Page 1 REPAIR MANUAL LEXION 480...
Page 3: Table Of Contents
General .................. 1.1.1 Removing the air conditioner compressor ....... 2.1.7 Introduction ..............1.1.1 Installing the air conditioner compressor ......2.1.8 Introduction to the CLAAS Repair Manual ....... 1.1.2 Removing the air conditioner compressor Key to symbols ..............1.1.3 electro-magnetic clutch ........... 2.1.8 Safety Rules ................
Page 4 ............3.3.8 (from serial no..) ............4.1.1 Disassembling the left-hand bearing assembly ..... 3.3.10 Raising and installing the return pan Assembling the left-hand bearing assembly ....3.3.11 (from serial no..) ............4.1.2 0.1.2 RHB LEXION 480 - 188 678.1...
Page 5 Removing the centre cleaning fan bearing ...... 4.6.9 unloading angle drive Centre cleaning fan bearing, disassembled ....4.6.9 (from serial no..) ............5.3.15 Installing the cleaning fan shaft ........4.6.10 Removing the cleaning fan rotors ........4.6.11 0.1.3 188 678.1 - RHB LEXION 480...
Page 6 Uni-spreader ................6.2.1 intermediate drive belt (14) ..........7.2.28 Removing the fan blade bearings ........6.2.1 Removing the sieve pan drive belt (15) ......7.2.29 Assembling and installing the fan blade bearing ..... 6.2.8 0.1.4 RHB LEXION 480 - 188 678.1...
Page 7 ....7.4.37 suction blower drive belt (34) ......... 7.3.27 Cutterbar drive V-belt pulley with a cutterbar Removing the straw spreader drive belt (36) ....7.3.28 variable-speed drive fitted, disassembled ..... 7.4.39 0.1.5 188 678.1 - RHB LEXION 480...
Page 8 ..............7.6.18 Assembling and installing the jockey pulley Threshing mechanism drive pulley, of straw chopper drive (11) .......... 7.10.13 disassembled ..............7.6.20 Removing the stage 3 chopper drive V-belt pulley ............7.10.13 0.1.6 RHB LEXION 480 - 188 678.1...
Page 9 (18) ..............7.15.7 (Version 1) ..............7.14.9 Removing the bearings of axial rotors Assembling the fan adjustment (electric) drive (18) ............... 7.15.7 (Version 1) ..............7.14.10 Bearing of axial rotors drive (18), disassembled ..............7.15.9 0.1.7 188 678.1 - RHB LEXION 480...
Page 10 Installing the shifter rails ..........7.19.19 Assembling the uni-spreader hydraulic pump ....9.3.3 Installing the manual gearbox ........7.19.22 Installing the uni-spreader hydraulic pump ...... 9.3.4 Servo gearshift ............. 7.19.25 Removing the ground drive hydraulic pump ....9.3.4 0.1.8 RHB LEXION 480 - 188 678.1...
Page 11 (from serial no..) ............9.6.9 tube swing hydraulic cylinder ......... 9.5.23 Engine speed control hydraulic cylinder, Grain tank unloading tube swing disassembled (from serial no..) ........9.6.11 hydraulic cylinder, disassembled ........9.5.25 0.1.9 188 678.1 - RHB LEXION 480...
Page 12 3-D sieve pan ............9.6.34 tube and straw chopper 4/3-way valves ......9.8.11 Installing the 3-D sieve pan pendulum Installing the concave, grain tank unloading control unit ..............9.6.34 tube and straw chopper 4/3-way valves ......9.8.11 0.1.10 RHB LEXION 480 - 188 678.1...
Page 13 Installing the fuel tank ............ 10.2.2 Installing the additional fuel tank ........10.2.2 Installing the additional fuel tank ........10.2.4 Engine .................. 10.3.1 Removing the engine ............. 10.3.1 Installing the engine ............10.3.7 11. Index Index ..................11.1.1 0.1.11 188 678.1 - RHB LEXION 480...
Page 14 Contents 0.1.12 RHB LEXION 480 - 188 678.1...
Page 15: General Information
General information...
Page 17: General
General 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.
Page 18: Introduction To The Claas Repair Manual
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.
Page 19: Key To Symbols
The meaning of these symbols will be easily recognised and remembered by the user. These This CLAAS REPAIR MANUAL uses some symbols as symbols are to help to quickly recognise recurring defined in the “DIN 30600 Symbol summary” by the service procedures and they also help to communicate German Standardisation Institute.
Page 20 General 1.1.4 RHB LEXION 480 - 188 678.1...
Page 21: Safety Rules
(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, acces- sories and ancillary equipment.
Page 22: Identification Of Warning And Danger Signs
Please pass all safety addition, also modifications and changes may only instructions on to other users, too. 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 DANGER! machine.
Page 23: Leaving The Machine
– Therefore, With valve-controlled pressure accumulators – as please take appropriate precautions when for example on the CLAAS Autopilot – first slacken working on the compressor-type air conditioner. the short-circuit bolt before carrying out any repair work at the pressure accumulator.
Page 24 Safety Rules 1.2.4 RHB LEXION 480 - 188 678.1...
Page 25: General Repair Information
When removing the gearboxes, first drain the oil and NLGI class 00 (e.g. CLAAS semi-fluid lubricant EP 00) then remove the gearbox. Separate parts which are is applied and that the components are tightened to firmly connected with each other by means of a soft the specified torque in the correct order of assembly.
Page 26: Liquid Locking Compound
Prior to installation, apply semi-fluid lubricant of lated adhesive rapidly to the specified tightening NLGI class 00 (e.g. CLAAS semi-fluid lubricant EP 00) torque. When removing these bolts, quickly unscrew to the inside ring and the shaft to make bearing them completely.
Page 27: Progressive Ring Fittings On Hydraulic Lines
Installation: Insert the pre-assembled tube into the well-oiled threaded joint, tighten the union nut up to the point where resistance is felt and then half a turn beyond this point. 1.3.3 188 678.1 - RHB LEXION 480...
Page 28: Welding
– Align sprockets and V-belt pulleys toward each other. – Care for strict cleanliness when working on hydraulic systems. – Never mix different oil types. – Run the machine or operate machine assemblies at low speed after any repair. 1.3.4 RHB LEXION 480 - 188 678.1...
Page 29: Tightening Torques
M 27 x 2 1050 1500 1800 M 30 x 2 1450 2050 2500 IMPORTANT! Cadmium or copper-plated screws and nuts must be fastened with a torque 25 % below the specified value. 1.4.1 188 678.1 - RHB LEXION 480...
Page 30: Hydraulic Fittings
M 27 x 2 M 30 x 2 M 33 x 2 M 36 x 2 M 38 x 2 +103 M 39 x 2 +127 M 42 x 2 +147 M 45 x 2 1.4.2 RHB LEXION 480 - 188 678.1...
Page 31: Brake Line Screw Joints
M 45 x 1.5 M 48 x 1.5 M 48 x 2 M 52 x 1.5 M 54 x 2 With cadmium-plated threads, 0.7 times the values given in the table shall be applied. 1.4.3 188 678.1 - RHB LEXION 480...
Page 32: Wheel Bolts
700 Nm ± 30 Nm Intake auger 840 ± 40 Nm Upper feed rake shaft Shear bolts Grain tank unloading Hex. bolt M 8 x 45 DIN 931-8.8 Self-locking nut VM 8 Torque setting 25 Nm 1.4.4 RHB LEXION 480 - 188 678.1...
Page 33: Specifications
< -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! 1.5.1 188 678.1 - RHB LEXION 480...
Page 34: Hydraulic Pressure Values
> 170 (DIN ISO 2909) S4 = SAUER 90 R 130 / 90 M 100 The oil must have detergent properties! NOTE! The working and the ground drive hydraulics have one common hydraulic oil tank. 1.5.2 RHB LEXION 480 - 188 678.1...
Page 35: Sectional View Of Machine
Sectional view of machine Sectional view of machine SECTIONAL VIEW OF MACHINE LEXION 480 1.6.1 188 678.1 - RHB LEXION 480...
Page 36 Sectional view of machine 1.6.2 RHB LEXION 480 - 188 678.1...
Page 37 28 Grain tank cover 29 Returns elevator 30 Returns distribution auger 31 Operator's platform 32 Cab 33 Final drives 34 Manual gearbox 35 Drive wheels 36 Steering wheels 37 Trailer hitch (Fig. 1) 1.6.3 188 678.1 - RHB LEXION 480...
Page 38 Sectional view of machine 1.6.4 RHB LEXION 480 - 188 678.1...
Page 39: Drive Diagram
13 Drive of sieve pan intermediate drive 14 Drive of sieve pan intermediate drive 15 Sieve pan drive 16 Uni-spreader drive 17 Grain tank unloading auger drive 34 Suction blower drive (feed rake conveyor) 36 Straw spreader drive 1.7.1 188 678.1 - RHB LEXION 480...
Page 40: Drive System Diagram, Right-Hand Side
25 Rotary chaff screen intermediate drive 26 Rotary radiator screen drive 27 Fan drive 28 Rotary chaff screen suction drive 29 Air conditioning compressor drive 30 Compressed air compressor drive 31 Alternator drive 1.7.2 RHB LEXION 480 - 188 678.1...
Page 41: Operator's Platform
Operator's platform...
Page 43: Air Conditioner
8. Never check tightness of air conditioning system using compressed air or oxygen – Danger of explosion! 9. Never clean filled air conditioning system with a hot water jet – Danger of explosion! 2.1.1 188 678.1 - RHB LEXION 480...
Page 44: Important Instructions Regarding The Installation Of Parts In The Compressor-Type Air Conditioner
4. Prior to connecting a refrigerant line, apply some drops of refrigerant oil on the thread and the O-ring seat. 5. When tightening or loosening the refrigerant lines, always use two spanners in order to keep the lines from twisting. 2.1.2 RHB LEXION 480 - 188 678.1...
Page 45: Air Conditioning System - Topping Up Refrigerant
Should the system have been left for a long time, then it may appear as if it requires refrigerant, but actually the level is correct. (Fig. 1, 2) 2.1.3 188 678.1 - RHB LEXION 480...
Page 46: Checking / Topping Up The Refrigerant Oil Level At The Air Conditioner Compressor
(A) in place and screw in hex. bolts with liquid locking compound, e.g. DELO-ML 5349. 10. Air conditioning system – Topping up refrigerant , see page 2.1.3 (Fig. 3, 4, 5) 2.1.4 RHB LEXION 480 - 188 678.1...
Page 47: Topping Up Refrigerant Oil
Unlock the back plate of the rotary chaff screen, then raise and secure. Secure the back plate with suitable means, e.g. a rope to ensure it cannot drop. Open the pin (V). Unscrew the support (T). (Fig. 7) 2.1.5 188 678.1 - RHB LEXION 480...
Page 48: Refitting The Condenser
4. Swing down the back plate with the rotary chaff screen and lock it. 5. Top up refrigerant oil. 6. Air conditioning system – Topping up refrigerant , see page 2.1.3 (Fig. 6, 7, 8, 9, 10) 2.1.6 RHB LEXION 480 - 188 678.1...
Page 49: Removing The Air Conditioner Compressor
Unscrew the cable clamps from the air conditioner compressor wiring loom (A). Unscrew air conditioner compressor from support (O). (Fig. 11) Disconnect plug-in connection (V) at the engine mounting frame. Mark and unscrew air conditioner hoses (P). (Fig. 11, 12) 2.1.7 188 678.1 - RHB LEXION 480...
Page 50: Installing The Air Conditioner Compressor
– see page 7.3.19, Removing the air condi- tioner compressor drive belt (29) . Unscrew the cable clamps from the air conditioner compressor wiring loom (A). Disconnect plug-in connection (V) at the engine mounting frame. (Fig. 15) 2.1.8 RHB LEXION 480 - 188 678.1...
Page 51 G = M 14 x 1.5 1 x hex. bolt M 14 x 1.5 x 50 DIN 961-8.8 part no. 233 634.0 3 x Hex. inch bolt ¼’’- 20 x 1¼’’ (Fig. 19) 2.1.9 188 678.1 - RHB LEXION 480...
Page 52 31 mm, 35 mm long (self-sourced) Disc, outside diameter 38 mm, inside diameter 6 mm, 2 mm thick (self-sourced) ATTENTION! Never exert axial pressure on the air conditioner compressor shaft! (Fig. 22) 2.1.10 RHB LEXION 480 - 188 678.1...
Page 53 Air conditioner Remove the outside circlip (G). Unscrew cable clamp (L). (Fig. 23) Remove magnet (M). (Fig. 24) 2.1.11 188 678.1 - RHB LEXION 480...
Page 54: Air Conditioner Compressor Sanden Sd 7H 15, Disassembled
Air conditioner Air conditioner compressor Sanden Sd 7h 15, disassembled 1 Compressor 2 Dust cap 3 Dust protection 4 Electro-magnetic clutch 5 Repair set 6 Set of gaskets 7 Set of gaskets (Fig. 25) 2.1.12 RHB LEXION 480 - 188 678.1...
Page 55: Installing The Air Conditioner Compressor Electro-Magnetic Clutch
Tube, outside diameter 60 mm, inside diameter 52 mm, 50 mm long (self-sourced) (Fig. 25, 28) 5. Push existing washers (S) on air conditioner compressor shaft. Insert curved washer (L). (Fig. 29) 2.1.13 188 678.1 - RHB LEXION 480...
Page 56 (29) at the front – see page 7.3.20, Installing and adjusting the air conditioner compressor drive belt (29) . 13. If compressed-air system is fitted: Installing and adjusting the compressed-air com- pressor drive belt (30) , see page 7.3.22 (Fig. 32) 2.1.14 RHB LEXION 480 - 188 678.1...
Page 57: Removing The Air Conditioner Compressor Cylinder Head / Cylinder Head Gasket
Unscrew cylinder head bolts (C). (Fig. 33) Remove cylinder head (D) and valve plate (E) from the compressor housing, using a flat scraping knife. ATTENTION! Ensure that the sealing faces will not be damaged. (Fig. 34, 35) 2.1.15 188 678.1 - RHB LEXION 480...
Page 58: Installing The Air Conditioner Compressor Cylinder Head / Cylinder Head Gasket
2nd step: Tightening torque = 32 Nm 4. Checking / topping up the refrigerant oil level at the air conditioner compressor , see page 2.1.4 5. Install the air conditioner compressor. (Fig. 33, 38) 2.1.16 RHB LEXION 480 - 188 678.1...
Page 59: Removing The Air Conditioner Compressor Shaft Seal
G = M 14 x 1.5 1 x hex. bolt M 14 x 1.5 x 50 DIN 961-8.8, part no. 233 634.0 3 x Hex. inch bolt ¼’’- 20 x 1¼’’ (Fig. 42) 2.1.17 188 678.1 - RHB LEXION 480...
Page 60 Remove curved washer (L) and washers (S) from the air conditioner compressor shaft. (Fig. 43) Remove dust protection (3), dirt scraper (A) and circlip (R). (Fig. 25, 43, 44, 45) Pull out shaft seal (6) with special tool. (Fig. 25, 46) 2.1.18 RHB LEXION 480 - 188 678.1...
Page 61: Installing The Air Conditioner Compressor Shaft Seal
Tube, outside diameter 60 mm, inside diameter 52 mm, 50 mm long (self-sourced) 4. Push existing washers (S) on air conditioner compressor shaft. Insert curved washer (L). (Fig. 25, 49) 2.1.19 188 678.1 - RHB LEXION 480...
Page 62: Removing The Expansion Valve
Proceed very slowly in order to prevent refrigerant oil from being extracted as well. (Observe the instructions given by the unit manufacturer.) (Fig. 52) Fold up the cab roof. Unscrew the cover (A) from the cab top. (Fig. 53) 2.1.20 RHB LEXION 480 - 188 678.1...
Page 63 (16) and plug with plugs on both sides. (Fig. 54, 56) Unscrew the support plate (C). Pull off expansion valve (14) and plug connections with plugs on both sides. (Fig. 55, 56) 2.1.21 188 678.1 - RHB LEXION 480...
Page 64: Air Conditioning System (Cab Side), Disassembled
20 Hex. bolt M 6 x 35 DIN 931-8.8 21 Contact washer A 6 22 Wire mesh 23 Evaporator 24 Mounting bracket 25 Hex. bolt M 8 x 40 DIN 933-8.8 (Fig. 56) 2.1.22 RHB LEXION 480 - 188 678.1...
Page 65: Installing The Expansion Valve
4. Screw down the cover (A) to the cab top. 5. Air conditioning system – Topping up refrigerant , see page 2.1.3 (Fig. 59) Removing the thermostat Fold up the cab roof. Unscrew the cover (A) from the cab top. (Fig. 60) 2.1.23 188 678.1 - RHB LEXION 480...
Page 66 Disconnect cable plug from the temperature switch (9). Loosen clamp (E). Pull off rotary control (10), unscrew temperature switch (9) from cover (D) and carefully pull out capillary tube (C). (Fig. 56, 63, 64) 2.1.24 RHB LEXION 480 - 188 678.1...
Page 67: Installing The Thermostat
4. Connect cable plug to temperature switch (9). 5. Isolate temperature switch (9) using sealing compound. 6. Install cover (D). (Fig. 56, 66) 7. Seal pipe leadthrough with sealing compound (B). 8. Glue on sealing plate (5). (Fig. 56, 67) 2.1.25 188 678.1 - RHB LEXION 480...
Page 68: Removing The Evaporator
(Fig. 69) Fold up the cab roof. Unscrew the cover (A) from the cab top. (Fig. 70) Carefully pull off the sealing plate (5). Remove sealing compound (B). (Fig. 56, 71) 2.1.26 RHB LEXION 480 - 188 678.1...
Page 69: Installing The Evaporator
Installing the evaporator 1. Insert evaporator (23) into the cab roof. 2. Push expansion valve (14) with new O-rings on the connections of evaporator (23) and bolt down support plate (C). (Fig. 56, 75) 2.1.27 188 678.1 - RHB LEXION 480...
Page 70 (Y) = 30 mm ATTENTION! Never push in capillary tube (C) using force or kink it. (Fig. 56, 77) 5. Glue on sealing plate (5). 6. Seal pipe leadthrough with sealing compound (B). (Fig. 56, 78) 2.1.28 RHB LEXION 480 - 188 678.1...
Page 71: Removing The Filter Receiver Drier
(Fig. 81, 84) Unscrew the high-pressure switch (12) from the filter receiver drier. NOTE! The high-pressure switch (12) can also be replaced without loss of refrigerant when air conditioner is filled. (Fig. 82, 84) 2.1.29 188 678.1 - RHB LEXION 480...
Page 72: Filter Receiver Drier, Disassembled
10 Hose line 11 Discharge line 12 High-pressure switch (Fig. 84) Installing the filter receiver drier 1. Bolt down low-pressure switch (1) to the filter receiver drier with a new O-ring. (Fig. 84, 85) 2.1.30 RHB LEXION 480 - 188 678.1...
Page 73 5. Fit the discharge line (11) and hose line (10) to the filter receiver drier with new O-rings. 6. Top up refrigerant oil. 7. Air conditioning system – Topping up refrigerant , see page 2.1.3 (Fig. 84, 87) 2.1.31 188 678.1 - RHB LEXION 480...
Page 74 Air conditioner 2.1.32 RHB LEXION 480 - 188 678.1...
Page 75: Steering
O-rings by new ones. 2. If oil is leaking from the pressure relief valve, the shock valve and in case of internal leaks, replace the complete valve block by a new one. 2.2.1 188 678.1 - RHB LEXION 480...
Page 76: Removing The Steering Column
Remove the M 5 x 16 cheese-head screw and then the multifunction switch (M). Remove the screw (S) so that the upper section of the steering column cover can be removed. (Fig. 4) 2.2.2 RHB LEXION 480 - 188 678.1...
Page 77 Unscrew the two lateral mushroom head bolts (F) and the cheese-head screw (Z). Remove the lower section (U) to the top. (Fig. 7) Unscrew the hex. bolts (K) and remove the floor section (B). (Fig. 8) 2.2.3 188 678.1 - RHB LEXION 480...
Page 78: Disassembling The Steering Column
Removing the gas strut (A): 1. Push the gas strut together. 2. Remove the lock nut (M). 3. Unscrew the hex. bolt (T) completely. 4. Remove the gas strut (A) from the steering column. (Fig. 12) 2.2.4 RHB LEXION 480 - 188 678.1...
Page 79 2. Remove the two side-mounted bolts (S). (Fig. 14) 3. Remove the bolt (B) located on the rear side. (Fig. 15) 4. Remove the complete steering tube (L) towards the open side of the bearing assembly. (Fig. 16) 2.2.5 188 678.1 - RHB LEXION 480...
Page 80 Put the support rings (S) and the circlips (R) into place. Check the max. permissible axial play on one side to be (X) = 0.3 mm and adjust it using shims. (Fig. 17) 2.2.6 RHB LEXION 480 - 188 678.1...
Page 81: Steering Column, Disassembled
8 Gas strut Hex. bolt M 8 x 65 DIN 931-8.8 Self-locking nut VM 8 Contact washer B 8 Spacer bushing Hex. nut M 10 x 1 DIN 936 9 Floor section 10 Lower section 2.2.7 188 678.1 - RHB LEXION 480...
Page 82: Assembling The Steering Column
Push the gas strut together, then using the M 8 bolt, the two spacer bushings, the self-locking nut and contact washers, screw into position at the joint. Tighten the lock nut. Tightening torque = 20 Nm (Fig. 18, 19) 2.2.8 RHB LEXION 480 - 188 678.1...
Page 83: Installing The Steering Column
Keep the engine at max. no-load speed. Turn the steering wheel from one end position to the other several times, thus bleeding the system. Check the oil level. (Fig. 20, 21, 22, 23) 2.2.9 188 678.1 - RHB LEXION 480...
Page 84 20 bar. Should the circulation pressure exceed the permissible limit, the system will overheat. (Fig. 20, 21, 22, 23) 2.2.10 RHB LEXION 480 - 188 678.1...
Page 85: Removing The Valve Block From The Orbitrol
Take care of the dowel pin. (Fig. 25) Valve block, removed: 1 O-ring OR 23, 47 x 2.62 N DIN 3771 2 Valve block, complete 3 Cheese-head screw M 10 x 1 x 45 DIN 912-10.9 (Fig. 26) 2.2.11 188 678.1 - RHB LEXION 480...
Page 86: Installing The Valve Block On The Orbitrol
4. Bolt the cheese-head screws (3) into position. Tightening torque = 65 Nm (Fig. 26) 5. Refit the hydraulic lines back to the Orbitrol. ATTENTION! Ensure that absolutely no dirt enters the system. 2.2.12 RHB LEXION 480 - 188 678.1...
Page 87 20 bar. Should the circulation pressure exceed the permissible limit, the system will overheat. (Fig. 26, 27) 2.2.13 188 678.1 - RHB LEXION 480...
Page 88: Removing The Orbitrol
2 Valve block, complete 3 Male connector L12 e-g DIN 3901 4 Male connector L15 b-g DIN 3901 5 Cheese-head screw M 10 x 1 x 45 DIN 912-10.9 6 Steering unit (Fig. 30) 2.2.14 RHB LEXION 480 - 188 678.1...
Page 89: Installing The Orbitrol
Steering column with Autopilot: Slide the quick-release fastener (A) and the set collar (B) onto the shaft (W). Now position the quick-release fastener (A) on the shaft at (X) = 43.3 mm. (Fig. 32) 32676 2.2.15 188 678.1 - RHB LEXION 480...
Page 90 CAUTION! The overrider switch should be free to turn. With a new overrider switch, it may be necessary to grind it down a little in order for it to fit. (Fig. 33, 34) 2.2.16 RHB LEXION 480 - 188 678.1...
Page 91 Connect the cable (K) of the overrider switch (D) to the existing wiring loom. (Fig. 33, 36) Refit the hydraulic lines back to the Orbitrol. Ensure that absolutely no dirt enters the system. (Fig. 37) 2.2.17 188 678.1 - RHB LEXION 480...
Page 92 20 bar. Should the circulation pressure exceed the permissible limit, the system will overheat. (Fig. 37) 2.2.18 RHB LEXION 480 - 188 678.1...
Page 93: Parking Brake
Disconnect the cable from switch (S). Unhook the cable (Z). For this, slacken off the lock nut and unscrew the hex. nut completely. (Fig. 2) Unbolt the parking brake assembly and remove from underneath. (Fig. 3) 2.3.1 188 678.1 - RHB LEXION 480...
Page 94: Installing The Parking Brake
3. Setting the parking brake on the gearbox: Reconnect the parking brake cable (H) at the retarder (W). Adjust the cable so that the parking brake is fully functional on the 3rd or 4th notch. (Fig. 4) 2.3.2 RHB LEXION 480 - 188 678.1...
Page 95: Foot Brake
2. Push the piston along with piston rod and compression spring into the housing. 3. Secure the piston rod with the fixing ring and the circlip. 4. Fit the bellows on the piston rod and screw in the yoke. (Fig. 2) 2.4.1 188 678.1 - RHB LEXION 480...
Page 96: Installing The Master Brake Cylinder
Secure the pin with a split pin. Afterwards, check the brakes, either on a special rolling road or in a secure area. DANGER! It is not permissible to check the brakes on the open road. (Fig. 3) 2.4.2 RHB LEXION 480 - 188 678.1...
Page 97: Engine Electric System
– The battery provides the current for the field excitation required to start the alternator via the battery charge indicator bulb. Blown bulbs must therefore be replaced to ensure reliable field excitation. (Fig. 1) 2.5.1 188 678.1 - RHB LEXION 480...
Page 98 Engine electric system 2.5.2 RHB LEXION 480 - 188 678.1...
Page 99: Threshing Mechanism
Threshing mechanism...
Page 101: Feed Rake Conveyor
V-belt (P) from the cutterbar drive pulley. DANGER! Please be particularly careful when screwing out the spring guide tube. Do not unscrew the spring guide tube too far – Danger of injury! (Fig. 4) 3.1.1 188 678.1 - RHB LEXION 480...
Page 102 Disconnect the screwed coupling (A) and the plug-in coupling (G) and plug the hose ends with the plastic caps. (Fig. 7) Remove the pins (C) from the yokes and unhook the cutterbar cylinders. (Fig. 8) 3.1.2 RHB LEXION 480 - 188 678.1...
Page 103: Installing The Feed Rake Conveyor
7. Refit all guards and bolt down the universal coupling on the left-hand side. 8. Relearn the cutterbar end stops (CAC). See Operator's Manual “Operation CEBIS” or “Operation IMO”. (Fig. 10) 3.1.3 188 678.1 - RHB LEXION 480...
Page 104: Removing The Intercepting Piece
Secure the hex. bolt (S) with self-locking nut VM 20. Up to serial no. …: Tighten hex. bolt (S) M 16 x 140 with a tightening torque of 195 Nm. (Fig. 11, 13) 3.1.4 RHB LEXION 480 - 188 678.1...
Page 105: Removing The Feed Rake Conveyor Suction Blower
Unscrew the support plate (3). Arrest the impeller (13) and unscrew the nut (29). (Fig. 16, 22) Pull off the V-belt pulley (27). Remove the supporting ring (25) and the key (26). (Fig. 17, 22) 3.1.5 188 678.1 - RHB LEXION 480...
Page 106 Unscrew the bearing housing completely from the cover (15). (Fig. 20) Pull off bearing housing (24) from the shaft (21). Drive bearing (22) out of the bearing housing. Pull the bearing (22) from the shaft. (Fig. 21, 22) 3.1.6 RHB LEXION 480 - 188 678.1...
Page 107: Feed Rake Conveyor Suction Blower, Disassembled
Contact washer A 6 15 Cover 16 Contact washer A 8 17 Hex. nut M 8 18 Circlip 19 Supporting ring 20 Parallel key 21 Shaft 22 Deep groove ball bearing 23 Circlip 24 Bearing housing 3.1.7 188 678.1 - RHB LEXION 480...
Page 108: Assembling The Feed Rake Conveyor Suction Blower
The impeller (13) must make contact with the circlip (18). 6. Arrest the impeller (13) using the set screw (12). Insert the pre-assembled suction blower into the housing (8) and screw down the cover (15). (Fig. 22, 25) 3.1.8 RHB LEXION 480 - 188 678.1...
Page 109: Installing The Feed Rake Conveyor Suction Blower
(34) , see page 7.3.27 (Fig. 28) Removing the top feed rake shaft Removing the feed rake conveyor , see page 3.1.1. Release the tension of the chain tensioner (P). (Fig. 29) 3.1.9 188 678.1 - RHB LEXION 480...
Page 110 Remove the anti-wrapping guards (W) and the sealing plate (D). Remove the filler blocks. (Fig. 32) Mark the sprockets with numbers. Using a key drawer, remove the gib head keys from each sprocket. (Fig. 33) 3.1.10 RHB LEXION 480 - 188 678.1...
Page 111 181 621.0 2 Hex. bolt M 16 x 30 with centralising head 3 Hex. bolt M 10 x 70 part no. 237 806.1 4 Washers ∅ 10.5 part no. 236 913.2 (Fig. 37) 31491 3.1.11 188 678.1 - RHB LEXION 480...
Page 112 Slacken off the cam wheel (N) using an Allen key and remove it. (Fig. 40) Unscrew the lock collar and remove it. Smooth impression mark of headless screw in the shaft, using emery paper. (Fig. 41) 3.1.12 RHB LEXION 480 - 188 678.1...
Page 113 236 172.0 (Fig. 43) 31254 Pull the bearing assembly off of the shaft on the left-hand side, using the special tool (Fig. 43). Now remove the shaft towards the left-hand side. (Fig. 44) 3.1.13 188 678.1 - RHB LEXION 480...
Page 114: Feed Rake Top Shaft, Disassembled
18 Set screw M 10 x 8 DIN 916 19 Bearing assembly, mounted Adjusting plate 20 Hex. bolt M 12 x 30 DIN 933-8.8 Contact washer A 12 21 Lock collar 50 22 Set screw M 10 x 1.25 x 8 3.1.14 RHB LEXION 480 - 188 678.1...
Page 115: Installing The Feed Rake Top Shaft
(7). (Fig. 45, 48) Special tool: Hex. bolt M 12 x 220 part no. 244 422.0 – 2 pieces Hex. nut M 12 part no. 236 172.0 – 2 pieces (Fig. 48) 3.1.15 188 678.1 - RHB LEXION 480...
Page 116 (15). Now slide the bearing housing (16) on the bearing assembly (7). Slide on the cam wheel (17) and secure with set screw (18). (Fig. 45, 52) 3.1.16 RHB LEXION 480 - 188 678.1...
Page 117 Bolt the centre bearing assembly (19) back into place using bolt (20). Refit the associated lock collar (21), tighten in direction of travel, then secure with the set screw (22). (Fig. 45, 53) 3.1.17 188 678.1 - RHB LEXION 480...
Page 118 Y = 577 mm 88 mm Refit the anti-wrapping guards (25, 26 and 28) back into place, using the bolts (29). Refit the sealing plate (27) and the filler sections (30). (Fig. 45, 54) 3.1.18 RHB LEXION 480 - 188 678.1...
Page 119: Removing The Bottom Feed Rake Roller
Releasing the tension of the chains on the left- and right-hand side: To do this, unlock the lock nut (S) on both sides and unscrew the tensioning screw (P). (Fig. 58) 3.1.19 188 678.1 - RHB LEXION 480...
Page 120 Unscrew the hex. nut M 16 on both sides, then pull out pin (B) from the chain tensioner and the supporting arm to the inside. (Fig. 61) Remove the shaft to the front. (Fig. 62) 3.1.20 RHB LEXION 480 - 188 678.1...
Page 121: Bottom Feed Rake Roller, Disassembled
(11) correctly engages in the supporting arm guide bush. Install the bolts (12) and the chain tensioner complete with the self-locking nut (14) and the hex. nuts (15). (Fig. 63, 64) 3.1.21 188 678.1 - RHB LEXION 480...
Page 122: Replacing The Wooden Ledges
Raise the feed rake conveyor and support it safely. Remove the wear plate and the drum inspection cover. Remove the dust guard (S) and the inspection door (P). Remove the mushroom head bolts from the wooden ledges. (Fig. 67) 3.1.22 RHB LEXION 480 - 188 678.1...
Page 123: Removing The Intermediate Floor
(Fig. 69) Removing the intermediate floor Raise the feed rake conveyor and support it safely. Remove the universal coupling (U) and the guard (S) on the left-hand side of the machine. (Fig. 70) 3.1.23 188 678.1 - RHB LEXION 480...
Page 124 Replacing the wooden ledges: When replacing the wooden ledges, insert the mushroom head bolts (2) M 8 x 35 and (3) M 8 x 25 into the wooden ledges (1) and tighten them. (Fig. 74) 3.1.24 RHB LEXION 480 - 188 678.1...
Page 125: Installing The Intermediate Floor
Pull the runners (G) towards the front and replace by new ones. Installing the runners: CAUTION! Tape the mushroom head bolts to the runners. Slide the runners up into the feed rake conveyor, then bolt into position. (Fig. 77) 3.1.25 188 678.1 - RHB LEXION 480...
Page 126: Removing The Intermediate Drive Shaft
On the right-hand side, remove the hex. bolt (B) M 12 x 45 and the eccentric. Remove the hex. bolt (A) M 8 x 65 and the M 12 x 25 hex. bolt located opposite, then remove cylinder. (Fig. 81) 3.1.26 RHB LEXION 480 - 188 678.1...
Page 127 (Fig. 83) Remove the three M 12 hex. nuts and remove the bracket. (Fig. 84) Remove the set screw and remove the lock collar by turning it against the direction of rotation. (Fig. 85) 3.1.27 188 678.1 - RHB LEXION 480...
Page 128 7 Reducing adapters M 12 to M 16 part no. 181 933.0 – 2 pieces 31287 (Fig. 88) Remove the intermediate drive shaft, with the left-hand bearing in place, to the side and lay on the bench. (Fig. 89) 3.1.28 RHB LEXION 480 - 188 678.1...
Page 129 235 816.0 – 2 pieces 5 Washers 17 part no. 235 127.2 6 Threaded pin 32290 part no. 181 889.0 – 2 pieces 7 Hex. nut M 16 part no. 244 059.0 – 2 pieces (Fig. 92) 3.1.29 188 678.1 - RHB LEXION 480...
Page 130 Hex. bolt M 6 x 12 DIN 933-8.8 Hex. nut M 6 DIN 934-8 Contact washer A 6 6 Guard 7 Guard Hex. bolt M 8 x 16 DIN 933-8.8 Self-locking nut VM 8 Contact washer B 8 (Fig. 93) 3.1.30 RHB LEXION 480 - 188 678.1...
Page 131: Installing The Intermediate Drive Shaft
– see page 7.2.4, Installing and adjusting the cutterbar drive belt (2) (Cutterbar drive with variable-speed drive) . 12. Install the left-hand guard and the universal coupling. (Fig. 93, 94, 95, 96) 3.1.31 188 678.1 - RHB LEXION 480...
Page 132: Removing The Reverser Drive
Remove the hose end that goes off to the tank from the hydraulic cylinder and plug it with a plastic cap. (Fig. 99) Loosen the M 8 x 180 hex. bolt. Remove the spring clamp. (Fig. 100) 3.1.32 RHB LEXION 480 - 188 678.1...
Page 133 Using a two-legged puller and a M 8 hex. bolt with centraliser, pull off the gear. (Fig. 103) Loosen the M 12 x 35 hex. bolts and remove the hydraulic motor from the supporting arm. (Fig. 104) 3.1.33 188 678.1 - RHB LEXION 480...
Page 134 6 Compression spring Hex. bolt M 8 x 180 DIN 931-8.8 Spring guide Hex. nut M 8 DIN 934-8 7 Bearing plate Hex. bolt M 10 x 20 DIN 933-8.8 Contact washer A 10 3.1.34 RHB LEXION 480 - 188 678.1...
Page 135: Installing The Reverser Drive
10. Check the hydraulic oil level. (Fig. 105, 106) Replacing the feeder chains Raise the feed rake conveyor and support it safely. First remove the universal coupling (U) on the left-hand side, then the guard (S). (Fig. 107) 3.1.35 188 678.1 - RHB LEXION 480...
Page 136 Bolt the feed rake slats onto the new chains. Connect the new chains to the old chains. Ensure that the feed rake slats are offset. Turn the roller so that the new chains are pulled in. (Fig. 110) 3.1.36 RHB LEXION 480 - 188 678.1...
Page 137 (G). (Fig. 111) Bolt down the dust guard, the right-hand end piece and the left-hand guide plate. Refit the guard on the left-hand side and the universal coupling. 3.1.37 188 678.1 - RHB LEXION 480...
Page 138 Feed rake conveyor 3.1.38 RHB LEXION 480 - 188 678.1...
Page 139: Threshing Concave
Swing stone trap up and screw on the turn lock. Release the lever, then fold back door and secure with the tensioning lever. 3.2.1 188 678.1 - RHB LEXION 480...
Page 140: Removing The Preconcave
Remove the screw plug (S) from both sides of the machine. Should the machine be fitted with the maize options, remove the feed plate for the stone trap. (Fig. 5) Remove the feed plate (B) along with the cover (K). (Fig. 6) 3.2.2 RHB LEXION 480 - 188 678.1...
Page 141 Lift both disawner plates (E) out at the front of the machine. (Fig. 9) Support the underside of the preconcave with pieces of squared timber (H) of approx. 170 mm height. (Fig. 10) 3.2.3 188 678.1 - RHB LEXION 480...
