CLAAS Rubber half-track LEXION 600 - 560 Terra-Trac Fitting and Operating Instructions Manual

LEXION 600 - 560 Terra-Trac up to serial no. 58900265 up to serial no. 58601340 up to serial no. 58501143 up to serial no. 58403002

Fitting and Operating Instructions Rubber half-track

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7838

7838

Contents 1 Introduction 1.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1.1.1 How to use this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1.1.2

Validity of instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.1.3

Rubber half-track identification plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2 Specifications 2.1 CLAAS LEXION 600 Terra-Trac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 2.1.1 Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 2.1.2

Tyres and tyre pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.1.3

Torque settings of wheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.1.4

Track width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.1.5

Transport position / Working position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.2 CLAAS LEXION 580 Terra-Trac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 2.2.1 Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 2.2.2

Tyres and tyre pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.2.3

Torque settings of wheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.2.4

Track width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2.2.5

Transport position / Working position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2.3 CLAAS LEXION 570 Terra-Trac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 2.3.1 Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 2.3.2

Tyres and tyre pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.3.3

Torque settings of wheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2.3.4

Track width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2.3.5

Transport position / Working position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2.4 CLAAS LEXION 560 Terra-Trac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 2.4.1 Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 2.4.2

Tyres and tyre pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2.4.3

Torque settings of wheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2.4.4

Track width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2.4.5

Transport position / Working position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3 Safety precautions 3.1 Important . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 3.1.1 Important information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 3.1.2

Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

3.1.3

Identification of warning and danger signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

3.2 Safety decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 3.2.1 General information on safety decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 3.2.2

Safety decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

4 Package list 4.1 Rubber half-track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 4.1.1 Pack joint 000 764 258 1 (type 589), 000 764 202 1 (type 586/584), 000 764 346 0 (type 585) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

5 Mounting 5.1 Rubber half-track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

3

7838

5.1.1

Fitting the rubber half-tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

5.1.2

Installing the front ladder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

5.1.3

Aligning the rubber tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

6 Fieldwork 6.1 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 6.1.1 Check rubber track tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 6.1.2

Ladder while driving on slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

6.1.3

Folding the ladder steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

6.1.4

Towing a machine with hydraulic parking brake and defective engine . . . . . . . . . . . . . . . . . . 52

7 Maintenance 7.1 Important maintenance instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 7.1.1 Important maintenance instructions and safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 7.2 Maintenance schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 7.2.1 Maintenance chart for rubber half-track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 7.2.2

Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

7.2.3

Aligning the rubber tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

7.2.4

Tension the rubber tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

7.2.5

Oil change / Oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

7.2.6

Wheel bolts and mounting bolts - torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

7.2.7

Inspection of rubber track / track roller unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

8 Lubrication chart 8.1 Lubrication points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 8.1.1 Greasing cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

4

8.1.2

Lubrication points - 50 h on the left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

8.1.3

Lubrication points - 50 h on the right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

8.1.4

Lubrication points - 100 h on the left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

8.1.5

Lubrication points - 100 h on the right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

8.1.6

Lubrication points - 500 h on the left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

8.1.7

Lubrication points - 500 h on the right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

1 Introduction 1.1 General Information 7839 1 EN

1 Introduction 1.1 General Information 1457

1.1.1 How to use this manual This manual shows you how to assembly the parts listed in the Package List section.

In the following chapters, the cutterbar is referred to as a front attachment. The combine harvester / forage harvester is referred to as the machine.

Text and pictures are kept neutral if possible.

Differences are indicated using picture headings or text notes.

In the assembly descriptions, for better clarification, existing parts are designated using letters and new parts are designated using numbers.

Directions such as front, back, right and left are always relative to the direction of travel.

Technical data, dimensions and weights are given as an indication only. We reserve the right to make changes in response to technical development and errors.

18478

1.1.2 Validity of instructions This manual is only valid for use in conjunction with the corresponding operator's manual for the associated machine. This manual only contains the information that differs from the user's manual.

These instructions apply to the following machine / front attachment: Description

TYPE

Serial number from

to

LEXION 600 Terra-Trac

589

58900011

58900265

LEXION 580 Terra-Trac

586

58600011

58601340

LEXION 570 Terra-Trac

585

58500011

58501143

LEXION 560 Terra-Trac

584

58400011

58403002

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

5

1 Introduction 1.1 General Information 7839 20299

1.1.3 Rubber half-track identification plate The identification plate with the serial number is mounted on the half-track frame.

(Fig. 1)

1 7269

6

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

2 Specifications 2.1 CLAAS LEXION 600 Terra-Trac 7840

2 Specifications 2.1 CLAAS LEXION 600 Terra-Trac Machine for calculating the technical data equipped with 8-cylinder engine, full fuel tank, cab, rubber half-tracks and 600/65 - 26.5 6 PR tyres.

18482

2.1.1 Chassis Ground drive

Ground speed Forwards

Reverse

Driving axle drive Steering Brakes Foot brake Parking brake

hydrostatic Operation via control lever in the right armrest of the driver's seat 2 transmission ranges each for forward and reverse travel 1st gear from 0 to 13.0 km/h 2nd gear from 0 to 20.0 km/h (from 0 to 25.0 km/h) (from 0 to 30.0 km/h) The reverse ground speed is about 70 % of the forward travel speed.

Ground speeds in parentheses apply only to certain countries.

The ground drive is adjusted accordingly for countries with a speed limitation up to 20 km/h, 25 km/h or 30 km/h.

Final drive, oil bath hydrostatic hydraulically operated multi-disc brake, designed to work independently electro-hydraulically operated accumulator-type multi-disc brake

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

7

2 Specifications 2.1 CLAAS LEXION 600 Terra-Trac 7840 6054

2.1.2 Tyres and tyre pressures

3925

1 17330

2.1.3 Torque settings of wheel bolts Tightening torque for wheel bolts on guide wheels / drive wheels / rubber half-track Tightening torque for wheel bolts on rear wheel drive axle Tightening torque for wheel bolts on rear wheel drive axle

8

see chapter on Maintenance M 22 x 1.5 x 45-8.8 and lock washers C 22.5 DIN 74361 (special lock washers) M 20 x 1.5 or countersunk collar nuts

520 Nm 520 Nm

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

2 Specifications 2.1 CLAAS LEXION 600 Terra-Trac 7840 18484

2.1.4 Track width

A = Clearance between the tyres /rubber tracks B = Wheel track C = Width over the tyres /rubber tracks Drive axle

Rubber half-track

A

B

C

2218 mm

2853 mm

3488 mm

Rear axle 000 768 740 3 / LA 2.87 m – 3.27 m / 10 t / 10 L Tyres

Flange width

A

B

C

500/85 R 24

3070 mm

2450 mm

2970 mm

3490 mm

500/85 R 24

3270 mm

2650 mm

3170 mm

3690 mm

600/55 - 26.5

3070 mm

2558 mm

3174 mm

3790 mm

600/55 - 26.5

3270 mm

2758 mm

3374 mm

3990 mm

700/50 - 26.5

3070 mm

2470 mm

3170 mm

3870 mm

700/50 - 26.5

3270 mm

2670 mm

3370 mm

4070 mm

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

9

2 Specifications 2.1 CLAAS LEXION 600 Terra-Trac 7840 18489

2.1.5 Transport position / Working position

B2 L5 B1

L1 L2 L3 L4

WIDTH B B1 B2 HEIGHT H

LENGTH L L1 L2 L3 L4 L5

Transport position

Working position

3488 mm

–

635 mm

–

Top edge of grain tank: LEXION 600 Terra-Trac 12000 litres

3990 mm

–

Basic machine (Height of bottom edge of feed rake conveyor 500 mm) to rear edge of rear hood to rear edge of straw chopper protective cover to rear edge of straw spreader safety frame to rear edge of grain tank unloading tube, extra long Contact length of rubber tracks

8780 mm 8890 mm 9250 mm 9200 mm 1825 mm

– – – – –

3700 mm 11540 mm 3820 mm 11670 mm

– – – –

without header (see also width over the tyres/tracks) Rubber track width

with Conspeed Dimension of front end from centre of steering wheel with Conspeed, 6-row Dimension of front end from centre of steering wheel with Conspeed, 8-row all linear measures to rear edge of rear hood

10

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

2 Specifications 2.1 CLAAS LEXION 600 Terra-Trac 7840

LEXION 600 Terra-Trac Rubber half-track Guide wheels Drive wheels Centre support wheels

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

Number per side 2 2 4

11

2 Specifications 2.1 CLAAS LEXION 600 Terra-Trac

H2

H1

H3

H4

H5

7840

B1 B2 B3 B4 B5

WIDTH B1 B2 B3

B4 B5 HEIGHT H1 H2 H3

H4 H5

Transport position

Working position

Bottom edge of grain tank unloading tube nozzle, short Bottom edge of grain tank unloading tube nozzle, long Bottom edge of grain tank unloading tube nozzle, XL (split) Bottom edge of grain tank unloading tube nozzle, extra long Bottom edge of grain tank unloading tube nozzle, XXL Bottom edge of grain tank unloading tube nozzle, 3XL

– – –

5947 mm 6838 mm 7342 mm

–

7342 mm

– –

7902 mm 8479 mm

Bottom edge of grain tank unloading tube nozzle, short Bottom edge of grain tank unloading tube nozzle, long Bottom edge of grain tank unloading tube nozzle, XL (split) Bottom edge of grain tank unloading tube nozzle, extra long Bottom edge of grain tank unloading tube nozzle, XXL Bottom edge of grain tank unloading tube nozzle, 3XL

– – –

4148 mm 4365 mm 4510 mm

–

4510 mm

– –

4655 mm 4805 mm

Height calculated for tyres 680/85 R 32, 900/60 R 32 Height difference for tyres 800/65 R 32 = -60 mm Height difference for machines with rubber half-tracks = +25 mm Additional height difference due to increased air pressure = +50 mm Additional height difference due to sag in the floor= -150 mm

12

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

2 Specifications 2.2 CLAAS LEXION 580 Terra-Trac 7840

2.2 CLAAS LEXION 580 Terra-Trac Machine for calculating the technical data equipped with 8-cylinder engine, full fuel tank, cab, rubber half-tracks and 600/65 - 26.5 6 PR tyres.

