Claas Lexion 560 550 Lexion 540 540C Lexion 530 520 510 Operator’s Manual – PDF DOWNLOAD

Description

Claas Lexion 560 550 Lexion 540 540C Lexion 530 520 510 Operator’s Manual – PDF DOWNLOAD

DESCRIPTION:

Claas Lexion 560 550 Lexion 540 540C Lexion 530 520 510 Operator’s Manual – PDF DOWNLOAD

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.

TABLE OF CONTENTS:

Claas Lexion 560 550 Lexion 540 540C Lexion 530 520 510 Operator’s Manual – PDF DOWNLOAD

1 Introduction
1 1 General Information 22
1 1 1 How to use this manual 22
1 1 2 Validity of instructions 24
2 General Information
2 1 Road traffic 25
2 2 Important notice 27
2 3 Identification plate / Serial number 28
2 3 1 Identification plate / Serial number 28
2 3 2 Identification plate 29
2 3 3 Machine serial number 29
2 3 4 Engine serial number 29
2 3 5 Straw chopper identification plate 31
2 3 6 Cab serial number 31
2 4 Attachment parts / machine body 32
2 4 1 Access to the workplace and maintenance areas 32
3 Safety Rules
3 1 Safety rules 35
3 1 1 General information 35
3 1 2 Identification of warning and danger signs 35
3 1 3 Intended use 36
3 1 4 Reasonable foreseeable misuse 37
3 1 5 General safety and accident prevention regulations 37
3 1 6 Transporting passengers, instructor, operating personnel 38
3 1 7 Driving operations 38
3 1 8 Leaving the combine harvester 39
3 1 9 Front attachments (cutterbar etc ) and other components 39
3 1 10 Air conditioner 40
3 1 11 Maintenance 40
3 1 12 Basic rule 40
3 1 13 Accumulators 40
3 1 14 Decommissioning and disposal 41
3 1 15 Cylinder safety lock 41
3 1 16 Fire extinguisher 42
3 1 17 Battery isolating switch 43
3 1 18 Wheel chocks 43
3 1 19 Jack up the machine 44
3 1 20 Loading and tying down the machine 45
3 1 21 Hydraulic system 46
3 1 22 Danger of injury due to escaping hydraulic liquid 46
3 2 Safety decals with pictorials 47
3 2 1 General information on safety decals 47
3 2 2 Safety decals 48
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4 Specifications
4 1 CLAAS LEXION 560 / 550 / 540 / 540 C 72
4 1 1 Cab / Operator’s platform 72
4 1 2 Cutterbar 72
4 1 3 Threshing mechanism 73
4 1 4 Separation 73
4 1 5 Cleaning (Standard cleaning system) 74
4 1 6 Grain delivery 74
4 1 7 Engine 75
4 1 8 Chassis 77
4 1 9 Tyres and tyre pressures 78
4 1 10 Torque settings of wheel bolts 80
4 1 11 Track width 81
4 1 12 Transport position / Working position 84
4 1 13 Weights 87
4 1 14 Safety features 87
4 2 CLAAS LEXION 530 / 520 88
4 2 1 Cab / Operator’s platform 88
4 2 2 Cutterbar 88
4 2 3 Threshing mechanism 89
4 2 4 Separation 89
4 2 5 Cleaning (Standard cleaning system) 90
4 2 6 Grain delivery 90
4 2 7 Engine 91
4 2 8 Chassis 92
4 2 9 Tyres and tyre pressures 93
4 2 10 Torque settings of wheel bolts 94
4 2 11 Track width 95
4 2 12 Transport position / Working position 99
4 2 13 Weights 102
4 2 14 Safety features 102
4 3 CLAAS LEXION 510 103
4 3 1 Cab / Operator’s platform 103
4 3 2 Cutterbar 103
4 3 3 Threshing mechanism 104
4 3 4 Separation 105
4 3 5 Cleaning (Standard cleaning system) 105
4 3 6 Grain delivery 105
4 3 7 Engine 106
4 3 8 Chassis 107
4 3 9 Tyres and tyre pressures 108
4 3 10 Torque settings of wheel bolts 108
4 3 11 Track width 109
4 3 12 Transport position / Working position 113
4 3 13 Weights 116
4 3 14 Safety features 116
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5 Prior to operation
5 1 General Information 117
5 1 1 Initial operation check list 117
5 1 2 Loading and tying down the machine 118
5 2 Cab 120
5 2 1 Cab with automatic air conditioner 120
5 2 2 Automatic air conditioner 122
5 2 3 Putting the automatic air conditioner into operation 123
5 2 4 Setting the cab temperature 124
5 2 5 Manually setting the evaporator blower speed 124
5 2 6 Activating ECON operating mode 125
5 2 7 Deactivating ECON operating mode 125
5 2 8 REHEAT operation (Dehumidify cab windows) 126
5 2 9 Displaying the outside temperature 127
5 2 10 Changing the temperature display to °Fahrenheit 127
5 2 11 Floor heating 127
5 2 12 Display of malfunction – Error in thermometer F0 (cab, blue) 128
5 2 13 Display of malfunction – Error in thermometer F1 (exhaust, yellow) 128
5 2 14 Display of malfunction – Error in thermometer F2 (outside, red) 128