Page 142 (Fig. 13, 15) Raise the preconcave (1) at the rear and push it over the edge of the main concave. Pull the preconcave out slowly towards the front on the squared timber. (Fig. 14) 3.2.4 RHB LEXION 480 - 188 678.1...
Page 143: Preconcave, Disassembled
5 Mounting plate with bushing 6 Hex. bolt M 20 x 80 DIN 931-8.8 Washer 21 Safety washer 20 7 Sealing plate 8 Mounting plate with bushing 9 Disawner plates 10 Brace (Fig. 15) 3.2.5 188 678.1 - RHB LEXION 480...
Page 144: Installing The Preconcave
Secure the mounting plates with set collars and/or split pins. (Fig. 16) 4. Bolt down the preconcave suspension bolts (6). Tightening torque = 370 Nm (Fig. 15, 17) 3.2.6 RHB LEXION 480 - 188 678.1...
Page 145: Removing The Main Concave
(22) . (The threshing drum can now easily be rotated.) (Fig. 18) Remove the preconcave. Move the preparation floor to the foremost position by turning the step 1 chopper drive V-belt pulley (1) by hand. (Fig. 19) 3.2.7 188 678.1 - RHB LEXION 480...
Page 146 120 mm in height. Remove the inspection hole cover (D) on the right- hand and left-hand side. DANGER! The hex. bolts (M) on the right-hand and left- hand side must be installed. (Fig. 21, 22) 3.2.8 RHB LEXION 480 - 188 678.1...
Page 147 (Fig. 24, 25) Remove the spring clip (4) from the eccentric bolt (7) and the safety plate (6) on the left- and right-hand machine side and remove the washers (5). (Fig. 26, 27) 3.2.9 188 678.1 - RHB LEXION 480...
Page 148: Main Concave, Disassembled
5 Washer 6 Holder plate Hex. bolt M 10 x 25 Contact washer A 10 7 Eccentric pin 8 Plate 9 Adjusting bolt Hex. nut M 12 Contact washer A 12 (Fig. 27) 3.2.10 RHB LEXION 480 - 188 678.1...
Page 149 ATTENTION! The main concave (1) must not rest on the lateral rubber seals (D) of the preparation floor as the seals may be damaged. (Fig. 31) 3.2.11 188 678.1 - RHB LEXION 480...
Page 150: Installing The Main Concave
(Do not rotate drum by force.) DANGER! Never move your hands between the main concave, threshing drum and drum housing – Danger of injury! 3.2.12 RHB LEXION 480 - 188 678.1...
Page 151 (A) when turning upwards. Cut the chain on the left-hand machine side approx. 10 mm shorter to allow passing a weld nut on the left- hand machine side. (Fig. 35) 3.2.13 188 678.1 - RHB LEXION 480...
Page 152 (6). The 0 position is reached when the mark (M) points to the rear (H). Remove the chain for lifting the main concave on the right-hand machine side. (Fig. 27, 37, 38) 3.2.14 RHB LEXION 480 - 188 678.1...
Page 153 Installing and adjusting the fan intermediate drive belt (20) , see page 7.3.4 Installing and adjusting the threshing mechanism variable-speed drive belt (22) , see page 7.3.7 Installing the preconcave , see page 3.2.6 3.2.15 188 678.1 - RHB LEXION 480...
Page 154: Basic Concave Setting
Measure the basic setting. To do this bleed the hydraulic cylinders and move the concave to the narrowest position. The lengths of the turnbuckles, hydraulic cylinders and potentiometer linkage must be set according to the specified dimensions. (Fig. 43, 44) 3.2.16 RHB LEXION 480 - 188 678.1...
Page 155 – Main concave output – 4th bar from the end Setting to be carried out at the adjusting bolt (V1) and the eccentric bolt (V2) = Adjusting bolt (left-hand machine side) = Eccentric bolt (right-hand machine side) (Fig. 43) 3.2.17 188 678.1 - RHB LEXION 480...
Page 156 – Main concave output – 4th bar from the end Setting to be carried out at the adjusting bolt (V1) and the eccentric bolt (V2) = Adjusting bolt (left-hand machine side) = Eccentric bolt (right-hand machine side) (Fig. 44) 3.2.18 RHB LEXION 480 - 188 678.1...
Page 157 Open doors (C and D). Set the main concave entrance (M2) to dimension (M2) in parallel on the left- and right-hand side by turning the piston rods (A). (Fig. 43, 44, 45, 46) 3.2.19 188 678.1 - RHB LEXION 480...
Page 158 Re-tighten all bolts after adjusting the concave and jam hex. nuts. Insert all doors and arrest them. (Fig. 43, 44 , 47, 48, 49) 5. Adjusting the concave potentiometer – see page 3.2.21, Adjusting the concave potentiome- ter . 3.2.20 RHB LEXION 480 - 188 678.1...
Page 159: Adjusting The Concave Potentiometer
The basic setting (L3) of the linkage is 180 mm. Up to serial no. … (Fig. 43, 44, 50, 51) 32548 Learning the limit stops See section 8 of Operator's Manual “Learning the limit stops”. 3.2.21 188 678.1 - RHB LEXION 480...
Page 160 From serial no. … The basic setting (L3) of the linkage is 726 mm. (Fig. 43, 44, 52, 53) Learning the limit stops See section 8 of Operator's Manual “Learning the limit stops”. 3.2.22 RHB LEXION 480 - 188 678.1...
Page 161: Accelerator
(Fig. 1) Remove the cover (D) on the accelerator. (Fig. 2) Clean the shaft with emery paper and grease it. Remove the M 12 x 65 hex. bolts from the clamping hubs. (Fig. 3) 3.3.1 188 678.1 - RHB LEXION 480...
Page 162 Remove the grease pipe from the bearing housing. Disconnect the cable from the magnetic pick-up (G). Unscrew the three cheese-head screws (Z) from the bearing assembly. (Fig. 7) 3.3.2 RHB LEXION 480 - 188 678.1...
Page 163: Disassembling The Right-Hand Bearing Assembly
Remove self-aligning roller bearing from the shaft using the puller. (Fig. 10) Assembling the right-hand bearing Press the self-aligning roller bearing into the bearing housing. Press the bearing assembly and the spacer on using the special tool. (Fig. 11) 3.3.3 188 678.1 - RHB LEXION 480...
Page 164 636 678.0 4 Axial bearing part no. 177 899.0 5 Centring disc part no. 181 879.0 6 Tube inside ∅ 42, outside ∅ 50 x 140 long 32628 (self-sourced) (Fig. 12) 3.3.4 RHB LEXION 480 - 188 678.1...
Page 165: Installing The Right-Hand Bearing Assembly And Shaft
(Fig. 13, 14) Using a tube, lift the shaft. Bolt the bearing assembly into place at the drum wall using three cheese-head screws. Tightening torque = 80 Nm (Fig. 13, 15) 3.3.5 188 678.1 - RHB LEXION 480...
Page 166 181 604.0 (Fig. 13, 17) Screw the M 12 x 65 hex. bolts into the clamping hubs of the drum. (Fig. 13, 18) Refit the cover (D) to the drum. (Fig. 13, 19) 3.3.6 RHB LEXION 480 - 188 678.1...
Page 167 Installing and adjusting the accelerator drive belt (24) . (Fig. 13, 22) Remove the wooden wedge from under the accelerator and replace and lock the drum inspection cover. Refit the guard. Refit the wheel. 3.3.7 188 678.1 - RHB LEXION 480...
Page 168: Removing The Bearing Assembly On The Left-Hand Side
– Danger of injury! (Fig. 24) Loosen the M 12 bolts and remove the V-belt pulley. (Fig. 25) Unscrew the grease pipe (S). Remove the circlip and the washer (D). (Fig. 26) 3.3.8 RHB LEXION 480 - 188 678.1...
Page 169 4 2 bolts M 10 x 70 part no. 235 538.0 5 2 washers 10.5 part no. 236 913.2 6 Bolt M 12 x 30 with punch point on the head 31401 (self-sourced) (Fig. 30) 3.3.9 188 678.1 - RHB LEXION 480...
Page 170: Disassembling The Left-Hand Bearing Assembly
5 Tube, outside ∅ 100, inside ∅ 80 x 130 long 6 Locating disc, part no. 181 879.0 7 Spindle, part no. 181 877.0 8 Sleeve, part no. 181 881.0 (Fig. 33) 32634 3.3.10 RHB LEXION 480 - 188 678.1...
Page 171: Assembling The Left-Hand Bearing Assembly
4 Tube, outside ∅ 70 inside ∅ 60 x 130 long 5 Locating disc, part no. 181 879.0 6 Spindle, part no. 181 877.0 7 Sleeve, part no. 181 881.0 (Fig. 35) 32636 3.3.11 188 678.1 - RHB LEXION 480...
Page 172: Installing The Left-Hand Bearing Assembly
(2) (Cutterbar drive with variable-speed drive) . (Fig. 38) Refit the guard and the mud guard. Remove the wooden wedge from under the accelera- tor and replace and lock the drum inspection cover. Refit the wheel. 3.3.12 RHB LEXION 480 - 188 678.1...
Page 173: Replacing The Accelerator Caps
– Up to serial no. …: Bolt down hex. bolt M 10 x 20 - 8.8 DIN 933 with a tightening torque of 45 Nm. (Fig. 40) Install the drum inspection cover (T). (Fig. 39) 3.3.13 188 678.1 - RHB LEXION 480...
Page 174: Removing The Accelerator
Remove the grease pipe (S) from the left-hand side. Remove the circlip and the washer (D). (Fig. 42) Remove the M 12 x 30 hex. bolt from the face end of the shaft. (Fig. 43) 3.3.14 RHB LEXION 480 - 188 678.1...
Page 175 5 Washers 10.5, part no. 236 913.2 – 2 pieces 6 Centraliser with ball, part no. 181 849.0 (Fig. 46) 31401 Remove the three M 8 x 20 hex. bolts holding the anti-wrapping guard. (Fig. 47) 3.3.15 188 678.1 - RHB LEXION 480...
Page 176 Using a suitable lever, start pulling the accelerator forward on the left-hand side of the machine and then remove the anti-wrap guard on the left-hand side. (Fig. 48) Using a suitable lifting device, lift out the accelerator drum. (Fig. 49) 3.3.16 RHB LEXION 480 - 188 678.1...
Page 177: Accelerator, Disassembled
15 Hex. bolt M 12 x 35 DIN 933-8.8 16 Self-aligning roller bearing 17 Circlip 18 Washer 19 Hex. bolt M 12 x 30 DIN 933-8.8 Contact washer A 12 20 Washer 21 Circlip 22 Spacer ring 23 Tapered ring 3.3.17 188 678.1 - RHB LEXION 480...
Page 178: Installing The Accelerator
Lift the accelerator (1) into the machine, using a suitable lifting device. (Fig. 50, 51, 52) Bolt the anti-wrapping guard (T) into the left-hand side of the machine housing. (Fig. 51, 53) 3.3.18 RHB LEXION 480 - 188 678.1...
Page 179 Push the bearing assembly (13 – 16) onto the shaft end. Using the special tool (W), push the bearing assembly to the drum wall. (Fig. 50, 57) 3.3.19 188 678.1 - RHB LEXION 480...
Page 180 Bolt the cover (31) back into place with bolts (32). Remove the two wooden wedges from under the accelerator, install and lock the drum inspection cover. Installing the feed rake conveyor , see page 3.1.3 (Fig. 50) 3.3.20 RHB LEXION 480 - 188 678.1...
Page 181 – see page 7.2.2, Installing and adjusting the cutterbar drive belt (1) (Cutterbar drive without varia- ble-speed drive) and/or – see page 7.2.4, Installing and adjusting the cutterbar drive belt (2) (Cutterbar drive with variable-speed drive) . (Fig. 63) 3.3.21 188 678.1 - RHB LEXION 480...
Page 182 Accelerator Grease both sets of bearings on the left-hand and right-hand side. Install the guard and the mud guard on both sides. Refit the drive wheels. 3.3.22 RHB LEXION 480 - 188 678.1...
Page 183: Threshing Drum
Relieve the tension of jockey pulley (P) and remove the belt. (Fig. 2) Remove the gib head key using a suitable key drawer. Remove the V-belt pulley. If necessary, Removing the threshing drum reduction gearbox , see page 7.7.1 (Fig. 3) 3.4.1 188 678.1 - RHB LEXION 480...
Page 184 Then unscrew the slotted nut. (Fig. 5) Remove the grease pipe from the bearing housing. (Fig. 6) Remove the M 12 x 100 bolts from the bearing assembly. (Fig. 7) 3.4.2 RHB LEXION 480 - 188 678.1...
Page 185: Disassembling The Right-Hand Drum Bearing
1. Separate the bearing assembly from the spacer. 2. Separate the outside bearing housing from the bearing assembly. 3. Using suitable tools, push the spherical roller bearing out of the inside bearing housing. (Fig. 9, 10) 3.4.3 188 678.1 - RHB LEXION 480...
Page 186: Right-Hand Drum Bearing, Disassembled
Contact washer A 12 8 Felt ring 9 Tab washer 10 From serial no. …: Face-end slotted nut M 65 x 2 Up to serial no. …: Face-end slotted nut M 60 x 2 (Fig. 11) 3.4.4 RHB LEXION 480 - 188 678.1...
Page 187: Installing The Right-Hand Drum Bearing
7.3.11, Installing and adjusting the accelera- tor drive belt (24) . Tension the jockey pulley (P) in the same manner. 8. Refit the guard and the right-hand wheel. (Fig. 11, 12, 13) 3.4.5 188 678.1 - RHB LEXION 480...
Page 188: Removing The Left-Hand Drum Bearing Assembly
. DANGER! Please be particularly careful when screwing out the spring guide tube. Do not unscrew the spring guide tube too far – Danger of injury! Remove the pulley (S). (Fig. 16) 3.4.6 RHB LEXION 480 - 188 678.1...
Page 189 Then remove the slotted nut. (Fig. 19) Unbolt the bearing assembly from the drum wall and if necessary pull it off the shaft, using a puller. (Fig. 20) 3.4.7 188 678.1 - RHB LEXION 480...
Page 190: Disassembling The Left-Hand Drum Bearing
4 Spherical roller bearing 5 Bearing housing Cheese-head screw M 12 x 35 DIN 7984-8.8 Detent-edged ring VSKZ 12 6 Felt seal 7 Tab washer 8 Face-end slotted nut M 50 x 1.5 (Fig. 22) 3.4.8 RHB LEXION 480 - 188 678.1...
Page 191: Installing The Left-Hand Drum Bearing Assembly
(1) (Cutterbar drive without varia- ble-speed drive) and/or – see page 7.2.4, Install- ing and adjusting the cutterbar drive belt (2) (Cutterbar drive with variable-speed drive) . 9. Install the guard. (Fig. 23, 24, 25) 3.4.9 188 678.1 - RHB LEXION 480...
Page 192: Removing The Threshing Drum
Loosen the assembly cover (D) on the right-hand side of the machine. Attach a suitable lifting belt to the shaft end. Lift the drum slightly and pull it slightly towards the right-hand side of the machine. (Fig. 28) 3.4.10 RHB LEXION 480 - 188 678.1...
Page 193 On the left-hand side of the machine, place a suitable tube onto the shaft end. (Fig. 29) Now relocate the lifting tool to the centre of the drum and remove the drum completely. (Fig. 30) 3.4.11 188 678.1 - RHB LEXION 480...
Page 194: Threshing Drum, Disassembled
Detent-edged ring VSKZ 8 (Fig. 31) 10 Taper lock sleeve 11 Spherical roller bearing 12 Bearing housing Hex. bolt M 12 x 100 DIN 931-8.8 Contact washer A 12 13 Felt ring 14 Circlip 3.4.12 RHB LEXION 480 - 188 678.1...
Page 195: Renewing The Beater Bars
Grind the drum discs so they are clean and bolt down the new beater bar. Tightening torque = 86 Nm Re-weld the back of the beater bar. (Fig. 34, 35) 3.4.13 188 678.1 - RHB LEXION 480...
Page 196: Removing The Threshing Drum Shaft
Clean the full length of the shaft (1) and ensure it has been greased well. Pull out the gib head keys. (Fig. 36) On the right-hand side, remove the M 14 x 55 bolts, then remove the flanged shaft (5). (Fig. 37) 3.4.14 RHB LEXION 480 - 188 678.1...
Page 197 181 849.0 4 Hex. bolt M 14 x 55 DIN 931 part no. 212 116.0 – 2 pieces 5 Contact washer A 14 part no. 239 390.0 – 2 pieces 31469 (Fig. 39) 3.4.15 188 678.1 - RHB LEXION 480...
Page 198: Installing The Threshing Drum Shaft
Observe dimension (X) = 3.5 mm according to Fig. 40. On the right-hand side of the drum, refit the flanged shaft (5) with the hex. bolts M 14 x 55. Tightening torque = 175 Nm 3.4.16 RHB LEXION 480 - 188 678.1...
Page 199: Installing The Threshing Drum
7. Installing the right-hand drum bearing , see page 3.4.5 Installing the left-hand drum bearing assembly , see page 3.4.9 CAUTION! Align the threshing drum to be centred in the drum housing. (Fig. 31) 3.4.17 188 678.1 - RHB LEXION 480...
Page 200 DIN 933-10.9 hex. bolt. Tightening torque = 72 Nm 12. On the left- and right-hand side, install the drive belts (R) and tension them. 13. Refit the guards and the wheels. (Fig. 31, 41, 42) 3.4.18 RHB LEXION 480 - 188 678.1...
Page 201: Impeller
Unscrew the set screw from the lock collar and knock off the lock collar against its normal rotational direction. (Fig. 3) Remove the four M 12 x 35 hex. bolts from bearing assembly (E). (Fig. 4) 3.5.1 188 678.1 - RHB LEXION 480...
Page 202 603 038.0 4 Hex. bolts M 12 x 140 part no. 233 011.0 – 2 pieces 5 Washer 13, part no. 239 387.0 6 Centraliser with ball part no. 181 849.0 31401 (Fig. 6) 3.5.2 RHB LEXION 480 - 188 678.1...
Page 203: Installing The Right-Hand Impeller Bearing
Removing the rear pulley of cutterbar drive (1) (from serial no..) , see page 7.4.17 Up to serial no. …: Removing the rear pulley of cutterbar drive (1) (up to serial no..) , see page 7.4.7 3.5.3 188 678.1 - RHB LEXION 480...
Page 204 4 Hex. bolt M 16 x 260 part no. 235 816.0 – 2 pieces 5 Washer 17, part no. 235 127.2 – 2 pieces 6 Threaded bolt, part no. 181 889.0 – 2 pieces (Fig. 11) 31487 3.5.4 RHB LEXION 480 - 188 678.1...
Page 205: Installing The Left-Hand Impeller Bearing
Installing the rear pulley of cutterbar drive (1) (from serial no..) , see page 7.4.24 Up to serial no. …: Installing the rear pulley of cutterbar drive (1) (up to serial no..) , see page 7.4.15 3.5.5 188 678.1 - RHB LEXION 480...
Page 206: Removing The Impeller
Removing the impeller drive belt (4) , see page 7.2.7 On machines equipped with cutterbar variable-speed drive: Removing the cutterbar variable-speed drive belt (3) , see page 7.2.5 Removing the impeller drive belt (4) , see page 7.2.7 3.5.6 RHB LEXION 480 - 188 678.1...
Page 207 Remove all bolts from the cover. Remove bolt (S) from the grain tank floor. (Fig. 19) Using a suitable lifting device, lift the impeller out of the machine to the left. (Fig. 20) 3.5.7 188 678.1 - RHB LEXION 480...
Page 208: Installing The Impeller
Installing and adjusting the cutterbar variable- speed drive belt (3) , see page 7.2.6 7. Reinstall the two bars. 8. Grease the impeller bearing and carry out a test run. 9. Reinstall the guard and the mud guard. 3.5.8 RHB LEXION 480 - 188 678.1...
Page 209: Removing The Flanged Shaft (From Serial No
(from serial no..) Removing the left-hand impeller bearing , see page 3.5.3 Unscrew cover (D). (Fig. 23) Key the impeller in position and remove the flanged shaft from the impeller. (Fig. 24) 3.5.9 188 678.1 - RHB LEXION 480...
Page 210: Impeller Disassembled
3 Hex. bolt M 14 x 25 DIN 933-8.8 Contact washer A 14 4 Reed 5 Mushroom head bolt M 8 x 20 x 13 DIN 603 Hex. nut M 8 DIN 934 Contact washer A 8 (Fig. 25) 3.5.10 RHB LEXION 480 - 188 678.1...
Page 211: Installing The Flanged Shaft
Bolt the flanged shaft to the impeller. Tightening torque = 122 Nm Remove the key from the impeller. (Fig. 27) Bolt down the cover (D). Installing the left-hand impeller bearing , see page 3.5.5 (Fig. 28) 3.5.11 188 678.1 - RHB LEXION 480...
Page 212: Removing The Impeller Shaft (Up To Serial No
(3). (Fig. 29) Clean the impeller shaft and pull out shaft with special tool. Special tool: Tie rod 450 mm part no. 181 605.0 Striking tool part no. 181 604.0 (Fig. 30) 3.5.12 RHB LEXION 480 - 188 678.1...
Page 213: Impeller Disassembled
4 Parallel key A 16 x 10 x 50 DIN 6885 5 Reed 6 Mushroom head bolt M 8 x 20 x 13 DIN 603 Hex. nut M 8 DIN 934 Contact washer A 8 (Fig. 31) 3.5.13 188 678.1 - RHB LEXION 480...
Page 214: Installing The Impeller Shaft
(X) is 268.2 mm. Secure the impeller shaft (2) with hex. bolt (3). (Fig. 31, 32, 33) Installing the impeller , see page 3.5.8 Installing the left-hand impeller bearing , see page 3.5.5 3.5.14 RHB LEXION 480 - 188 678.1...
Page 215: (Up To Serial No
Remove the guide (F) that is toward the centre. (Fig. 3) Slacken off the M 12 lock nuts at the rear separation grate. Undo the set screws. Thereby holding the separation grate up. (Fig. 4) 3.6.1 188 678.1 - RHB LEXION 480...
Page 216 To ease removal of the separation grates, place the grates crosswise on to the return floor. (Fig. 7) When the separation grates have been removed, the toothed bars can be renewed for instance. (Fig. 8) 3.6.2 RHB LEXION 480 - 188 678.1...
Page 217: Installing The Separation Grates
(Fig. 10) Unbolt the guide plate (E) at the top and fold it over the cutting cylinder as a mounting platform. Completely remove the sensor plate (D) and the insulation plate (B). (Fig. 11) 3.6.3 188 678.1 - RHB LEXION 480...
Page 218 Cover up the upper sieves with mounting plates. Pull out all separating grates to the rear. (Fig. 13) Only slacken off the hex. bolts (P and S) on the right- and left-hand side. (Fig. 14, 15) 3.6.4 RHB LEXION 480 - 188 678.1...
Page 219 Rotate the separating jacket by approx. 160° to the centre and slowly lower it with the lifting straps. Lift out the separating jacket with a suitable lifting device. (Fig. 16, 17, 18) 3.6.5 188 678.1 - RHB LEXION 480...
Page 220: Installing The Separating Jacket
9. Install the discharge plate (A). (Fig. 12) 10. Install the sensor plate (D) and the insulation plate (B) and bolt down guide plate (E). (Fig. 11) 11. Bolt down cover plate (S) and safety frame. (Fig. 10) 3.6.6 RHB LEXION 480 - 188 678.1...
Page 221: Removing The Axial Rotor Supporting Arm
Unscrew a mushroom head bolt from the serrated bar. Bolt down the lifting strap safely with a M 10 x 60 bolt. Suspend the lifting strap at the crossmember and thus secure the axial rotor. (Fig. 23) 3.6.7 188 678.1 - RHB LEXION 480...
Page 222: Disassembling The Axial Rotor Supporting Arm
3 Hex. nut M 10 DIN 934 part no. 236 171.0 4 Washer 10.5 DIN 125, part no. 236 913.2 (Fig. 26) 35137 Disassembling the axial rotor supporting arm Remove the circlip and force the bearing out. (Fig. 27) 3.6.8 RHB LEXION 480 - 188 678.1...
Page 223: Supporting Arm, Disassembled
2. Press the pre-assembled ball journal (2) on the bearing pin, using the special tool. Rotate ball journal (2) by hand while pressing it on so it will not tilt. (Fig. 28, 29, 30) 3.6.9 188 678.1 - RHB LEXION 480...
Page 224 7. Install dust plate (B, Fig. 21). 8. Screw in all hex. bolts (6) and tighten to 270 Nm. (Fig. 28, 29, 32) 9. Insert washer (7) and tighten hex. bolt (8) to 78 Nm. (Fig. 28, 29, 33) 3.6.10 RHB LEXION 480 - 188 678.1...
Page 225: Removing The Axial Rotor
Open the assembly cover in the grain tank. Unscrew cover (D) from the supporting arm. (Fig. 35) Removing the separation grates , see page 3.6.1 (Do not remove the front separating grate.) Re-install the guide rail (F). (Fig. 36) 3.6.11 188 678.1 - RHB LEXION 480...
Page 226 Suspend the axial rotor safely, raise it slightly and pull it out halfway to the rear. CAUTION! At the front, the axial rotor must rest on the separating grate and pull the grate along. (Fig. 39, 40) 3.6.12 RHB LEXION 480 - 188 678.1...
Page 227: Installing The Axial Rotor
6. Installing the axial rotor gearbox , see page 7.15.20 7. Adjust the wear edge of the axial rotor so that the clearance to the supporting arm is 0.5 8. Grease axial rotor. 3.6.13 188 678.1 - RHB LEXION 480...
Page 228: Removing The Hybrid Unit Completely
(Fig. 46) Remove the right-hand side panel. To do this, remove the catch ropes and the gas struts. Push the panel out of the holder (L). Remove the side railings. (Fig. 47) 3.6.14 RHB LEXION 480 - 188 678.1...
Page 229 (R) and disconnect the cable plug. (Fig. 50) Disconnect the cable plug from the wind door switch (S) and the magnetic pick-up (G). Unscrew the cable clamps and remove cables. (Fig. 51) 3.6.15 188 678.1 - RHB LEXION 480...
Page 230 (K) downward through the post. (Fig. 53) Unscrew the side wall from the post on the right- and left-hand side. (Fig. 54) Remove the left and right side panels. (Fig. 55) 3.6.16 RHB LEXION 480 - 188 678.1...
Page 231 Unscrew the straw chopper cover. (Fig. 57) DANGER! Cover up the cutting cylinder – Danger of injury! Unscrew the guide plate. (Fig. 58) Unscrew the insulation plate (B) and the sensor plate (S). (Fig. 59) 3.6.17 188 678.1 - RHB LEXION 480...
Page 232 Disconnect the cable plugs. Remove the cable clamps completely and guide the cable plugs through the side wall. (Fig. 61) Remove the cross connection (Q). (Fig. 62) Remove the loss indicator sensors on both sides. (Fig. 63) 3.6.18 RHB LEXION 480 - 188 678.1...
Page 233 Slacken off the set collars and pull off the jockey pulley arm. (Fig. 65) Slacken off bolts of discharge housing and crane eyelets. Slacken off another two bolts from the platform on the right-hand side. (Fig. 66) 3.6.19 188 678.1 - RHB LEXION 480...
Page 234 Axial rotors Remove the hex. bolts (M) from the inlet head on the left- and right-hand machine side. (Fig. 67, 68) Safeguard the hybrid unit with a suitable lifting device. (Fig. 69) 3.6.20 RHB LEXION 480 - 188 678.1...
Page 235 CAUTION! The thrust piece falls down inside. (Fig. 70, 71) Pull out the hybrid unit to the rear. Ensure it is moved in parallel to the machine frame. (Fig. 72) 3.6.21 188 678.1 - RHB LEXION 480...
Page 236: Installing The Hybrid Unit
(Fig. 62) 9. Bolt down the discharge plate (A), cover plate, insulation plate (B) and sensor plate (S). Bolt down the guide plate. (Fig. 58–60) 3.6.22 RHB LEXION 480 - 188 678.1...
Page 237 15. Bolt on front roof plate. Screw in bolts on the crossmember. Install the side guards. (Fig. 46, 47) 16. Install and connect air filter housing. Install engine back wall. Install and tension the axial rotor drive belt (18). (Fig. 44, 45) 3.6.23 188 678.1 - RHB LEXION 480...
Page 238 Axial rotors 3.6.24 RHB LEXION 480 - 188 678.1...
Page 239: Cleaning Unit
Cleaning unit...
Page 241: Return Pan
(D and E). Slacken off hex. bolts (H) and fold rocker arm (E) on the sieve pan. Remove the work light (N). (Fig. 3) Remove the pins (M and A) on both sides. (Fig. 4) 4.1.1 188 678.1 - RHB LEXION 480...
Page 242: Raising And Installing The Return Pan (From Serial No
Tighten the hex. bolts (B) on both sides. Tightening torque M 10 = 45 Nm (Fig. 2) 4. Slide the rocker arms (D and E) on the pins (M and A) and bolt on loosely. (Fig. 3, 4) 4.1.2 RHB LEXION 480 - 188 678.1...
Page 243: Removing The Return Pan
Unscrew the screws (A) on both sides of the chopper preparation floor. Now fold down the preparation floor. (Fig. 8) Slacken off the screws (C) on both sides and remove the preparation floor. (Fig. 9) 4.1.3 188 678.1 - RHB LEXION 480...
Page 244 Unbolt the return pan at the front rocker arms (V). (Fig. 11) Unbolt the rear rocker arms (H) at the combine side panel. (Fig. 12) Lift the return pan out of the combine to the rear. (Fig. 13) 4.1.4 RHB LEXION 480 - 188 678.1...
Page 245: Rear Rocker Arm, Disassembled
3. Bolt the return pan to the front rocker arms. 4. Install the sieve pan light. 4.1.5 188 678.1 - RHB LEXION 480...
Page 246 Return pan 4.1.6 RHB LEXION 480 - 188 678.1...
Page 247: Sieve Pan
Slacken off the screws (C) on both sides and remove the preparation floor. (Fig. 3) Removing the upper sieves (from serial no..) Unscrew positioning motor at the ball head. Unscrew cable from electric motor. Swing electric motor backwards. (Fig. 4) 4.2.1 188 678.1 - RHB LEXION 480...
Page 248 (N). The sieves are fixed properly only if the collecting plates (A) are mounted on the end profile (N). The rakes (R1) may be unscrewed from the collecting plate (A). (Fig. 7, 8) 4.2.2 RHB LEXION 480 - 188 678.1...
Page 249: Removing The Lower Sieves (From Serial No
Completely remove the wind board (W) along with the positioning motor. For this, unscrew the hex. bolts (S). (Fig. 11) Loosen clamps (M) of the axial mounting of the sieves. Pull out the sieves to the rear. (Fig. 12) 4.2.3 188 678.1 - RHB LEXION 480...
Page 250: Installing The Sieves (From Serial No
Tightening torques of axial mountings for the upper and lower sieves (from serial no..) Upper sieves = 110 Nm (M 12 hex. bolts) Lower sieve = 23 Nm (M 10 hex. bolts) 4.2.4 RHB LEXION 480 - 188 678.1...
Page 251: Sieves - Basic Setting (Electric Sieve Adjustment - From Serial No
To check the frogmouth sieve openings use a gauge (CLAAS special tool, part no. 181 625.0) if necessary. With this gauge the lower sieves can be checked too. But the upper sieves must then be in the fully open position.
Page 252 If the wire rake was unscrewed, it has to be re-fitted prior to installing the fixing rail (N). Then fit the mounting rail with the mounted wire rake to the combine. (Fig. 18) 4.2.6 RHB LEXION 480 - 188 678.1...
Page 253: Removing The Lower Sieves (Up To Serial No
For this unscrew the ball head joints on the adjusting levers of the sieves. (Fig. 21) Unscrew the ball joint from the Bowden cable on the adjustment lever of the right-hand lower sieve. (Fig. 22) 4.2.7 188 678.1 - RHB LEXION 480...
Page 254: Installing The Sieves (Up To Serial No
NOTE: Ensure that all bolts are securely tightened! When sieve installation is complete, re-install the prep- aration floor and bolt it down. 4.2.8 RHB LEXION 480 - 188 678.1...
Page 255: Tightening Torques Of Axial Mountings For The Upper And Lower Sieves (Up To Serial No
To check the frogmouth sieve openings use a gauge (CLAAS special tool, part no. 181 625.0) if necessary. With this gauge the lower sieves can be checked too. But the upper sieves must then be in the fully open position.
Page 256: Removing The 3-D Upper Sieve Frame
(Fig. 28) Unscrew the control arm at the metal/rubber bearing and pull the complete assembly out to the side. (Fig. 29, 30) Unscrew the rear control arm and pull it off. (Fig. 31) 4.2.10 RHB LEXION 480 - 188 678.1...
Page 257 Drive out the stud from the inside to the outside. (Fig. 33) Unbolt the connecting rod at the main rocker arm. (Fig. 34) Unscrew the connecting rod and rocker arm and pull it off using a puller. (Fig. 35) 4.2.11 188 678.1 - RHB LEXION 480...
Page 258 Drive out the stud from the inside to the outside. (Fig. 37) On the left-hand side of the combine, disconnect the battery and remove it. (Fig. 38) Unhook the retaining strut (S) and remove the tool box. (Fig. 39) 4.2.12 RHB LEXION 480 - 188 678.1...
Page 259 Unscrew the connecting rod and rocker arm and pull it off using a puller. (Fig. 42) Loosen the clamping bolts (K) at the front and rear and drive out the studs from the inside. (Fig. 43) 4.2.13 188 678.1 - RHB LEXION 480...
Page 260 Remove the feed pan support on the left- and right-hand side. Slacken off the hex. bolts in the metal/rubber bearings. (Fig. 44) Lift the sieve pan frame out of the combine to the rear. (Fig. 45) 4.2.14 RHB LEXION 480 - 188 678.1...
Page 261 13 Hex. bolt M 10 x 25 DIN 933-8.8 Contact washer A 10 14 Hex. bolt M 10 x 65 DIN 933-10.9 Contact washer A 10 Hex. nut M 10 DIN 934 (Fig. 46) 4.2.15 188 678.1 - RHB LEXION 480...
Page 262: Installing The 3-D Upper Sieve Frame
8. Install the sensor tray. 9. Install the complete tool box assembly and connect the battery. 10. Install the upper sieves. 11. Adjusting the 3-D sieve pan control system , see page 4.4.1 4.2.16 RHB LEXION 480 - 188 678.1...
Page 263: Removing The Sieve Pan
Unscrew and pull off the connecting rods on left-hand and right-hand sides of the combine. (Fig. 51) Remove the hex. bolt from the main rocker arm at (A) on both sides. Unscrew bridge (B). (Fig. 52) 4.2.17 188 678.1 - RHB LEXION 480...
Page 264 2 Hex. bolt M 16 x 300 DIN 933-8.8, part no. 237 173.0 3 Hex. nut M 16 DIN 934-8 4 Axial grooved ball bearing, part no. 177 899.0 5 Puller shoe, part no. 181 836.0 (Fig. 56) 32382 4.2.18 RHB LEXION 480 - 188 678.1...
Page 265 Sieve pan Lift the sieve pan out of the combine to the rear. (Fig. 57) 4.2.19 188 678.1 - RHB LEXION 480...
Page 266 16 Hex. bolt M 10 x 25 DIN 933-8.8 Contact washer A 10 Hex. nut M 10 DIN 934-8 17 Hex. bolt M 16 x 50 DIN 933-8.8 Contact washer A 16 Clamping washer 18 Connecting rod 19 Metal/rubber bearing 4.2.20 RHB LEXION 480 - 188 678.1...
Page 267: Installing The Sieve Pan
237 375.0 2 Hex. nut M 16 DIN 934-8, part no. 236 173.0 3 Axial grooved ball bearing part no. 177 899.0 4 Puller shoe part no. 181 836.0 (Fig. 61) 32387 4.2.21 188 678.1 - RHB LEXION 480...
Page 268 If the sequence is not followed, the rubber bushings will be subjected to premature wear. (Fig. 58, 63) 4.2.22 RHB LEXION 480 - 188 678.1...
Page 269 Installing the return pan , see page 4.1.5 Adjusting the 3-D sieve pan control system , see page 4.4.1 11. Checking and adjusting the alignment of prepara- tion floor and sieve pan , see page 4.2.24 4.2.23 188 678.1 - RHB LEXION 480...
Page 270: Checking And Adjusting The Alignment Of Preparation Floor And Sieve Pan
The alignment must be so that there is equal clearance on both sides of the sieve pan. Tighten the hex. bolts of the bearing assembly. Tightening torque M 10 = 45 Nm (Fig. 67) 4.2.24 RHB LEXION 480 - 188 678.1...
Page 271: Preparation Floor
Unscrew the front rocker arms from the preparation floor and the machine frame on both sides. CAUTION! Observe the installation positions of the two rocker arms when removing and mark this position. The rocker arms are not symmetrical. (Fig. 4) 4.3.1 188 678.1 - RHB LEXION 480...
Page 272 (Fig. 5) Unscrew the journals from the preparation floor. (Fig. 6) Lift out the preparation floor to the rear using a suitable hoist. (Fig. 7) 4.3.2 RHB LEXION 480 - 188 678.1...