18493

2.2.1 Chassis Ground drive

Gearbox

Ground speed Speed range

Driving axle drive Steering Brakes Foot brake Parking brake

hydrostatic Operation via control lever in the right armrest of the driver's seat 3 transmission ranges each for forward and reverse travel Transmission ranges 1 and 2: Working travel Transmission range 3: Road travel 1st gear from 0 to 7.6 km/h (from 0 to 6.7 km/h) 2nd gear from 0 to 12.3 km/h (from 0 to 10.8 km/h) 3rd gear from 0 to 20.0 km/h (from 0 to 25.0 km/h) The reverse ground speed is about 70 % of the forward travel speed.

Ground speeds in parentheses apply only to certain countries.

The ground drive is adjusted accordingly for countries with a speed limitation up to 20 km/h or 25 km/h.

Final drive, oil bath hydrostatic hydraulically operated disc brakes, designed to work independently foot-operated mechanical drum brake, independent

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

13

2 Specifications 2.2 CLAAS LEXION 580 Terra-Trac 7840 10537

2.2.2 Tyres and tyre pressures

17330

2.2.3 Torque settings of wheel bolts Tightening torque for wheel bolts on guide wheels / drive wheels / rubber half-track Tightening torque for wheel bolts on rear wheel drive axle Tightening torque for wheel bolts on rear wheel drive axle

14

see chapter on Maintenance M 22 x 1.5 x 45-8.8 and lock washers C 22.5 DIN 74361 (special lock washers) M 20 x 1.5 or countersunk collar nuts

520 Nm 520 Nm

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

2 Specifications 2.2 CLAAS LEXION 580 Terra-Trac 7840 18526

2.2.4 Track width

A = Clearance between the tyres /rubber tracks B = Wheel track C = Width over the tyres /rubber tracks Drive axle

Rubber half-track

A

B

C

2218 mm

2853 mm

3488 mm

Rear axle 000 768 705 1 / 3040 mm / 9 t / 10 x 225 / Standard cleaning system Tyres

Flange width

A

B

C

480/80 R 26 IND

3040 mm

2660 mm

3144 mm

3630 mm

500/70 R 24 IMP

3040 mm

2450 mm

2960 mm

3470 mm

500/85 R 24 IMP

3040 mm

2420 mm

2960 mm

3500 mm

600/55 - 26.5 IMP

3040 mm

2520 mm

3144 mm

3800 mm

Rear drive axle 000 694 760 1 / 2600 mm - 3200 mm / 9.5 t / 10 x 225 / Standard cleaning system Tyres

Flange width

A

B

C

480/80 R 26 IND

3050 mm

2670 mm

3154 mm

3640 mm

480/80 R 26 IND

3200 mm

2820 mm

3304 mm

3790 mm

500/70 R 24

2900 mm

2510 mm

2980 mm

3499 mm

500/70 R 24

3050 mm

2660 mm

3130 mm

3649 mm

500/70 R 24

3200 mm

2810 mm

3280 mm

3799 mm

500/85 R 24 IMP

2900 mm

2430 mm

2980 mm

3530 mm

500/85 R 24 IMP

3050 mm

2580 mm

3130 mm

3680 mm

500/85 R 24 IMP

3200 mm

2730 mm

3280 mm

3830 mm

600/55 - 26.5

3050 mm

2552 mm

3152 mm

3800 mm

600/55 - 26.5

3200 mm

2702 mm

3302 mm

3950 mm

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

15

2 Specifications 2.2 CLAAS LEXION 580 Terra-Trac 7840 18531

2.2.5 Transport position / Working position

B2

L4 L1

B1 L2 L3

WIDTH B B1 B2 HEIGHT H

LENGTH L L1 L2 L3 L4

without header (see also width over the tyres/tracks) Rubber track width Top edge of grain tank: LEXION 580 Terra-Trac, 10500 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 Basic machine (Height of bottom edge of feed rake conveyor 500 mm) to rear edge of rear hood to rear edge of straw spreader safety frame to rear edge of grain tank unloading tube, extra long Contact length of rubber tracks

Transport position

Working position

3488 mm

–

635 mm

–

3975 mm – – –

4895 mm 3840 mm 4050 mm 4160 mm

8780 mm 9060 mm 9200 mm 1825 mm

– – – –

LEXION 580 Terra-Trac Rubber half-track Guide wheels Drive wheels Centre support wheels

16

Number per side 2 2 4

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

2 Specifications 2.3 CLAAS LEXION 570 Terra-Trac 7840

2.3 CLAAS LEXION 570 Terra-Trac Machine for calculating the technical data equipped with 6-cylinder engine, full fuel tank, cab, rubber half-tracks and 600/55 - 26.5. 12 PR tyres.

18536

2.3.1 Chassis Ground drive

Gearbox

Ground speed Speed range

Driving axle drive Steering Brakes Foot brake Parking brake

hydrostatic Operation via control lever in the right armrest of the driver's seat 3 transmission ranges each for forward and reverse travel Transmission ranges 1 and 2: Working travel Transmission range 3: Road travel 1st gear from 0 to 7.6 km/h (from 0 to 7.6 km/h) 2nd gear from 0 to 12.3 km/h (from 0 to 12.3 km/h) 3rd gear from 0 to 20.0 km/h (from 0 to 25.0 km/h) The reverse ground speed is about 70 % of the forward travel speed.

Ground speeds in parentheses apply only to certain countries.

The ground drive is adjusted accordingly for countries with a speed limitation up to 20 km/h or 25 km/h.

Final drive, oil bath hydrostatic hydraulically operated disc brakes, designed to work independently foot-operated mechanical drum brake, independent

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

17

2 Specifications 2.3 CLAAS LEXION 570 Terra-Trac 7840 10553

2.3.2 Tyres and tyre pressures

18

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

2 Specifications 2.3 CLAAS LEXION 570 Terra-Trac 7840 17330

2.3.3 Torque settings of wheel bolts Tightening torque for wheel bolts on guide wheels / drive wheels / rubber half-track Tightening torque for wheel bolts on rear wheel drive axle Tightening torque for wheel bolts on rear wheel drive axle

see chapter on Maintenance M 22 x 1.5 x 45-8.8 and lock washers C 22.5 DIN 74361 (special lock washers) M 20 x 1.5 or countersunk collar nuts

520 Nm 520 Nm

18537

2.3.4 Track width

A = Clearance between the tyres /rubber tracks B = Wheel track C = Width over the tyres /rubber tracks Drive axle

Rubber half-track

A

B

C

2012 mm

2647 mm

3282 mm

Rear axle 000 769 610 3 / 2740 mm / 8.5 t / 10 x 255 / Standard cleaning system Tyres

Flange width

A

B

C

16.5/85 - 24 IMP

2740 mm

2220 mm

2660 mm

3160 mm

500/70 R 24

2740 mm

2200 mm

2660 mm

3180 mm

600/55 - 26.5

2740 mm

2220 mm

2844 mm

3499 mm

480/80 R 26 IND

2740 mm

2360 mm

2844 mm

3330 mm

Rear drive axle 000 669 835 5 / 9 t / 10 x 255 / Standard cleaning system Tyres

Flange width

A

B

C

16.5/85 - 24 IMP

2600 mm

2211 mm

2700 mm

3189 mm

16.5/85 - 24 IMP

2750 mm

2361 mm

2850 mm

3339 mm

500/70 R 24 IMP

2600 mm

2210 mm

2680 mm

3199 mm

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

19

2 Specifications 2.3 CLAAS LEXION 570 Terra-Trac 7840

Rear drive axle 000 669 835 5 / 9 t / 10 x 255 / Standard cleaning system Tyres

Flange width

A

B

C

500/70 R 24 IMP

2750 mm

2360 mm

2830 mm

3349 mm

600/55 - 26.5 IMP

2750 mm

2252 mm

2852 mm

3500 mm

480/80 R 26 IND

2750 mm

2370 mm

2854 mm

3340 mm

Rear axle 000 769 155 1 / 2770 mm / 10 t / 10 x 225 / JET STEAM cleaning system / up to serial no.

