Claas LEXION 480 Repair Manual Download Page 9

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0.1.7

Contents

Disassembling the stage 3 chopper
drive V-belt pulley ........................................................ 7.10.15
Stage 3 chopper drive V-belt pulley,
dismantled ................................................................... 7.10.17
Assembling and installing the stage 3 chopper
drive V-belt pulley ........................................................ 7.10.18

Straw spreader drive ............................................................ 7.11.1

Removing the straw spreader bearing housing ............. 7.11.1
Disassembling the straw spreader bearing housing ...... 7.11.2
Straw spreader bearing housing, disassembled ............ 7.11.5
Assembling the straw spreader bearing housing ........... 7.11.7
Installing the straw spreader bearing housing ............... 7.11.9

Uni-spreader drive ............................................................... 7.12.1

Removing the uni-spreader drive angle drive ................ 7.12.1
Mounting the uni-spreader drive angle drive ................. 7.12.2

Sieve pan drive .................................................................... 7.13.1

Fan drive .............................................................................. 7.14.1

Removing the stage 1 fan drive V-belt pulley  ................ 7.14.1
Stage 1 fan drive V-belt pulley, disassembled ............... 7.14.1
Installing the stage 1 fan drive V-belt pulley  .................. 7.14.1
Fan adjustment (electric)  ............................................... 7.14.2
Fan adjustment (electric)
Version 1
(up to serial no. ...) ......................................................... 7.14.3
Fan adjustment (electric)
Version 2
(from serial no. …

, up to serial no. …

) ............................... 7.14.4

Axial rotor drive ................................................................... 7.15.1

Summary of Contents for LEXION 480

Page 1: ...REPAIR MANUAL LEXION 480...

Page 2: ...R e a d a n d f o l l o w s a f e t y i n s t r u c t i o n s...

Page 3: ...r 2 1 4 Topping up refrigerant oil 2 1 5 Removing the condenser 2 1 5 Refitting the condenser 2 1 6 Removing the air conditioner compressor 2 1 7 Installing the air conditioner compressor 2 1 8 Removi...

Page 4: ...mbly on the left hand side 3 3 8 Disassembling the left hand bearing assembly 3 3 10 Assembling the left hand bearing assembly 3 3 11 Installing the left hand bearing assembly 3 3 12 Replacing the acc...

Page 5: ...cleaning fan shaft 4 6 10 Removing the cleaning fan rotors 4 6 11 Installing the cleaning fan rotors 4 6 11 Removing the cleaning fan housing 4 6 12 Installing the cleaning fan housing 4 6 14 5 Grain...

Page 6: ...talling the fan blade bearing 6 2 8 7 Drives Drive belts 7 1 1 General Information 7 1 1 Drive diagram 7 1 2 Drive diagram left hand 7 1 2 Drive system diagram right hand side 7 1 3 Left hand drive be...

Page 7: ...adjusting the feed rake conveyor suction blower drive belt 34 7 3 27 Removing the straw spreader drive belt 36 7 3 28 Installing and adjusting the straw spreader drive belt 36 7 3 29 Cutterbar drive 7...

Page 8: ...peed pulley assembly spring loaded 7 6 12 Installing the threshing drum variable speed pulley assembly spring loaded 7 6 16 Removing the threshing mechanism drive pulley 7 6 18 Disassembling the thres...

Page 9: ...justment electric disassembled Version 1 7 14 9 Assembling the fan adjustment electric Version 1 7 14 10 Installing the fan adjustment electric Version 1 7 14 12 Removing the fan adjustment electric V...

Page 10: ...shaft 7 19 17 Installing the drive shaft 7 19 18 Installing the shifter rails 7 19 19 Installing the manual gearbox 7 19 22 Servo gearshift 7 19 25 Removing the shifter pistons 7 19 25 Servo gearshift...

Page 11: ...hydraulic cylinder 9 5 23 Removing the grain tank unloading tube swing hydraulic cylinder 9 5 23 Disassembling the grain tank unloading tube swing hydraulic cylinder 9 5 23 Grain tank unloading tube s...

Page 12: ...inder 9 6 36 Yield meter moisture sensor hydraulic cylinder disassembled 9 6 37 Assembling the yield meter moisture sensor hydraulic cylinder 9 6 37 Installing the yield meter moisture sensor hydrauli...

Page 13: ...opilot solenoid valve 9 8 20 Removing the low pressure solenoid valve block 9 8 20 Low pressure solenoid valve block disassembled 9 8 22 Assembling the low pressure solenoid valve block 9 8 23 Install...

Page 14: ...0 1 12 RHB LEXION 480 188 678 1 Contents...

Page 15: ...1 General information...

Page 16: ......

Page 17: ...ribes the different adjustments to be made the use of CLAAS special tools etc The illustrations included in support to the expla nations show the sequence of major repairs so that minor repairs can ea...

Page 18: ...the machine names are not specifically given When supplements are to be added the subgroups are supplemented or exchanged Any possible supplements are filed in the respective main group subgroup and...

Page 19: ...help to quickly recognise recurring service procedures and they also help to communicate information shown on the illustrations Dismantle remove Grease Prevent damage to materials Disassemble Oil Use...

Page 20: ...1 1 4 RHB LEXION 480 188 678 1 General...

Page 21: ...n characteristics of this CLAAS machine or detract from its functional performance with a possible adverse effect on the active and or passive operational safety of the machine and its occupational sa...

Page 22: ...s any such actions may have considerable adverse effects on the safety and operational function of the machine Any arbitrary modifications carried out on the machine will relieve the manufacturer of a...

Page 23: ...ng fluid fuel or hydraulic oil under high pressure can penetrate the skin and cause serious injury In such a case consult a doctor immediately as otherwise serious infections may result 3 Always turn...

Page 24: ...1 2 4 RHB LEXION 480 188 678 1 Safety Rules...

Page 25: ...to start the alternator via the battery charge indicator bulb Blown bulbs must therefore be replaced to ensure reliable field excitation Tensioning the steel roller chains Find the centre point in th...

Page 26: ...ing over the inside bearing ring Prior to installation apply semi fluid lubricant of NLGI class 00 e g CLAAS semi fluid lubricant EP 00 to the inside ring and the shaft to make bearing removal easier...

Page 27: ...on the tube 3 Push the tube against the stop in the union and tighten union nut until the progressive ring grips the tube the tube must not rotate with the nut This point can be felt because increase...

Page 28: ...carried out Some advice for speedy and correct repair work Mark machine parts prior to disassembly to ensure their correct left to right positions and balance when reassembled Fit expansion pins with...

Page 29: ...210 0 M 16 195 0 270 0 325 0 M 18 260 0 370 0 440 0 M 20 370 0 525 0 630 0 M 22 510 0 720 0 870 0 M 24 640 0 900 0 1080 0 M 27 980 0 1400 0 1650 0 M 30 1260 0 1800 0 2160 0 Dimensions Metric fine pit...

Page 30: ...ng according to ISO 6149 M 8 x 1 7 2 Nm M 10 x 1 11 4 Nm M 12 x 1 5 16 5 Nm M 14 x 1 5 23 8 Nm M 16 x 1 5 29 10 Nm M 18 x 1 5 38 13 Nm M 20 x 1 5 46 15 Nm M 22 x 1 5 67 22 Nm M 24 x 1 5 86 29 Nm M 26...

Page 31: ...18 12 16 M 10 x 1 25 19 23 12 16 M 12 x 1 19 22 15 19 M 12 x 1 5 25 32 15 20 M 14 x 1 20 26 20 25 M 14 x 1 5 30 36 17 5 23 M 16 x 1 5 35 42 17 5 23 M 18 x 1 5 43 50 M 20 x 1 5 53 60 M 22 x 1 5 60 77 M...

Page 32: ...Wheel bolts M 22 x 1 5 x 45 8 8 with lock washers C 22 5 DIN 74361 Limes ring Wheel bolts M 18 x 1 5 with countersunk collar nuts or with flat collar nut with Limes ring 520 Nm 325 Nm 260 Nm Rear whee...

Page 33: ...ti grade gearbox oil conforming to MIL L 2105 API GL 4 90 specifications 90 1 8 litres Transfer gearbox engine output shaft 3 0 litres Rotor drives 1 75 litres each Grain tank unloading tube Upper ang...

Page 34: ...prox 70 approx 20 Operating pressure S4 420 30 Filling pressure Purge pressure 23 When making new settings note the circulation pressure and add the value to the one given Filling pressure 4 6 bar abo...

Page 35: ...188 678 1 RHB LEXION 480 1 6 1 Sectional view of machine SECTIONAL VIEW OF MACHINE LEXION 480 Sectional view of machine...

Page 36: ...1 6 2 RHB LEXION 480 188 678 1 Sectional view of machine 34835 11 13 16 1 2 3 4 8 9 10 10 15 5 6 7 12 14 17 19 20 24 25 26 29 30 33 35 36 37 18 22 23 27 28 31 32 34 21 1...

Page 37: ...3 Axial rotors 14 Return pan 15 Grain tank unloading tube 16 Rear hood 17 Straw chopper 18 Uni spreader fan 19 Preparation floor 20 Top sieves 21 Bottom sieves 22 Cleaning fan 23 Under ventilated clea...

Page 38: ...1 6 4 RHB LEXION 480 188 678 1 Sectional view of machine...

Page 39: ...intermediate drive 8 Intermediate drive to grain tank unloading system 9 Intermediate drive to straw chopper 10 Straw chopper and uni spreader drive 11 Straw chopper and uni spreader drive 12 Drive of...

Page 40: ...drive 22 Threshing mechanism variable speed drive 23 Threshing drum drive 24 Accelerator drive 25 Rotary chaff screen intermediate drive 26 Rotary radiator screen drive 27 Fan drive 28 Rotary chaff sc...

Page 41: ...2 Operator s platform...

Page 42: ......

Page 43: ...ult a doctor 4 Maintenance and repair should only be carried out by trained personnel with the correct equipment 5 Prior to disassembling the refrigerant circuit for maintenance and repair purposes th...

Page 44: ...umidity To achieve this close all loosened connections with suitable caps 2 Caps of new parts should be removed only directly before installing them 3 O rings must always be replaced 4 Prior to connec...

Page 45: ...ing up refrigerant Fill in refrigerant at connections D discharge side and S suction side of the air conditioning compressor ATTENTION Never fill in liquid at connection S Use refrigerant R134a exclus...

Page 46: ...instructions given by the unit manufacturer 4 Unscrew dust cap A and screw out oil filler plug B 5 Remove air conditioner compressor if required 6 Turn air conditioner compressor to a horizontal posi...

Page 47: ...em 310 cm Fill refrigerant oil into the air conditioner compressor prior to evacuating filling the air conditioning system Observe the instructions given by the unit manufacturer Use only SANDEN SP 20...

Page 48: ...pressed air max 5 bar ATTENTION When cleaning the condenser take care not to damage the fins Fig 9 Refitting the condenser 1 Place the condenser behind the bearing plate and secure with the mushroom h...

Page 49: ...he instructions given by the unit manufacturer If compressed air system is fitted Removing the compressed air compressor drive belt 30 see page 7 3 21 Remove air conditioner compressor drive belt 29 a...

Page 50: ...ressed air system is fitted Installing and adjusting the compressed air com pressor drive belt 30 see page 7 3 22 7 Checking topping up the refrigerant oil level at the air conditioner compressor see...

Page 51: ...tool for backing up Special tool Pin hole wrench part no 181 624 0 Fig 17 Pull off thrust plate C using special tool Fig 18 Special tool self sourced A 60 mm B 7 mm C 35 mm D 46 mm E 3 x 120 F 10 mm G...

Page 52: ...E Fig 21 Pull off V belt pulley F completely with bearing using a special tool Special tool Tube outside diameter 38 mm inside diameter 31 mm 35 mm long self sourced Disc outside diameter 38 mm insid...

Page 53: ...188 678 1 RHB LEXION 480 2 1 11 Air conditioner Remove the outside circlip G Unscrew cable clamp L Fig 23 Remove magnet M Fig 24 23 24...

Page 54: ...ION 480 188 678 1 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 gas...

Page 55: ...F completely with bearing using a block ended tube and secure with outside circlip E Tube outside diameter 46 mm inside diameter 41 mm 100 mm long self sourced Fig 21 24 25 26 27 4 Insert dust protec...

Page 56: ...9 Fit dust cap 2 Screw in the hex bolts with liquid locking compound e g DELO ML 5349 Fig 25 31 10 Connect plug in connection V at the engine mounting frame 11 Screw down wiring loom A using cable cl...

Page 57: ...Unscrew oil filler plug B and drain refrigerant oil ENVIRONMENT Dispose of the old oil in a way that is harmless to the environment and in accordance with existing environmental regulations Unscrew c...

Page 58: ...to valve plate E and set of gaskets 7 and fit them CAUTION The stamped side of the valve plate E must face the cylinder head D Fig 25 36 37 2 Apply refrigerant oil SANDEN SP 20 to sealing face of cyli...

Page 59: ...nscrew dust cap 2 Fig 25 39 Unscrew the thrust plate C Use special tool for backing up Special tool Pin hole wrench part no 181 624 0 Fig 40 Pull off thrust plate C using special tool Fig 41 Special t...

Page 60: ...ir conditioner 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 sp...

Page 61: ...nt oil SANDEN SP 20 to shaft seal 6 and insert it using a special tool Use a guide bush D while doing so Fig 25 47 2 Insert circlip R and dirt scraper A Fig 45 48 3 Insert dust protection 3 into the V...

Page 62: ...liquid locking compound e g DELO ML 5349 9 Checking topping up the refrigerant oil level at the air conditioner compressor see page 2 1 4 10 Install the air conditioner compressor Fig 25 51 Removing t...

Page 63: ...r Unscrew the support plate B Pull out the suction line 12 and the discharge line 16 and plug with plugs on both sides Fig 54 56 Unscrew the support plate C Pull off expansion valve 14 and plug connec...

Page 64: ...n DIN 3771 7 Cable ring 8 Cable ring 9 Temperature switch 10 Rotary knob 11 Insert 12 Suction line 13 Cable ring 14 Expansion valve 15 O ring 11 1 x 1 78 n DIN 3771 16 Discharge line 17 Pipe clamp 18...

Page 65: ...ush suction line 12 and discharge line 16 with new O rings into the expansion valve 14 and bolt down support plate B 3 Seal pipe leadthrough with sealing compound Fig 56 58 4 Screw down the cover A to...

Page 66: ...capillary tube C out of the evaporator 23 ATTENTION Never pull out capillary tube C using force or kink it Fig 56 62 Remove the cover D Disconnect cable plug from the temperature switch 9 Loosen clam...

Page 67: ...3 at X and Y X 60 mm Y 30 mm ATTENTION Never push in capillary tube C using force or kink it Fig 56 64 65 2 Fasten capillary tube C using clamp E 3 Screw down temperature switch 9 to cover D and fit r...

Page 68: ...arge side and S suction side of the air conditioning compressor Proceed very slowly in order to prevent refrigerant oil from being extracted as well Observe the instructions given by the unit manufact...

Page 69: ...line 12 and the discharge line 16 and plug with plugs on both sides Fig 56 73 Unscrew the support plate C Pull off expansion valve 14 and plug connections with plugs on both sides Pull evaporator 23...

Page 70: ...Fig 56 76 4 Guide capillary tube C of the temperature switch 9 through the cab covering bend a 90 angle approx 80 mm from the end and carefully push it into the evaporator 23 at X and Y X 60 mm Y 30 m...

Page 71: ...rom being extracted as well Observe the instructions given by the unit manufacturer Fig 80 Unscrew the discharge line 11 and hose line 10 from the filter receiver drier and plug with plugs on both sid...

Page 72: ...DIN 3771 3 Cylinder 4 Mounting bracket 5 Hex bolt M 6 x 12 DIN 933 8 8 Hex nut M 6 DIN 934 Contact washer B 6 6 Hose clamp As 60 80 12 c7 DIN 3017 7 O ring 11 1 x 1 78 n DIN 3771 8 Cable ring 9 Pipe c...

Page 73: ...ter receiver drier to bracket 4 using a hose clamp 6 4 Connect the cable plugs to the low pressure switch 1 and the high pressure switch 12 5 Fit the discharge line 11 and hose line 10 to the filter r...

Page 74: ...2 1 32 RHB LEXION 480 188 678 1 Air conditioner...

Page 75: ...edy In case of leaks replace the respective O rings by new ones Internal leaks Internal leaks might be the reason when the rear wheels do not respond immediately to steering on soft ground or when no...

Page 76: ...M 8 bolt each Pull the floor mat halves over the pedals E and F and then remove them from the cab Fig 1 Remove the inspection cover D from the cover to one side and disconnect the five cable plugs Re...

Page 77: ...uster S on the right hand side Fig 5 Remove the upper steering column cover to the top Fig 6 Unscrew the two lateral mushroom head bolts F and the cheese head screw Z Remove the lower section U to the...

Page 78: ...e hydraulic hoses from the valve block on the steering assembly Plug hydraulic lines and screwed joints with plugs Fig 10 Lift the complete steering column out to the top Fig 11 Disassembling the stee...

Page 79: ...ng rod 4 Push the gas strut B out of the tube Fig 13 Removing the steering tube with the shaft 1 Remove the lock nut M of gas strut A Fig 12 2 Remove the two side mounted bolts S Fig 14 3 Remove the b...

Page 80: ...the steering shaft W out of the steering tube L Replace the bushings B if required Assembling the steering tube Slide the steering shaft W back into the steering tube L Put the support rings S and th...

Page 81: ...Hex bolt M 8 x 65 DIN 931 8 8 Self locking nut VM 8 Contact washer B 8 Hex nut M 8 x 1 6 Rod 7 Bearing bracket 8 Gas strut Hex bolt M 8 x 65 DIN 931 8 8 Self locking nut VM 8 Contact washer B 8 Space...

Page 82: ...int Push the gas strut 5 together then using two M 8 x 1 nuts secure the connecting rod into position There should be a gap of Y 1 mm between the end of the connecting rod and the rod 6 Fig 19 Lock th...

Page 83: ...d bolt it down Tightening torque 35 Nm Refit the dust cover 7 Refit the floor mat halves over the pedals Put the parking brake and the two foot brake tops back into place and secure them with bolts Sc...

Page 84: ...x no load speed Connect the pressure gauge to the test port pressure line upstream of steering valve Start the engine Turn the steering wheel fully and hold it in that position Take the pressure readi...

Page 85: ...assembly Plug hydraulic lines and screwed joints with plugs Fig 24 Remove the two cheese head screws S from the valve block on the steering block then remove the valve block Take care of the dowel pin...

Page 86: ...ure that the valve block will not be offset when fitted 3 Fit the O rings 1 into position and put the valve block in place NOTE The dowel pin must engage in the bore of the steering block Ensure the O...

Page 87: ...essure relief valve 150 10 bar Double shock valve 200 bar ATTENTION Check pressures only with the oil at working temperature approx 50 in the tank and with the engine running at max no load speed Conn...

Page 88: ...spanner Steering column without Autopilot Remove the Orbitrol together with shaft and quick release fastener Steering column with Autopilot Remove the Orbitrol together with the shaft quick release f...

Page 89: ...roduce shaft into the Orbitrol Push the Orbitrol firmly under the console The axial play on the shaft W should be approx 1 mm adjust the quick release fastener A in order to achieve the setting if req...

Page 90: ...he overrider switch D from the side into the console K Pay particular attention to the fact that the support washer S of the overrider switch should be at the top and the wiring loom should come out a...

Page 91: ...he axial play of the shaft W For this push the Orbitrol firmly under the console K The axial play should be approx 1 mm should this not be the case then readjust the quick release fastener A Fig 33 35...

Page 92: ...pressure relief valve 150 10 bar Double shock valve 200 bar ATTENTION Check pressures only with the oil at working temperature approx 50 C in the tank and with the engine running at max no load speed...

Page 93: ...the switch Remove the cap K To do this unlock the pin located below the cap and remove it Remove the floor mat from around the parking brake area Fig 1 Disconnect the cable from switch S Unhook the c...

Page 94: ...embly from the platform underside CAUTION The O ring must not be damaged 2 Refit the cable and secure with the lock nut 3 Setting the parking brake on the gearbox Reconnect the parking brake cable H a...

Page 95: ...m the yoke of the cylinder Unscrew the hex securing bolts from the master cylinder and remove master cylinder Fig 1 Master brake cylinder disassembled 1 Spring guide tube 2 Compression spring 3 Seal 4...

Page 96: ...lowed 0 5 mm 4 Bleeding the braking system see page 7 20 2 Bleeding the brake system 5 Adjust master brake cylinder Adjusting the master brake cylinder Adjust the yoke on the master cylinder so that t...

Page 97: ...Do not carry out any work on live parts unless the engine is stopped and the battery cables are disconnected Do not under any circumstances flash connections to check current flow on three phase alte...

Page 98: ...2 5 2 RHB LEXION 480 188 678 1 Engine electric system...

Page 99: ...3 Threshing mechanism...

Page 100: ......

Page 101: ...hand machine side Fig 1 First remove the universal coupling U on the left hand side then the guard S Fig 2 Remove the mud guard K Fig 3 Release the tension of the spring loaded cylinder A and remove V...

Page 102: ...r this remove the bolts with brackets H on the left and right hand side of the machine Fig 5 Loosen the two cable clamps K and disconnect the 7 pin connector T Fig 6 Disconnect the screwed coupling A...

Page 103: ...g in coupling on the left hand side of the machine Bolt down the two cable clamps and connect the 7 pin connector 4 Raise the feed rake conveyor to its highest position secure then refit the feed plat...

Page 104: ...Installing the intercepting piece 1 Place the existing washers D under the intercepting piece and insert it Insert the hex bolt S The intercepting piece must make contact with the washers D without p...

Page 105: ...crew hex bolt 11 Fig 14 22 Remove the housing S Unscrew the hex bolts 4 from the support plate 3 Remove the suction blower completely Fig 15 22 Disassembling the feed rake conveyor suction blower Unsc...

Page 106: ...bearing Fig 18 Loosen the set screw 12 and pull off the impeller 13 Install parallel key 20 Fig 19 22 Unscrew the bearing housing completely from the cover 15 Fig 20 Pull off bearing housing 24 from...

Page 107: ...B 8 8 Housing 9 Washer 10 Contact washer A 8 11 Hex bolt M 8 x 20 12 Set screw M 8 x 12 13 Land wheel 14 Hex bolt M 6 x 40 Hex nut M 6 Contact washer A 6 15 Cover 16 Contact washer A 8 17 Hex nut M 8...

Page 108: ...upporting ring 25 and key 26 Drive on the V belt pulley 27 and support the shaft end on a wooden block 4 Place contact washer 28 in position and screw nut on loosely 29 Fig 22 24 5 Install parallel ke...

Page 109: ...ction blower Bolt down support plate 3 using the hex bolts 4 Place suction blower on the feed rake conveyor and bolt down loosely Fig 22 27 Installing and adjusting the feed rake conveyor suction blow...

Page 110: ...at the top Split the feed chains and secure both ends with wire so that they are kept out of the way but are not lost Fig 31 Remove the anti wrapping guards W and the sealing plate D Remove the fille...

Page 111: ...site of each other from the pulley Fig 35 Pull off the slip clutch and the pulley in one piece from the shaft using a special tool For the special tool screw a M 16 x 30 hex bolt with a centralising h...

Page 112: ...38 Loosen the M 12 x 65 countersunk head bolts from both bearing assemblies on either side Fig 39 Remove the bearing housing from the right hand side Slacken off the cam wheel N using an Allen key and...

Page 113: ...800 0 2 Threaded spindle part no 181 801 1 3 Centraliser with ball part no 181 849 0 4 Hex bolt M 12 x 220 DIN 933 8 8 part no 244 422 0 5 Washer part no 236 844 0 6 Hex nut M 12 DIN 934 8 part no 23...

Page 114: ...ntact washer A 10 12 Hex bolt M 16 x 50 DIN 933 8 8 Contact washer A 16 13 Washer 14 Lock collar 45 15 Set screw M 10 x 1 25 x 8 DIN 916 16 Bearing housing 17 Cam wheel 18 Set screw M 10 x 8 DIN 916 1...

Page 115: ...inside of the bearing assembly 3 Fig 45 46 Special tool 1 Tube inside 47 50 x 120 long self sourced 2 Bushing part no 181 807 1 3 Washer part no 636 678 0 4 Axial grooved ball bearing part no 177 899...

Page 116: ...17 x 10 part no 688 484 0 Fig 45 49 Bolt the two M 10 x 35 hex bolts through the V belt pulley 10 into the slip clutch Tightening torque 45 Nm Fig 45 50 Fit the bolt 12 and the washer 13 into the fac...

Page 117: ...EXION 480 3 1 17 Feed rake conveyor 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...

Page 118: ...ockets 23 into position using the gib head keys 24 Dimensions to watch for X 130 mm Y 577 mm Z 88 mm Refit the anti wrapping guards 25 26 and 28 back into place using the bolts 29 Refit the sealing pl...

Page 119: ...he feed slats are just touching the runners Fig 55 Refit the wear plates Lock the chains so that they cannot turn Tighten bolt 12 using a torque wrench Tightening torque 195 Nm Fig 56 Removing the bot...

Page 120: ...ng a suitable tube and arrest the pins 11 on both sides with a self grip wrench Fig 59 Remove the stops on both sides For this remove the M 16 x 35 hex bolts from the outside Fig 60 Unscrew the hex nu...

Page 121: ...20 DIN 934 8 Fig 63 Assembling the bottom feed rake roller 1 Press the deep groove ball bearing 2 into the supporting arm 1 2 Replace the felt seal 3 each time the unit is assembled and drive the pre...

Page 122: ...he tension of the chains can also be checked with a cutterbar fitted using the inspection door P provided on the feed rake conveyor Stops on either side of the feed rake conveyor limit the low positio...

Page 123: ...ired Fig 68 Installing 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 secure using suitable tape Push in the wooden ledges watching the correct...

Page 124: ...e W Turn the roller so that the chain connectors point to the front Split the chain and secure it with some wire to the bolt holes at the bottom Fig 72 Unscrew the inspection doors P Lift the feed rak...

Page 125: ...ly adjust to such an extent that the feed rake slats are just touching the runners G The tension of the chains can also be checked with a cutterbar fitted using the inspection door P provided on the f...