Page 273: Preparation Floor, Disassembled
Contact washer A 6 Hex. nut M 6 DIN 934 18 Hex. nut M 10 DIN 934 Contact washer A 10 19 Hex. bolt M 10 x 20 DIN 933-8.8 Contact washer A 10 4.3.3 188 678.1 - RHB LEXION 480...
Page 274: Installing The Preparation Floor
, see page 4.2.24 10. On both side of the combine, tighten the front rocker arms (8) on the preparation floor and on the machine frame to 45 Nm. (Fig. 10) 4.3.4 RHB LEXION 480 - 188 678.1...
Page 275: 3-D Sieve Pan Control System
CAUTION! Hold the pendulum housing in this position and switch off the engine (a second person is required for this). Now connect the pendulum housing again at (B). 4.4.1 188 678.1 - RHB LEXION 480...
Page 276: Adjusting Pivot Arm (A) With The "3-D Gauge
During adjustment, ensure that the pivot arm is makes contact with the 3-D gauge (D) and that the pendulum housing is not moved. After the adjustment, tighten all bolts. (Fig. 1, 2, 3) 4.4.2 RHB LEXION 480 - 188 678.1...
Page 277: Rocker Arm Drive
Loosen and pull off the bearing assembly. Pull out the intermediate drive shaft to the side. (Fig. 4) 4.5.1 188 678.1 - RHB LEXION 480...
Page 278: Intermediate Drive Shaft For Rocker Arm Drive, Disassembled
Hex. nut M 10 DIN 934-8 Contact washer A 10 10 Bearing assembly 11 Lock collar 30 12 Hex. bolt M 10 x 20 DIN 933-8.8 Contact washer A 10 13 Connecting rod (Fig. 5) 4.5.2 RHB LEXION 480 - 188 678.1...
Page 279: Installing The Intermediate Drive Shaft For The Rocker Arm Drive
The clearance (X) from the sidewall to the flange 32401 surface is 70.4 mm. 5. Bolt V-belt pulley (8) to the eccentric hub. The clearance (Z) is 85.5 mm. (Fig. 5, 6, 7) 32402 4.5.3 188 678.1 - RHB LEXION 480...
Page 280 Tightening torque: M 10 – 45 Nm M 16 – 195 Nm (Fig. 5, 8, 9) 10. Checking and adjusting the alignment of prepara- tion floor and sieve pan , see page 4.2.24 4.5.4 RHB LEXION 480 - 188 678.1...
Page 281: Cleaning Fan
3 Hex. nut M 12 DIN 934, part no. 236 172.0 4 Hex. bolt M 12 x 50 DIN 933-8.8, part no. 237 573.0 5 Threaded spindle, part no. 181 801.1 6 Centraliser with ball, part no. 181 849.0 (Fig. 3) 32407 4.6.1 188 678.1 - RHB LEXION 480...
Page 282 Using a block-ended tube of ∅ 50 x 4 x 300 (self-sourced), loosen the adapter sleeve of the bearing with a short, sharp blow. Then unscrew the slotted nut. (Fig. 6) Unscrew the bearing bracket and pull off the complete bearing. (Fig. 7) 4.6.2 RHB LEXION 480 - 188 678.1...
Page 283 Using a block-ended tube of ∅ 50 x 4 x 300 (self-sourced), loosen the adapter sleeve of the bearing with a short, sharp blow. Then unscrew the slotted nut. (Fig. 9) Unscrew the bearing bracket and pull off the complete bearing. (Fig. 10) 4.6.3 188 678.1 - RHB LEXION 480...
Page 284: Cleaning Fan Bearing, Disassembled
0.2 ± 0.1 mm. Connect the cable plug. 5. Installing and adjusting the fan drive belt (21) , see page 7.3.5 Installing and adjusting the fan variable-speed pulley assembly (spring-loaded) , see page 7.14.42 (Fig. 12) 4.6.4 RHB LEXION 480 - 188 678.1...
Page 285: Removing The Cleaning Fan Shaft
3 Hex. nut M 12 DIN 934, part no. 236 172.0 4 Hex. bolt M 12 x 50 DIN 933-8.8, part no. 237 573.0 5 Threaded spindle, part no. 181 801.1 6 Centraliser with ball, part no. 181 849.0 (Fig. 15) 32407 4.6.5 188 678.1 - RHB LEXION 480...
Page 286 Using a block-ended tube of ∅ 50 x 4 x 300 (self-sourced), loosen the adapter sleeve of the bearing with a short, sharp blow. Then unscrew the slotted nut. (Fig. 18) Unscrew end plate (A). (Fig. 19) 4.6.6 RHB LEXION 480 - 188 678.1...
Page 287 Make sure the centre bearing plate is held steady with a heavy object (hammer [H] or similar) at the same time. (Fig. 22) Loosen clamping bolt (K) and spread slightly using a chisel. (Fig. 23) 4.6.7 188 678.1 - RHB LEXION 480...
Page 288 (Fig. 26) Using a block-ended tube of ∅ 50 x 4 x 300 (self-sourced), loosen the adapter sleeve of the bearing with a short, sharp blow. Pull the bearing from the shaft. (Fig. 27) 4.6.8 RHB LEXION 480 - 188 678.1...
Page 289: Removing The Centre Cleaning Fan Bearing
5 Adapter sleeve bearing 6 Circlip 7 Face-end slotted nut M 40 x 1.5 8 Hex. bolt M 12 x 25 DIN 933-8.8 Hex. nut M 12 DIN 934 Contact washer A 12 (Fig. 30) 4.6.9 188 678.1 - RHB LEXION 480...
Page 290: Installing The Cleaning Fan Shaft
20 Nm, then turn further until the tab of the tab washer is aligned with a slot in the slotted nut. Turn the slotted nut by a further 62°, then lock with the tab washer. (Fig. 33) 4.6.10 RHB LEXION 480 - 188 678.1...
Page 291: Removing The Cleaning Fan Rotors
Unscrew cover (D) of the fan housing and remove the rotors from below. (Fig. 34) Installing the cleaning fan rotors Lift the cleaning fan rotors into the combine from below and bolt on cover (D). Install the cleaning fan shaft. (Fig. 34) 4.6.11 188 678.1 - RHB LEXION 480...
Page 292: Removing The Cleaning Fan Housing
Loosen the set collar and pull off the bearing. (Fig. 36) Unscrew and remove the V-belt pulley from the eccentric hub. (Fig. 37) Unscrew and remove control shutters (D) in the cleaning fan housing. (Fig. 38) 4.6.12 RHB LEXION 480 - 188 678.1...
Page 293 Loosen the set collars on the shaft. Pull out the shaft to the left-hand side of the combine. (Fig. 39, 40) Unscrew the cleaning fan housing at (A) and remove from below. (Fig. 41) 4.6.13 188 678.1 - RHB LEXION 480...
Page 294: Installing The Cleaning Fan Housing
Tightening torque: M 10 – 45 Nm M 16 – 195 Nm (Fig. 43, 44) Install the cleaning fan rotors. Install the cleaning fan shaft. 4.6.14 RHB LEXION 480 - 188 678.1...
Page 295: Grain Delivery
Grain delivery...
Page 297: Returns Elevator
1. Loosen the hex. nuts (H). 2. Loosen the hex. bolts (G). 3. Loosen the block tensioner (S). 4. Release the tension from the chain, by unscrewing the hex. bolt (M). (Fig. 3) 5.1.1 188 678.1 - RHB LEXION 480...
Page 298 Returns elevator Separate the chain at the chain connector. (Fig. 4) Unscrew the returns elevator cover (D). (Fig. 5) Unscrew the gas strut and the door. (Fig. 6, 7) 5.1.2 RHB LEXION 480 - 188 678.1...
Page 299: Installing The Returns Elevator Chain
5. Bolt down the cover (D). (Fig. 5) 6. Fit the door and the gas strut. (Fig. 6, 7) Removing the top returns auger Remove the block tensioner (S) and remove the drive chain. (Fig. 9) 5.1.3 188 678.1 - RHB LEXION 480...
Page 300 Disconnect the cable from the magnetic pick-up. Unscrew the screw plug. Unscrew the flange ball bearing on the right-hand side. (Fig. 12) Turn the returns auger out of the machine through the assembly slot. (Fig. 13) 5.1.4 RHB LEXION 480 - 188 678.1...
Page 301: Installing The Top Returns Auger
1 ± 0.5 mm. Connect the cable. 8. Refit the cover at the top of the returns elevator and the drum inspection cover. 5.1.5 188 678.1 - RHB LEXION 480...
Page 302: Removing The Returns Elevator
2. Loosen the hex. bolts (G). 3. Loosen the block tensioner (S). 4. Release the tension from the chain, by unscrewing the hex. bolt (M). (Fig. 18) Separate the chain at the chain connector. (Fig. 19) 5.1.6 RHB LEXION 480 - 188 678.1...
Page 303: Disassembling The Returns Elevator
Remove the returns elevator. (Fig. 22) Disassembling the returns elevator Remove the returns elevator. Unscrew the flange ball bearing on the left-hand side. Loosen the lock collar and pull off the bearing. (Fig. 23) 5.1.7 188 678.1 - RHB LEXION 480...
Page 304 Pull out the shaft to the right-hand side. (Fig. 25) Drive the expansion pin out of the sprocket, then pull sprocket from the shaft. Pull off the flange bearing. (Fig. 26) 5.1.8 RHB LEXION 480 - 188 678.1...
Page 305: Assembling The Returns Elevator
Re-tension the drive chain with the block tensioner (S). Re-tighten the clamping bolts (G) and nuts (H). (Fig. 18) 6. Close inspection door (A) and bolt down guard (C). (Fig. 16, 17) 5.1.9 188 678.1 - RHB LEXION 480...
Page 306: Removing The Returns Elevator Boot
6 Puller bridge, part no. 181 800.0 7 Washer ∅ 17 DIN 125 8 Hex. bolt M 16 x 50 DIN 933-8.8, part no. 235 586.0 9 Threaded spindle, part no. 181 801.1 32763 (Fig. 30) 5.1.10 RHB LEXION 480 - 188 678.1...
Page 307: Installing The Returns Elevator Boot
Remove belt (15). For this loosen clamping bolt (A) on the jockey pulley. Relieve the tension in compression spring (D) with nuts (K and E). Turn the elevator chain until the chain connector is at the bottom. (Fig. 33) 32397 5.1.11 188 678.1 - RHB LEXION 480...
Page 308 Thoroughly clean the returns auger shaft in the elevator boot. (Fig. 35) Remove the cap. Unlock the lock collar and knock it off. (Fig. 36) Remove the cover plate (V) on the left-hand side of the machine. (Fig. 37) 5.1.12 RHB LEXION 480 - 188 678.1...
Page 309: Installing The Lower Returns Auger
(2), the parallel key (3), the sprocket (4) and the outer set collar (2) in the elevator boot at the same time. (Fig. 40, 41) 5.1.13 188 678.1 - RHB LEXION 480...
Page 310 (S). Re-tighten the clamping bolts (G) and nuts (H). (Fig. 34) 8. Close inspection door (A) and bolt down guard (C). (Fig. 31, 32) 9. Refit the cover plate (V). (Fig. 37) 5.1.14 RHB LEXION 480 - 188 678.1...
Page 311: Grain Elevator
Release the tension from the chain. To release the tension, loosen the lock nut (G) and then release the chain tension on the nut (M). (Fig. 3) Separate the chain at the chain connector. (Fig. 4) 5.2.1 188 678.1 - RHB LEXION 480...
Page 312: Installing The Clean Grain Elevator Chain
Secure the adjustment with the lock nut (G). (Fig. 3) 4. Close inspection door (B) and bolt down guard (C). (Fig. 1, 2) 5. Bolt down cover plates (A and B). (Fig. 5) 5.2.2 RHB LEXION 480 - 188 678.1...
Page 313: Removing The Clean Grain Elevator Head
(K) and remove chain. (Fig. 7) Remove the chain adjusting straps (L) from their mounting plate. (Fig. 8) Unbolt the elevator head from the main housing and remove by lifting it off. (Fig. 9) 5.2.3 188 678.1 - RHB LEXION 480...
Page 314: Dismantling The Clean Grain Elevator Head
(Fig. 10, 11) Unlock the lock collars on both sides and knock them off against the direction of rotation. Remove the lock collars. (Fig. 12) Unscrew and pull off the flange ball bearing. (Fig. 13) 5.2.4 RHB LEXION 480 - 188 678.1...
Page 315 Loosen the two set collars on either side of the sprocket. Slide the sprocket to the side and remove the parallel key. Remove the shaft out of the side of the housing. (Fig. 14) 5.2.5 188 678.1 - RHB LEXION 480...
Page 316: Clean Grain Elevator Head, Disassembled
17 Circlip 20 x 1.2 DIN 471 18 Jockey pinion 19 Washer 20 Circlip 20 x 1.2 DIN 471 21 Sprocket 22 Expansion pin 8 x 40 B DIN 8752 Expansion pin 5 x 40 B DIN 8752 5.2.6 RHB LEXION 480 - 188 678.1...
Page 317: Assembling And Installing The Clean Grain Elevator Head
(Fig. 7–15) Removing the clean grain elevator shaft Remove the grain elevator chain. Remove the grain elevator head. Remove the cable brackets from the grain elevator. (Fig. 16) Remove the supporting brace. (Fig. 17) 5.2.7 188 678.1 - RHB LEXION 480...
Page 318: Installing The Grain Elevator Shaft
3. Refit the fuel pre-filter and fuel pump. 4. Bolt down the supporting brace and the cable bracket. 5. Install the grain elevator head. Install the grain elevator chain. (Fig. 15, 16, 17, 18, 19) 5.2.8 RHB LEXION 480 - 188 678.1...
Page 319: Removing The Clean Grain Elevator Boot
6 Puller bridge, part no. 181 800.0 7 Washer ∅ 17 DIN 125 8 Hex. bolt M 16 x 50 DIN 933-8.8, part no. 235 586.0 9 Threaded spindle, part no. 181 801.1 32763 (Fig. 24) 5.2.9 188 678.1 - RHB LEXION 480...
Page 320: Installing The Clean Grain Elevator Boot
Mount the returns elevator. (Fig. 21, 22, 23, 24) Removing the clean grain auger If fitted, remove the guard (C). Open the inspection door (B) on the clean grain elevator and then remove. (Fig. 25, 26) 5.2.10 RHB LEXION 480 - 188 678.1...
Page 321 Loosen the set collars next to the sprocket. Thoroughly clean the grain auger shaft in the elevator boot. (Fig. 29) Remove the cap. Unlock the lock collar and knock it off. (Fig. 30) 5.2.11 188 678.1 - RHB LEXION 480...
Page 322 This will drive off the sprocket and the set collars in the elevator boot from the shaft on the right-hand side. To make this job easier, temporarily fix the V-belt pulley and the key on the shaft. (Fig. 34) 5.2.12 RHB LEXION 480 - 188 678.1...
Page 323: Installing The Clean Grain Auger
It must be possible to push the conveyor chain to the side manually at the bottom chain wheel. Secure the adjustment with the lock nut (G). (Fig. 28) 5.2.13 188 678.1 - RHB LEXION 480...
Page 324: Removing The Grain Tank Filler Auger
Removing the grain tank filler auger Open the grain tank. Unscrew the filling tube from the flange joiner. (Fig. 37) Unscrew the cover plates (A and B). (Fig. 38) Unscrew the pivot control rod. (Fig. 39) 5.2.14 RHB LEXION 480 - 188 678.1...
Page 325: Removing The Grain Tank Filler Auger Angle Drive
Release the tension of the grain tank filler auger drive chain (K) and remove chain. Disconnect the cable from the magnetic pick-up. Drive out the double expansion pins, then remove sprocket. Unscrew the bearing plate. (Fig. 43) 5.2.15 188 678.1 - RHB LEXION 480...
Page 326: Disassembling The Grain Tank Filler Auger Angle Drive
Remove the sprocket, using a suitable puller. (Fig. 45) Remove the hex. bolt and then drive out the shaft. (Fig. 46) Using a suitable brass punch, drive out the bevel gear. (Fig. 47) 5.2.16 RHB LEXION 480 - 188 678.1...
Page 327: Grain Tank Filler Auger, Disassembled
14 Hex. bolt M 8 x 20 DIN 933-10.9 MK Washer 15 Housing 16 Shaft 17 Circlip 30 x 1.5 DIN 471 18 Deep-groove ball bearing 6006-2 RS 19 Circlip 55 x 2 DIN 472 20 Deep-groove ball bearing 6208-2 RS 5.2.17 188 678.1 - RHB LEXION 480...
Page 328: Installing The Grain Tank Filler Auger
Bolt down hex. bolt M 10 x 25 DIN 933-10.9 with a tightening torque of 63 Nm. Up to serial no. …: Bolt down hex. bolt M 8 x 20 DIN 933-10.9 with a tightening torque of 33 Nm. (Fig. 48, 49, 50) 5.2.18 RHB LEXION 480 - 188 678.1...
Page 329 (Fig. 48, 49, 53) 11. Bolt down the pivot control rod. (Fig. 39) 12. Bolt down the cover plates (A and B). (Fig. 38) 13. Bolt on the filler tube at the flange joiner. (Fig. 37) 5.2.19 188 678.1 - RHB LEXION 480...
Page 330 14. Slide the sprocket on the shaft and secure with the double expansion pin. Install chain (K) back and tension it. Bolt on the magnetic pick-up and adjust it. Clearance1 ± 0.5 mm. (Fig. 55) 15. Grease the angle drive. 5.2.20 RHB LEXION 480 - 188 678.1...
Page 331: Grain Tank Unloading
– see page 7.2.34, Removing the grain tank unloading drive chain (17) . Measure the clearance between shaft end and sprocket. (Fig. 3) From serial no. …: Remove gib head key using a key extractor. (Fig. 4) 5.3.1 188 678.1 - RHB LEXION 480...
Page 332 Remove the circlip from the sprocket. Pull off sprocket. (Fig. 6) Unscrew the hex. bolts from the bearing plate. (Fig. 7) Turn out the grain tank cross auger on the left-hand side of the combine. (Fig. 8) 5.3.2 RHB LEXION 480 - 188 678.1...
Page 333 Grain tank unloading Remove the circlip from the shaft. Unlock the lock collar and knock it off. Unscrew and pull off the flange ball bearing. (Fig. 9) 5.3.3 188 678.1 - RHB LEXION 480...
Page 334: Grain Tank Cross Augers, Disassembled
11 Lock collar 12 Hex. bolt M 12 x 30 DIN 933-8.8 Contact washer A 12 Washer 13 Graduation plates 14 Hex. bolt M 8 x 16 DIN 933-8.8 Contact washer A 12 (Fig. 10) 5.3.4 RHB LEXION 480 - 188 678.1...
Page 335: Installing The Grain Tank Cross Auger
(7, 8 and 9). (Fig. 10, 12) 3. Refit the bolt (12 or 6) on the right-hand side. (Fig. 10, 13) 4. Tap the lock collar (11) tight and secure. (Fig. 10, 14) 5.3.5 188 678.1 - RHB LEXION 480...
Page 336 6 o'clock position. The start (A) of the rear cross auger (H) must be in the 12 o'clock position. F = Direction of travel (Fig. 17, 18) 32832 From serial no. … 34709 5.3.6 RHB LEXION 480 - 188 678.1...
Page 337: Removing The Vertical Grain Tank Unloading Auger
– see page 7.2.34, Removing the grain tank unloading drive chain (17) . Measure the clearance between shaft end and sprocket. (Fig. 21) From serial no. …: Remove gib head key using a key extractor. (Fig. 22) 5.3.7 188 678.1 - RHB LEXION 480...
Page 338 To prevent the auger from dropping out unexpectedly, rotate the auger so that the flight end is not near the gap (S). (Fig. 25) From serial no. …: Unscrew the lower angle drive and remove it. (Fig. 26) 5.3.8 RHB LEXION 480 - 188 678.1...
Page 339 To prevent the auger from dropping out unexpectedly, rotate the auger so that the flight end is not near the gap (S). (Fig. 29) Up to serial no. …: Unscrew the lower angle drive and remove it. (Fig. 30) 5.3.9 188 678.1 - RHB LEXION 480...
Page 340: Installing The Vertical Grain Tank Unloading Auger
4. From serial no. …: Slide on sprocket and align it to the measured dimension, then secure gib head key. (Fig. 32) Up to serial no. …: Slide on shims and sprocket. Insert circlip. (Fig. 16) 5.3.10 RHB LEXION 480 - 188 678.1...
Page 341: Removing The Horizontal Grain Tank Unloading Auger
Remove the outlet spout (90°) and the cover. (Fig. 35) If a 35° outlet spout is fitted: Unscrew the outlet spout (35°). Loosen the lock collar (S) and pull bearing (L) off the shaft completely. (Fig. 36) 5.3.11 188 678.1 - RHB LEXION 480...
Page 342 Grain tank unloading Pull the horizontal grain tank unloading auger out towards the back of the machine. (Fig. 37, 38) 5.3.12 RHB LEXION 480 - 188 678.1...
Page 343: Installing The Horizontal Grain Tank Unloading Auger
Release the tension of the grain tank unloading drive chain and remove chain – see page 7.2.34, Removing the grain tank unloading drive chain (17) . Measure the clearance between shaft end and sprocket. (Fig. 40) 5.3.13 188 678.1 - RHB LEXION 480...
Page 344 Unscrew the grease pipe (P) and the cover (D). (Fig. 43) To prevent the auger from dropping out unexpectedly, rotate the auger so that the flight end is not near the gap (S). (Fig. 44) 5.3.14 RHB LEXION 480 - 188 678.1...
Page 345: Disassembling The Lower Grain Tank Unloading Angle Drive (From Serial No
(Fig. 47) Special tool: 1 Tie rod 450 mm, part no. 181 605.0 2 Striking tool, part no. 181 604.0 3 Adapter section M 10, part no. 181 609.0 (Fig. 48) 35227 5.3.15 188 678.1 - RHB LEXION 480...
Page 346 1 Tie rod 450 mm, part no. 181 605.0 2 Striking tool, part no. 181 604.0 3 Adapter section M 10, part no. 181 609.0 (Fig. 51) 35227 Drive out the cap using a soft metal punch. (Fig. 52) 5.3.16 RHB LEXION 480 - 188 678.1...
Page 347 Pull off both deep groove ball bearing with a puller. (Fig. 54) Force out the drive pin using a hydraulic press. (Fig. 55) Remove the bearing seal ring and the circlip. Pull off the deep groove ball bearing. (Fig. 56) 5.3.17 188 678.1 - RHB LEXION 480...
Page 348: Lower Grain Tank Unloading Angle Drive, Disassembled (From Serial No
6 Bearing seal ring 7 Shim 8 Circlip 9 Drive pin 10 Shaft 11 Bevel gear 12 Bushing 13 Washer 14 Hex. bolt M 10 x 30 MK DIN 933-10.9 15 Cap (Fig. 57) 5.3.18 RHB LEXION 480 - 188 678.1...
Page 349: Assembling The Lower Grain Tank Unloading Angle Drive (From Serial No
(5) to approx. 100 °C, then press it on the shaft (10). 4. Insert the number of shims (7) of corresponding thickness found when disassembling into the housing (1) along with the circlip (8). (Fig. 57, 58, 59) 5.3.19 188 678.1 - RHB LEXION 480...
Page 350 (Fig. 57, 58, 62) 8. Insert the bearing seal ring (6), the number of shims (7) of corresponding thickness found when disassembling and the circlip (8). (Fig. 57, 58, 63) 5.3.20 RHB LEXION 480 - 188 678.1...
Page 351 (Fig. 66) 12. Fill space (A and B) with grease, e.g. Shell Alvania R3, part no. 413 981.0. A = 100 g B = 800 g 13. Drive in cap (15). (Fig. 58, 67) 5.3.21 188 678.1 - RHB LEXION 480...
Page 352: Installing The Lower Grain Tank Unloading Angle Drive (From Serial No
(Fig. 68) 2. Refit the grease pipes (P) and the cover (D). (Fig. 69) 3. Slide on sprocket and align it to the measured dimension, then secure gib head key. (Fig. 70) 5.3.22 RHB LEXION 480 - 188 678.1...
Page 353: Removing The Lower Grain Tank Unloading Angle Drive (Up To Serial No
Removing the grain tank unloading drive chain (17) , see page 7.2.34 Remove the circlip and then pull off the sprocket. (Fig. 72) Unscrew the grease pipes and the cover (D). (Fig. 73) 5.3.23 188 678.1 - RHB LEXION 480...
Page 354: (Up To Serial No
Disassembling the lower grain tank unloading angle drive (up to serial no..) Remove the lower grain tank unloading angle drive. Drive out the drive pin. (Fig. 76) Unscrew the gearbox cover. (Fig. 77) 5.3.24 RHB LEXION 480 - 188 678.1...
Page 355 8 Hex. nut M 10, part no. 236 171.0 9 Hex. bolt M 10 x 180 DIN 933-8.8 part no. 237 796.0 32845 (Fig. 80) Pull off the deep groove ball bearing and remove the circlips. (Fig. 81) 5.3.25 188 678.1 - RHB LEXION 480...
Page 356 5 Hex. nut with flange, part no. 244 059.0 6 Hex. bolt M 16 x 300, part no. 237 375.1 (Fig. 84) 32849 Pull off the deep groove ball bearing and remove the circlips. (Fig. 85) 5.3.26 RHB LEXION 480 - 188 678.1...
Page 357 7 Shim 1 mm; 0.5 mm; 0.3 mm; 0.1 mm 8 Circlip 100 x 3 DIN 472 9 Bevel gear 10 Gearbox cover 11 Hex. bolt M 10 x 20 DIN 933-8.8 Contact washer A 10 12 Drive pin (Fig. 86) 5.3.27 188 678.1 - RHB LEXION 480...
Page 358 4 Washer ∅ 10.5, part no. 236 913.2 5 Hex. nut M 10 DIN 934, part no. 236 171.0 6 Hex. bolt M 10 x 180 DIN 933 part no. 237 796.0 (Fig. 89 32854 5.3.28 RHB LEXION 480 - 188 678.1...
Page 359 The torsional backlash is 0.2 – 0.3 mm. Adjust the torsional backlash using shims (7). (Fig. 86, 87, 92) 5.3.29 188 678.1 - RHB LEXION 480...
Page 360 Fill in approx. 150 g of grease all around at (G), e.g. Alvania R 3. (Fig. 87, 94) 10. Insert drive pin (12) so that it is centred to the bevel gear. (Fig. 86) 11. Install the lower angle drive. 5.3.30 RHB LEXION 480 - 188 678.1...
Page 361: Installing The Lower Grain Tank Unloading Angle Drive (Up To Serial No
The start (A) of the rear cross auger (H) must be in the 12 o'clock position. F = Direction of travel (Fig. 97) 32832 5. Installing and adjusting the grain tank unloading drive chain (17) , see page 7.2.35 5.3.31 188 678.1 - RHB LEXION 480...
Page 362: Removing The Upper Grain Tank Unloading Angle Drive
(Fig. 99) Unscrew the bolts at the front around the flange, then remove the tube. (Fig. 100) Remove the grease pipes. Unscrew the angle drive and remove it. (Fig. 101) 5.3.32 RHB LEXION 480 - 188 678.1...
Page 363: Disassembling The Upper Grain Tank Unloading Angle Drive
5 Hex. nut with flange, part no. 244 059.0 6 Hex. bolt M 16 x 300, part no. 237 375.1 (Fig. 104) 32849 Pull off the deep groove ball bearing and remove the circlips. (Fig. 105) 5.3.33 188 678.1 - RHB LEXION 480...
Page 364 8 Circlip 90 x 3 DIN 472 9 Drive pin 10 Hex. bolt M 12 x 25 DIN 933-8.8 Contact washer A 12 11 Hex. bolt M 12 x 20 DIN 933-8.8 Contact washer A 12 (Fig. 106) 5.3.34 RHB LEXION 480 - 188 678.1...
Page 365: Assembling The Upper Grain Tank Unloading Angle Drive
4 Washer ∅ 10.5, part no. 236 913.2 5 Hex. nut M 10 DIN 934, part no. 236 171.0 6 Hex. bolt M 10 x 180 DIN 933 part no. 237 796.0 (Fig. 109) 32854 5.3.35 188 678.1 - RHB LEXION 480...
Page 366 5. Remove the bevel gear (2) and have a look at the profile left in the Engineers blue. Correct the profile using shims (7). Example: A = Initial setting B = Required correction C = Correct setting (Fig. 106, 112) 5.3.36 RHB LEXION 480 - 188 678.1...
Page 367 (Fig. 106, 107, 113) 8. Insert drive pin (9) so that it is centred to the bevel gear. 9. Install the upper grain tank unloading angle drive. Refit the grain tank unloading tube. 5.3.37 188 678.1 - RHB LEXION 480...
Page 368: Installing The Upper Grain Tank Unloading Angle Drive
4. Unlock the lock collar in the unloading tube and knock it off. Up to serial no. … (Fig. 115, 116) 5. Bolt the unloading tube back onto the flange. (Fig. 117) 5.3.38 RHB LEXION 480 - 188 678.1...
Page 369: Removing The Grain Tank Unloading Tube
(Fig. 119) Unscrew the bolts at the front around the flange, then remove the tube. Removing the horizontal grain tank unloading auger , see page 5.3.11 (Fig. 120) 5.3.39 188 678.1 - RHB LEXION 480...
Page 370: Refitting The Unloading Auger Tube
Removing the upper grain tank unloading angle drive , see page 5.3.32 Remove the hydraulic cylinder. (Fig. 121) Remove the bearing plate. (Fig. 122) Unscrew the elbow from the flange and remove it. (Fig. 123) 5.3.40 RHB LEXION 480 - 188 678.1...
Page 371: Installing The Grain Tank Unloading Tube Elbow
5.3.7 Remove the grain tank unloading tube elbow. Remove the grease pipes and the cable clamps. (Fig. 124) Remove the swivel support plate. (Fig. 125) Remove the vertical unloading auger tube. (Fig. 126) 5.3.41 188 678.1 - RHB LEXION 480...
Page 372: Installing The Vertical Unloading Auger Tube
2. Bolt down the second swivel support plate. (Fig. 125) 3. Refit the grease pipes and the cable clamps. (Fig. 124) 4. Install the elbow section. 5. Installing the vertical grain tank unloading auger , see page 5.3.10 5.3.42 RHB LEXION 480 - 188 678.1...
Page 373: Straw Discharge
Straw discharge...
Page 375: Straw Chopper
Remove the hex. bolt from the face end of the shaft. (Fig. 2) Using a suitable puller, pull off the cam wheel. (Fig. 3) Unbolt the bearing housing from the machine side wall. (Fig. 4) 6.1.1 188 678.1 - RHB LEXION 480...
Page 376 233 011.0 4 Washer 13 (Fig. 6) 31491 Drive the self-aligning ball bearing out of the bearing housing using a tube ∅ 35 x ∅ 50 x 200 long. (Fig. 7) 6.1.2 RHB LEXION 480 - 188 678.1...
Page 377: Right-Hand Straw Chopper Bearing Assembly, Disassembled
M 12 x 180, part no. 236 302.0. (Fig. 9) 2. Press the self-aligning ball bearing (3) into the bearing housing (2), using the special tool. (Fig. 8, 10) 6.1.3 188 678.1 - RHB LEXION 480...
Page 378 Place washer (6) in position, then insert the hex. bolt (7). Tightening torque = 180 Nm (Fig. 8, 13) 7. Bolt the cover (8) into position. (Fig. 8, 14) 8. Grease the bearing. 6.1.4 RHB LEXION 480 - 188 678.1...
Page 379: Removing The Left-Hand Straw Chopper Bearing
233 011.0 4 Washer 13 (Fig. 17) 31491 Drive the self-aligning ball bearing out of the bearing housing using a tube ∅ 35 x ∅ 50 x 200 long. (Fig. 18) 6.1.5 188 678.1 - RHB LEXION 480...
Page 380: Left-Hand Straw Chopper Bearing Assembly, Disassembled
2 Locating disc, part no. 181 879.0 3 Axial grooved ball bearing, part no. 235 983.0 4 Hex. nut M 16 DIN 934 5 Hex. bolt M 16 x 300 DIN 933, part no. 237 375.1 (Fig. 22) 31384 6.1.6 RHB LEXION 480 - 188 678.1...
Page 381: Removing The Cutting Cylinder
Removing the right-hand straw chopper bearing , see page 6.1.1 Removing the left-hand straw chopper bearing , see page 6.1.5 Place valve combination part no. 181 619.0 on the hydraulic tank for creating a vacuum inside the tank. (Fig. 24) 6.1.7 188 678.1 - RHB LEXION 480...
Page 382 Disconnect the cable plug from the 4/3 way valve. Unscrew the cable clamps up to the machine housing. (Fig. 27) Disconnect the cable plug (P) from the magnetic pick-up and the potentiometer. Remove the cable clamps. (Fig. 28) 6.1.8 RHB LEXION 480 - 188 678.1...
Page 383 (Fig. 30) Lower the uni-spreader remove it to the rear. (Fig. 31) Remove the hydraulic cylinders on the left-hand and right-hand side panels of the combine and remove side panels. (Fig. 32) 6.1.9 188 678.1 - RHB LEXION 480...
Page 384 Straw chopper Suspend the cutting cylinder safely in a suitable lifting device. Remove the reinforcements on the left- and right-hand side. Remove the cutting cylinder towards the bottom. (Fig. 33) 6.1.10 RHB LEXION 480 - 188 678.1...
Page 385: Cutting Cylinder, Disassembled
10 Bushing ∅ 30 x 14.25 11 Bushing ∅ 48 x 10 x 8.5 12 Lock nut VM 10 DIN 980-10 F = Direction of travel G = Grain M = Maize (Fig. 34) 6.1.11 188 678.1 - RHB LEXION 480...
Page 386: Installing The Cutting Cylinder
9. Connect and lay the hydraulic hoses. (Fig. 25, 26) 10. Remove the stage 3 chopper drive V-belt pulley – see page 7.10.18, Assembling and installing the stage 3 chopper drive V-belt pulley . 6.1.12 RHB LEXION 480 - 188 678.1...
Page 387: Replacing The Free-Swinging Knives
To do this, swing the straw guide plate to the front and unbolt the nuts (M). Remove the straw guide plate (L). Unscrew all free-swinging knives from the cutting cylinder. (Fig. 35, 36) 6.1.13 188 678.1 - RHB LEXION 480...
Page 388 4 Hex. bolt M 12 x 65 DIN 931-10.9 5 Bushing ∅ 35 x 16 6 Washer ∅ 35 x 7.5 7 Lock nut VM 12 DIN 980-10 H Mounting plate F Direction of travel (Fig. 37) 6.1.14 RHB LEXION 480 - 188 678.1...
Page 389 11 Bushing ∅ 48 x 10 x 8.5 12 Lock nut VM 10 DIN 980-10 H Mounting plate F Direction of travel (Fig. 38) Insert the straw guide plate (L) and bolt down with nuts (M). (Fig. 35, 36) 6.1.15 188 678.1 - RHB LEXION 480...
Page 390 Straw chopper 6.1.16 RHB LEXION 480 - 188 678.1...
Page 391: Uni-Spreader
Remove the hydraulic hoses and seal the connections tightly with plastic caps. (Fig. 2) Remove the hose clamps. (Fig. 3) Disconnect the cable plug from the 4/3 way valve. Unscrew the cable clamps up to the machine housing. (Fig. 4) 6.2.1 188 678.1 - RHB LEXION 480...
Page 392 Make sure the uni-spreader is securely supported. Remove the left and right side panels. Remove the jockey pulley arm completely with the jockey pulley. (Fig. 7) Lower the uni-spreader remove it to the rear. (Fig. 8) 6.2.2 RHB LEXION 480 - 188 678.1...
Page 393 Uni-spreader Unscrew the 4/3 way valve from the feed hopper. (Fig. 9) Remove the feed hopper. (Fig. 10) Unbolt the scraper. (Fig. 11) Remove the hex. bolt from the fan blade. (Fig. 12) 6.2.3 188 678.1 - RHB LEXION 480...
Page 394 (Fig. 15) Using a suitable block-ended tube, apply a good sharp knock in order to release the tapered ring in the V-belt pulley. The block-ended tube must fit over the tapered ring. (Fig. 16) 6.2.4 RHB LEXION 480 - 188 678.1...
Page 395 Unscrew hex. socket head bolt and push out the hydraulic cylinder. (Fig. 18) Unbolt the hex. nuts and remove fan housing. (Fig. 19) Unscrew the lubricating line and remove the housing from the flange. (Fig. 20) 6.2.5 188 678.1 - RHB LEXION 480...
Page 396 16 Countersunk head bolt M 8 x 25 DIN 7991-8.8 Hex. nut M 8 DIN 934 Contact washer A 8 17 Hex. nut M 8 DIN 934 Contact washer A 8 (Fig. 23) 6.2.6 RHB LEXION 480 - 188 678.1...
Page 397 Uni-spreader 6.2.7 188 678.1 - RHB LEXION 480...
Page 398: Assembling And Installing The Fan Blade Bearing
(3) into the housing (2). 3. Pre-assemble the housing (8) with deep groove ball bearing (7) and circlip (6). 4. Press together housing (2) and housing (8) with special tool. (Fig. 23, 24, 25) 6.2.8 RHB LEXION 480 - 188 678.1...
Page 399 6. Drive shaft (1) in with a plastic-tip hammer. (Fig. 23, 24, 27) 7. Screw the pre-assembled housing to the flange. Attach the lubrication line. (Fig. 20) 8. Bolt the fan housing to the frame. (Fig. 19) 6.2.9 188 678.1 - RHB LEXION 480...