5 2 15 Cab with air conditioner (Standard version) 129
5 2 16 Putting the air conditioning system into operation 131
5 2 17 Heater 132
5 2 18 Floor heating 133
5 2 19 REHEAT operation (Dehumidify cab windows) 133
5 2 20 Problem, possible cause or remedy – air conditioner system 134
5 2 21 Cooling box 136
5 2 22 Cooling unit (option) 136
5 2 23 Cooling bag (option) 136
5 2 24 Ice bucket (option) 137
5 2 25 Windscreen washer 137
5 2 26 Crop inspection 137
5 2 27 Opening and closing the cab roof 138
5 2 28 Cab emergency exit 138
5 2 29 Operator’s platform overview 139
5 2 30 Control console 141
5 2 31 Screen (vehicle information display) 144
5 2 32 Screen (harvest display) 146
5 2 33 Keys C / Rotary switch D 148
5 2 34 Ignition switch 149
5 2 35 Multifunction switch 150
5 2 36 Vehicle information unit 151
5 2 37 Multifunction handle 152
5 2 38 Reel height limitation 153
5 2 39 Steering column adjustment 154
5 2 40 Steering wheel height adjustment 154
5 2 41 Central terminal compartment 155
5 2 42 Contents – Central terminal compartment (up to serial no ) 156
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5 2 43 Fuses (up to serial no ) 157
5 2 44 Relays (up to serial no ) 159
5 2 45 Contents – Central terminal compartment (from serial no ) 162
5 2 46 Fuses (from serial no ) 163
5 2 47 Relays (from serial no ) 165
5 2 48 Operator’s seat 168
5 2 49 Operator’s seat, mechanical 168
5 2 50 Air-suspended driver’s seat 170
5 3 Lighting and socket outlets 173
5 3 1 Headlights, working lights, mirrors 173
5 3 2 Sidefinder (option) 179
5 3 3 Pathfinder lighting 179
5 3 4 Side position lights in case of excess width 180
5 3 5 Socket outlet 12 V 182
5 3 6 CDS 5000 diagnosis connection socket outlet 184
5 4 Access ladder 185
5 4 1 Access and ladder extension 185
5 4 2 Pre-assembling the front ladder (from serial no ) 190
5 4 3 Installing the front ladder 190
5 4 4 Swivelling the front ladder (up to serial no ) 193
5 4 5 Swivelling the front ladder (from serial no ) 195
5 4 6 Ladder starting protection 196
5 4 7 Rear ladder 197
5 5 Side panels 199
5 5 1 Opening and closing the side panels and the tailgate 199
5 5 2 Opening the tailgate 200
5 5 3 Adjusting the gripping height of the side panels 201
5 5 4 Adjusting the side panel lock 202
5 5 5 Tool cabinet 202
5 6 Mud guards / Side panels / Hitch block / Transport trailer 204
5 6 1 Installing the mudguards 204
5 6 2 Adapting the side panels (Rice harvesting machines) 205
5 6 3 Fitting the hitch block 205
5 6 4 Converting the transport trailer to suit the machine 206
5 7 Rear axles (Standard cleaning system) 207
5 7 1 Rear axle overview 207
5 7 2 Rear drive axle 000 669 835 6 207
5 7 3 Rear axle 000 768 705 1 208
5 7 4 Rear axle 000 770 920 1 208
5 7 5 Rear axle 000 769 600 4 208
5 7 6 Rear axle 000 770 347 1 209
5 7 7 Rear axle 000 770 810 1 209
5 7 8 Converting the rear drive axle from transport to working position 209
5 7 9 Rear drive axle – Adjusting the track width 210
5 7 10 Rear drive axle 000 694 760 1 – Adjusting the steering stop 214
5 7 11 Converting the rear axle 000 770 920 1 / 000 768 705 1
from transport to working position 215
5 7 12 Converting the rear axle 000 769 600 4 from transport to working position 217
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5 7 13 Rear axle 000 769 600 4 – Adjusting the track width 218
5 7 14 Converting the rear axle 000 770 347 1 / 000 770 810 1
from transport to working position 220
5 7 15 Rear axle 000 770 347 1 – Adjusting the track width 221
5 8 Additional weights of rear axle 224
5 8 1 Additional weights on rear axle LEXION 560 – 540 Standard cleaning system 224
5 8 2 Additional weights on rear axle LEXION 530 – 510 Standard cleaning system 225
5 8 3 Liquid filling of rear axle tyres 226
5 8 4 Installing the rear axle weight 227
5 8 5 Shipping package – rear axle weight (Rear drive axle) 228
5 8 6 Installing the rear axle weight 229
5 8 7 Shipping package – rear axle weight (adjustable and rigid rear axle) 230
5 9 Cutterbar hydraulic cylinders 231
5 9 1 Fitting the cutterbar hydraulic cylinders with springs 231
5 9 2 Number of cutterbar cylinders (LEXION 560 – 540) 231