Tyres

Flange width

A

B

C

480/80 R 26 IND

2770 mm

2369 mm

2874 mm

3379 mm

500/70 R 24 IMP

2770 mm

2149 mm

2660 mm

3171 mm

500/85 R 24 IMP

2770 mm

2123 mm

2660 mm

3197 mm

600/55 - 26.5 IMP

2770 mm

2254 mm

2874 mm

3494 mm

700/50 - 26.5 IMP

2770 mm

2150 mm

2870 mm

3590 mm

Rear axle 000 769 100 1 / 2770 mm / 9 t / 10 x 225 / JET STREAM cleaning system Tyres

Flange width

A

B

C

500/70 R 24

2770 mm

2149 mm

2660 mm

3171 mm

500/85 R 24

2770 mm

2123 mm

2660 mm

3197 mm

600/55 - 26.5

2770 mm

2254 mm

2874 mm

3494 mm

700/55 - 26.5

2770 mm

2150 mm

2870 mm

3590 mm

Rear drive axle 000 694 900 1 / 2770 mm - 2920 mm / 10 t / 10 x 225 / JET STREAM cleaning system Tyres

Flange width

A

B

C

500/70 R 24 IMP

2770 mm

2149 mm

2660 mm

3171 mm

500/70 R 24 IMP

2920 mm

2299 mm

2810 mm

3321 mm

500/85 R 24 IMP

2920 mm

2273 mm

2810 mm

3347 mm

600/55 - 26.5 IMP

2770 mm

2254 mm

2874 mm

3494 mm

600/55 - 26.5 IMP

2920 mm

2404 mm

3024 mm

3644 mm

700/50 R 26.5 IMP

2770 mm

2150 mm

2870 mm

3590 mm

700/50 R 26.5 IMP

2920 mm

2300 mm

3020 mm

3740 mm

Rear axle 000 768 980 1 / 2870 mm - 3270 mm / 10 t / 10 x 225 / JET STREAM cleaning system Tyres

Flange width

A

B

C

500/85 R 24 IMP

3070 mm

2474 mm

2960 mm

3446 mm

620/75 R 26 (23.1R26)

3270 mm

2790 mm

3410 mm

4030 mm

750/65 R 26 (28LR26)

3270 mm

2660 mm

3410 mm

4160 mm

20

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

2 Specifications 2.3 CLAAS LEXION 570 Terra-Trac 7840 18539

2.3.5 Transport position / Working position

B2 L5 B1

L1 L2 L3 L4

WIDTH B B1 B2 HEIGHT H

LENGTH L L1 L2 L3 L4 L5

without header (see also width over the tyres/tracks) Rubber track width Top edge of grain tank: 10500 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 Basic machine (Height of bottom edge of feed rake conveyor 500 mm) to rear edge of rear hood to rear edge of straw chopper protective cover to rear edge of straw spreader safety frame to rear edge of grain tank unloading tube, extra long Contact length of rubber tracks

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

Transport position

Working position

3282 mm

–

635 mm

–

3990 mm – – –

4850 mm 3960 mm 4170 mm 4280 mm

8780 mm 8890 mm 9250 mm 9200 mm 1825 mm

– – – – –

21

2 Specifications 2.3 CLAAS LEXION 570 Terra-Trac 7840

LEXION 570 Terra-Trac Rubber half-track Guide wheels Drive wheels Centre support wheels

22

Number per side 2 2 4

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

2 Specifications 2.4 CLAAS LEXION 560 Terra-Trac 7840

2.4 CLAAS LEXION 560 Terra-Trac Machine for calculating the technical data equipped with 6-cylinder engine, full fuel tank, cab, rubber half-tracks and 600/55 - 26.5. 12 PR tyres.

18549

2.4.1 Chassis Ground drive

Gearbox

Ground speed Speed range

Driving axle drive Steering Brakes Foot brake Parking brake

hydrostatic Operation via control lever in the right armrest of the driver's seat 3 transmission ranges each for forward and reverse travel Transmission ranges 1 and 2: Working travel Transmission range 3: Road travel 1st gear from 0 to 6.7 km/h 2nd gear from 0 to 10.8 km/h 3rd gear from 0 to 20.0 km/h (from 0 to 25.0 km/h) The reverse ground speed is about 70 % of the forward travel speed.

Ground speeds in parentheses apply only to certain countries.

The ground drive is adjusted accordingly for countries with a speed limitation up to 20 km/h or 25 km/h.

Final drive, oil bath hydrostatic hydraulically controlled disc brakes, also designed as independent brake foot-operated mechanical drum brake, independent

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

23

2 Specifications 2.4 CLAAS LEXION 560 Terra-Trac 7840 18550

2.4.2 Tyres and tyre pressures

17330

2.4.3 Torque settings of wheel bolts Tightening torque for wheel bolts on guide wheels / drive wheels / rubber half-track Tightening torque for wheel bolts on rear wheel drive axle Tightening torque for wheel bolts on rear wheel drive axle

24

see chapter on Maintenance M 22 x 1.5 x 45-8.8 and lock washers C 22.5 DIN 74361 (special lock washers) M 20 x 1.5 or countersunk collar nuts

520 Nm 520 Nm

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

2 Specifications 2.4 CLAAS LEXION 560 Terra-Trac 7840 18556

2.4.4 Track width

A = Clearance between the tyres /rubber tracks B = Wheel track C = Width over the tyres /rubber tracks Drive axle

Rubber half-track

A

B

C

2218 mm

2853 mm

3488 mm

Steering drive axle Tyres

Flange width

A

B

C

16.5/85 - 24 IMP

2900 mm

2611 mm

3000 mm

3489 mm

16.5/85 - 24 IMP

3050 mm

2661 mm

3150 mm

3539 mm

500/70 R 24 IMP

2900 mm

2510 mm

2980 mm

3499 mm

500/70 R 24 IMP

3050 mm

2660 mm

3130 mm

3649 mm

600/55 - 26.5

3050 mm

2552 mm

3152 mm

3800 mm

7 t fixed rear axle Tyres

Flange width

A

B

C

16.5/85 - 24 IMP

2840 mm

2501 mm

2990 mm

3479 mm

500/70 R 24 IMP

2840 mm

2319 mm

2909 mm

3499 mm

7 t adjustable rear axle Tyres

Flange width

A

B

C

16.5/85 - 24 IMP

2770 mm

2501 mm

2990 mm

3479 mm

16.5/85 - 24 IMP

2990 mm

2651 mm

3140 mm

3629 mm

600/55 - 26.5 IMP

2990 mm

2437 mm

3110 mm

37830 mm

2556 mm

3107 mm

3658 mm

480/80 R 26 IND

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

25

2 Specifications 2.4 CLAAS LEXION 560 Terra-Trac 7840 18560

2.4.5 Transport position / Working position

B2 L5 B1

L1 L2 L3 L4

WIDTH B B1 B2 HEIGHT H

LENGTH L L1 L2 L3 L4 L5

without header (see also width over the tyres/tracks) Rubber track width Top edge of grain tank: 10500 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 Basic machine (Height of bottom edge of feed rake conveyor 500 mm) to rear edge of rear hood to rear edge of straw chopper protective cover to rear edge of straw spreader safety frame to rear edge of grain tank unloading tube, extra long Contact length of rubber tracks with 4.5 m folding cutterbar Dimension of front end from centre of steering wheel with 5.4 m folding cutterbar Dimension of front end from centre of steering wheel

26

Transport position

Working position

3488 mm

–

635 mm

–

3975 mm – – –

4640 mm 3840 mm 4050 mm 4160 mm

8780 mm 8890 mm 9060 mm 9200 mm 1825 mm

– – – – –

11420 mm 3490 mm 12020 mm 4120 mm

– –

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

2 Specifications 2.4 CLAAS LEXION 560 Terra-Trac 7840

LEXION 560 Terra-Trac with Conspeed Dimension of front end from centre of steering wheel with Conspeed, 6-row Dimension of front end from centre of steering wheel with Conspeed, 8-row

3700 mm 11540 mm 3820 mm 11670 mm

– – – –

all linear measures to rear edge of rear hood Rubber half-tracks Guide wheels Drive wheels Centre support wheels

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

Number per side 2 2 4

27

3 Safety precautions 3.1 Important 7841

3 Safety precautions 3.1 Important 1459

3.1.1 Important information In order to avert danger, the instructions in this manual must be read and heeded by all persons who carry out or check this assembly.

In particular, read the "Safety Rules" sections in the Operator's Manual of the machine and of the front attachment.

The use of spare parts, accessories and auxiliary equipment that are not original CLAAS products and have not specifically been tested and approved by CLAAS, can change the specified design characteristics of the CLAAS combine or detract from its functional performance, with a possible adverse effect on the active and/or passive operational safety and on its occupational safety standards (accident prevention).

CLAAS is in no way liable for any damage or personal injury caused as a result of the use of other than original or approved CLAAS parts, accessories and auxiliary equipment.

858

3.1.2 Proper use Both the front attachment and the machine are designed solely for use in customary agricultural operations (intended use).

Use in any other way is considered as contrary to the intended use. The manufacturer accepts no liability for any damage or injury resulting from this misuse and these risks must be born solely by the user.

Compliance and strict adherence to the conditions of operation, service and repair as specified by the manufacturer also constitute essential elements for the intended use.

This front attachment and the machine may be operated, serviced and repaired only by persons familiar with all its particular characteristics and acquainted with the relevant safety rules.