Page 126: ...articularly careful when screwing out the spring guide tube Do not unscrew the spring guide tube too far Danger of injury Fig 79 Remove the pulley along with the clamping hub For this remove the M 12...

Page 127: ...and remove the cover S from the bracket H Fig 82 Remove the circlip and slide the gear from the shaft Fig 83 Remove the three M 12 hex nuts and remove the bracket Fig 84 Remove the set screw and remo...

Page 128: ...l tool 1 Puller bridge part no 181 800 0 2 Threaded spindle part no 181 801 1 3 Centraliser with ball part no 181 849 0 4 Hex bolt M 16 x 140 part no 242 795 0 2 pieces 5 Washer 17 part no 235 127 2 2...

Page 129: ...heet metal flanges and using the special tool pull off the lock collar bearing Fig 91 Special tool 1 Puller bridge part no 181 800 0 2 Threaded spindle part no 181 801 0 3 Centraliser with ball part n...

Page 130: ...drive shaft 2 Lock collar bearing PEA 208 2 S 3 Sheet metal flange BF 80 4 Lock collar 40 Set screw M 10 x 1 25 x 8 5 Mounting bracket Hex bolt M 6 x 12 DIN 933 8 8 Hex nut M 6 DIN 934 8 Contact wash...

Page 131: ...tighten the clamping hub with the M 12 x 85 hex bolt 8 On the right hand side remove the gear and bolt down the bracket using the bolts that secure the sheet metal flanges Then fasten the gear with t...

Page 132: ...linder safety lock Loosen and remove the set collar from the bearing plate Fig 97 Loosen the M 10 x 20 hex bolt so that the bearing plate may be removed Fig 98 Remove the hose end that goes off to the...

Page 133: ...e the cylinder Fig 101 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 102 Using a two legged puller an...

Page 134: ...tact washer A 8 4 Hydraulic cylinder Hex bolt M 8 x 65 DIN 931 8 8 Hex nut M 8 DIN 934 Contact washer A 8 Hex bolt M 12 x 25 DIN 933 8 8 Contact washer A 12 5 Eccentric Hex bolt M 12 x 45 DIN 931 8 8...

Page 135: ...lay 6 Bolt the compression spring 6 in position Tighten the nut until the end of the bolt thread 7 Bolt down the bearing plate 7 slide on the set collar 8 and tighten 8 Adjusting the hydraulic cylinde...

Page 136: ...te T the right hand end piece V and the left hand guide plate W Fig 109 Loosen the M 10 hex bolts and remove the feed rake slats except two Turn the roller until the chain connectors are at the front...

Page 137: ...k nut C have been slackened the feeder chains may be tensioned using adjusting nuts B On both sides tension the chains evenly and only to such an extent that the feeder chains are just touching the ru...

Page 138: ...3 1 38 RHB LEXION 480 188 678 1 Feed rake conveyor...

Page 139: ...move the M 12 x 40 hex bolts K from both sides of the stone trap Remove the turn lock G and remove the stone trap Fig 2 Remove the 4 8 x 12 blind rivet from the terminal strip Replace the rubber seal...

Page 140: ...rted in a safe manner Remove both front wheels Remove the guard S and the mud guards K from the right hand side Fig 3 Remove the drum inspection cover A Fig 4 Remove the hex bolts T from both sides of...

Page 141: ...segments V Raise the segments and remove them from the machine Unscrew the cover F from the preparation floor and fold it open Fig 8 Unscrew hex bolt K in order to remove brace G Lift both disawner p...

Page 142: ...move the bolts A and B from the centre and the front concave suspension on the right and left hand side Fig 12 Pull out the sealing plates 3 and 7 At the front sealing plates 3 also remove the wear st...

Page 143: ...oncave with concave segment 2 Preconcave segment 3 Sealing plate 4 Wear strip 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...

Page 144: ...and left hand side Push the wear strips 4 into the elongated hole of the machine housing at the front sealing plates 3 Place the hex bolts 6 with securing rings and washers through the mounting plate...

Page 145: ...one trap 8 Close the stone trap and lock it 9 Set the basic concave adjustments see page 3 2 16 Basic concave setting 10 Bolt down the guard and drive wheels 11 Installing the feed rake conveyor see p...

Page 146: ...ing the rocker arms ensure that they have been marked as they are not symmetrical Fig 20 Securely support the underside of the concave with pieces of squared timber of approx 120 mm in height Remove t...

Page 147: ...ine through this opening Fig 23 24 27 DANGER Leave the inside of the machine after removing the deflector curtain 2 Fig 24 Remove the hex bolts S from the left and right hand machine side CAUTION The...

Page 148: ...oncave disassembled 1 Main concave 2 Deflector curtain 3 Hex bolt M 10 x 20 Contact washer A 10 4 Spring clip 5 Washer 6 Holder plate Hex bolt M 10 x 25 Contact washer A 10 7 Eccentric pin 8 Plate 9 A...

Page 149: ...crew plate 8 and adjusting bolt 9 CAUTION Upon removing the plate 8 the main concave 1 will drop in the drum housing Fig 27 30 Turn the main concave 1 to the front below the threshing drum and pull it...

Page 150: ...and support it with pieces of squared timber of approx 120 mm height 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...

Page 151: ...de approx 10 mm shorter to allow passing a weld nut on the left hand machine side Fig 34 Threshing drums with cover plates Attach the main concave with a chain of approx 740 mm length to a rasp bar R...

Page 152: ...rum housing use a mirror or a punch Danger of injury Slide on plate 8 at W and bolt down loosely using adjusting bolt 9 Fig 27 36 Remove the chain for lifting the main concave on the left hand machine...

Page 153: ...n 2 to the main concave Fig 24 27 Bolt down the front rocker arms supporting the preparation floor and the machine frame on both sides Observe correct installation position CAUTION Position the sieve...

Page 154: ...on the key C7 for a further 15 20 sec Important Check that the concave adjustment hydraulic cylinders H are fully extended Then move the concave to the closest position by actuating pushbutton C6 Onc...

Page 155: ...suring point 1 2 mm Pre concave entrance measure parallel position M2 Measuring point 2 7 1 mm Main concave entrance 3rd bar Set at hydraulic cylinders at A M3 Measuring point 3 4 1 mm Main concave ou...

Page 156: ...point 1 2 mm Pre concave entrance measure parallel position M2 Measuring point 2 13 2 mm Main concave entrance 2nd spike tooth bar Set at hydraulic cylinders at A M3 Measuring point 3 7 2 mm Main con...

Page 157: ...rum rasp bar with the largest radius measuring bar at the left and right hand machine side This marked rasp bar is later used for setting the clearance to the concave Fig 39 40 left hand machine side...

Page 158: ...ght From serial no up to serial no May be adjusted in 30 steps Up to serial no May be adjusted in 60 steps Re tighten the safety plate P right hand machine side Check for parallel position of preconca...

Page 159: ...ere must be a clearance of 7 1 mm between the 3rd concave bar and the rasp bar of the threshing drum at measuring point M2 The value on the screen should read 7 Should this not be the case adjust the...

Page 160: ...clearance of 7 1 mm between the 3rd concave bar and the rasp bar of the threshing drum at measuring point M2 The value on the screen should read 7 Should this not be the case adjust the threaded rod G...

Page 161: ...ely under the front axle on the right hand side Remove the right hand wheel Remove the drum inspection cover Remove the guard S and the mud guard K on the right hand side Fig 1 Remove the cover D on t...

Page 162: ...Remove the V belt pulley from the hub Remove the M 16 hex bolt from the face end of the shaft Fig 5 Using a suitable block ended tube S apply a good sharp knock in order to release the tapered ring Th...

Page 163: ...embling the right hand bearing assembly Remove the bearing housing using a puller For this turn a head centred hex bolt M 16 x 30 into the face end of the shaft Fig 9 Remove self aligning roller beari...

Page 164: ...bolt M 16 x 300 part no 237 375 1 2 Hex nut M 16 part no 244 059 0 3 Washer 50 x 17 x 15 thick part no 636 678 0 4 Axial bearing part no 177 899 0 5 Centring disc part no 181 879 0 6 Tube inside 42 o...

Page 165: ...lightly grease the bearing seat Using a plastic tip hammer drive the shaft together with the bearing assembly into the drum Fig 13 14 Using a tube lift the shaft Bolt the bearing assembly into place a...

Page 166: ...to the outside using the special tool so that its shoulder locates correctly against the inner ring of the self aligning ball bearing Special tool Tie rod 450 mm part no 181 605 0 Striking tool part n...

Page 167: ...hex bolt and the washers tighten to shaft face end Tightening torque 180 Nm Fig 13 20 Bolt the V belt pulley to the hub Connect the cable to the magnetic pick up G Check dimension X 1 0 5 mm accordin...

Page 168: ...rd S Release the tension from the spring loaded cylinder A and remove the threshing mechanism drive belt R on the right hand side of the machine DANGER Please be particularly careful when screwing out...

Page 169: ...M 12 x 35 hex bolts from the bearing housing Fig 28 Using the special tool pull the bearing assembly from the shaft Fig 29 Special tool 1 Puller bridge part no 181 800 0 2 Threaded spindle part no 181...

Page 170: ...ll bearing using the special tool Fig 32 Special tool 1 Lever nut part no 181 880 0 2 Axial grooved ball bearing part no 235 983 0 3 Locating disc part no 181 879 0 4 Tube outside 35 inside 25 x 100 l...

Page 171: ...nto place Insert the circlip into the bearing assembly Fig 34 Special tool 1 Lever nut part no 181 880 0 2 Axial grooved ball bearing part no 235 983 0 3 Locating disc part no 181 879 0 4 Tube outside...

Page 172: ...0 3 Thrust bearing part no 177 899 0 4 Hex nut M 12 part no 239 418 0 5 Hex bolt M 12 x 220 part no 244 422 0 Fig 37 Bolt down the washer with the M 12 x 30 bolt Fit the cover and the circlip Refit t...

Page 173: ...now be replaced When screwing in the mushroom head bolts hex bolts observe the following From serial no Bolt down mushroom head bolt M 10 x 25 x 20 10 9 DIN 603 with a tightening torque of 55 Nm From...

Page 174: ...a safe manner Now remove the two front wheels Remove the drum inspection cover Removing the bearing assembly and the shaft on the right hand side see page 3 3 1 Support the accelerator safely with tw...

Page 175: ...5 Special tool 1 Puller bridge part no 181 800 0 2 Threaded spindle part no 181 801 1 3 Bolt M 12 x 30 with punch point on the head self sourced 4 Bolts M 10 x 70 part no 235 538 0 2 pieces 5 Washers...

Page 176: ...or 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 li...

Page 177: ...7984 8 8 Lock washer 12 12 Felt ring 13 Felt ring 14 Bearing housing 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 wa...

Page 178: ...Bolt the anti wrapping guard 5 to the right hand side of the machine 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 h...

Page 179: ...Using a suitable lever raise the accelerator 1 up Bolt the bearing assembly to the drum housing using the three cheese head screws 11 Tightening torque 78 Nm Now reconnect the grease pipe to the beari...

Page 180: ...e circlip 21 Fix the grease pipe back onto the bearing housing 14 and grease thoroughly Fig 50 On the right hand side pull the shaft 2 slightly to the outside using the special tool so that its should...

Page 181: ...0 Bolt down the V belt pulley 29 to the hub 25 with bolts 30 Tightening torque 110 Nm Connect the cable to the magnetic pick up G Check dimension X 1 0 5 mm according to Fig 51 Fig 50 61 Install the V...

Page 182: ...3 3 22 RHB LEXION 480 188 678 1 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...

Page 183: ...ve the threshing mechanism drive belt K see page 7 3 10 Removing the accelerator drive belt 24 DANGER Please be particularly careful when screwing out the spring guide tube Do not unscrew the spring g...

Page 184: ...ial no Unlock face end slotted nut M 60 x 2 and loosen it using a special socket spanner part no 180 143 0 by about 2 turns Fig 4 Using a suitable block ended tube use a good sharp blow to release the...

Page 185: ...he underside of the threshing drum by a wooden wedge in order to prevent the drum from crashing down Fig 8 Disassembling the right hand drum bearing 1 Separate the bearing assembly from the spacer 2 S...

Page 186: ...t ring 4 Bearing housing Cheese head screw M 8 x 20 DIN 912 8 8 Detent edged ring VSKZ 8 5 Taper lock sleeve 6 Spherical roller bearing 7 Bearing housing Hex bolt M 12 x 100 DIN 931 8 8 Contact washer...

Page 187: ...en continue tightening by 64 and then to the next slot position matching it with the securing tab 9 Tap tab down into the slot Up to serial no Tighten the M 60 x 2 face end slotted nut 10 to 45 Nm usi...

Page 188: ...Removing the impeller drive belt 4 Relieve the tension on belt P and remove it see page 7 2 1 Removing the cutterbar drive belt 1 Cut terbar drive without variable speed drive and or see page 7 2 3 R...

Page 189: ...th suitable wooden blocks Fig 18 Unlock face end slotted nut M 50 x 1 5 and loosen it using a slot type spanner special tool part no 180 142 0 Back off the face end slotted nut by approx two turns Usi...

Page 190: ...le tools push the spherical roller bearing out Fig 21 Left hand drum bearing assembly disassembled 1 Felt seal 2 Bearing housing 3 Taper lock sleeve 4 Spherical roller bearing 5 Bearing housing Cheese...

Page 191: ...b 7 Tap tab down into the slot 5 Refit the grease pipe Remove the wooden wedge and refit the assembly cover 6 Place the parallel key into the slot on the shaft Slide the clamping hub on the shaft and...

Page 192: ...e right hand machine side remove the V belt pulleys from the accelerator and threshing drum hubs see page 3 4 1 Removing the right hand drum bearing assembly Remove bearing on left hand machine side s...

Page 193: ...XION 480 3 4 11 Threshing drum 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 complete...

Page 194: ...eese head screw M 8 x 20 DIN 912 8 8 Detent edged ring VSKZ 8 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 Ci...

Page 195: ...er bar with perfect ribs Fig 32 Loosen the M 12 x 20 bolts and remove the cover plates Fig 33 Remove the M 12 x 30 bolts and twist the beater bar back towards the weld seams The weld seams break and t...

Page 196: ...bars exceed 1 5 mm turn the outside of the drum in a lathe If damage is extensive e g if the drum discs or shaft are damaged a new threshing drum should be installed When the drum has been repaired re...

Page 197: ...o the right hand side Fig 38 Special tool 1 Puller bridge part no 181 800 0 2 Threaded spindle part no 181 801 1 3 Centraliser with ball part no 181 849 0 4 Hex bolt M 14 x 55 DIN 931 part no 212 116...

Page 198: ...ing drum shaft Push the shaft 1 through the centre of the drum starting from the left hand side Observe dimension X 3 5 1 mm according to Fig 40 On the right hand side of the drum refit the flanged sh...

Page 199: ...eeve and the shaft seat must be dry and free from grease 4 On the right hand machine side assemble the bearing assembly 8 12 the spacer 7 and the assembly cover 6 on the shaft end 5 Guide the M 12 x 1...

Page 200: ...ase pipe 10 Place the parallel key into the slot on the shaft Slide the clamping hub 26 onto the shaft and align it using the dimension X 61 mm according to Fig 41 Tighten the clamping hub using the M...

Page 201: ...nsion of threshing drum drive belt 23 Fig 1 Unbolt the jockey pulley S Fig 2 Remove the grease pipe L from the bearing assembly Unscrew the set screw from the lock collar and knock off the lock collar...

Page 202: ...ool S Fig 5 Special tool 1 Puller bridge part no 181 800 0 2 Threaded spindle part no 181 801 1 3 Head centred hex bolt part no 603 038 0 4 Hex bolts M 12 x 140 part no 233 011 0 2 pieces 5 Washer 13...

Page 203: ...ring assembly into place Tightening torque 78 Nm ATTENTION Ensure that there is no pre load on the bearing 4 Refit the lock collar and tighten it in direction of rotation then lock it with the set scr...

Page 204: ...9 Pull off the bearing assembly using a special tool Remove the cover D if necessary Fig 10 Special tool 1 Puller bridge part no 181 800 0 2 Threaded spindle part no 181 801 1 3 Centraliser with ball...

Page 205: ...no 239 418 0 5 Hex bolt M 12 x 220 part no 244 422 0 Fig 13 Bolt the bearing assembly to the cover Attach the grease pipe to the bearing assembly Fig 14 Install pulleys On machines equipped with cutte...

Page 206: ...ines without cutterbar variable speed drive Remove the cutterbar drive belt 1 at the rear see page 7 2 1 Removing the cutterbar drive belt 1 Cut terbar drive without variable speed drive Removing the...

Page 207: ...ey pulley S with bracket from the impeller drive Fig 17 Remove the grease pipe Fig 18 Remove all bolts from the cover Remove bolt S from the grain tank floor Fig 19 Using a suitable lifting device lif...

Page 208: ...eller drive jockey pulley S with the bracket Fig 22 6 Install belt On machines without cutterbar variable speed drive Installing and adjusting the impeller drive belt 4 see page 7 2 8 Installing and a...

Page 209: ...3 5 9 Impeller Removing the flanged shaft 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 t...

Page 210: ...8 1 Impeller Impeller disassembled from serial no 1 Impeller 2 Flanged shaft 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...

Page 211: ...peller 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 bear...

Page 212: ...impeller see page 3 5 6 Removing the left hand impeller bearing see page 3 5 3 Remove the impeller shaft To do this unscrew the hex bolt 3 Fig 29 Clean the impeller shaft and pull out shaft with speci...

Page 213: ...Impeller disassembled up to serial no 1 Impeller 2 Impeller shaft 3 Hex bolt M 10 x 30 RS Hex nut M 10 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...

Page 214: ...l no Insert parallel key 4 and drive the impeller shaft 2 into the impeller until the dimension X is 268 2 mm Secure the impeller shaft 2 with hex bolt 3 Fig 31 32 33 Installing the impeller see page...

Page 215: ...e inside of the machine through the respective opening Fig 1 2 Up to serial no Open the access door inside the engine compartment Enter the inside of the machine through this opening Fig 1 Remove the...

Page 216: ...e guide rail and place it on to the return floor Fig 5 Pull all the grates one after the other to the rear and remove Fig 6 To ease removal of the separation grates place the grates crosswise on to th...

Page 217: ...crews Close the access door in the engine compartment Raise and install the return pan if required see page 4 1 2 Raising and installing the return pan from serial no Removing the separating jacket Re...

Page 218: ...discharge plate A and the cover plate Fig 12 Removing the return pan see page 4 1 3 Cover up the upper sieves with mounting plates Pull out all separating grates to the rear Fig 13 Only slacken off t...

Page 219: ...g jacket around the rotor with two lifting straps Unscrew the hex bolts S Oil the face ends of separating jacket inlet head and of discharge housing well Rotate the separating jacket by approx 160 to...

Page 220: ...tate the separating jacket by 180 around the rotor and screw in the hex bolts S Fig 16 20 4 Remove the lifting straps 5 Install the intermediate plate Z and the step T Fig 16 6 Firmly tighten the hex...

Page 221: ...pporting arm Unscrew and remove the dust plate B Disconnect the lubrication line at the connector Fig 21 Unscrew one countersunk head bolt M 10 x 30 from the wear edge Bolt down the lifting strap safe...

Page 222: ...pull off the supporting arm with a special tool Fig 25 Special tool 1 Puller bridge with spindle part no 181 622 0 2 Hex bolt M 10 x 70 DIN 931 8 8 part no 235 538 0 3 Hex nut M 10 DIN 934 part no 236...

Page 223: ...her 13 x 40 x 6 8 Hex bolt M 12 x 30 DIN 933 8 8 Contact washer A 12 9 Cover 10 Hex bolt M 10 x 25 DIN 933 8 8 Contact washer A 10 Fig 28 Installing the axial rotor supporting arm 1 Pre assemble the b...

Page 224: ...slide the supporting arm 1 on the ball journal 4 Screw in two hex bolts 6 crosswise CAUTION The supporting arm must not tilt Correct axial rotor position with lifting straps if necessary Fig 28 29 31...

Page 225: ...grain tank 15 Installing the impeller see page 3 5 8 Removing the axial rotor Removing the axial rotors drive see page 7 15 11 Support the axial rotor at the discharge plate in the rear so it will not...

Page 226: ...p with a hex bolt M 10 x 60 Suspend the lifting strap at the crossmember and lift the rotor with a chisel Pull the axial rotor out to the rear by approx 0 5 m using the lifting strap Fig 38 Remove the...

Page 227: ...arm Fig 42 3 Unscrew one countersunk head bolt M 10 x 30 from the wear edge Bolt down the lifting strap safely with a M 10 x 60 bolt Now lift the axial rotor upwards through the grain tank opening Fig...

Page 228: ...screw the air filter housing completely and plug all openings tightly Fig 45 Unscrew the roof plate at the front Unscrew the bolts on the crossmember at the rear of the roof plate Fig 46 Remove the ri...

Page 229: ...ellar plate and bottom plate B Fig 49 Remove the jacket sheet M with its bracket Unscrew the cable clamp from the reversing signal generator R and disconnect the cable plug Fig 50 Disconnect the cable...

Page 230: ...and right hand covering V Fig 52 Disconnect the cable plug of the back up light and pull the cable K downward through the post Fig 53 Unscrew the side wall from the post on the right and left hand sid...

Page 231: ...traw cover completely using a suitable lifting device Fig 56 Unscrew the straw chopper cover Fig 57 DANGER Cover up the cutting cylinder Danger of injury Unscrew the guide plate Fig 58 Unscrew the ins...

Page 232: ...the left and right hand side and the cover plate Fig 60 Disconnect the cable plugs Remove the cable clamps completely and guide the cable plugs through the side wall Fig 61 Remove the cross connectio...

Page 233: ...intermediate drive 19 Remove the belt guard Fig 64 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 tw...

Page 234: ...0 RHB LEXION 480 188 678 1 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 67...

Page 235: ...l rotors Unscrew the bolt from the inlet head on the left and right hand side CAUTION The thrust piece falls down inside Fig 70 71 Pull out the hybrid unit to the rear Ensure it is moved in parallel t...

Page 236: ...he bolts of the discharge housing and the crane eyelets to the machine frame Screw the bolts into the platform Fig 66 5 Slide on jockey pulley arm and lock it with set collars Fig 65 6 Install and ten...

Page 237: ...the left and right hand side Fig 52 13 Lay and connect cables for wind door switch and magnetic pick up Fig 51 14 Bolt on mounting plate M with holder ladder rest A bottom plate B and covering Lay an...

Page 238: ...3 6 24 RHB LEXION 480 188 678 1 Axial rotors...

Page 239: ...4 Cleaning unit...

Page 240: ......

Page 241: ...gle nuts K on both sides and remove the feed pan Fig 1 Position the return pan exactly in the middle of its oscillating travel Slacken off the hex bolts B of the metal rubber bearings on both sides Fi...

Page 242: ...beneath the rotors Fig 6 Raising and installing the return pan from serial no 1 Raise the return pan and bolt down the rocker arm bearing C 2 Bolt down pins M and A Fig 4 3 Position the return pan exa...

Page 243: ...he return pan Move the uni spreader to transport position in order to afford easier access CAUTION Make sure that the sieve pan linkages are not misadjusted in the removing process Fig 7 Unscrew the s...

Page 244: ...eturn pan Remove the sieve pan light Fig 10 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 combin...

Page 245: ...nd ensure that the rubber sealing strips on the side are not bent down 2 Bolt on the rear rocker arm ATTENTION During installation of new rubber bushings 4 pay attention that the rubber bushings are n...

Page 246: ...4 1 6 RHB LEXION 480 188 678 1 Return pan...

Page 247: ...inkages are not misadjusted in the removing process Fig 1 Unscrew the screws A on both sides of the chopper preparation floor Now fold down the preparation floor Fig 2 Slacken off the screws C on both...

Page 248: ...he middle Fig 6 Remove end profile N For this unscrew the hex bolts E Remove the complete end profile N to the rear CAUTION The collecting plates A must not be removed from the end profile N The sieve...

Page 249: ...ing motor at the ball head Unscrew positioning motor at ball head Remove connecting linkage V from both sieves Fig 10 Loosen cable fixings Completely remove the wind board W along with the positioning...

Page 250: ...al mountings to the specified torques and then tighten the side clamps NOTE Ensure that all bolts are securely tightened When sieve installation is complete re install the preparation floor and bolt i...

Page 251: ...have identical positions Open sieves e g to position 15 Openings of the left hand frogmouth sieve must be identical with the openings of the right hand frogmouth sieve To check the frogmouth sieve op...

Page 252: ...s K and the side clamps K Unscrew the hex bolts S at the sides and in the middle Fig 17 Remove fixing rail N For this unscrew the hex bolts E CAUTION Do not unscrew the wire rake If the wire rake was...

Page 253: ...position of the sieve pan Fig 19 Removing the lower sieves up to serial no Remove upper sieves Disconnect retarder W from the return pan Loosen the rubber pad S Disconnect both returns pans R and rem...

Page 254: ...the sieves Pull out the sieves to the rear Fig 24 25 Installing the sieves up to serial no Installation is in reverse order When installing the sieves first tighten the axial mountings to the specifi...

Page 255: ...lled without stress and refit the Bowden cables The Bowden cables can be adjusted at the hex nuts A and B at the electric motors and or at the Bowden cable retarders behind the sieves 5 Checking the i...

Page 256: ...pper sieves Unscrew and remove the sensor tray On the 3 D version unbolt the control arm from the inside Fig 28 Unscrew the control arm at the metal rubber bearing and pull the complete assembly out t...

Page 257: ...ping bolt for the stud in the sieve pan frame Fig 32 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 roc...

Page 258: ...g bolt for the stud in the sieve pan frame Fig 36 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 r...

Page 259: ...m and pull it off Fig 40 Unbolt the connecting rod at the main rocker arm Fig 41 Unscrew the connecting rod and rocker arm and pull it off using a puller Fig 42 Loosen the clamping bolts K at the fron...

Page 260: ...N 480 188 678 1 Sieve pan 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 r...

Page 261: ...t M 10 x 20 DIN 933 8 8 Contact washer A 10 Washer 11 x 26 x 4 7 Pin 8 Metal rubber bearing 9 Front control arm 10 Thrust rod 11 Pin up to serial no Hex bolt M 10 x 90 DIN 931 8 8 from serial no Conta...