5 9 3 Number of cutterbar cylinders (LEXION 530 – 510) 233
5 9 4 Installing the cutterbar floatation springs hydraulic cylinder 234
5 10 Accumulator 235
5 10 1 Filling the accumulator for CLAAS AUTO CONTOUR II 235
5 10 2 Special tool for filling the CLAAS AUTO CONTOUR II accumulator 240
5 11 Dual fitments 241
5 11 1 Installing the dual wheels 241
5 11 2 Use of front ladder when dual fitments are fitted (up to serial no ) 243
5 11 3 Use of front ladder when dual fitments are fitted (from serial no ) 244
5 12 Grain tank 246
5 12 1 Closing the grain tank drain holes 246
5 12 2 Open the grain tank cover completely by hand 247
5 13 Driving the combine with mechanical control 248
5 13 1 Driving the combine in general 248
5 13 2 Ground speed control lever variants 248
5 13 3 Engine speed rotary switch 249
5 13 4 Medium engine idle speed 250
5 13 5 Starting the engine 251
5 13 6 Forward travel / reverse travel 252
5 13 7 Gear selection 252
5 13 8 Setting the ground speed control lever to move easily 254
5 13 9 Setting the ground speed control lever to move easily 254
5 13 10Stopping 255
5 13 11Machine driving characteristics 255
5 13 12Handling with cutterbar trailer 255
5 13 13Steering 255
5 13 14Coupling / decoupling brake pedals of the foot brake 256
5 13 15Brake lining wear indicator (up to serial no ) 256
5 13 16Parking brake 256
5 13 17Stopping the engine 257
5 13 18Engaging/disengaging the CLAAS 4-Trac system 258
5 13 19Towing the machine 258
5 13 20Forward towing 259
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5 13 21Reverse towing 259
5 13 22EHS emergency shifting using the gear pushbutton (from serial no ) 260
5 13 23Emergency operation decal – Electro-hydraulic gearshift (EHS) 262
5 13 24Engaging the neutral gearbox position mechanically 263
5 13 25Restoring the original state (gearbox can again be shifted electro-hydraulically) 264
5 13 26Engaging the neutral gearbox position hydraulically 267
5 13 27Engaging the 2nd gear hydraulically 268
5 14 CLAAS Autopilot (Maize picker) 269
5 14 1 Putting the CLAAS Autopilot into operation 269
5 15 CLAAS Autopilot (Grain cutterbar) 271
5 15 1 Adjusting the directional stability of the combine harvester 271
5 15 2 Setting the laser sensor in the field 273
5 15 3 Rough adjustment 274
5 15 4 Fine adjustment 275
5 15 5 Laser sensor (crop edge has moved out of visible range) 275
5 15 6 Adjusting the right laser sensor (accessory) 276
5 15 7 Putting the CLAAS Autopilot into operation 277
5 15 8 Use in rape with left side cutter 278
5 16 Information about hitching/unhitching trailers 279
5 16 1 General information 279
5 16 2 General safety instructions 279
5 16 3 Hitching the trailer 280
5 16 4 Unhitching the trailer 282
6 Installing and removing the cutterbar
6 1 Installing the cutterbar 283
6 1 1 Tilting the cutterbar from transport position 283
6 1 2 Adjusting the cutterbar cross levelling hydraulic cylinder (up to serial no ) 284
6 1 3 Adjusting the cutterbar cross levelling hydraulic cylinder (from serial no ) 285
6 1 4 Aligning the coupling pins 285
6 1 5 Attaching the front attachment 286
6 1 6 Locking cutterbars and maize pickers (Cutterbars without Auto Contour) 287
6 1 7 Connecting the universal drive shaft 288
6 1 8 Mounting the stands 289
6 2 Removing the cutterbar 290
6 2 1 Removing the universal coupling 290
6 2 2 Removing the universal drive shaft 291
6 2 3 Opening the cutterbar locking 291
6 2 4 Laying down the cutterbar on the ground 292
6 2 5 Placing the cutterbar on the cutterbar trailer 292
7 CEBIS operation (Version 8 23)
7 1 CLAAS CEBIS on-board information system 295
7 2 CEBIS monitor and rotary switch 296
7 2 1 C keys 296
7 2 2 Rotary switch D 296
7 2 3 Flagging Box 297
7 2 4 Multifunction handle 297
7 2 5 Monitor areas E (Harvest display) 298
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7 3 Rotary switch D 302
7 4 Prior to initial operation 304
7 5 Vehicle information display 305
7 6 Harvest display 306
7 7 Montana control system 307
7 7 1 Axle control mode 307
7 7 2 Cutting angle control 307
7 7 3 Lateral levelling control 308
7 7 4 Montana axle end stops 308
7 7 5 Cutting angle limits 308
7 7 6 Lateral levelling limits 309
7 7 7 Display period 309
7 8 CLAAS CRUISE PILOT 310