The accident prevention regulations, all other generally recognised regulations on safety and occupational medicine and the road traffic regulations must be observed at all times.

Any arbitrary modifications carried out on the front attachment and on the machine will relieve the manufacturer of all liability for any resulting damage or injury.

28

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

3 Safety precautions 3.1 Important 7841 1461

3.1.3 Identification of warning and danger signs All parts of this manual having to do with your safety or the safe operation of the front attachment or the machine are marked with the following signs. Please pass on all safety precautions to any other users of the machine as well.

Danger!

Nature and source of danger Consequences: death or severe injuries – Countermeasures Warning!

Nature and source of danger Consequences: injuries – Countermeasures Caution!

Nature and source of danger Consequences: material damage – Countermeasures Note!

Nature and source of information Consequences: enhanced machine economy or easy assembly – Measures Environment!

Nature and source of danger Consequences: damage to the environment – Countermeasures

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

29

3 Safety precautions 3.2 Safety decals 7841

3.2 Safety decals 859

3.2.1 General information on safety decals The danger zones on the machine or on the front attachment which cannot be eliminated by design or protective measures, are identified by safety decals.

These safety decals help to alert persons to hazards which can cause personal injury.

The safety decals consist of two components: – Part 1 shows the risk of injury in a warning triangle.

– Part 2 shows how injury and accidents can be prevented by appropriate actions.

The pictures on the safety decals consist of generally understandable pictograms. As far as possible, the safety decals must be located in close proximity to the hazardous area.

The original CLAAS safety decals are equipped with the CLAAS part number and the date of manufacture.

The positioning and meanings of the safety decals is explained below: – When ordering, please use the 10-digit CLAAS part number given ahead of every safety decal, – The safety decal number given in ( ) shows the correct position of the safety decals in the associated picture, – followed by an explanation of the safety decal graphics in text form.

Danger!

Hazard points on the machine.

Death or serious injuries!

– Hazard warning signs / safety decals that are damaged or unrecognisable must be replaced immediately by new ones.

– When parts that have hazard warning signs / safety decals are replaced, always make sure to attach the relevant new hazard warning signs / safety decals to each new part.

30

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

3 Safety precautions 3.2 Safety decals 7841 18693

3.2.2 Safety decals 000 516 039 0 (22)

22

1 12287

22

Do not open or remove safety shields while engine is running.

3

(Fig. 1, 2, 3) 2 12288

000 516 064 0 (22)

22

4 12287

Do not open or remove safety shields while engine is running.

5

(Fig. 4, 5)

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

31

3 Safety precautions 3.2 Safety decals 7841

000 515 139 1 (50)

50

6 7608

7 Hydraulic accumulator contains gas and oil under pressure. For removal and repair instructions in technical manual must be followed.

(Fig. 6, 7)

32

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

4 Package list 4.1 Rubber half-track 7842

4 Package list 4.1 Rubber half-track 18698

4.1.1 Pack joint 000 764 258 1 (type 589), 000 764 202 1 (type 586/584), 000 764 346 0 (type 585) Pos. No.

Designation

Dimensions

ISO/DIN standard

Quantity

1

Hex. bolt

M 20 x 70

4017-10.9

24

2

Universal drive shaft

3

4

5

LEXION 600 Terra-Trac

750 mm, 1200 Nm

2

LEXION 580 Terra-Trac

810 mm, 5200 Nm

2

LEXION 570 Terra-Trac

710 mm, 5500 Nm

2

LEXION 560 Terra-Trac

810 mm, 5200 Nm

2

Hex. bolt LEXION 600 Terra-Trac

M 12 x 35

4017-10.9

16

LEXION 580 Terra-Trac

M 12 x 40

4017-10.9

16

LEXION 570 Terra-Trac

M 12 x 40

4017-10.9

16

LEXION 560 Terra-Trac

M 12 x 40

4017-10.9

16

Self-locking nut

M 12

7042-10

16

Hex. bolt

M 12 x 30-MK

4017-10.9

8

Contact washer

A 12

8

O-ring LEXION 600 Terra-Trac

190 x 3 - N

3771

2

LEXION 580 Terra-Trac

140 x 3 - N

3771

2

LEXION 570 Terra-Trac

140 x 3 - N

3771

2

LEXION 560 Terra-Trac

140 x 3 - N

3771

2

6

Pipe clamp

Rsgu 21

7

Hex. bolt

M 8 x 30

Washer

8.5 x 30 x 2

5

Contact washer

A8

5

Hex. nut

M8

Self-locking strap

4.7 x 188

8

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

5 4014-8.8

4032-8

5

5 8

33

5 Mounting 5.1 Rubber half-track 7843

5 Mounting 5.1 Rubber half-track 34095

5.1.1 Fitting the rubber half-tracks Danger!

Moving machine components and / or unexpected machine movement.

Death or serious injuries!

– – – –

Diesel engine OFF. Engage the parking brake.

Remove the ignition key.

Remove the key of the battery isolating switch.

– Wait until all rotating parts have stopped moving.

– Secure the machine with wheel chocks.

– Loosen the wheel nuts on the auxiliary wheels on both sides of the machine.

(Fig. 1)

1 7260

– Support the machine securely under the axle and set the jacking height on both sides.

- Minimum height = 800 mm from middle of wheel to the ground – Remove the auxiliary wheels.

(Fig. 2)

2 7261

34

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

5 Mounting 5.1 Rubber half-track 7843

– Remove the auxiliary hubs (N).

(Fig. 3)

N

3 7262

– Pull track axles (R) out of the rubber half-track frame.

– Use screws (1) on the left and right to mount track axle (R) on the drive axle.

- Tightening torque = 594 Nm (Fig. 4, 5) R 1 4 LEXION 600 Terra-Trac

12297

R 1 5 LEXION 580/570/560 Terra-Trac (up to serial no. ...)

7263

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

35

5 Mounting 5.1 Rubber half-track 7843

– Check the fitted position of pressure ring (D).

- Pressure ring (D) must be positioned with the chamfer facing inwards towards the track axle.

– Check the fitted position of V ring (F).

- The projection on V ring (F) must face outwards.

(Fig. 6, 7)

6 LEXION 600 Terra-Trac

7264

LEXION 580/570/560 Terra-Trac (up to serial no. ...)

7265

7 – Use lifting equipment to lift the rubber half-tracks.

– Remove the pallet.

– Lower the rubber half-track.

(Fig. 8)

8 7266

Screw universal drive shafts (2) together with guide rails onto the rubber half-tracks.

2

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

3

– Mount universal drive shafts (2) using screws (3).

- Tightening torque = 123 Nm – Move the rubber half-tracks longitudinally by hand so that all screws (3) can be reached for final tightening.

(Fig. 9) 9 7267

36

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

5 Mounting 5.1 Rubber half-track 7843

LEXION 580/570/560 Terra-Trac (up to serial no. ...)

– Unscrew all self-locking nuts (S) on both sides of the machine and keep them to hand for mounting the universal drive shafts (2).

(Fig. 10)

S

10 LEXION 580/570/560 Terra-Trac (up to serial no. ...)

7268

– Unscrew cover (R).

- LEXION 600 Terra-Trac (up to serial no. 58900265): Keep cover (R) and five bolts M 6 x 50, O-ring D 190 x 3 is not needed any more.

- LEXION 580/570/560 Terra-Trac (up to serial no. ...): Keep cover (R) and bolts M 8 x 25, Oring D 140 x 3 is not needed any more.

R

(Fig. 11)

11 7269

– Unscrew washer (S).

- Keep washer (S) safe, dispose of screws M 12 x 30.

(Fig. 12)

S

12 7270

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

37

5 Mounting 5.1 Rubber half-track 7843

– Use lifting equipment to lift the rubber half-tracks.

– Lower rubber half-tracks onto two lifting trucks.

– With the two lifting trucks, carefully slide the rubber half-tracks onto the track axles, taking care not to damage the contact surfaces (A) of the bushings!

(Fig. 13, 14)

13 7271

A

14 8191

– As the half-track is pushed on, ensure that the contact surfaces (A) of the bushings are pressed flush against pressure ring (D) and V ring (F).

Avoid canting at all costs.

(Fig. 14, 15, 16)

15 LEXION 600 Terra-Trac

7264

LEXION 580/570/560 Terra-Trac (up to serial no. ...)

7265

16

38

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

5 Mounting 5.1 Rubber half-track 7843

– Fit washer (S) so that the chamfered side faces outwards.

– Mount washers (S) with four screws (4).

- Tightening torque = 123 Nm – Use a grease gun to pack grease nipple (N) with low-viscosity grease until the grease escapes from the side of washer (S).

N

4

(Fig. 17)

S

17 7270

LEXION 600 Terra-Trac (up to serial no. 58900265) – Fit O-ring (5) in the channel on the inside of cover (R) and screw into place with the existing five screws M 6 x 50.

- Tightening torque = 10 Nm R

LEXION 580/570/560 Terra-Trac (up to serial no. ...)

– Fit O-ring (5) in the channel in cover (R) and screw into place with the existing five screws M 8 x 25.

- Tightening torque = 24.5 Nm 18 7269

(Fig. 18) LEXION 600 Terra-Trac – Mount universal drive shaft (2) with screws (3).