Page 262: ...rsion bolt the control arm to the upper sieve frame and the metal rubber bearing Fig 46 47 48 7 Position the sieve pan exactly in the middle of its oscillating travel In this position secure the metal...

Page 263: ...e frame Unscrew the double rocker arms on the left hand and right hand sides of the sieve pan frame Fig 49 Unscrew the rocker arm assemblies completely from the sidewall Fig 50 Unscrew and pull off th...

Page 264: ...the two rocker arms as they are not symmetrical Fig 53 Remove the locking bolts for the studs on both sides Fig 54 Pull out the bolts to the outside using the special tool Fig 55 Special tool 1 Tube 5...

Page 265: ...188 678 1 RHB LEXION 480 4 2 19 Sieve pan Lift the sieve pan out of the combine to the rear Fig 57 57...

Page 266: ...rm 10 Metal rubber bearing 11 Metal rubber bearing 12 Metal rubber bearing 13 Washer 14 Hex bolt M 10 x 50 DIN 933 8 8 Contact washer A 16 15 Bridge 16 Hex bolt M 10 x 25 DIN 933 8 8 Contact washer A...

Page 267: ...to rocker arm 9 and connecting rod 18 The outer metal ring of the bearing must be flush with the housing 5 Screw in a hex bolt M 10 x 90 DIN 933 at S Pull main rocker arm 9 uniformly on the studs usin...

Page 268: ...Bolt on bridge 15 on the left hand and right hand sides 8 Position the sieve pan and preparation floor exactly in the middle of their oscillating travel In this position secure the metal rubber beari...

Page 269: ...n the middle position Fig 64 65 10 Install the 3 D upper sieve frame Install the lower sieves Install the upper sieves Installing the return pan see page 4 1 5 Adjusting the 3 D sieve pan control syst...

Page 270: ...CAUTION In the basic position of the bearing assemblies the grease nipples S and or the male connectors on the right hand and left hand machine side are facing forward Fig 66 2 Check the parallel pos...

Page 271: ...ylinder safety lock Open the stone trap Unscrew the three hex bolts S which secure the cover P to the preparation floor Open the cover P Pull out the stepped preparation floor sections with a suitable...

Page 272: ...he sealing plates D on the left and right and pull off the plates together with gasket and spacer ring from the journal Fig 5 Unscrew the journals from the preparation floor Fig 6 Lift out the prepara...

Page 273: ...x 6 11 Sealing plate 12 Hex bolt M 8 x 20 DIN 933 8 8 Contact washer A 8 Hex nut M 8 DIN 934 13 Seal 14 Spacer ring 15 Flap 16 Hinge 17 Hex bolt M 6 x 16 DIN 933 8 8 Contact washer A 6 Hex nut M 6 DI...

Page 274: ...not tighten the bolts at this stage CAUTION The nuts 10 for the front rocker arms 8 must not be tightened until the sieve pan has been adjusted 5 Install sealing plates 11 and push on the gasket with...

Page 275: ...Q from the combine wall to pivot point B Disconnect cylinder Z from pivot point B and control lever C at bracket H Start the engine and with the engine running push pendulum housing E outwards in the...

Page 276: ...D gauge D part no 181 993 1 so that the points 3 and 4 are against the rear panel and blocks 7 and 8 are against the lower web S of the bracket Then move the 3 D gauge in parallel to the sidewall unti...

Page 277: ...ley Relieve the tension in compression spring D with nuts K and E Fig 2 Loosen the lock collar of the lock collar bearing and pull it off the ball journal Unscrew the V belt pulley K Fig 3 Loosen the...

Page 278: ...934 8 Contact washer A 10 4 Lock collar 35 5 Hex bolt M 10 x 45 DIN 931 8 8 Hex nut M 10 DIN 934 8 Contact washer A 10 6 Parallel key A 10 x 8 x 45 DIN 6885 7 Eccentric hub 8 V belt pulley 9 Hex bolt...

Page 279: ...earing 2 and bolt to the combine sidewalls 3 Align the shaft so that clearance Y from the sidewall to the end of the shaft is 82 mm 4 Install eccentric hub 7 with parallel key 6 and hex bolt 5 The cle...

Page 280: ...e housing 8 Install and tension the V belt 15 For this pretension the compression spring D with nut E to the gauge rod length Lock the nuts K and E and tighten clamping bolt A on the jockey pulley 9 P...

Page 281: ...al guard Loosen the two set screws M 10 x 8 of the variable speed pulley Pull the variable speed pulley assembly off the shaft using the special tool and remove the parallel key Fig 1 2 Special tool 1...

Page 282: ...the face end slotted nut and loosen with a slot type spanner Unscrew the face end slotted nut by approx two turns Fig 5 Using a block ended tube of 50 x 4 x 300 self sourced loosen the adapter sleeve...

Page 283: ...uard Unlock the face end slotted nut and loosen with a slot type spanner Unscrew the face end slotted nut by approx two turns Fig 8 Using a block ended tube of 50 x 4 x 300 self sourced loosen the ada...

Page 284: ...o the shaft and bolt to the bearing plate Align the shaft The clearance X from the machine side wall to the end of the shaft is approx 244 mm 3 Pre tighten face end slotted nut M 40 x 1 5 to a torque...

Page 285: ...Loosen the two set screws M 10 x 8 of the variable speed pulley Pull the variable speed pulley assembly off the shaft using the special tool and remove the parallel key Fig 13 14 Special tool 1 Pulle...

Page 286: ...side of the combine For this remove the plug Unscrew the lateral guard Unlock the face end slotted nut and loosen with a slot type spanner Unscrew the face end slotted nut by approx two turns Fig 17...

Page 287: ...r sleeve bearing by driving the shaft from the left hand side of the machine a little bit inward to the right Hold a soft metal punch against the left outside end of the shaft and give it a short shar...

Page 288: ...pull out to the right hand side Fig 24 25 Unlock the face end slotted nut and loosen with a slot type spanner Unscrew the face end slotted nut by approx two turns Fig 26 Using a block ended tube of 50...

Page 289: ...t Unscrew the bearing plate of the centre bearing Fig 29 Centre cleaning fan bearing disassembled 1 Hex bolt M 10 x 20 DIN 933 8 8 Hex nut M 10 DIN 934 Contact washer A 10 2 Bearing plate 3 Sheet meta...

Page 290: ...leeve and face end slotted nut onto the shaft Bolt the bearing plate to the frame 4 Align the cleaning fan shaft so that clearance X on the right hand side of the combine is approx 244 mm Fig 31 32 5...

Page 291: ...onto the shaft and secure axially with two set screws M 10 x 8 9 Installing and adjusting the fan drive belt 21 see page 7 3 5 Align the variable speed pulley assembly see page 7 14 42 Installing and...

Page 292: ...he jockey pulley Relieve the tension in compression spring D with nuts K and E Fig 35 Unbolt the connecting rod on the metal rubber bearing and the flange ball bearing Loosen the set collar and pull o...

Page 293: ...HB LEXION 480 4 6 13 Cleaning fan 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...

Page 294: ...5 Push the connecting rod on the stud and bolt to the bearing assembly with the hex bolts CAUTION The bearing assemblies on the right hand and left hand sides must be in the same position Otherwise t...

Page 295: ...5 Grain delivery...

Page 296: ......

Page 297: ...elevator inspection door A and remove Fig 1 2 Turn the elevator chain until the chain connector is at the bottom Release the tension from the chain This is done as follows 1 Loosen the hex nuts H 2 Lo...

Page 298: ...5 1 2 RHB LEXION 480 188 678 1 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 4 5 6 7...

Page 299: ...ion the chain using the hex nut M so far that the paddles do not scrape the elevator housing It must be possible to push the conveyor chain to the side manually at the bottom chain wheel Re tension th...

Page 300: ...ar from the flange ball bearing at F Fig 10 Remove the cover D from the returns elevator Fig 11 Disconnect the cable from the magnetic pick up Unscrew the screw plug Unscrew the flange ball bearing on...

Page 301: ...right hand side 3 Screw the screw plug into the assembly slot 4 Fit the sprocket into position on the returns auger and secure using an expansion pin 5 Align the returns auger to the sprocket and tig...

Page 302: ...emove Fig 16 17 Turn the elevator chain until the chain connector is at the bottom Release the tension from the chain This is done as follows 1 Loosen the hex nuts H 2 Loosen the hex bolts G 3 Loosen...

Page 303: ...at A Fig 20 Unscrew the returns elevator from the support Disconnect the cables at C and D Unscrew the bolt S Fig 21 Loosen the bolts at the elevator boot Remove the returns elevator Fig 22 Disassemb...

Page 304: ...ove the cover plate Loosen the two set collars on either side of the sprocket Slide the sprocket to the left and then remove the parallel key Pull out the shaft to the right hand side Fig 25 Drive the...

Page 305: ...5 Align the sprocket so that it lies in the centre of the elevator housing then secure the sprocket with the set collars Bolt down the cover 6 Refit the returns elevator to the combine Installing the...

Page 306: ...ting beam Fig 28 Using the special tool pull the elevator boot off Fig 29 Special tool 1 Extension M 10 part no 181 943 0 2 Puller plate part no 181 935 3 3 Washer 10 5 DIN 125 part no 236 913 2 4 Hex...

Page 307: ...the lock collar then secure the lock collar Refit the cap 4 Refit the returns elevator to the combine Removing the lower returns auger If fitted remove the guard C Open the returns elevator inspection...

Page 308: ...sioner S 4 Release the tension from the chain by unscrewing the hex bolt M Fig 34 Separate the chain at the chain connector Loosen the set collars next to the sprocket Thoroughly clean the returns aug...

Page 309: ...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 40 Installing the lower returns auger...

Page 310: ...t E to the gauge rod length Lock the nuts K and E and tighten clamping bolt A on the jockey pulley Fig 42 5 Align sprocket 4 so that it is centred to the elevator then secure the sprocket with the set...

Page 311: ...nspection door B on the clean grain elevator and then remove Fig 1 2 Turn the elevator chain until the chain connector is at the bottom Release the tension from the chain To release the tension loosen...

Page 312: ...top Observe correct installation position 2 Connect the two ends of the chain with the chain connector at the bottom 3 Tension the chain using the hex nut M so far that the paddles do not scrape the e...

Page 313: ...head Remove the grain elevator chain Release the tension of the grain tank filler auger drive chain K and remove chain Fig 7 Remove the chain adjusting straps L from their mounting plate Fig 8 Unbolt...

Page 314: ...ove the expansion pin from the sprocket Using a suitable puller pull the sprocket off the shaft Fig 10 11 Unlock the lock collars on both sides and knock them off against the direction of rotation Rem...

Page 315: ...RHB LEXION 480 5 2 5 Grain elevator 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...

Page 316: ...roove ball bearing 6204 Z DIN 625 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 23 S...

Page 317: ...on the clean grain elevator housing and secure with mushroom head bolts 33 5 Bolt down the tubes 27 for tensioning the elevator chain 6 Align shaft 1 according to the sprockets 18 21 and 23 for the gr...

Page 318: ...levator boot Lift the elevator shaft out of the machine Fig 20 Installing the grain elevator shaft 1 Lower the grain elevator shaft into the elevator boot and bolt it down 2 Bolt down the extension pl...

Page 319: ...on of rotation Fig 21 Unscrew the bracket and remove it Fig 22 Unbolt the flange ball bearing and pull it off using the special tool Fig 23 Special tool 1 Extension M 10 part no 181 943 0 2 Puller pla...

Page 320: ...evator boot to the bracket 4 Align the sprocket in the elevator boot to line up with the centre of the elevator shaft To do this loosen the set collars and align the sprocket Once the sprocket is in p...

Page 321: ...n connector is at the bottom Fig 27 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 28 Separate the chain at the cha...

Page 322: ...ley and pull it off Fig 32 Unscrew the flange ball bearing Fig 33 Turn out the grain auger to the left hand side through the assembly slot This will drive off the sprocket and the set collars in the e...

Page 323: ...auger for free and easy rotation 4 Align the V belt pulley and insert the key Install and tension the V belt 15 To retension preten sion the compression spring D with the nut E to the gauge rod lengt...

Page 324: ...or B and bolt down guard C Fig 25 26 9 Refit the cover plate V Fig 31 Removing the grain tank filler auger Open the grain tank Unscrew the filling tube from the flange joiner Fig 37 Unscrew the cover...

Page 325: ...ain tank filler auger out from the top Fig 41 Remove the hex bolt and pull off the flange together with the bearing and the bevel gear Fig 42 Removing the grain tank filler auger angle drive Remove th...

Page 326: ...ousing Fig 44 Disassembling the grain tank filler auger angle drive Remove the bracket for the magnetic pick up Drive the expansion pin from the sprocket Remove the sprocket using a suitable puller Fi...

Page 327: ...Flange 11 Deep groove ball bearing 6208 2 RS 12 Circlip 80 x 2 5 DIN 472 13 Bevel gear 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 b...

Page 328: ...e bevel gear 13 into the deep groove ball bearing 11 Insert the felt ring 8 2 Install the filler auger 2 Insert hex bolt 30 with liquid locking compound and tighten it From serial no Bolt down hex bol...

Page 329: ...Fig 48 49 51 6 Fit the pre assembled housing 15 to the filler head with two hex bolts M 10 x 16 Do not tighten the bolts at this stage Fig 44 7 Secure the housing 15 the bearing plate 21 the shim 22 a...

Page 330: ...ring with the lock collar then secure the lock collar Fig 54 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 u...

Page 331: ...from the face end of cross augers on the right hand side of the combine Fig 2 From serial no On the left hand side of the combine release the tension of the grain tank unloading drive chain and remov...

Page 332: ...of the combine 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 Remove the circlip from the sprocket Pull o...

Page 333: ...188 678 1 RHB LEXION 480 5 3 3 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 9...

Page 334: ...metal flange 4 Lock collar bearing 5 Flange ring 6 Countersunk head bolt M 12 x 25 DIN 7991 Washer 7 Sheet metal flange 8 Lock collar bearing 9 Sheet metal flange 10 Hex nut M 10 Contact washer A 10 1...

Page 335: ...Screw the grain tank cross auger 1 or 2 into the left hand side of the combine Fig 10 11 2 Refit the bearing plate Bolt down the flange ball bearing 7 8 and 9 Fig 10 12 3 Refit the bolt 12 or 6 on th...

Page 336: ...he sprocket and secure with the front circlip Fig 16 Up to serial no From serial no 6 Align the grain tank cross augers The start A of the unloading auger K flight must point toward the front cross au...

Page 337: ...each other Fig 10 19 Removing the vertical grain tank unloading auger Remove the drive wheel and the mud guard K on the left hand side of the machine Fig 20 From serial no Release the tension of the...

Page 338: ...this use centred M 12 x 25 bolts Fig 23 From serial no Unscrew the grease pipe P and the cover D Fig 24 From serial no To prevent the auger from dropping out unexpectedly rotate the auger so that the...

Page 339: ...grain tank unloading drive chain 17 Remove the circlip and then pull off the sprocket Fig 27 Up to serial no Unscrew the grease pipes and the cover D Fig 28 Up to serial no To prevent the auger from...

Page 340: ...auger in the grain tank unloading tube The two flight ends must not touch each other Check correct position by turning the augers To prevent the auger from dropping out unexpectedly rotate the auger...

Page 341: ...e rear cross auger H must be in the 12 o clock position F Direction of travel Fig 33 34 7 Installing and adjusting the grain tank unloading drive chain 17 see page 7 2 35 8 Refit the drive wheel and t...

Page 342: ...5 3 12 RHB LEXION 480 188 678 1 Grain tank unloading Pull the horizontal grain tank unloading auger out towards the back of the machine Fig 37 38 37 38...

Page 343: ...ding auger fully to the front Slide the flange bearing onto the auger and bolt down cover D Fix and secure the auger with the lock collar Bolt on discharge spout 90 Fig 35 If a 35 outlet spout is fitt...

Page 344: ...tractor Fig 41 Remove the sprocket using a suitable puller To do this use a centred M 12 x 25 bolt Fig 42 Unscrew the grease pipe P and the cover D Fig 43 To prevent the auger from dropping out unexpe...

Page 345: ...ding angle drive Remove the circlip and the shims and remove the bearing seal ring from the bearing Mark the installation position of the two shaft ends W on the housing Fig 46 Using a special tool pu...

Page 346: ...al ring Fig 49 Using a special tool pull out the complete bevel gear with the bearing Fig 50 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 pa...

Page 347: ...shims Fig 53 Unscrew the hex bolt and remove the washer 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...

Page 348: ...sembled from serial no 1 Gearbox housing 2 Bevel gear 3 Deep groove ball bearing 6309 DIN 625 4 Circlip 5 Deep groove ball bearing 6309 RS C3 DIN 625 6 Bearing seal ring 7 Shim 8 Circlip 9 Drive pin 1...

Page 349: ...unt the bevel gear 11 with the bearing 5 washer 13 and hex bolt 14 on shaft 10 CAUTION Insert hex bolt with liquid locking compound Tightening torque 63 Nm 3 Insert circlip 4 and heat up deep groove b...

Page 350: ...ing seal ring 6 the number of shims 7 of corresponding thickness found when disassembling and the circlip 8 Fig 57 58 61 7 Apply pattern identification paste to the bevel gear 2 tooth flanks and drive...

Page 351: ...the torsional backlash using shims Fig 64 10 Remove the bevel gear 2 and have a look at the profile left in the Engineers blue Correct the profile using shims Example A Initial setting B Required corr...

Page 352: ...ATTENTION The vertical auger must be offset by 180 relating to the horizontal auger in the grain tank unloading tube The two flight ends must not touch each other Check correct position by turning th...

Page 353: ...ition The start A of the rear cross auger H must be in the 12 o clock position F Direction of travel Fig 71 5 Installing and adjusting the grain tank unloading drive chain 17 see page 7 2 35 Removing...

Page 354: ...the auger so that the flight end is not near the gap S Fig 74 Unscrew the lower angle drive and remove it Fig 75 Disassembling the lower grain tank unloading angle drive up to serial no Remove the low...

Page 355: ...Special tool 1 Hex bolt BM 16 x 120 part no 236 936 0 2 Extension part no 181 810 1 3 Puller plate part no 181 803 1 4 Washer 17 part no 235 127 2 5 Hex nut M 16 part no 236 173 0 6 Washer 17 x 55 pa...

Page 356: ...complete bevel gear out of the housing Fig 83 Special tool 1 Adapter section M 10 part no 181 609 0 2 Tube 115 x 105 x 200 long self sourced 3 Puller bridge part no 181 816 3 4 Axial grooved ball bea...

Page 357: ...rbox housing 2 Bevel gear 3 Deep groove ball bearing 6309 DIN 625 4 Circlip 45 x 1 75 DIN 471 5 Deep groove ball bearing 6309 RS C3 6 Bearing ring seal 6309 ZJV 7 Shim 1 mm 0 5 mm 0 3 mm 0 1 mm 8 Circ...

Page 358: ...bearings 3 and 5 and the circlips 4 Install the bearings with the special tool Fig 86 87 88 Special tool 1 Tube 60 x 50 x 180 long self sourced 2 Washer part no 688 484 0 3 Axial grooved ball bearing...

Page 359: ...g Insert circlip 8 and pull the bevel gear back up against it Fig 86 87 90 4 Refit the correct thickness and number of shims 7 found when disassembling Apply Engineer s blue to the tooth flanks of pre...

Page 360: ...etting Fig 86 93 7 Fill gearbox housing with approx 330 g of grease e g Alvania R 3 at E 8 Press the bevel gear 9 into the gearbox housing CAUTION Fill in approx 100 g of grease between the bearings e...

Page 361: ...ion by turning the augers 2 Refit the grease pipes and the cover D Fig 95 3 Slide on shims and sprocket Insert circlip Fig 96 Up to serial no 4 Align the grain tank cross augers The start A of the unl...

Page 362: ...e grain tank unloading tube out then remove the bolts at the back of the tube Swing the grain tank unloading tube back in and using a suitable lifting device support the tube Fig 99 Unscrew the bolts...

Page 363: ...102 Using the special tool pull the complete bevel gear out of the housing Fig 103 Special tool 1 Adapter section M 10 part no 181 609 0 2 Tube 115 x 105 x 200 long self sourced 3 Puller bridge part...

Page 364: ...l gear 3 Deep groove ball bearing 6210 DIN 625 4 Circlip 50 x 2 DIN 471 5 Deep groove ball bearing 6210 RS C3 6 Bearing ring seal 6210 ZJV 7 Shim 1 mm 0 5 mm 0 15 mm 0 1 mm 8 Circlip 90 x 3 DIN 472 9...

Page 365: ...5 and the circlips 4 Install the bearings with the special tool Fig 106 107 108 Special tool 1 Tube 60 x 50 x 180 long self sourced 2 Washer part no 688 484 0 3 Axial grooved ball bearing part no 177...

Page 366: ...number of shims 7 found when disassembling Insert circlip 8 and pull the bevel gear back up against it Fig 106 110 4 When determining the torsional backlash the measuring point must be located inside...

Page 367: ...prox 70 g of grease between the deep groove ball bearings at F e g Alvania R 3 ATTENTION Observe correct installation position of bevel gears 2 The drive pins 9 must have an angle X of 108 between eac...

Page 368: ...serial no Up to serial no 3 Slide the grain tank unloading tube including the auger on the angle drive ATTENTION The vertical auger must be offset by 180 relating to the horizontal auger in the grain...

Page 369: ...S Fig 118 Removing the grain tank unloading tube Remove the work light S Fig 118 Swing the grain tank unloading tube out then remove the bolts at the back of the tube Swing the unloading auger tube b...

Page 370: ...efit the work light S Fig 118 3 Installing the horizontal grain tank unloading auger see page 5 3 13 Removing the grain tank unloading tube elbow Removing the upper grain tank unloading angle drive se...

Page 371: ...lic cylinder Fig 121 4 Installing the upper grain tank unloading angle drive see page 5 3 38 Removing the vertical unloading auger tube Removing the vertical grain tank unloading auger see page 5 3 7...

Page 372: ...1 Slide the vertical unloading auger tube under the swivel support plate from the side Fig 126 2 Bolt down the second swivel support plate Fig 125 3 Refit the grease pipes and the cable clamps Fig 124...

Page 373: ...6 Straw discharge...

Page 374: ......

Page 375: ...he straw chopper is securely supported Remove the cover over the bearing housing on the right hand side of the machine Fig 1 Remove the hex bolt from the face end of the shaft Fig 2 Using a suitable p...

Page 376: ...he special tool Fig 5 Special tool 1 Puller bridge part no 181 621 0 2 Hex bolt M 16 x 30 with centralising head 3 Hex bolt M 12 x 140 DIN 933 8 8 part no 233 011 0 4 Washer 13 Fig 6 Drive the self al...

Page 377: ...x 16 DIN 912 Detent edged ring VSKZ 8 10 Hex bolt M 12 x 75 DIN 931 8 8 Contact washer A 12 Fig 8 Installing the right hand straw chopper bearing 1 Slide the felt ring 1 with bearing housing 2 on the...

Page 378: ...5 Hex bolt M 16 x 300 DIN 933 part no 237 375 1 Fig 11 5 Install the bearing cover 4 Insert hex bolts 10 with liquid locking compound e g DELO ML 5349 Tightening torque 78 Nm Fig 8 12 6 Slide the cam...

Page 379: ...ine side wall Fig 15 Remove the bearing cover Remove the bearing housing using the special tool Fig 16 Special tool 1 Puller bridge part no 181 621 0 2 Hex bolt M 16 x 30 with centralising head 3 Hex...

Page 380: ...sing 2 on the chopper shaft ensuring that the grease nipple S is facing down Raise the chopper shaft until the bearing housing can be fixed with three hex bolts M 12 x 180 part no 236 302 0 Fig 20 2 P...

Page 381: ...nd installing the stage 3 chopper drive V belt pulley 5 Grease the bearing Removing the cutting cylinder Make sure the straw chopper is securely supported Removing the stage 3 chopper drive V belt pul...

Page 382: ...ons tightly with plastic caps Fig 25 Remove the hose clamps Fig 26 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...

Page 383: ...curely supported Remove the left and right side panels Remove the jockey pulley arm completely with the jockey pulley Fig 30 Lower the uni spreader remove it to the rear Fig 31 Remove the hydraulic cy...

Page 384: ...XION 480 188 678 1 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 bott...

Page 385: ...r 3 Free swinging knife grain 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 8 Free swinging knife maize 9 Hex bolt M 10 x 50 DIN 931 10 9 10 Bushing...

Page 386: ...ide Fig 33 4 Installing the right hand straw chopper bearing see page 6 1 3 Installing the left hand straw chopper bearing see page 6 1 6 5 Bolt down the left and right hydraulic cylinders Fig 32 6 Bo...

Page 387: ...machine drives have been disengaged Caution Risk of injury Wear gloves during all work on the chopper knives Arrest the cutting cylinder so it will not rotate Unscrewing the free swinging knives For b...

Page 388: ...ging knives for grain 3 according to Fig 37 DANGER Use only the bolts and nuts recommended by the manufacturer Tightening torque M 12 10 9 80 Nm DANGER When using bolts and nuts with Dacromet coating...

Page 389: ...8 DANGER Use only the bolts and nuts recommended by the manufacturer Tightening torque M 10 10 9 65 Nm DANGER When using bolts and nuts with Dacromet coating silvery grey the tightening torque is redu...

Page 390: ...6 1 16 RHB LEXION 480 188 678 1 Straw chopper...

Page 391: ...er drive belt 16 see page 7 2 32 Place valve combination part no 181 619 0 on the hydraulic tank for creating a vacuum inside the tank Fig 1 Remove the hydraulic hoses and seal the connections tightly...

Page 392: ...and the potentiometer Remove the cable clamps Fig 5 Remove the safety frame Fig 6 Make sure the uni spreader is securely supported Remove the left and right side panels Remove the jockey pulley arm c...

Page 393: ...78 1 RHB LEXION 480 6 2 3 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 9 10 1...

Page 394: ...2 Hex bolt M 12 x 20 head centred 3 Hex bolt M 12 x 140 part no 233 011 0 4 Washer 13 Fig 14 Remove the hex bolt from the V belt pulley Fig 15 Using a suitable block ended tube apply a good sharp knoc...