7 8 1 Maximum ground speed 310
7 8 2 Zero throughput 310
7 9 Yield mapping 311
7 10 Flagging 313
7 11 GPS 314
7 11 1 Mapping ON/OFF 314
7 11 2 Mapping monitor 314
7 11 3 Load GPS data 315
7 12 Preset reel values 316
7 12 1 Horizontal reel position 316
7 12 2 Reel speed 316
7 12 3 Reel height 317
7 13 Preset front attachment values 318
7 13 1 Snapping plate clearance 318
7 13 2 Cutterbar table length 318
7 13 3 CAC settings 319
7 13 4 CAC setting for LEXION Montana 320
7 14 Partial width selection 321
7 15 Yield meter 322
7 15 1 Components 322
7 15 2 Basic settings and calibration 323
7 15 3 Preparations for yield measuring 323
7 15 4 Moisture measurement ON/OFF, Moisture correction, Storage moisture 325
7 15 5 A quick way to obtain reasonable measuring data 325
7 16 Yield measuring 326
7 16 1 Calibration factor 326
7 16 2 Yield zero point measuring 326
7 16 3 Test-weighing 327
7 16 4 Weight measured 327
7 16 5 Moisture correction 327
7 16 6 Moisture measurement ON/OFF 328
7 16 7 Zero angle 328
7 16 8 Storage moisture 328
7 16 9 Display dry yield 329
7 17 Crop-dependent settings 330
7 17 1 List of crops 330
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7 17 2 Cleaning by blowing 332
7 18 Recording 333
7 18 1 Planned records 333
7 18 2 Start / Stop 335
7 18 3 Completed records 335
7 18 4 Daily recorder 337
7 18 5 Total recorder 338
7 18 6 Crop recorder 338
7 18 7 Copying the chip card 339
7 19 Adjustments 340
7 19 1 Cutterbar 340
7 19 2 Speeds 345
7 19 3 Tachometer 347
7 19 4 Separation 350
7 19 5 CEBIS 351
7 19 6 Maintenance 356
7 19 7 Operator’s manual 357
7 19 8 Code protection 361
7 20 Engine loading 362
7 20 1 Engine diagnosis 362
7 21 Alarms 363
7 22 Messages 364
7 23 Fault / Remedy – Yield meter 365
7 24 Guideline values for pulses/100 m 367
8 Operation – Basic machine
8 1 HP feed rake conveyor 368
8 1 1 Adjusting the height of feeder chains 368
8 1 2 Adjusting the cutting angle of the HP feed rake conveyor (option)
to its basic adjustment 368
8 1 3 Adjusting the cutting angle of the HP feed rake conveyor (optional equipment) 371
8 1 4 Front attachment reverser 373
8 1 5 Cutting height indicator 373
8 1 6 Setting the drop rate of the front attachment 374
8 1 7 Engaging the front attachment 374
8 1 8 Disengaging the front attachment (switch console) 375
8 1 9 Disengaging the front attachment (multifunction handle) 375
8 2 Standard feed rake conveyor 376
8 2 1 Adjusting the height of feeder chains 376
8 2 2 Feeder chain safety feature 377
8 2 3 Front attachment reverser 377
8 2 4 Checking the setting of the cutterbar floatation springs 378
8 2 5 Cutting height indicator 379
8 2 6 Spring pressure indicator 380
8 2 7 Blocking the front attachment floatation springs (Hydraulic lock) 380
8 2 8 Unlocking the front attachment floatation springs (Hydraulic lock) 380
8 2 9 Blocking the front attachment floatation springs (Mechanical blocking) 381
8 2 10 Unlocking the front attachment floatation springs (Mechanical blocking) 381
8 2 11 Setting the drop rate of the front attachment 381
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8 2 12 Engaging the front attachment (switch console, up to serial no ) 382
8 2 13 Engaging the front attachment (switch console, from serial no ) 382
8 2 14 Disengaging the front attachment (switch console) 383
8 2 15 Disengaging the front attachment (multifunction handle) 383
8 3 Threshing mechanism 384
8 3 1 Stone trap (small stone trap) 384
8 3 2 Stone trap (large stone trap) 385
8 3 3 Engaging the threshing mechanism 385
8 3 4 Disengaging the threshing mechanism 386
8 3 5 Threshing drum 387
8 3 6 Cleaning the threshing mechanism 387
8 3 7 Concave setting 387
8 3 8 Basic concave setting 388
8 3 9 Designations and dimensions for grain concave / maize concave (small stone trap) 393
8 3 10 Designations and dimensions for grain concave / maize concave (large stone trap) 394
8 3 11 Designations and dimensions on spike tooth concave (large stone trap) 395
8 3 12 Designations and dimensions on spike tooth concave (small stone trap) 396
8 3 13 Adjusting the concave position sensor 397
8 3 14 Threshing drum speed 398
8 3 15 Drum drives 398
8 3 16 Two-step variable-speed drive 398