- Tightening torque = 123 Nm

2

(Fig. 19)

5 19 LEXION 600 Terra-Trac

7273

LEXION 580/570/560 Terra-Trac (up to serial no. ...)

– Screw on the universal drive shaft (2) with the existing self-locking nuts (S).

- Tightening torque = 123 Nm

2

(Fig. 20) S

20 LEXION 580/570/560 Terra-Trac (up to serial no. ...)

7274

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

39

5 Mounting 5.1 Rubber half-track 7843

LEXION 600/570 Terra-Trac 7

Run the wiring harness (K) from the left rubber halftrack.

6

– Run wiring harness (K) inwards behind strap (L).

– Mount wiring harness (K) on the drive axle with pipe clamp (6) and screws (7).

L

K

(Fig. 21)

21 LEXION 600/570 Terra-Trac

7275

LEXION 600/570 Terra-Trac – Mount the wiring harness (K) below the hydrostatic motor with pipe clamp (6) and screw (7).

– Connect the plug on wiring harness (K) to the plug on the pressure switch (see arrow).

– Secure wiring harness (K) to existing wiring harnesses using cable band (8).

6

K

(Fig. 22)

22 LEXION 600/570 Terra-Trac

7276

LEXION 600/570 Terra-Trac Running existing wiring harness (K) from the right rubber half-track.

– Run wiring harness (K) inwards as far as strap (L).

Mount wiring harness (K) on the drive axle with pipe clamp (6) and screws (7).

6

K

(Fig. 23)

L 23 LEXION 600/570 Terra-Trac

7277

LEXION 600/570 Terra-Trac

8

– Connect the plug on wiring harness (K) to the plug on the pressure switch (see arrow).

– Secure wiring harness (K) to existing wiring harnesses using cable band (8).

K

(Fig. 24)

24 LEXION 600/570 Terra-Trac

40

7278

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

5 Mounting 5.1 Rubber half-track 7843

LEXION 580/560 Terra-Trac Run the wiring harness (K) from the left rubber halftrack.

K

– Mount wiring harness (K) on the drive axle with pipe clamp (6) and screws (7).

6

(Fig. 25)

7

25 LEXION 580/560 Terra Trac

7279

LEXION 580/560 Terra-Trac

8

– Connect the plug on wiring harness (K) to the plug on the pressure switch (see arrow).

– Secure wiring harness (K) to existing wiring harnesses using cable band (8).

8

(Fig. 26) K 26 LEXION 580/560 Terra Trac

7280

LEXION 580/560 Terra-Trac Running existing wiring harness (K) from the right rubber half-track.

– Mount wiring harness (K) on the drive axle with pipe clamp (6) and screws (7).

6

7

(Fig. 27) K

27 LEXION 580/560 Terra Trac

7281

LEXION 580/560 Terra-Trac

8

– Connect the plug on wiring harness (K) to the plug on the pressure switch (see arrow).

– Secure wiring harness (K) to existing wiring harnesses using cable band (8).

(Fig. 28)

K 28 LEXION 580/560 Terra Trac

7282

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

41

5 Mounting 5.1 Rubber half-track 7843

The relay (K 67) is packed in a plastic bag. The plastic bag is attached to the central terminal compartment board.

– Fold the central terminal compartment open.

– Install relay (K 67).

K67

(Fig. 29)

29 12133 33393

5.1.2 Installing the front ladder Danger!

Moving machine components and / or unexpected machine movement.

Death or serious injuries!

– – – –

Diesel engine OFF. Engage the parking brake.

Remove the ignition key.

Remove the key of the battery isolating switch.

– Wait until all rotating parts have stopped moving.

– Secure the machine with wheel chocks.

42

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

5 Mounting 5.1 Rubber half-track 7843

– Unscrew hex. bolts of bracket (H) at positions (1) and (2).

– Slide the centre sections (F) completely into the ladder holder.

– Bolt bracket (H) and centre sections (F) down to position (1), using hex. bolts.

F

(Fig. 30, 31)

H 30 11634

H

1

2 2

1

31 11635

– Suspend the pre-assembled ladder (L) in a suitable lifting tool.

– Slacken off the hex. bolt at lever (K), remove wire of flat bar (M) and fit flat bar to lever (K).

K

L

(Fig. 32, 33)

M

32 11636

L

33 11637

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

43

5 Mounting 5.1 Rubber half-track 7843

– Slide ladder (L) into centre sections (F).

F

Important!

V

Do not kink the rope.

– Bolt down bracket (H) to position (2) and the ladder (L) with hex. bolts M 10 x 40 or M 10 x 35, contact washers and hex. nuts.

– Fasten the rope with the pre-assembled bracket (V) on the centre sections.

L S

H

34 11638

Important!

Move the swashing arm (S) to the correct position as shown.

(Fig. 31, 34) – Bolt down the ladder (L) with hex. bolts M 10 x 35 and contact washers.

(Fig. 35)

L 35 11640

– Cut the cable band (N).

– Actuate foot pedal (O) with the hand and fold the steps down.

O

(Fig. 36)

N 36 12112

44

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5 Mounting 5.1 Rubber half-track 7843

– Loosely screw in hex. bolts M 8 x 16 and contact washers in the operator's platform.

(Fig. 37)

37 11275

– Stick the railing (G) into the panel (F).

(Fig. 38)

G

F

38 11642

– Stick the railing (B) into the panel (F) and the operator's platform.

– Bolt down the raining base with hex. bolts M 8 x 25 and contact washers.

B

(Fig. 39)

39 11643

– Fasten the railing (B) beneath the ladder holder with hex. bolts M 10 x 20 and contact washers.

– Properly tighten the mounting bolts of panel (F).

B

(Fig. 39, 40)

40 11644

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

45

5 Mounting 5.1 Rubber half-track 7843

– Fasten the railing (G) beneath the ladder holder along with lever (R), using hex. bolts M 10 x 20 and contact washers.

– Hang in the yoke (K) in the lever of the ladder holder and secure it with cotter pins.

G

(Fig. 41) R K

41 11645 17880

5.1.3 Aligning the rubber tracks The guide blocks (1) guide the rubber track between the front guide wheels, the middle guide wheels and the rear drive wheels. Measurable temperature differences on the flanks of the guide blocks indicate that linkage (2) needs to be adjusted. Failure to make these adjustments can lead to increased wear, and the rubber track may have to be replaced sooner than necessary.

1 2

42 7283

The rubber tracks are aligned in several consecutive steps, which will be described in more detail below.

The following procedure is recommended: 1 2 3 4 5 6 7

46

Prepare measurement instrument.

Carry out test drive.

Measure the temperature.

Make first adjustment.

Carry out second test drive.

Measure the temperature.

Make further adjustment as necessary.

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

5 Mounting 5.1 Rubber half-track 7843

Preparing for temperature measurement You will need thermometer, spare part no. 000 369 269 0 and multimeter (Fluke 83-V) spare part no. 000 181 980 3.

Use new batteries in both the thermometer and the multimeter.

– Set sliding switch (T) on the thermometer to (C) degrees Celsius.

– Plug the red plug (R) on the thermometer into the V socket on the multimeter.

– Connect black plug (S) to the COM input. Set the multimeter to 300 mV. – Do not switch on the ON/OFF switch (W) on the thermometer until you are about to take a measurement, because it automatically switches back to sleep mode after 10 minutes.

(Fig. 43)

43

56037 7284

Carry out a test drive – Check the tension of the rubber tracks.

- The pressure must not fall below 8500 kPa (85 bar, 586 psi).

- If the pressure falls below this minimum value, the rubber tracks must be tightened again (see Tightening the rubber tracks).

Danger!

When starting the machine, persons are on the machine or in its hazard area.

Death or serious injury.

– Before starting the machine ensure that there are no persons or objects in the hazardous area.

– Drive to a flat road, if possible with a long, straight stretch of 1.6 km (1 mile).

- If the straight stretch is less than 1.6 km (1 mile) long, continue driving as far as possible after the last curve before stopping.

– Drive the machine forwards at top road speed.

– Avoid steering as much as possible.

– Bring the machine to stop without steering.

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

47

5 Mounting 5.1 Rubber half-track 7843

Measure the temperatures of the guide blocks Take the measurement immediately after stopping.

The measurement points (1) are located at a distance (Y) = 45 mm (1.77 in) from the foot of the guide block.

Take measurements at measurement points (1) on the inside and outside of the guide block at the top of the rubber track.

44 7285

2

3

– Switch on the ON/OFF switch on the thermometer.

– Place the measuring tip of the thermometer against the inside and the outside of the first fully visible guide block (3) beside the guide wheel (2).

– Read and record the temperature shown on the multimeter.

- Wait briefly before reading the temperature to allows the reading to stabilise.

– Measure and record the temperatures on several guide blocks on the left and right rubber tracks.

(Fig. 44, 45)

45 7286

Align the rubber track Bear in mind the following when measuring the temperature and adjusting: • The maximum permissible temperature difference between the inside and the outside of a guide block is 5 °C (9 °F).

• If the temperature in one guide block differs from the neighbouring blocks by more than 10 °C (18 °F), disregard this value.

• In the case of temperature differences of ≥ 11 °C (20 °F) between the inside and the outside of one guide block: Adjust incrementally, a half-turn (180 degrees) at a time.