Page 400 78 Nm. Bolt down the scraper. (Fig. 11, 29) 11. Slide on tapered ring and V-belt pulley. Install the front tapered ring and tighten the taper ring fastener to 78 Nm. (Fig. 30) 6.2.10 RHB LEXION 480 - 188 678.1...
Page 401 17. Connect and lay the hydraulic hoses. (Fig. 2, 3) 18. Installing and adjusting the uni-spreader drive belt (16) , see page 7.2.33 Installing and adjusting the uni-spreader interme- diate drive belt (12) , see page 7.2.24 6.2.11 188 678.1 - RHB LEXION 480...
Page 402 Uni-spreader 6.2.12 RHB LEXION 480 - 188 678.1...
Page 403: Drives
Drives...
Page 405: Drive Belts
CAUTION! If the pulley halves are difficult to move, use two bolts. If possible, always open the variable- speed pulleys with the drives still running and then switch off the engine and drives. 7.1.1 188 678.1 - RHB LEXION 480...
Page 406: Drive Diagram
13 Drive of sieve pan intermediate drive 14 Drive of sieve pan intermediate drive 15 Sieve pan drive 16 Uni-spreader drive 17 Grain tank unloading auger drive 34 Suction blower drive (feed rake conveyor) 36 Straw spreader drive 7.1.2 RHB LEXION 480 - 188 678.1...
Page 407: Drive System Diagram, Right-Hand Side
25 Rotary chaff screen intermediate drive 26 Rotary radiator screen drive 27 Fan drive 28 Rotary chaff screen suction drive 29 Air conditioning compressor drive 30 Compressed air compressor drive 31 Alternator drive 7.1.3 188 678.1 - RHB LEXION 480...
Page 408 Drive diagram 7.1.4 RHB LEXION 480 - 188 678.1...
Page 409: Left-Hand Drive Belts
Relieving the tension of cutterbar drive (1): (Pull-type cylinder) DANGER! Pay particular attention while unscrewing the spring guide tube (R). Do not unscrew the spring guide tube too far – Danger of injury! 7.2.1 188 678.1 - RHB LEXION 480...
Page 410: Installing And Adjusting The Cutterbar Drive Belt (1) (Cutterbar Drive Without Variable-Speed Drive)
(R) so that the end of the gauge rod (D) is level with the end of the spring. Tighten the lock nut (K). Spring length = 138 mm Installing and adjusting the cutterbar intermediate drive belt (5) , see page 7.2.10 (Fig. 1, 3, 4) 7.2.2 RHB LEXION 480 - 188 678.1...
Page 411: Removing The Cutterbar Drive Belt (2) (Cutterbar Drive With Variable-Speed Drive)
Remove the cutterbar variable-speed drive belt (3) at the bottom – see page 7.2.5, Removing the cutterbar variable-speed drive belt (3) . Remove bracket (H). (Fig. 7) 7.2.3 188 678.1 - RHB LEXION 480...
Page 412: Installing And Adjusting The Cutterbar Drive Belt (2) (Cutterbar Drive With Variable-Speed Drive)
(R) so that the end of the gauge rod (D) is level with the end of the spring. Tighten the lock nut (K). Spring length = 138 mm (Fig. 5, 6, 7, 8, 9) 7.2.4 RHB LEXION 480 - 188 678.1...
Page 413: Removing The Cutterbar Variable-Speed Drive Belt (3)
Block variable-speed pulleys with special tools, please refer to the text below. DANGER! Be careful when working on variable-speed drives. Never move your hands between the pulley halves – Danger of accidents! Unscrew guard (S). (Fig. 10, 11) 7.2.5 188 678.1 - RHB LEXION 480...
Page 414: Installing And Adjusting The Cutterbar Variable-Speed Drive Belt (3)
Firmly pull the belt between the pulley halves and unscrew the hex. bolts (B) from the threaded holes. Re-fit hydraulic hose. Re-fit guard (S). Check oil level and replenish if required. (Fig. 10, 11, 12, 13) 7.2.6 RHB LEXION 480 - 188 678.1...
Page 415: Removing The Impeller Drive Belt (4)
7.2.1, Removing the cutterbar drive belt (1) (Cut- terbar drive without variable-speed drive) . Relieving the tension of impeller drive belt (4): (Push-type cylinder) DANGER! Follow the correct order of assembly – Danger of injury! 7.2.7 188 678.1 - RHB LEXION 480...
Page 416: Installing And Adjusting The Impeller Drive Belt (4)
Loosen lock nut (K) and adjust the spring guide tube so that the end of the gauge rod (D) is level with the end of the spring with the lock nut tightened. Spring length = 130 mm (Fig. 14, 15, 16) 7.2.8 RHB LEXION 480 - 188 678.1...
Page 417: Removing The Cutterbar Intermediate Drive Belt (5)
Releasing the tension from the cutterbar intermediate drive belt (5): (Pull-type cylinder) DANGER! Pay particular attention while unscrewing the spring guide tube (R). Do not unscrew the spring guide tube too far – Danger of injury! (Fig. 17) 7.2.9 188 678.1 - RHB LEXION 480...
Page 418: Installing And Adjusting The Cutterbar Intermediate Drive Belt (5)
Loosen lock nut (K) and adjust the spring guide tube so that the end of the gauge rod (D) is level with the end of the spring. Tighten the lock nut (K). Spring length = 130 mm (Fig. 17, 18, 19, 20) 7.2.10 RHB LEXION 480 - 188 678.1...
Page 419: Removing The Uni-Spreader Hydraulic Pump Drive Belt (6)
(6) DANGER! Carry out the adjustment only with the engine switched off and the ignition key removed. Install belt (6). Push the hydraulic pump downwards and tighten hex. bolts (S). (Fig. 21, 22) 7.2.11 188 678.1 - RHB LEXION 480...
Page 420: Removing The Main Intermediate Drive Belt (7)
Remove drive belt (9) at the top from the engine output assembly (M). Unscrew jockey pulley (T). (Fig. 23, 24) Loosen belt guide assembly at drive belt (8) at (G). (Fig. 25) 33332 7.2.12 RHB LEXION 480 - 188 678.1...
Page 421 Completely remove belt cover assembly from belt (7). Remove belt (7) from main intermediate drive (V). (Fig. 23, 27) Unscrew hex. bolt at (L). Unhinge hydraulic cylinder (H) at lever (K). Tie up jockey pulley (S). (Fig. 28) 7.2.13 188 678.1 - RHB LEXION 480...
Page 422: Installing And Adjusting The Main Intermediate Drive Belt (7)
(13) , see page 7.2.26 Installing and adjusting the uni-spreader hydraulic pump drive belt (6) , see page 7.2.11 Installing and adjusting the cutterbar intermediate drive belt (5) , see page 7.2.10 7.2.14 RHB LEXION 480 - 188 678.1...
Page 423 7. Push lever (E) to the inside on the shaft up to the set collar and arrest using the second set collar. Hang in hydraulic cylinder (Z) on the lever. (Fig. 30, 31) 7.2.15 188 678.1 - RHB LEXION 480...
Page 424: Removing The Grain Tank Unloading Intermediate Drive Belt (8)
(Fig. 32, 33) Place drive belt (8) between grain tank unloading drive pulley and the bearing plate. Now remove belt (8) from the engine output assembly. Remove belt cover and belt (8). (Fig. 34) 7.2.16 RHB LEXION 480 - 188 678.1...
Page 425: Installing And Adjusting The Grain Tank Unloading Intermediate Drive Belt (8)
5. Push lever (E) to the inside on the shaft up to the set collar and arrest using the second set collar. Hang in hydraulic cylinder (Z) on the lever. (Fig. 32, 33, 34) 7.2.17 188 678.1 - RHB LEXION 480...
Page 426: Removing The Straw Chopper Intermediate Drive Belt (9)
Removing the straw chopper intermediate drive belt (9) Remove jockey pulley (S). Completely remove brace (T) as well as belt guide assembly (F). (Fig. 35, 36) Remove the belt (9) at the bottom. (Fig. 37) 7.2.18 RHB LEXION 480 - 188 678.1...
Page 427: Installing And Adjusting The Straw Chopper Intermediate Drive Belt (9)
130 Nm. (Fig. 36) 5. Pre-tension belt (9) by pushing the jockey pulley (S) downwards, mount and adjust the belt guide assembly (F). W = 4 – 6 mm (Fig. 35, 36, 37, 38) 7.2.19 188 678.1 - RHB LEXION 480...
Page 428: Removing The Straw Chopper Drive Belts (10 And 11)
Remove the brace (T) and the belt guide (F) completely. Remove the straw chopper intermediate drive belt (9) at the bottom – see page 7.2.18, Removing the straw chopper intermediate drive belt (9) . (Fig. 39, 40) 7.2.20 RHB LEXION 480 - 188 678.1...
Page 429 4. Remove brace (U). While doing so, observe cover and spacer at the rear intermediate drive. 5. Push the jockey pulley down and remove the belts (10 and 11). (Fig. 39, 41, 42) 7.2.21 188 678.1 - RHB LEXION 480...
Page 430: Installing And Adjusting The Straw Chopper Drive Belts (10 And 11)
(Fig. 40) 7. Pre-tension the belt (9) by pushing down the jockey pulley and bolt down and adjust the belt guide (F). W = 4 – 6 mm (Fig. 39, 40, 41, 42) 7.2.22 RHB LEXION 480 - 188 678.1...
Page 431: Removing The Uni-Spreader Intermediate Drive Belt (12)
Remove the straw chopper drive belt (11) at the bottom – see page 7.2.20, Removing the straw chopper drive belts (10 and 11) . DANGER! Follow the correct order of assembly – Danger of injury! (Fig. 43) 7.2.23 188 678.1 - RHB LEXION 480...
Page 432: Installing And Adjusting The Uni-Spreader Intermediate Drive Belt (12)
The spring length will then be 100 mm. Install the straw chopper drive belt (11) – see page 7.2.22, Installing and adjusting the straw chopper drive belts (10 and 11) . (Fig. 43, 44) 7.2.24 RHB LEXION 480 - 188 678.1...
Page 433: Removing The Sieve Pan Intermediate Drive Belt (13)
(9) . Remove the straw chopper drive belt (10) at the front – see page 7.2.20, Removing the straw chopper drive belts (10 and 11) . (Fig. 45, 46, 47) 7.2.25 188 678.1 - RHB LEXION 480...
Page 434: Installing And Adjusting The Sieve Pan Intermediate Drive Belt (13)
(10 and 11) . 7. Installing and adjusting the straw chopper inter- mediate drive belt (9) , see page 7.2.19 8. Mount brace (T) with a tightening torque of 130 Nm. (Fig. 45, 46, 47) 7.2.26 RHB LEXION 480 - 188 678.1...
Page 435: Removing The Sieve Pan Intermediate Drive Belt (14)
(10 and 11) . Remove the sieve pan intermediate drive belt (13) at the rear – see page 7.2.25, Removing the sieve pan intermediate drive belt (13) . (Fig. 46, 47, 48) 7.2.27 188 678.1 - RHB LEXION 480...
Page 436: Installing And Adjusting The Sieve Pan Intermediate Drive Belt (14)
(10 and 11) . 7. Installing and adjusting the straw chopper inter- mediate drive belt (9) , see page 7.2.19 Mount brace (T) with a tightening torque of 130 Nm. (Fig. 46, 47, 48, 49) 7.2.28 RHB LEXION 480 - 188 678.1...
Page 437: Removing The Sieve Pan Drive Belt (15)
2. From serial no. …: Fold the battery / tool box open. The cabinet may be folded open for better accessibility. For this, unscrew the two hex. bolts (S). (Fig. 50, 51, 52) 7.2.29 188 678.1 - RHB LEXION 480...
Page 438 3. Loosen clamping screw (A) at the jockey pulley. Loosen nuts (K and E) until the tension of the spring is relieved. (Fig. 50, 55) 4. Remove jockey pulley (S) and control arm (L). Remove belt (15). (Fig. 50, 56) 7.2.30 RHB LEXION 480 - 188 678.1...
Page 439: Installing And Adjusting The Sieve Pan Drive Belt (15)
6. From serial no. …: Close and bolt the toolbox. Up to serial no. …: Refit the toolbox. 7. Installing and adjusting the sieve pan intermediate drive belt (14) , see page 7.2.28 (Fig. 50–56) 7.2.31 188 678.1 - RHB LEXION 480...
Page 440: Removing The Uni-Spreader Drive Belt (16)
(R). Tighten the bolt until the tension in the drive belt is released. 6. Release and remove the pin (C). Slightly lift the jockey pulley and remove the belt. (Fig. 57, 58, 59, 60, 61) 7.2.32 RHB LEXION 480 - 188 678.1...
Page 441: Installing And Adjusting The Uni-Spreader
(K) tightened. The spring length will then be 134 mm. 5. Bolt down guard (S), stop (A) and mounting plate (L). (Fig. 57, 58, 59, 60, 61) 7.2.33 188 678.1 - RHB LEXION 480...
Page 442: Removing The Grain Tank Unloading Drive Chain (17)
1. Fully turn lock nut (K) backwards. 33381 2. Tighten spring guide tube (R) until pin (B) is slack. 3. Open the chain connector and remove the chain. H = Bracket (Fig. 62, 63, 64) 33382 7.2.34 RHB LEXION 480 - 188 678.1...
Page 443: Installing And Adjusting The Grain Tank Unloading Drive Chain (17)
Loosen lock nut (K) and adjust the spring guide tube (R) until the end of the gauge rod (D) is level with the end of the spring with the lock nut tightened. Spring length = 92 mm (Fig. 62, 63, 64) 7.2.35 188 678.1 - RHB LEXION 480...
Page 444 Left-hand drive belts 7.2.36 RHB LEXION 480 - 188 678.1...
Page 445: Right-Hand Drive Belts
Adjusting the spring-loaded cylinder: Loosen lock nut (K) and adjust the spring guide tube (R) so that the dimension (X) is 130 mm with the nut tightened and the belt tensioned. (Fig. 1) 7.3.1 188 678.1 - RHB LEXION 480...
Page 446: Adjusting The Axial Rotor Intermediate Drive (19)
(R) and the nut (K). 4. Remove pin (B). (Fig. 2, 3) 7.3.2 RHB LEXION 480 - 188 678.1...
Page 447: Removing The Fan Intermediate Drive Belt (20)
Removing the fan drive belt (21) , see page 7.3.5 Relieving the tension of fan intermediate drive belt (20): (Push-type cylinder) DANGER! Follow the correct order of assembly – Danger of injury! (Fig. 4) 7.3.3 188 678.1 - RHB LEXION 480...
Page 448: Installing And Adjusting The Fan Intermediate Drive Belt (20)
Spring length = 100 mm (Fig. 4, 5, 6) Installing and adjusting the threshing mechanism vari- able-speed drive belt (22) , see page 7.3.7 Installing and adjusting the fan drive belt (21) , see page 7.3.5 7.3.4 RHB LEXION 480 - 188 678.1...
Page 449: Removing The Fan Drive Belt (21)
First put the belt (21) on the spring-loaded variable speed pulley. Pull the belt until the variable speed pulley assembly is fully spread. Install the belt (21) on the upper variable speed pulley. (Fig. 7) 7.3.5 188 678.1 - RHB LEXION 480...
Page 450: Removing The Threshing Mechanism Variable-Speed Drive Belt (22)
Block variable-speed pulleys with special tools – please refer to the text below. DANGER! Be careful when working on variable-speed drives. Never move your hands between the pulley halves – Danger of accidents! Unscrew guard (S). (Fig. 8, 9) 7.3.6 RHB LEXION 480 - 188 678.1...
Page 451: Installing And Adjusting The Threshing Mechanism Variable-Speed Drive Belt (22)
Firmly pull the belt between the pulley halves and unscrew the hex. bolts (B) from the threaded holes. Re-fit hydraulic hose. Re-fit guard (S). Check oil level and replenish if required. (Fig. 8, 9, 10, 11) 7.3.7 188 678.1 - RHB LEXION 480...
Page 452: Removing The Threshing Drum Drive Belt (23)
Relieving the tension of threshing drum drive belt (23): (Pull-type cylinder) DANGER! Pay particular attention while unscrewing the spring guide tube (R). Do not unscrew the spring guide tube too far – Danger of injury! (Fig. 12) 7.3.8 RHB LEXION 480 - 188 678.1...
Page 453: Installing And Adjusting The Threshing Drum Drive Belt (23)
(D) is level with the washer (S). Tighten the lock nut (K). Spring length = 130 mm Installing and adjusting the threshing mechanism vari- able-speed drive belt (22) , see page 7.3.7 (Fig. 12, 13, 14) 7.3.9 188 678.1 - RHB LEXION 480...
Page 454: Removing The Accelerator Drive Belt (24)
Relieve the tension of accelerator drive belt (24): (Pull-type cylinder) DANGER! Pay particular attention while unscrewing the spring guide tube (R). Do not unscrew the spring guide tube too far – Danger of injury! (Fig. 15) 7.3.10 RHB LEXION 480 - 188 678.1...
Page 455: Installing And Adjusting The Accelerator Drive Belt (24)
(D) is level with the washer (S). Tighten the lock nut (K). Spring length = 92 mm Installing and adjusting the threshing drum drive belt (23) , see page 7.3.9 (Fig. 15, 16, 17) 7.3.11 188 678.1 - RHB LEXION 480...
Page 456: Removing The Radiator Chaff Screen Intermediate Drive Belt (25)
Slacken off the lock nut (B). Turn the nut (A) backwards until the belt tension is relieved. Unscrew clamping piece (N) if required in order to raise the bearing plate (L) by means of the eyebolt. Remove belt (25). (Fig. 18) 7.3.12 RHB LEXION 480 - 188 678.1...
Page 457: Installing And Adjusting The Rotary Chaff Screen Intermediate Drive Belt (25)
A distance between the spacer (H) and the tensioner (N) of approx. 1 mm is allowed. 4. Tighten the lock nut (B). 5. Installing and adjusting the fan drive belt (27) , see page 7.3.16 (Fig. 18) 7.3.13 188 678.1 - RHB LEXION 480...
Page 458: Removing The Radiator Chaff Screen Drive Belt (26)
(K). Turn the rotary chaff screen round by hand and check the tension of the drive belt. If necessary, repeat this procedure until the belt is evenly tensioned. (Fig. 18, 19, 20) 7.3.14 RHB LEXION 480 - 188 678.1...
Page 459: Removing The Fan Drive Belt (27)
(Fig. 21, 22, 23) U-piece (self-sourced): A = 38 mm B = 30 mm C = 38 mm D = 30 mm E = 5 mm F = ∅ 4 mm (Fig. 23) 7.3.15 188 678.1 - RHB LEXION 480...
Page 460: Installing And Adjusting The Fan Drive Belt (27)
(R) slightly backwards. Turn lock nut (K) until the dimension (X) has been reached. Lock spring guide tube (R) against the nut (K). Spring length (X) = 130 mm (Fig. 21, 22, 23) 7.3.16 RHB LEXION 480 - 188 678.1...
Page 461: Removing The Suction Blower Drive Belt (28)
Removing the fan drive belt (21) , see page 7.3.5 Removing the fan intermediate drive belt (20) , see page 7.3.3 Slacken off nut (A) until the belt tension is relieved. Remove belt (28). (Fig. 24) 7.3.17 188 678.1 - RHB LEXION 480...
Page 462: Installing And Adjusting The Suction Blower Drive Belt (28)
5. Length of gauge rod = 58 mm 6. Installing and adjusting the fan intermediate drive belt (20) , see page 7.3.4 7. Installing and adjusting the fan drive belt (21) , see page 7.3.5 (Fig. 24) 7.3.18 RHB LEXION 480 - 188 678.1...
Page 463 (30) , see page 7.3.21 Slacken off the lock nut (B). Slacken off hex. nut (A) until it reaches the stop. Slacken off bolt (T) of the tensioner (N). (Fig. 25, 26, 27) 7.3.19 188 678.1 - RHB LEXION 480...
Page 464: Installing And Adjusting The Air Conditioner Compressor Drive Belt (29)
(30) , see page 7.3.22 Installing and adjusting the rotary chaff screen inter- mediate drive belt (25) , see page 7.3.13 Installing and adjusting the fan drive belt (27) , see page 7.3.16 7.3.20 RHB LEXION 480 - 188 678.1...
Page 465: Removing The Compressed-Air Compressor Drive Belt (30)
Unscrew four hex. bolts (A) from the compressed-air compressor foot. Unscrew tensioning screw (S) until the tension of the compressed-air compressor drive belt (30) is released. Remove belt (30). (Fig. 30, 31, 32) 7.3.21 188 678.1 - RHB LEXION 480...
Page 466: Installing And Adjusting The Compressed-Air Compressor Drive Belt (30)
Installing and adjusting the compressed-air compressor drive belt (30) Install compressed-air compressor drive belt (30). Tension compressed-air compressor using the hex. bolt (S). Tighten hex. bolts (A) of the compressed-air compressor foot. (Fig. 30, 31, 32) 7.3.22 RHB LEXION 480 - 188 678.1...
Page 467: Removing The Alternator Drive Belt (31)
(30) , see page 7.3.21 Removing the air conditioner compressor drive belt (29) , see page 7.3.19 Loosen the hex. bolt (A) from the alternator holder. Unscrew hex. bolt (B) from the eyebolt. (Fig. 33, 34) 7.3.23 188 678.1 - RHB LEXION 480...
Page 468: Installing And Adjusting The Alternator Drive Belt (31)
(30) , see page 7.3.22 7. Installing and adjusting the rotary chaff screen intermediate drive belt (25) , see page 7.3.13 8. Installing and adjusting the fan drive belt (27) , see page 7.3.16 7.3.24 RHB LEXION 480 - 188 678.1...
Page 469 Tighten hex. nut (D) until the spacer tube (S) makes level contact with the ball washer (E). Tighten the lock nut (K). Tighten hex. bolt (B) of eyebolt and hex. bolt (A) of alternator holder. (Fig. 33, 34, 35) 7.3.25 188 678.1 - RHB LEXION 480...
Page 470: Removing The Feed Rake Conveyor Suction Blower Drive Belt (34)
Loosen the two hex. bolts (S) and pull the blower to the front (V) until the tension of belt (34) is released. (Fig. 37, 38, 39) Remove the feed rake conveyor suction blower drive belt (34). (Fig. 39) 7.3.26 RHB LEXION 480 - 188 678.1...
Page 471: Installing And Adjusting The Feed Rake Conveyor Suction Blower Drive Belt (34)
Install and adjust the cutterbar drive belt (1) and/or (2). CAUTION! The belts must not have contact at (P). Align pulley if required – see page 7.4.2, Installing the front pulley of cutterbar drive (1) . (Fig. 41) 7.3.27 188 678.1 - RHB LEXION 480...
Page 472: Removing The Straw Spreader Drive Belt (36)
Move the bearing housing (10) and first remove belt (36) from the toothed belt pulley (E). Then remove belt (36) from the toothed belt pulleys (F, G and H). (Fig. 42, 44, 49) 7.3.28 RHB LEXION 480 - 188 678.1...
Page 473: Installing And Adjusting The Straw Spreader Drive Belt (36)
(F, G and H). Now install belt (36) on toothed belt pulley (E). CAUTION! Install the toothed belt (36) so that the spreader blades (42) of both rotors are offset to each other (60° offset). (Fig. 42, 45) 7.3.29 188 678.1 - RHB LEXION 480...
Page 474 A force of 75 ± 3 N must be applied to the belt at deflection point (L). Observe clearance (K). K = 530 mm L = 21 mm If required, loosen the bearing housing (10) one more time and twist correspondingly. (Fig. 42, 44, 47) 7.3.30 RHB LEXION 480 - 188 678.1...
Page 475 The flatness deviation may be 1 mm max. at points (A, B, C and D). Adjust using the short support (50), the long support (52) or the mounting bracket (46). (Fig. 48, 49) 7.3.31 188 678.1 - RHB LEXION 480...
Page 476 M = 1.2 mm To do this, slacken off the hex. bolt (56) and turn the eccentric (62) correspondingly. Now tighten the hex. bolt (56). (Fig. 42, 49, 50) 9. Bolt down plate (P). (Fig. 43) 7.3.32 RHB LEXION 480 - 188 678.1...
Page 477: Cutterbar Drive
(34) if necessary – see page 7.3.26, Removing the feed rake conveyor suction blower drive belt (34) . Remove the clamping bolt from the clamping hub. Open the clamping hub slightly with a chisel and remove the pulley. (Fig. 1, 2) 7.4.1 188 678.1 - RHB LEXION 480...
Page 478: Installing The Front Pulley Of Cutterbar Drive (1)
Removing the deflection pulley of cutterbar drive (1) Removing the cutterbar drive belt (1) (Cutterbar drive without variable-speed drive) , see page 7.2.1 Unscrew the hex. bolt and remove the deflection pulley. (Fig. 5) 7.4.2 RHB LEXION 480 - 188 678.1...
Page 479: Deflection Pulley Of Cutterbar Drive (1), Disassembled
, see page 7.2.1 Remove the V-belt pulley from the slip clutch. Remove the M 16 x 50 hex. bolt from the clutch and, using the special tool, remove the complete clutch. (Fig. 7) 7.4.3 188 678.1 - RHB LEXION 480...
Page 480: Installing The Slip Clutch Of Cutterbar Drive (1)
Tightening torque = 195 Nm Bolt the V-belt pulley to the clutch. Installing and adjusting the cutterbar drive belt (1) (Cutterbar drive without variable-speed drive) , see page 7.2.2 Install the guard. Install the left-hand drive wheel. 7.4.4 RHB LEXION 480 - 188 678.1...
Page 481: Replacing The Slip Clutch Linings Of Cutterbar Drive (1)
(Fig. 11) Slip clutch of cutterbar drive (1), dismantled 1 Clutch hub 2 Clutch lining 3 Clutch plate 4 Cover 5 Compression spring 6 Washer 7 Hex. bolt M 10 x 50 (Fig. 12) 7.4.5 188 678.1 - RHB LEXION 480...
Page 482 11. Installing and adjusting the cutterbar drive belt (1) (Cutterbar drive without variable-speed drive) , see page 7.2.2 12. Install the guard and the drive wheel. (Fig. 11, 12, 13, 14, 15) 33394 7.4.6 RHB LEXION 480 - 188 678.1...
Page 483: Removing The Jockey Pulley Of Cutterbar Drive (1)
. Removing the impeller drive belt (4) , see page 7.2.7 DANGER! Follow the correct order of work steps when releasing the tension of spring-loaded cylinder – Danger of injury! 7.4.7 188 678.1 - RHB LEXION 480...
Page 484 (Fig. 19) Remove the front V-belt pulley. (Fig. 20) Screw the head-centred hex. bolt M 12 x 30 into the shaft. Using the special tool, pull off the rear V-belt pulley. (Fig. 21) 7.4.8 RHB LEXION 480 - 188 678.1...
Page 485 This should release the cones securing the pulley and the pulley should become loose. The block-ended tube must fit over the tapered ring. (Fig. 25) 7.4.9 188 678.1 - RHB LEXION 480...
Page 486: Dismantling The Rear Pulley Of Cutterbar Drive
11 Hex. bolt M 12 x 180, part no. 236 302.0 32528 (Fig. 27) Dismantling the rear pulley of cutterbar drive (1) (up to serial no..) Remove the circlip. Remove the snap ring using a screwdriver or a similar tool. (Fig. 28) 7.4.10 RHB LEXION 480 - 188 678.1...
Page 487 4 Locating disc, part no. 181 879.0 5 Socket, part no. 181 881.1 6 Tube, outside ∅ 70 x 170 long (self-sourced) 7 Tube, inside ∅ 80 x 150 long (self-sourced) (Fig. 30) 33399 7.4.11 188 678.1 - RHB LEXION 480...
Page 488: Rear Pulley Of Cutterbar Drive (1), Disassembled
Contact washer A 12 From serial no. …: Hex. bolt M 16 x 60 MK DIN 931-10.9 17 Cover 18 Hex. bolt M 6 x 12 DIN 933-8.8 Contact washer A 6 (Fig. 31) 7.4.12 RHB LEXION 480 - 188 678.1...
Page 489: (Up To Serial No
1. Insert the angular contact ball bearing (13) and the circlip (14) into the V-belt pulley (8). Observe installation position! CAUTION! Fill bearing assembly completely with multi- purpose grease DIN 51825 part no. 147 451.0. (Fig. 31, 32, 33) 7.4.13 188 678.1 - RHB LEXION 480...
Page 490 6 Tube, outside ∅ 70 x 170 long (self-sourced) (Fig. 35) 33404 3. Press in the inner ring (5) and the shaft seal (9), ensuring they are fitted in their correct installation position. (Fig. 31, 32, 36) 7.4.14 RHB LEXION 480 - 188 678.1...
Page 491: Installing The Rear Pulley Of Cutterbar Drive
2 Washer ∅ 75 x ∅ 13 x 6 part no. 642 929.0 3 Tube, inside ∅ 51 x 166 long (self-sourced) (Fig. 38) 31452 3. Press the pre-assembled V-belt pulley (8) on the shaft using the special tool. (Fig. 39) 7.4.15 188 678.1 - RHB LEXION 480...
Page 492 Bolt on the cover (17). (Fig. 43) 7. Installing and adjusting the impeller drive belt (4) , see page 7.2.8 Installing and adjusting the cutterbar drive belt (1) (Cutterbar drive without variable-speed drive) , see page 7.2.2 7.4.16 RHB LEXION 480 - 188 678.1...
Page 493: Removing The Rear Pulley Of Cutterbar Drive (1) (From Serial No
Remove the hex. bolt from the face end of impeller. (Fig. 45) Screw the head-centred hex. bolt M 12 x 30 into the shaft. Remove the V-belt pulley using the special tool. (Fig. 46, 47) 7.4.17 188 678.1 - RHB LEXION 480...
Page 494 3 Washer ∅ 17, part no. 235 127.2 – 2 pieces 4 Hex. bolt M 16 x 260 part no. 235 816.0 – 2 pieces 5 Head-centred hex. bolt M 16 x 30 (self-sourced) – 1 piece (Fig. 49) 7.4.18 RHB LEXION 480 - 188 678.1...
Page 495 3 Washer ∅ 10, part no. 236 913.2 – 2 pieces 4 Head-centred hex. bolt M 16 x 30 (self-sourced) 5 Threaded rod M 10 x 270 (self-sourced) – 2 pieces (Fig. 52) 7.4.19 188 678.1 - RHB LEXION 480...
Page 496: Dismantling The Rear Pulley Of Cutterbar Drive (1) (From Serial No
5 Sleeve, part no. 181 881.1 – 1 piece 6 Tube, outside ∅ 57 mm x 200 mm (self-sourced) – 1 piece 7 Tube, inside ∅ 80 mm x 100 mm (self-sourced) – 1 piece (Fig. 55) 7.4.20 RHB LEXION 480 - 188 678.1...
Page 497 5 Sleeve, part no. 181 881.1 – 1 piece 6 Tube, outside ∅ 65 mm x 250 mm (self-sourced) – 1 piece 7 Tube, inside ∅ 80 mm x 100 mm (self-sourced) – 1 piece (Fig. 57) 7.4.21 188 678.1 - RHB LEXION 480...
Page 498: Rear Pulley Of Cutterbar Drive (1), Disassembled
14 Circlip 72 x 2.5 DIN 472 15 Spacer ring 16 Hex. bolt M 16 x 60 DIN 931-10.9 17 Cover 18 Hex. bolt M 6 x 12 DIN 933-8.8 Contact washer A 6 (Fig. 58) 7.4.22 RHB LEXION 480 - 188 678.1...
Page 499: Assembling The Rear Pulley Of Cutterbar Drive (1) (From Serial No
Install angular contact ball bearing (13) using adhesive, e.g. DELO-ML 5328. Observe installation position! NOTE! Fill bearing assembly completely with multi- purpose grease DIN 51825 part no. 147 451.0. (Fig. 58, 59, 60) 7.4.23 188 678.1 - RHB LEXION 480...
Page 500: Installing The Rear Pulley Of Cutterbar Drive (1) (From Serial No
V-belt pulley (3) onto the shaft. 2. Then place the front taper ring in position and, using the special tool, pre-tighten it. Tightening torques M 16-10.9 = 180 Nm (Fig. 58, 59, 63) 7.4.24 RHB LEXION 480 - 188 678.1...
Page 501 Tightening torques M 16-10.9 = 180 Nm 5. Fill the hollow with grease. Clean the contact surfaces thoroughly and apply a sealing agent. Bolt on the cover (17). Grease existing grease nipples (11). (Fig. 58, 67) 7.4.25 188 678.1 - RHB LEXION 480...
Page 502: Removing The Cutterbar Variable-Speed Pulley Assembly (Spring-Loaded)
4 Contact washer A 16 5 Puller bridge, part no. 181 800.0 6 Threaded spindle, part no. 181 801.1 7 Hex. bolt M 16 x 50 DIN 933-8.8, part no. 235 586.0 33407 (Fig. 70) 7.4.26 RHB LEXION 480 - 188 678.1...
Page 503: Disassembling The Cutterbar Variable-Speed Pulley Assembly (Spring-Loaded)
2 Spindle, part no. 181 877.0 3 Axial grooved ball bearing 51305 DIN 711, part no. 235 983.0 4 Centraliser, part no. 181 437.0 5 Locating disc, part no. 181 879.0 (Fig. 73) 33410 7.4.27 188 678.1 - RHB LEXION 480...
Page 504 (Fig. 75) Remove the variable-speed pulley half. Drive out the roll pin. (Fig. 76) Remove the M 12 x 1.5 screw plug and both M 6 x 13 cheese-head screws. (Fig. 77) 7.4.28 RHB LEXION 480 - 188 678.1...
Page 505 Remove the sliding bushing. Remove the support runners using a screwdriver. Ensure that you note the installation position and mark it. (Fig. 80) Remove the expansion pins and then the support runners. (Fig. 81) 7.4.29 188 678.1 - RHB LEXION 480...
Page 506: Cutterbar Variable-Speed Pulley Assembly (Spring-Loaded), Disassembled
18 Thrust piece 19 Clamping washer 20 Hex. bolt M 16 x 50 DIN 933-8.8 Contact washer A 16 21 Dust cap 22 Hex. bolt M 6 x 12 DIN 933-8.8 Contact washer A 6 7.4.30 RHB LEXION 480 - 188 678.1...
Page 507: Assembling The Cutterbar Variable-Speed Pulley Assembly (Spring-Loaded)
Cutterbar drive Cutterbar drive Assembling the cutterbar variable-speed pulley assembly (spring-loaded) 1. Insert the sliding bushing (6). Ensure correct installation position. The rounded side must face inwards. (Fig. 82, 83, 84) 7.4.31 188 678.1 - RHB LEXION 480...
Page 508 The torsional backlash should be as small as possible while the sliding surfaces move smoothly. It must not exceed 1 mm. If necessary, the next thicker support runner (7) must be used. (Fig. 82, 83, 87) 7.4.32 RHB LEXION 480 - 188 678.1...
Page 509 (13) and the mounting flange (14) and twist so that the correct hole lines up with the expansion pin (9). 11. Screw hex. bolt (6) of the special tool through the mounting flange (14). (Fig. 82, 83) 7.4.33 188 678.1 - RHB LEXION 480...
Page 510 Tighten countersunk head bolts with a tightening torque of 49 Nm. (Fig. 82, 83, 91) 14. Install the cap (23) with expansion pin (24). Screw in screw plug (25). (Fig. 82, 83, 92) 7.4.34 RHB LEXION 480 - 188 678.1...
Page 511: Installing The Cutterbar Variable-Speed Pulley Assembly (Spring-Loaded)
(Y, length of shaft shoulder). W = Y – X The distance (W) must be 0.2 to 0.6 mm. Should this not be the case, then correct it with shims. (Fig. 96) 7.4.35 188 678.1 - RHB LEXION 480...
Page 512 (Fig. 99) Installing and adjusting the cutterbar variable-speed drive belt (3) , see page 7.2.6 Once the pulley has been completely installed, thoroughly grease at all grease nipples until all grease channels are full. 7.4.36 RHB LEXION 480 - 188 678.1...
Page 513: Removing The Cutterbar Drive V-Belt Pulley When A Cutterbar Variable-Speed Drive Is Fitted
Disassembling the cutterbar drive V-belt pulley when a cutterbar variable-speed drive is fitted Remove the cover. (Fig. 102) Remove the M 16 x 50 hex. bolt from the face end of the shaft. (Fig. 103) 7.4.37 188 678.1 - RHB LEXION 480...
Page 514 CAUTION! When assembling, ensure a new bearing is used. (Fig. 106) Using a soft metal punch, drive the inner bearing race out of the housing. (Fig. 107) 7.4.38 RHB LEXION 480 - 188 678.1...
Page 515: Cutterbar Drive V-Belt Pulley With A Cutterbar Variable-Speed Drive Fitted, Disassembled
14 Hex. bolt M 10 x 25 VP DIN 933-8.8 15 Parallel key A 12 x 8 x 98 DIN 6885 16 Hex. bolt M 16 x 45 DIN 933-8.8 Contact washer A 16 (Fig. 108) 7.4.39 188 678.1 - RHB LEXION 480...
Page 516: Assembling The Cutterbar Drive V-Belt Pulley With A Cutterbar Variable-Speed Drive Fitted
2 Hex. nut M 16 DIN 934, part no. 236 173.0 3 Axial grooved ball bearing, part no. 177 899.0 4 Washer, part no. 577 557.0 5 Tube, inside ∅ 55 x 100 long (self-sourced) (Fig. 111) 33443 7.4.40 RHB LEXION 480 - 188 678.1...