8 3 17 Removing and installing the preconcave segments (small stone trap) 399
8 3 18 Removing and installing the preconcave segments (large stone trap) 401
8 3 19 Concave segment 402
8 3 20 Removing the concave segment (small stone trap) 403
8 3 21 Installing the concave segment (small stone trap) 404
8 3 22 Removing a concave segment (large stone trap) 405
8 3 23 Installing the concave segment (large stone trap) 406
8 3 24 Disawner plates 407
8 3 25 Unslugging the threshing drum 407
8 3 26 Deflector curtain 408
8 3 27 Adjusting the deflector curtain 409
8 4 Straw walker 410
8 4 1 Straw walker – General 410
8 4 2 Cleaning the straw walker 410
8 4 3 Straw walker house plugging warning signal 411
8 4 4 Multiple finger separation system 411
8 4 5 Straw walker performance monitor 412
8 4 6 Straw walker sensors 412
8 4 7 Rice risers 413
8 4 8 Centre risers 415
8 4 9 Side risers 417
8 4 10 Parallel risers 419
8 4 11 CCM risers 420
8 5 Cleaning (Standard cleaning system) 422
8 5 1 Cleaning unit 422
8 5 2 Preparation floor 423
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8 5 3 Frogmouth sieves 423
8 5 4 Electric sieve adjustment 423
8 5 5 Removing the sieves 424
8 5 6 Installing the sieves 427
8 5 7 Tightening torques of axial mountings for the upper and lower sieves 428
8 5 8 Sieves – Basic adjustment 429
8 5 9 Harvesting without lower sieves 429
8 5 10 Covering the returns pan 430
8 5 11 Cleaning fan 430
8 5 12 Adjusting the fan speed adjustment 430
8 5 13 Under-ventilated cleaning step (LEXION 560 – 520) 431
8 5 14 Adjusting the pre-separation deflector (LEXION 560 – 520) 431
8 5 15 Wind board (LEXION 560 – 520) 431
8 5 16 Straw walker step (LEXION 510) 432
8 5 17 Wind boards (LEXION 510) 432
8 5 18 Fan shutters for threshing grass seed and similar crops (accessory) 433
8 5 19 3-D cleaning system 434
8 5 20 Returns 434
8 5 21 Inspecting the returns 435
8 5 22 Upper sieve performance monitor 435
8 5 23 Sieve pan sensor 436
8 6 Grain delivery 437
8 6 1 Augers and auger troughs 437
8 6 2 Elevators 437
8 6 3 Grain tank 438
8 6 4 Grain tank extension 439
8 6 5 Unloading the grain tank 440
8 6 6 Emergency unloading grain tank cover 440
8 6 7 Grain tank unloading aid (accessory) 441
8 6 8 Grain tank unloading tube 441
8 6 9 Swinging the grain tank unloading tube out and in 442
8 6 10 Grain tank unloading tube transport position 443
8 6 11 Cleaning covers on the grain tank unloading tube 444
8 6 12 Shear bolt for grain tank unloading 444
8 6 13 Engaging and disengaging grain tank unloading 445
8 6 14 Grain tank access 446
8 6 15 Automatic chain lubrication – grain tank unloading (accessory) 447
8 6 16 Grain tank fill indicator 447
8 7 Straw chopper with radial spreader 448
8 7 1 Straw chopper 448
8 7 2 Checks prior to putting the straw chopper with radial spreader into operation 448
8 7 3 Putting the straw chopper into operation
(swinging the radial spreader to chopping position) 449
8 7 4 Putting the straw chopper out of operation
(swinging the radial spreader to swathing position) 450
8 7 5 Swinging the radial spreader to cutterbar trailer transport position 451
8 7 6 Adjusting the cross knife (straw chopper with radial spreader) 452
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8 7 7 Adjusting the length of cut (straw chopper with radial spreader) 453
8 7 8 Activating the rasp bar (accessory) (straw chopper with radial spreader) 454
8 7 9 Adjusting the spreading width of radial spreader 455
8 7 10 Adjusting the spreading width centralising switch of radial spreader 456
8 7 11 Converting the radial spreader (spreader disc) to grain 457
8 7 12 Converting the radial spreader (spreader disc) to maize 458
8 7 13 Reducing the chopper speed 458
8 8 Straw chopper with standard spreader 461
8 8 1 Straw chopper 461
8 8 2 Checks prior to putting the straw chopper with standard spreader into operation 461
8 8 3 Straw chopper with standard spreader 461
8 8 4 Putting the straw chopper into operation
(swinging the standard spreader to chopping position) 462
8 8 5 Putting the straw chopper out of operation
(swinging the standard spreader to swathing position) 463
8 8 6 Swinging the standard spreader to cutterbar trailer transport position 464