• In the case of temperature differences of < 11 °C (20 °F) between the inside and the outside of the guide block: Adjust incrementally, 1/6 of a turn (60 degrees) at a time.

• When the adjustments are complete, take the machine for a test drive again, and repeat the measurements.

• If the opposite side is warmer, reverse the adjustment procedure. The smaller the temperature differences, the finer the adjustments must be.

48

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5 Mounting 5.1 Rubber half-track 7843

Adjustment:

1

2

46 7287

3

– Unscrew and remove screws (1) and tab washers (2) on both sides of the rubber track.

– Make adjustments by turning screw (3) in the appropriate direction (see example below).

– Do not forget to tighten the opposite screw (3).

- Tightening torque = 205 Nm – Carry out test drive.

– Measuring the temperature of the guide blocks.

– If necessary, repeat adjustment of the rubber track with screws (3).

– Tighten both screws (1).

- Tightening torque = 83.5 Nm – Continue turning both screws (1) and (3) just until both tab washers (2) can be fitted again.

– Continue turning both screws (1) until the two tab washers (2) are seated tightly.

(Fig. 46, 47)

47 7288

After the first adjustment remember the following: • Drive the machine on a straight stretch of road again and repeat measurement of the guide block temperatures.

• If the opposite side is warmer, reverse the adjustment procedure. As the temperature differences become smaller, the adjustments that need to be made are correspondingly to be more precise (see also the example).

Example: Aligning the rubber track The temperature measurement shows that the inside (side facing towards the machine) of one guide block is 20 °C (36 °F) warmer than the outside of the same block.

– Unscrew and remove screws (1) and tab washers (2) on both sides of the rubber half-track.

– Loosen screw (3) on the side of the rubber track facing away from the machine by a 1/2 turn (turn counterclockwise). Tighten the screw (3) on the opposite side.

- Tightening torque = 205 Nm – Carry out test drive.

– Measuring the temperature of the guide blocks.

– Tighten both screws (1).

- Tightening torque = 83.5 Nm

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49

5 Mounting 5.1 Rubber half-track 7843

– Continue turning both screws (1) and (3) just until both tab washers (2) can be fitted again.

– Continue turning the inner and outer screws (1) until the tab washers (2) are firmly seated.

After a second measurement, the temperature difference is now for example 10 °C (18 °F), the inside of the guide block still being warmer than the outside.

– Loosen inner screw (3) by 1/6 of a turn (60 °).

Tighten inner screw (1).

- Tightening torque = 205 Nm – Carry out test drive.

– Measuring the temperature of the guide blocks.

– Tighten both screws (1).

- Tightening torque = 83.5 Nm – Continue turning both screws (1) and (3) until both tab washers (2) can be fitted.

– Continue turning the inner and outer screws (1) until the tab washers (2) are firmly seated.

The outside of the guide block is still 6 °C (10 °F) warmer than the inside.

– Loosen the inner (3) by 1/12 a turn (30 °) and tighten the outer screw (3).

- Tightening torque = 205 Nm – Carry out test drive.

– Measure the temperature of the guide blocks again.

– Tighten both screws (1).

- Tightening torque = 83.5 Nm – Continue turning both screws (1) and (3) until both tab washers (2) can be fitted.

– Continue turning the inner and outer screws (1) until the tab washers (2) are firmly seated.

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

– Check the tightening torque of 205 Nm on the inner and the outer screws (3). Tighten as necessary.

- Tightening torque = 205 Nm – Tighten both screws (1).

- Tightening torque = 83.5 Nm – Continue turning both screws (1) and (3) until both tab washers (2) can be fitted.

– Continue turning the inner and outer screws (1) until the tab washers (2) are firmly seated.

(Fig. 46, 47)

50

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

6 Fieldwork 6.1 Operation 7844

6 Fieldwork 6.1 Operation 18738

6.1.1 Check rubber track tension The warning light (1) for the rubber track tension is located on the operating console.

If pressure in the track tension of the track roller unit falls below 8500 kPa (85 bar), the warning light (1) shines red. The hazard warning light (STOP) on the steering column also shines red and an acoustic signal is triggered. In this case:

1

– Tighten the rubber tracks.

(Fig. 1) 1 3088 18737

6.1.2 Ladder while driving on slopes Caution!

When travelling up a slope, the rubber track can collide with the front ladder (1), which is extended forwards (arrow).

2 1

Damage to front ladder (1) and/or rubber track (2).

– The front ladder (1) must be stowed to the side before driving up slopes.

2

(Fig. 2, 3)

7631

1

3 7630

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

51

6 Fieldwork 6.1 Operation 7844 33438

6.1.3 Folding the ladder steps Danger!

G

Operate the ladder only when the machine is stationary!

R

The steps must be folded up every time before starting off.

Caution!

The ladder has no collision protection.

4 12129

– When actuating the mechanism from the operator's platform, unlock the steps by pressing the foot pedal (R) and fold at the lever (G).

– When actuating the mechanism from the ground, unlock the steps by actuating the foot pedal (R) by hand and fold them up.

Danger!

R

The steps must be arrested in their respective limit stops.

(Fig. 4, 5) 5 11647 33497

6.1.4 Towing a machine with hydraulic parking brake and defective engine Danger!

Moving machine components and / or unexpected machine movement.

Death or serious injuries!

– – – –

Diesel engine OFF. Engage the parking brake.

Remove the ignition key.

Remove the key of the battery isolating switch.

– Wait until all rotating parts have stopped moving.

– Secure the machine with wheel chocks.

52

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6 Fieldwork 6.1 Operation 7844

Release the hydraulic parking brake mechanically.

– Unscrew both covers (1) and remove inside bolts.

(Fig. 6) 1

1 6 12155

– Pull spacers (2) off of the bolts (3).

(Fig. 7)

2

3 7 11666

– Screw in both bolts (3) completely.

(Fig. 8) Danger!

Hydraulic parking brake is not operative!

3

Death or serious injury.

Serious machine damage.

3

8 12156

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

– Tow machine only away from a hazard zone (road junction).

– Bear in mind that the steering is heavier when the engine is not running.

– The foot brake is supplied from a hydraulic accumulator. For this reason, pressing the foot brake is possible only a few times.

– Use a suitable towing tool.

– Tow machine only with no gear engaged.

53

7 Maintenance 7.1 Important maintenance instructions 7845

7 Maintenance 7.1 Important maintenance instructions 18630

7.1.1 Important maintenance instructions and safety rules Danger!

As a basic rule, carry out maintenance, service and cleaning work and remedy operational problems only after shutting down the machine.

Death or serious injury.

– – – –

Diesel engine OFF. Apply the parking brake.

Remove the ignition key.

Remove the key of the battery isolating switch.

– Safeguard machine by wheel chocks.

– Ensure that the machine cannot be started by another person.

Danger!

Pre-loaded energy accumulators (spring, accumulator, hydraulic cylinder).

Death or serious injury.

– Only have authorised and qualified workshops carry out work on energy accumulators.

54

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7 Maintenance 7.2 Maintenance schedules 7845

7.2 Maintenance schedules 18635

7.2.1 Maintenance chart for rubber half-track

every 100

100

op.h

250

op.h

after the harvest

40

daily

before start of harvesting

after first 10

if necessary

Maintenance intervals every year = every 500 op. h.

Maintenance work

Ground drive Hubs of the front idler wheels •

– Check oil level – Oil change

•

•

Hubs of the middle wheels •

– Check oil level – Oil change

•

•

Transmission: Gearbox of the drive wheels •

– Check oil level – Oil change

•

•

Gearbox •

– Check oil level – Oil change

•

•

Tighten screws: Guide and drive wheels – Tighten wheel bolts

•

•

•

•

•

•

Half-track transmission – Tighten screws Support wheels – Tighten screws

Op.h = Operating hours

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55

7 Maintenance 7.2 Maintenance schedules 7845 18637

7.2.2 Lubricants Component

Filling capacity

Lubricant type / Specification

Viscosity class / SAE class

Remarks

0.5 litre per hub

Multigrade transmission oil

SAE 90

Maintenance intervals see section 6.2.1

SAE 90

Maintenance intervals see section 6.2.1

SAE 90

Maintenance intervals see section 6.2.1

SAE 90

Maintenance intervals see section 6.2.1

SAE 90

Maintenance intervals see section 6.2.1

SAE 90

Maintenance intervals see section 6.2.1

Ground drive Hubs of the front idler wheels

(MIL-L-2105 B) API-GL-5-90 Middle support wheel hubs

0.25 litre per hub

Multigrade transmission oil (MIL-L-2105 B) API-GL-5-90

Gearbox of the drive wheels

15.5 litres

LEXION 580/570/560 Terra-Trac (up to serial no. ...)

Gearbox of the drive wheels

Multigrade transmission oil (MIL-L-2105 B) API-GL-5-90

31.0 litres

LEXION 600 Terra-Trac

Multigrade transmission oil (MIL-L-2105 B) API-GL-5-90

LEXION 580/570/560 Terra-Trac manual gearbox

10.8 litres

Multigrade transmission oil (MIL-L-2105 B) API-GL-5-90

LEXION 600 Terra-Trac manual gearbox

25.0 litres

Multigrade transmission oil (MIL-L-2104 D) Shell Harvella TX

56

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7 Maintenance 7.2 Maintenance schedules 7845 18626

7.2.3 Aligning the rubber tracks Required under the following criteria: • Wear of the guide block flanks on only one side.

