CLAAS LEXION 480 470 LEXION 460 – 405 Grain to Maize, Corn Cob Mix (CCM) Harvesting Equipment Maize

Conversion Instructions

Grain to Maize, Corn Cob Mix (CCM) Harvesting Equipment Maize, Corn Cob Mix (CCM) to Grain Harvesting Equipment

LEXION 480 / 470 LEXION 460 – 405

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1 Introduction

Introduction INTRODUCTION

These conversion instructions are for the CLAAS Lexion 480, Lexion 470 and the Lexion 460 – 405 range of combine harvesters.

The conversion instructions explain the correct method of machine side installation for – Grain to maize, corn cob mix (CCM) harvesting equipment And from: – Maize, corn cob mix (CCM) to grain harvesting equipment.

For the correct operation of the machine, then please refer to the relevant operators book.

The shipping package is shown on page 4.1.1 Each part has a number. The part specification e.g. for bolts is also stated in the “shipping package”. The list gives the dimensions and the quantity of the bolts as well as the parts belonging to it, like nuts and contact washers.

Text and pictures apply in general to all the machine types covered by this book and the information given applies equally, except where reference is made to a particular model in captions to the pictures or in the main text.

CLAAS Service department.

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

1.1.1

Introduction

1.1.2

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

2 Contents

Contents CONTENTS 1. Introduction Introduction ............................................................................ 1.1.1

2. Contents 3. General information General information ............................................................... 3.1.1 Important ......................................................................... 3.1.1 Identification of warning and danger signs ...................... 3.1.2 Correct use ...................................................................... 3.1.2 Torque settings ................................................................ 3.1.3 Bolts ................................................................................. 3.1.3 Hydraulic connections ..................................................... 3.1.4

4. Shipping package Shipping package .................................................................. 4.1.1 Conversion from cereals to maize, corn cob mix (CCM) harvesting ........................................................................ 4.1.1 Conversion from maize and corn cob mix (CCM) to cereals ......................................................................... 4.1.4

5. Fitting the maize harvesting equipment Safety ..................................................................................... 5.1.1 Additional weights ............................................................ 5.1.2 Trunking ................................................................................. 5.2.1 Adjustment of the support ................................................ 5.2.1 Locking the cutterbar ram springs ................................... 5.2.1 Hydraulic lock (optional extra) ................................................................. 5.2.1 Mechanical locking .......................................................... 5.2.1 Retracting the front attachment horns on the trunking .... 5.2.2 Drum housing ......................................................................... 5.3.1 Replacing the pre concave (small stone trap) ............................................................. 5.3.1 Replacing the pre concave (large stone trap) ............................................................. 5.3.2 Covering the stone trap (small stone trap) ............................................................. 5.3.3 Covering the stone trap (large stone trap) ............................................................. 5.3.3 Removing the threshing segments (small stone trap) ............................................................. 5.3.4 Removing the threshing segments (large stone trap) ............................................................. 5.3.6 Fitting the cover plates for the threshing drum (maize and corn cob mix CCM) ....................................... 5.3.7 Fitting the threshing cover bars to the threshing drum (corn cob mix CCM) ......................................................... 5.3.8 Adjusting the curtain behind the impeller LEXION 460 – 405 .......................................................... 5.3.9 Separation / cleaning / unloading ........................................... 5.4.1 Lateral risers LEXION 460 – 405 .......................................................... 5.4.1 CCM – Straw walker risers LEXION 460 – 405 .......................................................... 5.4.1 Multifinger separation system (Dependant on machine type) ......................................... 5.4.2

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

Changing the separation concaves LEXION 480 .................................................................... 5.4.3 Removing the separation concaves Lexion 480 (from machine serial number 466 00160) ....................... 5.4.4 Fitting the separation concaves LEXION 480 (from machine number 466 00160) ................................. 5.4.6 Removing the separation concaves Lexion 480 (to machine serial number 466 00159) ........................... 5.4.6 Fitting the separation concaves LEXION 480 (to machine number 466 00159) ..................................... 5.4.7 Unbolting the cover plates LEXION 480 .................................................................... 5.4.8 Changing the separation concaves and the plain concaves LEXION 470 .................................................................... 5.4.8 Removing the separation concaves and the plain concaves LEXION 470 .................................................................... 5.4.9 Fitting the separation concaves and the plain concaves LEXION 470 .................................................................. 5.4.12 Sieve selection .............................................................. 5.4.12 Fitting the riser plates (without the 3D cleaning system) .................................. 5.4.14 Operation without the lower sieve ................................. 5.4.14 Removing and fitting the sieves .................................... 5.4.16 Removing the preparation floor (chopper) LEXION 480 .................................................................. 5.4.16 Opening the chaff spreader LEXION 470 / 460 – 405 ............................................... 5.4.16 Removing the top sieves (to machine serial number ...) ....................................... 5.4.17 Removing the lower sieves (to machine serial number ….) ...................................... 5.4.18 Fitting in the sieves (to machine serial number ...) ....................................... 5.4.20 Torque settings for the axial clamping bolts for the top and lower sieves ........................................................... 5.4.20 Removing the top sieve (from machine serial number ...) ................................... 5.4.20 Removing the lower sieve (from machine serial number ...) ................................... 5.4.22 Fitting the sieves (from machine serial number ...) ................................... 5.4.23 Torque settings for the axial clamping bolts for the top and lower sieves ........................................................... 5.4.23 Sieve – basic adjustment (electric adjustment – to machine number ...) ............... 5.4.24 Sieve – basic adjustment (electrical sieve adjustment – from machine serial number ...) ................................. 5.4.25 Adjusting grain tank unloading / restrictor plates .......... 5.4.26 Straw chopper LEXION 460 – 405 ................................................................ 5.5.1 Straw guide plate ............................................................ 5.5.1

2.1.1

Contents Fitting the straw guide plate Lexion 410 / 405 (fixed chopper) type 452 ...................... 5.5.3 Fitting the straw guide plate Lexion 460 / 410 (fixed chopper) type 542, 543, 544 ...... 5.5.5 Fitting the straw guide plate Lexion 460 / 410 (hydraulically adjustable chopper) type 453, 454, 457, 543, 544, 547 ................................... 5.5.8 Adjusting the straw guide plate ........................................ 5.5.9 Straw chopper adjustment LEXION 460 – 405 ......................................................... 5.5.10 Retracting the stationary knives ..................................... 5.5.11 Adjusting the stationary knives ...................................... 5.5.12 Removing every blade from the stationary knife ............ 5.5.13 Removing every other blade from the stationary knife .. 5.5.13 Removing the blades from the chopper cylinder (cereals) (hydraulically adjustable chopper) ................................. 5.5.14 Removing the blades from the chopper cylinder (cereals) (fixed chopper) ............................................................... 5.5.14 Fitting the blades to the chopper cylinder (maize) ......... 5.5.15 Straw chopper LEXION 480 / 470 .................................................................. 5.6.1 Straw chopper adjustment LEXION 480 / 470 ............................................................ 5.6.1 Retracting the stationary knives ....................................... 5.6.2 Adjusting the stationary knives ........................................ 5.6.3 Removing every blade from the stationary knife .............. 5.6.4 Removing every other blade from the stationary knife .... 5.6.4 Removing the blades from the straw chopper cylinder (cereals) LEXION 480 ..................................................................... 5.6.5 Removing the blades from the straw chopper cylinder (cereals) LEXION 470 ..................................................................... 5.6.5 Fitting the blades to the chopper cylinder (maize) ........... 5.6.6 Chopper preparation pan (performance) ......................... 5.6.7 Chopper preparation pan – cereals ................................. 5.6.7 Chopper preparation pan – maize with rubber mat ......... 5.6.8 Drives ..................................................................................... 5.7.1 Threshing drum speed adjustment .................................. 5.7.1 Two step drive (optional) .......................................................................... 5.7.1 Adjusting the speeds of the separation rotors LEXION 480 / 470 ............................................................ 5.7.2 Stepped drive (optional) .......................................................................... 5.7.2 Rotor speed schematic LEXION 480 ............................... 5.7.3 Rotor speed schematic LEXION 470 ............................... 5.7.3 Rotor speed regulator (option) ............................................................................. 5.7.3 Chopper speed reduction LEXION 410 / 405 (fixed chopper) type 452 LEXION 430 – 410 (fixed chopper) type 543 ................... 5.7.4 Chopper speed reduction LEXION 460 – 415 (adjustable chopper) type 454 LEXION 430 – 410 (adjustable chopper) type 543, 542 .. 5.7.6 Chopper speed reduction LEXION 460 / 450 (fixed chopper) type 547 LEXION 470 (fixed chopper) type 545, 541 LEXION 480 (fixed chopper) type 466, 546, 548 ............. 5.7.9

2.1.2

Chopper speed reduction LEXION 480 (Uni spreader) .......................................... 5.7.12 Adjustment ............................................................................. 5.8.1 Note ................................................................................. 5.8.1

6. Fitting the grain harvesting equipment Safety .................................................................................... 6.1.1 Additional weights ........................................................... 6.1.2 Trunking ................................................................................. 6.2.1 Adjustment of the support ............................................... 6.2.1 Locking the cutterbar ram springs ................................... 6.2.1 Extending the front attachment horns on the trunking ..... 6.2.1 Threshing drum housing ........................................................ 6.3.1 Changing the pre concave segments (small stone trap) ............................................................. 6.3.1 Changing the pre concave segments (large stone trap) ............................................................. 6.3.1 Removing the cover plate for the stone trap (small stone trap) ............................................................. 6.3.1 Removing the cover plate for the stone trap (large stone trap) ............................................................. 6.3.1 Fitting the threshing segments (small stone trap) ............................................................. 6.3.2 Fitting the threshing segments (large stone trap) ............................................................. 6.3.3 Removing the cover bars ................................................ 6.3.4 Adjusting the curtain behind the impeller LEXION 460 – 405 .......................................................... 6.3.5 Separation / cleaning / unloading .......................................... 6.4.1 Lateral risers LEXION 460 – 405 .......................................................... 6.4.1 CCM – Straw walker risers LEXION 460 – 405 .......................................................... 6.4.1 Changing the separation concaves LEXION 480 .................................................................... 6.4.1 Removing separation concaves (from machine serial number 466 00160) ....................... 6.4.2 Fitting separation concaves (from machine serial number 466 00160) ....................... 6.4.2 Removing separation concaves (to machine serial number 466 00159) ............................ 6.4.2 Fitting separation concaves (to machine serial number 466 00159) ............................ 6.4.2 Changing the separation concaves and the plain concaves LEXION 470 .................................................................... 6.4.2 Fitting the cover plates LEXION 480 .................................................................... 6.4.3 Frog mouth sieves ........................................................... 6.4.4 Operating with lower sieve .............................................. 6.4.4 Grain tank unloading / restrictor plates ............................ 6.4.4 Straw chopper LEXION 460 – 405 ................................................................ 6.5.1 Removing the straw plate or raising it LEXION 410 / 405 (fixed chopper) type 452 ................... 6.5.1 Removing the straw plate LEXION 460 – 410 (fixed chopper) type 542, 543, 544 .. 6.5.3

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Contents Refitting the straw guide plate for cereal harvesting LEXION 460 – 415 .......................................................... 6.5.5 Adjusting the straw chopper LEXION 460 – 405 .......................................................... 6.5.6 Removing the straw chopper knives (maize) (hydraulically adjustable straw chopper) .......................... 6.5.7 Removing the straw chopper knives (maize) (fixed straw chopper) ....................................................... 6.5.7 Fitting the cereals blades to the chopper cylinder ........... 6.5.8 Removing the guard ........................................................ 6.5.9 Adjusting the stationary blades ........................................ 6.5.9 Adjusting the stationary blades ........................................ 6.5.9 Fitting all the blades into the stationary knife ................. 6.5.10 Straw chopper LEXION 480 / 470 .................................................................. 6.6.1 Adjusting the straw chopper ............................................ 6.6.1 Removing the maize knives from the stationary knife LEXION 480 .................................................................... 6.6.1 Removing the straw chopper knives (maize) LEXION 470 .................................................................... 6.6.2 Fitting the cereals blades to the chopper cylinder ........... 6.6.3 Remove the rubber curtain LEXION 480 .................................................................... 6.6.3 Adjusting the stationary blades ........................................ 6.6.4 Adjusting the stationary blades ........................................ 6.6.4 Fitting all the blades into the stationary knife ................... 6.6.5 Chopper preparation pan (optional) LEXION 480 .................................................................... 6.6.5 Drives ..................................................................................... 6.7.1 Threshing drum speed adjustment .................................. 6.7.1 Two step drive (optional) .......................................................................... 6.7.1 Adjusting the speeds of the separation rotors LEXION 480 / 470 ........................................................... 6.7.1 Increasing the chopper speed LEXION 410 / 405 (fixed chopper) type 452 LEXION 430 – 410 (fixed chopper) type 543 ................... 6.7.1 Increasing the chopper speed LEXION 460 – 415 (adjustable chopper) type 454 LEXION 430 – 410 (adjustable chopper) type 543, 542 .. 6.7.2 Reducing the chopper drum speed LEXION 460 / 450 (fixed chopper) type 547 LEXION 470 (fixed chopper) type 545, 541 LEXION 480 (fixed chopper) type 546, 548 ..................... 6.7.2 Increasing the chopper speed (LEXION 480 – uni spreader) .......................................... 6.7.3 Adjustment ............................................................................. 6.8.1 Note ................................................................................. 6.8.1

7. Index Index ...................................................................................... 7.1.1

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

2.1.3

Contents

2.1.4

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

3 General information

General information GENERAL INFORMATION

IMPORTANT The instructions contained in this manual should be carefully read and observed by all persons who are concerned with the operation, maintenance and inspection of this machine/ front attachment in order to prevent accidents.

Especially the »Safety Rules« in the operator's manual should be read with the utmost care and adhered to. In addition, please also observe the accident prevention regulations that apply for your own country.

Before commencing with the job, ensure that all the tools and service aids are available.

Compare existing machine type/front attachment type with the list in the chapter »Shipping Package« and the parts kit supplied.

The specification of the components, e.g. bolts, is shown on the shipping package. The shipping package shows the position number (pos. no.) of the components. Parts such as nuts and contact washers do not have a position number but belong to the bolt listed above which does have a position number.

In order to help with the assembly, existing components in the instructions are identified with letters, whereas new parts have been identified with a number (position number).

Texts and pictures apply, in general, to all machine types covered by this book and the information given applies equally, except where reference is made to a particular model in captions to the pictures or in the main text.

Technical data, dimensions and weights are given as an indication only. CLAAS reserve the right to make changes subsequently as technical developments continue.

Responsibility for errors or omissions not accepted.

Front, rear, right and left refer to the direction of forward travel.

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

3.1.1

General information Identification of warning and danger signs

Correct use

All parts of this manual having to do with your safety or the safe operation of the machine are marked with the following signs. Please pass all safety instructions on to other users, too.

Fitting and retrofitting of ancillary equipment which is not originally manufactured by CLAAS, and, in addition, also modifications and changes may only be carried out with the consent of CLAAS, as any such actions may have considerable adverse effects on the safety and operational function of the machine.

Danger!

Sign to indicate instructions which must be observed. Failure to do so would cause danger to life and limb to the operator and the people around him.

