CLAAS LEXION 580 TERRA TRAC LEXION 560 TERRA TRAC Fitting and Operating Instructions Manual

LEXION 580 TERRA TRAC LEXION 560 TERRA TRAC

Fitting and Operating Instructions

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1 Introduction

Introduction

Introduction INTRODUCTION

This present manual describes the fitting, operation and maintenance of the combine harvesters LEXION 580 Terra Trac and LEXION 560 Terra Trac.

The text and pictures were kept neutral as far as possible. Differences between the individual types are mentioned in picture titles or in the text.

Also have the regular inspections performed by your CLAAS certified garage. Neglect in maintenance or incorrect operation cause to reduced performance lag and loss of time.

This manual only applies when used in combination with the respective combine harvester manual. Only differences are listed.

Your CLAAS Service Department

0299 131.1 - ABA/BA LEXION 580/560 Terra Trac

1.1.1

Introduction

1.1.2

ABA/BA LEXION 580/560 Terra Trac - 0299 131.1

2 Contents

Contents

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

2. Contents Contents ................................................................................ 2.1.1

3. General information Traffic ..................................................................................... 3.1.1 Important ................................................................................ 3.2.1 Identification plate / serial number ......................................... 3.3.1 Basic machine ................................................................. 3.3.1 Track roller unit ................................................................ 3.3.1

4. Safety rules Safety rules ............................................................................ 4.1.1 Identification of warnings and danger signs .................... 4.1.1 Correct use ...................................................................... 4.1.1 General safety and accident prevention regulations ....... 4.1.1 Drive operation ................................................................ 4.1.2 Front attachments (cutterbar and others) and other components ............................................................ 4.1.2 Safety decals with pictorials ................................................... 4.2.1

5. Technical data

Maintenance instruction .................................................. 9.2.1 Aligning the rubber belt on the track roller unit ................ 9.2.1 Tensioning the track roller unit ........................................ 9.2.5 Bleeding the system ........................................................ 9.2.5 Tensioning the system .................................................... 9.2.6 Using the hydraulic system of the threshing drum variable speed drive ........................................................ 9.2.7 Oil change ....................................................................... 9.2.8 Preparing for oil change .................................................. 9.2.9 Hubs of the front idler wheels ........................................ 9.2.10 Hubs of the middle idler wheels .................................... 9.2.10 Gearbox of the drive wheels ......................................... 9.2.10 Gearbox ........................................................................ 9.2.11 Torque settings of the wheel bolts of the idler and drive wheels .................................................................. 9.2.12 Torque settings of the fastening screws at the half-track gearbox ......................................................... 9.2.12 Torque settings of the fastening screws at the support wheels .............................................................. 9.2.12

10. Lubrication chart Lubricants and notes ........................................................... 10.1.1

11. Index Index .................................................................................... 11.1.1

LEXION 580 Terra Trac ......................................................... 5.1.1 LEXION 560 Terra Trac ......................................................... 5.2.1

6. Shipping Package Shipping Package .................................................................. 6.1.1 Terra Trac suspension parts kit 764 605.0 ...................... 6.1.1 Half-track left/right parts kit 764 220.0 ............................. 6.1.2

7. Installation Installing the half-tracks ......................................................... 7.1.1 Installing the Terra Trac suspension ............................... 7.1.1 Preparing the installation ................................................. 7.1.1 Installing the half-track left / right ..................................... 7.1.5 Installing the mirror bracket extension (V). ...................... 7.1.9 Installing the electrical connection to the switch console . 7.1.9 Test of brake function .................................................... 7.1.10 Aligning the rubber belt on the track roller unit .............. 7.1.11 Installing the front ladder ........................................................ 7.2.1

8. Operation Operation ............................................................................... 8.1.1 Switch console ................................................................. 8.1.1 Threshing parts ................................................................ 8.1.1 Stone trap ........................................................................ 8.1.1 Removing and installing the preconcave segments ........ 8.1.2 Removing the threshing segment .................................... 8.1.3 Installing the threshing segment ...................................... 8.1.4 Disawning ........................................................................ 8.1.5

9. Maintenance Maintenance .......................................................................... 9.1.1 MaintenanceTable ........................................................... 9.1.1 Lubricants chart ............................................................... 9.1.2

0299 131.1 - ABA/BA LEXION 580/560 Terra Trac

2.1.1

Contents

2.1.2

ABA/BA LEXION 580/560 Terra Trac - 0299 131.1

3 General information

General information

General information TRAFFIC

Number plate

Aside from a driving licence, the machine operator must always carry a photocopy of the general operating approval of the federal motor vehicle department, a hazard warning triangle and, for machines with a total permissible load over 4 metric tons, at least one wheel chock when driving the combine harvester.

As a self-propelled machine with a maximum speed of 20 km/h, the combine harvester is not subject to registration and licensing. However, the machine must be marked on the left side with first and last name as well as the city or town of residence of the owner and this marking must be clear and waterproof.

When driving the combine harvester on public roads, all requirements listed in the photocopy of the general operating approval of federal motor vehicle department (§ 18 Sec. 5 StVZO = Straßenverkehrszulassungsordnung = road vehicle (registration and licensing) regulations) under the letter C must be observed.

Pulling trailers on the hitch when driving on public roads is not permitted.

The rules for road vehicle regulations may be different in the individual countries. In the case of deviations from the manufacturer's specifications, the regulations of the respective countries always apply.

For machines with wide load (load extending over the tyres), an operating approval for single vehicles (individual certification) and a special approval in accordance with § 70, sec. 1, no. 1 and 2 of the StVZO must be carried in place of the photocopy of the general operating approval. In addition, all requirements listed in the operating approval for single vehicles and/or in the special approval must be observed. Granting of the special approval is different for each state of FRG. The wide load must be signed following the guidelines for marking vehicles over normal width. (Two warning signs each in front and rear, protection bar, two warning lights for yellow flash light – warning beacon).

If parts of the combine harvester, whose condition is prescribed or whose operation can cause a risk of other road users, are changed later, then the operating approval is no longer valid and a new operating approval must be requested. For this purpose, it is necessary to present the machine to the responsible technical inspection station for motor vehicle traffic (TÜV) for certification (§ 19 Sec. 2 StVZO).

If you are in the doubt if this case applies, contact us as the manufacturer.

If a transport vehicle for front attachments is pulled behind the combine harvester, then the light cable must be connected and the light system must be checked for proper operation.

If the combine harvester is equipped with a maize picker and/or with a folding cutterbar, the regulations and requirements of the general operating approval must be observed, in particular the requirements for additional weights and tyres.

0299 131.1 - ABA/BA LEXION 580/560 Terra Trac

3.1.1

General information

3.1.2

ABA/BA LEXION 580/560 Terra Trac - 0299 131.1

General information

General information IMPORTANT

The instructions contained in this installation and operating manual should be carefully read and observed by all persons who are concerned with the operation, maintenance and inspection of this cutterbar in order to prevent accidents.

Especially the »Safety Rules« in the operator's manual should be read.

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

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

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.

0299 131.1 - ABA/BA LEXION 580/560 Terra Trac

3.2.1

General information

3.2.2

ABA/BA LEXION 580/560 Terra Trac - 0299 131.1

General information

General information

1

IDENTIFICATION PLATE / SERIAL NUMBER Basic machine A B C D E F G H I J

= = = = = = = = = =

Optional equipment Authorised total weight Type Identification no. (serial number of machine) Authorised front axle load Year of manufacture Rated capacity of the combine harvester (kW) Authorised rear axle load Approval no. according to ECE-R 24 Absorption coefficient according to ECE-R 24

The identification plate is located on the right side of the machine above the steering axle.

Track roller unit The identification plate stating the serial no. is fitted to the rear frame of the half tracks.

(Fig. 1)

0299 131.1 - ABA/BA LEXION 580/560 Terra Trac

3.3.1

General information

3.3.2

ABA/BA LEXION 580/560 Terra Trac - 0299 131.1

4 Safety rules

Safety rules

Safety rules SAFETY RULES Read and observe the fitting, operating and safety instructions before putting into operation!

Identification of warnings and danger signs All parts of this operating instructions 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.

Gefahr!

The warning and instruction signs placed on the combine harvester provide important recommendations for safe operation. These instructions involve your safety - observe them at all times!

Correct use The self-propelled combine harvester is designed exclusively for common applications in agriculture (correct use).

The use for any other than the originally intended purpose is considered as improper use; the manufacturer is not liable for damage that results from improper use; only the user bears the risk.

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

Proper use includes that the manufacturers instructions regarding operations, service and maintenance are observed.

☞ Preventive measures.

The combine harvester may be used, serviced, and repaired only by persons who are familiar with the machine and are instructed about the risks.

Achtung!

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.

Common accident prevention regulations and other established regulations for safety, occupational health and traffic rules must be observed.

Installation of, and refitting with, additional systems that are not original CLAAS equipment as well as changes and modifications may be performed only with permission by CLAAS as they may significantly affect the safety and function of the machine.

