152
5238 Reel height limitation 153
5239 Steering column adjustment 154
5240 Steering wheel height adjustment 154
5241 Central terminal compartment 155
5242 Contents – Central terminal compartment (up to serial no ) 156
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5243 Fuses (up to serial no ) 157
5244 Relays (up to serial no ) 159
5245 Contents – Central terminal compartment (from serial no ) 162
5246 Fuses (from serial no ) 163
5247 Relays (from serial no ) 165
5248 Operator’s seat 168
5249 Operator’s seat, mechanical 168
5250 Air-suspended driver’s seat 170
53 Lighting and socket outlets 173
531 Headlights, working lights, mirrors 173
532 Sidefinder (option) 179
533 Pathfinder lighting 179
534 Side position lights in case of excess width 180
535 Socket outlet 12 V 182
536 CDS 5000 diagnosis connection socket outlet 184
54 Access ladder 185
541 Access and ladder extension 185
542 Pre-assembling the front ladder (from serial no ) 190
543 Installing the front ladder 190
544 Swivelling the front ladder (up to serial no ) 193
545 Swivelling the front ladder (from serial no ) 195
546 Ladder starting protection 196
547 Rear ladder 197
55 Side panels 199
551 Opening and closing the side panels and the tailgate 199
552 Opening the tailgate 200
553 Adjusting the gripping height of the side panels 201
554 Adjusting the side panel lock 202
555 Tool cabinet 202
56 Mud guards / Side panels / Hitch block / Transport trailer 204
561 Installing the mudguards 204
562 Adapting the side panels (Rice harvesting machines) 205
563 Fitting the hitch block 205
564 Converting the transport trailer to suit the machine 206
57 Rear axles (Standard cleaning system) 207
571 Rear axle overview 207
572 Rear drive axle 000 669 835 6 207
573 Rear axle 000 768 705 1 208
574 Rear axle 000 770 920 1 208
575 Rear axle 000 769 600 4 208
576 Rear axle 000 770 347 1 209
577 Rear axle 000 770 810 1 209
578 Converting the rear drive axle from transport to working position 209
579 Rear drive axle – Adjusting the track width 210
5710 Rear drive axle 000 694 760 1 – Adjusting the steering stop 214
5711 Converting the rear axle 000 770 920 1 / 000 768 705 1
from transport to working position 215
5712 Converting the rear axle 000 769 600 4 from transport to working position 217
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5713 Rear axle 000 769 600 4 – Adjusting the track width 218
5714 Converting the rear axle 000 770 347 1 / 000 770 810 1
from transport to working position 220
5715 Rear axle 000 770 347 1 – Adjusting the track width 221
58 Additional weights of rear axle 224
581 Additional weights on rear axle LEXION 560 – 540 Standard cleaning system 224
582 Additional weights on rear axle LEXION 530 – 510 Standard cleaning system 225
583 Liquid filling of rear axle tyres 226
584 Installing the rear axle weight 227
585 Shipping package – rear axle weight (Rear drive axle) 228
586 Installing the rear axle weight 229
587 Shipping package – rear axle weight (adjustable and rigid rear axle) 230
59 Cutterbar hydraulic cylinders 231
591 Fitting the cutterbar hydraulic cylinders with springs 231
592 Number of cutterbar cylinders (LEXION 560 – 540) 231
593 Number of cutterbar cylinders (LEXION 530 – 510) 233
594 Installing the cutterbar floatation springs hydraulic cylinder 234
510 Accumulator 235
5101 Filling the accumulator for CLAAS AUTO CONTOUR II 235
5102 Special tool for filling the CLAAS AUTO CONTOUR II accumulator 240
511 Dual fitments 241
5111 Installing the dual wheels 241
5112 Use of front ladder when dual fitments are fitted (up to serial no ) 243
5113 Use of front ladder when dual fitments are fitted (from serial no ) 244
512 Grain tank 246
5121 Closing the grain tank drain holes 246
5122 Open the grain tank cover completely by hand 247
513 Driving the combine with mechanical control 248
5131 Driving the combine in general 248
5132 Ground speed control lever variants 248