Any arbitrary modifications carried out will relieve the manufacturer of all liability for any resulting damage or injury.

☞ Preventive measures

Caution!

Sign to indicate instructions which must be observed. Failure to do so could result in damage to the machine.

☞ Measures to prevent damage to the machine

Note!

Sign to indicate instructions for a more efficient and economic use of the machine.

Important!

Sign to indicate instructions to be followed during disassembly / assembly.

Environment!

Sign to indicate instructions which must be observed in order to avoid damage to the environment.

Danger to the environment is caused by irregular handling and incorrect disposal of toxic material (e.g. used oil).

The warning and instruction signs placed on the round baler provide recommendations for safe operation. These instructions involve your safety – observe them at all times!

3.1.2

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

General information Torque settings Bolts Torque settings (in Nm) from hex bolts, soc cap screws and hex nuts Bolts and nuts

Blackened, phosphated, or galvanized

Property class

8.8

Size

Hex bolts DIN 931 DIN 933

Soc cap screws DIN 912

Hex nuts DIN 934

Hex Nut DIN 934

12.9

Standard metric thread

M4

2.7

3.8

4.6

M5

5.5

8.0

9.5

M6

10.0

14.0

16.0

M8

23.0

33.0

40.0

M 10

45.0

63.0

75.0

M 12

78.0

110.0

130.0

M 14

122.0

175.0

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

Size

Hex bolts DIN 960 DIN 961

10.9

Metric fine pitch thread

M8x1

25

35

42

M 10 x 1.25

48

67

80

M 12 x 1.25

88

125

150

M 12 x 1.5

82

113

140

M 14 x 1.5

135

190

225

M 16 x 1.5

210

290

345

M 18 x 1.5

300

415

505

M 20 x 1.5

415

585

700

M 22 x 1.5

560

785

945

M 24 x 2

720

1000

1200

M 27 x 2

1050

1500

1800

M 30 x 2

1450

2050

2500

ATTENTION! Cadmium plated or copper plated screws and nuts are to be tightened with torque that is 25% under the stated.

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

3.1.3

General information Hydraulic connections Torque settings for hydraulic threading seal ring according to ISO 6149

3.1.4

Size

Torque setting according to ISO 6149

M8x1

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 x 1.5

103+34 Nm

M 27 x 2

103+34 Nm

M 30 x 2

170+57 Nm

M 33 x 2

200+67 Nm

M 36 x 2

245+82 Nm

M 38 x 2

245+82 Nm

M 39 x 2

310+103 Nm

M 42 x 2

380+127 Nm

M 45 x 2

440+147 Nm

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

4 Shipping package

Shipping package SHIPPING PACKAGE Conversion from cereals to maize, corn cob mix (CCM) harvesting Pos 1

2 3 4 5

6

7

8

9

10

11

12

13

14

Description

Quantity

Pre concave (small stone trap) 19 x 42 Holes, maize ............................................................................................................................. 3 Pre concave (large stone trap) 19 x 40 Holes, maize ............................................................................................................................. 3 Guide plate ............................................................................................................................................. 1 Hex bolt M 10 x 20 DIN 933 ................................................................................................................... 6 Contact washer B 10 .............................................................................................................................. 6 Concave extension ................................................................................................................................ 1 Cover plate Maize ..................................................................................................................................................... 8 Corn cob mix (CCM) Up to a certain percentage of cob matter ............................................................................................... 8 Corn cob mix (CCM) From a certain percentage of cob matter................................................................................................ 4 Hex bolt M 12 x 20 8.8 DIN 933 (to machine serial number ...)

Hex bolt M 12 x 25 10.9 DIN 933 (from machine serial number ...)

Contact washer A 12 Hex nut M 12 LEXION 430 – 405................................................................................................................................ 48 LEXION 460 – 440................................................................................................................................ 56 LEXION 470.......................................................................................................................................... 48 LEXION 480.......................................................................................................................................... 56 Cover threshing bar Corn cob mix (CCM) From a certain percentage of cob matter ............................................................................................... 4 CCM risers LEXION 430 – 405................................................................................................................................ 10 LEXION 460 – 440................................................................................................................................ 12 Mushroom headed bolts M 6 x 12 Contact washers B 6 Hex nuts M 6 LEXION 430 – 405................................................................................................................................ 50 LEXION 460 – 440................................................................................................................................ 60 Cover plate LEXION 430 – 405................................................................................................................................ 10 LEXION 460 – 440................................................................................................................................ 12 Clamping bracket Contact washer B 6 Hex nut M 6 LEXION 430 – 405 ............................................................................................................................... 20 LEXION 460 – 440 ............................................................................................................................... 24 Clamping brace LEXION 430 – 405 ............................................................................................................................... 20 LEXION 460 – 440 ............................................................................................................................... 24 Separation concave Maize (20 x 40 holes) ........................................................................................................................... 10 Corn cob mix (20 x 40 holes) ................................................................................................................. 6 Separation concave ............................................................................................................................... 8 Corn cob mix (40 x 40 holes) ................................................................................................................. 4

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

4.1.1

Shipping package Pos 15

16 17

18 19

20 21

22

23

24 25

26

27

28

29

4.1.2

Description

Quantity

Sieve selection Frog mouth sieve – cereals ................................................................................................................... 2 Frog mouth sieve – long fingered .......................................................................................................... 2 Frog mouth sieve – maize, deep toothed .............................................................................................. 2 Plain sieve Ø 16 mm round .................................................................................................................... 2 Plain sieve Ø 18 mm round .................................................................................................................... 2 Plain sieve Ø 18 mm round pressed ...................................................................................................... 2 Plain sieve Ø 20 mm round pressed ...................................................................................................... 2 Graepel sieve (CCM).............................................................................................................................. 2 Step plate (without 3D sieves)................................................................................................................................. 4 Mushroom headed bolt M 8 x 25 ........................................................................................................ 20 Washer 8.4 x 23 x 3 ............................................................................................................................. 20 Contact washer B 8 ............................................................................................................................. 20 Hex nut VM 8 ...................................................................................................................................... 20 Straw plate – assembled LEXION 410 / 405 (fixed chopper) type 452 .......................................................................................... 1 Hex bolt M 8 x 20 ................................................................................................................................ 10 Hex nut M 8 ......................................................................................................................................... 10 Contact washer A 8 ............................................................................................................................. 10 Straw plate – assembled LEXION 460 – 410 (fixed chopper) type 542, 543, 544 ........................................................................ 1 Hex bolt M 8 x 20 ................................................................................................................................ 10 Hex nut M 8 ......................................................................................................................................... 10 Contact washer A 8 ............................................................................................................................. 10 Straw plate - assembled LEXION 460 – 410 (Hydraulically adjustable chopper) Type 453, 454, 457, 543, 544, 547 ........................................................................................................ 1 Hex bolt M 8 x 20 .................................................................................................................................. 6 Hex nut M 8 ........................................................................................................................................... 6 Contact washer A 8 ............................................................................................................................... 6 Stop ....................................................................................................................................................... 2 Hex bolt M 8 x 16 .................................................................................................................................. 4 Hex nut M 8 ........................................................................................................................................... 4 Contact washer A 8 ............................................................................................................................... 4 Hammer knives (maize) LEXION 430 – 405 ....................................................................................................................... 26 (36) LEXION 460 – 440 ....................................................................................................................... 32 (44) LEXION 470 ................................................................................................................................. 26 (36) LEXION 480 ........................................................................................................................................ 44 Hex bolt M 10 x 50-10.9 LEXION 430 – 405 ....................................................................................................................... 26 (36) LEXION 460 – 440 ....................................................................................................................... 32 (44) LEXION 470 ................................................................................................................................. 26 (36) LEXION 480 ........................................................................................................................................ 44 Bush D 30 x 14.25 LEXION 430 – 405 ....................................................................................................................... 52 (72) LEXION 460 – 440 ....................................................................................................................... 64 (88) LEXION 470 ................................................................................................................................. 52 (72) LEXION 480 ........................................................................................................................................ 88 Bush D 48 x 10 x 8.5 LEXION 430 – 405 ....................................................................................................................... 26 (36) LEXION 460 – 440 ....................................................................................................................... 32 (44) LEXION 470 ................................................................................................................................. 26 (36) LEXION 480 ........................................................................................................................................ 44

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Shipping package Pos 30

31

32 33

34

Description

Quantity

Hex nut VM10-10.9 a3c LEXION 430 – 405 ....................................................................................................................... 26 (36) LEXION 460 – 440 ....................................................................................................................... 32 (44) LEXION 470 ................................................................................................................................. 26 (36) LEXION 480 ......................................................................................................................................... 44 Guard LEXION 430 – 405 ................................................................................................................................. 1 LEXION 460 – 440 ................................................................................................................................. 1 LEXION 470 ........................................................................................................................................... 1 LEXION 480 (fixed chopper) (rice) ......................................................................................................... 1 Rubber sheet LEXION 480 (Uni spreader).................................................................................................................... 1 Mushroom headed bolts M 8 x 25 ......................................................................................................... 4 Lock nut VM 8 ........................................................................................................................................ 4 Contact washer A 8 ............................................................................................................................... 4 LEXION 480 Preparation floor with rubber mat LEXION 480 ........................................................................................................................................... 1

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

4.1.3

Shipping package Conversion from maize and corn cob mix (CCM) to cereals Pos 51

52

53 54 55 56

57 58

59

60

61

62

4.1.4

Description

Quantity

Pre concave (small stone trap) 6,5 x 42 holes – cereals ......................................................................................................................... 3 12 x 40 holes – cereals .......................................................................................................................... 3 Pre concave (large stone trap) 6,5 x 40 holes – cereals ......................................................................................................................... 3 12 x 40 holes – cereals .......................................................................................................................... 3 Threshing segment LEXION 430 – 405 ................................................................................................................................ 2 LEXION 470 .......................................................................................................................................... 2 LEXION 440 – 460 ................................................................................................................................ 3 LEXION 480 .......................................................................................................................................... 3 Hex bolt M 10 x 25 ................................................................................................................................. 6 Contact washer A 10.............................................................................................................................. 6 Separation concave Cereals (40 x 20 holes) ........................................................................................................................ 10 Cover plate ............................................................................................................................................ 6 Hex bolt M 8 x 20 ................................................................................................................................. 12 Hex nut M 8.......................................................................................................................................... 12 Contact washer A 8.............................................................................................................................. 12 Washer 8,5 x 30 x 2 ............................................................................................................................. 12 Hammer knives (cereals) LEXION 430 – 405 ....................................................................................................................... 52 (72) LEXION 460 – 440 ....................................................................................................................... 64 (88) LEXION 470 ................................................................................................................................. 52 (72) LEXION 480 ........................................................................................................................................ 88 Hex bolt M 10 x 55-10.9 LEXION 430 – 405 ....................................................................................................................... 26 (36) LEXION 460 – 440 ....................................................................................................................... 32 (44) Hex bolt M 12 x 65-10.9 LEXION 470 ................................................................................................................................. 26 (36) LEXION 480 ........................................................................................................................................ 44 Bush D 30 x 14,25 LEXION 430 – 405 (available) ...................................................................................................... 52 (72) LEXION 460 – 440 (available) ...................................................................................................... 64 (88) Bush D 35 x 16 LEXION 470 (available) ................................................................................................................ 52 (72) LEXION 480 (available) ....................................................................................................................... 88 Washer D 30 x 10 x 5 LEXION 430 – 405 ....................................................................................................................... 52 (72) LEXION 460 – 440 ....................................................................................................................... 64 (88) Washer D 35 x 7,5 LEXION 470 ................................................................................................................................. 52 (72) LEXION 480......................................................................................................................................... 88 Hex nut VM 10-10.9 a3c LEXION 430 – 405 ....................................................................................................................... 26 (36) LEXION 460 – 440 ....................................................................................................................... 32 (44) Hex nut VM 12-10.9 LEXION 470 ................................................................................................................................. 26 (36) LEXION 480 ........................................................................................................................................ 44

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

5 Fitting the maize harvesting equipment

Fitting the maize harvesting equipment SAFETY Danger!

For all work on the machine, ensure that the engine has been stopped, the ignition key has been removed and the machine is prevented against rolling (parking brakes and wheel chocks).

For all work carried out on the straw chopper, ensure that the threshing has been switched off, the engine is not running and the ignition keys have been removed.

When switching off the machine, remember that the knife cylinder continues to rotate for a short while!

Caution – danger of injury!

☞ When carrying out any work on the straw chopper knives, always wear gloves!

☞ Stop the knife cylinder from rotating by locking it.

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

5.1.1

Fitting the maize harvesting equipment Additional weights Machines that have been fitted with a front attachment (e.g. maize picker head, folding cutterbar) need to have additional weights fitted when travelling on open roads or tracks. This is necessary to prevent the rear of the machine from lifting during braking or travelling down slopes.

The following weights can be fitted as follows: LEXION: • Fitted components to the back of the machine (e.g. straw chopper) • Filling the rear steering wheels with water • Additional weight on the steering axle The weight on the rear steering axle should be 20% of the machine’s weight including the fitted maize header.

For the required loading, please study the operator’s manual for the machine.

See, prior to operation, additional weights.

When the additional weight is no longer required for the front attachment, then it should be removed, otherwise excessive wear will result.

5.1.2

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Fitting the maize harvesting equipment TRUNKING Adjustment of the support The support adjustment on the left and right hand side of the trunking needs to be adjusted into the lower setting. The dowel should be in hole (A) when harvesting cereals and in hole (B) when harvesting maize.

S A

In order to adjust, slacken off the bolt (S). Once adjusted, ensure that the bolt (S) has been tightened again.

B

(Fig. 1) 1

Locking the cutterbar ram springs The cutterbar ram springs need to be locked when a maize header is going to be fitted to the machine.

Hydraulic lock (optional extra)

W

By operating the rocker switch (W) the hydraulic ram (H) will lock the cutterbar springserd.

2

When a cereals cutterbar is mounted on the machine, then the cutterbar springs can be locked, which will enable the cutterbar to be raised higher. For example for lifting the cutterbar over obstacles.

In order to unlock the cutterbar springs, then the rocker switch (W) can be switched back.

(Fig. 2, 3)

H 3 Mechanical locking Lower the maize header fully on the ground, so that the pressure has been released from the springs.

Insert the locking brace (K) on the guide bolts of the cutterbar springs. Secure the brace by inserting the clip. Secure the clamp axially by tightening up the nuts (M).

K M

In order to remove the locking brace, lower the front attachment fully so that the cutterbar springs are fully relaxed.

4

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

(Fig. 4)

5.2.1

Fitting the maize harvesting equipment Retracting the front attachment horns on the trunking Before fitting the maize header to the machine, both of the horns on the trunking need to be fully retracted.

The retraction of the trunking horns should be carried out with the cutterbar still attached.

Should this not be possible then it is possible to do the same thing by preventing one of the horns from extending.

The procedure is as follows: 1. Start the engine and switch on the safety switch (S).

S

2. Open the hydraulic tap (R). For this move the lever (H) into the (A) position.

W

Press the rocker switch (W) to the left so that the left hand horn fully retracts.

3. Close the hydraulic tap (R) so that the lever (H) is in the (Z) position.

5

Press the rocker switch (W) to the right. The right hand horn now retracts and the left hand horn extends.