Page 517 147 451.0. 8. Clean the sealing surfaces of the cover and the housing, then apply a suitable sealing compound such as Epple type 33. Bolt on the cover (11). (Fig. 108, 109) 7.4.41 188 678.1 - RHB LEXION 480...
Page 518: Installing The Cutterbar Drive V-Belt Pulley With A Cutterbar Variable-Speed Drive Fitted
Remove the hex. bolt M 16 x 100 and remove the deflection pulley. (Fig. 116) Place a M 16 x 50 hex. bolt (S) in the centering pin. Drive out the centering pin. (Fig. 117) 7.4.42 RHB LEXION 480 - 188 678.1...
Page 519: Assembling And Installing The Cutterbar Drive Deflection Pulley (2) With A Cutterbar Variable-Speed Drive Fitted
4. Installing and adjusting the cutterbar drive belt (2) (Cutterbar drive with variable-speed drive) , see page 7.2.4 Removing the cutterbar variable-speed pulley assembly (hydraulic) Remove the hydraulic hose and seal the connections with plastic caps. (Fig. 120) 7.4.43 188 678.1 - RHB LEXION 480...
Page 520 Unscrew the V-belt pulley. (Fig. 123) Removing the cutterbar variable-speed drive belt (3) , see page 7.2.5 Remove the piston holder. Remove the M 12 x 30 cheese-head screw and remove the thrust washer. (Fig. 124) 7.4.44 RHB LEXION 480 - 188 678.1...
Page 521 6 Threaded spindle, part no. 181 801.1 7 Hex. bolt M 16 x 50 DIN 933-8.8, part no. 235 586.0 33407 (Fig. 127) Using the special tool, remove the inner race. (Fig. 128) 7.4.45 188 678.1 - RHB LEXION 480...
Page 522: Disassembling The Cutterbar Variable-Speed Pulley Assembly (Hydraulic)
Disassembling the cutterbar variable-speed pulley assembly (hydraulic) Unscrew the spacer plate. (Fig. 130) Unscrew the cover and remove. (Fig. 131) Remove the variable-speed pulley half. Remove the sliding bushing. Observe installation position and mark it. (Fig. 132) 7.4.46 RHB LEXION 480 - 188 678.1...
Page 523 3 Locating disc, part no. 181 879.0 4 Tube, inside ∅ 80 x 150 long (self-sourced) 5 Locating disc, part no. 181 879.0 6 Spindle, part no. 181 877.0 7 Sleeve, part no. 181 881.1 (Fig. 135) 32636 7.4.47 188 678.1 - RHB LEXION 480...
Page 524: Cutterbar Variable-Speed Pulley Assembly (Hydraulic), Disassembled
17 Thrust washer 18 Cheese-head screw M 12 x 30 MK DIN 912-10.9 19 Piston holder 20 V-belt pulley 21 Plug 22 Hex. bolt M 12 x 35 DIN 933-8.8 Lock washer 12 (Fig. 136) 7.4.48 RHB LEXION 480 - 188 678.1...
Page 525 Cutterbar drive Cutterbar drive 33465 7.4.49 188 678.1 - RHB LEXION 480...
Page 526: Assembling The Cutterbar Variable-Speed Pulley Assembly (Hydraulic)
4 Tube, outside ∅ 70 x 150 long (self-sourced) 5 Washer, outside ∅ 70 x inside ∅ 20 x 8 6 Spindle, part no. 181 877.0 7 Sleeve, part no. 181 881.1 (Fig. 139) 33467 7.4.50 RHB LEXION 480 - 188 678.1...
Page 527: Installing The Cutterbar Variable-Speed Pulley Assembly (Hydraulic)
3 Axial grooved ball bearing, part no. 177 899.0 4 Hex. nut M 12 DIN 934, part no. 236 172.0 5 Hex. bolt M 12 x 180 DIN 933-8.8, part no. 236 302.0 (Fig. 142) 31384 7.4.51 188 678.1 - RHB LEXION 480...
Page 528: Removing The Cutterbar Clutch
Removing the cutterbar intermediate drive belt (5) , see page 7.2.9 Removing the uni-spreader hydraulic pump drive belt (6) , see page 7.2.11 Removing the sieve pan intermediate drive belt (13) , see page 7.2.25 7.4.52 RHB LEXION 480 - 188 678.1...
Page 529 (Fig. 147) Remove the three cheese-head screws. From serial no. …: Remove the hydraulic ram (34). Up to serial no. …: Remove the hydraulic ram (22) and the mounting ring (23). (Fig. 148, 164) 7.4.53 188 678.1 - RHB LEXION 480...
Page 530 If a new friction ring is used, the sequence of wedges is numbered. (Fig. 150) Remove the M 16 hex. bolt with the thrust washer from the shaft face end. (Fig. 151) 7.4.54 RHB LEXION 480 - 188 678.1...
Page 531 2 Hex. bolt M 8 x 80 DIN 931-8.8, part no. 235 525.0 3 Washer 8 4 Hex. bolt M 16 x 25 DIN 933-8.8 head-centred (Fig. 154) Remove the V-belt pulley, using a suitable puller. Remove the spacer ring. (Fig. 155) 7.4.55 188 678.1 - RHB LEXION 480...
Page 532 3 Washer ∅ 11, part no. 215 683.0 4 Hex. bolt M 16 x 25 DIN 933-8.8 head-centred (Fig. 158) Up to serial no. …: Remove the tapered ring and, using a suitable puller, remove the V-belt pulley. (Fig. 159) 7.4.56 RHB LEXION 480 - 188 678.1...
Page 533 (Fig. 160) Remove the belt guide from the main drive pulley. (Fig. 161) Remove the V-belt pulley using the special tool. Remove the parallel key and the tapered ring. (Fig. 162) 7.4.57 188 678.1 - RHB LEXION 480...
Page 534 7 Washer 17, part no. 235 127.2 – 5 pieces 8 Hex. nut M 16, part no. 236 173.0 – 5 pieces 9 Hex. bolt M 16 x 60 DIN 933 33489 head-centred, part no. 603 038.0 (Fig. 163) 7.4.58 RHB LEXION 480 - 188 678.1...
Page 535: Cutterbar Clutch, Disassembled
22 Hydraulic ram (up to serial no. …) 23 Mounting ring (up to serial no..) Cheese-head screw M 8 x 35 DIN 912 Detent-edged ring VSKZ 8 24 O-ring 25 Back-up ring 26 Cylinders 7.4.59 188 678.1 - RHB LEXION 480...
Page 536: Installing The Cutterbar Clutch
2. Insert the front tapered ring (3) and press into position using the special tool. For this, block the V-belt pulley up with a chain. Tightening torque = 210 Nm (Fig. 164, 165, 166) 7.4.60 RHB LEXION 480 - 188 678.1...
Page 537 C = 180 mm D = 20 mm 2 Washer ∅ 76 x ∅ 17 x 10 3 Hex. bolt M 16 x 110 DIN 931-8.8, part no. 238 642.0 (Fig. 170) 33493 7.4.61 188 678.1 - RHB LEXION 480...
Page 538 9. Insert the parallel key (14) and slide the clutch hub (12) with the tapered ring (13) on the shaft. 10. Tighten the hex. bolt (15) with washer (17) up to 210 Nm. (Fig. 164, 165, 174) 7.4.62 RHB LEXION 480 - 188 678.1...
Page 539 (19) in the numbered order. Tape the outer edge of the friction rings with suitable tape. 14. Place the friction ring in the clutch hub (12), then remove the tape. (Fig. 164, 165, 177) 7.4.63 188 678.1 - RHB LEXION 480...
Page 540 Take particular care not to damage the O-rings with sharp edges. 18. Apply gearbox grease G 00 to Belleville springs before inserting them. Observe correct installation position of Belleville springs. (Fig. 164, 165, 180) 7.4.64 RHB LEXION 480 - 188 678.1...
Page 541 (13) , see page 7.2.26 Installing and adjusting the uni-spreader hydraulic pump drive belt (6) , see page 7.2.11 Installing and adjusting the cutterbar intermediate drive belt (5) , see page 7.2.10 7.4.65 188 678.1 - RHB LEXION 480...
Page 542 Cutterbar drive 7.4.66 RHB LEXION 480 - 188 678.1...
Page 543: Left-Hand Threshing Mechanism Drive
(Fig. 1) Remove the two slotted nuts with the socket wrench part no. 181 809.0. Remove the back-up ring. (Fig. 2) Remove the cylinder and the six Belleville springs. (Fig. 3) 7.5.1 188 678.1 - RHB LEXION 480...
Page 544 The wedges of the friction ring must not be confused when re-using them, therefore mark the individual wedges. In case of new friction rings, the sequence of wedges is numbered. (Fig. 6) 7.5.2 RHB LEXION 480 - 188 678.1...
Page 545 1 Small puller bridge, part no. 181 621.0 2 Hex. bolt M 8 x 80 DIN 931-8.8, part no. 235 525.0 3 Washer 8 4 Hex. bolt M 16 x 25 DIN 933-8.8 head-centred (Fig. 10) 7.5.3 188 678.1 - RHB LEXION 480...
Page 546 2 Hex. bolt M 10 x 180 DIN 931-8.8, part no. 237 796.0 3 Washer ∅ 11, part no. 215 683.0 4 Hex. bolt M 16 x 25 DIN 933-8.8 head-centred (Fig. 14) 7.5.4 RHB LEXION 480 - 188 678.1...
Page 547 (Fig. 16) Remove the belt guide from the main drive pulley. (Fig. 17) Remove the V-belt pulley using the special tool. Remove the parallel key and the tapered ring. (Fig. 18) 7.5.5 188 678.1 - RHB LEXION 480...
Page 548 7 Washer 17, part no. 235 127.2 – 5 pieces 8 Hex. nut M 16, part no. 236 173.0 – 5 pieces 9 Hex. bolt M 16 x 60 DIN 933 33489 head-centred, part no. 603 038.0 (Fig. 19) 7.5.6 RHB LEXION 480 - 188 678.1...
Page 549: Threshing Mechanism Drive Pulley Assembly, Disassembled
22 Hydraulic ram (up to serial no. …) 23 Mounting ring (up to serial no..) Cheese-head screw M 8 x 35 DIN 912 Detent-edged ring VSKZ 8 24 O-ring 25 Back-up ring 7.5.7 188 678.1 - RHB LEXION 480...
Page 550: Installing The Threshing Mechanism Drive Pulley Assembly
2. Insert the front tapered ring (3) and press into position using the special tool. For this, block the V-belt pulley up with a chain. Tightening torque = 210 Nm (Fig. 20, 21, 22) 7.5.8 RHB LEXION 480 - 188 678.1...
Page 551 C = 180 mm D = 20 mm 1 Washer ∅ 76 x ∅ 17 x 10 2 Hex. bolt M 16 x 110 DIN 931-8.8, part no. 238 642.0 (Fig. 26) 33493 7.5.9 188 678.1 - RHB LEXION 480...
Page 552 9. Insert the parallel key (14) and slide the clutch hub (12) with the tapered ring (13) on the shaft. 10. Tighten the hex. bolt (15) with washer (17) up to 210 Nm. (Fig. 20, 21, 30) 7.5.10 RHB LEXION 480 - 188 678.1...
Page 553 (19) in the numbered order. Tape the outer edge of the friction rings with suitable tape. 14. Place the friction ring in the clutch hub (12), then remove the tape. (Fig. 20, 21, 33) 7.5.11 188 678.1 - RHB LEXION 480...
Page 554 Take particular care not to damage the O-rings with sharp edges. 18. Apply gearbox grease G 00 to Belleville springs before inserting them. Observe correct installation position of Belleville springs. (Fig. 20, 21, 36) 7.5.12 RHB LEXION 480 - 188 678.1...
Page 555 (13) , see page 7.2.26 Installing and adjusting the uni-spreader hydraulic pump drive belt (6) , see page 7.2.11 Installing and adjusting the cutterbar intermediate drive belt (5) , see page 7.2.10 7.5.13 188 678.1 - RHB LEXION 480...
Page 556 Left-hand threshing mechanism drive 7.5.14 RHB LEXION 480 - 188 678.1...
Page 557: Right-Hand Threshing Mechanism Drive
Remove the grease nipple and the grease pipe. Remove the hydraulic cylinder. CAUTION! Observe number, position and thickness of shims. (Fig. 2) Unscrew the M 16 x 60 hex. bolt and remove together with thrust washer. (Fig. 3) 7.6.1 188 678.1 - RHB LEXION 480...
Page 558: Disassembling The Threshing Drum Variable-Speed Pulley Assembly (Hydraulic)
6 Threaded spindle, part no. 181 801.1 7 Hex. bolt M 16 x 50 DIN 933-8.8, part no. 235 586.0 33407 (Fig. 6) Disassembling the threshing drum variable-speed pulley assembly (hydraulic) Remove the cover. (Fig. 7) 7.6.2 RHB LEXION 480 - 188 678.1...
Page 559 Drive the flanged bushings out of the front section of the pulley. (Fig. 9) Pull out the sliding bushing from the rear section of the pulley. Observe installation position and mark it. (Fig. 10) 7.6.3 188 678.1 - RHB LEXION 480...
Page 560: Threshing Drum Variable-Speed Pulley Assembly (Hydraulic), Disassembled
12 Parallel key A 16 x 10 x 120 DIN 6885 13 Thrust washer 14 Hex. bolt M 16 x 60 DIN 931-10.9 15 Sealing washer 16 Grease pipe 17 Grease nipple (Fig. 11) 7.6.4 RHB LEXION 480 - 188 678.1...
Page 561 Right-hand threshing mechanism drive Right-hand threshing mechanism drive 33573 7.6.5 188 678.1 - RHB LEXION 480...
Page 562: Assembling The Threshing Drum Variable-Speed Pulley Assembly (Hydraulic)
M 12 x 165. (If necessary, adjust the threshing mechanism variable-speed drive belt (22) using shims – see page 7.3.7, Installing and adjusting the threshing mechanism varia- ble-speed drive belt (22) .) Tightening torque = 86 Nm (Fig. 14) 7.6.6 RHB LEXION 480 - 188 678.1...
Page 563: Removing The Threshing Drum Variable-Speed Pulley Assembly (Spring-Loaded)
4 Contact washer A 16 5 Puller bridge, part no. 181 800.0 6 Threaded spindle, part no. 181 801.1 7 Hex. bolt M 16 x 50 DIN 933-8.8, part no. 235 586.0 33407 (Fig. 17) 7.6.7 188 678.1 - RHB LEXION 480...
Page 564: Disassembling The Threshing Drum Variable-Speed Pulley Assembly (Spring-Loaded)
4 Centraliser, part no. 181 437.0 5 Locating disc, part no. 181 879.0 (Fig. 19) 33410 By turning the handle of the lever nut, release all the pressure from the compression spring. (Fig. 20) 7.6.8 RHB LEXION 480 - 188 678.1...
Page 565 (Fig. 22) Remove the M 12 x 1.5 screw plug and both M 6 x 13 cheese-head screws. (Fig. 23) Remove the parallel key with a notched dowel using a suitable screwdriver. (Fig. 24) 7.6.9 188 678.1 - RHB LEXION 480...
Page 566 Remove the sliding bushing. Remove the support runners using a screwdriver. Ensure that you note the installation position and mark it. (Fig. 26) Remove the expansion pins and then the support runners. (Fig. 27) 7.6.10 RHB LEXION 480 - 188 678.1...
Page 567: Threshing Drum Variable-Speed Pulley Assembly (Spring-Loaded), Disassembled
18 Thrust piece 19 Clamping washer 20 Hex. bolt M 16 x 85 DIN 933-8.8 Contact washer A 16 21 Dust cap 22 Hex. bolt M 6 x 12 DIN 933-8.8 Contact washer A 6 7.6.11 188 678.1 - RHB LEXION 480...
Page 568: Assembling The Threshing Drum Variable-Speed Pulley Assembly (Spring-Loaded)
Right-hand threshing mechanism drive Right-hand threshing mechanism drive Assembling the threshing drum variable-speed pulley assembly (spring-loaded) 1. Insert the sliding bushing (6). Ensure correct installation position. The rounded side must face inwards. (Fig. 28, 29, 30) 7.6.12 RHB LEXION 480 - 188 678.1...
Page 569 The torsional backlash should be as small as possible while the sliding surfaces move smoothly. It must not exceed 1 mm, if necessary, the next thicker slide (7) must be used. (Fig. 28, 29, 33) 7.6.13 188 678.1 - RHB LEXION 480...
Page 570 (14) in position and twist so that the correct hole lines up with the expansion pin (9). 11. Screw hex. bolt (6) of the special tool through the mounting flange (14). (Fig. 28, 29) 7.6.14 RHB LEXION 480 - 188 678.1...
Page 571 Tighten countersunk head bolts with a tightening torque of 49 Nm. (Fig. 28, 29, 37) 14. Install the cap (23) with expansion pin (24). Screw in screw plug (25). (Fig. 28, 29, 38) 7.6.15 188 678.1 - RHB LEXION 480...
Page 572: Installing The Threshing Drum Variable-Speed Pulley Assembly (Spring-Loaded)
(Y, length of shaft shoulder). W = Y – X The distance (W) must be 0.2 to 0.6 mm. Should this not be the case, then correct it with shims. (Fig. 42) 7.6.16 RHB LEXION 480 - 188 678.1...
Page 573 Installing and adjusting the threshing mechanism vari- able-speed drive belt (22) , see page 7.3.7 Once the pulley has been completely installed, thoroughly grease at all grease nipples until all grease channels are full. 7.6.17 188 678.1 - RHB LEXION 480...
Page 574: Removing The Threshing Mechanism Drive Pulley
V-belt pulley from the side wall of the machine. (Fig. 47) Disassembling the threshing mechanism drive pulley Remove the cover plate. (Fig. 48) Remove the hex. bolt M 16 x 50 from the face end of the shaft. (Fig. 49) 7.6.18 RHB LEXION 480 - 188 678.1...
Page 575 CAUTION! When reassembling, ensure a new bearing is used. (Fig. 52) Using a soft metal punch, drive the inner bearing race out of the housing. (Fig. 53) 7.6.19 188 678.1 - RHB LEXION 480...
Page 576: Threshing Mechanism Drive Pulley, Disassembled
14 Hex. bolt M 10 x 25 VP DIN 933-8.8 15 Parallel key A 12 x 8 x 98 DIN 6885 16 Hex. bolt M 16 x 35 DIN 933-8.8 MK (Fig. 54) 7.6.20 RHB LEXION 480 - 188 678.1...
Page 577: Assembling The Threshing Mechanism Drive Pulley
2 Hex. nut M 16 DIN 934, part no. 236 173.0 3 Axial grooved ball bearing, part no. 177 899.0 4 Washer, part no. 577 557.0 5 Tube, inside ∅ 55 x 100 long (self-sourced) (Fig. 57) 33443 7.6.21 188 678.1 - RHB LEXION 480...
Page 578 4 Washer, part no. 577 557.0 5 Tube, inside ∅ 55 x 100 long (self-sourced) (Fig. 59) 33443 6. Insert the hex. bolt (10) with washer (9) and tighten. Tightening torque = 195 Nm (Fig. 54, 55, 60) 7.6.22 RHB LEXION 480 - 188 678.1...
Page 579: Installing The Threshing Mechanism Drive Pulley
Tightening torque = 195 Nm 2. Attach the lubrication line. 3. Installing and adjusting the threshing drum drive belt (23) , see page 7.3.9 Installing the threshing drum variable-speed pulley assembly (spring-loaded) , see page 7.6.16 7.6.23 188 678.1 - RHB LEXION 480...
Page 580 Right-hand threshing mechanism drive 7.6.24 RHB LEXION 480 - 188 678.1...
Page 581: Threshing Drum Reduction Gearbox
(Fig. 2) Remove the circlip and the centralising piece with the cap. Remove the hex. bolt (S) from the face end of the shaft. (Fig. 3) 7.7.1 188 678.1 - RHB LEXION 480...
Page 582: Disassembling The Threshing Drum Reduction Gearbox
Disassembling the threshing drum reduction gearbox Unscrew the V-belt pulley. The shaft seals can now be replaced. (Fig. 6) Unbolt the ring of bolts and remove the gearbox cover. Count number of shims (21). (Fig. 7) 7.7.2 RHB LEXION 480 - 188 678.1...
Page 583 (Fig. 9, 10) Remove the deep groove ball bearing, using a three-legged puller. For this use a head-centred hex. bolt M 16 x 30 and a puller plate, part no. 181 885.0. (Fig. 11) 7.7.3 188 678.1 - RHB LEXION 480...
Page 584 (Fig. 13) Remove the circlip, then remove the cylinder roller bearing using a suitable tube. (Fig. 14) Remove the circlip and drive out the cylinder roller bearing with a soft metal punch. (Fig. 15) 7.7.4 RHB LEXION 480 - 188 678.1...
Page 585 For this, use a Hex. nut M 16 x 60, part no. 603 038.0, a locating disc, part no. 181 879.0 and a thrust washer, part no. 667 414.0. (Fig. 16) 7.7.5 188 678.1 - RHB LEXION 480...
Page 586: Threshing Drum Reduction Gearbox, Disassembled
23 Shaft seal AS 13 x 160 x 12 DIN 3760 24 Hex. bolt M 8 x 90 DIN 931-8.8 25 O-ring 80 x 2 - N DIN 3771 26 Centralising piece 27 Cover 7.7.6 RHB LEXION 480 - 188 678.1...
Page 587 Threshing drum reduction gearbox Threshing drum reduction gearbox 7.7.7 188 678.1 - RHB LEXION 480...
Page 588: Assembling The Threshing Drum Reduction Gearbox
6. Using a tube with an inside ∅ 82 x 100 long and a special tool, press the inner bearing ring of cylinder roller bearing (10) onto the planetary carrier. (Fig. 17, 18, 22) 7.7.8 RHB LEXION 480 - 188 678.1...
Page 589 3 Axial grooved ball bearing, part no. 235 983.0 4 Locating disc, part no. 181 879.0 5 Sleeve, part no. 181 881.1 6 Tube, outside ∅ 70 x 170 long (self-sourced) (Fig. 24) 33404 7.7.9 188 678.1 - RHB LEXION 480...
Page 590 (31, if required) and the planet axle (15) into the planet carrier. Insert set screw (16) with liquid locking compound, e.g. DELO-ML 5349. CAUTION! Item (13 to 16) only replace in whole. (Fig. 17, 18, 26, 27) 7.7.10 RHB LEXION 480 - 188 678.1...
Page 591: Installing The Threshing Drum Reduction Gearbox
(Fig. 17, 18, 30) Installing the threshing drum reduction gearbox 1. Slide the threshing drum reduction gearbox onto the flanged shaft using the special tool part no. 181 617.0 and a suitable lifting device. (Fig. 31) 7.7.11 188 678.1 - RHB LEXION 480...
Page 592 DELO-ML 5349. Tightening torque = 110 Nm (Fig. 33) 4. Insert the centralising piece (26). Tap the cap (27) in using a suitable punch, then insert the circlip (28). (Fig. 17, 18, 34) 7.7.12 RHB LEXION 480 - 188 678.1...
Page 593 Fill in gearbox oil at the oil filler plug until the oil starts running out through the lower hole. Remove the elbow union (T) from the top hole and refit both caps. (Fig. 35, 36) 7. Refit the guard. Install the right-hand drive wheel. 7.7.13 188 678.1 - RHB LEXION 480...
Page 594 Threshing drum reduction gearbox 7.7.14 RHB LEXION 480 - 188 678.1...
Page 595: Threshing Mechanism Intermediate Drive
3 Centraliser with ball, part no. 181 849.0 4 Hex. bolt M 16 x 260, part no. 235 816.0 5 Washer 17, part no. 235 127.2 6 Threaded bolt, part no. 181 889.0 (Fig. 3) 31487 7.8.1 188 678.1 - RHB LEXION 480...
Page 596: Installing The Right-Hand Intermediate Drive Shaft Bearing
(hydraulic) , see page 7.6.6 Removing the left-hand intermediate drive shaft bearing Removing the threshing mechanism drive pulley assembly , see page 7.5.1 Remove the grease pipe and unbolt the bearing assembly. (Fig. 6) 7.8.2 RHB LEXION 480 - 188 678.1...
Page 597: Installing The Left-Hand Intermediate Drive Shaft Bearing
3 Axial grooved ball bearing, part no. 177 899.0 4 Thrust washer, part no. 667 414.0 5 Tube, inside ∅ 60 x 400 long (self-sourced) 6 Hex. bolt M 12 x 180 DIN 931-8.8, part no. 235 565.0 (Fig. 10) 33583 7.8.3 188 678.1 - RHB LEXION 480...
Page 598: Removing The Intermediate Drive Shaft
4. Installing the stage 1 fan drive V-belt pulley , see page 7.14.1 5. Installing the threshing drum variable-speed pulley assembly (hydraulic) , see page 7.6.6 6. Installing the threshing mechanism drive pulley assembly , see page 7.5.8 7.8.4 RHB LEXION 480 - 188 678.1...
Page 599: Grain Tank Unloading Drive
Unscrew the lock collar bearing and then remove the shaft completely. (Fig. 2, 3) From serial no. …: Mark the position of the V-belt pulley on the shaft. Loosen the clamping hub and pull off the V-belt pulley. (Fig. 4) 7.9.1 188 678.1 - RHB LEXION 480...
Page 600 Remove the gib head key and pull off the pulley. (Fig. 5) Knock off the lock collar and remove the bearing. (Fig. 6) Unscrew the hex. bolt and pull off the bearing. (Fig. 7) Pull off the shear bolt coupling. (Fig. 8) 7.9.2 RHB LEXION 480 - 188 678.1...
Page 601: Installing The Grain Tank Unloading Drive Pulley
Align the V-belt pulley and bolt down the clamping hub. (Fig. 9) Up to serial no. …: Align the V-belt pulley and secure the gib head key by knocking it into position. (Fig. 10) 7.9.3 188 678.1 - RHB LEXION 480...
Page 602 7. Install the belt guard (R), the belt guide bracket (B) and the lock collar bearing (S). (Fig. 1) 8. Installing and adjusting the grain tank unloading drive chain (17) , see page 7.2.35 7.9.4 RHB LEXION 480 - 188 678.1...
Page 603: Chopper Drive
3 Axial grooved ball bearing, part no. 177 899.0 4 Hex. nut M 16 with collar, part no. 244 059.0 5 Hex. bolt M 12 x 100, part no. 235 563.0 (Fig. 3) 7.10.1 188 678.1 - RHB LEXION 480...
Page 604 Removing the sieve pan intermediate drive belt (14) , see page 7.2.27 Unbolt the V-belt pulley completely with the bearing bracket. (Fig. 6) Remove the V-belt pulley using a suitable puller. (Fig. 7) 7.10.2 RHB LEXION 480 - 188 678.1...
Page 605: Stage 1 Chopper Drive V-Belt Pulley, Disassembled
11 Spacer bushing 12 Deep groove ball bearing 6207-RS-C3 13 Circlip 80 x 2.5 DIN 472 14 Brace 15 Hex. bolt M 16 x 110 DIN 931-10.9 Contact washer A 16 (Fig. 8) 7.10.3 188 678.1 - RHB LEXION 480...
Page 606: Assembling And Installing The Stage 1 Chopper Drive V-Belt Pulley
(approx. 70 g). The deep groove ball bearings (3) must be completely filled with roller bearing grease such as Shell “Alvania G 3” part no. 413 981.0 when being assembled. (Fig. 8, 9) 7.10.4 RHB LEXION 480 - 188 678.1...
Page 607 Shell “Alvania G3” part no. 413 981.0 when being assembled. (Fig. 8, 9) 4. Press the pre-assembled V-belt pulley (8) on the shaft using the special tool. (Fig. 12) 7.10.5 188 678.1 - RHB LEXION 480...
Page 608: Removing The Stage 2 Chopper Drive V-Belt Pulley
Removing the stage 2 chopper drive V-belt pulley Removing the straw chopper drive belts (10 and 11) , see page 7.2.20 Remove the complete assembly including the pulley and the jockey pulleys. (Fig. 15) 7.10.6 RHB LEXION 480 - 188 678.1...
Page 609 4 Puller plate, part no. 181 803.1 5 Hex. bolt M 16 x 79 DIN 933, part no. 242 467.0 6 Washer 17 DIN 125 7 Hex. nut M 16 DIN 934 part no. 236 173.0 (Fig. 18) 35384 7.10.7 188 678.1 - RHB LEXION 480...
Page 610: Stage 2 Chopper Drive V-Belt Pulley, Disassembled
11 V-belt pulley 12 Hex. bolt M 16 x 35 DIN 933-8.8 Contact washer A 16 13 Washer 14 Washer 15 Hex. bolt M 12 x 40 DIN 933-8.8 Contact washer A 12 (Fig. 19) 7.10.8 RHB LEXION 480 - 188 678.1...
Page 611: Assembling And Installing The Stage 2 Chopper Drive V-Belt Pulley
(3) must be completely filled with multi-purpose grease such as Shell “Retinax A” part no. 147 451.0 when being assembled. 2. Pre-assemble the base plate (5) with the bearing pin and the hex. bolt (8). (Fig. 19, 20) 7.10.9 188 678.1 - RHB LEXION 480...
Page 612 Tightening torque = 78 Nm 5. Bolt the complete base plate to the machine side wall. (Fig. 19, 20, 23) 6. Installing and adjusting the straw chopper drive belts (10 and 11) , see page 7.2.22 7.10.10 RHB LEXION 480 - 188 678.1...
Page 613: Removing The Jockey Pulley Of Straw Chopper Drive (10)
(approx. 5 g). The deep groove ball bearings (3) must be completely filled with roller bearing grease such as Shell “Alvania G3” 33545 part no. 413 981.0 when being assembled. (Fig. 25, 26) 7.10.11 188 678.1 - RHB LEXION 480...
Page 614: Removing The Jockey Pulley Of Straw Chopper Drive (11)
2 Circlip 52 x 2 DIN 472 3 Deep groove ball bearing 6205-2RS-C3 4 Spacer bushing 5 Lock collar 6 Hex. bolt M 16 x 105 DIN 7968-8.8 7 Hollow pin 8 Hex. nut M 16 (Fig. 29) 7.10.12 RHB LEXION 480 - 188 678.1...
Page 615: Assembling And Installing The Jockey Pulley Of Straw Chopper Drive (11)
Removing the stage 3 chopper drive V-belt pulley Removing the straw chopper drive belt (11) – see page 7.2.20, Removing the straw chopper drive belts (10 and 11) Unscrew the bolts (S) and remove the lever. (Fig. 32) 7.10.13 188 678.1 - RHB LEXION 480...
Page 616 Removing the uni-spreader intermediate drive belt (12) , see page 7.2.23 Remove circlip and washer. (Fig. 35) Put handwheel back in place. Block the V-belt pulley and remove the bolt. Remove handwheel again. (Fig. 36) 7.10.14 RHB LEXION 480 - 188 678.1...
Page 617: Disassembling The Stage 3 Chopper Drive V-Belt Pulley
6 Hex. bolt M 16 x 260 DIN 931-8.8 part no. 235 816.0 7 Centraliser, part no. 181 849.0 (Fig. 39) 35396 Disassembling the stage 3 chopper drive V-belt pulley Pull off hub using the special tool. (Fig. 40) 7.10.15 188 678.1 - RHB LEXION 480...
Page 618 181 849.0 8 Washer ∅ 78 x 20 (self-sourced) (Fig. 41) Pull off deep groove ball bearing from the hub. For this, use a disc of ∅ 78 x 20 long (self-sourced). (Fig. 42) 7.10.16 RHB LEXION 480 - 188 678.1...
Page 619: Stage 3 Chopper Drive V-Belt Pulley, Dismantled
12 Cheese-head screw M 5 x 6 DIN 912 13 Washer 14 Circlip 64 x 2 DIN 472 15 Plastic ring 16 Hand wheel 17 Bushing 18 Circlip 35 x 1.5 DIN 472 (Fig. 43) 7.10.17 188 678.1 - RHB LEXION 480...
Page 620: Assembling And Installing The Stage 3 Chopper Drive V-Belt Pulley
G 00, DIN 51502 part no. 411 423.0, applied prior to installation. 1. Press the deep groove ball bearing (2) on the hub (4) using the special tool. (Fig. 43, 44, 45) 7.10.18 RHB LEXION 480 - 188 678.1...
Page 621 Tube outside ∅ 125 x ∅ 110 x 150 long (Fig. 46) 5 Locating disc part no. 181 879.0 6 Spindle part no. 181 877.0 7 Sleeve part no. 181 881.0 (Fig. 48) 32636 7.10.19 188 678.1 - RHB LEXION 480...
Page 622 9. Bolt down lever and check function. Bolt down bracket (H). (Fig. 32, 33) 10. Refit and adjust the straw chopper drive belt (11) – see page 7.2.22, Installing and adjusting the straw chopper drive belts (10 and 11) . 7.10.20 RHB LEXION 480 - 188 678.1...
Page 623: Straw Spreader Drive
Screw the end of the hex. socket head bolts into the open hole of the toothed belt pulley (threaded face at the set collar). This pulls the set collar off of the toothed belt pulley. (Fig. 3) 7.11.1 188 678.1 - RHB LEXION 480...
Page 624: Disassembling The Straw Spreader Bearing Housing
Determine dimension (X) from shaft end to the bracket (H). Mark the position of bracket (37) and shaft (36) with respect to each other. (Fig. 6) Loosen hex. socket head bolt (38) and remove bracket (H). (Fig. 7, 14) 7.11.2 RHB LEXION 480 - 188 678.1...
Page 625 Secure sprocket (19) on the shaft (24) with the expansion pins (36). (Fig. 9, 14) Pull off the hub (24) using a puller. (Fig. 10) Drive expansion pins (30 and 31) out of the bearing bushing (32). (Fig. 11, 14) 7.11.3 188 678.1 - RHB LEXION 480...
Page 626 Drive shaft (36) out of the bearing housing (23), using a brass punch. (Fig. 12) Remove circlip (35). Drive out bearing (33) and spacer tube (13) with a brass punch. (Fig. 13, 14) 7.11.4 RHB LEXION 480 - 188 678.1...
Page 627: Straw Spreader Bearing Housing, Disassembled
Hex. nut M 8 22 Mushroom head bolt M 10 x 20 Contact washer B 8 Hex. nut M 10 DIN 934 46 Mounting bracket Lock washer 10 47 Short support 23 Bearing housing 7.11.5 188 678.1 - RHB LEXION 480...
Page 628 Contact washer B 8 52 Long support 53 Parallel key 54 Baffle plate 56 Hex. bolt 57 Contact washer 58 Contact washer 59 Hex. nut 60 Circlip 61 Deep groove ball bearing 62 Eccentric (Fig. 14) 7.11.6 RHB LEXION 480 - 188 678.1...
Page 629: Assembling The Straw Spreader Bearing Housing
Drive shaft (36) into the bearing housing using a plastic-tip hammer. Use a tube as a backing while doing so. Tube: Inside ∅ 30 mm Outside ∅ 40 mm Length 150 mm (Fig. 17) 7.11.7 188 678.1 - RHB LEXION 480...
Page 630 Tube: Inside ∅ 30 mm Outside ∅ 40 mm Length 150 mm CAUTION! The bores for the expansion pin (19) must be exactly above each other. (Fig. 14, 20) Drive in expansion pin (19). (Fig. 21) 7.11.8 RHB LEXION 480 - 188 678.1...
Page 631: Installing The Straw Spreader Bearing Housing
6. Align and/or check the toothed belt pulleys to the dimension (Y) vertically with respect to the housing, using a ruler. Y = 35.2 ± 0.5 mm If necessary, adjust the set collars vertically and tighten hand-tight. (Fig. 14, 15, 24) 7.11.9 188 678.1 - RHB LEXION 480...
Page 632 The flatness deviation may be 1 mm max. at points (A, B, C and D). 9. Bolt down the short support (50) and the long support (52). 10. Tighten the mounting bracket (46). (Fig. 14, 15, 25) 7.11.10 RHB LEXION 480 - 188 678.1...
Page 633 11. After aligning the toothed belt pulleys, tighten the socket head bolts. Tightening torque = 90 Nm (Fig. 26) 12. Installing and adjusting the straw spreader drive belt (36) , see page 7.3.29 7.11.11 188 678.1 - RHB LEXION 480...
Page 634 Straw spreader drive 7.11.12 RHB LEXION 480 - 188 678.1...
Page 635: Uni-Spreader Drive
(Fig. 2) Remove the tapered ring and then the V-belt pulley. (Fig. 3) Drive out the gib head key and pull off V-belt pulley. (Fig. 4) 7.12.1 188 678.1 - RHB LEXION 480...
Page 636: Mounting The Uni-Spreader Drive Angle Drive
Tightening torque = 78 Nm (Fig. 1, 2) 4. Installing and adjusting the uni-spreader drive belt (16) , see page 7.2.33 Installing and adjusting the uni-spreader interme- diate drive belt (12) , see page 7.2.24 7.12.2 RHB LEXION 480 - 188 678.1...
Page 637: Sieve Pan Drive
Remove the bracket for the hydraulic hoses at (A) from the side wall. (Fig. 1) Remove the V-belt pulley, using a suitable puller. (Fig. 2) Now the bracket (H) on the side wall can be renewed. (Fig. 3) 7.13.1 188 678.1 - RHB LEXION 480...