5133 Engine speed rotary switch 249
5134 Medium engine idle speed 250
5135 Starting the engine 251
5136 Forward travel / reverse travel 252
5137 Gear selection 252
5138 Setting the ground speed control lever to move easily 254
5139 Setting the ground speed control lever to move easily 254
51310Stopping 255
51311Machine driving characteristics 255
51312Handling with cutterbar trailer 255
51313Steering 255
51314Coupling / decoupling brake pedals of the foot brake 256
51315Brake lining wear indicator (up to serial no ) 256
51316Parking brake 256
51317Stopping the engine 257
51318Engaging/disengaging the CLAAS 4-Trac system 258
51319Towing the machine 258
51320Forward towing 259
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51321Reverse towing 259
51322EHS emergency shifting using the gear pushbutton (from serial no ) 260
51323Emergency operation decal – Electro-hydraulic gearshift (EHS) 262
51324Engaging the neutral gearbox position mechanically 263
51325Restoring the original state (gearbox can again be shifted electro-hydraulically) 264
51326Engaging the neutral gearbox position hydraulically 267
51327Engaging the 2nd gear hydraulically 268
514 CLAAS Autopilot (Maize picker) 269
5141 Putting the CLAAS Autopilot into operation 269
515 CLAAS Autopilot (Grain cutterbar) 271
5151 Adjusting the directional stability of the combine harvester 271
5152 Setting the laser sensor in the field 273
5153 Rough adjustment 274
5154 Fine adjustment 275
5155 Laser sensor (crop edge has moved out of visible range) 275
5156 Adjusting the right laser sensor (accessory) 276
5157 Putting the CLAAS Autopilot into operation 277
5158 Use in rape with left side cutter 278
516 Information about hitching/unhitching trailers 279
5161 General information 279
5162 General safety instructions 279
5163 Hitching the trailer 280
5164 Unhitching the trailer 282
6 Installing and removing the cutterbar
61 Installing the cutterbar 283
611 Tilting the cutterbar from transport position 283
612 Adjusting the cutterbar cross levelling hydraulic cylinder (up to serial no ) 284
613 Adjusting the cutterbar cross levelling hydraulic cylinder (from serial no ) 285
614 Aligning the coupling pins 285
615 Attaching the front attachment 286
616 Locking cutterbars and maize pickers (Cutterbars without Auto Contour) 287
617 Connecting the universal drive shaft 288
618 Mounting the stands 289
62 Removing the cutterbar 290
621 Removing the universal coupling 290
622 Removing the universal drive shaft 291
623 Opening the cutterbar locking 291
624 Laying down the cutterbar on the ground 292
625 Placing the cutterbar on the cutterbar trailer 292
7 CEBIS operation (Version 823)
71 CLAAS CEBIS on-board information system 295
72 CEBIS monitor and rotary switch 296
721 C keys 296
722 Rotary switch D 296
723 Flagging Box 297
724 Multifunction handle 297
725 Monitor areas E (Harvest display) 298
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73 Rotary switch D 302
74 Prior to initial operation 304
75 Vehicle information display 305
76 Harvest display 306
77 Montana control system 307
771 Axle control mode 307
772 Cutting angle control 307
773 Lateral levelling control 308
774 Montana axle end stops 308
775 Cutting angle limits 308
776 Lateral levelling limits 309
777 Display period 309
78 CLAAS CRUISE PILOT 310
781 Maximum ground speed 310
782 Zero throughput 310
79 Yield mapping 311
710 Flagging 313
711 GPS 314
7111 Mapping ON/OFF 314
7112 Mapping monitor 314
7113 Load GPS data 315
712 Preset reel values 316
7121 Horizontal reel position 316
7122 Reel speed 316
7123 Reel height 317
713 Preset front attachment values 318
7131 Snapping plate clearance 318
7132 Cutterbar table length 318
7133 CAC settings 319
7134 CAC setting for LEXION Montana 320
714 Partial width selection 321
715 Yield meter 322
7151 Components 322
7152 Basic settings and calibration 323
7153 Preparations for yield measuring 323