• Heating of the guide block contact surfaces on only one side.

1 2

1 7283

The guide blocks (1) guide the rubber track between the front guide wheels, the middle guide wheels and the rear drive wheels. Measurable temperature differences on the flanks of the guide blocks indicate that linkage (2) needs to be adjusted. Failure to make these adjustments can lead to increased wear, and the rubber track may have to be replaced sooner than necessary.

(Fig. 1) The rubber tracks are aligned in several consecutive steps, which will be described in more detail below.

The following procedure is recommended: 1 Prepare measurement instrument.

2 Carry out test drive.

3 Measure the temperature.

4 Make first adjustment.

5 Carry out second test drive.

6 Measure the temperature.

7 Make further adjustment as necessary.

Preparing for temperature measurement You will need thermometer, spare part no. 000 369 269 0 and multimeter (Fluke 83-V) spare part no. 000 181 980 3.

Use new batteries in both the thermometer and the multimeter.

– Set sliding switch (T) on the thermometer to (C) degrees Celsius.

– Plug the red plug (R) on the thermometer into the V socket on the multimeter.

– Connect black plug (S) to the COM input. Set the multimeter to 300 mV. – Do not switch on the ON/OFF switch (W) on the thermometer until you are about to take a measurement, because it automatically switches back to sleep mode after 10 minutes.

(Fig. 2)

2

56037 7284

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

57

7 Maintenance 7.2 Maintenance schedules 7845

Carry out a test drive – Check the tension of the rubber tracks.

- The pressure must not fall below 8500 kPa (85 bar, 586 psi).

- If the pressure falls below this minimum value, the rubber tracks must be tightened again (see Tightening the rubber tracks).

Danger!

When starting the machine, persons are on the machine or in its hazard area.

Death or serious injury.

– Before starting the machine ensure that there are no persons or objects in the hazardous area.

– Drive to a flat road, if possible with a long, straight stretch of 1.6 km (1 mile).

- If the straight stretch is less than 1.6 km (1 mile) long, continue driving as far as possible after the last curve before stopping.

– Drive the machine forwards at top road speed.

– Avoid steering as much as possible.

– Bring the machine to stop without steering.

Measure the temperatures of the guide blocks Take the measurement immediately after stopping.

The measurement points (1) are located at a distance (Y) = 45 mm (1.77 in) from the foot of the guide block.

Take measurements at measurement points (1) on the inside and outside of the guide block at the top of the rubber track.

3 7285

2

3

– Switch on the ON/OFF switch on the thermometer.

– Place the measuring tip of the thermometer against the inside and the outside of the first fully visible guide block (3) beside the guide wheel (2).

– Read and record the temperature shown on the multimeter.

- Wait briefly before reading the temperature to allows the reading to stabilise.

– Measure and record the temperatures on several guide blocks on the left and right rubber tracks.

(Fig. 3, 4)

4 7286

58

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7 Maintenance 7.2 Maintenance schedules 7845

Align the rubber track Bear in mind the following when measuring the temperature and adjusting: • The maximum permissible temperature difference between the inside and the outside of a guide block is 5 °C (9 °F).

• If the temperature in one guide block differs from the neighbouring blocks by more than 10 °C (18 °F), disregard this value.

• In the case of temperature differences of ≥ 11 °C (20 °F) between the inside and the outside of one guide block: Adjust incrementally, a half-turn (180 degrees) at a time.

• In the case of temperature differences of < 11 °C (20 °F) between the inside and the outside of the guide block: Adjust incrementally, 1/6 of a turn (60 degrees) at a time.

• When the adjustments are complete, take the machine for a test drive again, and repeat the measurements.

• If the opposite side is warmer, reverse the adjustment procedure. The smaller the temperature differences, the finer the adjustments must be.

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

59

7 Maintenance 7.2 Maintenance schedules 7845

Adjustment:

1

2

5 7287

3

– Unscrew and remove screws (1) and tab washers (2) on both sides of the rubber track.

– Make adjustments by turning screw (3) in the appropriate direction (see example below).

– Do not forget to tighten the opposite screw (3).

- Tightening torque = 205 Nm – Carry out test drive.

– Measuring the temperature of the guide blocks.

– If necessary, repeat adjustment of the rubber track with screws (3).

– Tighten both screws (1).

- Tightening torque = 83.5 Nm – Continue turning both screws (1) and (3) just until both tab washers (2) can be fitted again.

– Continue turning both screws (1) until the two tab washers (2) are seated tightly.

(Fig. 5, 6)

6 7288

After the first adjustment remember the following: • Drive the machine on a straight stretch of road again and repeat measurement of the guide block temperatures.

• If the opposite side is warmer, reverse the adjustment procedure. As the temperature differences become smaller, the adjustments that need to be made are correspondingly to be more precise (see also the example).

Example: Aligning the rubber track The temperature measurement shows that the inside (side facing towards the machine) of one guide block is 20 °C (36 °F) warmer than the outside of the same block.

– Unscrew and remove screws (1) and tab washers (2) on both sides of the rubber half-track.

– Loosen screw (3) on the side of the rubber track facing away from the machine by a 1/2 turn (turn counterclockwise). Tighten the screw (3) on the opposite side.

- Tightening torque = 205 Nm – Carry out test drive.

– Measuring the temperature of the guide blocks.

– Tighten both screws (1).

- Tightening torque = 83.5 Nm

60

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

7 Maintenance 7.2 Maintenance schedules 7845

– Continue turning both screws (1) and (3) just until both tab washers (2) can be fitted again.

– Continue turning the inner and outer screws (1) until the tab washers (2) are firmly seated.

After a second measurement, the temperature difference is now for example 10 °C (18 °F), the inside of the guide block still being warmer than the outside.

– Loosen inner screw (3) by 1/6 of a turn (60 °).

Tighten inner screw (1).

- Tightening torque = 205 Nm – Carry out test drive.

– Measuring the temperature of the guide blocks.

– Tighten both screws (1).

- Tightening torque = 83.5 Nm – Continue turning both screws (1) and (3) until both tab washers (2) can be fitted.

– Continue turning the inner and outer screws (1) until the tab washers (2) are firmly seated.

The outside of the guide block is still 6 °C (10 °F) warmer than the inside.

– Loosen the inner (3) by 1/12 a turn (30 °) and tighten the outer screw (3).

- Tightening torque = 205 Nm – Carry out test drive.

– Measure the temperature of the guide blocks again.

– Tighten both screws (1).

- Tightening torque = 83.5 Nm – Continue turning both screws (1) and (3) until both tab washers (2) can be fitted.

– Continue turning the inner and outer screws (1) until the tab washers (2) are firmly seated.

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

– Check the tightening torque of 205 Nm on the inner and the outer screws (3). Tighten as necessary.

- Tightening torque = 205 Nm – Tighten both screws (1).

- Tightening torque = 83.5 Nm – Continue turning both screws (1) and (3) until both tab washers (2) can be fitted.

– Continue turning the inner and outer screws (1) until the tab washers (2) are firmly seated.

(Fig. 5, 6)

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

61

7 Maintenance 7.2 Maintenance schedules 7845 18653

7.2.4 Tension the rubber tracks On newly shipped rubber half-tracks, the rubber tracks have been pre-tensioned by the manufacturer.

The hydraulic tensioning of the tracks described in the following is only necessary if the hydraulic clamping cylinder on the half-track has been depressurised beforehand (for example in order to replace the rubber tracks).

To tension the rubber tracks, use filler hose, spare part no. 000 350 189 0.

7 3

8

9

11

1 2 4

10

5 12

6

7578

7

Filler hose for machine, spare part no. 000 350 189 0

62

1

Diagnostic fitting

2

Male connector, straight

3

L connector

4

Female connector, straight

5

Threaded pressure gauge connector

6

Pressure gauge

7

Hose line

8

Male coupling

9

L connector

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

7 Maintenance 7.2 Maintenance schedules 7845

10

Female connector, straight

11

Elbow union

12

Female coupling

(Fig. 7) Preparations 1

(for filler hose, spare part no. 000 350 189 0) – Screw L connector (1) between the pipe and hose line on the drum variable speed drive pulley (2).

– Connect filler hose (3) to the quick release coupling.

3

(Fig. 8)

2

8 7582

1

– Remove protective cap from breather valve (1).

– Attach a suitable drain hose to breather valve (1).

– Place the other end of the drain hose in a sufficiently large container.

– Remove protective cap from filler valve (2).

– Attach the diagnostic fitting on the filler hose, spare part no. 000 359 189 0, to filler valve (2).

2

(Fig. 9)

9 7300

Bleeding and pressurising the system (Only necessary if the system has been opened for repairs.)

Danger!

When starting the machine, persons are on the machine or in its hazard area.

Death or serious injury.

– Before starting the machine ensure that there are no persons or objects in the hazardous area.

– Disengage gear and apply parking brake.

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

63

7 Maintenance 7.2 Maintenance schedules 7845

3

– – – –

2

1

Start the diesel engine.

Switch on master safety switch (1).