4. Open the hydraulic tap (R) again, by moving the lever (H) to the (A) position.

Operate the rocker switch to the left, lock down the right hand horn (if no front attachment is available) until the left hand horn in fully retracted.

R

5. Close the hydraulic tap (R) by moving the lever (H) to the (Z) position.

H Z

A

(Fig. 5, 6)

6

5.2.2

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Fitting the maize harvesting equipment DRUM HOUSING Replacing the pre concave (small stone trap) Open up the drum door. Remove the fixing bolts (B) from the segments 51 Important!

For machines where the trunking is still fitted, then remove the middle segment first.

1

Slide the outer segments slightly towards the middle, then remove.

Clean down the guides for the concave.

Insert the segments and bolt up.

When putting the machine into maize harvesting, then the maize segment (1) must be fitted.

B

When putting the machine into cereals harvesting, then the cereals segment (51) must be fitted.

(Fig. 1, 2)

2

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

5.3.1

Fitting the maize harvesting equipment Replacing the pre concave (large stone trap) 3

3

3

Lower the concave to the lowest position.

Raise the trunking to its highest position.

W

W

W

Danger!

Stop the engine and switch off the battery isolator switch.

S 3

Open up the stone trap door.

The stone trap (S) can be opened. For this unscrew the taper turn lock and open up the stone trap (S).

Unbolt the hex nut (3) and remove the bracket (W).

Important!

Remove the central segment first, then slide the outer segments towards the middle slightly before removing.

1

Clean the guides in the concave.

4

Insert the segments and secure. Please note that there is a difference between the securing of the segments between the maize and the cereals segments.

For putting the machine into maize harvesting, then the maize segments (1) need to be fitted. By bolting on the concave extension (4) they will be secured – see page 5.3.3, Covering the stone trap (large stone trap).

For putting the machine into cereals harvesting, then the cereals segments (51) need to be fitted. By bolting on the angle (W) they will be secured.

(Fig. 3, 4, 5)

5

5.3.2

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Fitting the maize harvesting equipment Covering the stone trap (small stone trap) For technical reasons of photographing the drive wheels and the trunking has been removed.

F

Maize harvesting: Remove the mushroom headed bolts (F) from both sides of the machine.

6

Lay the guide plate (2) onto the stone trap, then release the bar from both sides in the holes on the said wall. The guide plate (2) lies with the rear edge on the maize segment.

Cereals conversion: After the removal of the guide plate (2), screw in the mushroom headed bolts (F).

(Fig. 2, 6, 7)

2

7

Covering the stone trap (large stone trap) Maize threshing: Remove the mushroom headed bolts (F on Fig. 6) from both sides.

The pre concaves for maize must be inserted – see page 5.3.2, Replacing the pre concave (large stone trap).

4

8

R

The concave extension (4) needs to be bolted to the angle (W) using the hex bolt (3). This is the way the pre concave is secured.

Lay the guide plate (2) onto the concave extension (4), and lock into place by locating the bar (R) into the holes on the side wall on both sides. The guide plate (2) lies with the back edge on the concave extension (4).

R

Cereals threshing: After the guide plate (2) has been removed, screw in the mushroom headed bolts (F).

Remove the concave extension (4).

Fit the pre concave segment (51) – see page 5.3.2, Replacing the pre concave (large stone trap).

9

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

(Fig. 5, 8, 9, 11)

5.3.3

Fitting the maize harvesting equipment

10

Removing the threshing segments (small stone trap) – Lower the concave to its lowest position.

– Drop the trunking fully.

Danger!

Stop the engine and switch off the battery isolator switch!

– Remove the hex bolt (53) from the threshing segment fixing. The hex bolts (53) are accessible from the underside of the accelerator.

– The three piece (two piece) threshing segment (52) may be removed through either the open drum door or if necessary through the inspection hole on the left hand side of the machine.

E = detail

5.3.4

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Fitting the maize harvesting equipment

Important!

The hex bolts (53) for the threshing segments, must be replaced as soon as the segments have been removed otherwise the threads will become blocked or damaged.

(Fig. 10)

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

5.3.5

Fitting the maize harvesting equipment

11

Removing the threshing segments (large stone trap) Lower the concave to its lowest position. Completely raise the trunking.

53

Danger!

Stop the engine, and switch off the battery isolator switch!

12

Open the stone trap door.

Unbolt the hex bolts (53) from the threshing segments fixing. The hex bolts (53) are accessible from under the accelerator.

The threshing segments (52) can be removed via the open stone trap door.

52

13

5.3.6

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Fitting the maize harvesting equipment

Important!

The hex bolts (53) for the threshing segments, must be replaced as soon as the segments have been removed otherwise the threads will become blocked or damaged.

(Fig. 11, 12, 13)

Fitting the cover plates for the threshing drum (maize and corn cob mix CCM) The threshing drum must be fitted with eight cover plates (5) for harvesting maize.

The cover plates (5) can be used not just for maize heads but also for corn cob mix (CCM).

Caution!

The plates have been balanced and should always be used as a set (8 off). Otherwise the drum will be out of balance!

Fit the cover plates (5) to the drum. When fitting the cover plates, take note of the rotational direction of the drum.

Clean the threshing drum, in particular the areas that come into contact with the cover plates.

Place the cover plates (5) onto the threshing drum as in fig 14, ensuring that the lip is inserted under the threshing bars. Bolt the cover plates (5) onto the threshing drum using the hex bolts (6).

53081

Tighten up the hex bolts (6) Observe the tightening torque.

14

Torque setting: M 12 x 20 8.8 DIN 933 = 86 Nm M 12 x 25 10.9 DIN 933 = 115 Nm Should the machine be used in cereals, then the cover plates (3) may remain off the threshing drum.

(Fig. 14)

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

5.3.7

Fitting the maize harvesting equipment Fitting the threshing cover bars to the threshing drum (corn cob mix CCM) For harvesting corn cob mix (CCM) the threshing drum can be fitted with four cover threshing bars (7) and four cover plates (5).

Caution!

The cover plates and bars are all balanced and should always be used as a set (4 of each) otherwise the threshing drum will be out of balance!

Fit the cover pates (5) and the cover bars (7) to the threshing drum, observing the direction of rotation of the drum.

Clean the threshing drum, in particular the areas that come into contact with the cover plates (5) and the cover threshing bars (7).

Place the cover plates (5) onto the threshing drum as in fig 15, ensuring that the lip is inserted under the threshing bars. Bolt the cover plates (5) onto the threshing drum using the hex bolts (6).

53082

15

To fit the cover threshing bars (7), unscrew the hex bolt (S) from the threshing bar (L). Bolt the cover threshing bar (7) onto the exciting threshing bars using the available bolts.

Tighten the hex bolts (S), to the correct torque.

Torque settings: M 12 x 30 8.8 DIN 933 = 86 Nm M 12 x 30 10.9 DIN 933 = 115 Nm Bolt the cover plates (5) onto the threshing drum using the hex bolts (6).

Tighten up the hex bolts (6) Observe the tightening torque.

Torque setting: M 12 x 20 8.8 DIN 933 = 86 Nm M 12 x 25 10.9 DIN 933 =115 Nm When wishing to harvest cereals, then the four cover threshing bars (7) need to be replaced with four cover plates (5). If necessary all plates can be removed.

When in cereals then the cover plates (5) may remain in place.

(Fig. 15)

5.3.8

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Fitting the maize harvesting equipment Intensive separation system

Adjusting the curtain behind the impeller LEXION 460 – 405 Move the curtain (S) to its highest position, from the left hand side of the machine using the chain (C).

S

For harvesting maize, lock the chain (D) so that it is unable to move back.

For this the chain (D) needs to be located in the hook (A).

(Fig. 16, 17, 18) 16 Multifinger separation system

S

17

C A

D

18

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

5.3.9

Fitting the maize harvesting equipment

5.3.10

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Fitting the maize harvesting equipment

X Y 2

1

3

4

G

X

Y 9

8 11

53083

Z

10 12

3

2

4 1

SEPARATION / CLEANING / UNLOADING Lateral risers LEXION 460 – 405 For harvesting maize the lateral risers (A) have to be removed.

CCM – Straw walker risers LEXION 460 – 405 For harvesting corn cob mix (CCM) the CCM straw walker risers (8) need to be used.

2

The straw walkers, can be cut under the risers in the area of the 2nd and 3rd step. For this the first four row of holes have the bridges cut according to the details shown on (Z).

The CCM straw walker risers (8) need to be fitted as per (X) using the mushroom headed bolts (9).

For harvesting cereals, the CCM straw walker risers (8) need to be removed.

The cut straw walkers, cover with the cover plates (8).

Fit the cover plates (10) as per (Y) using the clamping bracket (11) and the clamping brace (12).

G = direction of travel 1 – 4 = straw walker steps

3

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

(Fig. 1, 2, 3)

5.4.1

Fitting the maize harvesting equipment

4

Multifinger separation system (Dependant on machine type) The multifinger (M) intensive separation system, is designed to increase the separation of the remains grains from the straw whilst on the straw walkers.

The adjustment of the multifingers is carried out using the lever (H) and can be set to match the crop settings.

The basic adjustment of the lever (H) is in position 2.

When harvesting maize, the lever (H) needs to be in the basic position (position 2).

5

In order to adjust the multifinger (M), unbolt the hex bolt (S).

T

H

S 6

5.4.2

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Fitting the maize harvesting equipment

Caution!

Before removing the hex bolt (S) from the lever (H), place a 19 mm spanner onto the hex bolt (T) and hold the load.

After adjustment, refit the hex bolt (S) and tighten.

(Fig. 4, 5, 6)

Changing the separation concaves

40 x 20 holes – standard

LEXION 480 For maize: The ten separation concaves for cereals (54, 40 x 20 holes) must be replaced with the ten maize separation concaves (13, 20 x 40 holes).

For corn cob mix (CCM): The ten separation concaves for cereals (54, 40 x 20 holes) must be replaced with six maize separation concaves (13, 20 x 40 holes) and for corn cob mix / CCM concaves (14, 40 x 40).

7 20 x 40 holes – maize

The four corn cob mix / CCM concaves (14, 40 x 40 holes) are to be fitted as the last ones under the separation cylinder.

(Fig. 7, 8, 9)

8 40 x 40 holes – CCM

9

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

5.4.3

Fitting the maize harvesting equipment Removing the separation concaves Lexion 480 (from machine serial number 466 00160) Danger!

Stop the engine, and switch off the battery isolator switch!

Open the cover in the engine compartment.

Climb into the separation chamber through the opening.

(Fig. 10)

10 Remove the middle guide plates (F).

(Fig. 11)

F

11 Slacken off the three lock nuts (M12) from the rear separation concave.

Remove the set screw, whilst holding the separation concave.

(Fig. 12)

12

5.4.4

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Fitting the maize harvesting equipment Drop the separation concave in the middle, then unhook from the outer guide rails and place on the returns pan.

(Fig. 13)

13 Slide all the separation concaves towards the back of the machine one by one, and remove.

(Fig. 14)

14 In order to ease the removal of the separation concaves, place them upside own on the returns pan.

(Fig. 15)

15 The separation concaves can be removed from the back of the machine.

(Fig. 16)

16

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

5.4.5

Fitting the maize harvesting equipment Fitting the separation concaves LEXION 480 (from machine number 466 00160) The fitting of the separation concaves is done in the reverse order as removal.

When fitting the separation concaves, ensure that the bolts are screwed in from the front.

Tighten all the bolts.

Close the cover in the engine compartment.

(Fig. 10 – 16)

Removing the separation concaves Lexion 480 (to machine serial number 466 00159) L

In order to remove the separation concaves, firstly raise the straw discharge hood.

S

S

S

Undo the bolts (S) and remove the straw plate (L).

(Fig. 17)

17 Remove the bolts (B) and remove the flap (K).

(Fig. 18)

B

B K

18 Remove the hex bolts (C), and then remove the cover plate (A).

(Fig. 19) C

A 19

5.4.6

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Fitting the maize harvesting equipment On both sides, remove the hex bolts (D) and remove the discharge housing.

(Fig. 20)

D

D 20 Remove the concaves from guides via the rear of the machine.

(Fig. 21)

21

Fitting the separation concaves LEXION 480 (to machine number 466 00159) When fitting the separation concaves, ensure that the bolts are screwed in from the front.

– Bolt back the discharge housing.

– Bolt back the cover plate (A).

– Move the flap (K) towards the front, and bolt into position.

22

– Insert the straw plate (L) and bolt into position.

– Close the discharge chute.

(Fig. 17 – 22)

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

5.4.7

Fitting the maize harvesting equipment

23

Unbolting the cover plates LEXION 480 The cover plates (55) for the rotors need to be bolted into position (X) when harvesting maize or corn cob mix (CCM).

(Fig. 23)

Changing the separation concaves and the plain concaves LEXION 470 As standard the Lexion 470 is fitted with two plain concaves and two separation concaves on each rotornteerd.

F

With this configuration of the concaves, the machine can be used to harvest cereals, maize and corn cob mix (CCM).

X 24

5.4.8

Should the machine be put into difficult conditions, where a higher separation rate is required, then the plain concave (2) and be exchanged for an additional separation concave.

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Fitting the maize harvesting equipment Removing the separation concaves and the plain concaves: Note!

The plain concaves must always be fitted at the front of the machine!

1, 2 = plain concaves 3, 4, 5 = separation concaves X = larger hole dimension for the middle of the machine F = Direction of travel (Fig. 24)

Removing the separation concaves and the plain concaves LEXION 470 Danger!

Stop the engine, and switch off the battery isolator switch!

In order to gain better access, hinge open the chaff spreader (when fitted).

(Fig. 25)

25 Drop the returns pan down at the back.

For this slacken the bolts (R) on the sieve box rocker arm from both sides.

(Fig. 26) R

26

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

5.4.9

Fitting the maize harvesting equipment Remove the lamp (L) from the bracket, and if necessary hang out the way.

Unbolt the lower part of the rear rocker arm (S) from the side of the machine.

S

L

Drop the returns pan down at the back.

Position the rocker arm (S) in the second set of holes (see arrows), then bolt into position using the available bolts.

The returns pan can now be used as an assembly platform.

27

(Fig. 27, 28)

S

28 For better access the sealing rubber (G) can be unscrewed.

Danger!

Take particular care when removing the concaves – danger from dust!

G

☞ Wear protective glasses!

(Fig. 29) 29 Unbolt the bracket (D) for the grain loss sensor from the separation rotor, and hang out of the way.

(Fig. 30) D

30

5.4.10

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Fitting the maize harvesting equipment Remove the guide rails (N) from the last concaves on each side, by unbolting the bolts (E).

E

(Fig. 31)

N E

E

N E

31 Undo the connecting bolt (B) between the fourth and fifth concaves. For this hold two concaves together.

Remove the separation concave from below.

(Fig. 32)

B 32 The segments can now be removed from the back of the machine.

(Fig. 33)

33

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

5.4.11

Fitting the maize harvesting equipment Fitting the separation concaves and the plain concaves LEXION 470 The fitting of the separation concaves and the plain concaves is done in the reverse order of the removal.

Insert the concaves and the plain concaves and push them fully towards the front of the machine.

Important!

34

The bolts for each concave must be engaged.

If necessary the bolts must be inserted individually and secured with a split pin.

Insert the last separation concave. Insert the bolt and secure with a split pin. Fit the guide rails (N) on both side of the machine and secure by screwing in the bolts (E).