7154 Moisture measurement ON/OFF, Moisture correction, Storage moisture 325
7155 A quick way to obtain reasonable measuring data 325
716 Yield measuring 326
7161 Calibration factor 326
7162 Yield zero point measuring 326
7163 Test-weighing 327
7164 Weight measured 327
7165 Moisture correction 327
7166 Moisture measurement ON/OFF 328
7167 Zero angle 328
7168 Storage moisture 328
7169 Display dry yield 329
717 Crop-dependent settings 330
7171 List of crops 330
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7172 Cleaning by blowing 332
718 Recording 333
7181 Planned records 333
7182 Start / Stop 335
7183 Completed records 335
7184 Daily recorder 337
7185 Total recorder 338
7186 Crop recorder 338
7187 Copying the chip card 339
719 Adjustments 340
7191 Cutterbar 340
7192 Speeds 345
7193 Tachometer 347
7194 Separation 350
7195 CEBIS 351
7196 Maintenance 356
7197 Operator’s manual 357
7198 Code protection 361
720 Engine loading 362
7201 Engine diagnosis 362
721 Alarms 363
722 Messages 364
723 Fault / Remedy – Yield meter 365
724 Guideline values for pulses/100 m 367
8 Operation – Basic machine
81 HP feed rake conveyor 368
811 Adjusting the height of feeder chains 368
812 Adjusting the cutting angle of the HP feed rake conveyor (option)
to its basic adjustment 368
813 Adjusting the cutting angle of the HP feed rake conveyor (optional equipment) 371
814 Front attachment reverser 373
815 Cutting height indicator 373
816 Setting the drop rate of the front attachment 374
817 Engaging the front attachment 374
818 Disengaging the front attachment (switch console) 375
819 Disengaging the front attachment (multifunction handle) 375
82 Standard feed rake conveyor 376
821 Adjusting the height of feeder chains 376
822 Feeder chain safety feature 377
823 Front attachment reverser 377
824 Checking the setting of the cutterbar floatation springs 378
825 Cutting height indicator 379
826 Spring pressure indicator 380
827 Blocking the front attachment floatation springs (Hydraulic lock) 380
828 Unlocking the front attachment floatation springs (Hydraulic lock) 380
829 Blocking the front attachment floatation springs (Mechanical blocking) 381
8210 Unlocking the front attachment floatation springs (Mechanical blocking) 381
8211 Setting the drop rate of the front attachment 381
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8212 Engaging the front attachment (switch console, up to serial no ) 382
8213 Engaging the front attachment (switch console, from serial no ) 382
8214 Disengaging the front attachment (switch console) 383
8215 Disengaging the front attachment (multifunction handle) 383
83 Threshing mechanism 384
831 Stone trap (small stone trap) 384
832 Stone trap (large stone trap) 385
833 Engaging the threshing mechanism 385
834 Disengaging the threshing mechanism 386
835 Threshing drum 387
836 Cleaning the threshing mechanism 387
837 Concave setting 387
838 Basic concave setting 388
839 Designations and dimensions for grain concave / maize concave (small stone trap) 393
8310 Designations and dimensions for grain concave / maize concave (large stone trap) 394
8311 Designations and dimensions on spike tooth concave (large stone trap) 395
8312 Designations and dimensions on spike tooth concave (small stone trap) 396
8313 Adjusting the concave position sensor 397
8314 Threshing drum speed 398
8315 Drum drives 398
8316 Two-step variable-speed drive 398
8317 Removing and installing the preconcave segments (small stone trap) 399
8318 Removing and installing the preconcave segments (large stone trap) 401
8319 Concave segment 402
8320 Removing the concave segment (small stone trap) 403
8321 Installing the concave segment (small stone trap) 404
8322 Removing a concave segment (large stone trap) 405
8323 Installing the concave segment (large stone trap) 406
8324 Disawner plates 407
8325 Unslugging the threshing drum 407
8326 Deflector curtain 408