8 8 7 Adjusting the cross knife (straw chopper with standard spreader) 465
8 8 8 Adjusting the length of cut (straw chopper with standard spreader) 466
8 8 9 Activating the rasp bar (accessory) (straw chopper with standard spreader) 467
8 8 10 Adjusting the standard spreader spreading width (up to serial no ) 468
8 8 11 Adjusting the standard spreader spreading width (from serial no ) 469
8 8 12 Adjusting the height of standard spreader 470
8 8 13 Adjusting the spreading width centralising switch of standard spreader 471
8 8 14 Reducing the chopper speed 471
8 9 Chaff spreader 474
8 9 1 Chaff spreader 474
8 9 2 Adjusting the chaff spreader speed 474
8 9 3 Adjusting the spreading width 475
8 9 4 Folding the chaff spreader open 475
8 9 5 Folding the chaff spreader in 477
8 9 6 Removing the chaff spreader feed pan 477
8 9 7 Installing the chaff spreader feed pan 478
8 10 Uni-spreader 479
8 10 1 Uni-spreader 479
8 10 2 Swinging the uni-spreader to the rear 479
8 10 3 Swinging the uni-spreader to the front 480
8 10 4 Removing the uni-spreader feed pan 480
8 10 5 Installing the uni-spreader feed pan 481
8 10 6 Converting the uni-spreader to grain 481
8 10 7 Converting the uni-spreader to maize 482
8 11 Straw spreader 483
8 11 1 Straw spreader 483
8 11 2 Adjusting the spreading width 483
8 11 3 Fitting the spreader blades 483
8 12 LEXION 560 – 510 sieve charts and suggested combine adjustments
(standard cleaning system) 484
8 12 1 LEXION 560 – 510 sieve chart (standard cleaning system) 484
8 12 2 Suggested combine adjustments LEXION 560 – 510 (standard cleaning system) 485
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8 13 Disawning 491
8 13 1 Disawner plates 491
8 13 2 Concave segment 492
8 14 Problem, cause and / or remedy – Basic machine 493
8 14 1 Front attachment 493
8 14 2 Threshing mechanism 494
8 14 3 Separation 495
8 14 4 Cleaning unit 496
8 14 5 Grain delivery 497
8 14 6 Straw / Putting down the material 499
9 Maintenance – Basic machine
9 1 Important maintenance instructions 500
9 1 1 Important maintenance instructions and safety rules 500
9 1 2 Front attachment 500
9 1 3 Correct tension of steel roller chains 500
9 1 4 Belts 500
9 1 5 Variable-speed drives 501
9 1 6 Bolts 501
9 1 7 Lubrication 501
9 1 8 Brakes 502
9 1 9 Wheels / tyres 503
9 1 10 Hydraulic system 504
9 1 11 Electrical system 505
9 1 12 Air conditioner 506
9 1 13 Safety guards / spare parts 507
9 1 14 Unbalance 507
9 1 15 Welding work (up to serial no ) 508
9 1 16 Welding work (from serial no ) 509
9 2 Maintenance schedules 510
9 2 1 Basic machine maintenance schedule 510
9 3 Lubricants charts 514
9 3 1 Lubricants 514
9 4 Hydraulic system 517
9 4 1 Accumulators 517
9 4 2 Checking the oil level 517
9 4 3 Hydraulic oil change 518
9 4 4 Changing the hydraulic oil filter 519
9 4 5 Saturation of hydraulic oil filter (from serial no ) 519
9 4 6 Replacing the return filter (up to serial no ) 520
9 4 7 Replacing the return filter (from serial no up to serial no ) 521
9 4 8 Replacing the return filter (from serial no ) 521
9 4 9 Filling instructions when replacing the hydraulic oil (Sauer 90 R 130 / 90 M 100) 522
9 4 10 Bleeding the cutterbar cross-levelling hydraulic cylinder
(machines with Auto Contour) (up to serial no ) 523
9 4 11 Bleeding the cutterbar cross-levelling hydraulic cylinder
(machines with Auto Contour) (from serial no ) 525
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9 5 Transmission / Brakes 527
9 5 1 Manual gearbox 527
9 5 2 Final drive (2-step) 528
9 5 3 Final drive 21 t, 1-step 529
9 5 4 Final drive gearbox (planetary gear) 529
9 5 5 Threshing drum reduction gearbox 530
9 5 6 Engine output transfer gearbox 531
9 5 7 Grain tank unloading gearbox 532
9 5 8 Foot brake and brake fluid 532
9 5 9 Parking brake 533
9 6 HP feed rake conveyor 534
9 6 1 Tensioning the feeder chains 534
9 6 2 Cleaning the suction blower (accessory) 535
9 7 Standard feed rake conveyor 536
9 7 1 Tensioning the feeder chains 536
9 7 2 Cleaning the suction blower (accessory) 537
9 8 Elevator chains 538
9 8 1 Tensioning the grain elevator chain (machine without yield meter) 538
9 8 2 Tensioning the grain elevator chain (machine with yield meter / without cock) 539