Page 395: ...pered ring and pull off the V belt pulley Fig 17 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...

Page 396: ...lip 72 x 2 5 DIN 472 5 Bushing 6 Circlip 110 x 4 DIN 472 7 Deep groove ball bearing 61817 2RS 8 Housing 9 Circlip 85 x 3 DIN 471 10 Hex nut M 8 DIN 934 Contact washer A 8 11 Bottom plate 12 Fan blade...

Page 397: ...188 678 1 RHB LEXION 480 6 2 7 Uni spreader 23...

Page 398: ...part no 177 533 1 applied prior to installation 1 Press the deep groove ball bearing 3 into the housing 2 2 Insert the circlip 4 and the bushing 5 Press the second deep groove ball bearing 3 into the...

Page 399: ...rt no 235 983 0 4 Locating disc part no 181 879 0 5 Sleeve part no 181 881 1 6 Puller plate part no 181 617 0 Fig 26 5 Install circlip 9 6 Drive shaft 1 in with a plastic tip hammer Fig 23 24 27 7 Scr...

Page 400: ...der and tighten the socket head bolt to 48 Nm Fig 28 10 Slide the blower on the shaft and tighten to 78 Nm Bolt down the scraper Fig 11 29 11 Slide on tapered ring and V belt pulley Install the front...

Page 401: ...preader and the jockey pulley arm Fig 7 15 Bolt down the safety frame Fig 6 16 Connect all cable plugs and lay the cables Fig 4 5 17 Connect and lay the hydraulic hoses Fig 2 3 18 Installing and adjus...

Page 402: ...6 2 12 RHB LEXION 480 188 678 1 Uni spreader...

Page 403: ...7 Drives...

Page 404: ......

Page 405: ...n the groove faces and or the contact faces of the pulleys Use special tools for fitting and removing the variable speed drive belts For variable speed pulleys which move easily the pulley halves can...

Page 406: ...intermediate drive 8 Intermediate drive to grain tank unloading system 9 Intermediate drive to straw chopper 10 Straw chopper and uni spreader drive 11 Straw chopper and uni spreader drive 12 Drive of...

Page 407: ...drive 22 Threshing mechanism variable speed drive 23 Threshing drum drive 24 Accelerator drive 25 Rotary chaff screen intermediate drive 26 Rotary radiator screen drive 27 Fan drive 28 Rotary chaff sc...

Page 408: ...7 1 4 RHB LEXION 480 188 678 1 Drive diagram...

Page 409: ...cutterbar intermediate drive belt 5 see page 7 2 9 Removing the cutterbar intermediate drive belt 5 Remove guards V Fig 1 2 Relieving the tension of cutterbar drive 1 Pull type cylinder DANGER Pay pa...

Page 410: ...he nut K 4 Remove pin B Fig 3 4 Installing and adjusting the cutterbar drive belt 1 Cutterbar drive without variable speed drive W Impeller DANGER Carry out the adjustment only with the engine switche...

Page 411: ...ble speed drive Remove guards V Fig 5 6 Unscrew the hydraulic hose from the cylinder Z ensuring the connections are tightly capped Remove the cutterbar variable speed drive belt 3 at the bottom see pa...

Page 412: ...e still a little tension on the pin then a little bit of adjustment may still be required at the spring guide tube R and the nut K 4 Remove pin B Fig 8 9 Installing and adjusting the cutterbar drive b...

Page 413: ...aged Stop the engine and remove the ignition key Remove the cutterbar intermediate drive belt 5 at the bottom see page 7 2 9 Removing the cutterbar intermediate drive belt 5 Block variable speed pulle...

Page 414: ...ore at the lowest feed rake speed due to belt growth or wear this condition is compensated using washers see detail A Unscrew the three countersunk head bolts F and remove hydraulic cylinder Z Place o...

Page 415: ...page 7 2 9 Removing the cutterbar intermediate drive belt 5 Remove the cutterbar drive belt 1 at the top see page 7 2 1 Removing the cutterbar drive belt 1 Cut terbar drive without variable speed dri...

Page 416: ...eller drive belt 4 DANGER Carry out the adjustment only with the engine switched off and the ignition key removed Install belt Insert pin B and secure with a split pin Adjusting spring loaded cylinder...

Page 417: ...ve belt 5 Unscrew hoses T and S Fig 18 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...

Page 418: ...he pin then a little bit of adjustment may still be required at the spring guide tube R and the nut K 4 Remove pin B Fig 17 19 20 Installing and adjusting the cutterbar intermediate drive belt 5 DANGE...

Page 419: ...ing the cutterbar interme diate drive belt 5 Loosen hex bolts S and push the hydraulic pump upwards Remove belt 6 Fig 21 22 Installing and adjusting the uni spreader hydraulic pump drive belt 6 DANGER...

Page 420: ...nge hydraulic cylinder Z at lever E Loosen set collar and push lever E to the outside on the shaft Remove drive belt 9 at the top from the engine output assembly M Unscrew jockey pulley T Fig 23 24 Lo...

Page 421: ...Removing the cutterbar intermediate drive belt 5 Removing the uni spreader hydraulic pump drive belt 6 see page 7 2 11 Remove the sieve pan straw walker intermediate drive belt 13 at the front see pa...

Page 422: ...rough between deflection pulley and V belt pulley Install belt 7 on main intermediate drive V Fig 23 27 29 2 Bolt on hex bolt at L Hang in hydraulic cylinder H at lever K Fig 28 3 Pre tension the belt...

Page 423: ...Pre tension belt 8 by pushing jockey pulley T downwards and adjust the belt guard assembly Z 5 7 mm W 10 mm V 3 mm Fig 23 30 6 Install drive belt 9 on engine output assembly M 7 Push lever E to the i...

Page 424: ...et collar and push lever E to the outside on the shaft Remove drive belt 9 at the top from the engine output assembly M Unscrew jockey pulley T Fig 32 33 Place drive belt 8 between grain tank unloadin...

Page 425: ...key removed 1 Install belt 8 2 Mount jockey pulley T with a tightening torque of 130 Nm 3 Pre tension belt 8 by pushing jockey pulley T downwards and adjust the belt guard assembly Z 5 7 mm W 10 mm V...

Page 426: ...88 678 1 Left hand drive belts 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...

Page 427: ...justment only with the engine switched off and the ignition key removed 1 Install belt 9 on engine output assembly M 2 Push lever E to the inside on the shaft up to the set collar and arrest using the...

Page 428: ...per 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 dr...

Page 429: ...f assembly Danger of injury 1 Remove both the end stop bolts at L 2 Fully turn the lock nut K backwards 3 Screw the spring guide tube R in completely 4 Remove brace U While doing so observe cover and...

Page 430: ...htening torque of 130 Nm 3 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 138 mm 4...

Page 431: ...moving 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...

Page 432: ...only with the engine switched off and the ignition key removed Install belt 12 Insert pin B and secure with a split pin Adjusting the spring loaded cylinder Loosen lock nut K and adjust the spring gui...

Page 433: ...ove brace T as well as belt guide assembly F Remove the straw chopper intermediate drive belt 9 at the bottom see page 7 2 18 Removing the straw chopper intermediate drive belt 9 Remove the straw chop...

Page 434: ...switched off and the ignition key removed 1 Install belt 13 2 Tighten nut K until the gauge rod F makes contact with stop G without exerting any pressure The distance between stop G and gauge rod F m...

Page 435: ...w chopper intermediate drive belt 9 at the bottom see page 7 2 18 Removing the straw chopper intermediate drive belt 9 Remove the straw chopper drive belt 10 at the front see page 7 2 20 Removing the...

Page 436: ...Mount jockey pulley loosely with clamping screw B 3 Pre tension compression spring D by way of nut E to the gauge rod length Spring length D 131 mm 4 Lock nuts E and H and re tighten clamping screw B...

Page 437: ...the sieve pan intermediate drive belt 14 at the bottom see page 7 2 27 Removing the sieve pan intermediate drive belt 14 2 From serial no Fold the battery tool box open The cabinet may be folded open...

Page 438: ...he minus terminal is the first disconnected and then the plus Take out the battery Unclip the stay F and then remove the complete toolbox Fig 53 54 3 Loosen clamping screw A at the jockey pulley Loose...

Page 439: ...tion and tighten the control arm with 45 Nm 3 Bolt down the jockey pulley S loosely with the clamping bolt A 4 Pre tension compression spring D by way of nut E to the gauge rod length Spring length D...

Page 440: ...S stop A and mounting plate L 4 Position the longer stop bracket B right in the middle over the spring guide tube R 5 Screw a M 12 x 35 bolt through the bracket B into the spring guide tube R Tighten...

Page 441: ...osition the shorter stop bracket B right in the middle over the spring guide tube R 4 Adjust the spring loaded cylinder To do this slacken off lock nut K and adjust the spring guide tube R so that the...

Page 442: ...in 17 Push type cylinder DANGER Follow the correct order of assembly Danger of injury 1 Fully turn lock nut K backwards 2 Tighten spring guide tube R until pin B is slack 3 Open the chain connector an...

Page 443: ...ugers must be timed relative to each other when installing the chain The start A of the unloading auger K flight must point toward the front cross auger V The start A of the front cross auger V must b...

Page 444: ...7 2 36 RHB LEXION 480 188 678 1 Left hand drive belts...

Page 445: ...p drive 18 DANGER Carry out the adjustment only with the engine switched off and the ignition key removed Adjusting the spring loaded cylinder Loosen lock nut K and adjust the spring guide tube R so t...

Page 446: ...Determine the dimension X 2 Slacken off the lock nut K 3 Slacken off the spring guide tube R by the previously determined distance X At the same time tighten the nut K until the washer E is up agains...

Page 447: ...elt 20 Removing the threshing mechanism variable speed drive belt 22 see page 7 3 6 Removing the fan drive belt 21 see page 7 3 5 Relieving the tension of fan intermediate drive belt 20 Push type cyli...

Page 448: ...ed off and the ignition key removed Install belt Insert pin B and secure with a split pin Fig 4 6 Adjusting the spring loaded cylinder Loosen lock nut K and adjust the spring guide tube R so that the...

Page 449: ...remove the ignition key Tension the belt 21 manually until the spring loaded variable speed pulley is fully spread Remove belt 21 Fig 7 Installing and adjusting the fan drive belt 21 First put the bel...

Page 450: ...ngaged set the variable speed drive to maximum speed Disengage the threshing mechanism Stop the engine and remove the ignition key Block variable speed pulleys with special tools please refer to the t...

Page 451: ...any more at the lowest threshing drum speed due to belt growth or wear this condition is compensated using washers see detail A Unscrew the three countersunk head bolts F and remove hydraulic cylinde...

Page 452: ...rive belt 22 at the front see page 7 3 6 Removing the threshing mechanism variable speed drive belt 22 Relieving the tension of threshing drum drive belt 23 Pull type cylinder DANGER Pay particular at...

Page 453: ...may still be required at the spring guide tube R and the nut K 4 Remove pin B 5 Remove belt 23 Fig 12 13 14 Installing and adjusting the threshing drum drive belt 23 DANGER Carry out the adjustment o...

Page 454: ...ive belt 23 at the front see page 7 3 8 Removing the threshing drum drive belt 23 Relieve the tension of accelerator drive belt 24 Pull type cylinder DANGER Pay particular attention while unscrewing t...

Page 455: ...of adjustment may still be required at the spring guide tube R and the nut K 4 Remove pin B 5 Remove belt 24 Fig 15 16 17 Installing and adjusting the accelerator drive belt 24 DANGER Carry out the a...

Page 456: ...drive belt 25 Removing the fan drive belt 27 see page 7 3 15 Slacken off the clamping bolt M Slacken off the lock nut B Turn the nut A backwards until the belt tension is relieved Unscrew clamping pie...

Page 457: ...engine switched off and the ignition key removed 1 Install belt 25 2 Slacken off the lock nut B 3 Tighten the nut A until the spacer H makes contact with the tensioner N without exerting any pressure...

Page 458: ...and adjusting the rotary chaff screen drive belt 26 DANGER Carry out the adjustment only with the engine switched off and the ignition key removed 1 Install belt 26 2 Slacken off the clamping bolt K...

Page 459: ...easing the tension of fan drive belt 27 Push type cylinder DANGER Follow the correct order of assembly Danger of injury 1 Insert U piece self sourced at position T and secure with spring clip Fig 21 2...

Page 460: ...ing the fan drive belt 27 DANGER Carry out the adjustment only with the engine switched off and the ignition key removed Install belt 27 Insert pin B and secure with a split pin Remove U piece Adjusti...

Page 461: ...belts 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 re...

Page 462: ...ds 3 Tighten nut A until the gauge rod F makes contact with stop G without exerting any pressure The distance between stop G and gauge rod F may be up to 1 mm 4 Retighten the lock nut A 5 Length of ga...

Page 463: ...he fan drive belt 27 see page 7 3 15 Removing the radiator chaff screen intermediate drive belt 25 see page 7 3 12 Removing the compressed air compressor drive belt 30 see page 7 3 21 Slacken off the...

Page 464: ...without exerting any pressure A distance between the spacer H and the tensioner N of approx 1 mm is allowed 3 Tighten the lock nut B 4 Tighten bolt T of the tensioner Tighten bolts S at the support F...

Page 465: ...moving 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...

Page 466: ...belts 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...

Page 467: ...age 7 3 15 Removing the radiator chaff screen intermediate drive belt 25 see page 7 3 12 Removing the compressed air compressor drive belt 30 see page 7 3 21 Removing the air conditioner compressor dr...

Page 468: ...ghten hex nut D until the spacer tube S makes level contact with the ball washer E 3 Tighten the lock nut K 4 Tighten hex bolt B of eyebolt and hex bolt A of alternator holder Fig 33 34 36 5 Installin...

Page 469: ...tes and repeat adjusting procedure To do this unscrew the hex bolts A and B Slacken off the lock nut K Tighten hex nut D until the spacer tube S makes level contact with the ball washer E Tighten the...

Page 470: ...blower drive belt 34 Remove cutterbar drive belt 1 or 2 at the front Slightly loosen the hex bolt A Loosen the two hex bolts S and pull the blower to the front V until the tension of belt 34 is releas...

Page 471: ...Push the suction blower to the rear H by hand until belt 34 is sufficiently tensioned Tighten the two hex bolts S Tighten the hex bolt A Fig 39 40 Install and adjust the cutterbar drive belt 1 and or...

Page 472: ...drive belt 36 Unscrew plate P and pull it out to the rear Fig 43 Loosen the hex bolts 11 of the bearing housing 10 Move the bearing housing 10 and first remove belt 36 from the toothed belt pulley E T...

Page 473: ...justing the straw spreader drive belt 36 1 Install belt 36 on the toothed belt pulleys F G and H Now install belt 36 on toothed belt pulley E CAUTION Install the toothed belt 36 so that the spreader b...

Page 474: ...tion to the left must be aligned N with the pivot point of the bearing housing 10 3 Tighten the hex bolts 11 of the bearing housing 10 Fig 44 46 47 4 Check belt tension A force of 75 3 N must be appli...

Page 475: ...the hydraulic motor 16 Adjust using the short support 47 the long support 49 or the mounting bracket 46 6 Check and if necessary adapt the flatness deviations of toothed belt pulleys F and E using a r...

Page 476: ...n one more time and adapt if required Fig 47 8 Set the clearance M between roller bearing 61 and belt 36 M 1 2 mm To do this slacken off the hex bolt 56 and turn the eccentric 62 correspondingly Now t...

Page 477: ...ar drive belt 1 or 2 at the front Remove the feed rake conveyor suction blower drive belt 34 if necessary see page 7 3 26 Removing the feed rake conveyor suction blower drive belt 34 Remove the clampi...

Page 478: ...by hand ATTENTION The belts 1 or 2 must not touch the belt 34 or the pulley of the suction blower The belts 1 or 2 must not touch the cutterbar drive deflection pulley 1 either Firmly tighten the clam...

Page 479: ...Install deflection pulley according to Fig 6 Using hex bolt 5 bolt the deflection pulley to the bracket Tightening torque 130 Nm Fig 5 6 Removing the slip clutch of cutterbar drive 1 Remove the left...

Page 480: ...x 17 x 12 part no 575 774 0 2 Axial grooved ball bearing part no 235 983 0 3 Washer 17 part no 235 127 2 4 Hex nut M 16 DIN 934 part no 236 173 0 5 Hex bolt M 16 SP DIN 933 8 8 part no 237 375 1 Fig...

Page 481: ...ng the cutterbar drive belt 1 Cutterbar drive without variable speed drive see page 7 2 1 Remove the V belt pulley from the slip clutch Remove the locking wire and disassemble the clutch Fig 11 Slip c...

Page 482: ...5 Bolt the test bridge part no 181 623 0 into place 6 Allow the slip clutch to slip twice first 7 Now check the slip torque and adjust it if necessary Slip torque 840 Nm 40 Nm 8 Seal the clutch linin...

Page 483: ...r 8 Contact washer A 16 9 Hex nut M 16 Fig 16 Assemble the jockey pulley according to Fig 16 Bolt the jockey pulley to the bracket with hex bolt 6 Tightening torque 130 Nm Fig 17 Removing the rear pul...

Page 484: ...bolts and remove the cover Fig 18 Unscrew the hex bolt from the face end of impeller shaft Fig 19 Remove the front V belt pulley Fig 20 Screw the head centred hex bolt M 12 x 30 into the shaft Using...

Page 485: ...1 Puller bridge part no 181 800 0 2 Threaded spindle part no 181 801 1 3 Centraliser with ball part no 181 849 0 4 Hex bolt M 16 x 260 part no 235 816 0 2 pieces 5 Washer 17 part no 235 127 2 2 pieces...

Page 486: ...o 181 801 1 4 Centraliser with ball part no 181 849 0 5 Hex bolt M 12 x 30 with centralising head 6 Hex bolt M 16 x 140 part no 242 795 0 7 Washer 17 part no 235 127 2 8 Hex nut M 12 part no 236 172 0...

Page 487: ...nd spacer ring using the special tool Fig 29 Special tool 1 Lever nut part no 181 880 0 2 Spindle part no 181 877 0 3 Axial grooved ball bearing part no 235 983 0 4 Locating disc part no 181 879 0 5 S...

Page 488: ...Intermediate ring 8 V belt pulley 9 Shaft seal A 58 x 72 x 8 DIN 3760 10 Snap ring 11 Needle bearing RNA 4910 12 Spacer bushing up to serial no 13 Angular contact ball bearing 3306 RS C3 DIN 628 14 Ci...

Page 489: ...rial 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 51...

Page 490: ...pose grease DIN 51825 part no 147 451 0 Fig 31 32 34 Special tool 1 Lever nut part no 181 880 0 2 Spindle part no 181 877 0 3 Axial grooved ball bearing part no 235 983 0 4 Locating disc part no 181 8...

Page 491: ...red ring 1 the parallel key 2 and the 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 M 12 10...

Page 492: ...r 15 and bolt it down Up to serial no Screw in the hex bolt 16 with washer 15 and tighten Tightening torques M 16 10 9 180 Nm M 12 10 9 125 Nm Fig 41 5 Place the V belt pulley into position and tighte...

Page 493: ...out variable speed drive 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 Remove th...

Page 494: ...t no 236 173 0 3 pieces 7 Washer 7 part no 235 127 2 5 pieces 8 Head centred hex bolt M 16 x 30 self sourced 1 piece Fig 47 Remove the inner race ring of the bearing and the spacer ring from the shaft...

Page 495: ...e block ended tube must fit over the tapered ring Remove tapered ring Fig 50 Using the special tool remove the V belt pulley from the shaft Fig 51 52 Special tool 1 Puller bridge part no 181 622 0 1 p...

Page 496: ...d spacer bushing 9 using the special tool Fig 53 54 55 58 Special tool 1 Lever nut part no 181 880 0 1 piece 2 Spindle part no 181 877 0 1 piece 3 Axial grooved ball bearing part no 235 983 0 1 piece...

Page 497: ...pecial tool Fig 56 57 58 Special tool 1 Lever nut part no 181 880 0 1 piece 2 Spindle part no 181 877 0 1 piece 3 Axial grooved ball bearing part no 235 983 0 1 piece 4 Locating disc part no 181 879 0...

Page 498: ...t seal A 58 x 72 x 8 6 Snap ring 7 Needle bearing RNA 4910 8 Inner ring Ir 50 x 58 x 40 9 Inner spacer bushing 10 Intermediate ring 11 Grease nipple AM 8 x 1 12 V belt pulley 13 Angular contact ball b...

Page 499: ...l no Insert the angular contact ball bearing 13 and the circlip 14 into the V belt pulley 12 Install angular contact ball bearing 13 using adhesive e g DELO ML 5328 Observe installation position NOTE...

Page 500: ...al 5 and the inner ring 8 into the V belt pulley 12 Observe correct installation position of shaft seal 5 Fig 58 59 62 Installing the rear pulley of cutterbar drive 1 from serial no CAUTION Ensure tha...

Page 501: ...933 part no 237 375 1 1 piece 2 Hex nut M 16 DIN 934 part no 236 170 0 1 piece 3 Axial grooved ball bearing part no 235 983 0 1 piece 4 Thrust washer 65 mm x 16 5 mm x 15 mm part no 667 414 0 1 piece...

Page 502: ...the face end of the shaft and remove along with washer Fig 68 Screw a head centred M 16 x 30 hex bolt into the shaft Using a special tool and a suitable lifting device such as Hydrobull pull the varia...

Page 503: ...the countersunk head bolts from the mounting flange until the compression spring has been blocked with the special tool extremely hazardous Using the special tool block the compression spring and rem...

Page 504: ...nut release all the pressure from the compression spring Fig 74 Remove the compression spring and the mounting flange Fig 75 Remove the variable speed pulley half Drive out the roll pin Fig 76 Remove...

Page 505: ...ed dowel using a screwdriver Fig 78 Remove the bearing bushings Fig 79 Remove the sliding bushing Remove the support runners using a screwdriver Ensure that you note the installation position and mark...

Page 506: ...IN 7346 9 Expansion pin 10 x 14 A DIN 8752 10 Cover 11 Snap ring 12 Bearing sleeve 13 Compression spring 14 Mounting flange 15 Countersunk head bolt M 10 x 30 DIN 7991 16 Thrust washer 17 Shim 56 x 72...

Page 507: ...31 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...

Page 508: ...cheese head screws 5 Tightening torque 10 Nm Fig 82 83 86 4 Clean both variable speed pulleys thoroughly 5 Apply oil to the sliding bushing 6 and support runner 7 all around insert and then join the v...

Page 509: ...g faces Fig 82 83 88 8 Insert the expansion pin 9 to fix the mounting flange 14 and the cover 10 9 Thoroughly grease the sliding bushing 6 and the sliding faces with good quality grease 10 Join the tw...

Page 510: ...rt no 235 983 0 4 Centraliser part no 181 437 0 5 Locating disc part no 181 879 0 6 Hex bolt M 10 x 200 DIN 931 8 8 part no 211 739 0 Fig 90 13 Screw in the countersunk head bolts 15 but do not tighte...

Page 511: ...ing shims 17 and a thrust washer 16 Fig 93 Determine the distance X between the thrust piece 18 and the top edge of the pulley Fig 94 95 Slide a thrust washer 16 on the shaft shoulder and determine di...

Page 512: ...ley so it will not slip off the thrust piece 18 Fig 97 Bolt down the M 16 x 50 DIN 933 8 8 hex bolts with lock washers Tightening torque 180 Nm Fig 98 Using suitable feel gauges check the axial play b...

Page 513: ...d drive see page 7 2 3 Removing the cutterbar variable speed pulley assembly spring loaded see page 7 4 26 Remove the grease pipes Fig 100 Remove the V belt pulley complete with the flange plate Fig 1...

Page 514: ...g with the taper roller bearing Fig 104 Unscrew the V belt pulley Fig 105 Using two tyre mounting levers raise the outside taper roller bearing just enough to place a puller underneath CAUTION When as...

Page 515: ...ng inner race 4 Bearing outer race 5 Inner spacer 6 Snap ring 7 Outer spacer 8 Housing 9 Washer 10 Hex bolt M 16 x 50 DIN 933 8 8 Contact washer A 16 11 Cover 12 Countersunk head bolt M 6 x 12 DIN 963...

Page 516: ...earing inner race 3 onto the flanged shaft using the special tool Fig 108 109 110 Special tool 1 Hex bolt M 16 x 300 SP DIN 933 8 8 part no 237 375 1 2 Hex nut M 16 DIN 934 part no 236 173 0 3 Axial g...

Page 517: ...t using the special tool Fig 108 109 112 Special tool 1 Hex bolt M 16 x 300 SP DIN 933 8 8 part no 237 375 1 2 Hex nut M 16 DIN 934 part no 236 173 0 3 Axial grooved ball bearing part no 177 899 0 4 W...

Page 518: ...embly spring loaded see page 7 4 35 Installing and adjusting the cutterbar drive belt 2 Cutterbar drive with variable speed drive see page 7 2 4 Removing and disassembling the cutterbar drive deflecti...

Page 519: ...he spacer bushing 2 Insert the circlips then drive in the centering pin using a plastic tip hammer 3 Place the pre assembled deflection pulley into position and bolt it down using the M 16 x 100 hex b...

Page 520: ...mediate drive belt 5 at the front see page 7 2 9 Removing the cutterbar intermediate drive belt 5 Remove the cutterbar drive belt 2 at the rear see page 7 2 3 Removing the cutterbar drive belt 2 Cut t...

Page 521: ...speed pulley assembly off of the shaft Fig 126 Special tool 1 Hex bolt M 16 x 30 DIN 933 8 8 head centred 2 Puller plate part no 181 617 0 3 Hex bolt M 16 x 40 DIN 933 8 8 part no 235 821 0 4 Contact...

Page 522: ...no 235 816 0 2 pieces 5 Washer 17 part no 235 127 2 2 pieces 6 Complete puller assembly part no 181 857 0 Fig 129 Disassembling the cutterbar variable speed pulley assembly hydraulic Unscrew the space...

Page 523: ...ating ring and the angular contact ball bearing with the special tool Fig 134 Special tool 1 Lever nut part no 181 880 0 2 Axial grooved ball bearing part no 235 983 0 3 Locating disc part no 181 879...