8327 Adjusting the deflector curtain 409
84 Straw walker 410
841 Straw walker – General 410
842 Cleaning the straw walker 410
843 Straw walker house plugging warning signal 411
844 Multiple finger separation system 411
845 Straw walker performance monitor 412
846 Straw walker sensors 412
847 Rice risers 413
848 Centre risers 415
849 Side risers 417
8410 Parallel risers 419
8411 CCM risers 420
85 Cleaning (Standard cleaning system) 422
851 Cleaning unit 422
852 Preparation floor 423
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853 Frogmouth sieves 423
854 Electric sieve adjustment 423
855 Removing the sieves 424
856 Installing the sieves 427
857 Tightening torques of axial mountings for the upper and lower sieves 428
858 Sieves – Basic adjustment 429
859 Harvesting without lower sieves 429
8510 Covering the returns pan 430
8511 Cleaning fan 430
8512 Adjusting the fan speed adjustment 430
8513 Under-ventilated cleaning step (LEXION 560 – 520) 431
8514 Adjusting the pre-separation deflector (LEXION 560 – 520) 431
8515 Wind board (LEXION 560 – 520) 431
8516 Straw walker step (LEXION 510) 432
8517 Wind boards (LEXION 510) 432
8518 Fan shutters for threshing grass seed and similar crops (accessory) 433
8519 3-D cleaning system 434
8520 Returns 434
8521 Inspecting the returns 435
8522 Upper sieve performance monitor 435
8523 Sieve pan sensor 436
86 Grain delivery 437
861 Augers and auger troughs 437
862 Elevators 437
863 Grain tank 438
864 Grain tank extension 439
865 Unloading the grain tank 440
866 Emergency unloading grain tank cover 440
867 Grain tank unloading aid (accessory) 441
868 Grain tank unloading tube 441
869 Swinging the grain tank unloading tube out and in 442
8610 Grain tank unloading tube transport position 443
8611 Cleaning covers on the grain tank unloading tube 444
8612 Shear bolt for grain tank unloading 444
8613 Engaging and disengaging grain tank unloading 445
8614 Grain tank access 446
8615 Automatic chain lubrication – grain tank unloading (accessory) 447
8616 Grain tank fill indicator 447
87 Straw chopper with radial spreader 448
871 Straw chopper 448
872 Checks prior to putting the straw chopper with radial spreader into operation 448
873 Putting the straw chopper into operation
(swinging the radial spreader to chopping position) 449
874 Putting the straw chopper out of operation
(swinging the radial spreader to swathing position) 450
875 Swinging the radial spreader to cutterbar trailer transport position 451
876 Adjusting the cross knife (straw chopper with radial spreader) 452
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877 Adjusting the length of cut (straw chopper with radial spreader) 453
878 Activating the rasp bar (accessory) (straw chopper with radial spreader) 454
879 Adjusting the spreading width of radial spreader 455
8710 Adjusting the spreading width centralising switch of radial spreader 456
8711 Converting the radial spreader (spreader disc) to grain 457
8712 Converting the radial spreader (spreader disc) to maize 458
8713 Reducing the chopper speed 458
88 Straw chopper with standard spreader 461
881 Straw chopper 461
882 Checks prior to putting the straw chopper with standard spreader into operation 461
883 Straw chopper with standard spreader 461
884 Putting the straw chopper into operation
(swinging the standard spreader to chopping position) 462
885 Putting the straw chopper out of operation
(swinging the standard spreader to swathing position) 463
886 Swinging the standard spreader to cutterbar trailer transport position 464
887 Adjusting the cross knife (straw chopper with standard spreader) 465
888 Adjusting the length of cut (straw chopper with standard spreader) 466
889 Activating the rasp bar (accessory) (straw chopper with standard spreader) 467
8810 Adjusting the standard spreader spreading width (up to serial no ) 468
8811 Adjusting the standard spreader spreading width (from serial no ) 469