Page 638: Sieve Pan Drive V-Belt Pulley, Disassembled
7 Mounting bracket 8 Hex. bolt M 10 x 25 DIN 933-8.8 Contact washer A 10 9 Spacer ring 10 Spacer washer 11 Hex. bolt M 16 x 40 DIN 933-8.8 (Fig. 4) 7.13.2 RHB LEXION 480 - 188 678.1...
Page 639: Installing The Sieve Pan Drive V-Belt Pulley
(15) , see page 7.2.31 Installing and adjusting the sieve pan intermediate drive belt (14) , see page 7.2.28 4. Install the bracket for the hydraulic hoses at (A) on the side wall. (Fig. 1) 7.13.3 188 678.1 - RHB LEXION 480...
Page 640: Removing The Front Sieve Pan Drive Deflection Pulley
3 Hex. precision-fit bolt M 16 x 85 DIN 7968 4 Deep groove ball bearing 6203 rs / c3 5 Circlip 40 x 1.75 DIN 472 6 Spacer ring 7 Thrust washer 8 Self-locking nut Vm 16 (Fig. 10) 7.13.4 RHB LEXION 480 - 188 678.1...
Page 641: Assembling The Front Sieve Pan Drive Deflection Pulley
M 16 = 130 Nm (Fig. 8, 12) Removing the rear sieve pan drive deflection pulley From serial no. …: Fold down the toolbox. For this, unscrew the two hex. bolts (S). (Fig. 13) 7.13.5 188 678.1 - RHB LEXION 480...
Page 642: Rear Sieve Pan Drive Deflection Pulley, Disassembled
3 Circlip 62 x 2 DIN 472 4 Spacer ring 5 Washer 6 Pin 7 Shim 8 Hex. bolt M 12 x 130 DIN 931 9 Contact washer A 12 10 Hex. nut M 12 DIN 934 (Fig. 17) 7.13.6 RHB LEXION 480 - 188 678.1...
Page 643: Assembling The Rear Sieve Pan Drive Deflection Pulley
(Fig. 15, 19) From serial no. …: Bolt down tool box with the two hex. bolts (S). (Fig. 13) Up to serial no. …: Bolt down adapter (C) with hex. bolts (B). (Fig. 14) 7.13.7 188 678.1 - RHB LEXION 480...
Page 644 Sieve pan drive 7.13.8 RHB LEXION 480 - 188 678.1...
Page 645: Fan Drive
1. Assemble the V-belt pulley (1) with the tapered rings (2) and the parallel key (3). 2. Using the special tool, pre-stress the tapered rings. Tightening torque = 310 Nm (Fig. 2, 3) 7.14.1 188 678.1 - RHB LEXION 480...
Page 646: Fan Adjustment (Electric)
NOTE: There are three different fan adjustment versions (electric): Versions 1 and 3 are combined. Version 2 is described separately. With the protective cap removed, the differences are as described below: (Fig. 5) 7.14.2 RHB LEXION 480 - 188 678.1...
Page 647: Fan Adjustment (Electric) Version
The fan adjustment is bolted to the supporting ring with three hex. bolts (3) and three hex. nuts (18). 3 Hex. bolt M 6 x 120 mm – 3 pieces 18 Hex. nut M 6 – 3 pieces (Fig. 6) 7.14.3 188 678.1 - RHB LEXION 480...
Page 648 (from serial no. …, up to serial no. …) The fan adjustment is bolted to the supporting ring using three cheese-head screws (3). Cheese-head screw M 6 x 110 mm – 3 pieces (Fig. 7) 7.14.4 RHB LEXION 480 - 188 678.1...
Page 649 The fan adjustment is bolted to the supporting ring with three cheese-head screws (3) and one hex. nut (18). 3 Cheese-head screw M 6 x 105 mm – 3 pieces 18 Hex. nut M 6 – 1 piece (Fig. 8) 7.14.5 188 678.1 - RHB LEXION 480...
Page 650: Up To Serial No
Slacken off the support washer and the capstan nut (39). Unscrew the supporting ring (16). Up to serial no. …: Slacken off the support ring and the hex. nut (39). Unscrew the supporting ring (16). (Fig. 12, 18) 7.14.6 RHB LEXION 480 - 188 678.1...
Page 651: Disassembling The Fan Adjustment (Electric) (Version 1)
(8). Remove the left-hand and right-hand axial bearing from the adjusting nut. (Fig. 6, 15) Remove the ring (7), the quick-release fastener (6) and the and the catch (5). (Fig. 6, 16) 7.14.7 188 678.1 - RHB LEXION 480...
Page 652 Fan drive Unscrew cheese-head screws (4) and remove flange (2) along with hex. bolts (3). (Fig. 6, 17) 7.14.8 RHB LEXION 480 - 188 678.1...
Page 653: Fan Adjustment (Electric), Disassembled (Version 1)
13 Hex. bolt M 6 x 60 DIN 931-8.8 Lock washer 14 Thrust piece 15 Spacer tube 16 Supporting ring 17 Bushing 18 Hex. nut M 6 DIN 934 19 Hose clamp 20 Rubber cap 7.14.9 188 678.1 - RHB LEXION 480...
Page 654: Assembling The Fan Adjustment (Electric) (Version 1)
(4). Tightening torque M 6 x 16 = 8 Nm (Fig. 6, 19, 20) 2. Slide on the catch (5) and push on the quick-release fastener using a tube. (Fig. 6, 21) 7.14.10 RHB LEXION 480 - 188 678.1...
Page 655 CAUTION! The pressure pins (D) of thrust piece (14) must be offset by 30° relative to the centre axis of the DC motor when being screwed into the adjusting nut (10). (Fig. 24) 7.14.11 188 678.1 - RHB LEXION 480...
Page 656: Installing The Fan Adjustment (Electric) (Version 1)
With the hole pattern, set the supporting ring to the measure (P) = 42° ± 5° from the horizontal line, then secure with the capstan nut or the hex. nut. Observe locking dimension (K). (Fig. 26, 27, 81, 82) 7.14.12 RHB LEXION 480 - 188 678.1...
Page 657 3. Refit the rubber cap (20) and reconnect the push-on receptacle. 4. Installing and adjusting the fan variable-speed pulley assembly (spring-loaded) , see page 7.14.42 5. Installing and adjusting the fan drive belt (21) , see page 7.3.5 7.14.13 188 678.1 - RHB LEXION 480...
Page 658: Removing The Fan Adjustment (Electric)
Slacken off the support washer and the capstan nut (39). Unscrew the supporting ring (16). Up to serial no. …: Slacken off the support ring and the hex. nut (39). Unscrew the supporting ring (16). (Fig. 32, 38) 7.14.14 RHB LEXION 480 - 188 678.1...
Page 659: Disassembling The Fan Adjustment (Electric) (Version 1, Version 3)
Remove the left-hand and right-hand axial bearing from the adjusting nut. (Fig. 6, 8, 35) Remove the ring (7), the quick-release fastener (6) and the and the catch (5). (Fig. 6, 8, 36) 7.14.15 188 678.1 - RHB LEXION 480...
Page 660 Fan drive Unscrew cheese-head screws (4) and remove flange (2) along with hex. bolts or cheese-head screws (3). (Fig. 6, 8, 37) 7.14.16 RHB LEXION 480 - 188 678.1...
Page 661: Fan Adjustment (Electric), Disassembled (Version 1, Version 3)
17 Bushing 18 Hex. nut M 6 DIN 934 – 1 piece (from serial no. …) Hex. nut M 6 DIN 934 – 3 pieces (up to serial no. …) 19 Hose clamp 7.14.17 188 678.1 - RHB LEXION 480...
Page 662: Assembling The Fan Adjustment (Electric) (Version 1, Version 3)
Tightening torque M 6 x 16 = 8 Nm (Fig. 6, 8, 39, 40) 2. Slide on the catch (5) and push on the quick-release fastener using a tube. (Fig. 6, 8, 41) 7.14.18 RHB LEXION 480 - 188 678.1...
Page 663 CAUTION! The pressure pins (D) of thrust piece (14) must be offset by 30° relative to the centre axis of the DC motor when being screwed into the adjusting nut (10). (Fig. 44) 7.14.19 188 678.1 - RHB LEXION 480...
Page 664: Installing The Fan Adjustment (Electric) (Version 1, Version 3)
(P) = 42° ± 5° from the horizontal line, then secure with the capstan nut or the hex. nut. Observe locking dimension (K) of capstan nut (39) or of hex. nut (39). (Fig. 46, 47, 81, 82) 7.14.20 RHB LEXION 480 - 188 678.1...
Page 665 3. Refit the rubber cap (20) and reconnect the push-on receptacle. 4. Installing and adjusting the fan variable-speed pulley assembly (spring-loaded) , see page 7.14.42 5. Installing and adjusting the fan drive belt (21) , see page 7.3.5 7.14.21 188 678.1 - RHB LEXION 480...
Page 666: Removing The Fan Adjustment (Electric) (Version 2)
(cranked). NOTE! The motor can be rotated to the right and the left by approx. 300° (to make installation easier). (Fig. 51, 59) Remove complete DC motor with spacer tube (15). (Fig. 52) 7.14.22 RHB LEXION 480 - 188 678.1...
Page 667: Disassembling The Fan Adjustment (Electric) (Version 2)
Pull off clamping piece (12) and remove adjustment nut (10) along with needle bearing (9) and axial washer (8). Remove the left-hand and right-hand axial bearing from the adjusting nut. Remove ring (7). (Fig. 7, 56) 7.14.23 188 678.1 - RHB LEXION 480...
Page 668 Fan drive Remove the quick-release fastener (6) and the catch (5). (Fig. 7, 57) Unscrew cheese-head screws (4) and remove flange (2). (Fig. 7, 58) 7.14.24 RHB LEXION 480 - 188 678.1...
Page 669: Fan Adjustment (Electric), Disassembled (Version 2)
19 Hose clamp 20 Rubber cap 39 Capstan nut M 16 x 1 DIN 934 (from serial no. …) Hex. nut M 16 x 1 DIN 934 (up to serial no. …) (Fig. 59) 7.14.25 188 678.1 - RHB LEXION 480...
Page 670: Assembling The Fan Adjustment (Electric) (Version 2)
(4). Tightening torque M 6 x 16 = 8 Nm (Fig. 7, 61) 2. Slide on the catch (5) and push on the quick-release fastener using a tube. (Fig. 7, 62) 7.14.26 RHB LEXION 480 - 188 678.1...
Page 671 (8) and the needle bearing (9) and push it on. (Fig. 7, 63) 5. Slide on clamping piece (12) and bolt down to the flange (2) with hex. bolts (13) at position B. (Fig. 7, 59, 64) 7.14.27 188 678.1 - RHB LEXION 480...
Page 672 30° relative to the centre axis of the DC motor when being screwed into the adjusting nut (10). The through-holes of the thrust piece now match position A of flange (2). (Fig. 59, 65, 66) 7.14.28 RHB LEXION 480 - 188 678.1...
Page 673: Installing The Fan Adjustment (Electric) (Version 2)
4. Check the adjustments of the fan variable-speed pulley assembly (electric) and correct if necessary – see page 7.14.33, Assembling and installing the electric fan variable-speed pulley assembly . (Fig. 59, 81, 82) 7.14.29 188 678.1 - RHB LEXION 480...
Page 674 6. Refit the rubber cap (20) and reconnect the push-on receptacle. 7. Installing and adjusting the fan variable-speed pulley assembly (spring-loaded) , see page 7.14.42 8. Installing and adjusting the fan drive belt (21) , see page 7.3.5 7.14.30 RHB LEXION 480 - 188 678.1...
Page 675: Removing The Fan Variable-Speed Drive (Electric)
Removing the fan intermediate drive belt (20) , see page 7.3.3 Remove the circlip. Loosen the three hex. bolts (42) by approx. 5 mm to be able to apply a puller. (Fig. 72, 73) Pull off both pulleys completely. (Fig. 73) 7.14.31 188 678.1 - RHB LEXION 480...
Page 676: Electric Fan Variable-Speed Pulley Assembly, Disassembled
41 Deep-groove ball bearing 6205-2RS-C3 DIN 625 42 Hex. bolt M 8 x 45 DIN 931-8.8 Contact washer A 8 43 Hex. bolt M 10 x 25 DIN 933-8.8 Contact washer B 10 44 Bearing bracket (Fig. 74) 7.14.32 RHB LEXION 480 - 188 678.1...
Page 677: Assembling And Installing The Electric Fan Variable-Speed Pulley Assembly
1. Press the bearing (41) into the V-belt pulley (40). 2. Bolt the V-belt pulley (40) to the variable-speed pulley (30). Tightening torque = 23 Nm (Fig. 74, 75) 7.14.33 188 678.1 - RHB LEXION 480...
Page 678 (Fig. 74, 75, 78) Special tool: 1 Hex. nut M 16 x 1, part no. 238 928.0 2 Washer, part no. 688 484.0 3 Tube, outside ∅ 21 x 100 long (self-sourced) (Fig. 79) 33948 7.14.34 RHB LEXION 480 - 188 678.1...
Page 679 (A), turn back the capstan nut (39) until the locking dimension (K) is 25 The stroke dimension (H) of 22 mm is limited by the thrust piece of the motor. A dimension (Y) of 62 mm results. (Fig. 75, 81) 7.14.35 188 678.1 - RHB LEXION 480...
Page 680: Removing The Fan Drive Jockey Pulley (20)
2 Deep-groove ball bearing 6204-2RS-C3 DIN 625 3 Circlip 47 x 1.75 DIN 472 4 Pin 5 Circlip 20 x 1.2 DIN 471 6 Contact washer A 12 7 Hex. nut M 12 (Fig. 84) 7.14.36 RHB LEXION 480 - 188 678.1...
Page 681: Installing The Fan Drive Jockey Pulley (20)
3 Hex. nut M 12 DIN 934, part no. 236 172.0 4 Hex. bolt M 12 x 50 DIN 933-8.8, part no. 237 573.0 5 Threaded spindle, part no. 181 801.1 6 Centraliser with ball, part no. 181 849.0 (Fig. 88) 32407 7.14.37 188 678.1 - RHB LEXION 480...
Page 682: Disassembling The Fan Drive Variable-Speed Pulley Assembly (Spring-Loaded)
6 Hex. bolt M 16 x 140 DIN 931-8.8, part no. 242 795.0 7 Sleeve, part no. 181 881.1 (Fig. 90) 33966 By turning the handle of the lever nut, release all the pressure from the compression spring. (Fig. 91) 7.14.38 RHB LEXION 480 - 188 678.1...
Page 683 Remove the variable-speed pulley half. (Fig. 93) Remove the cheese-head screws and then lift out the parallel key. (Fig. 94) Remove the bushing from the rear half of the variable-speed pulley. (Fig. 95) 7.14.39 188 678.1 - RHB LEXION 480...
Page 684: Fan Variable-Speed Pulley Assembly (Spring-Loaded), Disassembled
9 Cheese-head screw M 8 x 25 DIN 912 Lock washer 8 10 Parallel key A 8 x 5 x 75 DIN 6885 11 Set screw M 10 x 8 DIN 916 (Fig. 96) 7.14.40 RHB LEXION 480 - 188 678.1...
Page 685: Assembling The Fan Variable-Speed Pulley Assembly (Spring-Loaded)
6 Hex. bolt M 16 x 140 DIN 931-8.8, part no. 242 795.0 7 Sleeve, part no. 181 881.1 (Fig. 98) 33966 5. Bolt the cheese-head screws (9) into position and remove the special tool. 7.14.41 188 678.1 - RHB LEXION 480...
Page 686: Installing And Adjusting The Fan Variable-Speed Pulley Assembly (Spring-Loaded)
5. Operating the fan speed from slow to fast must not reduce the distance (D). Should this not be the case, then adjust the fan variable-speed pulley assembly (electric) down or up at the bearing bracket and check the adjustments. (Fig. 100) 33976 7.14.42 RHB LEXION 480 - 188 678.1...
Page 687: Axial Rotor Drive
Unscrew the hex. nuts and remove the front V-belt pulleys. (Fig. 2) Remove the cover and unscrew the bolt from the shaft face end. (Fig. 3) Remove the V-belt pulley using the special tool. (Fig. 4) 7.15.1 188 678.1 - RHB LEXION 480...
Page 688 6 Hex. nut M 16 DIN 934 part no. 236 173.0 7 Washer 17 DIN 125 part no. 235 127.2 (Fig. 5) Unbolt the bearing pin from the machine side wall. (Fig. 6) 7.15.2 RHB LEXION 480 - 188 678.1...
Page 689: Axial Rotor Intermediate Drive V-Belt Pulley, Disassembled
15 Hex. bolt M 12 x 35 DIN 933-8.8 16 Cover 17 Hex. bolt M 6 x 12 DIN 933-8.8 Contact washer A 6 18 V-belt pulley 19 V-belt pulley 20 Hex. nut M 16 DIN 934-8 Contact washer A 16 7.15.3 188 678.1 - RHB LEXION 480...
Page 690: Assembling And Installing The Axial Rotor Intermediate Drive V-Belt Pulley
2 Washer ∅ 55 x ∅ 13 3 Axial grooved ball bearing, part no. 177 899.0 4 Hex. nut M 12 DIN 934 5 Hex. bolt M 12 x 220 DIN 933-8.8 part no. 244 422.0 (Fig. 10) 31384 7.15.4 RHB LEXION 480 - 188 678.1...
Page 691 177 899.0 4 Washer, part no. 712 415.0 (Fig. 7, item 14) (Fig. 12) 35427 7. Fit the hex. bolt (15) along with washer (14). Tightening torque = 78 Nm (Fig. 13) 7.15.5 188 678.1 - RHB LEXION 480...
Page 692: Removing The Axial Rotors Drive Jockey Pulley (18)
2 Bearing pin 3 Deep groove ball bearing 6205 RS/C3 4 Circlip 52 x 2 DIN 472 5 Spacer ring 6 Hex. bolt M 12 x 30 DIN 933-8.8 Contact washer A 12 (Fig. 16) 7.15.6 RHB LEXION 480 - 188 678.1...
Page 693: Installing The Axial Rotors Drive Jockey Pulley (18)
Arrest the threshing drum and slacken off the bolts. (Fig. 18) Remove the axial rotor step drive (18). Remove the hex. nuts and the V-belt pulleys. (Fig. 19) Remove the grease pipe. (Fig. 20) 7.15.7 188 678.1 - RHB LEXION 480...
Page 694 Using a suitable block-ended tube, use a good sharp blow to release the taper lock sleeve of the bearing. Then unscrew the slotted nut. (Fig. 24) Disassemble bearing according to Fig. 25. 7.15.8 RHB LEXION 480 - 188 678.1...
Page 695: Bearing Of Axial Rotors Drive (18), Disassembled
11 Hex. bolt M 12 x 35 DIN 933-8.8 Contact washer A 12 12 Hub 13 Hex. bolt M 16 x 70 DIN 933-8.8 Contact washer A 16 14 Gib head key 14 x 9 x 75 DIN 6887 (Fig. 25) 7.15.9 188 678.1 - RHB LEXION 480...
Page 696: Installing The Bearings Of Axial Rotors
(Fig. 28) 4. Slide the hub (12) onto the stub and secure slightly with the gib head key. Place the V-belt pulley into position and adjust belt alignment. Knock in gib-head key. (Fig. 29) 7.15.10 RHB LEXION 480 - 188 678.1...
Page 697: Removing The Axial Rotors Drive
M 12 x 50 hex. bolts make contact with the side wall. (Fig. 32) Slacken off the bolts of the clamping hub and shift them to the left. (Fig. 33) 7.15.11 188 678.1 - RHB LEXION 480...
Page 698: Disassembling The Axial Rotor Gearbox
Dispose of the old oil in a way that is harmless to the environment and in accordance with existing environmental regulations. Unscrew cover of gearbox housing. (Fig. 35) Unscrew the power take-off housing. (Fig. 36) 7.15.12 RHB LEXION 480 - 188 678.1...
Page 699 Slightly chuck the tube in a vice and drive shaft out of the bearing. (Fig. 38) Remove circlip and bevel gear. Remove the taper roller bearings. (Fig. 39) Unlock and unscrew lock nut. Remove O-ring. (Fig. 40) 7.15.13 188 678.1 - RHB LEXION 480...
Page 700 Axial rotor drive Using a suitable light metal punch, drive out the bevel gear. Pull off the taper roller bearing from the bevel gear. (Fig. 41) 7.15.14 RHB LEXION 480 - 188 678.1...
Page 701: Axial Rotor Gearbox, Disassembled
14 Taper roller bearing 32012 DIN 720 15 O-ring 16 Compensating washer 17 Power take-off housing 18 O-ring 19 Self-locking nut 20 Shaft seal 21 Hex. bolt M 10 x 30 DIN 933-8.8 22 Seal 7.15.15 188 678.1 - RHB LEXION 480...
Page 702: Assembling The Axial Rotor Gearbox
3. Slide on the spacer ring (9) and the tube (10). Heat the taper roller bearing (11) to approx. 100 °C and press it on the shaft. (Fig. 42, 43, 45) 7.15.16 RHB LEXION 480 - 188 678.1...
Page 703 (Fig. 42, 43, 48) 7. Put the power take-off housing (17) in position and heat the second taper roller bearings (14) to approx. 100 °C and press it on the bevel gear. (Fig. 42, 43, 49) 7.15.17 188 678.1 - RHB LEXION 480...
Page 704 (minimum torsional backlash 0.1 mm). Use the adjusting bolts for adjusting the shaft if necessary. Tightening torque = 45 Nm (Fig. 42, 43, 52) 7.15.18 RHB LEXION 480 - 188 678.1...
Page 705 C = Correct setting (Fig. 42, 43, 55) 14. Screw out hex. bolts (21) one by one and insert them with liquid locking compound, e.g. DELO-ML 5349. Tightening torque = 45 Nm (Fig. 42, 43, 56) 7.15.19 188 678.1 - RHB LEXION 480...
Page 706: Installing The Axial Rotor Gearbox
1.5.1, Lubricants chart . (Fig. 59) Move the clamping hub to the right and screw in hex. bolts with liquid locking compound, e.g. DELO-ML 5349. Tightening torque = 78 Nm (Fig. 60) 7.15.20 RHB LEXION 480 - 188 678.1...
Page 707 Replace the hex. bolts M 12 x 50 by the hex. bolts M 12 x 35. Bolt the bearing housing (L) to the machine side wall. Install and adjust the axial rotor step drive (18). Bolt down the safety frame. (Fig. 61) 7.15.21 188 678.1 - RHB LEXION 480...
Page 708 Axial rotor drive 7.15.22 RHB LEXION 480 - 188 678.1...
Page 709: Engine Output
2. Tighten the castellated nut M 36 x 1.5 to 520 Nm. Secure the castellated nut with a split pin. 3. Installing and adjusting the straw chopper inter- mediate drive belt (9) , see page 7.2.19 (Fig. 4) 7.16.1 188 678.1 - RHB LEXION 480...
Page 710: Removing The Transfer Gearbox
Remove the silencer (A) complete with the brackets from the machine. (Fig. 7) Remove the hydraulic hose (H) and protect the ends with plastic caps. Remove the clamp and then the bolt (P). (Fig. 8) 7.16.2 RHB LEXION 480 - 188 678.1...
Page 711 Dispose of the old oil in a way that is harmless to the environment and in accordance with existing environmental regulations. (Fig. 11) Remove the hose clamps (P) from the hydraulic tank. (Fig. 12) 7.16.3 188 678.1 - RHB LEXION 480...
Page 712 Removing the main intermediate drive belt (7) , see page 7.2.12 Removing the grain tank unloading intermediate drive belt (8) , see page 7.2.16 Removing the straw chopper intermediate drive belt (9) , see page 7.2.18 7.16.4 RHB LEXION 480 - 188 678.1...
Page 713 Lock the castellated nut again after loosening it. Using a suitable crane, take the weight of the hydraulic pump, then unbolt the pump from the gearbox. (Fig. 18) 7.16.5 188 678.1 - RHB LEXION 480...
Page 714 Remove the starter and unbolt the transfer gearbox. Pull out the transfer gearbox to the left first and then remove it from the machine. (Fig. 21) Remove the torsion damper. (Fig. 22) 7.16.6 RHB LEXION 480 - 188 678.1...
Page 715: Disassembling The Transfer Gearbox
233 011.0 5 Hex. nut M 12, part no. 236 172.0 6 Washer 13 x 30 x 3, part no. 236 844.0 (Fig. 25) 41134 Remove the engine cover. (Fig. 26) 7.16.7 188 678.1 - RHB LEXION 480...
Page 716 With drive shafts (15) fitted with an inner ring, it is not possible to remove the inner ring and the taper roller bearing (16). When damaged, the drive shaft must be replaced completely. (Fig. 29) 7.16.8 RHB LEXION 480 - 188 678.1...
Page 717 Using the special tool unscrew the slotted nut and press the bearing outer ring out of the slotted nut. Special tool: 1 Tube, part no. 181 611.0 2 Castellated spanner, part no. 174 357.0 (Fig. 33) 7.16.9 188 678.1 - RHB LEXION 480...
Page 718 Special tool: 1 Socket wrench, part no. 181 809.0 (Fig. 34) Using a suitable soft punch, drive the intermediate shaft out of the gearbox. (Fig. 35) Remove the spur gear. (Fig. 36) 7.16.10 RHB LEXION 480 - 188 678.1...
Page 719: Transfer Gearbox, Disassembled
18 Locating ring 19 Taper roller bearing 20 Seal 21 Engine cover 22 Hex. bolt M 10 x 30 DIN 933-8.8 Lock washer 10 23 Shaft seal 24 O-ring 25 Cover 26 Shaft seal 7.16.11 188 678.1 - RHB LEXION 480...
Page 720: Assembling The Transfer Gearbox
(Fig. 37, 38, 39) The gearbox versions (A and B) can be identified by: Gearbox version (A) has a bearing neck shoulder. (Fig. 38) 41137 Gearbox version (B) has no bearing neck shoulder. (Fig. 39) 41138 7.16.12 RHB LEXION 480 - 188 678.1...
Page 721 (Fig. 37, 40, 41) Apply some oil to the O-ring (2) and insert it into the housing. Drive the intermediate shaft (1) into the gearbox housing using a plastic-tip hammer. (Fig. 37, 40, 42) 7.16.13 188 678.1 - RHB LEXION 480...
Page 722 (Fig. 37, 40) Insert the pre-assembled spur gear (9) into the gearbox housing (observe installation position) and bolt down the cover (12) with the seal (11). Tightening torque = 45 Nm (Fig. 37, 40, 45) 7.16.14 RHB LEXION 480 - 188 678.1...
Page 723 The oil guide plate (30) must have space towards the intermediate gear (5) and the pre-assembled drive shaft (15). Insert the hex. bolts (31) with sealing compound. Press the bearing outer ring (16) into the housing. (Fig. 37, 40, 48) 7.16.15 188 678.1 - RHB LEXION 480...
Page 724 Slightly grease the O-ring (24) and place it into the cover (25). CAUTION! The threads of cover (25) and the gearbox housing (27) must be dry and free from grease when assembling. (Fig. 37, 38, 40) 7.16.16 RHB LEXION 480 - 188 678.1...
Page 725 1 Tube, part no. 181 611.0 2 Castellated spanner, part no. 174 356.1 3 Angle washer, part no. 174 358.0 (Fig. 52) Gearbox version (A) – Caulk the cover without cracks. (Fig. 53) 7.16.17 188 678.1 - RHB LEXION 480...
Page 726 Special tool: 1 Tube, part no. 181 611.0 2 Castellated spanner, part no. 174 356.1 3 Angle washer, part no. 174 358.0 (Fig. 37, 39, 40, 55) 7.16.18 RHB LEXION 480 - 188 678.1...
Page 727: Installing The Transfer Gearbox
The castellated nut can also be tightened to a given torque if the transfer gearbox is bolted to the engine. (Fig. 57, 59) Installing the transfer gearbox 1. Bolt down the torsion damper. Tightening torque = 45 Nm (Fig. 58) 7.16.19 188 678.1 - RHB LEXION 480...
Page 728 K = Oil level check plug E = Oil filler plug and gearbox breather A = Oil drain plug Insert the oil drain plug (A) with sealing compound, part no. 241 743.0. Tightening torque = 40 (Fig. 61) 7.16.20 RHB LEXION 480 - 188 678.1...
Page 729 Refit the Bowden cable and connect the hydraulic hoses. (Fig. 8–15) 8. Install the silencer (A) and the intermediate panel (S). (Fig. 6, 7) 9. Install the side guards. (Fig. 5) 7.16.21 188 678.1 - RHB LEXION 480...
Page 730 Engine output 7.16.22 RHB LEXION 480 - 188 678.1...
Page 731: Rotary Screen Drive
Remove the VM 16 x 1.5 lock nut. Pull off the V-belt pulley and remove the key along with the washer. (Fig. 3) Unlock the lock collar and knock it off against the normal direction of rotation. (Fig. 4) 7.17.1 188 678.1 - RHB LEXION 480...
Page 732 Remove the snap ring, catch, compression spring and supporting ring. Unlock the lock collar and knock it off against the normal direction of rotation. Remove the flange bearing along with the support plate from the spline shaft. (Fig. 6) 7.17.2 RHB LEXION 480 - 188 678.1...
Page 733: Rotary Screen Drive, Disassembled
16 Hex. bolt M 8 x 16 DIN 933-8.8 17 Bearing plate (Fig. 7) 18 Flange bearing 19 Lock collar 20 Washer 21 Key 22 V-belt pulley 23 Washer 24 Lock nut VM 16 x 1.5 7.17.3 188 678.1 - RHB LEXION 480...
Page 734: Assembling And Installing The Rotary Screen Drive
9. Bolt down the extension above the fuel tank. (Fig. 1) 10. Installing and adjusting the rotary chaff screen intermediate drive belt (25) , see page 7.3.13 Installing and adjusting the fan drive belt (27) , see page 7.3.16 7.17.4 RHB LEXION 480 - 188 678.1...
Page 735: Removing The Fan Drive
Installing the fan drive 1. Bolt down the V-belt pulley. (Fig. 9) 2. Bolt down axial fan with spacer washers. (Fig. 8) 3. Installing and adjusting the fan drive belt (27) , see page 7.3.16 7.17.5 188 678.1 - RHB LEXION 480...
Page 736 Rotary screen drive 7.17.6 RHB LEXION 480 - 188 678.1...
Page 737: Final Drives
Dispose of the old oil in a way that is harmless to the environment and in accordance with existing environmental regulations. Remove the hex. bolts from cover (D) and lift cover off. (Fig. 3) 7.18.1 188 678.1 - RHB LEXION 480...
Page 738 NOTE! The castellated nut is tightened to a torque of 600 Nm. (Fig. 5) Push out the wheel drive shaft. (Fig. 6) Remove the taper roller bearing and the spacer bushing. (Fig. 7) 7.18.2 RHB LEXION 480 - 188 678.1...
Page 739: Removing The Intermediate Shaft
Pull the outside bearing ring out of the gearbox. (Fig. 10) Removing the intermediate shaft Remove the wheel drive shaft. Drive out the expansion pin (S) and unscrew the cover (D). (Fig. 11) 7.18.3 188 678.1 - RHB LEXION 480...
Page 740 2 Hex. nut M 16 DIN 934-8, part no. 236 173.0 3 Washer 17 4 Bushing, part no. 181 807.1 5 Push-off bridge, part no. 181 816.3 6 Flat steel 30 x 15 x 150 (self-sourced) (Fig. 15) 31979 7.18.4 RHB LEXION 480 - 188 678.1...
Page 741: Removing The Drive Shaft
Pull the intermediate shaft out of the gearbox towards the side. (Fig. 17) Using a flat steel, drive the taper roller bearings off of the shaft so that a puller can be applied. Remove the taper roller bearings. (Fig. 18) 7.18.5 188 678.1 - RHB LEXION 480...
Page 742 23 Spacer sleeve 24 Taper roller bearing 25 Castellated nut M 60 x 2 26 Expansion pin 5 x 85 A DIN 8752 Expansion pin 8 x 85 A DIN 8752 27 Spacer ring 7.18.6 RHB LEXION 480 - 188 678.1...
Page 743: Assembling The Final Drive Gearbox
(4) into position. (Fig. 19, 20, 21) 3. Drive the shaft seal (7) into the bearing cover (5) so that it meets the end stop. Insert the O-ring (6). (Fig. 19, 20, 22) 7.18.7 188 678.1 - RHB LEXION 480...
Page 744: Installing The Intermediate Shaft
Install the final drive gearbox. Installing the intermediate shaft 1. Heat the taper roller bearing (10) to approx. 100 °C and press it onto the intermediate shaft using the special tool. (Fig. 19, 20, 25) 7.18.8 RHB LEXION 480 - 188 678.1...
Page 745 (A) which should be 0.4 to 0.8 mm. Should this not be the case, repeat installation of taper roller bearing (11). (Fig. 19, 20, 27, 28) 31993 7.18.9 188 678.1 - RHB LEXION 480...
Page 746 250 Nm. (Fig. 19, 20, 30) 6. Secure the bearing cover (15) with an expansion pin (16). (Fig. 19, 20, 31) Install the wheel drive shaft. Install the final drive gearbox. 7.18.10 RHB LEXION 480 - 188 678.1...
Page 747: Installing The Wheel Drive Shaft
20 t. CAUTION! There must be no more gap between the taper roller bearing and the shaft shoulder. Should this be the case, repeat the procedure. (Fig. 34, 35, 36) 7.18.11 188 678.1 - RHB LEXION 480...
Page 748 32001 4. Press the outer race of taper roller bearing (20) into the gearbox housing. (Fig. 37) 5. Place the spur gear (22) with the spacer (21) into the gearbox housing. (Fig. 38) 7.18.12 RHB LEXION 480 - 188 678.1...
Page 749 Tighten the castellated nut to 600 Nm. Hit the wheel drive shaft with several short, sharp blows to eliminate the settling effect. Tighten the castellated nut to 600 Nm and then tighten to the next notch. (Fig. 41, 42) 7.18.13 188 678.1 - RHB LEXION 480...
Page 750 13. Use a double expansion pin (26) to secure the castellated nut. (Fig. 45) 14. Insert spacer bushing. Insert the O-ring into the groove with grease. Press in the cap (29). (Fig. 46) 7.18.14 RHB LEXION 480 - 188 678.1...
Page 751: Disassembling The Planetary Final Drive Gearbox
(Fig. 48) Drive out the double expansion pin (S) and unscrew the castellated nut (K). NOTE! The castellated nut is tightened to a torque of 580 Nm. (Fig. 49) 7.18.15 188 678.1 - RHB LEXION 480...
Page 752 A = 300 mm B = 180 mm C = ∅ 22 mm 2 Threaded rods M 20 x 450 (4 pieces) 3 Hex. nuts M 20 DIN 934-8 (12 pieces) (Fig. 51) 32016 7.18.16 RHB LEXION 480 - 188 678.1...
Page 753 (W) does not touch the spur gear (S). Failure to observe this procedure may damage the gearbox. CAUTION! Observe number, position and thickness of shims. Remove compensating washer and spacer sleeve. (Fig. 54, 55) 7.18.17 188 678.1 - RHB LEXION 480...
Page 754 (P), ring gear (H) and the deep groove ball bearing (L). (Fig. 57, 58) Pull off taper roller bearing (A) from the wheel drive shaft. Remove the mechanical shaft seal (G). (Fig. 59) 7.18.18 RHB LEXION 480 - 188 678.1...
Page 755 Remove the hex. bolts from the spur gear (S) and remove the bushings. CAUTION! The hex. bolts have been fitted with liquid locking compound and will therefore be tight. (Fig. 62) Drive out the expansion pin. (Fig. 63) 7.18.19 188 678.1 - RHB LEXION 480...
Page 756 1 Tube, part no. 181 611.0 2 Socket wrench, part no. 174 048.0 (Fig. 65) 32030 Using a flat steel, drive the taper roller bearings off of the shaft so that a puller can be applied. (Fig. 66) 7.18.20 RHB LEXION 480 - 188 678.1...
Page 757 Final drives 13 16 32031 32032 7.18.21 188 678.1 - RHB LEXION 480...
Page 758: Planetary Final Drive Gearbox, Disassembled
Expansion pin 6 x 100 A DIN 8752 34 O-ring 190 x 3 -n DIN 3771 35 Dust cap 36 Wheel studs 37 Thrust piece nut H 12 38 Reflector (Fig. 67, 68) 7.18.22 RHB LEXION 480 - 188 678.1...
Page 759: Assembling The Planetary Final Drive Gearbox
(Fig. 67, 68, 69, 70) 5. Fit the O-ring (6) with grease into the groove of the ring gear (7). Place the ring gear on the gearbox housing. (Fig. 67, 68, 71) 7.18.23 188 678.1 - RHB LEXION 480...
Page 760 (29) and O-ring (26). Oil the sealing lips of the shaft seal and the O-ring. 15. Drive the outer race of taper roller bearing (23) into the housing and insert the pre-assembled pinion shaft. (Fig. 67, 68) 7.18.24 RHB LEXION 480 - 188 678.1...
Page 761 17. Attach the pre-assembled axle housing (22) using a lifting device. CAUTION! A second person is required to guide the axle housing so that the bearing (23) does not touch the spur gear (15). (Fig. 67, 68, 77) 7.18.25 188 678.1 - RHB LEXION 480...