Page 524: ...Snap ring 7 Shaft seal A 58 x 72 x 8 DIN 3760 8 Inner ring Ir 50 x 58 x 40 9 Sliding bushing 10 Cover 11 Hex bolt M 6 x 12 DIN 933 8 8 Lock washer 6 12 Spacer ring 13 Felt seal 14 Bushing 15 Spacer p...

Page 525: ...188 678 1 RHB LEXION 480 7 4 49 Cutterbar drive 33465 18 13 16 1 2 3 4 8 9 10 10 15 5 6 7 11 12 17 19 20 F 137 Cutterbar drive...

Page 526: ...CAUTION Insert the outer race of the angular contact ball bearing with liquid locking compound e g DELO ML 5349 Fig 136 137 138 Special tool 1 Lever nut part no 181 880 0 2 Axial grooved ball bearing...

Page 527: ...ble both variable speed pulley halves together 6 Bolt down the cover 10 and the spacer plate 15 Fig 136 137 Installing the cutterbar variable speed pulley assembly hydraulic Using the special tool par...

Page 528: ...the cutterbar variable speed drive belt 3 Tightening torque 86 Nm Fig 144 Screw in the grease nipple and the grease pipe Place the V belt pulley into position and tighten Tightening torque 78 Nm Insta...

Page 529: ...that is harmless to the environment and in accordance with existing environmental regulations Fig 145 Remove the two slotted nuts with the socket wrench part no 181 809 0 Remove the back up ring Fig 1...

Page 530: ...t of the clutch housing only half of their size Using suitable insulation tape bind the rings together and remove completely The wedges of the friction ring must not be confused therefore mark the ind...

Page 531: ...th a hammer to slacken off the tapered ring Fig 152 Remove the tapered ring and pull off the clutch hub using the special tool Remove the parallel key and the tapered ring Fig 153 Special tool 1 Small...

Page 532: ...m serial no Remove the tapered ring and pull off the V belt pulley using the special tool Fig 157 Special tool 1 Universal puller bridge part no 181 622 0 2 Hex bolt M 10 x 180 DIN 931 8 8 part no 237...

Page 533: ...an inner diameter greater than the tapered ring give the pulley a good sharp blow to loosen the tapered ring Fig 160 Remove the belt guide from the main drive pulley Fig 161 Remove the V belt pulley u...

Page 534: ...e part no 181 801 1 4 Centraliser with ball part no 181 849 0 5 Hex bolt M 16 x 140 part no 242 795 0 2 pieces 6 Hex bolt M 16 x 260 part no 235 816 0 3 pieces 7 Washer 17 part no 235 127 2 5 pieces 8...

Page 535: ...x 50 11 Circlip 80 x 2 5 12 Clutch hub 13 Tapered ring 14 Parallel key 15 Hex bolt M 16 x 40 DIN 933 8 8 16 Circlip 16 17 Washer 18 Friction ring 19 Inner spring 20 Compression spring 21 Pressure plat...

Page 536: ...prior to installation 1 Slide the rear tapered ring 3 the parallel key 4 and the V belt pulley 2 onto the shaft 2 Insert the front tapered ring 3 and press into position using the special tool For th...

Page 537: ...to 7 mm and dimension W is 10 mm Fig 168 4 Slide the rear tapered ring 6 and the V belt pulley 5 onto the shaft 5 Insert the front tapered ring 6 and press into position using the special tool For th...

Page 538: ...11 into the V belt pulley 8 CAUTION Fill the space between the two deep groove ball bearings with multi purpose grease Fig 164 165 173 8 Slide the pre assembled spacer ring 7 and V belt pulley 8 on t...

Page 539: ...mm Fig 175 176 12 Refit hex bolt 15 and tighten to 210 Nm Fig 174 13 When fitting new friction rings 18 lay them around the inner spring 19 in the numbered order Tape the outer edge of the friction ri...

Page 540: ...aulic ram 34 Up to serial no Refit the hydraulic ram 22 with mounting ring 23 Fig 164 165 179 17 Place the O rings 24 and 28 the back up ring 25 and the scraper ring 29 into the cylinder 26 and piston...

Page 541: ...support ring 32 individually Tightening torque 150 Nm Fig 164 165 181 20 Installing and adjusting the sieve pan intermediate drive belt 13 see page 7 2 26 Installing and adjusting the uni spreader hy...

Page 542: ...7 4 66 RHB LEXION 480 188 678 1 Cutterbar drive...

Page 543: ...diate drive belt 13 see page 7 2 25 Remove the rotary coupling from the cutterbar drive clutch Collect any leaking oil and seal the hydraulic connections with suitable plastic caps ENVIRONMENT Dispose...

Page 544: ...he pressure plate with compression springs Fig 5 Number the individual friction rings R CAUTION Pull the friction rings out of the clutch housing only half of their size Using suitable insulation tape...

Page 545: ...diameter greater than the centralising ring on the clutch hub give the hub a good sharp blow with a hammer to slacken off the tapered ring Fig 8 Remove the tapered ring and pull off the clutch hub usi...

Page 546: ...greater than the tapered ring give the pulley a good sharp blow to loosen the tapered ring Fig 12 From serial no Remove the tapered ring and pull off the V belt pulley using the special tool Fig 13 S...

Page 547: ...V belt pulley Fig 15 Using a suitable block ended tube with an inner diameter greater than the tapered ring give the pulley a good sharp blow to loosen the tapered ring Fig 16 Remove the belt guide f...

Page 548: ...0 3 Spindle part no 181 801 1 4 Centraliser with ball part no 181 849 0 5 Hex bolt M 16 x 140 part no 242 795 0 2 pieces 6 Hex bolt M 16 x 260 part no 235 816 0 3 pieces 7 Washer 17 part no 235 127 2...

Page 549: ...ng ring S 40 x 50 11 Circlip 80 x 2 5 12 Clutch hub 13 Tapered ring 14 Parallel key 15 Hex bolt M 16 x 40 DIN 933 8 8 16 Circlip 16 17 Washer 18 Friction ring 19 Inner spring 20 Compression spring 21...

Page 550: ...7 553 1 applied prior to installation 1 Slide the rear tapered ring 3 the parallel key 4 and the V belt pulley 2 onto the shaft 2 Insert the front tapered ring 3 and press into position using the spec...

Page 551: ...istance Y is 5 to 7 mm and dimension W is 10 mm Fig 24 4 Slide the rear tapered ring 6 and the V belt pulley 5 onto the shaft 5 Insert the front tapered ring 6 and press into position using the specia...

Page 552: ...10 and circlip 11 into the V belt pulley 8 CAUTION Fill the space between the two deep groove ball bearings with multi purpose grease Fig 20 21 29 8 Slide the pre assembled spacer ring 7 and V belt pu...

Page 553: ...e at least 0 8 mm Fig 31 32 12 Refit hex bolt 15 and tighten to 210 Nm Fig 30 13 When fitting new friction rings 18 lay them around the inner spring 19 in the numbered order Tape the outer edge of the...

Page 554: ...olt down hydraulic ram 34 Up to serial no Refit the hydraulic ram 22 with mounting ring 23 Fig 20 21 35 17 Place the O rings 24 and 28 the back up ring 25 and the scraper ring 29 into the cylinder 26...

Page 555: ...nuts 31 with support ring 32 individually Tightening torque 150 Nm Fig 20 21 37 20 Installing and adjusting the sieve pan intermediate drive belt 13 see page 7 2 26 Installing and adjusting the uni sp...

Page 556: ...7 5 14 RHB LEXION 480 188 678 1 Left hand threshing mechanism drive...

Page 557: ...ydraulic Removing the threshing mechanism variable speed drive belt 22 see page 7 3 6 Remove the tube R Fig 1 Remove the grease nipple and the grease pipe Remove the hydraulic cylinder CAUTION Observe...

Page 558: ...ifting device such as Hydrobull pull the variable speed pulley assembly off of the shaft Fig 5 Special tool 1 Hex bolt M 16 x 30 DIN 933 8 8 head centred 2 Puller plate part no 181 617 0 3 Hex bolt M...

Page 559: ...variable speed pulley half Remove the cover from the front section of the pulley Fig 8 Drive the flanged bushings out of the front section of the pulley Fig 9 Pull out the sliding bushing from the rea...

Page 560: ...iding bushing 4 Felt seal 5 Bushing 6 Cover 7 Hex bolt M 8 x 20 DIN 933 8 8 Contact washer A 8 8 Cover 9 Hex bolt M 6 x 12 DIN 933 8 8 Lock washer 6 10 Thrust washer 11 Tapered ring 12 Parallel key A...

Page 561: ...188 678 1 RHB LEXION 480 7 6 5 Right hand threshing mechanism drive 33573 3 4 8 9 10 10 6 7 11 12 14 12 Right hand threshing mechanism drive...

Page 562: ...N Ensure that all taper ring fasteners and hub bores have gearbox grease type G 00 DIN 51502 part no 177 553 1 applied prior to installation 1 Insert the thrust washer 10 the tapered ring 11 and the p...

Page 563: ...Remove bar S Fig 15 Unscrew the hex bolt from the shaft face end and remove along with the washer Screw a head centred M 16 x 30 hex bolt into the shaft Using a special tool and a suitable lifting dev...

Page 564: ...ompression spring has been blocked with the special tool Danger of accident Using the special tool block the compression spring and remove all countersunk head bolts from the mounting flange Fig 18 Sp...

Page 565: ...ression spring and the mounting flange Fig 21 Remove the variable speed pulley half Drive out the roll pin Fig 22 Remove the M 12 x 1 5 screw plug and both M 6 x 13 cheese head screws Fig 23 Remove th...

Page 566: ...anism drive Remove the bearing bushings Fig 25 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 ex...

Page 567: ...346 9 Expansion pin 10 x 14 A DIN 8752 10 Cover 11 Snap ring 12 Bearing sleeve 13 Compression spring 14 Mounting flange 15 Countersunk head bolt M 10 x 30 DIN 7991 16 Thrust washer 17 Shim 56 x 72 x 0...

Page 568: ...g 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...

Page 569: ...hten the cheese head screws 5 Tightening torque 10 Nm Fig 28 29 32 4 Clean both variable speed pulleys thoroughly 5 Apply oil to the sliding bushing 6 and support runner 7 all around insert and then j...

Page 570: ...nner sliding faces Fig 28 29 34 8 Insert the expansion pin 9 to fix the mounting flange 14 and the cover 10 9 Thoroughly grease the sliding bushing 6 and the sliding faces with good quality grease 10...

Page 571: ...DIN 711 part no 235 983 0 4 Centraliser part no 181 437 0 5 Locating disc part no 181 879 0 6 Hex bolt M 10 x 200 DIN 931 8 8 part no 211 739 0 Fig 36 13 Screw in the countersunk head bolts 15 but do...

Page 572: ...18 with existing shims 17 and a thrust washer 16 Fig 39 Determine the distance X between the thrust piece 18 and the top edge of the pulley Fig 40 41 Slide a thrust washer 16 on the shaft shoulder and...

Page 573: ...d pulley so it will not slip off the thrust piece 18 Fig 43 Bolt down the M 16 x 85 DIN 933 8 8 hex bolts with lock washers Tightening torque 195 Nm Fig 44 Using suitable feel gauges check the axial p...

Page 574: ...e page 7 6 7 Removing the threshing drum drive belt 23 see page 7 3 8 Remove the grease pipe from the bearing assembly Fig 46 Remove the complete flanged shaft including the V belt pulley from the sid...

Page 575: ...off using two M 10 x 140 hex bolts Fig 50 Unscrew the V belt pulley Fig 51 Using two tyre mounting levers raise the outside taper roller bearing just enough to place a puller underneath CAUTION When...

Page 576: ...e 4 Bearing outer race 5 Inner spacer 6 Snap ring 7 Outer spacer 8 Housing 9 Washer 10 Hex bolt M 16 x 50 DIN 933 8 8 Contact washer A 16 11 Cover 12 Countersunk head bolt M 6 x 12 DIN 963 5 8 13 V be...

Page 577: ...4 onto the flanged shaft using the special tool Fig 54 55 56 Special tool 1 Hex bolt M 16 x 300 SP DIN 933 8 8 part no 237 375 1 2 Hex nut M 16 DIN 934 part no 236 173 0 3 Axial grooved ball bearing p...

Page 578: ...LO ML 5349 Tightening torque 45 Nm 5 Place the pre assembled housing into position Press the second bearing inner race on the flanged shaft using the special tool Fig 54 55 58 Special tool 1 Hex bolt...

Page 579: ...le sealing compound such as Epple type 33 Bolt on the cover 11 Fig 54 55 Installing the threshing mechanism drive pulley 1 Bolt the complete flanged shaft to the side wall of the machine using hex bol...

Page 580: ...7 6 24 RHB LEXION 480 188 678 1 Right hand threshing mechanism drive...

Page 581: ...ive belt 24 see page 7 3 10 Remove the V belt pulley from the threshing drum reduction gearbox Fig 1 Drain the gearbox oil into a sufficiently large container approx 1 8 litres ENVIRONMENT Dispose of...

Page 582: ...nd then remove Fig 4 Special tool 1 Puller bridge part no 181 621 0 2 Hex bolt M 16 x 30 head centred 3 Hex bolt M 12 x 70 DIN 931 8 8 part no 235 558 0 4 Washer 13 Fig 5 Disassembling the threshing d...

Page 583: ...r and planetary carrier P Fig 8 Unscrew the set screws and drive out the planetary axles Remove the planetary gears Fig 9 10 Remove the deep groove ball bearing using a three legged puller For this us...

Page 584: ...that a two legged puller may be attached Pull off the inner bearing ring Fig 12 Remove the circlip from the sun gear carrier Remove the sun gear Fig 13 Remove the circlip then remove the cylinder rol...

Page 585: ...Threshing drum reduction gearbox Remove the deep groove ball bearing using a three legged puller 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 wash...

Page 586: ...016 C3 DIN 5412 11 Snap ring 12 Deep groove ball bearing 16022 C3 DIN 625 13 Planetary gear 14 Needle ring K 18 x 25 x 22 15 Planetary gear axle 16 Set screw M 8 x 16 DIN 915 17 Gearbox housing 18 Sea...

Page 587: ...188 678 1 RHB LEXION 480 7 7 7 Threshing drum reduction gearbox 18 Threshing drum reduction gearbox...

Page 588: ...ylinder roller bearing 10 into the sun gear carrier 1 Fig 17 18 20 3 Insert the snap ring 9 and the circlip 4 into the sun gear carrier 1 4 Using a puller shell part no 181 848 0 and a special tool pr...

Page 589: ...ial tool press the deep groove ball bearing 12 onto the planetary carrier Fig 17 18 23 Special tool 1 Lever nut part no 181 880 0 2 Spindle part no 181 877 0 3 Axial grooved ball bearing part no 235 9...

Page 590: ...mbly with thrust washer 31 X 44 4 0 2 mm installation without thrust washer 31 Fig 18 25 9 Fit the planetary gear 13 the needle ring 14 the thrust washer 31 if required and the planet axle 15 into the...

Page 591: ...ck the residual play between the gearbox housing and the planetary carrier and or sun gear carrier to be 0 3 to 0 8 mm and correct play with shims 21 if required Fig 17 18 29 14 Insert the shaft seals...

Page 592: ...with liquid locking compound e g DELO ML 5349 Tightening torque 120 Nm Fig 32 3 Bolt down V belt pulley using the hex bolt M 12 x 35 DIN 933 10 9 Insert hex bolts with liquid locking compound e g DEL...

Page 593: ...ll the gearbox with oil For this first bolt in the two conical seat bolts K in the Reduction ON position Unscrew both caps S Insert an elbow union T part no 669 885 0 into the top hole Fill in gearbox...

Page 594: ...7 7 14 RHB LEXION 480 188 678 1 Threshing drum reduction gearbox...

Page 595: ...ive V belt pulley see page 7 14 1 Remove the grease pipe from the bearing assembly Fig 1 Unbolt the bearing assembly from the side wall and remove it using the special tool Fig 2 Special tool 1 Puller...

Page 596: ...rust washer part no 667 414 0 5 Tube inside 60 x 200 long self sourced 6 Hex bolt M 12 x 180 DIN 931 8 8 part no 235 565 0 Fig 5 2 Bolt down the bearing assembly and the grease pipe Fig 1 3 Installing...

Page 597: ...r 17 part no 235 127 2 6 Threaded bolt part no 181 889 0 Fig 8 Installing the left hand intermediate drive shaft bearing 1 Press the bearing assembly onto the shaft using a special tool Fig 9 Special...

Page 598: ...ft bearing see page 7 8 1 Removing the left hand intermediate drive shaft bearing see page 7 8 2 The intermediate drive shaft may be removed from the side of the machine Fig 11 Installing the intermed...

Page 599: ...ave been suitably marked Removing the grain tank unloading drive chain 17 see page 7 2 34 Remove the belt guard R the belt guide bracket B and the lock collar bearing S Fig 1 Unscrew the lock collar b...

Page 600: ...ial no Mark the position of the V belt pulley on the shaft 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 of...

Page 601: ...bearings The lock collars must face each other 4 From serial no Place the V belt pulley in position and tighten clamping hub slightly Up to serial no Place the V belt pulley on the shaft and lightly...

Page 602: ...ON 480 188 678 1 Grain tank unloading drive 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 s...

Page 603: ...drive belt 10 at the front see page 7 2 20 Removing the straw chopper drive belts 10 and 11 Fig 1 From serial no Remove the V belt pulley using the special tool Fig 2 Special tool from serial no 1 Fl...

Page 604: ...r with ball part no 181 849 0 4 Hex bolt BM 12 x 60 DIN 933 8 8 part no 266 300 0 5 Washer 13 x 30 x 3 part no 236 844 0 6 Washer 8 5 x 30 x 3 part no 237 957 0 Fig 5 Removing the sieve pan intermedia...

Page 605: ...aring 6208 RS C3 4 Spacer tube 5 Mounting bracket 6 Hex bolt M 10 x 25 DIN 933 8 8 Contact washer A 10 7 Spacer bushing 8 V belt pulley 9 Circlip 72 x 2 5 DIN 472 10 Deep groove ball bearing 6207 RS C...

Page 606: ...he circlip 2 the deep groove ball bearing 3 and the spacer tube 4 into the V belt pulley 1 CAUTION Fill 60 of the space F with roller bearing grease approx 70 g The deep groove ball bearings 3 must be...

Page 607: ...part no 236 173 0 5 Hex bolt M 16 x 300 DIN 933 8 8 part no 237 375 1 Fig 11 3 Place the circlips 9 and 13 the deep groove ball bearings 10 and 12 and the spacer bushing 11 into the V belt pulley 8 CA...

Page 608: ...nstalling and adjusting the straw chopper drive belts 10 and 11 see page 7 2 22 Installing and adjusting the straw chopper inter mediate drive belt 9 see page 7 2 19 6 Refit the brace 14 Tightening to...

Page 609: ...ey using the special tool Fig 17 Special tool 1 Threaded spindle part no 181 801 1 2 Puller bridge part no 181 800 0 3 Hex bolt M 16 x 150 DIN 931 part no 242 369 0 4 Puller plate part no 181 803 1 5...

Page 610: ...bearing 6308 RS C3 DIN 625 4 Spacer tube 5 Base plate 6 Bearing pin 7 Washer 8 Hex bolt M 12 x 40 DIN 933 8 8 Contact washer A 12 9 Hex bolt M 10 x 45 DIN 931 8 8 Contact washer A 10 10 Thrust washer...

Page 611: ...tube 4 into the V belt pulley 1 CAUTION Fill 58 of space F with multi purpose grease approx 180 g The deep groove ball bearings 3 must be completely filled with multi purpose grease such as Shell Ret...

Page 612: ...olt M 12 x 220 DIN 933 8 8 part no 244 422 0 2 Axial grooved ball bearing part no 177 899 0 3 Hex nut M 12 DIN 934 part no 236 172 0 4 Washer 13 Fig 22 4 Bolt down the hex bolt 15 with washers 13 and...

Page 613: ...ove ball bearing 6203 RS C3 4 Spacer ring 5 Spacer washer 6 Hex bolt M 16 x 75 DIN 7968 8 8 7 Contact washer A 16 8 Hex nut M 16 Fig 25 Assembling and installing the jockey pulley of straw chopper dri...

Page 614: ...1 Removing the jockey pulley of straw chopper drive 11 Removing the straw chopper drive belt 11 see page 7 2 20 Removing the straw chopper drive belts 10 and 11 Unscrew the jockey pulley from the brac...

Page 615: ...olt the pre assembled jockey pulley to the bracket Tightening torque 130 Nm Fig 31 3 Install the straw chopper drive belt 11 see page 7 2 22 Installing and adjusting the straw chopper drive belts 10 a...

Page 616: ...UTION Observe any balls falling out Fig 33 Remove circlips and bushings Fig 34 Removing the uni spreader intermediate drive belt 12 see page 7 2 23 Remove circlip and washer Fig 35 Put handwheel back...

Page 617: ...lt pulley using the special tool Fig 38 Special tool 1 Spindle part no 181 801 1 2 Puller bridge part no 181 800 0 3 Hex bolt M 16 x 50 DIN 933 8 8 part no 235 586 0 4 Washer 17 DIN 125 5 Puller plate...

Page 618: ...DIN 933 8 8 part no 235 586 0 4 Washer 17 DIN 125 5 Puller plate part no 181 617 0 6 Hex bolt M 16 x 260 DIN 931 8 8 part no 235 816 0 7 Centralising piece part no 181 849 0 8 Washer 78 x 20 self sour...

Page 619: ...groove ball bearing 3 Circlip 80 x 2 5 DIN 472 4 Hub 5 Spacer bushing 6 Tapered ring 7 Parallel key 8 Washer 9 Hex bolt M 16 x 40 DIN 933 8 8 10 Ball 11 Leaf spring 12 Cheese head screw M 5 x 6 DIN 91...

Page 620: ...ulley CAUTION Ensure that all taper ring fasteners and hub bores have gearbox grease type G 00 DIN 51502 part no 411 423 0 applied prior to installation 1 Press the deep groove ball bearing 2 on the h...

Page 621: ...prox 40 i e 50 gr of grease e g Shell Alvania G3 part no 413 981 0 Fig 43 44 47 Special tool 1 Lever nut part no 181 880 0 2 Axial grooved ball bearing part no 235 983 0 3 Locating disc part no 181 87...

Page 622: ...ng torque 180 Nm Fig 43 44 50 7 Insert the balls 10 with leaf springs 11 into the hub Slide the pre assembled handwheel 16 with plastic rings 15 on the hub Install circlip 3 Fig 43 44 8 Installing and...

Page 623: ...spreader drive belt 36 see page 7 3 28 Unscrew the angular brace 45 Fig 1 Unscrew hex socket head bolts of set collar 20 Fig 2 Screw the end of the hex socket head bolts into the open hole of the toot...

Page 624: ...head bolts 22 from the bearing housing 23 and remove the complete bearing housing 23 to the bottom Fig 5 Disassembling the straw spreader bearing housing Determine dimension X from shaft end to the b...

Page 625: ...hex bolts 27 of conical guard 25 and remove the washer 26 Fig 8 14 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...

Page 626: ...B LEXION 480 188 678 1 Straw spreader drive 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...

Page 627: ...ollar 21 Toothed belt pulley 22 Mushroom head bolt M 10 x 20 Hex nut M 10 DIN 934 Lock washer 10 23 Bearing housing 24 Hub 25 Universal drive shaft guard 26 Washer 27 Hex bolt M 6 x 12 DIN 933 Contact...

Page 628: ...6885 49 Long support 50 Short support 51 Mushroom head bolt M 8 x 16 Hex nut M 8 Contact washer B 8 52 Long support 53 Parallel key 54 Baffle plate 56 Hex bolt 57 Contact washer 58 Contact washer 59 H...

Page 629: ...nsert the lower bearing 33 and the circlip 35 into the bearing housing 23 Insert spacer tube 34 and upper bearing 33 Fig 14 16 Drive shaft 36 into the bearing housing using a plastic tip hammer Use a...

Page 630: ...ve each other Fig 14 18 Drive in expansion pins 30 and 31 CAUTION The expansion pins must not protrude on the sides grind off on the outside if required Fig 14 19 Using a tube drive the hub 24 on the...

Page 631: ...haft and secure it with linch pin 28 Fig 14 23 3 Loosely bolt on the mounting bracket 46 the short supports 47 and 50 and the long supports 49 and 52 Fig 14 4 Insert the parallel key 53 into the beari...

Page 632: ...ydraulic motor 16 Bolt down the short support 47 and the long support 49 8 Check and if necessary adapt the flatness deviations of toothed belt pulleys F and E using a ruler To do this adjust the toot...

Page 633: ...N 480 7 11 11 Straw spreader drive 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...

Page 634: ...7 11 12 RHB LEXION 480 188 678 1 Straw spreader drive...

Page 635: ...the uni spreader drive belt 16 see page 7 2 32 Remove the bolt from the V belt pulley Fig 1 Using a suitable block ended tube with an inner diameter greater than the tapered ring give the pulley a go...

Page 636: ...rst 1 Bolt on the angle drive Fig 5 2 Put V belt pulley in position align it and arrest it with gib head key Fig 4 3 Insert the parallel key and the tapered ring and slide on V belt pulley Insert the...

Page 637: ...the sieve pan intermediate drive belt 14 see page 7 2 27 Removing the sieve pan drive belt 15 see page 7 2 29 Remove the bracket for the hydraulic hoses at A from the side wall Fig 1 Remove the V belt...

Page 638: ...pulley 2 Circlip 72 x 2 5 DIN 472 3 Deep groove ball bearing 6306 2RS C3 4 Spacer bushing 5 Deep groove ball bearing 6206 2RS C3 6 Circlip 62 x 2 DIN 472 7 Mounting bracket 8 Hex bolt M 10 x 25 DIN 9...

Page 639: ...using the special tool Fig 4 5 Special tool 1 Washer part no 629 071 1 2 Axial grooved ball bearing part no 177 899 0 3 Hex nut M 16 DIN 934 part no 236 173 0 4 Hex bolt M 16 x 300 DIN 933 8 8 part n...

Page 640: ...rew A at the jockey pulley S Loosen nuts K and E until the tension of spring D is relieved Fig 8 Unscrew base plate 1 with deflection pulley 2 completely Fig 8 9 Front sieve pan drive deflection pulle...