8812 Adjusting the height of standard spreader 470
8813 Adjusting the spreading width centralising switch of standard spreader 471
8814 Reducing the chopper speed 471
89 Chaff spreader 474
891 Chaff spreader 474
892 Adjusting the chaff spreader speed 474
893 Adjusting the spreading width 475
894 Folding the chaff spreader open 475
895 Folding the chaff spreader in 477
896 Removing the chaff spreader feed pan 477
897 Installing the chaff spreader feed pan 478
810 Uni-spreader 479
8101 Uni-spreader 479
8102 Swinging the uni-spreader to the rear 479
8103 Swinging the uni-spreader to the front 480
8104 Removing the uni-spreader feed pan 480
8105 Installing the uni-spreader feed pan 481
8106 Converting the uni-spreader to grain 481
8107 Converting the uni-spreader to maize 482
811 Straw spreader 483
8111 Straw spreader 483
8112 Adjusting the spreading width 483
8113 Fitting the spreader blades 483
812 LEXION 560 – 510 sieve charts and suggested combine adjustments
(standard cleaning system) 484
8121 LEXION 560 – 510 sieve chart (standard cleaning system) 484
8122 Suggested combine adjustments LEXION 560 – 510 (standard cleaning system) 485
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813 Disawning 491
8131 Disawner plates 491
8132 Concave segment 492
814 Problem, cause and / or remedy – Basic machine 493
8141 Front attachment 493
8142 Threshing mechanism 494
8143 Separation 495
8144 Cleaning unit 496
8145 Grain delivery 497
8146 Straw / Putting down the material 499
9 Maintenance – Basic machine
91 Important maintenance instructions 500
911 Important maintenance instructions and safety rules 500
912 Front attachment 500
913 Correct tension of steel roller chains 500
914 Belts 500
915 Variable-speed drives 501
916 Bolts 501
917 Lubrication 501
918 Brakes 502
919 Wheels / tyres 503
9110 Hydraulic system 504
9111 Electrical system 505
9112 Air conditioner 506
9113 Safety guards / spare parts 507
9114 Unbalance 507
9115 Welding work (up to serial no ) 508
9116 Welding work (from serial no ) 509
92 Maintenance schedules 510
921 Basic machine maintenance schedule 510
93 Lubricants charts 514
931 Lubricants 514
94 Hydraulic system 517
941 Accumulators 517
942 Checking the oil level 517
943 Hydraulic oil change 518
944 Changing the hydraulic oil filter 519
945 Saturation of hydraulic oil filter (from serial no ) 519
946 Replacing the return filter (up to serial no ) 520
947 Replacing the return filter (from serial no up to serial no ) 521
948 Replacing the return filter (from serial no ) 521
949 Filling instructions when replacing the hydraulic oil (Sauer 90 R 130 / 90 M 100) 522
9410 Bleeding the cutterbar cross-levelling hydraulic cylinder
(machines with Auto Contour) (up to serial no ) 523
9411 Bleeding the cutterbar cross-levelling hydraulic cylinder
(machines with Auto Contour) (from serial no ) 525
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95 Transmission / Brakes 527
951 Manual gearbox 527
952 Final drive (2-step) 528
953 Final drive 21 t, 1-step 529
954 Final drive gearbox (planetary gear) 529
955 Threshing drum reduction gearbox 530
956 Engine output transfer gearbox 531
957 Grain tank unloading gearbox 532
958 Foot brake and brake fluid 532
959 Parking brake 533
96 HP feed rake conveyor 534
961 Tensioning the feeder chains 534
962 Cleaning the suction blower (accessory) 535
97 Standard feed rake conveyor 536
971 Tensioning the feeder chains 536
972 Cleaning the suction blower (accessory) 537
98 Elevator chains 538
981 Tensioning the grain elevator chain (machine without yield meter) 538
982 Tensioning the grain elevator chain (machine with yield meter / without cock) 539
983 Tensioning the grain elevator chain (machine with yield meter / with cock) 539
984 Relieving the tension of the grain elevator chain (machine with yield meter) 540
985 Tensioning the returns elevator chain 541
99 Drive belts / drive chains 542
991 General Information 542