Page 762 Tighten the castellated nut to 580 Nm and then tighten to the next notch. The spinning torque of the pinion shaft may be 8 to 11 Nm. (Fig. 67, 68, 79, 80, 81) 7.18.26 RHB LEXION 480 - 188 678.1...
Page 763: Installing The Final Drive Gearbox
9. Slide the determined number of washers (D) and profiled bushings (C) on the intermediate drive shaft. 10. Bolt down the final drive gearbox to the drive axle with hex. bolts (B) and new safety washers. (Fig. 83, 84, 85) 7.18.27 188 678.1 - RHB LEXION 480...
Page 764 13. Tighten the hex. bolts (B). Tightening torque M 20 = 370 Nm 14. Grease profiled bushing (C) with multi-purpose grease, e.g. CLAAS multi-purpose grease EP 2. (Fig. 83, 84, 85) 15. Fill in gearbox oil. E = Oil filler plug and gearbox breather...
Page 765 Final drives E = Oil filler plug and gearbox breather A = Oil drain plug K = Oil level check plug (Fig. 87) 16. Install wheel. 32049 7.18.29 188 678.1 - RHB LEXION 480...
Page 766 Final drives 7.18.30 RHB LEXION 480 - 188 678.1...
Page 767: Manual Gearbox
Unlock the pin (B) at the gearshift linkage and pull it out. Unhinge the parking brake rope (H) and unscrew it from the retarder (W). (Fig. 2) Unscrew clamps (S) for attaching the hydraulic hoses. (Fig. 3) 7.19.1 188 678.1 - RHB LEXION 480...
Page 768 Unscrew the hex. bolts (S) and remove the brake calliper. CAUTION! The hex. bolts have been fitted with liquid locking compound. (Fig. 5) Pull both drive shafts with brake discs out of the side of the manual gearbox. (Fig. 6) 7.19.2 RHB LEXION 480 - 188 678.1...
Page 769: Disassembling The Manual Gearbox
Remove the magnetic pick-up (I). Unscrew the gearbox cover (D). (Fig. 9) Remove the compression springs. Remove the arresting balls with the magnetic rod (M, special tool part no. 171 842.0). (Fig. 10) 7.19.3 188 678.1 - RHB LEXION 480...
Page 770 Drive out the expansion pin. Pull out the shifter rail out to the right and remove the shifter fork. (Fig. 13) Drive out the expansion pin. Pull out the shifter rail out to the right and remove the shifter fork. (Fig. 14) 7.19.4 RHB LEXION 480 - 188 678.1...
Page 771: Removing The Drive Shaft
Remove the shifter rails. Remove the brake linings and the right-hand gearbox cover. (Fig. 17) Push the drive shaft through to the right-hand side. Pull off the deep groove ball bearing with a puller. (Fig. 18) 7.19.5 188 678.1 - RHB LEXION 480...
Page 772: Removing The Main Shaft
Remove manual gearbox. Remove the shifter rails. Remove the brake linings and the right-hand gearbox cover. (Fig. 21) Shift the main shaft to the right and remove the cylinder roller bearing (Z). (Fig. 22) 7.19.6 RHB LEXION 480 - 188 678.1...
Page 773 Pull off the inner race of the cylinder roller bearing using a puller. (Fig. 24) Shift the circlip along the shaft and pull the shaft to the right until the sliding gear can be removed. (Fig. 25, 26) 7.19.7 188 678.1 - RHB LEXION 480...
Page 774: Removing The Differential
Remove manual gearbox. Remove the shifter rails. Remove the main shaft. Remove the support plate on both sides. (Fig. 29) Remove the cheese-head screws on both sides and remove the brake plate flange. (Fig. 30) 7.19.8 RHB LEXION 480 - 188 678.1...
Page 775: Disassembling The Differential
Remove the differential. Pull off deep groove ball bearing with a puller. (Fig. 32) Unbolt the ring gear from the differential housing. (Fig. 33) Remove the claw flange and the crown wheel. (Fig. 34) 7.19.9 188 678.1 - RHB LEXION 480...
Page 776 Drive the expansion pins out of the ring gear. (Fig. 36) Pull off deep groove ball bearing from the differential housing. (Fig. 37) Drive expansion pins out of the differential housing. (Fig. 38) 7.19.10 RHB LEXION 480 - 188 678.1...
Page 777: Differential, Disassembled
14 Deep groove ball bearing 6018 DIN 625 (Fig. 40) Assembling the differential Apply a coat of Molykote paste, part no. 177 571.0, to the contact areas of the crown wheels and the bevel gears. (Fig. 41) 32088 7.19.11 188 678.1 - RHB LEXION 480...
Page 778 Once the bearing has cooled down, check bearing seat with a short hammer blow. (Fig. 44) Place the ring gear (9) on the differential housing and fix it using the expansion pins (10). (Fig. 40, 45) 7.19.12 RHB LEXION 480 - 188 678.1...
Page 779: Installing The Differential
Push the complete differential with ring gear and bearings into the right-hand side of the gearbox housing. (Fig. 48) Replace the shaft seals (W) in the left-hand and right-hand brake plate flanges. (Fig. 49) 7.19.13 188 678.1 - RHB LEXION 480...
Page 780 The axial play must be between 0.30 mm and 1.40 mm. (Fig. 51) Bolt down the left and right support plates. Tightening torque = 78 Nm (Fig. 52) Install main shaft. Install shifter rails. Install manual gearbox. 7.19.14 RHB LEXION 480 - 188 678.1...
Page 781: Manual Gearbox, Disassembled
22 Hex. bolt M 10 x 25 DIN 933-8.8 Lock washer 10 DIN 128 23 Hex. bolt M 8 x 20 DIN 933-8.8 24 Shift gate 25 O-ring 20 x 4 DIN 3771 7.19.15 188 678.1 - RHB LEXION 480...
Page 782: Assembling The Manual Gearbox
Manual gearbox Manual gearbox 32109 Assembling the manual gearbox Clean all threads in the gearbox housing. 7.19.16 RHB LEXION 480 - 188 678.1...
Page 783: Installing The Main Shaft
CAUTION! Screw in the precision fit bolt (21) at (P), the M 10 x 25 hex. bolts at (A) and the M 10 x 30 hex. bolts at (B). (Fig. 53, 58) 7.19.17 188 678.1 - RHB LEXION 480...
Page 784: Installing The Drive Shaft
2. Insert the circlip (11) into the notch. (Fig. 61) 3. Feed the drive shaft into the gearbox from the left-hand side and slide on the double sliding gear. 4. Install circlip (11). (Fig. 61, 62) 7.19.18 RHB LEXION 480 - 188 678.1...
Page 785: Installing The Shifter Rails
8. Check the axial play of the drive shaft. The play must be 0.20 mm to 1.16 mm. (Fig. 65) Installing the shifter rails 1. Replace the three O-rings (25) every time the rails are installed. (Fig. 66) 7.19.19 188 678.1 - RHB LEXION 480...
Page 786 (Fig. 53, 69) 5. Push in the shifter rail (33) and the shifter finger (34), then fix with an expansion pin. (Fig. 53, 70) 7.19.20 RHB LEXION 480 - 188 678.1...
Page 787 Lock in place with the lock nut. (Fig. 73) 9. Install the brake linings and the drum brake and key them in position. (Fig. 74) Install the manual gearbox. 7.19.21 188 678.1 - RHB LEXION 480...
Page 788: Installing The Manual Gearbox
Remove the key from the brake disc. (Fig. 77) Bolt down the brake calliper. Insert the precision fit bolt (P) and the hex. bolt (S) with liquid locking compound, e.g. DELO-ML 5349. Tightening torque = 210 Nm (Fig. 78) 7.19.22 RHB LEXION 480 - 188 678.1...
Page 789 (Fig. 80) Insert the O-ring and bolt on the hydrostatic motor. (Fig. 81) Bolt down the clamps (S) for attaching the hydrostatic hoses. (Fig. 82) 7.19.23 188 678.1 - RHB LEXION 480...
Page 790 A = Oil drain plug E = Oil filler plug and gearbox breather (Fig. 85, 86) Install the drive wheels. For servo gearshift: Bolt down the hose (R) to the cover of the manual gearbox. (Fig. 86) 7.19.24 RHB LEXION 480 - 188 678.1...
Page 791: Servo Gearshift
Raise the feed rake conveyor and safely support it in that position. Remove the left-hand stepped preparation floor section. (Fig. 89) Unscrew the cylinder cover (13) with the hex. bolts (14). (Fig. 90) 7.19.25 188 678.1 - RHB LEXION 480...
Page 792 (Fig. 92) Remove the arresting ball (5) with the magnetic rod (M, special tool part no. 171 842.0). CAUTION! Loosen the hex. bolts (1) from the gearbox cover (2) if required. (Fig. 93, 94) 7.19.26 RHB LEXION 480 - 188 678.1...
Page 793: Servo Gearshift, Disassembled
14 Hex. bolt M 8 x 40 (Fig. 94) Installing the shifter pistons Insert the locking balls (5). Bolt down gearbox cover (2) if necessary. (Fig. 94, 95) Insert the lower compression springs (6). (Fig. 96) 7.19.27 188 678.1 - RHB LEXION 480...
Page 794: Bleeding The Shifter Piston
(3) until the oil comes out without bubbles. After bleeding check the oil level and top up if necessary. Install the left-hand stepped preparation floor section. (Fig. 89, 98) 7.19.28 RHB LEXION 480 - 188 678.1...
Page 795: Brake
Secure the brake drum with a key. Reconnect the parking brake cable (H) at the retarder (W). Adjust the cable so that the parking brake is fully functional on the 3rd or 4th notch. (Fig. 4) 7.20.1 188 678.1 - RHB LEXION 480...
Page 796: Bleeding The Brake System
(S) holding the brake pads on the disc brake calliper. (Fig. 6) Push back the brake cylinders by forcing the brake pads apart. Remove the brake pads (B) from above. (Fig. 7) 7.20.2 RHB LEXION 480 - 188 678.1...
Page 797: Removing A Brake Calliper
Remove the brake line from the calliper and disconnect the cable. (Fig. 10) Unscrew the hex. bolts (S) and remove the brake calliper. CAUTION! The hex. bolts have been fitted with liquid locking compound. (Fig. 11) 7.20.3 188 678.1 - RHB LEXION 480...
Page 798: Installing A Brake Calliper
Consider the axial play in the intermediate drive shaft. Secure the brake disc with a key. Bleeding the brake system , see page 7.20.2 7.20.4 RHB LEXION 480 - 188 678.1...
Page 799: Steering Axle
Screw out the wheel bolts and remove the wheels. (Fig. 2) Remove cap (K). – The cap will be destroyed in this process. (Fig. 3) Remove the expansion pin from the castellated nut. (Fig. 4) 7.21.1 188 678.1 - RHB LEXION 480...
Page 800 If necessary, first drive the inner taper roller bearing forward a little with a chisel. Now pull off the bearing with a puller. ATTENTION! Take care not to damage the sealing rings. (Fig. 8) 7.21.2 RHB LEXION 480 - 188 678.1...
Page 801 Steering axle Pull off the seal retainer (T) with the seals from the stub axle, using a puller. (Fig. 9) 7.21.3 188 678.1 - RHB LEXION 480...
Page 802: Wheel Bearing, Disassembled
5 Taper roller bearing 332 11 DIN 720 6 Shim 7 Castellated nut M 42 x 1.5 8 Expansion pin 5 x 60-A DIN 8752 9 Expansion pin 10 Dust cap (Fig. 10) 7.21.4 RHB LEXION 480 - 188 678.1...
Page 803: Installing The Wheel Bearing
Apply some oil to the outer bearing seat of the wheel hub and grease the outer taper roller bearing (5). Drive on the outer taper roller bearing, using a block-ended tube. (Fig. 10, 13) 7.21.5 188 678.1 - RHB LEXION 480...
Page 804 Apply the tube on the cap only inside the flanged edge! Grease the bearing using the grease nipple provided on the wheel hub. Install the wheels with M 22 x 1.5 wheel bolts. Tightening torque = 520 Nm (Fig. 10, 17) 7.21.6 RHB LEXION 480 - 188 678.1...
Page 805: Removing The Stub Axle
Remove the castellated nuts completely. (Fig. 19) Unscrew the two bolts from the steering track arm. Remove steering track arm (H). (Fig. 20) Remove the upper cover. (Fig. 21) 7.21.7 188 678.1 - RHB LEXION 480...
Page 806 Screw out set screw. (Fig. 23) Drive out the kingpin with a brass punch. Remove the stub axle. (Fig. 24) Remove axial taper roller bearing (13) and O-rings from the stub axle. (Fig. 25) 7.21.8 RHB LEXION 480 - 188 678.1...
Page 807 3 Centring disc part no. 181 879.0 4 Tube Outside diameter: 50 mm Inside diameter: 40 mm Length: 150 mm 5 Spindle part no. 181 877.0 6 Sleeve part no. 181 881.1 (Fig. 27) 35064 7.21.9 188 678.1 - RHB LEXION 480...
Page 808: Stub Axle, Disassembled
13 mm. Press in the bottom needle bushings until the bottom needle bushing is flush with the bottom stub axle surface. (Fig. 30) 7.21.10 RHB LEXION 480 - 188 678.1...
Page 809 Carefully drive in the kingpin using a plastic-tip hammer – observe correct installation position! 96 mm Y = 109 mm CAUTION! Ensure that the O-rings are not pushed away to the bottom. (Fig. 33, 34) 7.21.11 188 678.1 - RHB LEXION 480...
Page 810 Castellated nut of steering cylinder (M 20 x 1.5): Tightening torque = 200 Nm Secure the castellated nuts with split pins. (Fig. 37) Grease the stub axle bearing by means of grease nipples. Install the wheel bearing. 7.21.12 RHB LEXION 480 - 188 678.1...
Page 811: Setting The Track Width
Adjust the steering axle wheel track width to a toe-in of 0 to 15 mm. For this reason set check distance (Y) 0 to 15 mm larger than check distance (X). (Fig. 38) 7.21.13 188 678.1 - RHB LEXION 480...
Page 812 Remove the castellated nut completely. (Fig. 39, 40) The setting is made by adjusting the steering track rod. Loosen clamp (S) and adjust the ball joint as needed. (Fig. 41) 7.21.14 RHB LEXION 480 - 188 678.1...
Page 813: Adjusting The Steering Axle End Stops
(L) still has about 2.5 mm possible travel before it meets the stops. Carry out the same procedure on the other side of the machine. Secure the stop bolts with the lock nuts. (Fig. 43, 44) 7.21.15 188 678.1 - RHB LEXION 480...
Page 814: Removing The Steering Axle
Tie up the hydraulic cylinder at the side. (Fig. 46) Remove the split pin (T) from the castellated nut. (Fig. 47) Remove the castellated nut (K). Remove the supporting ring and the back-up ring. (Fig. 48) 7.21.16 RHB LEXION 480 - 188 678.1...
Page 815 Drive out the axle pivot pin (A) using a soft metal punch. CAUTION! Take particular care of shims falling out! (Fig. 49, 50) Lower the steering axle and move it away from the machine to the rear. (Fig. 51) 7.21.17 188 678.1 - RHB LEXION 480...
Page 816: Steering Axle Bearing, Disassembled
Hex. nut M 12 2 Pin 3 Bushing 4 Steering axle housing 5 Back-up ring 6 Supporting ring Shim 7 Castellated nut M 42 x 1.5 8 Split pin 8 x 71 (Fig. 52) 7.21.18 RHB LEXION 480 - 188 678.1...
Page 817: Installing The Steering Axle
5. Grease the axle pivot pin bearing. 6. Install the steering cylinder and secure with castellated nuts (M 20 x 1.5). Tightening torque = 200 Nm 7. Install wheels. (Fig. 52, 53, 54, 55, 56) 7.21.19 188 678.1 - RHB LEXION 480...
Page 818 Steering axle 7.21.20 RHB LEXION 480 - 188 678.1...
Page 819: Machine Body
Machine body...
Page 821: Rotary Screen
Drive the expansion pin out of the axle and remove the rotary screen. (Fig. 2) Disassembling the rotary screen Remove the deflector plate and the bracket (H). (Fig. 3) Unlock the lock collar and knock it off against the normal direction of rotation. 8.1.1 188 678.1 - RHB LEXION 480...
Page 822 Rotary screen Unbolt the flange ball bearing and remove along with the axle. (Fig. 5) 8.1.2 RHB LEXION 480 - 188 678.1...
Page 823: Rotary Screen, Disassembled
Hex. nut M 8 DIN 934 15 Suction tube 16 Mushroom head bolt M 8 x 20 Hex. nut M 8 Contact washer A 8 17 Hex. nut M 6 Contact washer B 6 (Fig. 6) 8.1.3 188 678.1 - RHB LEXION 480...
Page 824: Assembling And Installing The Rotary Screen
3. Install bracket (9) and deflector plate (12) and align so that the dimensions Y = 6 mm and Z = 5 4. Place rotary screen into the back plate and secure with the expansion pin (4). (Fig. 6, 7) 8.1.4 RHB LEXION 480 - 188 678.1...
Page 825 Adjust the suction tube (15) so that dimension (B) is 10 ± 2 mm. (Fig. 6, 8) On machines with a suction blower (drive): Adjust the trough and the lateral panel. (Fig. 8, 9) 8.1.5 188 678.1 - RHB LEXION 480...
Page 826: Trough And Lateral Panel, Disassembled
13 Nozzle 14 Suction tube 15 Mounting bracket 16 Clamp 17 Hex. bolts M 8 x 45 Hex. nut M 8 Contact washer A 8 18 Plastic hose 19 Sealing strip 20 Clamping rail 8.1.6 RHB LEXION 480 - 188 678.1...
Page 827: Adjusting The Trough And The Lateral Panel
Fold down the back plate along with the rotary screen and lock it. The nozzle (13) must make tight contact with the trough (12), if necessary loosen the hose clamp (8) and shift the nozzle to the correct position. (Fig. 12) 8.1.7 188 678.1 - RHB LEXION 480...
Page 828: Removing The Fan Drive
Installing the fan drive 1. Bolt down the V-belt pulley. (Fig. 14) 2. Bolt down axial fan with spacer washers. (Fig. 13) 3. Installing and adjusting the fan drive belt (27) , see page 7.3.16 8.1.8 RHB LEXION 480 - 188 678.1...
Page 829: Removing The Rotary Screen Suction Blower
Loosen two bolts from the spindle and remove spindle. (Fig. 16) Unscrew the bolt from the bracket and remove the complete suction blower. (Fig. 17) Disassembling the rotary screen suction blower Unbolt the blower housing and remove it. (Fig. 18) 8.1.9 188 678.1 - RHB LEXION 480...
Page 830 Loosen the set screw and pull off the blower wheel. (Fig. 19) Remove parallel key and sheet metal cover. Drive bearing housing out of the bracket. Remove the circlips and drive out the shaft. (Fig. 20) 8.1.10 RHB LEXION 480 - 188 678.1...
Page 831: Rotary Screen Suction Blower, Disassembled
14 Set screw M 8 x 12 DIN 916 15 Mounting bracket 16 Hex. bolt M 6 x 40 DIN 931-8.8 Hex. nut M 6 DIN 934 Lock washer 6 17 Back plate 8.1.11 188 678.1 - RHB LEXION 480...
Page 832: Assembling And Installing The Rotary Screen Suction Blower
9. Installing and adjusting the suction blower drive belt (28) , see page 7.3.18 10. Tighten the M 12 x 90 bolt to 78 Nm. 11. Place the suction tube in position and fasten with a clamp. (Fig. 25) 8.1.12 RHB LEXION 480 - 188 678.1...
Page 833: Drive Axle
Unbolt the four hex. bolts (T) from the hydrostatic motor and pull motor off of the gearbox. (Fig. 3) Jack up the machine safely on both sides and underneath the machine frame. Remove the drive wheels. (Fig. 4) 8.2.1 188 678.1 - RHB LEXION 480...
Page 834 (Fig. 6) Unhook the parking brake cable (H) and unscrew it from retarder (W). Remove the clamps from the drive axle and hang the cable on the side of the machine. (Fig. 7, 8) 8.2.2 RHB LEXION 480 - 188 678.1...
Page 835 Unbolt the complete axle from the frame of the machine and remove towards the front of the machine. (Fig. 11) Removing the final drive gearbox , see page 7.18.1 Removing the manual gearbox , see page 7.19.1 8.2.3 188 678.1 - RHB LEXION 480...
Page 836: Installing The Drive Axle
Adjust shifter rails (C and D) underneath the operator’s platform at ball joints (K) if necessary so that the gears are fully in mesh and the detent balls lock properly in the selector shafts. (Fig. 1, 12) 8.2.4 RHB LEXION 480 - 188 678.1...
Page 837 Slide on profiled bushing (P) with the turned-out area of the toothed hub profile facing the manual gearbox. Insert O-ring and bolt down hydrostatic motor with hex. bolts (T). (Fig. 15, 16) 10. Bolt down hydraulic hose clamps. (Fig. 2) 8.2.5 188 678.1 - RHB LEXION 480...
Page 838 Start diesel engine, actuate servo gearshift on the gear lever and loosen the bleed valve (3) until the oil comes out without bubbles. After bleeding check the oil level and top up if necessary. (Fig. 17, 18) 8.2.6 RHB LEXION 480 - 188 678.1...
Page 839: Hydraulic System
Hydraulic system...
Page 841: Oil Cooler
Once the oil has been drained, re-tighten the cap to the oil drain nozzle. (Fig. 1) Fold up the rotary screen. Remove the pin from the gas strut. Remove the bolt from the bearing and remove the rotary screen completely. (Fig. 2) 9.1.1 188 678.1 - RHB LEXION 480...
Page 842 ENVIRONMENT! Dispose of the old oil in a way that is harmless to the environment and in accordance with existing environmental regulations. Plug the hydraulic connections tightly. (Fig. 6) 9.1.2 RHB LEXION 480 - 188 678.1...
Page 843 Swing the condenser out of the way and hold back safely with a rope. (Fig. 7) Unbolt the bracket (H) from the air intake box and remove along with the bearing plate. (Fig. 8) Remove the oil cooler. (Fig. 9) 9.1.3 188 678.1 - RHB LEXION 480...
Page 844: Installing The Oil Cooler
(Fig. 2) 6. Close the rotary screen and lock it. 7. Refill the hydraulic system with oil – see page 9.2.3, Filling instructions when changing the hydraulic oil . 9.1.4 RHB LEXION 480 - 188 678.1...
Page 845: Maintenance
(if available) to Slow. T = Hydraulic oil reservoir S = Oil level dipstick and oil filling The hydraulic oil level must be at least at the lower mark on the dipstick (S). (Fig. 1) 9.2.1 188 678.1 - RHB LEXION 480...
Page 846: Changing The Hydraulic Oil
Place a sufficiently large container under the oil drain nozzle. Unscrew the cap from the oil drain nozzle and drain the oil. Once the oil has been drained, re-tighten the cap to the oil drain nozzle. (Fig. 2) 9.2.2 RHB LEXION 480 - 188 678.1...
Page 847: Filling Instructions When Changing The Hydraulic Oil
4. With the ground speed control lever in neutral, stop the diesel engine. Should it be required, top up hydraulic oil up to the mark on the dipstick. 5. Test run (Fig. 1) 9.2.3 188 678.1 - RHB LEXION 480...
Page 848 Maintenance 9.2.4 RHB LEXION 480 - 188 678.1...
Page 849: Hydraulic Pumps
(D) side of the pump. Remove the lines and plug them with plastic caps. Remove the bolts (G and L) and the hydraulic pump, the bracket and the V-belt pulley. (Fig. 3, 4) 9.3.1 188 678.1 - RHB LEXION 480...
Page 850: Disassembling The Uni-Spreader Hydraulic Pump
Disassembling the uni-spreader hydraulic pump Remove the key (F) and the shaft seal (D) from the pump shaft. Remove the M 8 cheese-head screws from the pump housing and disassemble the pump. (Fig. 8) 9.3.2 RHB LEXION 480 - 188 678.1...
Page 851: Uni-Spreader Hydraulic Pump, Disassembled
3. Fit the shaft seal and the key on the pump shaft. Bolt the V-belt pulley to the pump with the M 12 x 1.5 hex. nut. Tightening torque = 50 (Fig. 9, 10) 9.3.3 188 678.1 - RHB LEXION 480...
Page 852: Installing The Uni-Spreader Hydraulic Pump
Push the side guard out of the locating bearings (L) and remove it. (Fig. 13) Unscrew two inside hydraulic hose clamps (S) from the intermediate panel (Z). Unbolt the intermediate panel (Z) from the left- and right-hand side. (Fig. 14) 9.3.4 RHB LEXION 480 - 188 678.1...
Page 853 Remove one mounting plate (L) on the left-hand side. Push the cylinder sideways out of the mounting plate from the right-hand side and remove it. Remove the left-hand and right-hand brace (S). (Fig. 17) 9.3.5 188 678.1 - RHB LEXION 480...
Page 854 Using the lifting device, lift the pump slightly and remove the four bolts (S) from the flange. Pull the pump out of the transfer gearbox and remove from the machine. (Fig. 20) 9.3.6 RHB LEXION 480 - 188 678.1...
Page 855: Installing The Ground Drive Hydraulic Pump
7. Bolt down the intermediate panel. Bolt two hydraulic hose clamps to the intermediate panel from the inside. 8. Push the side guard into the bearings. Fit the gas struts and the cables. (Fig. 21, 22) 9.3.7 188 678.1 - RHB LEXION 480...
Page 856: Removing The Hydraulic Double Pump
Tightening torque = 45 Nm 2. Connect the hydraulic hoses. 3. Fill in hydraulic oil at the filler plug (S) of tank (T) – see page 9.2.3, Filling instructions when changing the hydraulic oil . (Fig. 25) 9.3.8 RHB LEXION 480 - 188 678.1...
Page 857: Hydrostatic Fixed Displacement Motors
Plug all lines and connections tightly with suitable caps. For servo gearshift: Unscrew the hose (R) from the cover of the manual gearbox. Plug the hose and unions tightly with plastic caps. (Fig. 3) 9.4.1 188 678.1 - RHB LEXION 480...
Page 858 Support the underside of the motor with a suitable adjustable jack (B). Remove the bolts (S) from the flange housing. Pull the motor straight out of the profiled bushing. Remove damaged O-ring from the flange facing. (Fig. 4) 9.4.2 RHB LEXION 480 - 188 678.1...
Page 859: Installing The Ground Drive Hydrostatic Fixed Displacement Motor
33107 gearbox (1) and hydrostatic motor (4). 2. Install profiled bushing (2) with rolling bearing grease. CAUTION! Slide in the profiled bushing (2) with side (A) towards the gearbox (1). (Fig. 5, 6) 9.4.3 188 678.1 - RHB LEXION 480...
Page 860 Start diesel engine, actuate servo gearshift on the gear lever and loosen the bleed valve (3) until the oil comes out without bubbles. After bleeding check the oil level and top up if necessary. (Fig. 8, 9) 9.4.4 RHB LEXION 480 - 188 678.1...
Page 861: Removing The Reverser Drive Hydrostatic Fixed Displacement Motor
(Fig. 10, 11) Loosen and remove the set collar from the bearing plate. (Fig. 12) Loosen the M 10 x 20 hex. bolt so that the bearing plate may be removed. (Fig. 13) 9.4.5 188 678.1 - RHB LEXION 480...
Page 862 (Fig. 16) Remove the supporting arm with the hydraulic motor and the drive gear. Unscrew the M 8 x 25 hex. bolt from the face end of the hydraulic motor. (Fig. 17) 9.4.6 RHB LEXION 480 - 188 678.1...
Page 863 Using a two-legged puller and a head-centred M 8 hex. bolt, pull the gear off of the shaft. (Fig. 18) Loosen the M 12 x 35 hex. bolts and remove the hydraulic motor from the supporting arm. (Fig. 19) 9.4.7 188 678.1 - RHB LEXION 480...
Page 864: Reverser Drive Hydrostatic Fixed Displacement Motor, Disassembled
6 Compression spring Hex. bolt M 8 x 180 DIN 931-8.8 Spring guide Hex. nut M 8 DIN 934-8 7 Bearing plate Hex. bolt M 10 x 20 DIN 933-8.8 Contact washer A 10 9.4.8 RHB LEXION 480 - 188 678.1...
Page 865: Installing The Reverser Drive Hydrostatic Fixed Displacement Motor
10. Either refill the hydraulic oil tank (T) through the filler plug (S) – see page 9.2.3, Filling instructions when changing the hydraulic oil or remove the valve combination for creating a vacuum from the tank. (Fig. 21) 9.4.9 188 678.1 - RHB LEXION 480...
Page 866 Hydrostatic fixed displacement motors 9.4.10 RHB LEXION 480 - 188 678.1...
Page 867: Hydraulic Cylinders - High-Pressure Hydraulic Circuit
Chuck the cylinder and turn the cylinder head until the securing wire (D) comes out of the groove in the cylinder barrel. (Fig. 2) Pull the cylinder head and the ram rod out of the cylinder barrel. (Fig. 3) 9.5.1 188 678.1 - RHB LEXION 480...
Page 868 It can be released easily by heating it to about 200 °C. (Fig. 5) Pull the ram rod out of the cylinder head. The dust guard, seal, back-up ring and O-ring can now be removed from the cylinder head. 9.5.2 RHB LEXION 480 - 188 678.1...
Page 869: Cutterbar Cross Levelling Hydraulic Cylinder, Disassembled
Back-up ring (up to serial no..) 7 Securing wire 8 Cylinder head Hex. bolt M 16 x 140 DIN 931-8.8 Contact washer A 16 Washer 9 Seal 10 Dirt scraper (Fig. 6) 9.5.3 188 678.1 - RHB LEXION 480...
Page 870: Assembling The Cutterbar Cross Levelling Hydraulic Cylinders
1. Place the existing shims (D) underneath the cylinder and insert the cylinder. Insert the hex. bolt (S). The cylinder must make contact with the shims (D) without play. (Fig. 7) 9.5.4 RHB LEXION 480 - 188 678.1...
Page 871 Tighten hex. bolt (S) M 16 x 140 with a tightening torque of 195 Nm. (Fig. 1, 8) 3. Connect the hydraulic lines. 4. Bleeding the cutterbar cross levelling hydraulic cylinders , see page 9.5.6 9.5.5 188 678.1 - RHB LEXION 480...
Page 872: Bleeding The Cutterbar Cross Levelling Hydraulic Cylinders
(Fig. 9, 10, 11) 9. Carry out a test run. Check system tightness and hydraulic oil level in the tank (T), top up oil if required. (Fig. 12) 9.5.6 RHB LEXION 480 - 188 678.1...
Page 873: Removing The Cutterbar Hydraulic Cylinders
(D) is pushed out of the groove of the cylinder barrel. (Fig. 15) Pull the cylinder head out of the cylinder barrel. (Fig. 16) All seals may now be changed. 9.5.7 188 678.1 - RHB LEXION 480...
Page 874: Disassembling The Cutterbar Hydraulic Cylinders
Remove the snap ring (R) and the spring guide (F) from the cylinder. (Fig. 18) Remove the two hex. bolts (S) from the rear spring plate and remove the position indicator. (Fig. 19) 9.5.8 RHB LEXION 480 - 188 678.1...
Page 875 Pull the cylinder head and the ram out of the cylinder barrel. Clean the ram rod and remove the cylinder head. (Fig. 22) Clean the ram. The dust guard, seal, back-up ring and the O-ring in the cylinder head can now be replaced. 9.5.9 188 678.1 - RHB LEXION 480...
Page 876 DIN 912-8.8 16 Lock nut VM 16 x 1.5 17 Washer 16.5 x 33 x 5 18 Position indicator Hex. bolt M 10 x 20 DIN 933-8.8 Contact washer A 10 (Fig. 23) 9.5.10 RHB LEXION 480 - 188 678.1...
Page 877: Assembling The Cutterbar Hydraulic Cylinder
(14), then bolt down with the cheese-head screws (15) and washers. CAUTION! Pre-tension the compression spring only slightly. 7. Bolt the position indicator (18) to the cylinder flange. (Fig. 23) 9.5.11 188 678.1 - RHB LEXION 480...
Page 878: Installing The Cutterbar Hydraulic Cylinders
This setting applies to cutterbar cylinders with a mechanical lock (Fig. 25) and for cutterbar cylinders with a hydraulic lock (Fig. 26). CAUTION! Ensure that all compression springs are adjusted evenly! (Fig. 25, 26) 30291 9.5.12 RHB LEXION 480 - 188 678.1...
Page 879: Removing The Cutterbar Variable-Speed Drive Hydraulic Cylinder
Unscrew three M 12 x 165 countersunk head bolts from the thrust flange and remove the variable speed drive cylinder. (Fig. 29) Remove the complete hydraulic coupling from the thrust plate. (Fig. 30) 9.5.13 188 678.1 - RHB LEXION 480...
Page 880: Installing The Cutterbar Variable-Speed Drive Hydraulic Cylinder
7. Start the diesel engine and operate the variable speed drive cylinder several times until all the air has been expelled. (Fig. 32, 33) Disassembling the rotary coupling Remove circlip (3). (Fig. 34, 40) 9.5.14 RHB LEXION 480 - 188 678.1...
Page 881 4 Hex. nut M 8 DIN 934 (2 pieces) 5 Union nut 12 S DIN 3870, part no. 244 061.1 (Fig. 36) 32276 Remove snap ring (8) from the hydraulic coupling (2). (Fig. 37, 40) 9.5.15 188 678.1 - RHB LEXION 480...
Page 882: Rotary Coupling, Disassembled
6 Spacer ring (from serial no..) 7 Belleville spring (from serial no..) 8 Circlip 9 Stop washer 10 Adapter 11 Back-up ring (from serial no..) 12 Seal 13 Stepped washer 14 Circlip 15 O-ring (Fig. 40) 9.5.16 RHB LEXION 480 - 188 678.1...
Page 883: Assembling The Rotary Coupling
Observe installation position of seal (12) and stepped washer (13). (Fig. 40, 41, 42) When installing the back-up ring (11) and the stop washer (9) into the adapter (10), observe correct installation position. (Fig. 41, 43) 9.5.17 188 678.1 - RHB LEXION 480...
Page 884: Removing The Concave Adjustment Hydraulic Cylinder
Support the drive axle safely and remove the wheel on the side where the cylinder is to be removed. Remove the guard. Remove the hydraulic lines (H) from the cylinder and plug them tightly with caps. (Fig. 46) 9.5.18 RHB LEXION 480 - 188 678.1...
Page 885: Disassembling The Concave Adjustment Hydraulic Cylinder
Loosen the M 20 x 1.5 lock nut and unscrew together with the cylinder eye. (Fig. 49) Chuck the cylinder and turn the cylinder head until the securing wire (D) comes out of the groove in the cylinder barrel. (Fig. 50) 9.5.19 188 678.1 - RHB LEXION 480...
Page 886 It can be released easily by heating it to about 200 °C. Remove the valves along with compression spring, cylinder pin and the stop ring. The seals and the O-rings can now be replaced. (Fig. 53) 9.5.20 RHB LEXION 480 - 188 678.1...
Page 887: Concave Adjustment Hydraulic Cylinder, Disassembled
13 Dual seal ring (from serial no..) Back-up ring (up to serial no..) 14 Securing wire 15 Cylinder head Male connector 16 Seal 17 Scraper ring 18 Hex. nut M 20 x 1.5 19 Eye section (Fig. 54) 9.5.21 188 678.1 - RHB LEXION 480...
Page 888: Assembling The Concave Adjustment Hydraulic Cylinder
8. Screw the hex. nut (18) and the eye section (19) on the ram rod (11). Adjust the retracted cylinder to the basic settings, which is (L1) = 370 mm, by adjusting on the eye section and lock this setting. (Fig. 54) 9.5.22 RHB LEXION 480 - 188 678.1...
Page 889: Installing The Concave Adjustment Hydraulic Cylinder
The cylinder may now be removed. (Fig. 56) Disassembling the grain tank unloading tube swing hydraulic cylinder Remove the hydraulic line from the cylinder head. (Fig. 57) 9.5.23 188 678.1 - RHB LEXION 480...
Page 890 NOTE! The joint is secured with liquid locking compound. It can be released easily by heating it to about 200 °C. The ram seal and the O-ring can now be replaced. (Fig. 61) 9.5.24 RHB LEXION 480 - 188 678.1...
Page 891: Grain Tank Unloading Tube Swing Hydraulic Cylinder, Disassembled
10 Snap ring 11 Damping ring 12 Cylinder head Male connector 13 Seal 14 Dirt scraper 15 Hex. nut M 18 x 1.5 16 Yoke 17 Pin Self-locking nut VM 16 Washer 17 (Fig. 62) 9.5.25 188 678.1 - RHB LEXION 480...
Page 892: Assembling The Grain Tank Unloading Tube Swing Hydraulic Cylinder
The securing wire is pulled into the groove. For every assembly of the cylinder, use a new securing wire. 8. Screw the hex. nut (15) and the yoke (16) to the ram rod (6). (Fig. 62) 9.5.26 RHB LEXION 480 - 188 678.1...
Page 893: Installing The Grain Tank Unloading Tube Swing Hydraulic Cylinder
Remove the hydraulic hoses from the cylinder and seal tightly. (Fig. 64) Remove the hex. bolt M 12 x 120 from the cylinder and remove the bushing, the compression spring and the cylinder barrel. (Fig. 65) 9.5.27 188 678.1 - RHB LEXION 480...