Unauthorised modifications to the machine void the manufacturer's liability for resulting damages.

Hinweis!

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

Beachten!

Sign to indicate instructions which must be observed on disassembly/assembly.

Umwelt!

General safety and accident prevention regulations 1. Apart from the recommendations in this manual, observe general safety rules and accident prevention regulations.

2. Observe the respective regulations when using public traffic routes.

3. Before beginning the work, make yourselves familiar with all operating equipment and their function. Once you are driving, it will be too late for this!

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

4. Before starting the engine, make sure that all safety devices are installed and are in protection position.

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

5. Start the engine only from the driver’s seat.

The engine must not be started by short circuiting the electrical connections at the starter as the machine may otherwise be set in motion immediately!

0299 131.1 - ABA/BA LEXION 580/560 Terra Trac

4.1.1

Safety rules 6. Before starting, check close range (children!).

Make sure to have sufficient view. Honk the horn as an additional safety precaution!

7. Before driving and work begin, adjust mirrors in such a way that the roadway and the work area rear can be fully seen.

7. Do not let engine run in closed areas!

8. Special caution is required when crossing railroad tracks.

If railroad tracks cannot be crossed quickly and without stopping because of traffic or because of an obstacle, then the machine must be stopped at the diagonal cross. Otherwise, railroad tracks must be crossed without stopping.

8. The driver's clothing should fit tightly. Avoid wearing loose clothes!

9. Be careful when handling fuel. - Increased risk of fire.

Never refuel in the proximity of open flames or ignitable sparks.

Do not smoke when refuelling!

10. Always turn off engine and remove ignition key before refuelling. Do not refuel in closed areas.

Wipe up spilled fuel immediately!

11. Keep machine clean to avoid risk of fire!

12. Be careful when handling brake fluid and battery acid (poisonous and corrosive)!

13. Before starting the engine and before switching on the threshing mechanism, honk the horn.

Watch out for children.

Transportation of people, guide, operating personnel 1. Beyond that, transporting people is not permissible!

2. The guide's seat may only be used by persons instructing the driver in the operation of the machine.

Drive operation 1. Observe permissible axle load and total weight!

2. The driving behaviour of a combine harvester are affected for example by the road and by the attachments. For this reason, driving must be adapted to the respective terrain and soil conditions. Special caution is required when operating and turning on a slope. Never shift gear to neutral on an incline!

3. On public roads and streets, the combine harvester may be driven only with an empty grain tank.

4. Never leave the operator's platform while driving.

5. Ensure sufficient safety distance from low-hanging power lines (watch out for radio antenna if applicable)!

6. When travelling on public roads with lifted attachment, the safety switch must be switched off.

4.1.2

Leaving the combine harvester 1. When leaving the combine harvester, secure it against rolling (parking brake, wheel chock).

Stop engine, remove ignition key and lock cab if necessary!

2. If the combine harvester is stopped for longer periods of time, disconnect battery isolator switch.

3. Never leave combine harvester unsupervised while the engine is in operation!

4. Before leaving the combine harvester, fully lower front attachments (cutterbar and others)!

Front attachments (cutterbar and others) and other components 1. Perform work under the lifted front attachments (cutterbar and others) only with the support secured!

2. Be especially careful when attaching front attachments (cutterbar and others) and when hitching a trailer!

3. Mower unit and cutterbar, intake auger, reel and the like cannot be completely secured by constructional measures due to their function.

Therefore a sufficient safety distance from these moving parts must be kept during the operation!

4. Feed chains and picking rollers of the maize picker head also cannot be completely secured within their picking area due to their function.

Therefore a sufficient safety distance from these moving parts must also be kept during the operation. These recommendations apply to all other attachments in a general manner!

5. Under the protection device of the straw chopper, there are dangerous cutting tools, which may run on after switching off the drive.

Therefore, a sufficient safety distance from the chopper must be kept until it comes to a standstill.

ABA/BA LEXION 580/560 Terra Trac - 0299 131.1

Safety rules 6. In the grain tank, there are conveyor auger, which cannot be secured completely against contact due to their function.

7. Before entering the grain tank, it must be ensured that not other person can start the machine again.

8. Only enter the grain tank through the opening provided.

9. On public roads and streets, the finger bar and the crop lifter must be covered if the cutterbar is carried along.

Air conditioner

Sound pressure level The sound pressure level at the driver's ear in the cab (door and window closed) is 79 dB (A).

Pressure accumulator Special caution when working on the pressure accumulators! Pressure accumulators are under high pressure!

For valve-controlled pressure accumulators, e.g. for the Autopilot, the short-circuit screw must first be released before beginning the repair work on the pressure reservoir. This is necessary to reduce the hydraulic pressure.

1. The air conditioner is filled with the HFC cooling agent R 134 A. HFC cooling agents must not enter the atmosphere! – Therefore be very cautions when handling the air conditioner.

2. Maintenance and repair work on the air conditioner may be performed only by professional cooling service garages. Refrigerant must always be sucked off and disposed for recycling.

Maintenance 1. Perform repair, maintenance and cleaning work and well as malfunction elimination only with the drive switched off and the engine standing still. Remove ignition key and disconnect the battery isolator switch.

2. Spilled fluids under high pressure (fuel, hydraulic oil, etc.) can penetrate the skin and cause severe injuries. Therefore see a physician immediately. Otherwise severe infections may result!

3. Careful when opening the radiator cap. The radiator is under pressure when the engine is hot!

4. Dispose of oil, fuels, and filters properly.

5. Mounting tyres requires sufficient qualification and proper assembly tools!

6. Re-tighten wheel nuts regularly!

7. Repair work on the hydraulic system may be performed only by a professional garage.

Basic rule Check the combine harvester for safe traffic and operating conditions before each putting into operation!

0299 131.1 - ABA/BA LEXION 580/560 Terra Trac

4.1.3

Safety rules

4.1.4

ABA/BA LEXION 580/560 Terra Trac - 0299 131.1

Safety rules

Safety rules SAFETY DECALS WITH PICTORIALS

Safety pictorials are attached to the danger areas of this machine. These safety signs help to alert persons to hazards which can cause personal injury.

The pictorials on these decals show how by correct behaviour can avoid injuries and accidents.

The placement of the safety pictorials on the machine and short text explanations are listed in the following The CLAAS parts no. of the decal is given before the text.

The numbers in ( ) show the correct placement of the corresponding safety decal on the machine in the accompanying figure.

Damaged and unrecognisable safety decals must be replaced immediately If parts with safety decals are replaced, it must be ensured that the corresponding safety decals are attached to the new parts.

0299 131.1 - ABA/BA LEXION 580/560 Terra Trac

4.2.1

Safety rules

Safety rules

56

1

2 515 139.0 (56) Pressure accumulators are under gas and oil pressure. Always perform dismounting and repair according to instruction in the technical manual.

(Fig. 1, 2)

4.2.2

ABA/BA LEXION 580/560 Terra Trac - 0299 131.1

5 Technical data

Technical data

Technical data

LEXION 580 TERRA TRAC For determining the technical specifications, machine was equipped with 8-cylinder engine, full fuel tank, cab with operator, rubber half-track, and tyres 600/55 - 26.5.

Cutterbar Specifications of the cutterbars - see operating instructions of „Cutterbars LEXION“ Height adjustment

electrohydraulical

Cutting height – Cutterbar with Auto-Contour

from -595 mm up to max. +1,440 mm*

– Cutterbar without Auto-Contour

from -625 mm up to max. +1,410 mm*

Clearance height (Bottom edge cutterbar skids) – Cutterbar with Auto-Contour

980 mm* with cutterbar suspension 1,270 mm* with locked cutterbar suspension

– Cutterbar without Auto-Contour

950 mm* with cutterbar suspension 1,240 mm* with locked cutterbar suspension *

Depending on tyre manufacturer, deviations of up to -50 mm are possible

Feeder housing

Chain conveyor

Cutterbar clutch

operated electrohydraulically

Threshing parts Stone trap

standard equipment

Concave

electrohydraulical instant adjustment, width 1700 mm

– Preconcave

3 segments, exchangeable for grain or the like: 7 bars, 6 sets of holes, wire N10, 10 x 35 for maize or the like: no bars, 6 sets of holes 19 x 40

Disawning – Main concave

1 threaded three-part threshing segment

– Preconcave

2 insertable disawner plates

Main concave

15 bars 3 sets of holes 12 x 32 12 sets of holes 19 x 40

Accelerator

Paddle drum ∅ 450 mm with wear caps

Threshing drum

Width 1680 mm Diameter 600 mm 8 beater bars (screwed), 7 drum floors

0299 131.1 - ABA/BA LEXION 580/560 Terra Trac

5.1.1

Technical data

LEXION 580 TERRA TRAC Drive – Two-stage variable speed drive (extra equipment)

V-belt variable speed drive: Continuous speed from 362-1050 rpm Continuous speed: first stage from 362-1050 rpm second stage from 158-457 rpm