Page 641: ...ulley Tightening torque M 16 8 8 130 Nm Fig 10 11 Installing the front sieve pan drive deflection pulley Bolt down the base plate 1 completely with the deflection pulley Install and tension the sieve...

Page 642: ...until the tension of spring D is relieved Remove the belt 15 from the deflection pulley 1 Fig 15 19 Unscrew deflection pulley 1 and remove along with pin 6 Fig 16 17 Rear sieve pan drive deflection p...

Page 643: ...n pulley 1 with pin 6 and hex bolt 8 NOTE At position P the deflection pulley may be backed up with shims 7 if required Fig 18 19 Installing and adjusting the sieve pan drive belt 15 see page 7 2 31 P...

Page 644: ...7 13 8 RHB LEXION 480 188 678 1 Sieve pan drive...

Page 645: ...w to loosen the tapered ring Remove the tapered ring and then the V belt pulley Fig 1 Stage 1 fan drive V belt pulley disassembled 1 V belt pulley 2 Tapered ring 3 Parallel key Fig 2 Installing the st...

Page 646: ...threshing drum variable speed pulley assembly hydraulic see page 7 6 6 4 Installing and adjusting the fan intermediate drive belt 20 see page 7 3 4 Fan adjustment electric NOTE There are three differe...

Page 647: ...14 3 Fan drive Fan adjustment electric Version 1 up to serial no 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 He...

Page 648: ...188 678 1 Fan drive Fan adjustment electric Version 2 from serial no up to serial no The fan adjustment is bolted to the supporting ring using three cheese head screws 3 3 Cheese head screw M 6 x 110...

Page 649: ...an drive Fan adjustment electric Version 3 from serial no 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 piec...

Page 650: ...the hose clamp and remove the protective cap Fig 9 Remove the three hex bolts or cheese head screws 3 and remove the complete DC motor with the spacer tube Fig 6 10 11 From serial no Slacken off the...

Page 651: ...s is not possible loosen the bolts 13 Fig 6 13 Unscrew the hex bolts 13 Fig 6 14 Pull off clamping piece 12 and remove adjustment nut 10 along with needle bearing 9 and axial washer 8 Remove the left...

Page 652: ...7 14 8 RHB LEXION 480 188 678 1 Fan drive Unscrew cheese head screws 4 and remove flange 2 along with hex bolts 3 Fig 6 17 17...

Page 653: ...no Detent edged ring 5 Catch 6 Quick release fastener 7 Ring 8 Axial washer 9 Needle bearing 10 Adjustment nut 11 Bushing 12 Clamping piece 13 Hex bolt M 6 x 60 DIN 931 8 8 Lock washer 14 Thrust piec...

Page 654: ...multi purpose grease e g Shell Alvania G2 or similar brands to all sliding faces shims sheet gaskets and bearings Fig 6 19 1 Slide the hex bolts 3 through flange 2 at position A and bolt on the DC mot...

Page 655: ...the cable and connect a 12 V battery to the plus and minus poles Connect the cables to the blade terminals of the DC motor and make the motor run check that the motor rotates in the correct direction...

Page 656: ...osition Before locking the supporting ring 16 with the capstan nut or the hex nut check all adjustments of the fan variable speed pulley assembly elec tric and adjust if necessary see page 7 14 33 Ass...

Page 657: ...th the three hex bolts 3 and nuts 18 Observe correct motor position dimension R Dimension R 18 5 Fig 27 28 3 Refit the rubber cap 20 and reconnect the push on receptacle 4 Installing and adjusting the...

Page 658: ...osen the hose clamp and remove the protective cap Fig 29 Remove the three hex bolts or cheese head screws 3 and remove the complete DC motor with the spacer tube Fig 6 8 30 31 From serial no Slacken o...

Page 659: ...is is not possible loosen the bolts 13 Fig 6 8 33 Unscrew the hex bolts 13 Fig 6 8 34 Pull off clamping piece 12 and remove adjustment nut 10 along with needle bearing 9 and axial washer 8 Remove the...

Page 660: ...7 14 16 RHB LEXION 480 188 678 1 Fan drive Unscrew cheese head screws 4 and remove flange 2 along with hex bolts or cheese head screws 3 Fig 6 8 37 37...

Page 661: ...ring 5 Catch 6 Quick release fastener 7 Ring 8 Axial washer 9 Needle bearing 10 Adjustment nut 11 Bushing 12 Clamping piece 13 Hex bolt M 6 x 60 DIN 931 8 8 Lock washer 14 Thrust piece 15 Spacer tube...

Page 662: ...pose grease e g Shell Alvania G2 or similar brands to all sliding faces shims sheet gaskets and bearings Fig 6 8 39 1 Slide the hex bolts or cheese head screws 3 through flange 2 at position A and bol...

Page 663: ...f the cable and connect a 12 V battery to the plus and minus poles Connect the cables to the blade terminals of the DC motor and make the motor run check that the motor rotates in the correct directio...

Page 664: ...m serial no Before locking the supporting ring 16 with the capstan nut or the hex nut check all adjustments of the fan variable speed pulley assembly elec tric and adjust if necessary see page 7 14 33...

Page 665: ...hex bolts or cheese head screws 3 and nuts 18 Observe correct motor position dimension R Dimension R 18 5 Fig 6 8 47 48 3 Refit the rubber cap 20 and reconnect the push on receptacle 4 Installing and...

Page 666: ...ctive cap Fig 49 Loosen the capstan nut 39 with a punch Fig 50 59 Loosen the cheese head screws 3 To do this push variable speed pulley 34 close to variable speed pulley 30 The cheese head screws can...

Page 667: ...screw the thrust piece 14 by hand or extend it using the DC motor If this is not possible loosen the bolts 13 Fig 7 54 55 Unscrew the hex bolts 13 Fig 7 55 Pull off clamping piece 12 and remove adjust...

Page 668: ...7 14 24 RHB LEXION 480 188 678 1 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 57 58...

Page 669: ...912 Detent edged ring 5 Catch 6 Quick release fastener 7 Ring 8 Axial washer 9 Needle bearing 10 Adjustment nut 11 Bushing 12 Clamping piece 13 Hex bolt M 6 x 60 DIN 931 8 8 Lock washer 14 Thrust pie...

Page 670: ...51825 lithium stiffened multi purpose grease e g Shell Alvania G2 or similar brands to all sliding faces shims sheet gaskets and bearings Fig 7 60 1 Bolt flange 2 on the DC motor with the cheese head...

Page 671: ...ive 3 Slide on ring 7 4 Pre assemble the adjusting nut 10 with the axial washer 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 b...

Page 672: ...G2 or similar brands to the thread of thrust piece 14 Screw in thrust piece 14 by hand approx 90 CAUTION The pressure pins of thrust piece 14 must be offset by 30 relative to the centre axis of the DC...

Page 673: ...bserve installation position 2 With the hole pattern set the supporting ring to the measure P 42 5 from the horizontal line Fig 59 67 68 3 Observe locking dimension K of capstan nut 39 or of hex nut 3...

Page 674: ...rotated to the right and the left by approx 300 to make installation easier Lock the supporting ring 16 with the capstan nut 39 or the hex nut 39 Observe correct motor position dimension R Dimension...

Page 675: ...the fan adjustment electric Version 2 see page 7 14 22 Remove variable speed pulley half Fig 70 Remove the sliding bushing and replace the bearing Fig 71 Removing the fan intermediate drive belt 20 s...

Page 676: ...4 Variable speed pulley half 35 Circlip 52 x 2 DIN 472 36 Deep groove ball bearing 6304 2 RS DIN 625 37 Shim 38 Thrust sleeve 39 Capstan nut M 16 x 1 DIN 934 from serial no Hex nut M 16 x 1 DIN 934 up...

Page 677: ...ssembly apply K2K grease according to DIN 51825 lithium stiffened multi purpose grease e g Shell Alvania G2 or similar brands to all sliding faces shims sheet gaskets and bearings 1 Press the bearing...

Page 678: ...928 0 2 Washer part no 688 484 0 3 Tube outside 26 x 140 long self sourced Fig 77 4 Using the special tool press the deep groove ball bearing 31 into position Ensure that the bearing is not at an ang...

Page 679: ...ith capstan nut or hex nut 39 at A Pull variable speed pulley half 34 towards the thrust sleeve 38 so that the shims 37 make contact at B without play The distance X must be 40 1 mm if required correc...

Page 680: ...rsion 3 see page 7 14 20 Installing the fan adjustment electric Version 2 see page 7 14 29 Installing and adjusting the fan variable speed pulley assembly spring loaded see page 7 14 42 Removing the f...

Page 681: ...ly spring loaded Removing the fan drive belt 21 see page 7 3 5 Loosen the two set screws M 10 x 8 of the variable speed pulley Fig 86 Pull off the variable speed pulley assembly from the shaft using t...

Page 682: ...r of accident Using the special tool block the compression spring and remove all countersunk head bolts from the mounting flange Fig 89 Special tool 1 Lever nut part no 181 880 0 2 Spindle part no 181...

Page 683: ...compression spring and the mounting flange Fig 92 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...

Page 684: ...1 Variable speed pulley half 2 Bushing 3 Variable speed pulley half 4 Parallel key 5 Cheese head screw M 8 x 12 6 Cheese head screw M 8 x 20 7 Compression spring 8 Thrust plate 9 Cheese head screw M 8...

Page 685: ...es of the pulley together 4 Insert the thrust plate 8 and the compression spring and pre stress the spring using the special tool Screw in a M 8 x 100 hex bolt S for guiding the thrust plate Fig 96 97...

Page 686: ...g loaded and close the variable speed pulley assembly until dimension C is 51 9 0 5 mm Lock the fan variable speed pulley assembly spring loaded on the shaft with the M 10 x 8 set screws Fig 99 4 Inst...

Page 687: ...y Remove the axial rotor step drive 18 Remove the axial rotor intermediate drive 19 Unscrew the round plate Fig 1 Unscrew the hex nuts and remove the front V belt pulleys Fig 2 Remove the cover and un...

Page 688: ...ge part no 181 800 0 3 Puller plate part no 181 803 1 4 Extension pin part no 181 810 1 5 Hex bolt M 16 x 150 DIN 931 8 8 part no 242 396 0 6 Hex nut M 16 DIN 934 part no 236 173 0 7 Washer 17 DIN 125...

Page 689: ...bearing RNA 4910 7 Outer spacer 8 V belt pulley 9 Hex bolt M 16 x 70 DIN 933 8 8 10 Inner spacer 11 Intermediate ring 12 Angular contact ball bearing 3306 RS C3 DIN 628 13 Circlip 72 x 2 5 DIN 472 14...

Page 690: ...e 2 Press the inner race ring 3 on the bearing pin using the special tool Fig 7 8 9 Special tool 1 Tube 55 x 46 x 120 long 2 Washer 55 x 13 3 Axial grooved ball bearing part no 177 899 0 4 Hex nut M 1...

Page 691: ...eve 10 and the compensating washer 11 on the bearing pin 5 Fill the bearing units and the spaces at F completely with multi purpose grease K2K DIN 81825 part no 411 056 0 6 Press the pre assembled V b...

Page 692: ...o 195 Nm Fig 14 10 Install and adjust the axial rotor intermediate drive 19 Install and adjust the axial rotor step drive 18 Removing the axial rotors drive jockey pulley 18 Relieve the tension of axi...

Page 693: ...illed and the space must be 60 i e 120 g filled with grease e g Shell Alvania G3 part no 413 981 0 2 Bolt the jockey pulley to the mounting bracket Tightening torque 78 Nm Fig 16 17 Removing the beari...

Page 694: ...and bearing out of the side wall of the machine Fig 22 Drive gib head key out of the hub Fig 23 Unlock the face end slotted nut and turn it out by approx two turns Using a suitable block ended tube us...

Page 695: ...8 Contact washer A 14 3 Felt ring 4 Bearing housing 5 Taper lock sleeve 6 Spherical roller bearing 20210 K C3 DIN 635 7 Bearing housing 8 Felt ring 9 Tab washer 10 Face end slotted nut M 50 x 1 5 11 H...

Page 696: ...wall of the machine Fig 27 3 Pre tighten face end slotted nut M 50 x 1 5 to a torque of 30 Nm then turn further until the tab of the tab washer is aligned with the slot of the slotted nut Turn the fa...

Page 697: ...frames for better accessibility during installation Remove the axial rotor step drive 18 Fig 31 Remove the bearing housing L from the side panel Now screw hex bolts M 12 x 50 approx 10 mm deep into t...

Page 698: ...le lifting it CAUTION Let the gearbox drop until the expansion pins are not engaged any more Fig 34 Disassembling the axial rotor gearbox Remove the axial rotors gearbox Drain the gearbox oil ENVIRONM...

Page 699: ...move the set screws Pull the shaft completely out of the housing Fig 37 Slightly chuck the tube in a vice and drive shaft out of the bearing Fig 38 Remove circlip and bevel gear Remove the taper rolle...

Page 700: ...7 15 14 RHB LEXION 480 188 678 1 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 41...

Page 701: ...Bevel gear 8 Circlip 45 x 1 75 DIN 471 9 Spacer ring 10 Tube 11 Taper roller bearing 30208 DIN 720 12 Shaft seal 13 Bevel gear 14 Taper roller bearing 32012 DIN 720 15 O ring 16 Compensating washer 1...

Page 702: ...t the taper roller bearing 6 to approx 100 C and press it on the shaft CAUTION The bevel gear and the bearing must make contact without play 3 Slide on the spacer ring 9 and the tube 10 Heat the taper...

Page 703: ...mbled shaft with the adjusting bolts into the gearbox housing Tighten the adjusting bolts to 100 Nm to ensure bearing seat without play Fig 42 43 47 6 Heat up taper roller bearing 14 to approx 100 C a...

Page 704: ...nd tighten until the spinning torque is 3 5 Nm The allowed axial play is 0 to 0 03 mm Caulk the lock nut 19 without cracks Fig 42 43 51 11 Use the same number and thickness of shims 16 and bolt down t...

Page 705: ...o 0 06 mm Fig 42 43 53 54 13 Apply Engineer s blue to the tooth flanks and check the contact pattern Correct setting using compensating washers 16 if required and check settings A Initial setting B Re...

Page 706: ...ble lifting device and move it into the machine using a lever Ensure that the expansion pins are correctly seated Screw in hex bolts at A and tighten to 122 Nm Screw in gearbox cover hex bolts M 10 x...

Page 707: ...xial rotor drive Screw in the stub Z 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 Bol...

Page 708: ...7 15 22 RHB LEXION 480 188 678 1 Axial rotor drive...

Page 709: ...hreaded spindle part no 181 801 1 3 Centraliser with ball part no 181 849 0 4 Hex bolt M 12 x 140 DIN 933 8 8 part no 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...

Page 710: ...the guard up out of the hinges and remove it Fig 5 Swing the grain tank unloading tube out completely Unscrew the clamps of the intermediate panel S and then remove the intermediate panel Fig 6 Remov...

Page 711: ...move the hose and cable clamp from the bracket H Fig 10 Remove the brace F and the hose clamp Loosen the hoses G to the hydraulic pump Collect any leaking oil and cap the connections tightly ENVIRONME...

Page 712: ...he connector Fig 13 Remove the bracket with the hydraulic cylinders Fig 14 Remove the elbow W from the machine Push the tank towards the left and by using a bolt and self grips secure in place Fig 15...

Page 713: ...ff in a safe and orderly manner K Oil level check plug E Oil filler plug and gearbox breather A Oil drain plug Fig 17 NOTE If the engine output pulley has to be removed for follow up repairs of the tr...

Page 714: ...lower bolt from the gearbox housing and safely secure the underside of the engine with suitable blocks Lower the engine gently Fig 20 Using a suitable lifting device attached to the transfer gearbox g...

Page 715: ...the drive shaft Remove the split pin from the castellated nut M and remove nut Fig 23 Pull off the engine output pulley using the special tool Fig 24 Special tool 1 Puller bridge part no 181 800 0 2...

Page 716: ...reads must be warmed CAUTION The dowel pins of the special tool must be inserted according to the pitch circle diameter 90 mm or 92 mm Special tool 1 Tube part no 181 611 0 2 Castellated spanner part...

Page 717: ...move the spur gear along with the taper roller bearings Fig 31 Pull off the taper roller bearing from the spur gear Fig 32 Using the special tool unscrew the slotted nut and press the bearing outer ri...

Page 718: ...te shaft Remove the split pin from the slotted nut N then using the special tool remove the nut Special tool 1 Socket wrench part no 181 809 0 Fig 34 Using a suitable soft punch drive the intermediate...

Page 719: ...11 Seal 12 Bearing cover 13 Hex bolt M 10 x 25 DIN 933 8 8 Lock washer 10 14 Cover 15 Drive shaft 16 Taper roller bearing 17 Spur gear 18 Locating ring 19 Taper roller bearing 20 Seal 21 Engine cover...

Page 720: ...age of the text With the two different gearbox versions A and B the following should be observed when ordering spare parts 55 mm 60 mm or 65 mm as measured on the shaft seal W Cover 25 with or without...

Page 721: ...ings 3 and insert the inner bearing parts Insert the pre assembled intermediate gear 5 into the gearbox housing Fig 37 40 41 Apply some oil to the O ring 2 and insert it into the housing Drive the int...

Page 722: ...intermediate gear wheel 5 in both directions The intermediate gear should be easily rotated Special tool 1 Socket wrench part no 181 809 0 2 Angle washer part no 174 358 0 Secure the slotted nut 8 wit...

Page 723: ...n tightening it with a torque wrench the setting has to be repeated If the cover does not turn when tightening it with a torque wrench the cover with the angle washer needs to be loosened by 55 Check...

Page 724: ...shaft 15 into the gearbox housing Fig 37 40 49 Place engine cover 21 in position with gasket 20 and bolt it down CAUTION Insert hex bolts 22 with sealing compound Tightening torque 45 Nm Fig 37 40 50...

Page 725: ...wn further and tighten to 85 Nm Special tool 1 Tube part no 181 611 0 2 Castellated spanner part no 174 356 1 Fig 37 38 40 51 Gearbox version A If the cover turns more than 15 mm at its circumference...

Page 726: ...to 85 Nm Special tool 1 Tube part no 181 611 0 2 Castellated spanner part no 174 356 1 Fig 37 39 40 54 Gearbox version B If the cover turns more than 15 mm at its circumference when tightening it wit...

Page 727: ...Refit the engine output pulley Ensure that the taper ring fastener is free from grease Tighten the castellated nut M 36 x 1 5 to 520 80 Nm Secure the castellated nut with a split pin NOTE The castell...

Page 728: ...s from under the engine Tighten the castellated nut M 36 x 1 5 to 520 80 Nm Secure the castellated nut with a split pin Fig 59 3 Introduce the hydraulic pump with a new O ring into the gearing and bol...

Page 729: ...ting the grain tank unloading intermediate drive belt 8 see page 7 2 17 Installing and adjusting the straw chopper inter mediate drive belt 9 see page 7 2 19 7 Install the hydraulic tank and the brack...

Page 730: ...7 16 22 RHB LEXION 480 188 678 1 Engine output...

Page 731: ...emove the M 6 x 16 hex bolts Fig 1 Remove the hex bolt S M 12 x 55 from the eye bolt and the hex bolt T M 12 x 85 from the metal rubber bearings Unscrew the mushroom head bolts F and lift out the comp...

Page 732: ...earing and pull off the bearing Fig 5 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 flan...

Page 733: ...olt M 8 x 16 DIN 933 8 8 17 Bearing plate 18 Flange bearing 19 Lock collar 20 Washer 21 Key 22 V belt pulley 23 Washer 24 Lock nut VM 16 x 1 5 25 Cheese head screw M 10 x 20 DIN 7984 Contact washer A...

Page 734: ...ion of rotation and secure it 4 Insert the washer 20 and key 21 Slide the V belt pulley 22 into position and bolt down with lock nut 24 5 Place the metal rubber bearing 26 into position 6 Lift the pre...

Page 735: ...ive belt 27 see page 7 3 15 Unbolt the axial fan and remove along with the spacers Fig 8 Unbolt the hex bolts at A and remove the V belt pulley Fig 9 Installing the fan drive 1 Bolt down the V belt pu...

Page 736: ...7 17 6 RHB LEXION 480 188 678 1 Rotary screen drive...

Page 737: ...nvironmental regulations Suspend the final drive gearbox using a suitable lifting device Remove the hex bolts and the cheese head screws at S Lift off the final drive gearbox Fig 2 Disassembling the f...

Page 738: ...have been removed they must be replaced by new ones Fig 4 Drive out the double expansion pin S and unscrew the castellated nut K NOTE The castellated nut is tightened to a torque of 600 Nm Fig 5 Push...

Page 739: ...e the taper roller bearings Remove the shaft seal W The shaft seal must always be replaced when re assembling Fig 9 Pull the outside bearing ring out of the gearbox Fig 10 Removing the intermediate sh...

Page 740: ...arbox so that the shaft cannot tilt Fig 13 Remove the intermediate shaft using the special tool Fig 14 Special tool 1 Hex bolt M 16 x 260 DIN 931 8 8 part no 235 816 0 2 Hex nut M 16 DIN 934 8 part no...

Page 741: ...pplied Using the puller remove the taper roller bearing Fig 16 Removing the drive shaft Remove the wheel drive shaft Remove the intermediate shaft Drive out the expansion pin S and unscrew the cover D...

Page 742: ...1 Taper roller bearing 331 14 DIN 720 12 Supporting ring 13 Spur gear 14 O ring 110 x 3 5 72 NBR DIN 3771 15 Bearing cover 16 Expansion pin 8 x 32 A DIN 8752 17 Wheel drive shaft 18 Shaft seal 19 Axia...

Page 743: ...to approx 100 C and press them onto the drive shaft 2 Press the outer race of taper roller bearing 3 into the gearbox housing Insert the drive shaft and press the outer race of bearing 4 into position...

Page 744: ...sured Tighten the bearing cover to a tightening torque of 110 Nm using the special tool Secure the bearing cover with an expansion pin The spinning torque of the shaft may be 1 8 to 3 5 Nm Special too...

Page 745: ...ousing Heat the taper roller bearing 11 to approx 100 C and insert it into the outer bearing race Stick the supporting ring 12 with grease to the spur gear 13 Lift the spur gear into the gearbox housi...

Page 746: ...tall it on the bearing cover Tighten the bearing cover by constantly turning the intermediate shaft until no more play can be measured Once the play has been removed tighten to a tightening torque of...

Page 747: ...sure correct installation position Fig 33 3 Heat the taper roller bearing 20 up to approx 100 C and press it on the wheel drive shaft Once the bearing 20 has cooled down press it into position using a...

Page 748: ...680 mm 3 Puller plate part no 181 803 1 4 Tube 125 x 110 x 305 mm 5 Washer 21 6 Hex nut M 20 part no 237 521 0 7 Jack 20 t Fig 35 36 4 Press the outer race of taper roller bearing 20 into the gearbox...

Page 749: ...nd press on the main shaft 10 Check the thread of the castellated nut Replace castellated nut if damaged Oil the thread and the contact face of the castellated nut Tighten up the castellated nut while...

Page 750: ...o its end stop The axial play at X should be 0 2 mm to 0 9 mm The spinning torque of the main shaft may be 9 to 12 Nm Fig 43 44 13 Use a double expansion pin 26 to secure the castellated nut Fig 45 14...

Page 751: ...e gearbox oil ENVIRONMENT Dispose of the old oil in a way that is harmless to the environment and in accordance with existing environmental regulations Clean magnetic plug in oil drain plug at every o...

Page 752: ...special tool lift the gearbox housing only so that the gap S is 5 mm max Failure to observe this procedure may damage the gearbox Then lower the gearbox housing again Fig 50 Special tool Self manufac...

Page 753: ...bridge part no 181 800 0 5 Puller bridge part no 174 047 0 Fig 53 Lift the gearbox housing off using a lifting device ATTENTION A second person is required to guide the gearbox housing G so that the...

Page 754: ...ur gear Fig 56 Bolt on the axle housing with 8 bolts Using a jack and a special tool see Fig 51 remove the complete axle housing including the planetary carrier P ring gear H and the deep groove ball...

Page 755: ...g 60 Remove the ring gear H and the circlips from the planetary gears Remove the planetary gears Fig 57 61 Remove the hex bolts from the spur gear S and remove the bushings CAUTION The hex bolts have...

Page 756: ...the bearing cover using the special tool Fig 64 Special tool 1 Tube part no 181 611 0 2 Socket wrench part no 174 048 0 Fig 65 Using a flat steel drive the taper roller bearings off of the shaft so th...

Page 757: ...N 480 7 18 21 Final drives 67 32031 13 16 1 2 3 4 8 9 10 10 15 5 6 7 12 14 17 6 11 19 20 24 25 26 29 30 33 18 22 23 27 28 31 32 34 21 36 37 35 38 68 32032 1 2 3 4 8 10 10 15 5 7 12 14 19 24 25 30 33 1...

Page 758: ...M 10 x 45 DIN 912 10 9 up to serial no Round bushing up to serial no 18 Deep groove ball bearing 6020 DIN 625 19 Spacer sleeve 20 Compensating washer 21 Shim 22 Axle housing 23 Taper roller bearing 3...

Page 759: ...ssure of 20 t ATTENTION There must be no more gap between the taper roller bearing and the shaft shoulder Should this be the case repeat the procedure 3 Press the outer race of taper roller bearing 4...

Page 760: ...spur gear 15 and the sun gear 12 together CAUTION Insert bolts with liquid locking compound e g DELO ML 5349 Tightening torque 63 Nm 10 Push the pre assembled spur gear on the wheel drive shaft 11 Pr...

Page 761: ...s no more play in the shaft A guide value of approx 110 Nm applies The spinning torque of the pinion shaft must be between 1 8 and 3 5 Nm Now secure the bearing cover with an expansion pin Fig 67 68 7...

Page 762: ...and the contact face of the castellated nut Tighten up the castellated nut while constantly turning the wheel drive shaft until no more axial play can be measured 21 Tighten the castellated nut to 980...

Page 763: ...s D on the intermediate drive shaft and bolt the final drive gearbox to the drive axle with four hex bolts B without sealant 7 Determine the axial play of the intermediate drive shafts on the brake di...

