Claas Lexion 480 Repair Manual

188 678.1 - RHB LEXION 480 1.2.1 Safety Rules SAFETY RULES Important notice The instructions contained in this manual should be carefully read and observed by all persons involved with the operation, maintenance and inspection of this machine in order to prevent accidents. In particular, read the section “Safety rules”. The use of spare parts, accessories and ancillary equipment other than genuine CLAAS products or those which have been tested and approved by CLAAS, may change the specified design characteristics of this CLAAS machine or detract from its functional performance, with a possible adverse effect on the active and/or passive operational safety of the machine and its occupational safety standards (accident prevention). CLAAS is in no way liable for any damage or personal injury caused through the use of other than original or approved CLAAS parts, accessories and ancillary equipment. Technical data, dimensions and weights are given as an indication only. CLAAS reserve the right to make changes subsequently as technical developments continue. Responsibility for errors or omissions not accepted. Front, rear, right and left refer to the direction of forward travel. Safety Rules

1.2.2 RHB LEXION 480 - 188 678.1 Safety Rules Identification of warning and danger signs All parts of this manual having to do with your safety or the safe operation of the machine are marked with the following signs. Please pass all safety instructions on to other users, too. DANGER! Sign to indicate instructions which must be observed. Failure to do so would cause danger to life and limb to the operator and the people around him. ☞ Preventive measures ATTENTION! Sign to indicate instructions which must be observed. Failure to do so could result in damage to the machine. ☞ Measures to prevent damage to the machine. NOTE! Sign to indicate instructions for a more efficient and economic use of the machine. CAUTION! Sign to indicate instructions to be followed during disassembly / assembly. ENVIRONMENT! Sign to indicate instructions which must be observed in order to avoid damage to the environment. Danger to the environment is caused by irregular handling and incorrect disposal of toxic material (e.g. old oil). The warning and instruction signs placed on the machine provide important recommendations for safe operating. These instructions involve your safety – observe them at all times! Correct use of the machine Fitting and retrofitting of ancillary equipment which is not originally manufactured by CLAAS, and, in addition, also modifications and changes may only be carried out with the consent of CLAAS, as any such actions may have considerable adverse effects on the safety and operational function of the machine. Any arbitrary modifications carried out on the machine will relieve the manufacturer of all liability for any resulting damage or injury. General safety and accident prevention regulations 1. In addition to the instructions contained in this manual, also observe the general safety and accident prevention regulations. 2. Always comply with local traffic regulations when driving on public roads. 3. Before starting the engine ensure that the transmission is in neutral and that all guards are installed and in their correct position. 4. Start the engine only from the operator's seat. Never attempt to start the engine by shortening across the starting motor terminals as the machine may immediately start to move. 5. Before moving away, always check the immediate vicinity of the machine. Ensure adequate visibility. For a warning, always blow the horn before starting up! 6. Never run the engine in a closed building! 7. Clothing worn by the fitter must be close-fitting. Avoid wearing loose jackets, shirts or ties. 8. Handle fuel with care. – It is highly flammable. Never refuel the machine in the vicinity of naked flames or sparks. Do not smoke during refuelling! 9. Always stop the engine and remove the ignition key before refuelling. Fill the fuel tank outdoors. Clean up any spilled fuel immediately! 10. Prevent fires by keeping the machine clean! 11. Take care when handling brake fluid and battery acid (toxic and corrosive)! 12. Always blow the horn before starting the engine and engaging the main drive.

188 678.1 - RHB LEXION 480 1.2.3 Safety Rules Leaving the machine 1. When leaving the machine, ensure that it will not roll away (apply parking brake, chock blocks). Shut off the engine, remove the main switch key (ignition key) and lock the operator’s cab (if installed)! – Turn off the battery isolating switch! 2. Never leave the machine unattended as long as the engine is still running! 3. Lower the front attachments to the ground before leaving the combine-harvester. Compressor-type air conditioner 1. The air conditioning system is filled with HFC refrigerant R 134 A. HFC refrigerants must not be vented to the atmosphere! – Therefore, please take appropriate precautions when working on the compressor-type air conditioner. 2. Maintenance and repairs are only to be carried out by competent, professional service centres qualified to handle refrigerants. Refrigerants must always be discharged by use of the correct recovery equipment and disposed of for recycling. Maintenance 1. Repair, service and cleaning work and the elimination of malfunctions should only be performed with the drive and the tractor engine switched off – remove the ignition key! 2. Escaping fluid (fuel or hydraulic oil) under high pressure can penetrate the skin and cause serious injury. In such a case, consult a doctor immediately as otherwise serious infections may result! 3. Always turn off the battery isolating switch before carrying out any electrical repairs on the machine. 4. Be careful when opening the radiator cap. The radiator is under pressure when the engine is hot! 5. Dispose of oil, fuel and filters in a way that is harmless to the environment and in accordance with existing anti-pollution regulations! 6. Do not attempt to mount a tyre unless you have the proper equipment and experience to perform the job safely. 7. Retighten the wheel nuts and wheel bolts regularly! 8. Only have qualified workshops carry out repair work on the hydraulic system! 9. Always turn off the battery isolating switch before carrying out any maintenance work on the machine and on the engine. Basic rule Always check the operating and road safety of the machine before using it. Pressure accumulator Be especially careful when working on the pressure accumulators! Pressure accumulators are under high pressure! With valve-controlled pressure accumulators – as for example on the CLAAS Autopilot – first slacken the short-circuit bolt before carrying out any repair work at the pressure accumulator. This is necessary to dump the hydraulic pressure.