Threshing mechanism clutch

Belt clutch, operated electrohydraulically

Forced separation

2 axial rotors, 10 separating grates

Axial rotors – Diameter

445 mm

– Speed

Stage drive: 640, 800, 962 rpm Special speed: 500 / 300 rpm

– Hydraulic variable speed drive (optional equipment)

Continuous speed from 360-1050 rpm

Separating grates – Standard

Perforation 40 x 20

– Maize / CCM

Perforation 40 x 40

Separating area

7.48 m2

Total separating area

9.85 m2

Cleaning

Radial fan, 6-part

Air amount

continuous speed control, operated electrically

Sieve pan

under-ventilated step in the preparation floor, stepped sections removable towards the front

Dynamic side hill levelling (extra equipment)

3-D sieve pan (effective in three dimensions)

Top sieve

long-lipped frogmouth sieve

Lower sieve

short-lipped frogmouth sieve

Total grain sieve area

5.80 m²

Returns

Return to the accelerator

Grain tank Contents

10,500 litres (about 8.2 tonnes of wheat) Calculation in tonnes based on litre weight of 780g/l

Unloading tube

5.1.2

slewed hydraulically, operated electrohydraulically

ABA/BA LEXION 580/560 Terra Trac - 0299 131.1

Technical data

LEXION 580 TERRA TRAC Engine

DAIMLER CHRYSLER OM 502 LA

Cubic capacity [litres]

16

Maximum speed - no load [rpm]

2080

Rated speed [rpm]

2000

Mean idle speed (1/2) [rpm]

1500

Slow idle speed [rpm]

1200 ± 20

Reduced speed [rpm] in third gear at 20 km/h

1695 ± 10

Reduced speed [rpm] in third gear at 25 km/h

2080 ± 10

+10

Engine power at rated speed Power (EEC 80/1269) kW (HP) at 2,100 rpm

340 (462)

Power (ECE R 24) kW (HP) at 2,100 rpm

316 (430)

Cooling liquid Alternator

160 A

Battery

12 V, 210 Ah

Fuel tank Contents

800 litres

Auxiliary fuel tank (optional equipment) Contents

180 litres

Ground drive

hydrostatic, Operation via control lever in right arm rest of driver's seat

Gearbox

3 drive levels each for forward and reverse drive first and second drive level:operating gear third drive level: road gear

0299 131.1 - ABA/BA LEXION 580/560 Terra Trac

5.1.3

Technical data

LEXION 580 TERRA TRAC

Ground speeds Speed range

first from 0 to6.7 km/h second from 0 to10.8 km/h third from 0 to20.0 km/h(from 0 to25.0 km/h) The reverse ground speed is about 70 % of the forwardtravel speed.

Ground speeds in parentheses apply only to certain countries.

For countries with a speed limit of 20 km/h, the drive control is adjusted accordingly.

Driving axle drive

Final drive, oil bath

Steering

hydrostatic

Brakes Foot brake

hydraulically controlled disc brakes, also designed as independent brake

Parking brake

foot-operated mechanical drum brake, independent

5.1.4

ABA/BA LEXION 580/560 Terra Trac - 0299 131.1

Technical data

LEXION 580 TERRA TRAC Tyre and air pressures

Torque settings of the wheel bolts Drive axle

Wheel bolts M 24 x 3 - 10.9 = 1000 Nm

Steering axle

Wheel bolts M 22 x 1.5 x 45-8.8 and spring washer C 22.5 DIN 74361 (limes type conical spring washer)= 520 Nm

Steering drive axle

Wheel bolts M 20 x 1.5 and countersunk collar nut= 500 Nm

Total weight Base machine without front attachment with variable speed drive for front attachment drive (maize picker) with straw chopper and uni-spreader fan with steering drive axle with full fuel tank with driver

0299 131.1 - ABA/BA LEXION 580/560 Terra Trac

21,700 kg

5.1.5

Technical data LEXION 580 TERRA TRAC Dimensions of the combine harvester

A = Clearance between the tyre / rubber belts B = Track width C = Width over tyre / rubber belts

Options tyre

A

B

C

Options steering axle Rigid steering axle – flange width 3.04 m (◆ = wheel rims reversed) 500/70 R 24 IMP

2,501 mm

2,990 mm

3,479 mm

600/55 - 26.5 IMP

2,275 mm

2,759 mm

3,800 mm

480/80 R 26 IND

2,575 mm

3,059 mm

3,649 mm

Steering drive axle – flange width 2.90 m1) / 3.05m2) 500/70 R 24

1)

2,510 mm

2,980 mm

3,499 mm

500/70 R 24

2)

2,660 mm

3,130 mm

3,649 mm

600/55 - 26.5

2)

2,461 mm

3,134 mm

3,807 mm

2,853 mm

3,488 mm

Drive axle Rubber track roller unit

5.1.6

2,218 mm

ABA/BA LEXION 580/560 Terra Trac - 0299 131.1

Technical data LEXION 580 TERRA TRAC

Transport position / working position WIDTH B

without front attachment – see also width over tyre / rubber belts

Transport position

Working position

3,488 mm

–

3,975 mm

4,895 mm

– – –

3,840 mm 4,050 mm 4,160 mm

8,780 mm 9,060 mm 9,200 mm

– – –

with cutterbar or maize picker, see »front attachments«

– see manual of front attachments HEIGHT H

Top edge grain tank Bottom edge of grain tank unloading tube sleeve, short Bottom edge of grain tank unloading tube sleeve long Bottom edge of grain tank unloading tube sleeve, extra long

LENGTH

Basic machine (height of bottom edge feeder housing 500 mm)

L1 L2 L3

to rear edge rear hood to rear edge of straw spreader safety frame to rear edge of grain tank unloading tube sleeve, extra long with maize picker, 8-row with maize picker, 6-row with straw chopper, rear edge of rear hood to safety frame with straw spreader, rear edge of rear hood to safety frame all linear measures to rear edge of rear hood

0299 131.1 - ABA/BA LEXION 580/560 Terra Trac

5.1.7

Technical data LEXION 580 TERRA TRAC

Rubber track roller unit Belt width C Length of drive belt surface area A

635 mm 1,825 mm

Number of idler wheels per side

2

Number of drive wheels per side

2

Number of medium wheels per side

4

5.1.8

ABA/BA LEXION 580/560 Terra Trac - 0299 131.1

Technical data

Technical data

LEXION 560 TERRA TRAC For determining the technical specifications, machine was equipped with 6-cylinder engine, full fuel tank, cab with operator, rubber half-track, and tires 16.24/85 - 24 - 14 PR. Cutterbar Specifications of the cutterbars - see operating instructions of „Cutterbars LEXION“ Height adjustment

electrohydraulical

Cutting height – Cutterbar with Auto-Contour

from -595 mm up to max. +1,440 mm*

– Cutterbar without Auto-Contour

from -625 mm up to max. +1410 mm*

Clearance height (Bottom edge cutterbar skids) – Cutterbar with Auto-Contour

980 mm* with cutterbar suspension 1,270 mm* with locked cutterbar suspension

– Cutterbar without Auto-Contour

950 mm* with cutterbar suspension 1,240 mm* with locked cutterbar suspension *

Depending on tyre manufacturer, deviations of up to -50 mm are possible

Feeder housing

Chain conveyor

Cutterbar clutch

operated electrohydraulically

Threshing parts Stone trap

standard equipment

Concave

electrohydraulical instant adjustment, width 1700 mm

– Preconcave

3 segments, exchangeable for grain or the like: 7 bars, 6 sets of holes, wire N10, 10 x 35 for maize or the like: no bars, 6 sets of holes 19 x 40

Disawning – Main concave

1 threaded three-part threshing segment

– Preconcave

2 insertable disawner plates

Main concave

3 bars, 3 sets of holes 12 x 32 (pre-concave) Wire grate N18, 13 bars, 13 sets of holes Wire grate N10, 13 bars, 13 sets of holes (optional equipment)

Accelerator

Paddle drum ∅ 450 mm with wear caps

Threshing drum

Width 1680 mm Diameter 600 mm 8 beater bars (screwed), 7 drum floors

0299 131.1 - ABA/BA LEXION 580/560 Terra Trac

5.2.1

Technical data

LEXION 560 TERRA TRAC Drive – Two-stage variable speed drive (extra equipment)

V-belt variable speed drive: Continuous speed from 395– 1150 rpm Continuous speed: first stage from 395– 1150 rpm second stage from 166– 483 rpm

Threshing mechanism clutch

Belt clutch, operated electrohydraulically

Straw walkers

consisting of straw walker rack Number of racks Number of straw walker crankshafts

6 2 7.48 m2 9.85 m2

Straw walkers area Separating area Drum with 44 multiple fingers Cleaning Forced air cleaning fan

Radial fan, 6-part

Air amount

continuous speed control, operated electrically

Sieve pan

under-ventilated step in the preparation floor, stepped sections removable towards the front

– Standard sieve pan

divided

– 3-D sieve pan (optional equipment)