Page 894: Disassembling The Straw Chopper Drive Hydraulic Cylinder
The joint is secured with liquid locking compound. It can be released easily by heating it to about 200 °C. The ram seal and the rod lead ring can now be replaced. (Fig. 69) 9.5.28 RHB LEXION 480 - 188 678.1...
Page 895: Straw Chopper Drive Hydraulic Cylinder, Disassembled
Hang in the greased securing wire (8) with its hook in the cylinder head bore and turn the cylinder head. The securing wire is pulled into the groove. For every assembly of the cylinder, use a new securing wire. (Fig. 70) 9.5.29 188 678.1 - RHB LEXION 480...
Page 896: Installing The Straw Chopper Drive Hydraulic Cylinder
Unscrew the grease tube (S) completely from the vari- able-speed pulley assembly. (Fig. 72) Remove the countersunk head bolts M 12 x 165 in order to loosen the thrust flange. (Fig. 73) 9.5.30 RHB LEXION 480 - 188 678.1...
Page 897: Installing The Threshing Drum Variable-Speed Drive Hydraulic Cylinder
– see page 9.2.3, Filling instructions when changing the hydraulic oil . 6. Start the diesel engine and operate the variable speed drive cylinder several times until all the air has been expelled. (Fig. 76, 77) 9.5.31 188 678.1 - RHB LEXION 480...
Page 898: Removing The Reverser Drive Hydraulic Cylinder
(Fig. 80) Disassembling the reverser drive hydraulic cylinder Chuck the cylinder and turn the cylinder head until the securing wire (D) comes out of the groove in the cylinder barrel. (Fig. 81) 9.5.32 RHB LEXION 480 - 188 678.1...
Page 899: Reverser Drive Hydraulic Cylinder, Disassembled
3 Dual seal ring (from serial no..) Back-up ring (up to serial no..) 4 Securing wire 5 Cylinder head 6 Seal 7 Dirt scraper 8 Snap ring 9 Ram rod (Fig. 83) 9.5.33 188 678.1 - RHB LEXION 480...
Page 900: Assembling The Reverser Drive Hydraulic Cylinder
– Press the drive motor down into the gear. – Pull out the ram. – Adjust and lock the bolt (B) so there is 0.5 mm of play (1/4 turns) up to the stop. (Fig. 85) 9.5.34 RHB LEXION 480 - 188 678.1...
Page 901 Fill in hydraulic oil at the filler plug (S) of tank (T) – see page 9.2.3, Filling instructions when changing the hydraulic oil . (Fig. 86) 6. Check the hydraulic system for any leeks. Operate the cylinder several times in order to bleed it. 9.5.35 188 678.1 - RHB LEXION 480...
Page 902 Hydraulic cylinders – High-pressure hydraulic circuit 9.5.36 RHB LEXION 480 - 188 678.1...
Page 903: Hydraulic Cylinders For Low-Pressure Hydraulics
Remove the hex. bolt (1) from the cylinder (7). DANGER! The compression spring is tensioned! Remove the contact washer (2), the washer (3), thrust washer (4), bushing (5) and the compression spring (6). (Fig. 3) 9.6.1 188 678.1 - RHB LEXION 480...
Page 904: Disassembling The Threshing Mechanism Engagement Hydraulic Cylinder
6 Dual seal ring (from serial no..) Back-up ring (up to serial no..) 7 Securing wire 8 Cylinder head 9 Seal 40 x 48 x 6 32176 10 Dirt scraper (Fig. 7) 9.6.2 RHB LEXION 480 - 188 678.1...
Page 905: Assembling The Threshing Mechanism Engagement Hydraulic Cylinder
(8). 5. Insert the complete cylinder head (5 to 10) on the ram rod and then slide it into the cylinder barrel (1). (Fig. 8) 9.6.3 188 678.1 - RHB LEXION 480...
Page 906: Installing The Threshing Mechanism Engagement Hydraulic Cylinder
4. Check the hydraulic system for any leaks. Bleed the cylinder by operating it several times. (Fig. 9) Removing the grain tank unloading engagement hydraulic cylinder Remove the hydraulic lines from the cylinder plug them with plastic caps. (Fig. 10) 9.6.4 RHB LEXION 480 - 188 678.1...
Page 907: Disassembling The Grain Tank Unloading Engagement Hydraulic Cylinder
(Fig. 13) Pull the cylinder head (Z) and the ram rod (K) out of the cylinder barrel. Clean the ram rod (K) and remove the cylinder head (Z). (Fig. 14) 9.6.5 188 678.1 - RHB LEXION 480...
Page 908: Grain Tank Unloading Engagement Hydraulic Cylinder, Disassembled
7 Dual seal ring (from serial no..) Slotted back-up ring (up to serial no. …) 8 Securing wire 9 Cylinder head 10 Seal 30 x 38 x 6 11 Dirt scraper (Fig. 16) 9.6.6 RHB LEXION 480 - 188 678.1...
Page 909: Assembling The Grain Tank Unloading Engagement Hydraulic Cylinder
Insert a dual seal ring into the ring groove of the cylinder head (9). Up to serial no. …: Insert the oiled O-ring (6) and the back-up ring (7) into the groove of the cylinder head (9). (Fig. 17) 9.6.7 188 678.1 - RHB LEXION 480...
Page 910: Installing The Grain Tank Unloading Engagement Hydraulic Cylinder
3. Fill in hydraulic oil at the filler plug (S) of tank (T) – see page 9.2.3, Filling instructions when changing the hydraulic oil . 4. Check the hydraulic system for any leaks. Bleed the cylinder by operating it several times. (Fig. 18) 9.6.8 RHB LEXION 480 - 188 678.1...
Page 911: Removing The Engine Speed Control Hydraulic Cylinder (From Serial No
Pull out ram (16) approx. 10 mm with the special tool. Press the cylinder head (13) into the cylinder barrel (19) over the special tool for approx. 2 mm and remove snap ring from the cylinder barrel. (Fig. 21, 26) 9.6.9 188 678.1 - RHB LEXION 480...
Page 912 3 Hex. bolt M 8 x 100 DIN 933 (Fig. 23, 24) Cylinder side A (35 mm stroke) Cylinder side B (30 mm stroke) Unscrew cheese-head screw (18) and guide (17) from ram (16) if required. (Fig. 25, 26) 9.6.10 RHB LEXION 480 - 188 678.1...
Page 913: Engine Speed Control Hydraulic Cylinder, Disassembled (From Serial No
12 O-ring 13 Cylinder head 14 Square ring 15 Compression spring 16 Ram 17 Guide 18 Cheese-head screw M 6 x 20 19 Cylinder barrel 20 Spacer tube (right-hand cylinder side) (Fig. 26) 9.6.11 188 678.1 - RHB LEXION 480...
Page 914: Assembling The Engine Speed Control Hydraulic Cylinder (From Serial No
(16) and pre-stress with a special tool. Observe installation position of cylinder head! 3. Slide the complete unit into the cylinder barrel (cylinder side A) and secure with a snap ring. (Fig. 22, 27, 28) 9.6.12 RHB LEXION 480 - 188 678.1...
Page 915 8. Bolt on the complete threaded bushing (8) with the threaded piece (9), the compression spring (6), the spacer tube (5) and the spring plate (4) with the hex. bolt (2). (Fig. 27, 32) 9.6.13 188 678.1 - RHB LEXION 480...
Page 916: Pre-Setting The Engine Speed Control Hydraulic Cylinder (From Serial No
4. Fill in hydraulic oil at the filler plug (S) of tank (T) – see page 9.2.3, Filling instructions when changing the hydraulic oil . 5. Check the hydraulic system for any leaks. Bleed the cylinder by operating it several times. (Fig. 35) 9.6.14 RHB LEXION 480 - 188 678.1...
Page 917: Setting The Engine Speed Control Hydraulic Cylinder (From Serial No
2184 –30 MERCEDES OM 441 LA Set the clearance (Z) to 5 mm by twisting the rod (D). Lock that setting with the lock nut (K). (Fig. 36) 9.6.15 188 678.1 - RHB LEXION 480...
Page 918: Changing The Road Travel Engine Speed (Country Variants 20 Km/H And/Or 25 Km/H) By Converting The Cylinder
Cylinder side B (35 mm stroke) 2. Unscrew the hex. bolt (2) and remove spring plate (4), spacer tube (5), compression spring (6) and threaded bushing (8) with the threaded rod (9) completely. (Fig. 26, 37) 9.6.16 RHB LEXION 480 - 188 678.1...
Page 919 The max. no-load speed has been set by the engine manufacturers. This speed may only be adapted by specialist engine workshops. Failure to observe this rule results in expiry of the operating permit! 2184 –30 MERCEDES OM 441 LA 9.6.17 188 678.1 - RHB LEXION 480...
Page 920 Hydraulic cylinders for low-pressure hydraulics Set the clearance (Z) to 5 mm by twisting the rod (D). Lock that setting with the lock nut (K). (Fig. 39) 9.6.18 RHB LEXION 480 - 188 678.1...
Page 921: Removing The Engine Speed Control Hydraulic Cylinder (Up To Serial No
First mark the position of the hydraulic lines (H) on the cylinder barrel (R), then remove them. Remove the circlip (C). Remove the split pin (P) from the mounting (B). Remove the cylinder with the mounting (B). (Fig. 41) 9.6.19 188 678.1 - RHB LEXION 480...
Page 922: Disassembling The Engine Speed Control Hydraulic Cylinder (Up To Serial No
(S) from the cylinder (Z). (Fig. 44) Using the special tool (M), press the scraper seal deeper into the cylinder, thus allowing removal of the snap ring from the cylinder. (Fig. 45) 9.6.20 RHB LEXION 480 - 188 678.1...
Page 923 3 Washer ∅ 30 x ∅ 6.5 x 3 thick, part no. 236 823.0 4 Tube, inside ∅ 22 x 70 long (Fig. 48) 32193 Disassembling the ram: Unscrew the M 6 x 30 hex. bolt and remove the guide (F). (Fig. 49) 9.6.21 188 678.1 - RHB LEXION 480...
Page 924 By unscrewing the M 6 lock nut, remove rod (D) from the ram of the second cylinder (W). (Fig. 50) Unscrew the second cylinder (W) from the union (V). Disassemble cylinder (W) in the same order as the previous cylinder. (Fig. 51) 9.6.22 RHB LEXION 480 - 188 678.1...
Page 925: Engine Speed Control Hydraulic Cylinder, Disassembled (Up To Serial No
16 Spring plate 17 Washer 18 Hex. bolt M 6 x 50 DIN 931-8.8 19 Washer 18.5 x 28 x 3 20 Seal 21 Screw plug AM 10 x 1 DIN 7604 (Fig. 52) 9.6.23 188 678.1 - RHB LEXION 480...
Page 926: Assembling The Engine Speed Control Hydraulic Cylinder (Up To Serial No
3. Fill the cavities of the scraper seal (3) with multi-purpose grease, e.g. Shell “Retinax A”, part no. 147 451.0. Using the assembly tool (M), press the scraper seal into the cylinder barrel and secure with the snap ring (2). 9.6.24 RHB LEXION 480 - 188 678.1...
Page 927: Pre-Setting The Engine Speed Control Hydraulic Cylinder (Up To Serial No
4. Fill in hydraulic oil at the filler plug (S) of tank (T) – see page 9.2.3, Filling instructions when changing the hydraulic oil . 5. Check the hydraulic system for any leaks. Bleed the cylinder by operating it several times. (Fig. 56, 57) 9.6.25 188 678.1 - RHB LEXION 480...
Page 928: Setting The Engine Speed Control Hydraulic Cylinder (Up To Serial No
Failure to observe this rule results in expiry of the operating permit! 2184 –30 MERCEDES OM 441 LA Set the clearance (Z) to 5 mm by twisting the rod (D). Lock that setting with the lock nut (K). 9.6.26 RHB LEXION 480 - 188 678.1...
Page 929 Pay particular attention to the speed limit for your country. Failure to observe this rule results in expiry of the operating permit! 3. Secure the adjustment with the set screw. (Fig. 58, 59) 9.6.27 188 678.1 - RHB LEXION 480...
Page 930: Removing The 3-D Sieve Pan Hydraulic Cylinder
Unscrew the ram (H) from the male screwed end of the ram rod (K). For this unscrew the M 8 hex. nut. The ram seal and the O-ring can now be replaced. (Fig. 63) 9.6.28 RHB LEXION 480 - 188 678.1...
Page 931: 3-D Sieve Pan Hydraulic Cylinder, Disassembled
7 O-ring 45 x 3 DIN 3771 8 Securing wire 9 Cylinder head 10 Ram seal 11 Cable band 12 Bellows 13 Hex. nut M 8 DIN 934-8 14 Angle joint CS 13 DIN 71802 (Fig. 64) 9.6.29 188 678.1 - RHB LEXION 480...
Page 932: Assembling The 3-D Sieve Pan Hydraulic Cylinder
7. Slide the bellows (12) with both cable bands (11) on the ram rod (6), then tighten the cable bands (11). 8. Loosely bolt on the hex. nut (13) and the angle joint (14) to the ram rod (6). (Fig. 64) 9.6.30 RHB LEXION 480 - 188 678.1...
Page 933: Installing The 3-D Sieve Pan Hydraulic Cylinder
(Fig. 66) Disassembling the 3-D sieve pan pendulum control unit Unbolt the hex. nuts (K) and pull cover (D) along with the valve housing and the pendulum out of the cylinder. (Fig. 67) 9.6.31 188 678.1 - RHB LEXION 480...
Page 934 Replace the O-ring (R) of the pendulum. (Fig. 68) Remove the cheese-head screw from the cover and remove the valve housing (V). Replace the O-ring (R) of the cover. (Fig. 69) 9.6.32 RHB LEXION 480 - 188 678.1...
Page 935: Pendulum Control Unit Of 3-D Sieve Pan, Disassembled
Detent-edged ring VSKZ 6 4 Pendulum Set screw M 6 x 8 5 O-ring 85 x 5 DIN 3771 6 Cylinder pin 8 x 80 DIN 7979 7 Cylinder Plastic bushing (Fig. 70) 9.6.33 188 678.1 - RHB LEXION 480...
Page 936: Assembling The Pendulum Control Unit For 3-D Sieve Pan
2. Connect the hydraulic lines. Fill in hydraulic oil at the filler plug (S) of tank (T) – see page 9.2.3, Filling instructions when changing the hydraulic oil . (Fig. 71) 9.6.34 RHB LEXION 480 - 188 678.1...
Page 937: Removing The Yield Meter Moisture Sensor Hydraulic Cylinder
Removing the yield meter moisture sensor hydraulic cylinder Unscrew the hydraulic lines (A and B) from cylinder (1). Plug all connection carefully with plugs. (Fig. 73, 79) Unscrew the eyebolt (G) from the ram (K). (Fig. 74, 79) 9.6.35 188 678.1 - RHB LEXION 480...
Page 938: Disassembling The Yield Meter Moisture Sensor Hydraulic Cylinder
(3). Remove the two-part ram seal (4). Pull off the cylinder head (7). Remove the double scraper (8) and the O-ring (6) from the cylinder head (7). (Fig. 78, 79) 9.6.36 RHB LEXION 480 - 188 678.1...
Page 939: Yield Meter Moisture Sensor Hydraulic Cylinder, Disassembled
Oil all parts with hydraulic oil. Slide cylinder head (7) with O-ring (6) on the ram rod (5). Slide the pre-assembled ram rod (5) into the cylinder barrel (3). Tighten cylinder head (7). (Fig. 79, 81) 9.6.37 188 678.1 - RHB LEXION 480...
Page 940: Installing The Yield Meter Moisture Sensor Hydraulic Cylinder
1. The cylinder (1) must be fully retracted. 2. Unscrew the hex. nuts (10 and 11). 3. Loosen hex. nuts (12 and 13) and turn them to the end of the thread. (Fig. 85, 90) 9.6.38 RHB LEXION 480 - 188 678.1...
Page 941 The washers (22) must have no play when making contact with the eyebolt (20). Jam hex. nut (10) with hex. nut (11). Jam hex. nut (12) with hex. nut (13). (Fig. 88, 89, 90) 9.6.39 188 678.1 - RHB LEXION 480...
Page 942: Yield Meter Hydraulic Cylinder, Disassembled
16 Outside lever 17 Bushing 18 Hex. bolt M 6 x 40 Compression spring Self-locking nut Vm 6 19 Hex. bolt M 6 x 25 20 Eyebolt 21 Washer (rubber) 22 Washer 10.5 (Fig. 90) 9.6.40 RHB LEXION 480 - 188 678.1...
Page 943: Hydraulic Cylinders - Steering Hydraulics
Remove the cylinder. (Fig. 2) Disassembling the steering cylinder Unscrew the ball joint (G) at the cylinder head from the ram rod. (Fig. 3) 9.7.1 188 678.1 - RHB LEXION 480...
Page 944 Unscrew the ram (H) from the male screwed end of the ram rod (K). For this remove lock nut VM 16 x 1.5. The ram seal and the O-ring can now be replaced. (Fig. 6) 9.7.2 RHB LEXION 480 - 188 678.1...
Page 945: Steering Cylinder, Disassembled
14 Ball joint, part no. 668 997.0 15 Bellows 16 Castellated nut M 20 x 1.5 17 Split pin 4 x 36 18 Hex. nut M 24 x 1.5 19 Male connector (Fig. 7) 9.7.3 188 678.1 - RHB LEXION 480...
Page 946: Assembling The Steering Cylinder
The securing wire is pulled into the groove. For every assembly of the cylinder, use a new securing wire. 8. Connect the ball joint (13) to the ram rod (6). (Fig. 7) 9.7.4 RHB LEXION 480 - 188 678.1...
Page 947: Installing The Steering Cylinder
Alternatively, the ball joint should come loose after tapping with a hammer on one side of the tapered seat and holding a hammer against it on the other side. Remove the cylinder. (Fig. 11) 9.7.5 188 678.1 - RHB LEXION 480...
Page 948: Disassembling The Autopilot Steering Cylinder
The scraper ring (18), seal (17), back-up ring (14) and O-ring (13) can now be removed from the cylinder head for replacement. Remove the male connector (T) and replace the O-ring. (Fig. 15, 20) 33188 9.7.6 RHB LEXION 480 - 188 678.1...
Page 949 It can be released easily by heating it to about 200 °C. (Fig. 16) 33189 Twist the cylinder base (1) so that the second securing wire (D) comes out of the groove in the cylinder barrel. (Fig. 17) 9.7.7 188 678.1 - RHB LEXION 480...
Page 950 (1) so far that the soldered cable can be removed. Remove the circlip (R), washer (U), wave washer (W) and the position sensor (4) from the cylinder base (1). (Fig. 18, 19) 33190 9.7.8 RHB LEXION 480 - 188 678.1...
Page 951: Autopilot Steering Cylinder, Disassembled
10 Rod guide ring 11 Ram seal 12 Ram rod 13 O-ring (up to serial no. …) 14 Dual seal ring (from serial no..) Back-up ring (up to serial no..) 15 Securing wire 9.7.9 188 678.1 - RHB LEXION 480...
Page 952: Assembling The Autopilot Steering Cylinder
The securing wire is pulled into the groove. For every assembly of the cylinder, use a new securing wire. 8. Connect the ball joint (19) to the ram rod (12). (Fig. 20, 21) 9.7.10 RHB LEXION 480 - 188 678.1...
Page 953: Installing The Autopilot Steering Cylinder
2. Screw the cable to the sensor connector. 3. Connect the hydraulic lines. 4. Fill in hydraulic oil at the filler plug (S) of tank (T) – see page 9.2.3, Filling instructions when changing the hydraulic oil . (Fig. 23) 9.7.11 188 678.1 - RHB LEXION 480...
Page 954 Jack up and support the steering axle. Start the engine, then turn the steering from right to left and vice versa until the system is completely bled. 6. Check the hydraulic system for any leeks. (Fig. 24) 9.7.12 RHB LEXION 480 - 188 678.1...
Page 955: Valve Combinations
4 Solenoid 3 mm / 12 V DC / 60 % on-load factor 5 O-ring 40 x 1.5 - N DIN 3771 6 O-ring 15.4 x 2.1 - N DIN 3771 7 Compression spring 8 Male connector with insert – 2 pieces (Fig. 4) 9.8.1 188 678.1 - RHB LEXION 480...
Page 956: Removing The Cutterbar Cross Levelling 4/3-Way Valve
(G). Mark the power supply plugs before removing them. Remove the hydraulic lines (A, B, P and T). Plug the lines and connections tightly with plastic caps. Remove the hex. bolts (K) and remove the valve. (Fig. 7) 9.8.2 RHB LEXION 480 - 188 678.1...
Page 957: Cutterbar Cross Levelling 4/3-Way Valve, Disassembled
18 Seal – 2 pieces 19 Set screw M 6 x 6 DIN 914 – 4 pieces 20 O-ring 15.4 x 2.1 - N DIN 3771 21 Pressure accumulator 22 Restrictor screw 23 Flange nut 9.8.3 188 678.1 - RHB LEXION 480...
Page 958: Removing The Concave Adjustment Pressure Relief Valve
DELO-ML 5328, part no. 201 802.0. (Fig. 10) Removing the cutterbar and threshing drum variable-speed drive 3/3-way valves Fold up the left-hand guard. CAUTION! Thoroughly clean the area around the valve (V). (Fig. 11) 9.8.4 RHB LEXION 480 - 188 678.1...
Page 959 Loosen the bolts and disconnect the four power supply connectors (G). Remove the hydraulic lines (A1, A2, P and T). Plug the lines and connections tightly with plastic caps. Remove the hex. bolts (S) and then the valves. (Fig. 12) 33684 9.8.5 188 678.1 - RHB LEXION 480...
Page 960 11 Solenoid 3 mm / 12 V DC / 60 % on-load factor – 2 pieces 12 Valve insert – 2 pieces 13 Set screw M 6 x 6 DIN 916 – 2 pieces (Fig. 13) 9.8.6 RHB LEXION 480 - 188 678.1...
Page 961: Removing The Threshing Drum Variable-Speed Drive 3/3-Way Valve
Loosen the screws and disconnect the power supply plugs (G). Remove the hydraulic lines (A1, P and T). Plug the lines and connections tightly with plastic caps. Remove the hex. bolts (S) and then the valve. (Fig. 16) 33686 9.8.7 188 678.1 - RHB LEXION 480...
Page 962: Threshing Drum Variable-Speed Drive 3/3-Way Valve, Disassembled
12 Solenoid 3 mm / 12 V DC / 60 % on-load factor 13 Valve insert 14 Plug – 2 pieces 15 Set screw M 6 x 6 DIN 916 – 2 pieces (Fig. 17) 9.8.8 RHB LEXION 480 - 188 678.1...
Page 963: Removing The Concave, Grain Tank Unloading Tube And Straw Chopper 4/3-Way Valves
A2 = Valve cartridge with orifice plate ∅ 0.6 caulked B1 = Valve cartridge with orifice plate ∅ 0.8 caulked C2 = Valve cartridge with orifice plate ∅ 0.8 caulked 33689 (Fig. 20) 9.8.9 188 678.1 - RHB LEXION 480...
Page 964: Concave, Grain Tank Unloading Tube And Straw Chopper 4/3-Way Valve, Disassembled
20 Valve insert – 2 pieces 21 Valve insert – 2 pieces 22 Valve cartridge – 5 pieces 23 Male connector L 8 F-M DIN 3901 – 5 pieces 24 Spring guide – 5 pieces 9.8.10 RHB LEXION 480 - 188 678.1...
Page 965: Assembling The Concave, Grain Tank Unloading Tube And Straw Chopper 4/3-Way Valves
(B) and secure. (Fig. 23) 33690 Removing the concave and grain tank unloading tube 4/3 way valves Fold up the left-hand guard. CAUTION! Thoroughly clean the area around the valve (V). (Fig. 24) 9.8.11 188 678.1 - RHB LEXION 480...
Page 966 Before disassembling the valve, please ensure the valve cartridges have been marked accordingly. A2 = Valve cartridge with orifice plate ∅ 0.6 caulked B1 = Valve cartridge with orifice plate ∅ 0.8 caulked (Fig. 26) 33693 9.8.12 RHB LEXION 480 - 188 678.1...
Page 967: Concave And Grain Tank Unloading Tube 4/3-Way Valve, Disassembled
21 Valve insert – 2 pieces 22 Valve cartridge – 3 pieces 23 Male connector L 8 F-M – 3 pieces O-ring 9.4 x 2.1 - N DIN 3771 - 3 pieces 24 Spring guide – 3 pieces 9.8.13 188 678.1 - RHB LEXION 480...
Page 968: Assembling The Concave And Grain Tank Unloading Tube 4/3-Way Valves
Connect the power supply plugs with the blue cable band to (B) and secure. (Fig. 29) 33694 Removing the main valve Fold up the left-hand guard. CAUTION! Thoroughly clean the area around the valve (V). (Fig. 30) 9.8.14 RHB LEXION 480 - 188 678.1...
Page 969 Loosen the screws and disconnect the power supply plugs (G). Remove the hydraulic lines (A, P, P1 and T). Plug the lines and connections tightly with plastic caps. Remove the hex. bolts (S) and then the valves. (Fig. 31) 33696 9.8.15 188 678.1 - RHB LEXION 480...
Page 970: Main Valve, Disassembled
25 O-ring 6 x 2 - N DIN 3771 – 2 pieces 26 Solenoid 3 mm / 12 V DC / 60 % OLF – 2 pieces 27 Compression spring 28 Compression spring 9.8.16 RHB LEXION 480 - 188 678.1...
Page 971: Assembling The Main Valve
(V) = 60° and (W) = 75°. 2. Connect the power supply plugs with the red cable band to (R) and secure. Connect the power supply plugs with the blue cable band to (B) and secure. (Fig. 36) 33700 9.8.17 188 678.1 - RHB LEXION 480...
Page 972: Removing The Claas Autopilot Solenoid Valve
Remove the hydraulic lines (A, B, P and T). Plug the lines and connections tightly with plastic caps. Remove the hex. bolts and remove the valve with the bracket. (Fig. 39, 40) 33925 9.8.18 RHB LEXION 480 - 188 678.1...
Page 973: Claas Autopilot Solenoid Valve, Disassembled
22 Male connector L 10 F-M DIN 3901 – 2 pieces O-ring – 2 pieces 23 Male connector L 12 F-M DIN 3901 O-ring 13.4 x 2.1 - N DIN 3771 24 Profiled ring P-R 12 L / S DIN 3861 9.8.19 188 678.1 - RHB LEXION 480...
Page 974: Assembling The Claas Autopilot Solenoid Valve
2. Connect the respective hydraulic lines to the marked male connectors. Removing the low-pressure solenoid valve block CAUTION! Thoroughly clean the area around the valve. Loosen the screws and disconnect the power supply plugs (G). (Fig. 44) 9.8.20 RHB LEXION 480 - 188 678.1...
Page 975 A1 = Valve cartridge with one-way restrictor valve A3 A2 A1 A2 = Valve cartridge with one-way restrictor valve A3 = Valve cartridge with orifice plate ∅ 0.8 caulked (Fig. 46) 33706 9.8.21 188 678.1 - RHB LEXION 480...
Page 976: Low-Pressure Solenoid Valve Block, Disassembled
24 O-ring 10 x 1.5 - N DIN 3771 – 6 pieces 25 Valve insert – 6 pieces 26 O-ring 13 x 2 - N DIN 3771 – 6 pieces 27 O-ring 30 x 1.5 - N DIN 3771 – 6 pieces 9.8.22 RHB LEXION 480 - 188 678.1...
Page 977: Assembling The Low-Pressure Solenoid Valve Block
(Fig. 49, 50) Removing the low-pressure solenoid valve (yield meter) 1 Yield meter 3/2-way solenoid valve A Working line (extend) B Working line (retract) T Tank connection P Ground drive feed pump connection (Fig. 51) 9.8.23 188 678.1 - RHB LEXION 480...
Page 978 Loosen and pull off the power supply plug (11). (Fig. 53, 58) Unscrew the screwed cap from the solenoid (8) and pull off solenoid (8). (Fig. 54, 58) Unscrew the iron core (E). (Fig. 55) 9.8.24 RHB LEXION 480 - 188 678.1...
Page 979: Yield Meter 3/2-Way Solenoid Valve, Disassembled
2 Male connector O-ring 3 O-ring 4 O-ring 5 Valve insert 6 O-ring 7 O-ring 8 Solenoid 9 O-ring 10 Cheese-head screw M 3 x 35 11 Power supply plug 12 Rectangular seal (Fig. 58) 9.8.25 188 678.1 - RHB LEXION 480...
Page 980: Installing The Low-Pressure Solenoid Valve (Yield Meter)
(F) for a short period while the engine is running. CAUTION! For a flawless function of the 3/2-way solenoid valve (in operating status), the adjusting screw (F) must be turned counterclockwise to the stop. (Fig. 58, 60) 9.8.26 RHB LEXION 480 - 188 678.1...
Page 981: Engine
Engine...
Page 983: Cooling System
Fold up the rotary screen. Remove the pin from the gas strut. Remove the bolt from the bearing and remove the rotary screen completely. (Fig. 2) Remove the cover (B) from the air intake box. (Fig. 3) 10.1.1 188 678.1 - RHB LEXION 480...
Page 984 Remove the bracket (H) and the stop plate (A). Remove the side brackets (S) from the intercooler. Remove the rubber mountings from the bracket (S). (Fig. 5) Remove the intercooler from the side of the machine. (Fig. 6) 10.1.2 RHB LEXION 480 - 188 678.1...
Page 985: Installing The Intercooler
Drain the water from the radiator at tap (A). DANGER! Take care when opening the hot radiator! ☞ Only open the tap to the end stop only and let the overpressure escape first – Danger of burns! (Fig. 8) 10.1.3 188 678.1 - RHB LEXION 480...
Page 986 Move the oil cooler out of the way, along with the pipes, and secure with suitable means, e.g. a rope. (Fig. 10) Loosen the hose clamps and remove the hoses (K) from the radiator. (Fig. 11) 10.1.4 RHB LEXION 480 - 188 678.1...
Page 987 Remove the locking plate (S). Remove the radiator brackets (P) on both sides. (Fig. 13) Remove the radiator to the side and remove the rubber cushions from the brackets if necessary. (Fig. 14) 10.1.5 188 678.1 - RHB LEXION 480...
Page 988: Installing The Radiator
Fill the system with coolant at point (E), until the level is at the edge. Now let the engine run for a short period of time. Stop the engine and check coolant level again. Top up coolant if required. (Fig. 15, 16) 10.1.6 RHB LEXION 480 - 188 678.1...
Page 989: Fuel System
Remove the cover plate (A) from the catwalk. (Fig. 2) Remove the tank bracket (T). (Fig. 3) Remove the return fuel pipe. Remove the cable from the fuel level sensor. Remove the fuel tank. (Fig. 4) 10.2.1 188 678.1 - RHB LEXION 480...
Page 990: Installing The Fuel Tank
Connect a fuel-resistant hose to the drive-in connection and secure it. Open the shut-off tap (A) and drain the fuel into a clean container. (Fig. 6) 10.2.2 RHB LEXION 480 - 188 678.1...
Page 991 Unscrew the four hex. bolts (G) and remove the steel straps. Close shut-off tap (A) and remove the drain hose. Using a suitable lifting device, lift the fuel tank out of the machine. (empty weight approx. 35 kg) (Fig. 6, 8, 9) 10.2.3 188 678.1 - RHB LEXION 480...
Page 992 Open shut-off tap (A) and close cover (M). (Fig. 6) Fold up feed pan and push on the rocker arms (S). Bolt on toggle nut (N). (Fig. 5) 10.2.4 RHB LEXION 480 - 188 678.1...
Page 993: Engine
Plug all openings so they are dust-tight. (Fig. 3) Disconnect three air-intake pipes (L) from the engine block and remove them completely. Plug all openings so they are dust-tight. (Fig. 4) 10.3.1 188 678.1 - RHB LEXION 480...
Page 994 Unscrew the compressor completely with its bracket and place it on the air intake box. CAUTION! The compressor hoses must not be loosened. (Fig. 6, 7) Unscrew the coolant pipes (A and B). (Fig. 8) 10.3.2 RHB LEXION 480 - 188 678.1...
Page 995 (Fig. 10) Unscrew the bolts (F and G) and remove the tensioning arm. (Fig. 11) Remove the clamp (S). Unscrew the blower bracket (L) and remove it. (Fig. 12) 10.3.3 188 678.1 - RHB LEXION 480...
Page 996 Remove the alternator wiring loom from the engine block and from the alternator. (Fig. 14) Completely disconnect the shut-off solenoid wiring loom from the engine block. (Fig. 15) Unscrew the cable from starter. (Fig. 16) 10.3.4 RHB LEXION 480 - 188 678.1...
Page 997 Unscrew guide (F) and pull it out. (Fig. 19) Remove castellated nut and pull off the V-belt pulley using a special tool. Ensure that the pulley, the jockey pulley arm and the belt guide will not tilt. (Fig. 20) 10.3.5 188 678.1 - RHB LEXION 480...
Page 998 Suspend the engine block in a suitable lifting device (cross beam) at the crane eyelets. Unscrew the brackets on the left-hand side of the engine block and the engine mounting frame. (Fig. 24, 25) 10.3.6 RHB LEXION 480 - 188 678.1...
Page 999: Installing The Engine
Be careful not to jam any hoses and wiring looms. (Fig. 25) 3. Bolt the engine block down to the engine mounting frame. Tightening torque M 16 = 195 Nm (Fig. 26) 10.3.7 188 678.1 - RHB LEXION 480...
Page 1000 10. Install the grain tank unloading intermediate drive belt (8) and adjust. 11. Fold back the lever and the hydraulic cylinder. Bolt on mounting plate (L) and connect the hydraulic cylinder. (Fig. 19) 10.3.8 RHB LEXION 480 - 188 678.1...
Page 1001 20. Install the rotary screen drive belt (26) and adjust. 21. Slide in the blower wheel and tighten M 10 bolt with 45 Nm. (Fig. 9) 22. Install the fan drive belt (27) and adjust. 10.3.9 188 678.1 - RHB LEXION 480...
Page 1002 28. Fit the rear silencer (E) and the exhaust gas pipe to the turbocharger. (Fig. 3) 29. Bolt on the intermediate panel (S) and the intermediate panel clamps. (Fig. 2) 30. Install side panel. Bolt on safety rope and gas strut. (Fig. 1) 10.3.10 RHB LEXION 480 - 188 678.1...
Page 1003: Index
Index...
Page 1005 Index Index INDEX Assembling the CLAAS Autopilot solenoid valve ....9.8.20 Assembling the concave adjustment Numerical hydraulic cylinder ..............9.5.22 3-D sieve pan control system ..........4.4.1 Assembling the concave adjustment 3-D sieve pan hydraulic cylinder, pressure relief valve .............. 9.8.4 disassembled ...............
Page 1006 (hydraulic), disassembled ............ 7.4.48 Bolts ..................1.4.1 Cutterbar variable-speed pulley assembly Bottom feed rake roller, (spring-loaded), disassembled ..........7.4.30 disassembled ............... 3.1.21 Cutting cylinder, disassembled ..........6.1.11 Brake ..................7.20.1 Brake line screw joints ............1.4.3 11.1.2 RHB LEXION 480 - 188 678.1...
Page 1007 (up to serial no..) ............... 5.3.24 Engine speed control hydraulic cylinder, disassembled Disassembling the manual gearbox ........7.19.3 (up to serial no. … ) ..............9.6.23 Disassembling the returns elevator ........5.1.7 External leaks ................ 2.2.1 11.1.3 188 678.1 - RHB LEXION 480...
Page 1008 Hydraulic cylinders – High-pressure hydraulic circuit ..... 9.5.1 Installing and adjusting the sieve pan Hydraulic cylinders – Steering hydraulics ......9.7.1 drive belt (15) ............... 7.2.31 Hydraulic cylinders for low-pressure hydraulics ..... 9.6.1 11.1.4 RHB LEXION 480 - 188 678.1...
Page 1009 Installing the final drive gearbox ........7.18.27 Installing the bottom feed rake roller ........3.1.21 Installing the flanged shaft ........... 3.5.11 Installing the CLAAS Autopilot solenoid valve ..... 9.8.20 Installing the front pulley of cutterbar drive (1) ...... 7.4.2 Installing the clean grain auger ..........5.2.13 Installing the front sieve pan drive deflection pulley ....
Page 1010 Internal leaks ................. 2.2.1 fixed displacement motor ............9.4.9 Introduction ................1.1.1 Installing the right-hand bearing assembly and shaft ..... 3.3.5 Introduction to the CLAAS Repair Manual ......1.1.2 Installing the right-hand drum bearing ........3.4.5 11.1.6 RHB LEXION 480 - 188 678.1...
Page 1011 Removing the bottom feed rake roller ......... 3.1.19 disassembled ..............7.18.22 Removing the centre cleaning fan bearing ......4.6.9 Preconcave, disassembled ............ 3.2.5 Removing the CLAAS Autopilot solenoid valve ....9.8.18 Preparation floor ..............4.3.1 Removing the clean grain auger ......... 5.2.10 Preparation floor, disassembled ..........4.3.3 Removing the clean grain elevator boot ........
Page 1012 Removing the fan adjustment (electric) Removing the intermediate shaft ......... 7.18.3 (Version 1, version 3) ............7.14.14 Removing the jockey pulley of cutterbar Removing the fan adjustment (electric) drive (1) ................. 7.4.7 (Version 2) ................. 7.14.22 11.1.8 RHB LEXION 480 - 188 678.1...

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