Bolt back the sensor for the grain loss monitors.

Screw back the sealing rubber (D) Reposition the returns pan into the high position and bolt up.

Tighten the bolts (R) for the sieve box rocker arm. For this ensure that the sieve box is in the middle of its travel.

Refit the sieve box lamp.

Put the chaff spreader back into its working position (if fitted).

(Fig. 24 – 34)

Sieve selection The sieve (15) selection is dependant on the harvesting conditions.

For work in maize and under dry conditions, then the long lip frog mouth sieves can be utilised.

For wet conditions, then the pressed round holed sieves, or the graepel sieves can be used.

When harvesting corn cob mix (CCM), where minimal spindles are present, then a deep toothed frog mouth sieve should be used.

When harvesting corn cob mix (CCM) where there is a high spindle content, then the graepel sieve should be used.

(Fig. 1– 5)

5.4.12

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Fitting the maize harvesting equipment Frog mouth sieve, deep toothed Frog mouth sieve, long lip Frog mouth sieve, short lip (Fig. 35)

35 Plain sieve (maize) Round ∅ 16 mm Round ∅ 18 mm (Fig. 36)

36 Plain sieve (maize) Round pressed ∅ 18 mm Round pressed ∅ 20 mm (Fig. 37)

37 80/40 graepel sieve (for corn cob mix, CCM) (Fig. 38)

38

When fitting the frog mouth sieves into the machine then the basic adjustment for the sieves must be checked, – see page 5.4.23, Sieve – basic adjustment (electric adjustment – to machine number ...)

– see page 5.4.24, Sieve – basic adjustment (electrical sieve adjustment – from machine serial number ...).

(Fig. 27, 28, 29, 30)

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

5.4.13

Fitting the maize harvesting equipment Fitting the riser plates (without the 3D cleaning system) The riser plates (16) can be fitted to the plain sieves when the machine is being used on steep slopes by bolting them on using the mushroom headed bolts (17).

The riser plates are used on steep slopes to help ensure an even usage of the sieves.

(Fig. 39) 53085

39

Operation without the lower sieve When the machine is going into maize harvesting or corn cob mix (CCM), then it can be run without the bottom sieves fitted.

For this the returns need to be closed.

To machine serial number ...

Unhook the Bowden cable for the lower sieve adjustment.

From machine serial number ...

Remove the lower sieve adjusting motor.

Close the returns: Remove the top and bottom sieves.

Slacken off the returns floor (L) at (A), and then the returns (B) needs to be unhooked from the grain returns (C).

Retighten the returns floor at (A).

Refit the top and lower sieves back into the machine.

(Fig. 40) 40

5.4.14

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Fitting the maize harvesting equipment Unhook the Bowden cable from the sieve adjustment (to machine serial number ...)

When operating the machine without the lower sieve, and with a plain sieve in the top, then both the Bowden cables need to be hung in a suitable location.

The best position to hang the Bowden cable is on the left hand side of the machine.

We will show an example as to where the Bowden cables can be fixed to.

For this carry out the following: – Unscrew the ball joint from the Bowden cable to the adjusting lever of the lower sieve, or the top sieve.

– Slacken the Bowden cable from the support.

– Fix the support with the rubber bearing beneath the perforated plate.

– Feed both Bowden cables through the side wall of the machine, and up through the guard with all the holes.

H

– Fix the Bowden cables from the bottom sieves to the hydraulic line (H) using two 17 mm pipe clamps. The pipe clamps should be bolted together using a suitable bolt. The rod from the Bowden cable should be tied down using a suitable cable tie.

41

– The Bowden cable from the top sieves should be fixed to the dividing plate (T) tight up against the side wall of the machine.

– The support clamp for the Bowden cable (using a 30 x 30mm approx angle) needs to be bolted to the dividing plate using a suitable bolt. A hole needs to be drilled into the dividing plate, where the bracket is to be fitted.

T

Caution!

The Bowden cable should be fixed up so that it cannot get damaged.

42

The ball joint end of the cable must be left free, so that should it happen to get operated from the drivers platform, no damage will occur!

(Fig. 41, 42)

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

5.4.15

Fitting the maize harvesting equipment Removing the adjustment motors (from machine serial number ...)

When the machine is going to be operated with the lower sieves removed and the top sieves replaced with plain sieves, then the two wiring looms (K) that feed the adjusting motors need to be sealed using the rubber caps.

K

(Fig. 43)

K 43

Removing and fitting the sieves Removing the preparation floor (chopper) LEXION 480 F

In order to gain better access to the sieves, it is better for the Uni spreader to be put into the transport position.

C

C

Remove the chopper preparation floor (F).

44

After the fitment of the sieves, the re-fitment of the preparation floor for the chopper in maize is dependant upon performance – see page 5.6.7, Chopper preparation pan – cereals.

(Fig. 44)

Opening the chaff spreader LEXION 470 / 460 – 405 In order to gain better access to the sieves, it is better to unlock the chaff spreader and fold open.

After the sieves have been put into the machine, ensure that the chaff spreader has been put back into the working position.

Caution!

S

The chaff spreader (cereals) must not be used in maize, otherwise material damage will occur.

45

(Fig. 45)

5.4.16

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Fitting the maize harvesting equipment Removing the top sieves (to machine serial number ...)

Remove the connecting rod (G).

For this, slacken off the ball joint from the sieve adjusting lever.

G

(Fig. 46)

46 Unhook the Bowden cable (B) and the support (W).

Unbolt the top rubber clamp (L).

(Fig. 47)

L

W

B

47 Unbolt the middle and side sieve clamps (K).

Remove the hex bolts (S) from the side and the middle of the sieves.

K S

K

(Fig. 48) S

48

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

5.4.17

Fitting the maize harvesting equipment Remove the fixing rail (N). For this the fixing bolts (E) must be removed.

Important!

N

E

E

E

Do not unbolt the wire rake, otherwise before re-fitting the fixing rail (N), the wire rake will have to be refitted.

Then install the fixing rail (N) together with the refitted wire rake.

49

(Fig. 49)

Withdraw the frogmouth sieves towards the back of the machine.

Important!

In a certain position of the sieve box, the L.H. sieve could get caught on the support of the rubber bearing. In that case the position of the sieve box should be altered by turning the drives.

50

(Fig. 50) Removing the lower sieves (to machine serial number ….)

Remove the top sieves.

S

Slacken the support (W) on the returns floor.

R

Slacken off and remove the two returns floors (R).

Unbolt the rubber clamp (S).

W

(Fig. 51)

M

51

5.4.18

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Fitting the maize harvesting equipment Remove the connecting rod (G). For this the ball joint on the adjusting lever for the sieves needs to be slackened off.

(Fig. 52)

G

52 Unbolt the ball joints from the Bowden cable on the adjustment lever (E) from the right hand lower sieve.

(Fig. 53)

E

53 Slacken the support (W) for the Bowden cable and lay to one side.

Remove the wind plate (F) (to machine serial number ...).

F

(Fig. 54)

F

W

54 Slacken off the axial fixing clamps (M) from the sieves.

Pull the sieves out towards the back of the machine.

(Fig. 55)

M

M 55

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

5.4.19

Fitting the maize harvesting equipment Fitting in the sieves (to machine serial number ...)

The sieves are fitted in the reverse procedure as removal.

When fitting the sieves back, the axial clamps need to be tightened to their correct torque settings, and then the side clamps can be put into place.

Ensure that all the bolts are correctly seated!

Torque settings for the axial clamping bolts for the top and lower sieves Top sieve = 45 Nm (Hex bolt M 12) Lower sieve = 23 Nm (Hex bolt M 10)

Removing the top sieve (from machine serial number ...)

Unscrew the adjusting motor from the ball joint.

Unscrew the wiring loom from the adjustment motor.

Swing the adjustment motor towards the rear.

(Fig. 56)

56 Unbolt the adjustment rod (V) from both sieves.

(Fig. 57)

V

57

5.4.20

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Fitting the maize harvesting equipment Unbolt the middle and side sieve clamps (K).

Unbolt the side hex bolts (S) as well as the ones in the middle.

K

K

(Fig. 58)

S

S

58 Remove the end profile (N). For this remove the hex bolts (E).

Remove the end profile (N) completely towards the rear of the machine.

N

Important!

E

E

E

59

The plate (A) should not be removed from the end profile (N). The sieves will only be complete when the plate (A) is bolted to the end profile (N). The comb (R1) may be removed from the plate (A).

(Fig. 59, 60)

R1

A

N

A

60 Pull out the top sieve.

(Fig. 61)

61

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

5.4.21

Fitting the maize harvesting equipment Removing the lower sieve (from machine serial number ...)

Remove the returns floor.

Unscrew the adjusting motor from the ball joint.

Unscrew the cable from the adjusting motor.

Unjust the connecting rod (V) from both sieves.

Y

(Fig. 62)

62 Remove the wind plate (W) complete with the adjustment motor. For this the hex bolt (S) needs to be removed.

(Fig. 63) S

S

W

63 Slacken off the axial clamps (M) for the sieves.

Remove the sieves towards the rear of the machine.

(Fig. 64)

M

M

64

5.4.22

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Fitting the maize harvesting equipment Fitting the sieves (from machine serial number ...)

The sequence is as for removal but in reverse.

Note!

When fitting plain or graepel sieves, the adjustment motor needs to be removed.

When fitting the sieves back, the axial clamps need to be tightened to their correct torque settings, and then the side clamps can be put into place.

Ensure that all the bolts are correctly seated!

Torque settings for the axial clamping bolts for the top and lower sieves Top sieve = 110 Nm (Hex bolt M 12) Lower sieve = 23 Nm (Hex bolt M 10)

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

5.4.23

Fitting the maize harvesting equipment

B

B

A

A

Sieve – basic adjustment (electric adjustment – to machine number ...)

Should the basic adjustment of the sieves have been changed due to the alteration of the adjusting rod, then the basic adjustment of the sieves has to be carried out again.

This can be carried out as follows: 1. Detach the ball joint from the Bowden cable to the adjustment lever of the sieves.

65

2. Using the rotary switch in the cab, set on the sieve position, adjust the sieves to read zero.

3. Close the sieves completely.

4. Adjust the Bowden cable so that it can be attached without any lateral loading. Bolt back the Bowden cable.

The Bowden cable can be adjusted either on the hex nuts (A and B on the electric motors) and / or the support (rear on the sieves).

5. Check that the sieves open correctly: Open the sieves e.g. onto position 15.

66

Both of the frog mouthed sieves should open equally.

In order to test the opening of the two frog mouthed sieves, then if necessary use the CLAAS special tool part number 181 625.0.

This tool will also enable the bottom sieve to be checked, when the top sieve is completely open.

When adjusting the rod on the frog mouth sieves, ensure that they do not close too tight.

In order to adjust the bottom sieves to each other, then at least one of the top sieves must be removed.

(Fig. 65, 66)

5.4.24

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Fitting the maize harvesting equipment Sieve – basic adjustment (electrical sieve adjustment – from machine serial number ...)

Should the basic adjustment of the sieves have been changed due to the alteration of the adjusting rod, then the basic adjustment of the sieves has to be carried out again.

T

This can be carried out as follows: H

1. Unbolt the ball joint (T) from the sieve adjustment lever.

67

2. Using the rotary switch in the cab, set on the sieve position, adjust the sieves to read zero.

3. Close the sieves completely.

4. Slacken off the lock nut (H).

5. Adjust the ball joint (T) so that it can be attached without any lateral loading. Tighten up the ball joint by tightening the lock nut (H).

6. Check that the sieves open correctly.

Open the sieves e.g. onto position 15.

Both of the frog mouthed sieves should open equally.

68

In order to test the opening of the two frog mouthed sieves, then if necessary use the CLAAS special tool part number 181 625.0.

This tool will also enable the bottom sieve to be checked, when the top sieve is completely open.

When adjusting the rod on the frog mouth sieves, ensure that they do not close too tight.

In order to adjust the bottom sieves to each other, then at least one of the top sieves must be removed.

(Fig. 67, 68)

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

5.4.25

Fitting the maize harvesting equipment Adjusting grain tank unloading / restrictor plates

E

B

Cereals are sent via the steep slope to the unloading augers (E).

B

From here the grain is sent to the left (arrow direction) to the unloading auger, where it is lifted from the machine and deposited into the trailers.

B 69

Due to the conical shape of the restrictor plates (B), the feed in opening for the unloading augers is wider on the left hand side of the machine than on the right hand side.

In the basic setting, the restrictor plates (B) are in their lowest position.

S

This ensures that for good flowing crops, the chances of blockage in the unloading auger is minimised.

For crops that do not flow well (such as for grass) then it might be required that the restrictor plates are raised.

Caution!

70

Do not open the restrictor plates (B) too high.

When the unloading auger is overloaded, then the shear bolt (S) will break before damage occurs.

S = hex bolt M 8 x 45 DIN 931-8.8 Lock nut VM 8 Torque setting = 25 Nm

5.4.26

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Fitting the maize harvesting equipment STRAW CHOPPER LEXION 460 – 405

Straw guide plate The straw guide plate is only fitted to straw walker machines.

There are several guide plates for the straw choppers, depending on the machine type and the type of straw chopper fitted.

There are two types of choppers available: 1. Fixed chopper 2. Hydraulically adjustable chopper

1. Type 452 machines with the fixed chopper (Fig. 1) and have the straw guide plate (18) fitted (Fig. 2).

1

2 Type 542, 543, 544 machines with the fixed chopper (Fig. 1) have the straw guide plate (20) fitted (Fig. 3).

3

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

5.5.1

Fitting the maize harvesting equipment 2. Type 453, 454, 457, 543, 544 and 547 with the hydraulically adjusted straw chopper (Fig. 4) have the straw guide plate (22) fitted (Fig. 5).

4

5

5.5.2

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Fitting the maize harvesting equipment

53070

6

Fitting the straw guide plate Lexion 410 / 405 (fixed chopper) type 452 Danger!

Cover the knife cylinder – risk of injury!

R R

When fitting the straw guide plate (18) it is advantageous to have a working platform up over the chopper.

Open the rear guard from the chopper housing.

7

Remove the bolts (19) from both side of the machine.

(Fig. 6, 7)

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

5.5.3

Fitting the maize harvesting equipment Fit the right hand bracket (B) to the straw guide plate using the two washers (D) and the expansion pins (E).

B D

(Fig. 8)

D

E

8 Bolt on the left hand bracket (C) onto the side wall using the hex bolts (19) and straighten.

Drill the two holes at (A), 8.5 mm in diameter.

A

Insert the hex bolts (19) and tighten.

19

(Fig. 9) A

C

9 Slide one washer (D) onto the left hand side of the straw guide plate. Lift the straw guide plate into the machine and locate onto the left hand bracket (C).

Bolt the right hand bracket (B) onto the side wall of the machine using the hex bolt (19) and straighten.

19

Drill the two holes at (A), 8.5 mm in diameter.

A

Insert the hex bolts (19) and tighten.

On the right hand bracket (B), insert the inner expansion pin.

10

On the left hand bracket (C), fit the outer washer (D) and the outer expansion pin (E).

(Fig. 8, 9, 10)

5.5.4

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Fitting the maize harvesting equipment

11

Fitting the straw guide plate Lexion 460 / 410 (fixed chopper) type 542, 543, 544 Danger!