Dynamic side hill levelling, effective in three dimensions

Top sieve

long-lipped frogmouth sieve

Lower sieve

short-lipped frogmouth sieve

Total grain sieve area

5.80 m²

Returns

Return to the accelerator

Grain tank Contents

10.500 litres (about 8.2 tonnes of wheat) Calculation in tonnes based on litre weight of 780g/l

Unloading tube

5.2.2

slewed hydraulically, operated electrohydraulically

ABA/BA LEXION 580/560 Terra Trac - 0299 131.1

Technical data

LEXION 560 TERRA TRAC Engine

CATERPILLAR C10

Cubic capacity [litres]

10,3

Maximum speed - no load [rpm]

2184 –30

Rated speed [rpm]

2100

Mean idle speed (1/2) [rpm]

1500

Slow idle speed [rpm]

1200 ± 20

Reduced speed [rpm] in third gear at 20 km/h

1781 ± 10

Reduced speed [rpm] in third gear at 25 km/h

2180 ± 10

+20

Engine power at rated speed Power (EEC 80/1269) kW (HP) at 2100 rpm

266 (362)

Power (ECE R 24) kW (HP) at 2,100 rpm

250 (340)

Cooling liquid

approx. 40.0 litres

Alternator

160 A / 12 V

Battery

12 V, 210 Ah

Fuel tank Contents

800 litres

Ground drive

hydrostatic, Operation via control lever in right arm rest of driver's seat

Gearbox

3 drive levels each for forward and reverse drive first and second drive level:operating gear third drive level: road gear

0299 131.1 - ABA/BA LEXION 580/560 Terra Trac

5.2.3

Technical data

LEXION 560 TERRA TRAC Ground speeds Speed range

1. from 0 to6.7 km/h 2. from 0 to10.8 km/h 3. from 0 to20.0 km/h (from 0 to25.0 km/h) The reverse ground speed is about 70 % of the forwardtravel speed.

Ground speeds in parentheses apply only to certain countries.

For countries with a speed limit of 20 km/h, the drive control is adjusted accordingly.

Driving axle drive

Final drive, oil bath

Steering

hydrostatic

Brakes Foot brake

hydraulically controlled disc brakes, also designed as independent brake

Parking brake

foot-operated mechanical drum brake, independent

5.2.4

ABA/BA LEXION 580/560 Terra Trac - 0299 131.1

Technical data

LEXION 560 TERRA TRAC Tyre and air pressures

Torque settings of the wheel bolts Drive axle

Wheel bolts M 24 x 3 - 10.9 = 1000 Nm

Steering axle

Wheel bolts M 22 x 1.5 x 45-8.8 and spring washer C 22.5 DIN 74361 (limes type conical spring washer)= 520 Nm

Steering drive axle

Wheel bolts M 20 x 1.5 and countersunk collar nut= 500 Nm

Total weight Base machine without front attachment with variable speed drive for front attachment drive (maize picker) with straw chopper and uni-spreader fan with steering axle with full fuel tank with driver

0299 131.1 - ABA/BA LEXION 580/560 Terra Trac

18500 kg

5.2.5

Technical data LEXION 560 TERRA TRAC Dimensions of the combine harvester

A = Clearance between the tyre / rubber belts B = Track width C = Width over tyre / rubber belts

Options tyre

A

B

C

Options steering axle Rigid steering axle – flange width 3.04 m (◆ = wheel rims reversed) 500/70 R 24 DMP

2501 mm

2990 mm

3479 mm

600/55 - 26.5 DMP

2275 mm

2759 mm

3800 mm

Steering drive axle – flange width 2.90 m1) / 3.05m2) 16.5/85 - 24 IMP1)

2611 mm

3000 mm

3489 mm

16.5/85 - 24 IMP2)

2661 mm

3150 mm

3539 mm

500/70 R 24 IMP1)

2510 mm

2980 mm

3499 mm

500/70 R 24 IMP2)

2660 mm

3130 mm

3649 mm

2552 mm

3152 mm

3800 mm

2853 mm

3488 mm

600/55 - 26.5

2)

Drive axle Rubber track roller unit

5.2.6

2218 mm

ABA/BA LEXION 580/560 Terra Trac - 0299 131.1

Technical data LEXION 560 TERRA TRAC

Transport position / working position WIDTH B

without front attachment

Transport position

Working position

3488 mm

–

3975 mm

4640 mm

– – –

3840 mm 4050 mm 4160 mm

8780 mm 8890 mm 9060 mm 9200 mm

– – – –

11420 mm 3490 mm

– –

(see also width over tyre / rubber belts) with cutterbar or maize picker, see »front attachments«

HEIGHT H

Top edge grain tank 10,500 litres Bottom edge of grain tank unloading tube sleeve, short Bottom edge of grain tank unloading tube sleeve, long Bottom edge of grain tank unloading tube sleeve, extra long

LENGTH

Basic machine (height of bottom edge feeder housing 500 mm)

L1 L2 L3 L4

to rear edge rear hood to rear edge straw chopper safety cover to rear edge of straw spreader safety frame to rear edge of grain tank unloading tube sleeve, extra long with cutterbar 4.5 m, hinged with cutterbar, hinged Front attachment measurement from centre steering wheel

0299 131.1 - ABA/BA LEXION 580/560 Terra Trac

5.2.7

Technical data LEXION 560 TERRA TRAC with cutterbar 5,4 m, hinged with cutterbar, hinged Front attachment measurement from centre steering wheel Conspeed Front attachment measurement from centre steering wheel with 6-row Conspeed Front attachment measurement from centre steering wheel with 8-row Conspeed

12020 mm 4120 mm

– –

3700 mm 11540 mm 3820 mm 11670 mm

– – – –

all linear measures to rear edge of rear hood Rubber track roller unit Belt width D Length of drive belt surface area E

635 mm 1825 mm

Number of idler wheels per side

2

Number of drive wheels per side

2

Number of medium wheels per side

4

5.2.8

ABA/BA LEXION 580/560 Terra Trac - 0299 131.1

6 Shipping Package

Shipping Package

Shipping Package

3

5

2

2

5

4 6

1

1

SHIPPING PACKAGE Terra Trac suspension parts kit 764 605.0 Pos. no. Parts no.

1

2 3 4 5 6

764 570.0 764 581.0 764 577.0 236 901.2 235 650.2 764 569.0 237 591.0 327 965.0 212 191.0 764 576.0

Description Wedge, mounted Connector Shaft, short Expansion pin Expansion pin Wedge bearing Hexagon head bolt Hexagon head bolt Contact washer Shaft long

Dimension

ISO

D 30 x 195 8 x 36 5 x 36 M 20 x 60 M 20 x 55 A 20 D 35 x 285

4017-8.8 4017-8.8

Quantity 2 2 2 4 4 4 4 4 8 1

(Fig. 1)

0299 131.1 - ABA/BA LEXION 580/560 Terra Trac

6.1.1

Shipping Package

2

3 1

9

10 7 4 11 8

2

Half-track left/right parts kit 764 220.0 Pos. no. Parts no.

1

2 3 4 5 6 7 8 9 10 11 12 13

14

6.1.2

764 593.0 750 067.0 750 432.0 218 060.0 212 191.0 750 256.2 233 419.0 233 323.0 764 221.0 764 222.0 750 057.1 233 893.0 239 389.0 213 588.0 750 057.1 244 378.0 235 132.1 215 226.0 237 370.0 239 387.0 236 170.0 237 370.0 239 387.0 236 828.0 236 170.0

Description

Dimension

Track axle Pressure ring O-ring Hexagon head bolt Contact washer Universal drive shaft Hexagon head bolt Self-locking nut Half-track left Half-track right Washer Hexagon head bolt Contact washer O-ring Lid Hexagon head bolt Spring washer Pipe clamp Hexagon head bolt Contact washer Hexagonal nut Hexagon head bolt Contact washer Washer Hexagonal nut

D 385 x 350 D 190 x 12 V 190 A M 20 x 70 A 20 M 12 x 40 VM 12

D 130 M 12 x 30 A 12 140 x 3 - N D 178 x 28 M 8 x 25 8 Rsgu 21 M 8 x 30 A8 M8 M 8 x 30 A8 30 x 8.5 x 2 M8

ISO

Quantity

4014-10.9

4014-10.9 7042-10

4014-10.9

4014-10.9

4014-8.8

4014-8.8

2 2 2 24 24 2 16 16 1 1 2 8 8 2 2 10 10 2 1 1 1 1 1 2 1

ABA/BA LEXION 580/560 Terra Trac - 0299 131.1

Shipping Package Pos. no. Parts no.

15

237 871.0

Description

Dimension

Cable band

4.7 x 188

ISO

Quantity 8

(Fig. 2)

0299 131.1 - ABA/BA LEXION 580/560 Terra Trac

6.1.3

Shipping Package

6.1.4

ABA/BA LEXION 580/560 Terra Trac - 0299 131.1

7 Installation

Installation

Installation INSTALLING THE HALF-TRACKS Installing the Terra Trac suspension Gefahr!