9 8 3 Tensioning the grain elevator chain (machine with yield meter / with cock) 539
9 8 4 Relieving the tension of the grain elevator chain (machine with yield meter) 540
9 8 5 Tensioning the returns elevator chain 541
9 9 Drive belts / drive chains 542
9 9 1 General Information 542
9 9 2 Drive diagram, left side (LEXION 560 – 510 with standard cleaning system) 543
9 9 3 Drive diagram, right side (LEXION 560 – 510 with standard cleaning system) 545
9 9 4 Removing the belt (1) 547
9 9 5 Installing the belt (1) 547
9 9 6 Removing the belt (2) 548
9 9 7 Installing the belt (2) 550
9 9 8 Removing the belt (3) 551
9 9 9 Installing the belt (3) 552
9 9 10 Removing the belt (4) 554
9 9 11 Installing the belt (4) 556
9 9 12 Removing the belt (5) 557
9 9 13 Installing the belt (5) 559
9 9 14 Removing belt (6) (without torque support) 560
9 9 15 Installing belt (6) (without torque support) 561
9 9 16 Removing the belt (7) 562
9 9 17 Installing the belt (7) 564
9 9 18 Removing the belt (8) 566
9 9 19 Installing the belt (8) 568
9 9 20 Removing the belt (9) 569
9 9 21 Installing the belt (9) 571
9 9 22 Removing the belt (10) 573
9 9 23 Installing the belt (10) 574
9 9 24 Removing the chain (11) 576
9 9 25 Installing the chain (11) 577
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9 9 26 Removing the belt (12) 578
9 9 27 Installing the belt (12) 579
9 9 28 Removing the belt (13) 581
9 9 29 Installing the belt (13) 583
9 9 30 Removing the belt (14) 584
9 9 31 Installing the belt (14) 585
9 9 32 Removing the belt (17) 586
9 9 33 Installing the belt (17) 587
9 9 34 Removing the belt (18) 589
9 9 35 Installing the belt (18) 591
9 9 36 Removing the belt (19) 592
9 9 37 Installing the belt (19) 593
9 9 38 Removing the belt (20) 595
9 9 39 Installing the belt (20) 597
9 9 40 Removing the belt (22) 599
9 9 41 Installing the belt (22) 600
9 9 42 Removing the belt (45) 601
9 9 43 Installing the belt (45) 602
9 9 44 Removing the belt (46) 604
9 9 45 Installing the belt (46) 605
9 9 46 Removing the belt (48) 606
9 9 47 Installing the belt (48) 607
9 9 48 Removing the belt (51) 608
9 9 49 Installing the belt (51) 609
9 9 50 Removing the belt (52) 610
9 9 51 Installing the belt (52) 611
9 9 52 Removing the belt (53) 613
9 9 53 Installing the belt (53) 615
9 9 54 Removing the belt (54) 616
9 9 55 Installing the belt (54) 617
9 9 56 Removing the chain (55) 618
9 9 57 Installing the chain (55) 619
9 9 58 Removing the chain (56) 619
9 9 59 Installing the chain (56) 620
9 9 60 Removing the belt (57) 621
9 9 61 Installing the belt (57) 622
9 9 62 Remove belt (58) (CATERPILLAR C-9 / 3126 B) 624
9 9 63 Install belt (58) (CATERPILLAR C-9 / 3126 B) 625
9 9 64 Remove belt (58) (CATERPILLAR C-13 / C-10) 626
9 9 65 Install belt (58) (CATERPILLAR C-13 / C-10) 627
9 9 66 Removing the belt (59) 628
9 9 67 Installing the belt (59) 629
9 10 Cab / air conditioner 630
9 10 1 Cleaning the cab filters 630
9 10 2 Cleaning the units located in the cab roof 630
9 10 3 Cleaning the windscreen and the side windows 631
9 10 4 Cleaning the condenser 632
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9 10 5 Checking the refrigerant level 632
9 10 6 Replacing the filter receiver drier 633
9 10 7 Required refrigerant quantity – refrigerant R 134 a 633
9 10 8 Oil for the compressor 633
9 10 9 Maintenance work before the harvest 633
9 11 Fire extinguisher 634
9 11 1 Checking the fire extinguisher 634
9 12 Compressed-air system (accessory) 635
9 12 1 Compressed-air system 635
9 12 2 Compressed-air connections 636
9 12 3 Compressed-air gun and woven hose 636
9 12 4 Draining the accumulator 637
9 12 5 Pressure controller 637
9 12 6 Checking the safety valve 638
9 13 Straw chopper with radial spreader 639
9 13 1 Replacing the free-swinging knives for grain 639
9 13 2 Removing the straw guide plate (straw chopper with radial spreader) 639
9 13 3 Installing the straw guide plate (straw chopper with radial spreader) 640
9 13 4 Removing the free-swinging knives for grain 641
9 13 5 Bolting down the free-swinging knives for grain 642
9 13 6 Replacing the stationary knives 644
9 14 Straw chopper with standard spreader 645
9 14 1 Replacing the free-swinging knives for grain 645