21

Cover the knife cylinder – risk of injury!

21 When fitting the straw guide plate (20) it is advantageous to have a working platform up over the chopper.

Open the rear guard from the chopper housing.

12

Remove the bolts (21) from both side of the machine.

(Fig. 11, 12)

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

5.5.5

Fitting the maize harvesting equipment Fit the right hand bracket (B) to the straw guide plate using the two washers (D) and the expansion pins (E).

B D

D

(Fig. 13)

E

13 Bolt on the left hand bracket (C) onto the side wall using the hex bolts (21) and straighten.

Drill the two holes at (A), 8.5 mm in diameter.

A

Insert the hex bolts (21) and tighten.

21

(Fig. 14) A

C

14 Slide one washer (D) onto the left hand side of the straw guide plate. Lift the straw guide plate into the machine and locate onto the left hand bracket (C).

Bolt the right hand bracket (B) onto the side wall of the machine using the hex bolt (19) and straighten.

21

Drill the two holes at (A), 8.5 mm in diameter.

A

Insert the hex bolts (21) and tighten.

On the right hand bracket (B), insert the inner expansion pin.

15

On the left hand bracket (C), fit the outer washer (D) and the outer expansion pin (E).

(Fig. 13, 14, 15)

5.5.6

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Fitting the maize harvesting equipment Raise the rubber curtain (G) in the machine and bolt into position using two hex bolts (F).

F = hex bolt M8 x 40 Lock nut VM8 Contact washer A8

G

(Fig. 16) F

F

16 Lift the rubber curtain (G) at the rear. Insert the tube (H) and fix using the two hex bolts (F).

G

(Fig. 17) F H

F

17

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

5.5.7

Fitting the maize harvesting equipment

53071

18

Fitting the straw guide plate Lexion 460 / 410 (hydraulically adjustable chopper) type 453, 454, 457, 543, 544, 547 Danger!

R

Cover the knife cylinder – risk of injury!

R

When fitting the straw guide plate (22) it is advantageous to have a working platform up over the chopper.

19

Open the rear guard from the chopper housing.

Remove the bolts (23) from both side of the machine.

(Fig. 18, 19)

5.5.8

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Fitting the maize harvesting equipment Lift the straw guide plate (22) into the machine.

23 G

Bolt the straw guide plate onto both sides of the side walls of the machine using the three hex bolts (23).

23

22

(Fig. 20)

20 Bolt the end stops (24) onto the side walls of the machine in front of the straw guide plate (22) using the hex bolts (25).

24

Adjust the end stops so that the straw guide plate is pressed back against the gas springs (G) by approx 10 to 15 mm. In this position bolt up the end stops (24).

22

(Fig. 21)

25

21 Adjusting the straw guide plate The lower rubber section is adjustable.

In order to adjust, pull the bar (R) from both sides, move the rubber section to the desired position, then re locate the bar.

The lower rubber section should always be as far forward as possible and never over the middle or towards the rear.

(Fig. 18)

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

5.5.9

Fitting the maize harvesting equipment Straw chopper adjustment LEXION 460 – 405 Danger!

When ever working on the straw chopper, always ensure that the threshing has been disengaged, the engine has been stopped and the ignition keys have been removed.

When switching off the machine, remember that the knife cylinder continues to rotate for a short while!

Caution – danger of injury!

☞ When carrying out any work on the straw chopper knives, always wear gloves!

☞ Stop the knife cylinder from rotating by locking it.

The adjustment of the straw chopper is dependant on the machine type.

With the same machine types, the number of the knives can vary (cereal or maize). This is dependant on the type of chopper that’s been fitted.

Danger!

By not checking on the correct knives used, or the correct quantity of knives, then there is a risk that the knives on the rotor will foul the stationary blades.

Count the number of knives on the straw chopper rotor.

In order to determine the correct straw chopper adjustment, the following table is supplied.

The retraction of the stationary blades and the changing of the knives on the cyclinder must be carried out for all machines.

5.5.10

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Fitting the maize harvesting equipment

Straw chopper adjustment LEXION 460 – 405

LEXION

Type

Quantity of knives on the cylinder Cereals

Quantity of knives on the cylinder Maize

Knife carrier adjustment

Remove every stationary blade

Remove every other stationary blade

410 / 405

452

52

26

+

–

+

430 – 415

453

52

26

+

–

+

460 – 440

454

64

32

+

–

+

460 / 450

457

64

32

+

–

+

430

542

52

26

+

–

+

430 – 410

543

52

26

+

–

+

430 – 410

543

72

36

–

–

–

460 – 440

544

64

32

+

–

+

460 – 440

544

88

44

–

+

–

460

547

88

44

–

+

–

– = not necessary, + = necessary

Retracting the stationary knives Slacken off all the fixing bolts (U).

Pull the stationary knife (Q) back and tighten up the fixing bolts.

(Fig. 22)

22

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

5.5.11

Fitting the maize harvesting equipment Adjusting the stationary knives

C

(see table, straw chopper adjustment Lexion 460 – 405)

R

1. When harvesting in maize, and every other blade on the stationary knife is removed, then the stationary knife needs to be put into the lowest (B) position.

E

D

In order to do this, slacken off the hex bolts (D and E) on both sides, then tip the stationary knife down.

23

The round bar (R), is now sitting at the same height as the hole (C).

After adjustment, tighten the hex bolts (D and E).

After moving the stationary knives down (B), the guard (31) needs to be bolted to the front of the chopper using the two hex bolts (E).

E

2. When harvesting in maize, and every blade on the stationary knife is removed then the stationary knife needs to be put in the upper position (A).

31 E

In order to do this, slacken off the hex bolts (D and E) from both sides. The stationary knife can now be moved into the upper position.

24

After the adjustment of the stationary knife, tighten up the two hex bolts (D and E).

When the chopper is in the upper position (A) then the guard should be removed.

(Fig. 22, 23, 24)

5.5.12

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Fitting the maize harvesting equipment Removing every blade from the stationary knife (see table straw chopper adjustment Lexion 460 – 405)

R

C

Carry out the procedure as follows: D

E

– The round bar (R) must be aligned with the hole (C) (Fig. 25).

– Remove the spring clip (K) from the bar (R), on the right hand side of the machine.

25

– Remove the round bar.

– Remove all the blades.

– Slide the bar back into position and re insert the spring clip.

Removing every other blade from the stationary knife

C

R

(see table straw chopper adjustment Lexion 460 – 405) D

Carry out the procedure as follows: 26

– The round bar (R) must be aligned with the hole (C) (Fig. 25).

– Remove the spring clip (K) from the bar (R), on the right hand side of the machine.

– Remove the round bar.

– Begin with the first blade, then remove every other blade. That means that the first, third, fifth blade and so on.

– Slide the bar back into position and re insert the spring clip.

(Fig. 25, 26, 27)

27

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

5.5.13

Fitting the maize harvesting equipment Removing the blades from the chopper cylinder (cereals) (hydraulically adjustable chopper)

L

M

In order to gain better access to the chopper cylinder, the straw plate (L) can be swung down.

For this, remove the straw deflector fixing bolts (S), then remove the two straw deflectors.

P S

Slacken the nuts (M) for the fixing of the plate (P). Pull the plate (P) forward, so that the guide plate (L) is still held. Swing the guide plate down.

28

Unbolt all the blades from the knife cylinder.

(Fig. 28, 29)

L

29

Removing the blades from the chopper cylinder (cereals) R

(fixed chopper) L

In order to gain better access to the chopper cylinder, the straw plate (L) can be swung down.

Then remove the fixing hex bolts (S) for the straw deflectors.

S

Remove the pin (R) then take off the straw deflectors.

Hold the guide plate (L) and remove the soc cap screws (Z).

30

Pull the plate (P) approx 10 mm towards the outside and then remove the guide plate.

Remove all the blades from the chopper cylinder.

(Fig. 30, 31)

31

5.5.14

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Fitting the maize harvesting equipment Fitting the blades to the chopper cylinder (maize) For chopping maize straw, there is a particularly high force on the blades.

On each blade mount (H) on the cylinder, only one blade must be fitted. The blades must also be free to move.

Bolt the blades (22) onto the cylinder as per fig. 18.

Danger!

53076

32

Only use genuine nuts and bolts.

Torque setting: M 10-10.9 = 65 Nm Caution!

Bolts that have been subject to the Dacromet thread lock additive (silver / grey) are torqued up to a slightly lower degree.

Torque setting: Bolts with the Dacromet thread lock additive M 10-10.9 = 55 Nm Note the sticker on the chopper cylinder!

26 27 28 29 30

Blade (maize) Hex bolt M 10 x 50 DIN 931-10.9 Bush D 30 x 14.25 Bush D 48 x 10 x 8.5 Hex nut VM 10 DIN 980-10

H Blade mount F Direction of travel Bolt back the straw guide plate (L) and tighten.

If necessary bolt back the two straw guides.

(Fig. 32)

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

5.5.15

Fitting the maize harvesting equipment

5.5.16

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Fitting the maize harvesting equipment STRAW CHOPPER LEXION 480 / 470

Straw chopper adjustment LEXION 480 / 470 Danger!

When ever working on the straw chopper, always ensure that the threshing has been disengaged, the engine has been stopped and the ignition keys have been removed.

When switching off the machine, remember that the knife cylinder continues to rotate for a short while.

Caution – Danger of injury!

☞ When carrying out any work on the straw chopper knives, always wear gloves!

☞ Stop the knife cylinder from rotating by locking it.

The adjustment of the straw chopper is dependant on the machine type.

With the same machine types, the number of the knives can vary (cereal or maize). This is dependant on the type of chopper that’s been fitted.

Danger!

By not checking on the correct knives used, or the correct quantity of knives, then there is a risk that the knives on the rotor will foul the stationary blades.

Count the number of knives on the straw chopper rotor.

In order to determine the correct straw chopper adjustment, the following table is supplied.

The retraction of the stationary blades and the changing of the knives on the cylinder must be carried out for all machines.

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

5.6.1

Fitting the maize harvesting equipment

Straw chopper adjustment LEXION 480 / 470

LEXION

Type

Quantity of knives on the cylinder Cereals

Quantity of knives on the cylinder Maize

Knife carrier adjustment

Remove every stationary blade

Remove every other stationary blade

480

466

88

44

+

–

+

480

468

88

44

+

–

+

470

541

52

26

+

–

+

470

541

72

36

–

+

–

470

545

52

26

+

–

+

470

545

72

36

–

+

–

480

546

88

44

+

–

+

480

548

88

44

+

–

+

– = not necessary, + = necessary

Retracting the stationary knives Slacken off all the fixing bolts (U).

Pull the stationary knife (Q) back and tighten up the fixing bolts.

(Fig. 1)

1

5.6.2

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Fitting the maize harvesting equipment Adjusting the stationary knives (see table, straw chopper adjustment Lexion 480 / 470) C

D

R

1. When harvesting in maize, and every other blade on the stationary knife is removed, then the stationary knife needs to be put into the lowest (B) position.

E

In order to do this, slacken off the hex bolts (D and E) on both sides, then tip the stationary knife down.

2

The round bar (R), is now sitting at the same height as the hole (C).

After adjustment, tighten the hex bolts (D and E).

LEXION 480 After the adjustment of the stationary knife into the lower position (B), rubber curtain (32) with the rails needs to be bolted to the chopper using the mushroom headed bolts (33) (Fig. 3).

33 32

LEXION 470 After the adjustment of the stationary knife into the lower position (B), the guard (31) needs to be bolted to the front of the chopper using the two hex bolts (E) (Fig. 4).

3

2. When harvesting in maize, and every blade on the stationary knife is removed then the stationary knife needs to be put in the upper position (A).

In order to do this, slacken off the hex bolts (D and E) from both sides. The stationary knife can now be moved into the upper position.

E

After the adjustment of the stationary knife, tighten up the two hex bolts (D and E).

31 E

When the chopper is in the upper position (A) then the guard (31) should be removed.

(Fig. 1, 2, 3, 4) 4

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

5.6.3

Fitting the maize harvesting equipment Removing every blade from the stationary knife (see table straw chopper adjustment Lexion 480 / 470) K

Carry out the procedure as follows: – The round bar (R) must be aligned with the hole (C) (Fig. 6).

– Remove the spring clip (K) from the bar (R), on the right hand side of the machine.

5

– Remove the round bar.

– Remove all the blades.

– Slide the bar back into position and re insert the spring clip.

C

R

Removing every other blade from the stationary knife (see table straw chopper adjustment Lexion 480 / 470)

D

Carry out the procedure as follows: 6

– The round bar (R) must be aligned with the hole (C) (Fig. 6).

– Remove the spring clip (K) from the bar (R), on the right hand side of the machine.

– Remove the round bar.

– Begin with the first blade, then remove every other blade. That means that the first, third, fifth blade and so on.

Slide the bar back into position and re insert the spring clip.(Fig. 5, 6, 7)

7

5.6.4

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Fitting the maize harvesting equipment Removing the blades from the straw chopper cylinder (cereals) LEXION 480

L

In order to gain better access to the chopper cylinder, the straw plate (L) can be swung down.

M

For this, fold the straw plate to the front and unbolt the nuts (M).

Remove the straw deflectors Remove all the blades from the cylinder.

8

(Fig. 8, 9)

9

Removing the blades from the straw chopper cylinder (cereals) LEXION 470 In order to gain better access to the chopper cylinder, the straw plate (L) should be removed.

L

Hold the guide plate (L) and remove the soc cap screws (Z).

Pull the plate (P) approx 10 mm towards the outside, then remove the guide plate.

Remove all the blades from the cylinder.

10

(Fig. 10, 11)

11

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

5.6.5

Fitting the maize harvesting equipment Fitting the blades to the chopper cylinder (maize) For chopping maize straw, there is a particularly high force on the blades.

On each blade mount (H) on the cylinder, only one blade must be fitted. The blades must also be free to move.

Bolt the blades (26) onto the cylinder as per fig. 12.

53076

Danger!

12

Only use genuine nuts and bolts.

Torque setting: M 10-10.9 = 65 Nm Caution!

Bolts that have been subject to the Dacromet thread lock additive (silver / grey) are torqued up to a slightly lower degree.

Torque setting: Bolts with the Dacromet thread lock additive M 10-10.9 = 55 Nm Note the sticker on the chopper cylinder!

26 27 28 29 30

Blade (maize) Hex bolt M 10 x 50 DIN 931-10.9 Bush D 30 x 14,25 Bush D 48 x 10 x 8.5 Hex nut VM 10 DIN 980-10

H Blade mount F Direction of travel Bolt back the straw guide plate (L) and tighten.

(Fig. 12)

5.6.6

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Fitting the maize harvesting equipment Chopper preparation pan (performance) Chopper preparation pan – cereals Caution!

The chopper preparation pan for cereals (A or B) must be removed when harvesting maize, otherwise material damage will occur.

A

13

When harvesting cereals then the preparation pan (A or B) should be refitted.

(Fig. 13, 14, 15)

14

15

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

5.6.7

Fitting the maize harvesting equipment Chopper preparation pan – maize with rubber mat The chopper preparation pan – maize (34) can be used when harvesting maize.

When harvesting cereals then the chopper preparation pan – maize (34) can be used.