Installing the Terra Trac suspension only for harvest operation and not for transport of the machine.

Preparing the installation Gefahr!

Stop the engine and switch off the battery isolator switch (T).

T (Fig. 1)

1 Raise the feeder housing and secure it with a lifting device.

(Fig. 2)

2 Hang out the cutterbar cylinder in front: Remove the split pins and push out the pin (B).

(Fig. 3)

B

B

3

0299 131.1 - ABA/BA LEXION 580/560 Terra Trac

7.1.1

Installation Lift the drive axle with a hydraulic device on the mounting side.

(Fig. 4)

4 Remove the lock for rocker arm on the rear side of the drive axle.

Remove the split pin and push out the pin (Z).

(Fig. 5)

Z

5 Screw on the wedge bearing (2) with a hexagon head bolt (3) and a contact washer (5).

Hang in the mounted wedge (1) with the shaft (6).

3

Make the shaft (6) flush.

6

(Fig. 6)

2 1

6 Screw on the second wedge bearing (2) with a hexagon head bolt (4) and a contact washer (5).

(Fig. 7) 4

2

1

7

7.1.2

ABA/BA LEXION 580/560 Terra Trac - 0299 131.1

Installation Fold the mounted wedge (1) up into the housing.

Fasten the wedge bearing (2) with the second hexagon head bolt (3) and (4) on both sides.

Torque = 370 Nm (Fig. 8) 4 1

3

8 Positioning the wedge on one side (see arrow).

Align the wedge in centre with a mounting lever.

(Fig. 9, 10)

9

10 Slowly lower the drive axle with uniform contact of the spring elements on both sides (see arrows).

(Fig. 11)

11

0299 131.1 - ABA/BA LEXION 580/560 Terra Trac

7.1.3

Installation Correct end position of the spring elements after complete lowering of the drive axle (see arrows).

(Fig. 12, 13)

12

13 Incorrect position of the wedge!

After lowering the drive axle, the spring elements on one side are not in contact.

(Fig. 14)

14 Reattach the lock of the rocker.

Compress the spring elements with a chain hoist (750 kg of tensile force).

Insert the pin (B) and secure it with split pins on both sides.

(Fig. 15) Hang the cutterbar cylinders back in with pins and secure it with split pins.

B

15

7.1.4

ABA/BA LEXION 580/560 Terra Trac - 0299 131.1

Installation Installing the half-track left / right Release the auxiliary wheels on both sides.

(Fig. 16)

16 Support the machine securely under the axle and align it on both sides.

Minimum height = 800 mm from middle of wheel to the ground (Fig. 17)

17 Remove the auxiliary wheels and the auxiliary hubs.

18

0299 131.1 - ABA/BA LEXION 580/560 Terra Trac

7.1.5

Installation Screw the track axle (1) to the drive axle with hexagon head bolts (2) on the left and on the right.

Torque = 525 Nm. (Fig. 19) 1

19

1 2

20 Check if the pressure ring (D) was pushed onto the track axle (1) with the chamfer towards the inside.

Check if the nose of the o-ring (F) points outward.

(Fig. 21)

21 Lift the half-track (6) up with lifting devices.

Remove the pallet.

Lower half-track (6) onto two elevating trucks.

(Fig. 22)

6

22

7.1.6

ABA/BA LEXION 580/560 Terra Trac - 0299 131.1

Installation

6

Always screw one universal drive shaft (3) to the roller unit together with the telescoping section. When doing this, pay attention to the mounting position of the stud in the telescopic section. To do so, use eight hexagon head bolts (4).

3

4

Move the half-track (6) in longitudinal direction by hand to be able to reach all hexagon head bolts (4) when tightening them.

Torque = 110 Nm

23

The larger diameter of the telescopic section must point in direction of the gearbox when doing this.

(Fig. 23)

Remove the self-locking nuts (S) and the washers in front of the brake disk of the gearbox!

(Fig. 24)

S

24 Carefully push the half-track (6) onto the track axle (1) with an elevating truck without damaging the bushing!

(Fig. 25)

6

25

0299 131.1 - ABA/BA LEXION 580/560 Terra Trac

7.1.7

Installation When pushing onto the contact surface (G) of the receiving drilled hole, push against the O-ring (F) and the pressure ring (D).

(Fig. 26, 27)

G

26

27 Screw on one disk (7) with four hexagon head bolts (8).

Torque = 110 Nm (Fig. 28)

7

28 Fill receiving drilled hole with fluid lubricant, using a grease gun, until grease flows out of the drilled hole (see arrow).

(Fig. 29)

29

7.1.8

ABA/BA LEXION 580/560 Terra Trac - 0299 131.1

Installation Place one O-ring (9) onto the lid (10) and screw it on with five hexagon head bolts (11).

Torque = 33 Nm (Fig. 30) 10

30 Screw on the universal drive shaft (3) with the existing self-locking nuts (S).

3

Torque = 110 Nm. (Fig. 31)

S

31 Installing the mirror bracket extension (V).

Screw on the mirror bracket extension (V) on the left side of the machine.

(Fig. 32) V

32 Installing the electrical connection to the switch console From the right half-track, lay the cable (K1) along the drive axle.

13

12

Fasten the cable (K1) with a pipe clamp (12) and a hexagon head bolt (13).

(Fig. 33)

K1

33

0299 131.1 - ABA/BA LEXION 580/560 Terra Trac

7.1.9

Installation Fasten the cable (K1) to the existing hydraulic lines with cable band (15).

Join the cable plug with pressure switch (see arrow).

(Fig. 34)

15 K1

34 From the left half-track, lay the cable (K2) along the drive axle.

Fasten the cable (K2) with a tube clamp (12) and a hexagon head bolt (14).

(Fig. 35)

12 14

K2 35 Fasten the cable (K2) to the existing hydraulic lines with cable band (15).

15

Join the cable plug with pressure switch (see arrow).

(Fig. 36)

15

K2

36

Test of brake function Beachten!

Perform the test at maximum road travel speed.

During the braking process, check for one-sided braking action!

After this test, with the machine being stopped, check the brake disks at the gearbox behind the drive axle for free movement.

7.1.10

ABA/BA LEXION 580/560 Terra Trac - 0299 131.1

Installation Aligning the rubber belt on the track roller unit Required under the following criteria: 1. Installing new roller units.

2. Installing new rubber belts.

3. Installing new idler wheels or drive wheels.

Preparing the temperature measurement: This measurement requires the probe 360 269.0 and the multimeter (Fluke 75) 181 980.1.

Ideally, only operate the multimeter and the probe with fresh batteries.

Set the shift switch (T) on the probe to degrees Celsius (°C).

Stick the red plug (R) of the probe into the V-socket of the multimeter.

Stick the black plug (S) into the COM socket.

Set the multimeter to 300 mV. Only turn on the ON/OFF switch (W) at the probe immediately before the measurement, as it automatically switches back to standby after 10 minutes.

Preparing the road travel: 37

The tension of the belts should be around 15,000 kPa (150 bar, 2,160 psi).

Locate an even road with a straight section as long as possible.

(Fig. 37)

Begin the procedure: Drive the machine forward at maximum road speed over a distance of about 1.6 km (1 mile), avoiding steering movements if possible. Then let the machine roll in neutral gear without steering movements until it comes to a stop.

If the distance of the straight travel is less than 1.6 km (1 mile), only stop after the maximum possible distance of the final turn.

38

Immediately measure the temperature at the visible guide blocks in the upper area of the belt, at the points (F) inside and outside of one guide block. A temperature of a single guide block that deviates 10°C (18°F) from the neighbouring guide blocks should be ignored.

The measuring points (F) are located according to the measurement (Y) about 45 mm (1.77 in) from the base of the guide block. Switch the probe on at the ON/OFF switch (W) and keep it about 50 mm (1.97 in) away from the idler wheel. Read the temperature on the multimeter.

0299 131.1 - ABA/BA LEXION 580/560 Terra Trac

7.1.11

Installation When doing this, wait a moment until the value is stabilised and then note the values of several guide blocks of the left and right side of the rubber belt.

The permissible temperature difference between the inner and the outer side of a guide block is 5°C (9°F).

(Fig. 37, 38)

If the temperature difference is more than 5°C (9°F), make adjustments to the link (X).

(Fig. 39)

X

39 Unscrew the hexagon head bolts (K) and remove the lock tabs (S) from the half-track frame on both sides.

(Fig. 40) K

S

40 On the guide block side with the lower temperature, release the hexagon head bolts (L) (turn counterclockwise).

(Fig. 41) L

41

7.1.12

ABA/BA LEXION 580/560 Terra Trac - 0299 131.1

Installation Tighten both hexagon head bolts (L) (turn clockwise) Torque = 200 Nm. First tighten the hexagon head bolt (L) on the side with the highest temperature.

Then keep turning the two hexagon head bolts (L) until the lock tab (S) can be screwed on with the hexagon head bolt (K).

(Fig. 40, 41)

If the temperature difference is more than 11°C (20°F), start by releasing the first hexagon head bolt (L) with 1/2 turns.