1.2.4 RHB LEXION 480 - 188 678.1 Safety Rules

188 678.1 - RHB LEXION 480 1.5.1 Specifications SPECIFICATIONS Lubricants chart Component Type of lubricant Viscosity Capacity Hydraulic system Multi-grade hydraulic oil ISO-VG 46 conforming to DIN 51 524 specifications, part 3** approx. 20 litres (oil change) approx. 70 litres (new system filling) Manual gearbox 20 t / 17 t Multi-grade gearbox oil conforming to (MIL-L-2105 B) API-GL-5-90 specifications 90 7.0 litres Manual gearbox 20 t HD 6.5 litres Final drives 20 t / 17 t 8.0 litres each Planetary gearbox 20 t 5.0 litres each Uni-spreader fan gearbox (751 480.1) 0.48 litres Uni-spreader fan gearbox (763 099.1) 0.6 litres Threshing drum reduction gearbox Multi-grade gearbox oil conforming to (MIL-L-2105) API-GL-4-90 specifications 90 1.8 litres Transfer gearbox (engine output shaft) 3.0 litres Rotor drives 1.75 litres each Grain tank unloading tube Upper angle drive Rolling bearing grease, e.g. Alvania R3 270 g Grain tank unloading tube Lower angle drive (up to serial no. …) 530 g Grain tank unloading tube Lower angle drive (from serial no. …) 900 g Foot brake ATE brake fluid SAE-specifications DOT 4 Reservoir must always be full SANDEN compressor SD 7 H 15 Sanden oil SP 20 PAG as required (approx. 300 cm³ for initial filling) Refrigerant R 134a 1800 g ** When selecting the hydraulic oil, the following conditions need to be met: Pour point < -25 °C (DIN ISO 3016) Viscosity 0 °C < 600 cSt. (DIN 51 562) Viscosity 40 °C max. 50.6 cSt. (DIN 51 562) Viscosity index > 170 (DIN ISO 2909) The oil must have detergent properties! Specifications

1.5.2 RHB LEXION 480 - 188 678.1 Specifications Hydraulic pressure values Machine type Working hydraulics Quantity / Litres Set pressure bar Refill Oil change at corresponding pressure relief valve LEXION 480 approx. 70 approx. 20 Lifting hydraulics 175 +15 Steering * 150 +15 Low pressure 19 +2 Machine type Hydrostatic ground drive Quantity / Litres Set pressure bar Refill Oil change at corresponding pressure relief valve LEXION 480 approx. 70 approx. 20 Operating pressure S4 420 +30 Filling pressure ** Purge pressure 23 * = When making new settings, note the circulation pressure and add the value to the one given. ** = Filling pressure 4 – 6 bar above purge pressure = Max. absolute pressure Hydrostatic ground drives: S4 = SAUER 90 R 130 / 90 M 100 When selecting the hydraulic oil, the following conditions need to be met: Pour point < -25 °C (DIN ISO 3016) Viscosity 0 °C < 600 cSt. (DIN 51 562) Viscosity 40 °C max. 50.6 cSt. (DIN 51 562) Viscosity index > 170 (DIN ISO 2909) The oil must have detergent properties! NOTE! The working and the ground drive hydraulics have one common hydraulic oil tank. +2 –1

188 678.1 - RHB LEXION 480 1.1.1 General GENERAL Introduction This CLAAS REPAIR MANUAL is to assist in pre- serving the permanent working order and therefore the high value of your CLAAS combine-harvester by careful maintenance and service. Experience gathered by both our service engineers and factory staff has been compiled in this REPAIR MANUAL. The figures explain the procedure of repairs and the text describes the different adjustments to be made, the use of CLAAS special tools etc. The illustrations included in support to the expla- nations show the sequence of major repairs so that minor repairs can easily be followed. The CLAAS REPAIR MANUAL is filled in a folder which allows to insert supplementary pages as issued following technical developments and to always have an updated manual at hand for reference. To be sure, always compare settings and filling capacities with specifications stated in the current Operator’s Manual which applies to the combine- harvester. CLAAS KGaA mbH Service Department General

1.1.2 RHB LEXION 480 - 188 678.1 General Introduction to the CLAAS Repair Manual The CLAAS REPAIR MANUAL is divided into main groups and subgroups. The first figure at the bottom of each page refers to the main group whereas the second figure following the point indicates the subgroup; the figure behind the second point indicates the page number. In each subgroup, the figures and pages are numbered consecutively, starting at 1. Where differences between the machine types must be observed, this is indicated in headings. Where a service procedure applies to all machines covered by this book, the machine names are not specifically given. When supplements are to be added, the subgroups are supplemented or exchanged. Any possible supplements are filed in the respective main group / subgroup and the table of contents is updated and replaced. The symbols communicate brief messages when recurring service procedures are described. Their meaning is explained at the beginning of this manual. The section “GENERAL REPAIR INSTRUCTIONS” at the beginning of this manual contains useful practical hints. Read and follow these fundamental instructions. They are the basis for reliable service and durability of parts after repairs have been carried out. The description of a particular service procedure can easily be found by checking the table of contents of the appropriate main group / subgroup.

188 678.1 - RHB LEXION 480 1.1.3 General Key to symbols This CLAAS REPAIR MANUAL uses some symbols as defined in the “DIN 30600 Symbol summary” by the German Standardisation Institute. The meaning of these symbols will be easily recognised and remembered by the user. These symbols are to help to quickly recognise recurring service procedures and they also help to communicate information shown on the illustrations. Dismantle, remove Grease Prevent damage to materials Disassemble Oil Use special tool Assemble Adjust / set Drain, outlet Install, mount on Check visually Fill, filler opening Mark Unlock, release, secure Overflow Balance Lock by means of liquids, glue, seal Bleed Possibly reusable Underprop, support Renew on each assembly Observe direction of installation General

1.1.4 RHB LEXION 480 - 188 678.1 General

Claas Lexion 480 Repair Manual

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