Page 764: ...the opposite side must be held tight for checking smooth operation 12 Arrest the final drive gearbox and drive axle with new expansion pins CAUTION If the existing bores do not match a new bore must b...

Page 765: ...188 678 1 RHB LEXION 480 7 18 29 Final drives E Oil filler plug and gearbox breather A Oil drain plug K Oil level check plug Fig 87 16 Install wheel 32049 A E K 87...

Page 766: ...7 18 30 RHB LEXION 480 188 678 1 Final drives...

Page 767: ...T Dispose of the old oil in a way that is harmless to the environment and in accordance with existing environmental regulations Clean magnetic plug in oil drain plug at every oil change Screw the drai...

Page 768: ...way from manual gearbox Fig 4 Disconnect the cable plugs from the manual gearbox and bend up the cable clamps on the gearbox On both sides remove the brake lines from the brake callipers and plug the...

Page 769: ...olts A Slowly lower the gearbox and remove it to the right hand side of the machine Fig 7 8 Disassembling the manual gearbox Removing the shifter rails Remove manual gearbox Remove the magnetic pick u...

Page 770: ...self Fig 11 Remove the profiled bushing P and then remove the flange housing Fig 12 Drive out the expansion pin Pull out the shifter rail out to the right and remove the shifter fork Fig 13 Drive out...

Page 771: ...d remove the shifter finger Fig 15 Remove the shift gate Fig 16 Removing the drive shaft Remove manual gearbox Remove the shifter rails Remove the brake linings and the right hand gearbox cover Fig 17...

Page 772: ...t Remove the circlip and pull off the inner bearing race I Fig 20 Removing the main shaft Remove manual gearbox Remove the shifter rails Remove the brake linings and the right hand gearbox cover Fig 2...

Page 773: ...ft to the left and remove the cylinder roller bearing L Fig 23 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...

Page 774: ...e gear and the pinion Fig 27 Remove the inner race of the bearing from the main shaft Fig 28 Removing the differential Remove manual gearbox Remove the shifter rails Remove the main shaft Remove the s...

Page 775: ...it to the top Fig 31 Disassembling the differential Remove manual gearbox Remove the shifter rails Remove the main shaft Remove the differential Pull off deep groove ball bearing with a puller Fig 32...

Page 776: ...gear from the differential housing using a plastic tip hammer Fig 35 Drive the expansion pins out of the ring gear Fig 36 Pull off deep groove ball bearing from the differential housing Fig 37 Drive...

Page 777: ...rential pinions 6 Bearing sleeve 7 Differential axle 8 Expansion pin 6 x 50 DIN 1481 Expansion pin 10 x 50 DIN 1481 9 Ring gear 10 Expansion pin 13 x 30 DIN 1481 Expansion pin 8 x 30 DIN 1481 11 Claw...

Page 778: ...Fig 40 42 Secure the differential axle 7 with expansion pins 8 Fig 40 43 Heat the inner race of deep groove ball bearing 13 to approx 100 C and place into position Once the bearing has cooled down che...

Page 779: ...ts 12 Tightening torque 100 Nm Fig 40 46 Heat the inner race of deep groove ball bearing 14 to approx 100 C and place into position Fig 47 Installing the differential Push the complete differential wi...

Page 780: ...with gaskets Ensure correct installation position Fig 50 Check the axial play of the differential The axial play must be between 0 30 mm and 1 40 mm Fig 51 Bolt down the left and right support plates...

Page 781: ...x 30 DIN 933 8 8 Lock washer 10 18 Seal 19 Right hand gearbox cover 20 Shaft seal BASL 40 x 58 x 9 21 Precision fit bolt Lock washer 10 DIN 128 22 Hex bolt M 10 x 25 DIN 933 8 8 Lock washer 10 DIN 128...

Page 782: ...7 19 16 RHB LEXION 480 188 678 1 Manual gearbox Assembling the manual gearbox Clean all threads in the gearbox housing 54 32109 13 16 19 20 2 3 4 8 9 15 22 5 6 7 11 12 21 17 10 11 3 Manual gearbox...

Page 783: ...roller bearings 4 and 9 to approx 100 C and press on the main shaft with one supporting ring 3 each Once the cylinder roller bearings 4 and 9 have cooled down press them into the gearbox housing Fig 5...

Page 784: ...he main shaft The play must be 0 10 mm to 1 04 mm Fig 60 Install the shifter rails Install manual gearbox Installing the drive shaft 1 Heat the inner race of cylinder roller bearing 15 to approx 100 C...

Page 785: ...n 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 63 7 Bolt on the flanged housing 16 with its seal Insert the hex bolts 17 with sealing compound Fi...

Page 786: ...gearbox and through the gate Push on the shifter fork 32 and fix into position with an expansion pin Fig 53 68 4 Push the shifter rail 26 into the gearbox and through the gate Push on the shifter for...

Page 787: ...ct installation position CAUTION Check the installation position of the clamps Fig 53 72 8 Screw in the magnetic pick up I with sealing compound up to the stop of the tooth tip then loosen by half a t...

Page 788: ...S Drive in the expansion pins T and then tighten the hex bolts S Fig 75 Introduce the complete left and right intermediate drive shafts with brake discs into the gearbox Fig 76 Install the left and r...

Page 789: ...into position and refit the brake lines Bleed the brake system Fig 79 Grease the external spline of the drive shaft from the manual gearbox Slide on profiled bushing P with the turned out area of the...

Page 790: ...t the shifter rails C and D next to the operator s platform at the ball joints K so that the shifter wheels are fully intermesh and the arresting balls of the selector shafts engage Fig 84 Fill in gea...

Page 791: ...ear 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 86 87 Servo gearshift Removing the shifter pistons Set up...

Page 792: ...compression springs 11 Fig 91 98 Remove lower compression spring 6 with the magnetic rod M special tool part no 171 842 0 Fig 92 Remove the arresting ball 5 with the magnetic rod M special tool part n...

Page 793: ...ing ball 6 Compression spring lower 7 Square ring 8 Square ring 9 Shifter piston front 10 Shifter piston rear 11 Compression spring upper 12 Seal 13 Cylinder cover 14 Hex bolt M 8 x 40 Fig 94 Installi...

Page 794: ...97 Bleeding the shifter piston Remove valve combination for creating a vacuum Take the machine out of gear and secure against rolling away Connect a bleed hose to the bleed valve 3 and place the end o...

Page 795: ...drum Fig 2 Remove the brake linings and replace with new linings Fig 3 Install the brake linings and refit the tension spring Slide on the brake drum and align so that it does not touch the new brake...

Page 796: ...bleed valve D Release the brake lever Repeat this procedure until the brake fluid comes out of the bleed hose without bubbles CAUTION Ensure that there is sufficient brake fluid in the brake fluid re...

Page 797: ...Place the spring in position and drive the pins into the brake calliper Install the cap and connect the cable Fig 9 Removing a brake calliper Press the brake pedals down and secure in this position T...

Page 798: ...e g DELO ML 5349 Tightening torque 210 Nm Fig 12 Install the brake lines and connect the cable Once the calliper has been completely fitted align the brake disc to the intermediate drive shaft so that...

Page 799: ...g Slacken off the wheel bolts on the rim Fig 1 Safely support the steering axle with a stand Screw out the wheel bolts and remove the wheels Fig 2 Remove cap K The cap will be destroyed in this proces...

Page 800: ...cess the outer taper roller bearing will slip out of the hub without its outer race Fig 6 Drive the outer races V and H of the outer and inner bearing out of the hub using a punch Fig 7 If necessary f...

Page 801: ...188 678 1 RHB LEXION 480 7 21 3 Steering axle Pull off the seal retainer T with the seals from the stub axle using a puller Fig 9 9...

Page 802: ...le Wheel bearing disassembled 1 Seals 2 Seal retainer 3 Taper roller bearing 332 14 DIN 720 4 Hub 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...

Page 803: ...inner taper roller bearing 3 to approx 100 C and slide it on Once the bearing has cooled down give the bearing a short hammer blow with a block ended tube Fig 10 12 Grease taper roller bearing 3 and s...

Page 804: ...he spinning torque using a special tool S Special tool S 1 Test bridge part no 181 623 0 2 Hex bolt M 10 x 180 DIN 931 8 8 3 Hex nut M 10 DIN 934 Fig 15 Secure the castellated nut with expansion pins...

Page 805: ...ball joints out of the tapered seats using a ball head puller Alternatively the ball joint should come loose after tapping with a hammer on one side of the tapered seat and holding a hammer against i...

Page 806: ...1 Steering axle Remove the bottom cover Fig 22 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...

Page 807: ...ecial tool T Fig 26 Special tool T 1 Lever nut part no 181 880 0 2 Axial deep groove ball bearing part no 235 983 0 3 Centring disc part no 181 879 0 4 Tube Outside diameter 50 mm Inside diameter 40 m...

Page 808: ...cover 9 Needle bushing 10 O ring 11 Kingpin 12 Stub axle 13 Axial taper roller bearing 14 Bottom cover Fig 28 Installing the stub axle Press the needle bushings 9 into the stub axles one after another...

Page 809: ...e the cover Fig 28 31 Grease the needle bushings Grease and insert new O rings 10 Grease and insert axial taper roller bearings 13 Fig 28 32 Slide the stub axles on the adjusting element Carefully dri...

Page 810: ...0 Nm Fig 28 36 Installing the steering cylinders and the steering track rod Using a plastic tip hammer push the ball joints into the tapered seats Bolt down the castellated nuts Castellated nut of ste...

Page 811: ...axle Setting the track width The track width is measured on the rim flanges 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...

Page 812: ...sh the ball head out of the tapered seat using a suitable puller Alternatively the ball joint should come loose after tapping with a hammer on one side of the tapered seat and holding a hammer against...

Page 813: ...end stop bolts A on both sides every track width adjustment 1 Place a suitable jack under the centre of the steering axle and then raise the machine off the ground 2 Screw the steering end stop bolt A...

Page 814: ...ed nuts at the ball heads Slacken off castellated nuts Push the ball heads out of the tapered seats using a suitable puller Unscrew the castellated nuts Fig 45 Tie up the hydraulic cylinder at the sid...

Page 815: ...ith a mobile lifting device e g a pallet truck Raise the steering axle slightly so that the load is off the axle pivot pin A Drive out the axle pivot pin A using a soft metal punch CAUTION Take partic...

Page 816: ...ring axle bearing disassembled 1 Hex bolt M 12 x 40 DIN 933 8 8 Washer 13 DIN 125 Contact washer A 12 Hex nut M 12 2 Pin 3 Bushing 4 Steering axle housing 5 Back up ring 6 Supporting ring Shim 7 Caste...

Page 817: ...lightly grease the pin 2 and insert it 2 Compensate the axial play with shims P ATTENTION The steering axle should not have any play once the axle pivot pin has been fitted 3 Secure the pin 2 with hex...

Page 818: ...7 21 20 RHB LEXION 480 188 678 1 Steering axle...

Page 819: ...8 Machine body...

Page 820: ......

Page 821: ...belt For this loosen the clamping bolt K push the jockey pulley S back by hand and then remove the V belt Fig 1 Drive the expansion pin out of the axle and remove the rotary screen Fig 2 Disassemblin...

Page 822: ...8 1 2 RHB LEXION 480 188 678 1 Rotary screen Unbolt the flange ball bearing and remove along with the axle Fig 5 5...

Page 823: ...head bolt M 10 x 20 x 12 DIN 603 Contact washer A 10 Hex nut M 10 DIN 934 9 Support plate 10 Clamp 11 Hex bolt M 8 x 25 DIN 933 8 8 Contact washer A 8 Hex nut M 8 DIN 934 12 Deflector plate 13 Sealing...

Page 824: ...2 Align the axle 3 so that dimensions X centre of bore up to outer edge of brush with a solid support is 4 3 0 5 mm Lock axle in place with lock collars 5 3 Install bracket 9 and deflector plate 12 an...

Page 825: ...tical brace of back wall R 6 Installing and adjusting the rotary chaff screen drive belt 26 see page 7 3 14 7 Adjust the suction unit On machines with a suction tube Adjust the suction tube 15 so that...

Page 826: ...se clamp 9 Mushroom head bolt M 6 x 16 x 10 Hex nut M 6 Contact washer A 8 Washer 105 x 22 x 3 10 Hex bolt M 8 x 20 Hex nut M 8 Contact washer A 8 11 Mounting bracket 12 Trough 13 Nozzle 14 Suction tu...

Page 827: ...y screen to the dimension B 5 3 mm Dimension B can be corrected by compensating with washers 2 and by adjusting the bolts 9 Fig 9 10 11 Fold down the back plate along with the rotary screen and lock i...

Page 828: ...lt 27 see page 7 3 15 Unbolt the axial fan and remove along with the spacers Fig 13 Unbolt the hex bolts at A and remove the V belt pulley Fig 14 Installing the fan drive 1 Bolt down the V belt pulley...

Page 829: ...e belt 28 see page 7 3 17 Loosen the clamp and remove suction hose Fig 15 Loosen two bolts from the spindle and remove spindle Fig 16 Unscrew the bolt from the bracket and remove the complete suction...

Page 830: ...188 678 1 Rotary screen 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 t...

Page 831: ...x 32 DIN 6885 7 Curved washer 5 x 7 5 DIN 6888 8 V belt pulley 9 Contact washer A 16 10 Hex nut BM 16 x 1 5 DIN 439 11 Supporting ring 20 x 28 DIN 988 12 Circlip 20 x 1 2 DIN 471 13 Blower wheel 14 S...

Page 832: ...ing housing 1 Fig 21 22 4 Bolt the back plate 17 to the bracket 5 Insert the parallel key 6 and slide on the blower wheel up to the stop at the circlip Secure blower wheel with set screw 14 Fig 21 23...

Page 833: ...ig 1 Remove the hydraulic hose clamps S located on the left hand side of the machine Fig 2 For servo gearshift Unscrew the hose R from the cover of the manual gearbox Plug the hose and unions tightly...

Page 834: ...inders and plug connections tightly with plastic caps Remove the two or three where fitted cutterbar cylinders Separate the brake lines B Fig 5 Remove the brake lines B from the drive axle Fig 6 Unhoo...

Page 835: ...hang it somewhere on the side Fig 9 Move a suitable lifting device e g a pallet truck under the axle and the manual gearbox Fig 10 Unbolt the complete axle from the frame of the machine and remove tow...

Page 836: ...the bracket H complete with the hydraulic line Fig 11 4 Fit the parking brake cable H at its retarder W and reconnect Adjust the cable so that the brake is applied on the 3rd or 4th tooth Bolt the cl...

Page 837: ...he hydraulic lines and electrical connections 9 Grease the external spline of the drive shaft from the manual gearbox Slide on profiled bushing P with the turned out area of the toothed hub profile fa...

Page 838: ...arshift Take the machine out of gear and secure against rolling away Connect a bleed hose to the bleed valve 3 and place the end of the hose in a suitable container Start diesel engine actuate servo g...

Page 839: ...9 Hydraulic system...

Page 840: ......

Page 841: ...container under the oil drain nozzle Unscrew the cap from the oil drain nozzle and drain the oil ENVIRONMENT Dispose of the old oil in a way that is harmless to the environment and in accordance with...

Page 842: ...e the bearing plate G Fig 5 Open the condenser and unbolt the bearing plate L Remove the hydraulic hoses S from the oil cooler and collect any leaking oil ENVIRONMENT Dispose of the old oil in a way t...

Page 843: ...480 9 1 3 Oil cooler 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 oi...

Page 844: ...h its bracket and the bearing plate to the oil cooler Fig 5 6 3 Close the radiator and secure with stop A Fig 4 4 Fit the hydraulic hoses to the oil cooler Bolt on the cover B CAUTION Always use new s...

Page 845: ...isassembling any hydraulic components use a clean surface e g paper or cardboard When leaving hydraulic components for a period of time plug all ports tightly in order to keep dirt out of the componen...

Page 846: ...IRONMENT Dispose of the old oil in a way that is harmless to the environment and in accordance with existing environmental regulations H Hydraulic oil drain fitting M Engine oil drain fitting Fig 2 Pl...

Page 847: ...un engine at slow idling speed for approx 10 seconds Stop the engine Top up the missing oil in the hydraulic oil tank Repeat this procedure until a constant oil level is being obtained in the oil tank...

Page 848: ...9 2 4 RHB LEXION 480 188 678 1 Maintenance...

Page 849: ...hot oil Beware of burns ENVIRONMENT Dispose of the old oil in a way that is harmless to the environment and in accordance with existing environmental regulations Fig 1 2 Release the tension on the V...

Page 850: ...hree legged puller remove the V belt pulley Fig 6 Remove the four bolts S from the bracket and remove the pump Fig 7 Disassembling the uni spreader hydraulic pump Remove the key F and the shaft seal D...

Page 851: ...eader hydraulic pump 1 Check the seal 2 back up ring 3 and the slide plate 4 and replace if necessary Insert the gears 5 and 6 into the housing parts 1 7 and 8 Assemble the pump with the cheese head s...

Page 852: ...efill 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 11...

Page 853: ...of burns ENVIRONMENT Dispose of the old oil in a way that is harmless to the environment and in accordance with existing environmental regulations Fig 16 Remove the grain tank unloading hydraulic cyl...

Page 854: ...owden cable Z from the lever Remove the hydraulic hoses 8 and 9 from the main pump and plug them Fig 19 Screw in the special eye bolt B part no 181 618 0 into the top of the pump and then attach to a...

Page 855: ...olt down the left hand mounting plate Push in the dowel screw and tighten Tightening torque 122 Nm Bolt the hydraulic hoses to the cylinder with new copper washers 4 Bolt the brace into position Tight...

Page 856: ...23 Remove the hydraulic hoses 1 to 4 from the double pump and plug them Remove two bolts S from the flange Pull the double pump out of the main pump Fig 24 Installing the hydraulic double pump 1 Apply...

Page 857: ...ons Fig 1 Drain the hydraulic oil from the motor into a sufficiently large container after loosening the screw plug V on the underside of the motor After the oil has been drained re tighten the screw...

Page 858: ...fixed displacement motors 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 dam...

Page 859: ...drostatic motor has to be changed the hydraulic pump must also be replaced Flush the oil cooler and the hydraulic lines 1 Thoroughly clean the flange facings of manual gearbox 1 and hydrostatic motor...

Page 860: ...illing instructions when changing the hydraulic oil 6 Test run the machine and check for any leaks Fig 7 For servo gearshift Bolt down the hose R to the cover of the manual gearbox Fig 8 Bleeding the...

Page 861: ...e a vacuum in the hydraulic oil tank see special tool U part no 181 619 0 which is a valve combination enabling a vacuum to be created DANGER Be careful when draining hot oil Beware of burns ENVIRONME...

Page 862: ...p Fig 14 Remove the M 8 x 180 hex bolt from the spring tensioner Fig 15 Remove the M 8 x 65 the M 12 x 25 and the M 12 x 45 hex bolts with eccentric bolt from the hydraulic cylinder and remove the cyl...

Page 863: ...ydrostatic fixed displacement motors 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...

Page 864: ...25 DIN 933 8 8 Contact washer A 8 4 Hydraulic cylinder Hex bolt M 8 x 65 DIN 931 8 8 Hex nut M 8 DIN 934 Contact washer A 8 Hex bolt M 12 x 25 DIN 933 8 8 Contact washer A 12 5 Eccentric Hex bolt M 1...

Page 865: ...so there is some play 6 Bolt the compression spring 6 in position Tighten the nut until the end of the bolt thread 7 Bolt down the bearing plate 7 slide on the set collar 8 and tighten 8 Adjusting the...

Page 866: ...9 4 10 RHB LEXION 480 188 678 1 Hydrostatic fixed displacement motors...

Page 867: ...nveyor is fitted unscrew tab washer B If a 1420 mm feed rake conveyor is fitted unscrew the VM 20 lock nut Up to serial no Unbolt the hex bolt S M 16 x 140 Observe number of washers C Remove cylinder...

Page 868: ...id locking compound It can be released easily by heating it to about 200 C The seals can now be replaced Fig 4 Remove the M 10 x 20 cheese head screw NOTE The joint is secured with liquid locking comp...

Page 869: ...assembled 1 Hydraulic cylinder Male connector 2 Seal 3 Ram 4 Ram rod Male connector Cheese head screw M 10 x 20 DIN 912 8 8 5 O ring up to serial no 6 Dual seal ring from serial no Back up ring up to...

Page 870: ...r head 5 to 10 on the ram rod and then slide it into the cylinder barrel 1 Insert the cheese head screw M 10 x 20 into the ram rod 4 using liquid locking compound e g DELO ML 5328 part no 201 802 0 6...

Page 871: ...0 x 150 x 30 4 with a tightening torque of 78 Nm If a 1700 mm feed rake conveyor is fitted secure hex bolt S with tab washer B If a 1420 mm feed rake conveyor is fitted secure hex bolt S with VM 20 lo...

Page 872: ...that is harmless to the environment and in accordance with existing environmental regulations 3 Open the shut off tap R by setting lever H to position A 4 Actuate rocker switch 5 to the right until b...

Page 873: ...the cylinder Disconnect cable K from the potentiometer of the position indicator Unscrew the hex bolts S from the drive axle and pull the flanged bushings out of the rear spring plate of the cylinder...

Page 874: ...head bore and turn cylinder head The securing wire is pulled into the groove N For every assembly of the cylinder use a new securing wire Fig 15 16 Disassembling the cutterbar hydraulic cylinders Uns...

Page 875: ...g plate and remove it Fig 20 Chuck the cylinder and turn the cylinder head until the securing wire D comes out of the groove in the cylinder barrel Fig 21 Pull the cylinder head and the ram out of the...

Page 876: ...serial no Back up ring up to serial no 6 Securing wire 7 Cylinder head 8 Seal 9 Dirt scraper 10 Spring plate Lock nut VM 16 x 1 5 Washer 16 5 x 33 x 5 11 Compression spring 12 Spring guide 13 Snap ri...

Page 877: ...s the stop and turn until the bore in the cylinder head groove is below the slot of the cylinder barrel Hang in the greased securing wire 6 with its hook in the cylinder head bore and turn The securin...

Page 878: ...and that there are no leaks Fig 24 Adjusting the cutterbar hydraulic cylinders Adjust the compression springs of the re fitted cylinder with the cutterbar attached The reel should be in a middle posi...

Page 879: ...ariable speed drive cylinder and plug tightly with a plastic cap Fig 27 Unscrew the grease nipple along with the grease tube complete from the variable speed pulley assembly Fig 28 Unscrew three M 12...

Page 880: ...complete variable speed drive cylinder to the variable speed drive using the three countersunk head bolts 4 M 12 x 165 and shims 4 Bolt the grease nipple and the grease tube with the sealing washer in...

Page 881: ...ool 1 Tie rod part no 181 606 0 2 Striking tool part no 181 604 0 From serial no 3 Adapter section M 10 part no 181 609 0 4 Hex nut M 10 DIN 934 2 pieces 5 Union nut 15 L DIN 3870 part no 633 589 1 Up...

Page 882: ...eady exist Tube self sourced Inside 6 mm outside 8 mm 30 mm long Fig 38 40 Remove snap ring 14 stepped washer 13 and seal 12 from the adapter 10 Fig 39 40 Rotary coupling disassembled 1 Rotary feed 2...

Page 883: ...nsert the O ring 15 the seal 12 and the stepped washer 13 into the adapter 10 and secure with circlip 14 Observe installation position of seal 12 and stepped washer 13 Fig 40 41 42 When installing the...

Page 884: ...e bearings 4 must be filled with grease Rhenus Norlith STM3 Observe the installation position of the belleville springs 7 The hydraulic coupling 2 must absolutely not be twisted while pressing on Tube...

Page 885: ...10 x 25 hex bolts from the mounting bracket and remove the cylinder completely Fig 48 Disassembling the concave adjustment hydraulic cylinder Loosen the M 20 x 1 5 lock nut and unscrew together with...

Page 886: ...O ring can now be removed from the cylinder head Fig 51 Knock the expansion pins out of the stop ring Fig 52 Unscrew the ram H from the male screwed end of ram rod K using a sickle spanner NOTE The j...

Page 887: ...8 x 2 5 DIN 3771 5 Valve 6 Cylinder pin 7 Compression spring 8 Expansion pin 9 Expansion pin 10 Stop ring 11 Ram rod 12 O ring 34 2 x 3 DIN 3771 up to serial no 13 Dual seal ring from serial no Back u...

Page 888: ...of the cylinder head 15 Up to serial no Insert the oiled O ring 12 and the back up ring 13 into the groove of the cylinder head 15 6 Insert the complete cylinder head 12 to 17 on the ram rod and then...

Page 889: ...ons when changing the hydraulic oil 3 Set the basic concave adjustments see page 3 2 16 Basic concave setting Fig 55 Removing the grain tank unloading tube swing hydraulic cylinder Swing out the grain...

Page 890: ...ing wire D comes out of the groove in the cylinder barrel Fig 59 Pull the cylinder head Z and the ram rod K out of the cylinder barrel Clean the ram rod and pull off the cylinder head Fig 60 Unscrew t...

Page 891: ...eal 3 O ring 37 x 3 5 DIN 3771 4 Ram 5 Damper 6 Ram rod 7 O ring 44 2 x 3 DIN 3771 up to serial no 8 Dual seal ring from serial no Back up ring up to serial no 9 Securing wire 10 Snap ring 11 Damping...

Page 892: ...roove of the cylinder head 12 Up to serial no Insert the oiled O ring 7 and the back up ring 8 into the groove of the cylinder head 12 5 Insert the damping ring 11 with the snap ring 10 into the cylin...

Page 893: ...r Fill in hydraulic oil at the filler plug S of tank T see page 9 2 3 Filling instructions when changing the hydraulic oil 3 Start the diesel engine and operate the cylinder several times until the ai...

Page 894: ...the securing wire D comes out of the groove in the cylinder barrel Fig 67 Pull the cylinder head Z and the ram rod K out of the cylinder barrel Clean the ram rod and pull off the cylinder head The O r...

Page 895: ...ram 4 on the ram rod 5 with liquid locking compound e g DELO ML 5328 3 Insert seal 10 and dirt scraper 11 into the cylinder head 9 4 From serial no Insert a dual seal ring into the ring groove of the...