If the temperature difference is less than 11°C (20°F) release the hexagon head bolt (L) with 1/6 turns (60°).

(Fig. 41)

After making the adjustments drive the machine again and check the guide block temperatures.

In case of temperature differences between interior and exterior of a guide block that are lower than 11°C (20°F), make adjustment in steps of 1/6 turns (60°).

If the opposite side is now warmer, reverse the adjustment process until the guide block temperature shows a difference of less than 5°C (9°F).

The smaller the temperature differences, the finer the adjustments must be.

0299 131.1 - ABA/BA LEXION 580/560 Terra Trac

7.1.13

Installation Example:

K

1. The temperature check shows that the inner side of a guide block is 20°C (36°F) warmer than the outer side.

S

• Remove the lock tabs (S) and the screws (K).

• Release the outer set screw (L) by 1/2 turn (turn counterclockwise). Tighten the opposite screw.

• Torque = 200 Nm

42

• Perform another road test and temperature measurement.

2. The temperature difference is now 10°C (18°F), with the inner side still being the warmer side.

• Release the outer set screw (L) by 1/6 turn (60°). Tighten the inner screw (L).

• Torque 200 Nm

L

• Perform the road test.

3. Now the outer side is 6°C (10°F) warmer than the inside.

• Release the inner set screw (L) by 1/12 turn (30°) and tighten the outer screw (L).

43

• Torque = 200 Nm • Perform the road test.

4. The temperature difference is now 2°C (4°F).

• Check the torque of 200 Nm at the inner and outer set screw (L).

• Attach all lock tabs (S) and tighten them with screws (K).

(Fig. 42, 43)

7.1.14

ABA/BA LEXION 580/560 Terra Trac - 0299 131.1

Installation

Installation INSTALLING THE FRONT LADDER Unscrew the holder (H) from the ladder carrier.

Loosely insert the centre pieces (B) into the ladder carrier.

B

(Fig. 1)

H 1 Hang the pre-assembled ladder (L) into a suitable lifting tool.

Pre-assemble widening (A) with hexagonal head bolts (M 8 x 16).

(Fig. 2) L A

2 Insert the ladder (L) into the centre pieces (B).

Beachten!

L

B

Do not bend the rope.

Screw on holder (H) and ladder (L) with hexagonal head bolts (M 10 x 40 or M 10 x 35).

Screw on the brace (P) and the ladder (L) with the hexagon head bolts (M 10 x 40 or M 10 x 35).

H 3

(Fig. 3, 4)

P

H 4

0299 131.1 - ABA/BA LEXION 580/560 Terra Trac

7.2.1

Installation Insert the rail (G) into the widening (A).

G

Screw on the rail foot and the widening (A) with the hexagon head bolts (M 8 x 20).

(Fig. 5)

A

5 Insert the rail (B) into the widening (A) and the operator's platform.

Screw on the rail foot and the widening (A) with the hexagon head bolts (M 8 x 25).

B

(Fig. 6)

A 6 Fasten the rail (B) with the hexagon head bolts (M 10 x 20) below the ladder carrier.

B

Fasten the rope (Z) to the centre piece with pre-assembled holder (H).

Beachten!

Z

Position the holder (H) and the swivel arm (S) as shown.

H S 7

(Fig. 7)

Fasten the rail (G) below the ladder carrier together with the lever (L) and the brace (P), using the hexagon head bolts (M 10 x 20).

G

Hang the clevis (K) into the lever (L) of the ladder carrier and secure it with a split pin.

L

(Fig. 8) P K 8

7.2.2

ABA/BA LEXION 580/560 Terra Trac - 0299 131.1

Installation Installing the first level to the ladder: (before first putting into operation of the machine) Screw on the level with two rubber plates (P), four hexagonal head bolts M 8 x 25, and four self-locking nuts Vm 8.

(Fig. 9) P

P

9

0299 131.1 - ABA/BA LEXION 580/560 Terra Trac

7.2.3

Installation

7.2.4

ABA/BA LEXION 580/560 Terra Trac - 0299 131.1

8 Operation

Operation

Operation OPERATION LEXION 580 Terra Trac

Switch console In the switch console, there is an indicator light (28) for the rubber belt tension. In case of a drop in the belt tension of the track roller unit below 12,000 kPa (120 bar), the indicator light (28) lights up red. The hazard warning light (STOP) at the steering column also lights up red and an acoustic signal sounds.

28

In this case, perform the operating steps in the chapter ”Maintenance”, section ”Tensioning the track roller unit”.

1

(Fig. 1, 2)

LEXION 560 Terra Trac

28

2

Threshing parts Stone trap K Gefahr!

Whenever performing work below the feeder housing, the safety lock must be engaged.

R H

3

The stone trap located in front of the concave traps stones and other foreign elements and thus protects the threshing parts from damage.

Clean the stone trap daily. Clean it more frequently when operating on rocky soil and when working with lodged grain.

Open the stone trap:

F

Bring the feed rake into the highest position and engage the safety lock.

H

Unlock the latch (R) and fold up the door (K) at the lever (H). To lock the door (K), the spring (F) may be hung into the lever (H).

After emptying the stone trap, close and lock the door (K) again.

4

0299 131.1 - ABA/BA LEXION 580/560 Terra Trac

(Fig. 3, 4)

8.1.1

Operation

Removing and installing the preconcave segments S

S

S

Move the concave into the lowest position.

Completely lift the feeder housing.

W

W

Gefahr!

W

Stop the engine and switch off the battery isolator switch.

Whenever performing work below the feeder housing, the safety lock must be engaged.

5 Open the stone trap door.

Unscrew the hexagon head bolts (S) and remove the angle plates (W).

Beachten!

First remove the middle segment (K). Then push the outer segments slightly to the centre and remove them.

K

6

Clean the segment guides in the concave before installing the segments.

Insert the segments and screw on the angle plates (W).

(Fig. 5, 6, 7)

7

8.1.2

ABA/BA LEXION 580/560 Terra Trac - 0299 131.1

Operation Removing the threshing segment Move the concave into the lowest position. Fully lift the feed rake.

K

Gefahr!

M

F

Stop the engine and switch off the battery isolator switch.

Whenever performing work below the feeder housing, the safety lock must be engaged.

8 Open the stone trap door (K).

Open the stone trap. To do so, unscrew the tapped turn lock (M) and fold down the stone trap (F).

S

Unscrew the hexagon head bolts (S) of the threshing segment holder. The hexagon head bolts (S) are accessible from below the accelerator drum.

The threshing segment (D) can be removed through the opened door of the stone trap.

Achtung!

9

The hexagon head bolts (S) must be screwed back into the concave immediately after dismounting the threshing segment.

Otherwise, the tapped holes will be clogged.

(Fig. 8, 9, 10, 11)

D 10

0299 131.1 - ABA/BA LEXION 580/560 Terra Trac

8.1.3

Operation

11 Installing the threshing segment Move the concave into the lowest position.

Completely lift the feeder housing.

K Gefahr!

Stop the engine and switch off the battery isolator switch.

Whenever performing work below the feeder housing, the safety lock must be engaged.

D 12

Open the stone trap door (K).

Unscrew the hexagon head bolts (S) of the threshing segment holder. The hexagon head bolts (S) are accessible from below the accelerator drum.

S

The threshing segment (D) can be inserted through the opened door of the stone trap.

Screw on the threshing segment with the hexagon head bolts (S).

E = detail drawing (Fig. 11, 12, 13) 13

8.1.4

ABA/BA LEXION 580/560 Terra Trac - 0299 131.1

Operation Disawning U

Below the preconcave, there are the disawner doors (P), which can added on for better disawning by using the lever (N) if necessary.

N

Gefahr!

Operate the disawner doors only when the engine is stopped!

14

U = disawner doors added V = disawner doors switched off Hinweis!

Remove the disawner doors before maize threshing.

(Fig. 11, 14, 15)

V

N

15

0299 131.1 - ABA/BA LEXION 580/560 Terra Trac

8.1.5

Operation

8.1.6

ABA/BA LEXION 580/560 Terra Trac - 0299 131.1

9 Maintenance

Maintenance

Maintenance MAINTENANCE MaintenanceTable

100

working hours

every 50

100 working hours

250

after the harvest

daily

40

if necessary

after the first

each year = every 500 working hours

Maintenance intervals before harvest begin

Maintenance work

TRAVELLING MECHANISM – Hubs of the front idler wheels – Check oil level – Oil change – Hubs of the middle wheels – Check oil level – Oil change GEARBOX – Gearbox of the drive wheels – Check oil level – Oil change – Gearbox – Check oil level – Oil change

0299 131.1 - ABA/BA LEXION 580/560 Terra Trac

9.1.1

Maintenance Lubricants chart Component

Lubricant type

Filling capacity

SAE grade

Hubs of the front idler wheels

Transmission oil API-GL-5-90

0.5 litres / hub

90

Hubs of the middle wheels

Transmission oil API-GL-5-90

0.25 litres / hub

90

Gearbox of the drive wheels

Transmission oil API-GL-5-90

15.5 litres

90

Gearbox

Transmission oil API-GL-5-90

9 litres

90

9.1.2

Change times

Control

– siehe Seite 9.1.1, MaintenanceTable

– siehe Seite 9.1.1, MaintenanceTable

ABA/BA LEXION 580/560 Terra Trac - 0299 131.1

Maintenance

Maintenance Maintenance instruction Gefahr!