(Fig. 16, 17) 34

16

17

5.6.8

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Fitting the maize harvesting equipment DRIVES Threshing drum speed adjustment Two step drive (optional) Note!

When harvesting particularly brittle crops, then a two stepped drive can be fitted to the threshing drum. This will enable two different speed ranges.

Step-less speeds: 1st step from 362 – 1050 rpm 2nd step from 158 – 457 rpm Recommended threshing drum speeds: e.g. maize corn cob mix (CCM) winter barley wheat

= 400 rpm = 650 rpm = 900 rpm = 750 rpm

Adjusting the speeds: 1st step: Screw in both the conical bolts into the small holes of the pulley at (N) and into the carrier of the reduction gearbox.

N

The carrier of the reduction gearbox will then be driven.

N

(Fig. 1)

1 2nd step: Screw in both the conical bolts into the large holes of the pulley at (M) so that the carrier of the reduction gearbox is bolted to the chassis of the machine.

M

The carrier of the reduction gearbox is then fixed.

(Fig. 2)

M 2

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

5.7.1

Fitting the maize harvesting equipment Adjusting the speeds of the separation rotors LEXION 480 / 470

K

Stepped drive (optional) Speed adjustment: Danger!

Only change the speeds, when all the drives have come to a complete stop, the engine has been switched off and the ignition key has been removed.

3

The speeds of the separation rotors can be changed, by changing the position of the drive connecting belt (K) on either one of the three positions on the pulleys.

(Fig. 3, 4)

F H 4 The drive connecting belt (K) for the stepped drive, is kept tensioned by beans of a sprung loaded (F) jockey pulley.

In order to change the speeds, the connecting drive belt must be de-tensioned using the lever (H).

Lay the drive connecting belt (K) into the desired position on the pulleys, then using the lever (H) re tension.

(Fig. 4)

Recommended rotor speeds: e.g. maize corn cob mix (CCM) winter barley wheat

= 500 (300) rpm = 500 (300) rpm = 960 rpm = 960 rpm

Speed schematic: A = Drive pulley

5

5.7.2

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Fitting the maize harvesting equipment Rotor speed schematic LEXION 480 Pulley

Pulley

no.

no.

Speed of the separation rotors rpm

1

∅ 430

2

∅ 353

962

2

∅ 395

4

∅ 390

800

5

∅ 351

6

∅ 433

640

Special speeds 1

∅ 302

2

∅ 477

500

1

∅ 210

2

∅ 477

300

Rotor speed schematic LEXION 470 Pulley

Pulley

no.

no.

Speed of the separation rotors rpm

1

∅ 302

2

∅ 477

500

3

∅ 352

4

∅ 433

640

5

∅ 395

6

∅ 390

800

Special speeds ∅ 430

1

∅ 453

2

962

Rotor speed regulator (option) The rotors are driven via the pulley (A and B) using the drive belt (33).

33

B

The speed of the rotors can be adjusted anywhere from 360 rpm to 1050 rpm depending on the crop types, and in a stepless manor.

A

In order to adjust the speeds of the rotors, then see the section 8 “CEBIS” in the operators book for the machine.

6 (Fig. 6)

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

5.7.3

Fitting the maize harvesting equipment

A

R

H F

M X

EK

B

41674

7

Chopper speed reduction LEXION 410 / 405 (fixed chopper) type 452 LEXION 430 – 410 (fixed chopper) type 543 When harvesting maize, it is recommended that the speed is reduced.

S F

Release the tension on the sprung cylinder (F).

Carry out the following procedure: 1. Measure the distance (X).

8

2. Slacken off the lock nut (K).

3. Turn the cylinder back to the original dimension of (X). At the same time tighten the nut (K) until the washer (E) sits on the bracket (H).

The bolt should now sit without tension on it.

If necessary tighten the cylinder (R) and the nut (K).

5.7.4

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Fitting the maize harvesting equipment 4. Unlock the bolt (B) and remove.

Danger!

Take particular care when unscrewing the cylinder (R), do not unscrew it too far – danger of injury!

5. On the Lexion 410 / 405 (fixed chopper) type 452, unbolt the jockey pulley (S).

Turn the jockey pulley with the distance piece around and then screw back into position. The distance piece should lie on the right hand side of the jockey pulley.

6. Place the drive belt (A) on the outer step of the intermediate drive as well as the chopper drive.

(Fig. 7, 8) Adjusting the cylinder (F): Adjust the cylinder (R), by slackening off the lock nut (K) and adjusting until the tube (M) lightly touches the bracket (H).

Retighten the lock nut (K).

(Fig. 7)

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

5.7.5

Fitting the maize harvesting equipment

C

H

B M

E

F A

R

D

K

L

L

41675

9

Chopper speed reduction LEXION 460 – 415 (adjustable chopper) type 454 LEXION 430 – 410 (adjustable chopper) type 543, 542 When harvesting maize, it is recommended that the speed is reduced.

Danger!

Take care when removing the drive belt – danger of injury!

R

K 10

1. Remove both of the end stop bolts (L).

2. Slacken off the lock nut (K) on the cylinder (E) completely.

C

3. Screw in the cylinder (R) completely.

4. Press down the jockey pulley (S) and remove the drive belt (C) from the intermediate drive (H).

Move the jockey pulley (S) to slowly move upwards, if necessary the rear jockey pulley should swing down.

S

Remove the drive belt (B).

(Fig. 9 – 13) 11

5.7.6

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Fitting the maize harvesting equipment Remove the drive belt (A): De-tension the drive belt (A).

Carry out the following procedure: 1. Unbolt the lower guard from the chopper drive.

S

2. Determine the dimension (X).

3. Slacken off the lock nut (U).

4. Tighten the cylinder (T) back to the original dimension (X). At the same time tighten the nut (U) until the washer (W) lies on the bracket (N).

12

The bolt should now be without tension.

If necessary tighten the cylinder (T) and the nut (U).

N V WU

5. Unlock the bolt (G) and remove.

Danger!

X

T

Take particular care when unscrewing the cylinder (R), do not unscrew it too far – danger of injury!

41857

13

7. Place the drive belt (A) onto the inner step of the chopper and the intermediate drive (M).

G

N W U

6. Remove the drive belt (B) from the intermediate drive (M).

Place the drive belt (B) onto the outer step of the intermediate drive (M) and on the middle step of the intermediate drive (H).

Re insert the bolt (G) and secure.

T

(Fig. 9 – 15)

41858

14

M

A

B

15

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

5.7.7

Fitting the maize harvesting equipment Tension the drive belt (A) using the cylinder (F): Slacken off the lock nut (U) and adjust the cylinder (T) until the end of the measurement tab (V) is level with the washer (W). Tighten the lock nut (U). Bolt back the lower guard to the chopper drive.

Tension the drive belts (C and B) using the cylinder (E): Slacken off the lock nut (K) and adjust the cylinder (R) until the end of the measurement tab (D) is level with the washer. Tighten the lock nut (K). Bolt back the end stop bolts (L).

(Fig. 9, 13 – 15)

5.7.8

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Fitting the maize harvesting equipment

53080

16

Chopper speed reduction LEXION 460 / 450 (fixed chopper) type 547 LEXION 470 (fixed chopper) type 545, 541 LEXION 480 (fixed chopper) type 466, 546, 548 When harvesting maize, it is recommended that the speed is reduced.

Danger!

Stop the engine, and switch off the battery isolator switch!

Release the tension on the cylinder (M): – Remove the rear end stop bolt (L).

(Fig. 16, 17)

L

17

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

5.7.9

Fitting the maize harvesting equipment – Undo completely the lock nut (K).

(Fig. 18)

K 18 – Turn off the drive belt (11) firstly from the rear pulley of the chopper.

G

– Lay the drive belt on the intermediate drive (G) on the inner step of the pulley.

– Lay the drive belt on the inner step of the pulley of the chopper drive.

11

(Fig. 19, 20)

19

20

5.7.10

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Fitting the maize harvesting equipment Tension up the drive belt (11): Adjust the cylinder (R), when the lock nut (K) has been slackened off so that the end on the measurement tab (D) is level with the end of the spring, when the lock nut (K) has been tightened. The spring length should be set to 138 mm.

Refit the end stop bolts (L).

K Important!

L 21

The end stop bolts (L) should touch the bracket for the jockey pulley.

(Fig. 16 – 21)

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

5.7.11

Fitting the maize harvesting equipment

C M B

G R D

K

L L

41678

22

Chopper speed reduction LEXION 480 (Uni spreader) When harvesting maize, it is recommended that the speed is reduced.

Danger!

Take care when removing the drive belt – danger of injury!

R K 23

1. Remove both of the end stop bolts (L).

2. Slacken off the lock nut (K) on the cylinder (G) completely.

3. Screw in the cylinder (R) completely.

4. Press down the jockey pulley (S) and remove the drive belt (C) from the intermediate drive (M).

S Danger!

Do not allow the jockey pulley (S) to get pushed over the top dead centre.

– Risk of injury!

24

5.7.12

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Fitting the maize harvesting equipment Move the jockey pulley (S) to slowly move upwards, if necessary the rear jockey pulley should swing down.

5. Move the drive belt (B) from the inner groove of the intermediate drive (M) and the chopper to the outer groove.

6. Place the drive belt (C) on the intermediate drive (M) and tension.

(Fig. 22 – 26)

Tension the drive belt (C and B) on the cylinder (G): Adjust the cylinder (R), when the lock nut (K) has been slackened off so that the end on the measurement tab (D) is level with the end of the spring, when the lock nut (K) has been tightened. The spring length should be set to 138 mm.

S

Refit the end stop bolts (L).

Important!

25

The stop bolts (L) must lie against the bracket for the jockey pulley.

(Fig. 22 – 26)

26

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

5.7.13

Fitting the maize harvesting equipment

5.7.14

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Fitting the maize harvesting equipment ADJUSTMENT Note Depending on the crop type, the adjustments such as drum speed, fan speed, concave adjustment etc can be done, depending on the machine.

The adjustment is carried out as follows: – Machine and system adjustment with the instrument monitor IMO or – CLAAS bordinformationsystem CEBIS The exact description of the adjustments can be found in the relative operators book under the CEBIS or if necessary IMO sections.

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

5.8.1

Fitting the maize harvesting equipment

5.8.2

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

6 Fitting the grain harvesting equipment

Fitting the grain harvesting equipment SAFETY Danger!

When ever working on the machine, always ensure that the engine has been switched off, the ignition keys have been removed from the ignition, and that the machine has been prevented from rolling i.e. Parking brake applied and wheel chocks under the wheels.

When ever working on the straw chopper, ensure that the threshing system has been switched off, the engine has been stopped and that the ignition keys have been removed.

When switching off the machine, please be advised that the straw chopper cylinder will continue to rotate for a short while.

Caution – Risk of injury!

☞ When ever working on the straw chopper knives, always wear gloves.

☞ Always lock the straw chopper from rotating.

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

6.1.1

Fitting the grain harvesting equipment Additional weights Machines that have been fitted with a front attachment (e.g. maize picker head, folding cutterbar) need to have additional weights fitted when travelling on open roads or tracks. This is necessary to prevent the rear of the machine from lifting during braking or travelling down slopes.

The following weights can be fitted as follows: LEXION: • Fitted components to the back of the machine (e.g. straw chopper) • Filling the rear steering wheels with water • Additional weight on the steering axle The weight on the rear steering axle should be 20% of the machine’s weight including the fitted maize header.

For the required loading, please study the operator’s manual for the machine.

See, prior to operation, additional weights.

When the additional weight is no longer required for the front attachment, then it should be removed, otherwise excessive wear will result.

6.1.2

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Fitting the grain harvesting equipment TRUNKING Adjustment of the support – see page 5.2.1, Adjustment of the support

Locking the cutterbar ram springs – see page 5.2.1, Locking the cutterbar ram springs

Extending the front attachment horns on the trunking Before fitting a cereals cutterbar to the machine, the horns on the trunking must be extended and then put in the middle position.

R

The procedure is as follows: H

1. Unhook the cutterbar up to the machine.

A

Z

2. Start the engine and switch on the safety switch (S).

1

3. Open the hydraulic tap (R). For this move the lever (H) into the (A) position.

4. Press the rocker switch (W) to the right until both horns fully extend.

5. Press the rocker switch (W) in the opposite direction. The left hand ram will retract. Retract the ram until it reaches the end stop.

S W

6. Close the hydraulic tap (R). For this move the lever (H) into the (Z) position.

7. By operating the rocker switch (W), move the rams until they have reached the middle position.

8. Refit the cutterbar.

2

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

(Fig. 1, 2)

6.2.1

Fitting the grain harvesting equipment

6.2.2

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Fitting the grain harvesting equipment THRESHING DRUM HOUSING Changing the pre concave segments (small stone trap) – see page 5.3.1, Replacing the pre concave (small stone trap)

Changing the pre concave segments (large stone trap) – see page 5.3.2, Replacing the pre concave (large stone trap)

Removing the cover plate for the stone trap (small stone trap) – see page 5.3.3, Covering the stone trap (small stone trap)

Removing the cover plate for the stone trap (large stone trap) – see page 5.3.3, Covering the stone trap (large stone trap)

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

6.3.1

Fitting the grain harvesting equipment

E

E P V N 40859

3

Fitting the threshing segments (small stone trap) – Lower the concave to its lowest position.

– Lower the trunking to its lowest position.

Danger!

Stop the engine and switch off the battery isolator switch.

– Unbolt the fixing bolts (53) located at the rear of the threshing segment (52).

– Clean the area at the concave exit.

– Install the three concave segments (52) through the open drum door, or if necessary through the inspection hole on the left hand side of the machine.

– Bolt in the threshing segments using the hex bolts (53).

E = detail (Fig. 3)

6.3.2

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Fitting the grain harvesting equipment

4

Fitting the threshing segments (large stone trap) – Lower the concave to its lowest position.

53

– Lower the trunking to its lowest position.

Danger!

Stop the engine and switch off the battery isolator switch.

5

Open the drum door.

Unbolt the hex bolts (53) from the threshing segments.

The hex bolts (53) are accessible from under the accelerator.

The threshing segment (52) can be installed through the opened stone trap.

52

Bolt in the threshing segments using the hex bolts (53).

E = detail (Fig. 4, 5, 6) 6

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

6.3.3

Fitting the grain harvesting equipment Removing the cover bars The four cover bars (7) need to be remove from the drum when harvesting cereals.

The four remaining cover plates (5) need to be either removed, or four more additional cover plates fitted.

(Fig. 7)

53082

7 For cereal harvesting the threshing drum can be operated with eight cover plates (5).

Caution!

The plates and the bars have all been balanced. It is therefore important that they are always fitted in groups of four. Failure to do this will result in the drum being out of balance.

Cover plates may be fitted if so desired – see page 5.3.7, Fitting the cover plates for the threshing drum (maize and corn cob mix CCM).

(Fig. 7, 8)

53081

6.3.4

8

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Fitting the grain harvesting equipment Intensive separation system

Adjusting the curtain behind the impeller LEXION 460 – 405 The curtain (S) behind the impeller can be adjusted from the left hand side of the machine using the chain (C).

S

For heavy conditions, or with green material or with long straw, then the curtain should be raised in a higher position.

With lighter conditions, short straw and limited straw mass, then the curtain should be set deeper.

9 Multifinger separation system

For this the chain (C) can be locked onto the hook (A).