Page 896: ...ylinder pin clamp and M 6 x 12 hex bolt 4 Connect the hydraulic hoses to the cylinder Fill in hydraulic oil at the filler plug S of tank T see page 9 2 3 Filling instructions when changing the hydraul...

Page 897: ...lt the complete hydraulic coupling 5 into the thrust flange 3 3 Bolt the complete variable speed drive cylinder to the variable speed drive using the three countersunk head bolts 4 and shims 4 Bolt do...

Page 898: ...d plug them with plastic caps Fig 78 Remove the M 8 x 65 hex bolts A the M 12 x 25 B on the opposite side and the M 12 x 45 bolt C with the eccentric from the hydraulic cylinder and remove the cylinde...

Page 899: ...am rod Fig 82 Clean the ram rod and pull off the cylinder head The dust guard seal back up ring and O ring can now be removed from the cylinder head Reverser drive hydraulic cylinder disassembled 1 Hy...

Page 900: ...er Hang in the greased securing wire 4 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 secur...

Page 901: ...rcuit 5 Bolt the hydraulic lines to the cylinder 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 s...

Page 902: ...9 5 36 RHB LEXION 480 188 678 1 Hydraulic cylinders High pressure hydraulic circuit...

Page 903: ...Remove the split pin S from the pin Remove the pin from the lever Remove the mounting plate L on the right hand side Push the cylinder out of the mounting plate and remove to the left hand side Fig 2...

Page 904: ...rod and pull off the cylinder head Fig 5 Unscrew the ram H from the male screwed end of ram rod K NOTE The joint is secured with liquid locking compound It can be released easily by heating it to abou...

Page 905: ...the complete ram rod 2 to 4 into the cylinder barrel 1 3 Insert seal 9 and dirt scraper 10 into the cylinder head 8 4 From serial no Insert a dual seal ring into the ring groove of the cylinder head...

Page 906: ...washer 15 and bolt 16 Tightening torque 78 Nm Fig 8 Installing the threshing mechanism engagement hydraulic cylinder 1 Insert the cylinder into the lever and into the left hand mounting plate then pus...

Page 907: ...r 7 DANGER The compression spring is tensioned Remove the washer 2 thrust washer 3 bushing 4 compression spring 5 and the guide tube 6 Unscrew the hex nut 8 and remove the hex bolt 9 Remove the extens...

Page 908: ...be released easily by heating it to about 200 C All seals can now be replaced Fig 15 Grain tank unloading engagement hydraulic cylinder disassembled 1 Cylinder barrel 2 Rod guide ring 3 Ram seal 4 Ram...

Page 909: ...crew the complete ram 2 to 4 to the ram rod 5 Use liquid locking compound e g DELO ML 5328 for this 3 Slide the complete ram rod 2 to 5 into the cylinder barrel 1 4 Lightly oil the seal 10 and the dir...

Page 910: ...ith bushing 14 thrust washer 15 washer 16 and bolt 17 Insert bolt with liquid locking compound e g DELO ML 5328 part no 201 802 0 Tightening torque 110 Nm 9 Slide the extension 18 on the ram rod 5 Ins...

Page 911: ...out of its fixing and remove it Loosen the hex nut and remove rod D Fig 19 26 Disassembling the engine speed control hydraulic cylinder from serial no Cylinder side B 35 mm stroke Unscrew the hex bolt...

Page 912: ...completely out of the cylinder barrel using the special tool Cylinder side B 30 mm stroke Pull the cylinder head 13 compression spring 15 spacer tube 20 and the ram completely out of the cylinder bar...

Page 913: ...75 3 Washer 8 4 x 17 x 1 4 Spring plate 5 Spacer tube 6 Compression spring 7 Tear off bolt M 6 x 10 8 Threaded bushing 9 Threaded piece 10 Snap ring B30 11 Scraper ring 12 O ring 13 Cylinder head 14 S...

Page 914: ...the guide to the ram using the cheese head screw 2 Slide the compression spring 15 the spacer tube 20 and the complete cylinder head 13 on the ram 16 and pre stress with a special tool Observe instal...

Page 915: ...end the ram 16 using the special tool Connect the special tool to the measuring port low pressure 19 4 bar max of another machine and extend the ram Close the blocking ball valve and remove the mini t...

Page 916: ...to full throttle Fig 33 Installing the engine speed control hydraulic cylinder from serial no 1 Introduce the hydraulic cylinder into the mounting F 2 Introduce the hydraulic cylinder into the mountin...

Page 917: ...o load speed Take the machine out of gear and start the engine Set engine to max no load speed at the rotary switch Check the max no load speed ATTENTION The max no load speed has been set by the engi...

Page 918: ...km h by converting the cylinder NOTE The existing cylinder 1 on one machine has been set to a road travel engine speed at the factory this setting being secured by the tear off bolt 7 Adjusting the r...

Page 919: ...34 35 5 Adjusting the engine speed control hydraulic cylinder from serial no CAUTION For this operation a second person is required for operating the machine 5 1 Setting the hydraulic cylinder at max...

Page 920: ...9 6 18 RHB LEXION 480 188 678 1 Hydraulic cylinders for low pressure hydraulics Set the clearance Z to 5 3 mm by twisting the rod D Lock that setting with the lock nut K Fig 39 39...

Page 921: ...ird gear only for certain countries Engine speed MERCEDES OM 441 LA 1950 20 rpm ATTENTION Pay particular attention to the speed limit for your country Failure to observe this rule results in expiry of...

Page 922: ...42 Separating the stop collar S from the cylinder Z Remove the hex bolt K then take off the spacer with three washers the compression spring and the spring plate Fig 43 Remove the set screw from the...

Page 923: ...pull the scraper seal out of the cylinder Z Remove the compression spring and the back up ring Fig 47 Special tool 1 Hex bolt M 6 x 60 part no 211 371 0 2 Hex nut M 6 part no 236 169 0 3 Washer 30 x...

Page 924: ...ders for low pressure hydraulics 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 s...

Page 925: ...ng 5 Compression spring 6 Guide 7 Cylinder barrel 8 Hex bolt M 6 x 30 DIN 933 8 8 9 O ring 17 x 2 N DIN 3771 10 Union 11 Cylinder barrel 12 Set screw M 6 x 6 DIN 916 13 Stop collar 14 Spacer 15 Compre...

Page 926: ...and insert into the cylinder barrels 7 and 11 Insert the compression spring 5 and place back up ring 4 in position with the larger surface facing the compression spring 5 3 Fill the cavities of the s...

Page 927: ...ydraulic cylinder up to serial no Screw in rod D until the dimension Y is about 20 mm Lock that setting with the lock nut K Y Thread length Fig 55 Installing the engine speed control hydraulic cylinde...

Page 928: ...ax no load speed Take the machine out of gear and start the engine Set engine to max no load speed at the rotary switch Check the max no load speed ATTENTION The max no load speed has been set by the...

Page 929: ...tion and engage third gear The engine speed can be adjusted by twisting the spacer bushing 14 Ground speed of 20 km h in third gear Engine speed MERCEDES OM 441 LA 1560 20 rpm Ground speed of 25 km h...

Page 930: ...trol unit Remove the complete cylinder Fig 60 Disassembling the 3 D sieve pan hydraulic cylinder Unscrew the angle joint from the ram rod Loosen the two cable bands and remove the bellows Chuck the cy...

Page 931: ...c cylinder disassembled 1 Hydraulic cylinder 2 Hex nut M 8 DIN 934 8 Contact washer A 8 3 Ram 4 Ram seal 5 O ring 37 x 3 5 DIN 3771 6 Ram rod 7 O ring 45 x 3 DIN 3771 8 Securing wire 9 Cylinder head 1...

Page 932: ...th multi purpose grease e g Shell Retinax A part no 147 451 0 and then press into the cylinder head 9 5 Guide the complete cylinder head 7 to 9 on the ram rod and then slide into the hydraulic cylinde...

Page 933: ...ydraulic system for any leaks Bleed cylinders by operating them several times 5 Adjust and or check the 3 D cleaning system see page 4 4 1 Adjusting the 3 D sieve pan control system Fig 65 Removing th...

Page 934: ...hydraulics Loosen the set screw G at the pendulum and push the cylinder pin out of the pendulum Replace the O ring R of the pendulum Fig 68 Remove the cheese head screw from the cover and remove the v...

Page 935: ...D sieve pan disassembled 1 Cover Hex nut M 8 Contact washer A 8 Set screw M 6 x 8 2 O ring 115 x 3 DIN 3771 3 Valve housing Cheese head screw M 6 x 20 DIN 912 Detent edged ring VSKZ 6 4 Pendulum Set...

Page 936: ...along with the cylinder pin 6 and secure with the set screw 5 Insert the pendulum 4 along with the valve housing 3 and cover 1 into the cylinder 7 Bolt the cylinder 7 and the cover 1 together using t...

Page 937: ...10 mm at P Push the pendulum housing in and out by hand until the oil comes out of the bleed screw free of bubbles Once the air has been bleed out of the system retighten the bleed screw DANGER Stop t...

Page 938: ...cylinder 1 Fig 76 79 Disassembling the yield meter moisture sensor hydraulic cylinder Unscrew the cylinder head 7 from the cylinder barrel 3 Fig 77 79 Pull off the cylinder head 7 and the ram rod 5 f...

Page 939: ...eld meter moisture sensor hydraulic cylinder Insert the two part double scraper 8 into the groove of the cylinder head 7 Ensure that the double scraper is installed with the O ring facing the top side...

Page 940: ...llel to the ram K and the cylinder 1 Fig 83 5 Check hydraulic oil level and top up if necessary 6 Start the engine and operate the valve T manually Extend and retract the cylinders several times Stop...

Page 941: ...thus guaranteed that the flap 14 is opened and closed fully by rod 9 When the flap is at its end stops rod 9 slides through the bushings 17 accordingly Fig 86 87 90 7 Set the clearance X between bushi...

Page 942: ...barrel 4 Ram seal 5 Ram rod 6 O ring 7 Cylinder head 8 Double scraper 9 Rod 10 Hex nut Bm 10 11 Hex nut Bm 10 12 Hex nut Bm 10 13 Hex nut Bm 10 14 Flap 15 Inside lever 16 Outside lever 17 Bushing 18...

Page 943: ...uts K from the ball joints Fig 1 Push the ball joints out of the tapered seats using a suitable puller Alternatively the ball joint should come loose after tapping with a hammer on one side of the tap...

Page 944: ...D is pushed out of the groove in the cylinder barrel Fig 4 Pull the cylinder head Z and the ram rod K out of the cylinder barrel Clean the ram rod and pull off the cylinder head Fig 5 Unscrew the ram...

Page 945: ...al 6 Ram rod 7 O ring 44 2 x 3 DIN 3771 up to serial no 8 Dual seal ring from serial no Back up ring up to serial no 9 Securing wire 10 Cylinder head 11 Seal 12 Dirt scraper 13 Ball joint part no 668...

Page 946: ...the ring groove of the cylinder head 10 Up to serial no Oil the O ring 7 and the back up ring 8 and insert them into the groove of the cylinder head 10 6 Insert the complete cylinder head 7 to 12 on t...

Page 947: ...pport the steering axle Start the engine then turn the steering from right to left and vice versa until the system is completely bled 5 Check the hydraulic system for any leeks Fig 8 9 Removing the Au...

Page 948: ...that the securing wire D is pushed out of the groove in the cylinder barrel Fig 13 Pull the cylinder head 16 and the ram rod 12 out of the cylinder barrel Fig 14 First clean the ram rod 12 then remov...

Page 949: ...11 and the rod guide ring 10 can also be replaced Unscrew the ram 9 from the male screwed end of ram rod 12 using a sickle spanner NOTE The joint is secured with liquid locking compound It can be rel...

Page 950: ...he back up ring 6 can now be replaced Remove the cheese head screws from the sensor connector 3 Pull the sensor connector 3 out of the cylinder base 1 so far that the soldered cable can be removed Rem...

Page 951: ...4 Position sensor Wave washer Washer Circlip 5 Securing wire 6 Dual seal ring from serial no Back up ring up to serial no 7 O ring up to serial no 8 Cylinder barrel 9 Ram 10 Rod guide ring 11 Ram seal...

Page 952: ...the cylinder head 16 5 From serial no Insert a dual seal ring into the ring groove of the cylinder head 16 Up to serial no Lightly oil the O ring 13 and the back up ring 14 and insert into the groove...

Page 953: ...12 Fig 20 22 13 Twist the cylinder base so that the bore in the base groove lines up with the slot in the cylinder barrel Hang in the greased securing wire 5 with its hook in the cylinder head bore a...

Page 954: ...Steering hydraulics 5 Bleeding the steering system 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...

Page 955: ...ower supply plug G Remove the hydraulic lines A P and T Plug the lines and connections tightly with plastic caps Remove the hex bolts K and remove the valve Fig 2 3 Feeder reversing 3 2 way valve disa...

Page 956: ...rd S Fig 5 CAUTION Thoroughly clean the area around the valve Loosen the flange nut B and unscrew the restrictor bolt D about one turn in order to release the internal pressure Fig 6 Loosen the screws...

Page 957: ...11 Compression spring 12 Non return valve 13 O ring 22 x 2 N DIN 3771 2 pieces 14 Solenoid coil 3 mm 12 V DC 60 OLF 2 pieces 15 O ring 40 x 1 5 N DIN 3771 2 pieces 16 O ring 15 4 x 2 1 N DIN 3771 2 pi...

Page 958: ...e 4 Compression spring 5 Shim 10 x 16 x 0 5 DIN 988 4 pieces 6 Supporting ring S 10 x 16 x 1 2 7 Spring hood from serial no 8 Screw plug M 18 x 1 5 DIN 906 9 Male connector L 15 B M DIN 3901 10 O ring...

Page 959: ...s 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 t...

Page 960: ...DIN 3771 4 pieces 5 O ring 15 4 x 2 1 N DIN 3771 4 pieces 6 Valve insert 2 pieces 7 Seal 4 pieces 8 Assembled restrictor 2 pieces 9 O ring 9 4 x 2 1 N DIN 3771 2 pieces 10 Male connector L 10 F M DIN...

Page 961: ...Connect the power supply plugs with the blue cable band to B and secure Fig 14 Removing the threshing drum variable speed drive 3 3 way valve Fold up the left hand guard CAUTION Thoroughly clean the...

Page 962: ...771 2 pieces 5 O ring 15 4 x 2 1 N DIN 3771 4 pieces 6 Valve insert 7 Seal 4 pieces 8 Assembled restrictor 9 O ring 9 4 x 2 1 N DIN 3771 10 Male connector L 10 F M DIN 3901 2 pieces O ring 2 pieces 11...

Page 963: ...B2 C1 C2 P and T Plug the lines and connections tightly with plastic caps Remove the hex bolts S and then the valves Fig 19 CAUTION Before disassembling the valve please ensure the valve cartridges h...

Page 964: ...3 pieces 12 Screw plug VSTI M 14 x 1 5 OR 2 pieces 13 Male connector L 10 F M DIN 3901 2 pieces O ring 2 pieces 14 O ring 22 x 2 N DIN 3771 6 pieces 15 Solenoid 3 mm 12 V DC 60 OLF 6 pieces 16 O ring...

Page 965: ...0 8 caulked C2 Valve cartridge with orifice plate 0 8 caulked Fig 22 Installing the concave grain tank unloading tube and straw chopper 4 3 way valves Once the valve has been fitted connect the power...

Page 966: ...ps Remove the hex bolts S and then the valves Fig 25 CAUTION Before disassembling the valve please ensure the valve cartridges have been marked accordingly A2 Valve cartridge with orifice plate 0 6 ca...

Page 967: ...6 12 Screw plug VSTI M 14 x 1 5 OR 2 pieces 13 Male connector L 10 F M DIN 3901 2 pieces O ring 2 pieces 14 O ring 22 x 2 N DIN 3771 4 pieces 15 Solenoid 3 mm 12 V DC 60 OLF 4 pieces 16 O ring 40 x 1...

Page 968: ...ith orifice plate 0 6 caulked B1 Valve cartridge with orifice plate 0 8 caulked Fig 28 Installing the concave and grain tank unloading tube 4 3 way valves Once the valve has been fitted connect the po...

Page 969: ...nations 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 v...

Page 970: ...DIN 3771 20 Ram 21 O ring 8 3 x 2 4 N DIN 3771 22 Compression spring 23 Pressure balance 24 Circlip 15 x 1 DIN 472 25 O ring 6 x 2 N DIN 3771 2 pieces 26 Solenoid 3 mm 12 V DC 60 OLF 2 pieces 27 Comp...

Page 971: ...ms P part no 213 250 0 s 0 2 and part no 213 251 0 s 0 3 to control dimension X 4 3 0 1 4 Bolt down the spring housing 37 Tightening torque 20 Nm Fig 32 33 34 35 Installing the main valve 1 Set the so...

Page 972: ...turn in order to release the internal pressure Fig 37 Mark the power supply plugs and the solenoid valves accordingly Loosen the screws and disconnect the power supply plugs D E and F Fig 38 Mark the...

Page 973: ...1 M 6 DIN 5402 13 Non return valve 14 Compression spring 15 Screw plug VSTI M 14 x 1 5 OR 16 O ring 22 x 2 N DIN 3771 2 pieces 17 Solenoid coil 3 mm 12 V DC 60 OLF F 2 pieces 18 O ring 40 x 1 5 N DIN...

Page 974: ...the union nut 25 Tightening torque 20 to 30 Nm Fig 41 42 43 Installing the CLAAS Autopilot solenoid valve 1 Connect the corresponding power supply plugs to the marked solenoid coils and fasten them 2...

Page 975: ...tic caps Remove the hex bolts S and then the valve Fig 45 CAUTION Before disassembling the valve mark the valve cartridges accordingly A1 Valve cartridge with one way restrictor valve A2 Valve cartrid...

Page 976: ...e plate 12 Restricted one way valve 2 pieces 13 Orifice plate 2 pieces 14 Snap ring B 7 2 pieces 15 O ring 10 x 1 5 N DIN 3771 16 Low pressure PRV insert 17 Spring plate 18 Compression spring 19 O rin...

Page 977: ...ng of PRV 21 1 bar at 4 0 l min CAUTION Only check the oil pressure when the oil is at operating temperature i e approx 50 C and with the engine running at max no load speed Connect the pressure gauge...

Page 978: ...l tank using the special tool U Special tool Valve combination for creating a vacuum part no 181 619 0 Fig 52 Loosen and pull off the power supply plug 11 Fig 53 58 Unscrew the screwed cap from the so...

Page 979: ...may be too strong Fig 52 56 58 To completely disassemble the 3 2 way valve the hydraulic lines must be removed and plugged with plugs at both ends Unscrew hex bolts S Fig 57 Yield meter 3 2 way solen...

Page 980: ...supply plug 11 with rectangular seal 12 and bolt it on Fig 58 6 Check hydraulic oil level and top up if necessary see page 9 2 3 Filling instructions when changing the hydraulic oil 7 Start the engine...

Page 981: ...10 Engine...

Page 982: ......

Page 983: ...ake hoses from the intercooler For this loosen the jubilee clips Plug the connections tightly Fig 1 Fold up the rotary screen Remove the pin from the gas strut Remove the bolt from the bearing and rem...

Page 984: ...it is safe CAUTION The hoses remain connected to the condenser Move the oil cooler out of the way along with the pipes and secure with suitable means e g a rope Fig 4 Remove the bracket H and the stop...

Page 985: ...Fasten the rotary screen in the pivot and secure with a bolt Insert the gas strut bolt and secure with a split pin Fig 2 6 Connect the two intake pipes and tighten the jubilee clips Fig 1 Removing the...

Page 986: ...the air intake box Fig 9 Remove the hose clamps from the condenser and the oil cooler hoses Remove the condenser and place it on the grain tank so that it is safe CAUTION The hoses remain connected to...

Page 987: ...oosen the bolts F and G and turn them back slightly Fig 12 Remove the support T Remove the locking plate S Remove the radiator brackets P on both sides Fig 13 Remove the radiator to the side and remov...

Page 988: ...mps Fig 10 5 Bolt down the cover B of the air intake box Fig 9 6 Fasten the rotary screen in the pivot and secure with a bolt Insert the gas strut bolt and secure with a split pin Fig 7 7 Changing the...

Page 989: ...ank either remove the suction pipe from the fuel filter or open the drain plug on the tank or if the tank is full pump off the fuel Fig 1 Remove the cover plate A from the catwalk Fig 2 Remove the tan...

Page 990: ...g the additional fuel tank Move uni spreader to transport position Unscrew the toggle nuts N on both sides and pull off the rocker arms S Fold down the feed pan Z Fig 5 The cover M is located above th...

Page 991: ...from plate B Unscrew the fuel filler cap and remove plate B CAUTION Be careful not to damage seal T Screw the fuel filler cap on again Fig 8 DANGER Do not walk on surfaces without floor covering E Dan...

Page 992: ...ck and bolt it down all around CAUTION The seal T must be placed tightly around the fuel tank nozzle Screw on the fuel filler cap Bolt down air filter mounting bracket H Fig 10 Bolt down the engine ba...

Page 993: ...ube out completely Unscrew the clamps of the intermediate panel S and then remove the intermediate panel Fig 2 Remove the battery isolating switch Remove the exhaust gas pipe from the turbocharger Uns...

Page 994: ...ders from the air conditioner and heater hoses Remove the two heater hoses from the shut off taps and at the engine block Remove the compressor drive belt Disconnect the cable plugs from the compresso...

Page 995: ...rotary screen drive belt 26 Remove the clamp S Unscrew the bolts A and B with mounting bracket Unscrew the bolts C D and E and remove the jockey pulley bracket completely with the spring Fig 10 Unscre...

Page 996: ...raulic connections tightly Stow away the diesel line in the air intake box ATTENTION Be careful not to kink the diesel line Fig 13 Remove the alternator wiring loom from the engine block and from the...

Page 997: ...ket W and the clamp S Fig 18 Remove mounting plate L and unhook the hydraulic cylinder Loosen the jockey pulley S and remove the belt from the lever The hydraulic cylinder and the lever overlap Remove...

Page 998: ...n the hose clamps and place the reeled up hose under the engine oil pan Fig 22 Unscrew the hydraulic oil tank from the machine housing and secure it Suspend the transfer gearbox completely with the hy...

Page 999: ...the repair needed the components still mounted to the engine block can be removed Installing the engine 1 Pre assemble the engine block with starter alternator shut off solenoid and hydraulic cylinder...

Page 1000: ...with the lock nut Mount the hose clamps and ensure that the hose will not chafe Fig 22 7 Slide the pulley on the drive shaft and tighten the castellated nut with 520 Nm Secure the castellated nut wit...

Page 1001: ...shut off solenoid wiring loom completely on the engine block and connect it Fig 15 16 Install the alternator wiring loom on the engine block and connect it Fig 14 17 Lay the diesel line completely at...

Page 1002: ...Lay and connect the heater and water hoses Fig 6 26 Fit the catwalk Fig 5 27 Fit the air intake pipes L at the engine block Ensure that the pipes have been pushed on sufficiently on both sides Fig 4...

Page 1003: ...11 Index...

Page 1004: ......

Page 1005: ...rive gearbox 7 18 23 Assembling the 3 D sieve pan hydraulic cylinder 9 6 30 Assembling the Autopilot steering cylinder 9 7 10 Assembling the axial rotor gearbox 7 15 16 Assembling the bottom feed rake...

Page 1006: ...sembled 3 1 21 Brake 7 20 1 Brake line screw joints 1 4 3 C Centre cleaning fan bearing disassembled 4 6 9 Changing the hydraulic oil 9 2 2 Changing the road travel engine speed country variants 20 km...

Page 1007: ...rain tank unloading angle drive up to serial no 5 3 24 Disassembling the manual gearbox 7 19 3 Disassembling the returns elevator 5 1 7 Disassembling the reverser drive hydraulic cylinder 9 5 32 Disas...

Page 1008: ...Hydraulic system 9 2 1 Hydrostatic fixed displacement motors 9 4 1 I Identification of warning and danger signs 1 2 2 Impeller 3 5 1 Impeller disassembled from serial no 3 5 10 Impeller disassembled...

Page 1009: ...concave and grain tank unloading tube 4 3 way valves 9 8 14 Installing the concave grain tank unloading tube and straw chopper 4 3 way valves 9 8 11 Installing the cutterbar and threshing drum variab...

Page 1010: ...ser drive hydrostatic fixed displacement motor 9 4 9 Installing the right hand bearing assembly and shaft 3 3 5 Installing the right hand drum bearing 3 4 5 Installing the right hand impeller bearing...

Page 1011: ...rom serial no 7 4 22 Rear pulley of cutterbar drive 1 disassembled up to serial no 7 4 12 Rear rocker arm disassembled 4 1 5 Rear sieve pan drive deflection pulley disassembled 7 13 6 Reason of damage...

Page 1012: ...an adjustment electric Version 2 7 14 22 Removing the fan blade bearings 6 2 1 Removing the fan drive 7 17 5 Removing the fan drive 8 1 8 Removing the fan drive belt 21 7 3 5 Removing the fan drive be...

Page 1013: ...moving the right hand drum bearing assembly 3 4 1 Removing the right hand impeller bearing 3 5 1 Removing the right hand intermediate drive shaft bearing 7 8 1 Removing the right hand straw chopper be...

Page 1014: ...isassembled 9 5 16 Rotary screen 8 1 1 Rotary screen drive 7 17 1 Rotary screen drive disassembled 7 17 3 Rotary screen suction blower disassembled 8 1 11 Rotary screen disassembled 8 1 3 S Safety fea...

Page 1015: ...of axial mountings for the upper and lower sieves from serial no 4 2 4 Tightening torques of axial mountings for the upper and lower sieves up to serial no 4 2 9 Topping up refrigerant oil 2 1 5 Tran...

Page 1016: ...11 1 12 RHB LEXION 480 188 678 1 Index...

Page 1017: ...will not be implemented on these machines Technical data dimensions and weights are given as an indication only Responsibility for errors or omissions not accepted Reproduction or translation of this...

Page 1018: ...CLAAS KGaA mbH 33426 HARSEWINKEL Germany 188 678 1 RHB LEXION 480 GB 01 04 BEV Printed in Germany...

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Claas LEXION 480, Repair Manual

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