Perform repair, maintenance and cleaning work and well as malfunction elimination only with the drive switched off and the engine standing still. Remove the ignition key!

☞ Repairs to the energy storage devices (springs, accumulators, etc.) require sufficient qualification and proper assembly tools and may only be performed by certified garages.

Aligning the rubber belt on the track roller unit Required under the following criteria: 1. In case of one-sided wear of the guide block edges.

2. In case of one-sided heated contact surface at the guide blocks.

Preparing the temperature measurement: This measurement requires the probe 360 269.0 and the multimeter (Fluke 75) 181 980.1.

Ideally, only operate the multimeter and the probe with fresh batteries.

Set the shift switch (T) on the probe to degrees Celsius (°C).

Stick the red plug (R) of the probe into the V-socket of the multimeter.

Stick the black plug (S) into the COM socket.

Set the multimeter to 300 mV. Only turn on the ON/OFF switch (W) at the probe immediately before the measurement, as it automatically switches back to standby after 10 minutes.

Preparing the road travel: 1

The tension of the belts should be around 15,000 kPa (150 bar, 2,160 psi).

Locate an even road with a straight section as long as possible.

(Fig. 1)

0299 131.1 - ABA/BA LEXION 580/560 Terra Trac

9.2.1

Maintenance Begin the procedure: Drive the machine forward at maximum travel speed over a distance of about 1.6 km (1 mile), avoiding steering movements if possible.

Then let the machine roll in neutral gear without steering movements until it comes to a stop.

If the distance of the straight run is less than 1.6 km (1 mile), only stop after the maximum possible distance of the last turn.

2

Immediately measure the temperature at the exposed guide blocks in the upper area of the rubber belt, at the points (F) inside and outer side of one guide block.

A temperature of a single guide block that deviates 10°C (18°F) from the neighbouring guide blocks should be ignored.

The measuring points (F) are located according to the measurement (Y) about 45 mm (1.77 in) from the base of the guide block. Switch the probe on at the ON/OFF switch (W) and keep it about 50 mm (1.97 in) away from the idler wheel. Read the temperature on the multimeter.

When doing this, wait a moment until the value is stabilised and then note the values of several guide blocks of the left and right side of the rubber belt.

The permissible temperature difference between the inner and the outer side of a guide block is 5°C (9°F).

(Fig. 2)

If the temperature difference is more than 5°C (9°F), make adjustments to the link (X).

(Fig. 3)

X

3

9.2.2

ABA/BA LEXION 580/560 Terra Trac - 0299 131.1

Maintenance Unscrew the hexagon head bolts (k) and remove the lock tabs (S) from the half-track frame on both sides.

(Fig. 4) K

S

4 On the guide block side with the lower temperature, release the hexagon head bolts (L) (turn counterclockwise).

(Fig. 5) L

5 Tighten both hexagon head bolts (L) (turn clockwise) Torque = 200 Nm First tighten the hexagon head bolt (L) on the side with the highest temperature. Then keep turning the two hexagon head bolts (L) until the lock tab (S) can be screwed on with the hexagon head bolt (K).

(Fig. 4, 5)

If the temperature difference is more than 11°C (20°F), start by releasing the first hexagon head bolt (L) with 1/2 turns. If the temperature difference is less than 11°C (20°F) release the hexagon head bolt (L) with 1/6 turns (60°).

(Fig. 5)

0299 131.1 - ABA/BA LEXION 580/560 Terra Trac

9.2.3

Maintenance After making the adjustments drive the machine again and check the guide block temperatures.

In case of temperature differences between interior and exterior of a guide block that are lower than 11°C (20°F), make adjustment in steps of 1/6 turns (60°).

If the opposite side is now warmer, reverse the adjustment process until the guide block temperature shows a difference of less than 5°C (9°F).

The smaller the temperature differences, the finer the adjustments must be.

Example:

K

1. The temperature check shows that the inner side of a guide block is 20 °C (36°F) warmer than the outer side.

S

• Remove the lock tabs (S) and the screws (K).

Release the outer set screw (L) by 1/2 turn (turn counterclockwise). Tighten the opposite screw.

• Torque = 200 Nm • Perform another road test and temperature measurement.

6

2. The temperature difference is now 10°C (18°F), with the inside still being the warmerside.

• Release the outer set screw (L) by 1/6 turn (60°). Tighten the inner screw (L).

• Torque = 200 Nm • Perform the road test.

L

3. Now the outer side is 6°C (10°F) warmer than the inside.

• Release the inner set screw (L) by 1/12 turn (30°) and tighten the outer screw (L).

• Torque = 200 Nm 7

• Perform the road test.

4. The temperature difference is now 2°C (4°F).

• Check the torque of 200 Nm at the inner and outer set screw (L).

• Attach all lock tabs (S) and tighten them with screws (K).

(Fig. 6, 7)

9.2.4

ABA/BA LEXION 580/560 Terra Trac - 0299 131.1

Maintenance Tensioning the track roller unit L

This requires the hydraulic system of the threshing drum variable speed drive and the filling hose 350 189.0.

Screw on the L-connector (L) between the tube line and the hose line of the threshing drum variable speed drive (T).

F

Connect the filling hose (F) onto the quick release coupling.

T

(Fig. 8) 8 Remove the protective cap and connect the other end of the hose line (F) onto the filling connector (4) of the collector block.

(Fig. 9, 10) 4

9 Bleeding the system (only necessary after the system was opened for repair) This procedure requires two people.

1. Lead the oil drain hose (3) into a suitable container. If necessary, use a hose extension.

2. Open the breather valve (2) by about 1/4 to 1/2 turn.

F

3 10

3. Apply pressure to the system by using the hydraulic system of the threshing drum variable speed drive.

4. Open the filling valve (1) about 1/2 to 1 turn so that the tensioning cylinder can fill up and air can exit through the oil drain hose.

5. When no more bubbles exit, screw the breather valve (2) tight with 28 ± 7 Nm. (Fig. 10, 11)

11

0299 131.1 - ABA/BA LEXION 580/560 Terra Trac

9.2.5

Maintenance Tensioning the system This procedure requires two people.

After bleeding the system, tension the belts.

1. Open the filling valve (1) by about 1/2 to 1 turn.

2. Apply pressure to the system by using the hydraulic system of the threshing drum variable speed drive. Keep the pressure for at least 50 seconds, so that the system can load.

M

F 12

3. Keep applying pressure to the system and, at the same time, close the shut-off valve at the filling hose.

4. Turn off the hydraulic system of the threshing drum variable speed drive.

5. Verify that the pressure gauge (M) indicates 15,000 ± 520 kPa (150 ± 5.2 bar). If the pressure is to low, repeat the work procedures mentioned above.

6. Tighten the filling valve (1) with 28 ± 7 Nm. 7. Open the shut-off valve at the filling hose to release the pressure in the hose.

8. Remove the filling hose (F).

13

9. Check oil level in the hydraulic tank and fill up if necessary (see manual, chapter Maintenance).

(Fig. 12, 13)

9.2.6

ABA/BA LEXION 580/560 Terra Trac - 0299 131.1

Maintenance CEBIS

Using the hydraulic system of the threshing drum variable speed drive Remember the threshing drum speed as it may change after the following work procedures.

Turn on the threshing mechanism and set the maximum speed - no load.

Set the rotary switch to the position (D1).

Build up pressure: Push the button (C7).

Release pressure: Push the button (C6).

14

Tighten the filling valve (1) with 28 ± 7 Nm. Check the threshing drum speed and set it to the old value if necessary.

IMO

(Fig. 14, 15)

15 Hinweis!

There is a second possibility of tensioning the track roller unit. This procedure requires a tractor with hydraulic connection and the filling hose parts no. 360 268.0

0299 131.1 - ABA/BA LEXION 580/560 Terra Trac

9.2.7

Maintenance

16

Oil change Umwelt!

Dispose of waste oil properly!

Hinweis!

Oil type and oil filling capacity - c.f. page 9.1.2, Lubricants chart.

When checking the oil level, the machine must be in horizontal position. Oil must reach the drilled hole of the check plug.

Tighten all plug screws again firmly after the oil change or oil level check.

Gearbox drive wheels: A - Oil drain plug, E - Oil filler cap, K- Oil level check plug Hubs of the front idler wheels F - Oil drain and oil filler cap Hubs of the middle wheels M - Oil drain plug and oil filler cap (Fig. 16)

9.2.8

ABA/BA LEXION 580/560 Terra Trac - 0299 131.1

Maintenance Preparing for oil change Beachten!

Before an oil change, release the rubber belts.