992 Drive diagram, left side (LEXION 560 – 510 with standard cleaning system) 543
993 Drive diagram, right side (LEXION 560 – 510 with standard cleaning system) 545
994 Removing the belt (1) 547
995 Installing the belt (1) 547
996 Removing the belt (2) 548
997 Installing the belt (2) 550
998 Removing the belt (3) 551
999 Installing the belt (3) 552
9910 Removing the belt (4) 554
9911 Installing the belt (4) 556
9912 Removing the belt (5) 557
9913 Installing the belt (5) 559
9914 Removing belt (6) (without torque support) 560
9915 Installing belt (6) (without torque support) 561
9916 Removing the belt (7) 562
9917 Installing the belt (7) 564
9918 Removing the belt (8) 566
9919 Installing the belt (8) 568
9920 Removing the belt (9) 569
9921 Installing the belt (9) 571
9922 Removing the belt (10) 573
9923 Installing the belt (10) 574
9924 Removing the chain (11) 576
9925 Installing the chain (11) 577
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9926 Removing the belt (12) 578
9927 Installing the belt (12) 579
9928 Removing the belt (13) 581
9929 Installing the belt (13) 583
9930 Removing the belt (14) 584
9931 Installing the belt (14) 585
9932 Removing the belt (17) 586
9933 Installing the belt (17) 587
9934 Removing the belt (18) 589
9935 Installing the belt (18) 591
9936 Removing the belt (19) 592
9937 Installing the belt (19) 593
9938 Removing the belt (20) 595
9939 Installing the belt (20) 597
9940 Removing the belt (22) 599
9941 Installing the belt (22) 600
9942 Removing the belt (45) 601
9943 Installing the belt (45) 602
9944 Removing the belt (46) 604
9945 Installing the belt (46) 605
9946 Removing the belt (48) 606
9947 Installing the belt (48) 607
9948 Removing the belt (51) 608
9949 Installing the belt (51) 609
9950 Removing the belt (52) 610
9951 Installing the belt (52) 611
9952 Removing the belt (53) 613
9953 Installing the belt (53) 615
9954 Removing the belt (54) 616
9955 Installing the belt (54) 617
9956 Removing the chain (55) 618
9957 Installing the chain (55) 619
9958 Removing the chain (56) 619
9959 Installing the chain (56) 620
9960 Removing the belt (57) 621
9961 Installing the belt (57) 622
9962 Remove belt (58) (CATERPILLAR C-9 / 3126 B) 624
9963 Install belt (58) (CATERPILLAR C-9 / 3126 B) 625
9964 Remove belt (58) (CATERPILLAR C-13 / C-10) 626
9965 Install belt (58) (CATERPILLAR C-13 / C-10) 627
9966 Removing the belt (59) 628
9967 Installing the belt (59) 629
910 Cab / air conditioner 630
9101 Cleaning the cab filters 630
9102 Cleaning the units located in the cab roof 630
9103 Cleaning the windscreen and the side windows 631
9104 Cleaning the condenser 632
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9105 Checking the refrigerant level 632
9106 Replacing the filter receiver drier 633
9107 Required refrigerant quantity – refrigerant R 134 a 633
9108 Oil for the compressor 633
9109 Maintenance work before the harvest 633
911 Fire extinguisher 634
9111 Checking the fire extinguisher 634
912 Compressed-air system (accessory) 635
9121 Compressed-air system 635
9122 Compressed-air connections 636
9123 Compressed-air gun and woven hose 636
9124 Draining the accumulator 637
9125 Pressure controller 637
9126 Checking the safety valve 638
913 Straw chopper with radial spreader 639
9131 Replacing the free-swinging knives for grain 639
9132 Removing the straw guide plate (straw chopper with radial spreader) 639
9133 Installing the straw guide plate (straw chopper with radial spreader) 640
9134 Removing the free-swinging knives for grain 641
9135 Bolting down the free-swinging knives for grain 642
9136 Replacing the stationary knives 644
914 Straw chopper with standard spreader 645
9141 Replacing the free-swinging knives for grain 645
9142 Removing the straw guide plate (straw chopper with standard spreader) 645
9143 Installing the straw guide plate (straw chopper with standard spreader) 647