9 14 2 Removing the straw guide plate (straw chopper with standard spreader) 645
9 14 3 Installing the straw guide plate (straw chopper with standard spreader) 647
9 14 4 Removing the free-swinging knives for grain 648
9 14 5 Bolting down the free-swinging knives for grain 648
9 14 6 Replacing the stationary knives 651
9 15 Winter storage 652
9 15 1 Winter storage instructions for combines 652
10 Maintenance – Engine
10 1 Important maintenance instructions 653
10 1 1 Important maintenance instructions and safety rules 653
10 1 2 Cooling water and air intake hoses 653
10 1 3 Coolant 653
10 1 4 Belts 653
10 1 5 Cleaning the engine compartment and hazard areas 654
10 1 6 Alternator 654
10 1 7 Warranty on non genuine CATERPILLAR products 654
10 1 8 Approved engine oils 654
10 1 9 Engine oils with dry lubricant additives 654
10 2 Maintenance schedules 655
10 2 1 Maintenance schedule CATERPILLAR C-10 / C-9 / 3126 B, exhaust gas class 2 655
10 2 2 Maintenance schedule CATERPILLAR C-13 / C-9 / C-6 6, exhaust gas class 3a 657
10 3 Lubricants charts 659
10 3 1 Lubricants chart CATERPILLAR C-10 / C-9 / 3126 B engines,
exhaust gas class 2 659
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10 3 2 Cooling system lubricants chart of CATERPILLAR C-10 / C-9 / 3126 B,
exhaust gas class 2 660
10 3 3 Lubricants chart of CATERPILLAR C-13, C-9, C-6 6 engines,
exhaust gas class 3a 661
10 3 4 Cooling system lubricants chart of CATERPILLAR C-13, C-9, C-6 6,
exhaust gas class 3a 662
10 4 Engine overview 663
10 4 1 Engine overview CATERPILLAR C-13 663
10 4 2 Engine overview CATERPILLAR C-10 664
10 4 3 Engine overview of CATERPILLAR C-9 (exhaust gas class 3a) 665
10 4 4 Engine overview of CATERPILLAR C-9 (exhaust gas class 2) 666
10 4 5 Engine overview CATERPILLAR C-6 6 667
10 4 6 Engine overview CATERPILLAR 3126 B 668
10 5 Fuel system / engine oil 669
10 5 1 Fuel system 669
10 5 2 Fuel tank 669
10 5 3 Fuel tank breather (from serial no ) 670
10 5 4 Fuel shut-off tap 670
10 5 5 Water separator / fuel prefilter (standard equipment – small version) 670
10 5 6 Water separator / Fuel pre-filter (accessory) 671
10 5 7 Replacing the fuel filter cartridge (CATERPILLAR C-13 / C-10 / C-9 / 3126 B) 672
10 5 8 Replacing the fuel filter cartridge (CATERPILLAR C-6 6) 673
10 5 9 Bleeding the fuel system (CATERPILLAR C-13 / C-10 / C-9 / 3126 B) 674
10 5 10Manual fuel primer pump with fuel sediment bowl (CATERPILLAR C-6 6) 675
10 5 11Engine oil level check 676
10 5 12Engine oil change 676
10 5 13Draining used oil 677
10 5 14Oil filter 679
10 5 15Topping up engine oil 681
10 6 Cooling system 683
10 6 1 Coolant 683
10 6 2 Draining coolant from the water radiator 683
10 6 3 Topping up coolant 684
10 6 4 Identify the coolant type 686
10 6 5 Checking the coolant mixing ratio 687
10 6 6 Changing the coolant 687
10 6 7 Shut down the overheated engine 689
10 6 8 Rotary chaff screen 690
10 6 9 Cleaning the radiator 692
10 6 10Diesel engine fault 693
10 7 Dry-type air cleaner 694
10 7 1 Dry-type air cleaner in general 694
10 7 2 Warning device 695
10 7 3 Cleaning the air filter intake screen 696
10 7 4 Cleaning the air filter with plastic housing 696
10 7 5 Cleaning the air filter with metal housing 698
10 7 6 Safety filter cartridge 700
10 7 7 Removing and installing safety cartridge (plastic housing) 701
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10 7 8 Removing and installing safety cartridge (metal housing) 702
10 8 Alternator 703
10 8 1 Cleaning the alternator 703
10 9 Electrical / electronic equipment 704
10 9 1 Battery 704
10 9 2 Alternator 705
10 10Problem, cause and / or remedy 706
10 10 1Engine 706
10 11Winter storage 708
10 11 1Engine winter storage 708
11 Lubrication chart
11 1 Lubrication points 709
11 1 1 Greasing cycles 709
11 1 2 Lubrication points – 10 h on the left 712
11 1 3 Lubrication points – 50 h on the left 713
11 1 4 Lubrication points – 50 h on the right 715
11 1 5 Lubrication points – 100 h on the left 716
11 1 6 Lubrication points – 100 h on the right 719
11 1 7 Lubrication points – 500 h on the left 721
11 1 8 Lubrication points – 500 h on the right 722

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