The chain (D) must remain free to move, so that the curtain can move backwards should the need arise.

(Fig. 9, 10, 11)

S

10

C A

D

11

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

6.3.5

Fitting the grain harvesting equipment

6.3.6

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Fitting the grain harvesting equipment SEPARATION / CLEANING / UNLOADING Lateral risers LEXION 460 – 405 For harvesting grain the lateral risers (A) can be reinstalled if necessary.

CCM – Straw walker risers LEXION 460 – 405

1

The corn cob mix (CCM) the CCM straw walker risers (8) need to be removed when operating the machine in cereals – see page 5.4.1, CCM – Straw walker risers LEXION 460 – 405 (Fig. 1, 2)

2 40 x 20 holes – standard

Changing the separation concaves LEXION 480 For cereals: The ten separation concaves for maize (11, 20 x 40 holes) and the separation concaves for corn cob mix CCM (12, 40 x 40 holes) must be replaced with the ten cereals separation concaves (54, 40 x 20 holes).

(Fig. 3)

3

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

6.4.1

Fitting the grain harvesting equipment Removing separation concaves (from machine serial number 466 00160) – see page 5.4.4, Removing the separation concaves Lexion 480 (from machine serial number 466 00160)

Fitting separation concaves (from machine serial number 466 00160) – see page 5.4.6, Fitting the separation concaves LEXION 480 (from machine number 466 00160)

Removing separation concaves (to machine serial number 466 00159) – see page 5.4.6, Removing the separation concaves Lexion 480 (to machine serial number 466 00159)

Fitting separation concaves (to machine serial number 466 00159) – see page 5.4.7, Fitting the separation concaves LEXION 480 (to machine number 466 00159)

Changing the separation concaves and the plain concaves LEXION 470 As standard the Lexion 470 is fitted with two plain concaves and two separation concaves on each rotor.

F

With this configuration of the concaves, the machine can be used to harvest cereals.

Separation and plain concaves can be fitted if so wished X 4

– see page 5.4.8, Changing the separation concaves and the plain concaves LEXION 470.

Positioning of the separation concaves and the plain concaves: Note!

The plain concaves must always be fitted at the front of the machine.

1, 2 = plain concaves 3, 4, 5 = separation concaves X = larger hole dimension for the middle of the machine F = Direction of travel (Fig. 4)

6.4.2

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Fitting the grain harvesting equipment

5

Fitting the cover plates LEXION 480 Should the machine suffer from an overload on the sieve box e.g. with loads of broken straw, then it is possible to cover the separation rotor with from 2 to 6 cover plates (55).

The cover plates must always be fitted in pairs, starting from the back of the machine and always on the inner side of the rotors (X).

(Fig. 5)

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

6.4.3

Fitting the grain harvesting equipment Frog mouth sieves For harvesting cereals, the cereal frog mouth sieve must be installed.

Operating with lower sieve When harvesting cereals, both the lower and upper sieves are utilised.

For this, the returns need to be opened.

Opening the returns: In order to open the returns – see page 5.4.16, Removing and fitting the sieves.

6

Slacken the returns floor (L) at (A), place the grain return (C) onto the returns (B). Tighten the bolts for the returns pan at (A).

(Fig. 6)

Fit the top and bottom sieves back into the machine – see page 5.4.16, Removing and fitting the sieves.

Dependant on the machine, either fit the Bowden cable or the adjustment motors back to the sieves.

To machine serial number …

Refit the Bowden cable back to the top and bottom sieves – see page 5.4.24, Sieve – basic adjustment (electric adjustment – to machine number ...)

From machine serial number ...

Fit the top and bottom adjustment motors – see page 5.4.25, Sieve – basic adjustment (electrical sieve adjustment – from machine serial number ...)

Grain tank unloading / restrictor plates – see page 5.4.26, Adjusting grain tank unloading / restrictor plates

6.4.4

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Fitting the grain harvesting equipment

H

41652

1

STRAW CHOPPER LEXION 460 – 405

Removing the straw plate or raising it LEXION 410 / 405 (fixed chopper) type 452 Danger!

Cover the chopper cylinder – risk of injury!

When wishing to remove the straw plate it is advantageous to have a working platform above the chopper cylinder.

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

6.5.1

Fitting the grain harvesting equipment When the machine is going to be put into cereal harvesting, then the two rubber curtains (D and G) must be removed from the machine. Either the curtains are removed on their own or along with the brackets.

Should only the curtains be removed from the machine, then it is necessary that the bracket (H) is raised up under the hood of the machine, where the gas springs will hold it in position.

G

D

(Fig. 1, 2, 3) 2

H

3

6.5.2

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Fitting the grain harvesting equipment

4

Removing the straw plate LEXION 460 – 410 (fixed chopper) type 542, 543, 544 Danger!

Cover the chopper cylinder – risk of injury!

When wishing to remove the straw plate (20) it is advantageous to have a working platform above the chopper cylinder.

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

6.5.3

Fitting the grain harvesting equipment When the machine is going to go into cereal harvesting then the straw plate (20) must be removed.

C G B

Remove the hex bolts (F) and remove the rubber curtain (G) out of the back of the machine.

F

On the left hand bracket (C), knock out the expansion pin and remove the washer. On the right hand bracket (B) knock out the inner expansion pin.

F

Unbolt the right hand bracket (B) from the side wall of the machine and then remove the straw plate out through the rear of the machine.

5

Unbolt the left hand bracket (C).

(Fig. 4, 5, 6)

B

6

6.5.4

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Fitting the grain harvesting equipment

53090

7

Refitting the straw guide plate for cereal harvesting LEXION 460 – 415 Danger!

Cover the chopper cylinder – risk of injury!

When wishing to remove the straw plate (22) it is advantageous to have a working platform above the chopper cylinder.

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

6.5.5

Fitting the grain harvesting equipment – The bolts (T) on both sides need to be slackened and turned back.

– The bar (R), needs to be pulled back and the guide rubber swung up.

T

– Lock the rubber with the bar (R).

– Swing the straw plate (22) towards the rear.

– Fix the straw plate (22) in the rear position using the bolts (T). Counter the bolts to the side wall.

R

(Fig. 7, 8, 9) 8

9

Adjusting the straw chopper LEXION 460 – 405 Danger!

For all work carried out on the straw chopper, ensure that the threshing has been switched off, the engine is stopped and the ignition keys have been removed.

When the engine is switched off, please note that the chopper cylinder will continue to run for a short period afterwards.

Caution – risk of injury!

☞ Whenever working on the chopper cylinder, always ensure that you wear gloves.

☞ Always stop the chopping cylinder from rotating.

6.5.6

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Fitting the grain harvesting equipment Removing the straw chopper knives (maize) (hydraulically adjustable straw chopper) L

In order to gain better access to the chopping cylinder, the straw plate (L) can be lowered down.

M

For this, the straw deflector fixing bolts (S) need to be removed, then remove the deflectors themselves.

P

Slightly slacken the nuts (M) for the fixing of the plate (P). Then pull the plate (P) so far that the guide plate (L) is still being held. Swing the guide plate downwards.

S

10

Remove all the blades from the cylinder.

(Fig. 10, 11)

L

11

Removing the straw chopper knives (maize) (fixed straw chopper) R

In order to gain better access to the chopping cylinder, the straw plate (L) can be removed.

L

For this, the straw deflector fixing bolts (S) need to be removed.

Remove the pin (R) from the straw deflectors so that the deflectors may be removed.

S

12

Hold the guide plate (L), then remove the soc cap screws (Z). The plate (P) needs to be pulled approx 10 mm towards the outside, then remove the guide plate.

Remove all the bladed from the cylinder.

(Fig. 12, 13)

13

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

6.5.7

Fitting the grain harvesting equipment Fitting the cereals blades to the chopper cylinder For chopping cereal straw, lighter knives can be used.

On each blade mount (H) on the cylinder, two blades can be fitted. The blades must also be free to move.

Bolt the cereal blades (58) onto the cylinder as per fig. 14.

H F

Danger!

Only use genuine nuts and bolts.

41682

14 Torque setting: M 10-10.9 = 65 Nm Important!

Bolts that have been subject to the Dacromet thread lock additive (silver / grey) are torqued up to a slightly lower degree.

Torque setting: Bolts with the Dacromet thread lock additive M 10-10.9 = 55 Nm Note the sticker on the chopper cylinder.

58 59 60 61 62

Blade (maize) Hex bolt M 10 x 55 DIN 931-10.9 Bush D 30 x 14,25 Bush D 30 x 10 x 5 Hex nut VM 10 DIN 980-10

H = Blade mount F = Direction of travel Bolt back the straw guide plate (L) and tighten.

If necessary fit back the straw deflectors.

(Fig. 14)

6.5.8

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Fitting the grain harvesting equipment Removing the guard Unbolt the guard (31) Retighten the bolts (E).

(Fig. 15) 31

E

E

15

Adjusting the stationary blades Danger!

Take care – risk of injury, always wear gloves.

In order to adjust the two piece stationary knife, slacken off the fixing bolts (U) in the slots.

16

Adjust the single stationary knife (Q), so that the distance (Y) when the blades are at their closest, i.e when completely swung out, is 5 mm.

After adjusting, retighten the fixing bolts (U).

(Fig. 16)

Adjusting the stationary blades R

C

D

By rotating the stationary blades in their holder, the chop length can be changed.

For this the hex bolts (E and D) on both sides of the housing need to be slackened.

E

Direction A = shorter chop Direction B = longer chop After adjustment retighten the hex bolts (E and D) on both sides.

17

When harvesting rape, the knives need to be positioned in the completely lowered position.

(Fig. 17)

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

6.5.9

Fitting the grain harvesting equipment Fitting all the blades into the stationary knife Carry out the following procedure: – The bar (R) must be positioned at the same height as the hole (C) (Fig. 17).

– Remove the spring clip (K) from the right hand side of the bar (R).

K

– Remove the bar – From the outside, start inserting all the blades.

– Reinsert the bar and secure with the spring clip.

18

(Fig. 18, 19, 20)

C

R

D

19

20

6.5.10

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Fitting the grain harvesting equipment STRAW CHOPPER LEXION 480 / 470

Adjusting the straw chopper For all work carried out on the straw chopper, ensure that the threshing has been switched off, the engine is stopped and the ignition keys have been removed.

When the engine is switched off, please note that the chopper cylinder will continue to run for a short period afterwards.

Caution – risk of injury!

☞ When ever working on the chopper cylinder, always ensure that you wear gloves!

☞ Always stop the chopping cylinder from rotating.

Removing the maize knives from the stationary knife L

LEXION 480 In order to gain better access to the chopper cylinder, the straw guide plate (L) can be swung down.

M

For this the straw guide plate needs to be swung forwards and the nuts (M) removed.

Remove the straw guide plate (L).

Remove all the blades from the chopping cylinder.

1

(Fig. 1, 2)

2

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

6.6.1

Fitting the grain harvesting equipment Removing the straw chopper knives (maize) LEXION 470 In order to gain better access to the chopping cylinder, the straw plate (L) can be removed.

For this, the straw deflector fixing bolts (S) need to be removed.

Remove the pin (R) from the straw deflectors so that the deflectors may be removed.

3

Hold the guide plate (L), then remove the soc cap screws (Z). The plate (P) needs to be pulled approx 10 mm towards the outside, then remove the guide plate.

Remove all the bladed from the cylinder.

(Fig. 3, 4)

4

6.6.2

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Fitting the grain harvesting equipment Fitting the cereals blades to the chopper cylinder For chopping cereal straw, lighter knives can be used.

On each blade mount (H) on the cylinder, two blades can be fitted. The blades must also be free to move.

Bolt the cereal blades (58) onto the cylinder as per fig. 5.

H F

Danger!

41682

Only use genuine nuts and bolts.

5

Torque setting: M 12-10.9 = 80 Nm Important!

Bolts that have been subject to the Dacromet thread lock additive (silver / grey) are torqued up to a slightly lower degree.

Torque setting: Bolts with the Dacromet thread lock additive M 12-10.9 = 65 Nm Note the sticker on the chopper cylinder.

58 59 60 61 62

Blade (maize) Hex bolt M 12 x 65 DIN 931-10.9 Bush D 35 x 16 Bush D 35 x 7,5 Hex nut VM 12 DIN 980-10

H = Blade mount F = Direction of travel Bolt back the straw guide plate (L) and tighten.

(Fig. 5)

Remove the rubber curtain LEXION 480 Unbolt the rubber curtain (28) along with the rails and the mushroom headed bolts (29).

29

(Fig. 6) 28

6

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

6.6.3

Fitting the grain harvesting equipment Adjusting the stationary blades Danger!

Take care – risk of injury, always wear gloves.

In order to adjust the two piece stationary knife, slacken off the fixing bolts (U) in the slots.

7

Adjust the single stationary knife (Q), so that the distance (Y) when the blades are at their closest, i.e. when completely swung out, is 5 mm.

After adjusting, retighten the fixing bolts (U).

(Fig. 7)

Adjusting the stationary blades By rotating the stationary blades in their holder, the chop length can be changed.

C

R

For this the hex bolts (E and D) on both sides of the housing needs to be slackened.

Direction A = shorter chop

D

E

Direction B = longer chop After adjustment retighten the hex bolts (E and D) on both sides.

8

When harvesting rape, then the knives need to be positioned in the completely lowered position.

(Fig. 7, 8)

6.6.4

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Fitting the grain harvesting equipment Fitting all the blades into the stationary knife Carry out the following procedure: – The bar (R) must be positioned at the same height as the hole (C) (Fig. 8).

K

– Remove the spring clip (K) from the right hand side of the bar (R).

– Remove the bar – From the outside, start inserting all the blades.

– Reinsert the bar and secure with the spring clip.

9

(Fig. 9, 10, 11)

C

R

D

10

11

Chopper preparation pan (optional) LEXION 480 – see page 5.6.7, Chopper preparation pan (performance)

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

6.6.5

Fitting the grain harvesting equipment

6.6.6

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Fitting the grain harvesting equipment DRIVES Threshing drum speed adjustment Two step drive (optional) – see page 5.7.1, Threshing drum speed adjustment

N

(Fig. 1) N

1

Adjusting the speeds of the separation rotors LEXION 480 / 470 – see page 5.7.2, Adjusting the speeds of the separation rotors LEXION 480 / 470 (Fig. 2)

F H 2

Increasing the chopper speed LEXION 410 / 405 (fixed chopper) type 452 LEXION 430 – 410 (fixed chopper) type 543

A

When harvesting cereals, it is recommended that the speed is increased.

– see page 5.7.4, Chopper speed reduction LEXION 410 / 405 (fixed chopper) type 452 LEXION 430 – 410 (fixed chopper) type 543

S 41683

With Lexion 410 / 405 (Fixed chopper) Type 452: 3

Important!

The jockey pulley (S) along with the distance piece need to be turned round and bolted back into position. This means that the distance piece needs to be on the left hand side of the jockey pulley.

Place the drive belt (A) from the intermediate drive to the chopper, needs to be put into the inner step.

(Fig. 3)

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

6.7.1

Fitting the grain harvesting equipment Increasing the chopper speed LEXION 460 – 415 (adjustable chopper) type 454 LEXION 430 – 410 (adjustable chopper) type 543, 542

C

H

B M

When harvesting cereals, it is recommended that the speed is increased.