9144 Removing the free-swinging knives for grain 648
9145 Bolting down the free-swinging knives for grain 648
9146 Replacing the stationary knives 651
915 Winter storage 652
9151 Winter storage instructions for combines 652
10 Maintenance – Engine
101 Important maintenance instructions 653
1011 Important maintenance instructions and safety rules 653
1012 Cooling water and air intake hoses 653
1013 Coolant 653
1014 Belts 653
1015 Cleaning the engine compartment and hazard areas 654
1016 Alternator 654
1017 Warranty on non genuine CATERPILLAR products 654
1018 Approved engine oils 654
1019 Engine oils with dry lubricant additives 654
102 Maintenance schedules 655
1021 Maintenance schedule CATERPILLAR C-10 / C-9 / 3126 B, exhaust gas class 2 655
1022 Maintenance schedule CATERPILLAR C-13 / C-9 / C-66, exhaust gas class 3a 657
103 Lubricants charts 659
1031 Lubricants chart CATERPILLAR C-10 / C-9 / 3126 B engines,
exhaust gas class 2 659
1032 Cooling system lubricants chart of CATERPILLAR C-10 / C-9 / 3126 B,
exhaust gas class 2 660
1033 Lubricants chart of CATERPILLAR C-13, C-9, C-66 engines,
exhaust gas class 3a 661
1034 Cooling system lubricants chart of CATERPILLAR C-13, C-9, C-66,
exhaust gas class 3a 662
104 Engine overview 663
1041 Engine overview CATERPILLAR C-13 663
1042 Engine overview CATERPILLAR C-10 664
1043 Engine overview of CATERPILLAR C-9 (exhaust gas class 3a) 665
1044 Engine overview of CATERPILLAR C-9 (exhaust gas class 2) 666
1045 Engine overview CATERPILLAR C-66 667
1046 Engine overview CATERPILLAR 3126 B 668
105 Fuel system / engine oil 669
1051 Fuel system 669
1052 Fuel tank 669
1053 Fuel tank breather (from serial no ) 670
1054 Fuel shut-off tap 670
1055 Water separator / fuel prefilter (standard equipment – small version) 670
1056 Water separator / Fuel pre-filter (accessory) 671
1057 Replacing the fuel filter cartridge (CATERPILLAR C-13 / C-10 / C-9 / 3126 B) 672
1058 Replacing the fuel filter cartridge (CATERPILLAR C-66) 673
1059 Bleeding the fuel system (CATERPILLAR C-13 / C-10 / C-9 / 3126 B) 674
10510Manual fuel primer pump with fuel sediment bowl (CATERPILLAR C-66) 675
10511Engine oil level check 676
10512Engine oil change 676
10513Draining used oil 677
10514Oil filter 679
10515Topping up engine oil 681
106 Cooling system 683
1061 Coolant 683
1062 Draining coolant from the water radiator 683
1063 Topping up coolant 684
1064 Identify the coolant type 686
1065 Checking the coolant mixing ratio 687
1066 Changing the coolant 687
1067 Shut down the overheated engine 689
1068 Rotary chaff screen 690
1069 Cleaning the radiator 692
10610Diesel engine fault 693
107 Dry-type air cleaner 694
1071 Dry-type air cleaner in general 694
1072 Warning device 695
1073 Cleaning the air filter intake screen 696
1074 Cleaning the air filter with plastic housing 696
1075 Cleaning the air filter with metal housing 698
1076 Safety filter cartridge 700
1077 Removing and installing safety cartridge (plastic housing) 701
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1078 Removing and installing safety cartridge (metal housing) 702
108 Alternator 703
1081 Cleaning the alternator 703
109 Electrical / electronic equipment 704
1091 Battery 704
1092 Alternator 705
1010Problem, cause and / or remedy 706
10101Engine 706
1011Winter storage 708
10111Engine winter storage 708
11 Lubrication chart
111 Lubrication points 709
1111 Greasing cycles 709
1112 Lubrication points – 10 h on the left 712
1113 Lubrication points – 50 h on the left 713
1114 Lubrication points – 50 h on the right 715
1115 Lubrication points – 100 h on the left 716
1116 Lubrication points – 100 h on the right 719
1117 Lubrication points – 500 h on the left 721
1118 Lubrication points – 500 h on the right 722
IMAGES PREVIEW OF THE MANUAL:

CLAAS LEXION 560 / 550 LEXION 540 / 540 C LEXION 530 / 520 / 510 OPERATOR’S MANUAL – PDF DOWNLOAD:

PLEASE NOTE:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

S.M