Lead the oil drain hose (3) into a suitable container.

Open the breather valve (2) by about 1/4 to 1/2 turn.

The tensioning cylinders release automatically and thus relieve the belts.

2

3 17

If necessary, move the machine against wheel chocks (brake chocks) or the like to further push back the tensioning cylinders. Put wheel chocks down in front of the tracks and move the machine against it until the tensioning cylinders are pushed back completely.

Another option is attaching tensioning belts between the half-track frame and the front idler wheels and using it to push back the tensioning cylinders.

1. For the oil change of the gearbox of the drive wheels, the outer drive wheel of the track roller unit must be removed.

18

2. To check the oil level, the hole in the rim must be positioned correctly. The hole must be on the imagined horizontal hub centre. Then unscrew the oil level check plug (K). If necessary, fill up oil through the oil filler plug (E) until if flows out of the tapped hole for the oil level check plug.

3. To change the oil of the hubs of the front idler wheels, unscrew the screws (G) and remove the lid. Let oil drain into a suitable container. Screw the lid back on with new seal. Unscrew the oil level check plug (F) and fill up oil until it flows out of the tapped hole. Screw on the oil level check plug (F).

4. Check the oil level in the same operational sequence for screw (F).

19

(Fig. 17–20)

G F

20

0299 131.1 - ABA/BA LEXION 580/560 Terra Trac

9.2.9

Maintenance Hubs of the front idler wheels F

Oil change F = Oil check plug and oil filler cap (Fig. 21)

F

21

Hubs of the middle idler wheels Check oil level and change oil M = Oil check plug, oil drain plug and oil filler cap The oil must be checked at an angle of (X) approx. 7.5°.

(Fig. 22)

X

M

22

Gearbox of the drive wheels Check oil level

E

K= Oil level check plug Oil change A = Oil drain plug E = oil filler cap (Fig. 23, 24) A

23

24

9.2.10

ABA/BA LEXION 580/560 Terra Trac - 0299 131.1

Maintenance Gearbox Check oil level K = Oil level check plug (Fig. 25)

K

A 25 Oil change A = Oil drain plug with magnetic plug E

E = Oil filler plug and gear ventilation (Fig. 25, 26)

26

0299 131.1 - ABA/BA LEXION 580/560 Terra Trac

9.2.11

Maintenance Torque settings of the wheel bolts of the idler and drive wheels Re-tighten the wheel bolts (R) after the first 10 and 100 hours.

N

Hexagon head bolts M 24 x 70 DIN 933-10.9 Torque = 1000 Nm

R

Torque settings of the fastening screws at the half-track gearbox 27

Re-tighten wheel bolts (N) after the first 10 and 100 hours.

Hexagon head bolts M 16 x 1.5 x 65 DIN 961-10.9 Torque = min. 260 Nm - max. 300 Nm. Re-tighten wheel bolts (S) after the first 10 and 100 hours.

Securing bolt M 16 x 1.5 x 25 DIN 961-8.8 Torque = 210 Nm. (Fig. 27, 28)

28

Torque settings of the fastening screws at the support wheels Re-tighten the wheel bolts (R) after the first 10 and 100 hours.

Torque = 110 Nm. (Fig. 29)

29

9.2.12

ABA/BA LEXION 580/560 Terra Trac - 0299 131.1

10 Lubrication chart

Lubrication chart

Lubrication chart

LUBRICANTS AND NOTES

Brand-name grease Examples: Manufacturer Designation FINA ARAL FUCHS SHELL DEA AVIA EP» FAG SKF

«Marson EPL 2» «Aralub HLP 2» «Renolit EP 2» «Retinax EP 2» or «Alvania G3» «Glisando EP2» «Avilup special grease «Arcanol L 135 V» «LGEP2»

Every 100 working hours Every 50 working hours

If the pressure is too high, seals can burst!

Lubricate carefully!

Once a year (500 working hours)

0299 131.1 - ABA/BA LEXION 580/560 Terra Trac

10.1.1

Lubrication chart

10.1.2

ABA/BA LEXION 580/560 Terra Trac - 0299 131.1

Lubrication chart

Lubrication chart

1

1

0299 131.1 - ABA/BA LEXION 580/560 Terra Trac

10.1.3

Lubrication chart

2

2

10.1.4

ABA/BA LEXION 580/560 Terra Trac - 0299 131.1

Lubrication chart

1

2

1

0299 131.1 - ABA/BA LEXION 580/560 Terra Trac

2

10.1.5

Lubrication chart

3

3

10.1.6

4

4

ABA/BA LEXION 580/560 Terra Trac - 0299 131.1

Lubrication chart

1

1

0299 131.1 - ABA/BA LEXION 580/560 Terra Trac

10.1.7

Lubrication chart

2

2

10.1.8

ABA/BA LEXION 580/560 Terra Trac - 0299 131.1

11 Index

Index

Index INDEX A Aligning the rubber belt on the track roller unit .................... 7.1.11 Aligning the rubber belt on the track roller unit ...................... 9.2.1 B Basic machine ........................................................................ 3.3.1 Bleeding the system ............................................................... 9.2.5 C Contents ................................................................................ 2.1.1 Correct use ............................................................................ 4.1.1 D Disawning .............................................................................. 8.1.5 Drive operation ....................................................................... 4.1.2 F Front attachments (cutterbar and others) and other components ........................................................................... 4.1.2 G Gearbox ............................................................................... 9.2.11 Gearbox of the drive wheels ................................................ 9.2.10 General safety and accident prevention regulations .............. 4.1.1 H Half-track left/right parts kit 764 220.0 ................................... 6.1.2 Hubs of the front idler wheels .............................................. 9.2.10 Hubs of the middle idler wheels ........................................... 9.2.10

R Removing and installing the preconcave segments .............. 8.1.2 Removing the threshing segment .......................................... 8.1.3 S Safety decals with pictorials ..................................................

Safety rules ...........................................................................

Shipping Package .................................................................

Stone trap ..............................................................................

Switch console ......................................................................

4.2.1 4.1.1 6.1.1 8.1.1 8.1.1

T Tensioning the system .......................................................... 9.2.6 Tensioning the track roller unit .............................................. 9.2.5 Terra Trac suspension parts kit 764 605.0 ............................ 6.1.1 Test of brake function .......................................................... 7.1.10 Threshing parts ..................................................................... 8.1.1 Torque settings of the fastening screws at the half-track gearbox ................................................................ 9.2.12 Torque settings of the fastening screws at the support wheels .................................................................... 9.2.12 Torque settings of the wheel bolts of the idler and drive wheels ........................................................................ 9.2.12 Track roller unit ...................................................................... 3.3.1 Traffic .................................................................................... 3.1.1 U Using the hydraulic system of the threshing drum variable speed drive ............................................................................ 9.2.7

I Identification of warnings and danger signs ........................... 4.1.1 Identification plate / serial number ......................................... 3.3.1 Important ................................................................................ 3.2.1 Index .................................................................................... 11.1.1 Installing the electrical connection to the switch console ....... 7.1.9 Installing the front ladder ........................................................ 7.2.1 Installing the half-track left / right ........................................... 7.1.5 Installing the half-tracks ......................................................... 7.1.1 Installing the mirror bracket extension (V). ............................ 7.1.9 Installing the Terra Trac suspension ...................................... 7.1.1 Installing the threshing segment ............................................ 8.1.4 Introduction ............................................................................ 1.1.1 L LEXION 560 Terra Trac ......................................................... 5.2.1 LEXION 580 Terra Trac ......................................................... 5.1.1 Lubricants and notes ........................................................... 10.1.1 Lubricants chart ..................................................................... 9.1.2 M Maintenance .......................................................................... 9.1.1 Maintenance instruction ......................................................... 9.2.1 MaintenanceTable ................................................................. 9.1.1 O Oil change .............................................................................. 9.2.8 Operation ............................................................................... 8.1.1 P Preparing for oil change ......................................................... 9.2.9 Preparing the installation ....................................................... 7.1.1

0299 131.1 - ABA/BA LEXION 580/560 Terra Trac

11.1.1

Index

11.1.2

ABA/BA LEXION 580/560 Terra Trac - 0299 131.1

In the course of technical development CLAAS KGaA is permanently active in improving its products. CLAAS reserves the right to make alterations which must not necessarily correspond with the illustrations and descriptions in these operating instructions and without incurring the obligation to alter any machines previously delivered.

Technical data, dimensions and weights are non-binding.

Errors reserved.

Reproduction or translation of this publication, in whole or part, is not permitted without the written consent of CLAAS KGaA. All rights under the provision of the Copyright Law are reserved.

CLAAS KGaA mbH 33426 HARSEWINKEL Germany

CLAAS protects the environment.

The paper for this manual was made of 100 % chlorine-free cellulose.

CLAAS KGaA mbH Postfach 1163 33426 Harsewinkel Tel. +49 (0)5247 12-0 www.claas.com

0299 131.1 ABA/BA LEXION 580/560 Terra Trac EN- 02.04 - BEV Printed in Germany