– see page 5.7.6, Chopper speed reduction LEXION 460 – 415 (adjustable chopper) type 454 LEXION 430 – 410 (adjustable chopper) type 543, 542

A

Important!

41684

4

The drive belt (B) on the inner step of the intermediate drive (M) and on the middle step on the intermediate drive (H).

Place the drive belt (A) onto the outer step of the chopper drive, and the intermediate drive (M).

Put on the drive belt (C).

(Fig. 4)

Reducing the chopper drum speed LEXION 460 / 450 (fixed chopper) type 547 LEXION 470 (fixed chopper) type 545, 541 LEXION 480 (fixed chopper) type 546, 548 When harvesting cereals, it is recommended that the speed is increased.

– see page 5.7.9, Chopper speed reduction LEXION 460 / 450 (fixed chopper) type 547 LEXION 470 (fixed chopper) type 545, 541 LEXION 480 (fixed chopper) type 466, 546, 548 5

Important!

The drive belt (11) on the intermediate drive (G) and on the chopper drive needs to be moved from the inner groove to the outer groove of the pulleys.

(Fig. 5)

6.7.2

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Fitting the grain harvesting equipment Increasing the chopper speed (LEXION 480 – uni spreader)

C

When harvesting cereals, it is recommended that the speed is increased.

M

Recommended working conditions – see page 5.7.12, Chopper speed reduction LEXION 480 (Uni spreader).

B

Important!

41685

6

The drive belt (B) from the intermediate drive (M) and to the chopper needs to be moved from the inner groove to the outer groove of the pulley.

(Fig. 6)

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

6.7.3

Fitting the grain harvesting equipment

6.7.4

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Fitting the grain harvesting equipment ADJUSTMENT Note Depending on the crop type, the adjustments such as drum speed, fan speed, concave adjustment etc can be done, depending on the machine.

The adjustment is carried out as follows: – Machine and system adjustment with the instrument monitor IMO Or – CLAAS bordinformationsystem CEBIS The exact description of the adjustments can be found in the relative operators book under the CEBIS or if necessary IMO sections.

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

6.8.1

Fitting the grain harvesting equipment

6.8.2

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

7 Index

Index INDEX A Additional weights .................................................................. 5.1.2 Additional weights .................................................................. 6.1.2 Adjusting grain tank unloading / restrictor plates ................. 5.4.26 Adjusting the curtain behind the impeller LEXION 460 – 405 ................................................................. 5.3.9 Adjusting the curtain behind the impeller LEXION 460 – 405 ................................................................. 6.3.5 Adjusting the speeds of the separation rotors LEXION 480 / 470 .................................................................. 5.7.2 Adjusting the speeds of the separation rotors LEXION 480 / 470 .................................................................. 6.7.1 Adjusting the stationary blades .............................................. 6.5.9 Adjusting the stationary blades .............................................. 6.5.9 Adjusting the stationary blades .............................................. 6.6.4 Adjusting the stationary blades .............................................. 6.6.4 Adjusting the stationary knives ............................................ 5.5.12 Adjusting the stationary knives .............................................. 5.6.3 Adjusting the straw chopper ................................................... 6.6.1 Adjusting the straw chopper LEXION 460 – 405 ................................................................. 6.5.6 Adjusting the straw guide plate .............................................. 5.5.9 Adjustment ............................................................................. 5.8.1 Adjustment ............................................................................. 6.8.1 Adjustment of the support ...................................................... 5.2.1 Adjustment of the support ...................................................... 6.2.1 B Bolts ....................................................................................... 3.1.3 C CCM – Straw walker risers LEXION 460 – 405 ................................................................. 5.4.1 CCM – Straw walker risers LEXION 460 – 405 ................................................................. 6.4.1 Changing the pre concave segments (large stone trap) .................................................................... 6.3.1 Changing the pre concave segments (small stone trap) ................................................................... 6.3.1 Changing the separation concaves and the plain concaves LEXION 470 ........................................................................... 5.4.8 Changing the separation concaves and the plain concaves LEXION 470 ........................................................................... 6.4.2 Changing the separation concaves LEXION 480 ........................................................................... 6.4.1 Changing the separation concaves LEXION 480 ........................................................................... 5.4.3 Chopper preparation pan – cereals ....................................... 5.6.7 Chopper preparation pan – maize with rubber mat ................ 5.6.8 Chopper preparation pan (optional) LEXION 480 ........................................................................... 6.6.5 Chopper preparation pan (performance) ............................... 5.6.7 Chopper speed reduction LEXION 480 (Uni spreader) ................................................. 5.7.12 Chopper speed reduction LEXION 410 / 405 (fixed chopper) type 452 LEXION 430 – 410 (fixed chopper) type 543 ......................... 5.7.4

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

Chopper speed reduction LEXION 460 – 415 (adjustable chopper) type 454 LEXION 430 – 410 (adjustable chopper) type 543, 542 ........

Chopper speed reduction LEXION 460 / 450 (fixed chopper) type 547 LEXION 470 (fixed chopper) type 545, 541 LEXION 480 (fixed chopper) type 466, 546, 548 ..................

Conversion from cereals to maize, corn cob mix (CCM) harvesting ..............................................................................

Conversion from maize and corn cob mix (CCM) to cereals .

Correct use ............................................................................

Covering the stone trap (large stone trap) ...................................................................

Covering the stone trap (small stone trap) ...................................................................

5.7.6

5.7.9 4.1.1 4.1.4 3.1.2 5.3.3 5.3.3

D Drives .................................................................................... 5.7.1 Drives .................................................................................... 6.7.1 Drum housing ........................................................................ 5.3.1 E Extending the front attachment horns on the trunking ........... 6.2.1 F Fitting all the blades into the stationary knife ...................... 6.5.10 Fitting all the blades into the stationary knife ........................ 6.6.5 Fitting in the sieves (to machine serial number ...) .............................................. 5.4.20 Fitting separation concaves (from machine serial number 466 00160) ............................. 6.4.2 Fitting separation concaves (to machine serial number 466 00159) .................................. 6.4.2 Fitting the blades to the chopper cylinder (maize) ............... 5.5.15 Fitting the blades to the chopper cylinder (maize) ................. 5.6.6 Fitting the cereals blades to the chopper cylinder ................. 6.5.8 Fitting the cereals blades to the chopper cylinder ................. 6.6.3 Fitting the cover plates for the threshing drum (maize and corn cob mix CCM) ............................................. 5.3.7 Fitting the cover plates LEXION 480 .......................................................................... 6.4.3 Fitting the riser plates (without the 3D cleaning system) ........................................ 5.4.14 Fitting the separation concaves and the plain concaves LEXION 470 ........................................................................ 5.4.12 Fitting the separation concaves LEXION 480 (from machine number 466 00160) ....................................... 5.4.6 Fitting the separation concaves LEXION 480 (to machine number 466 00159) ........................................... 5.4.7 Fitting the sieves (from machine serial number ...) ......................................... 5.4.23 Fitting the straw guide plate Lexion 410 / 405 (fixed chopper) type 452 ............................ 5.5.3 Fitting the straw guide plate Lexion 460 / 410 (fixed chopper) type 542, 543, 544 ............ 5.5.5 Fitting the straw guide plate Lexion 460 / 410 (hydraulically adjustable chopper) type 453, 454, 457, 543, 544, 547 ......................................... 5.5.8

7.1.1

Index Fitting the threshing cover bars to the threshing drum (corn cob mix CCM) ............................................................... 5.3.8 Fitting the threshing segments (large stone trap) .................................................................... 6.3.3 Fitting the threshing segments (small stone trap) ................................................................... 6.3.2 Frog mouth sieves ................................................................. 6.4.4 G General information ............................................................... 3.1.1 Grain tank unloading / restrictor plates .................................. 6.4.4 H Hydraulic connections ............................................................ 3.1.4 Hydraulic lock (optional extra) ....................................................................... 5.2.1 I Identification of warning and danger signs ............................. 3.1.2 Important ................................................................................ 3.1.1 Increasing the chopper speed (LEXION 480 – uni spreader) ................................................ 6.7.3 Increasing the chopper speed LEXION 460 – 415 (adjustable chopper) type 454 LEXION 430 – 410 (adjustable chopper) type 543, 542 ........ 6.7.2 Increasing the chopper speed LEXION 410 / 405 (fixed chopper) type 452 LEXION 430 – 410 (fixed chopper) type 543 ......................... 6.7.1 Index ...................................................................................... 7.1.1 Introduction ............................................................................ 1.1.1 L Lateral risers LEXION 460 – 405 ................................................................. 5.4.1 Lateral risers LEXION 460 – 405 ................................................................. 6.4.1 Locking the cutterbar ram springs .......................................... 5.2.1 Locking the cutterbar ram springs .......................................... 6.2.1 M Mechanical locking ................................................................. 5.2.1 Multifinger separation system (Dependant on machine type) ................................................ 5.4.2 N Note ....................................................................................... 5.8.1 Note ....................................................................................... 6.8.1 O Opening the chaff spreader LEXION 470 / 460 – 405 ...................................................... 5.4.16 Operating with lower sieve ..................................................... 6.4.4 Operation without the lower sieve ........................................ 5.4.14 R Reducing the chopper drum speed LEXION 460 / 450 (fixed chopper) type 547 LEXION 470 (fixed chopper) type 545, 541 LEXION 480 (fixed chopper) type 546, 548 ........................... 6.7.2 Refitting the straw guide plate for cereal harvesting LEXION 460 – 415 ................................................................. 6.5.5

7.1.2

Remove the rubber curtain LEXION 480 .......................................................................... 6.6.3 Removing and fitting the sieves ........................................... 5.4.16 Removing every blade from the stationary knife ................. 5.5.13 Removing every blade from the stationary knife ................... 5.6.4 Removing every other blade from the stationary knife ........ 5.5.13 Removing every other blade from the stationary knife .......... 5.6.4 Removing separation concaves (from machine serial number 466 00160) .............................. 6.4.2 Removing separation concaves (to machine serial number 466 00159) .................................. 6.4.2 Removing the blades from the chopper cylinder (cereals) (fixed chopper) ..................................................................... 5.5.14 Removing the blades from the chopper cylinder (cereals) (hydraulically adjustable chopper) ....................................... 5.5.14 Removing the blades from the straw chopper cylinder (cereals) LEXION 470 .......................................................................... 5.6.5 Removing the blades from the straw chopper cylinder (cereals) LEXION 480 .......................................................................... 5.6.5 Removing the cover bars ....................................................... 6.3.4 Removing the cover plate for the stone trap (large stone trap) ................................................................... 6.3.1 Removing the cover plate for the stone trap (small stone trap) ................................................................... 6.3.1 Removing the guard .............................................................. 6.5.9 Removing the lower sieve (from machine serial number ...) .......................................... 5.4.22 Removing the lower sieves (to machine serial number ….) ............................................ 5.4.18 Removing the maize knives from the stationary knife LEXION 480 .......................................................................... 6.6.1 Removing the preparation floor (chopper) LEXION 480 ........................................................................ 5.4.16 Removing the separation concaves and the plain concaves LEXION 470 .......................................................................... 5.4.9 Removing the separation concaves Lexion 480 (to machine serial number 466 00159) .................................. 5.4.6 Removing the separation concaves Lexion 480 (from machine serial number 466 00160) .............................. 5.4.4 Removing the straw chopper knives (maize) (fixed straw chopper) ............................................................. 6.5.7 Removing the straw chopper knives (maize) (hydraulically adjustable straw chopper) ............................... 6.5.7 Removing the straw chopper knives (maize) LEXION 470 .......................................................................... 6.6.2 Removing the straw plate or raising it LEXION 410 / 405 (fixed chopper) type 452 .......................... 6.5.1 Removing the straw plate LEXION 460 – 410 (fixed chopper) type 542, 543, 544 ......... 6.5.3 Removing the threshing segments (large stone trap) ................................................................... 5.3.6 Removing the threshing segments (small stone trap) ................................................................... 5.3.4 Removing the top sieve (from machine serial number ...) .......................................... 5.4.20

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Index Removing the top sieves (to machine serial number ...) .............................................. 5.4.17 Replacing the pre concave (large stone trap) .................................................................... 5.3.2 Replacing the pre concave (small stone trap) ................................................................... 5.3.1 Retracting the front attachment horns on the trunking ........... 5.2.2 Retracting the stationary knives ........................................... 5.5.11 Retracting the stationary knives ............................................. 5.6.2 Rotor speed regulator (option) ................................................................................... 5.7.3 Rotor speed schematic LEXION 470 ..................................... 5.7.3 Rotor speed schematic LEXION 480 ..................................... 5.7.3 S Safety ..................................................................................... 5.1.1 Safety ..................................................................................... 6.1.1 Separation / cleaning / unloading ........................................... 5.4.1 Separation / cleaning / unloading ........................................... 6.4.1 Shipping package .................................................................. 4.1.1 Sieve – basic adjustment (electric adjustment – to machine number ...) ...................... 5.4.24 Sieve – basic adjustment (electrical sieve adjustment – from machine serial number ...) ........................................... 5.4.25 Sieve selection ..................................................................... 5.4.12 Stepped drive (optional) ................................................................................ 5.7.2 Straw chopper adjustment LEXION 460 – 405 ............................................................... 5.5.10 Straw chopper adjustment LEXION 480 / 470 .................................................................. 5.6.1 Straw chopper LEXION 460 – 405 ................................................................. 5.5.1 Straw chopper LEXION 460 – 405 ................................................................. 6.5.1 Straw chopper LEXION 480 / 470 .................................................................. 5.6.1 Straw chopper LEXION 480 / 470 .................................................................. 6.6.1 Straw guide plate ................................................................... 5.5.1 T Threshing drum housing ........................................................ 6.3.1 Threshing drum speed adjustment ........................................ 5.7.1 Threshing drum speed adjustment ........................................ 6.7.1 Torque settings ...................................................................... 3.1.3 Torque settings for the axial clamping bolts for the top and lower sieves .................................................................. 5.4.20 Torque settings for the axial clamping bolts for the top and lower sieves .................................................................. 5.4.23 Trunking ................................................................................. 5.2.1 Trunking ................................................................................. 6.2.1 Two step drive (optional) ........................................................ 5.7.1 Two step drive (optional) ........................................................ 6.7.1 U Unbolting the cover plates LEXION 480 ........................................................................... 5.4.8

188 312.4 - UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405

7.1.3

Index

7.1.4

UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 - 188 312.4

Following the policy of CLAAS KGaA mbH to improve their products as technical developments continue, CLAAS reserve the right to make alterations which must not necessarily correspond to text and illustrations contained in this publication, and without incurring obligation to alter any machines previously delivered.

Technical data, dimensions and weights are given as an indication only. Responsibility for errors and omissions not accepted.

Reproduction or tanslation of this publication, in whole or in part, is not permitted without the written consent of CLAAS KGaA mbH. All rights under the provision of the Copyright Act are reserved.

CLAAS KGaA mbH 33426 HARSEWINKEL Germany

Our contribution to the environment: CLAAS have printed this manual on 100% chlorine free paper.

CLAAS KGaA mbH 33426 HARSEWINKEL Germany

188 312.4 UA Getreide- / Maisdrusch LEXION 480 / 470 / 460 - 405 GB - 06.03 - BEV Printed in Germany