Switch on the threshing mechanism at switch (2).

Set the top idle speed with rotary switch (3).

(Fig. 10)

10 7139

Caution!

Overfilling of rubber half-tracks hydraulic system when tensioning the rubber tracks.

Damaged components in the rubber halftracks hydraulic system.

– Do not exceed the max. allowed pressure of 105 ± 5 bar (10500 kPa ± 500 kPa).

– Select the threshing drum speed with rotary switch (4).

– Mark or note the speed of the threshing drum when it is displayed because it can change after the following steps.

– Press button (5).

The system will be pressurised.

5

(Fig. 10, 11)

4

11 7553

Danger!

Residual oil pressure in hydraulic lines / hydraulic components.

1

Serious injury of eyes/skin.

– Wear safety goggles.

– Wear safety gloves.

12 7300

– Open breather valve (1) about a 1/4 turn and no more than a 1/2 turn.

– Allow the hydraulic oil and the bubbles in it to drain into the container.

– Close breather valve (1) again when no more bubbles escape.

(Fig. 12)

64

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

7 Maintenance 7.2 Maintenance schedules 7845

Caution!

Overfilling of rubber half-tracks hydraulic system when tensioning the rubber tracks.

Damaged components in the rubber halftracks hydraulic system.

– Do not exceed the max. allowed pressure of 105 ± 5 bar (10500 kPa ± 500 kPa).

– Fill up the tensioner of the rubber half tracks until the pressure gauge displays 105 ± 5 bar (10500 kPa ± 500 kPa).

– Press key (6) until no more residual pressure remains in the filling hose.

– Remove filling hose and put on protective cap.

– Remove drain hose and put on protective cap.

– Check threshing drum speed. Set it to the old value if required.

6

(Fig. 13) 13 7553

– Check the hydraulic oil level.

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65

7 Maintenance 7.2 Maintenance schedules 7845 34104

7.2.5 Oil change / Oil level check Warning!

Contact with hot liquids or machine parts.

Danger of burns – Wear suitable protective clothing.

– Let liquids or machine parts cool down.

– Comply with instructions.

Environment!

Lubricants and fuels end up in the environment.

Environmental pollution.

– Lubricants and fuels must be collected and stored in suitable containers and disposed of in a way that is harmless to the environment and in accordance with existing anti-pollution regulations.

General Note!

For oil grades and fill quantities, see the section Lubricants at the beginning of the chapter.

When checking the oil level, the machine must be standing on a level surface.

After the oil has been changed or the oil level checked, all screw plugs must be tightened firmly.

Replace the seals on the screw plugs as necessary.

Oil level checks The following steps must be carried out on all check plugs (unless specified otherwise).

– Turn out the check plug.

The oil must be up to the bottom edge of the hole in the oil level check plugs.

– If the oil level is too low, add oil through the oil filler opening until it escapes through the hole in the check plug.

– Screw in the check plug.

66

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7 Maintenance 7.2 Maintenance schedules 7845

Check plug (1) on the transmission for the drive wheels.

The oil must be up to the hole in the check plug.

LEXION 600 Terra-Trac

2

1 14 LEXION 600 Terra-Trac

7583

– Unscrew the check plug (1).

– If the oil level is too low, screw the special tool into the threaded hole in the check plug (1).

Special tool: Oil filler element, spare part no. 000 669 885 0 – Top up with transmission oil.

– Screw in the check plug (1).

(Fig. 14) LEXION 580/570/560 Terra-Trac (up to serial no. ...)

Check plug (1) on the transmission for the drive wheels.

The oil must be up to the hole in the check plug.

In order to check the oil level, one of the holes in the driving wheel rim must be located directly over the check plug (1).

1 15 LEXION 580/570/560 Terra-Trac (up to serial no. ...)

7584

– Unscrew the check plug (1).

– If the oil level is too low, top up with transmission oil through oil level check plug (2), see Oil change.

(Fig. 15, 16)

2

1 16 LEXION 580/570/560 Terra-Trac (up to serial no. ...)

7557

Check plug (1) on front guide wheels.

The oil must be up to the hole in the check plug.

(Fig. 17) 1

17 7585

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

67

7 Maintenance 7.2 Maintenance schedules 7845

Check plug (1) on centre support wheels.

The oil must be up to the hole in the check plug.

– Check the oil at an angle (X) of about 7.5 ° above the imaginary horizontal centre of the hub.

X 1

(Fig. 18)

18 7339

LEXION 600 Terra-Trac Check plug (1) on the manual gearbox.

The oil must be up to the hole in the check plug.

(Fig. 19) 1

19 LEXION 600 Terra-Trac

7586

LEXION 580/570/560 Terra-Trac Check plug (1) on the manual gearbox.

The oil must be up to the hole in the check plug.

1

(Fig. 20)

20 LEXION 580/570/560 Terra-Trac

68

7473

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7 Maintenance 7.2 Maintenance schedules 7845

Oil change LEXION 600 Terra-Trac Oil change on the drive wheel transmission: 2

1 21 LEXION 600 Terra-Trac

7583

– Place a sufficiently large container under the hub of the guide wheel.

– Carefully open grooved cap (1) and allow the oil to drain out completely.

– Close grooved cap (1).

– Unscrew the check plug (2).

– Screw the special tool into the threaded hole in the check plug (2).

Special tool: Oil filler element, spare part no. 000 669 885 0 – Fill in new transmission oil until it escapes through the hole in the oil level check plug (2).

– Screw in the check plug (2).

(Fig. 21) LEXION 580/570/560 Terra-Trac (up to serial no. ...)

Oil change on the drive wheel transmission:

1

Depressurising the clamping cylinder: – Remove the protective cap from the breather valve (1) on the clamping cylinder.

– Attach a suitable drain hose to breather valve (1).

– Place the other end of the drain hose in a sufficiently large container.

– Open breather valve (1) about a 1/4 turn and no more than a 1/2 turn.

22

LEXION 580/570/560 Terra-Trac (up to serial no. ...)

7300

The tensioning cylinders release automatically and thus relieve the belts.

– Repeat these steps for the second rubber halftrack.

If necessary, drive the machine against chocks (brake chocks) or similar to compress the clamping cylinders yet further.

Another option is to tie tensioning belts between the half-track frame and the front guide wheels so that the cylinders are forced back.

(Fig. 22)

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69

7 Maintenance 7.2 Maintenance schedules 7845

1

23 LEXION 580/570/560 Terra-Trac (up to serial no. ...)

7584

(Fig. 23, 24)

3

4

2

LEXION 580/570/560 Terra-Trac (up to serial no. ...)

– Remove the outer drive wheel (1).

– Place a sufficiently large container under the hub of the guide wheel.

– Unscrew oil drain plug (2) and allow the oil to drain out completely.

– Screw oil drain plug (2) back in.

– Top up with clean transmission oil through the oil filler port (3).

– Unscrew the check plug (4).

– Fill in new transmission oil until it escapes through the hole in the check plug (4).

– Screw check plug (4) and oil filler cap (3) back in.

– Tighten the rubber tracks.

24 7557

Oil change on middle support wheels:

1 25 7339

– Place a sufficiently large container under the middle of the support wheel hub.

– Unscrew plug (1) and allow the oil to drain out completely.

– Turn pick-up wheels until the bore of bolt (1) is at an angle (X) of about 7.5 ° above an imaginary horizontal line through the hub centre.

– Fill in new transmission oil until it escapes through the hole in bolt (1).

– Screw plug (1) in.

(Fig. 25, 26)

X 1

26 7339

70

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

7 Maintenance 7.2 Maintenance schedules 7845

Oil change on front guide wheels:

2

– Place a sufficiently large container under cover (1) of the guide wheel.

– Unscrew cover (1) and allow the oil to drain out completely.

– Screw cover (1) back on with new seal.

– Unscrew oil filler cap (2).

– Fill in new transmission oil until it escapes through the oil filler plug (2).

– Screw oil filler cap (2) back in.

1

27

(Fig. 27)

7585

LEXION 600 Terra-Trac Oil change in the gearbox: – Place a sufficiently large container under each of the two oil drain plugs (1) of the gearbox.

– Unscrew drain plugs (1) and allow the oil to drain out completely.

– Screw drain plugs (1) back in.

– Unscrew the check plug (2).

1

(Fig. 28, 29) 28 LEXION 600 Terra-Trac

7587

2

29 LEXION 600 Terra-Trac

7586

– Unscrew oil filler cap (3).

– Fill in new transmission oil until it escapes through the check plug (2).

– Screw check plug (2) and oil filler cap (3) back in.

3

(Fig. 30)

30 LEXION 600 Terra-Trac

3606

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7 Maintenance 7.2 Maintenance schedules 7845

LEXION 580/570/560 Terra-Trac Oil change in the gearbox: – Place a sufficiently large container under oil drain plug (1) of the gearbox.

– Unscrew oil drain plug (1) and allow the oil to drain out completely.

– Screw oil drain plug (1) back in.

– Unscrew the check plug (2).

2

(Fig. 31)

1 31 LEXION 580/570/560 Terra-Trac

7473

– Unscrew oil filler cap (3).

– Fill in new transmission oil until it escapes through the check plug (2).

– Screw check plug (2) and oil filler cap (3) back in.

3

(Fig. 32)

32 LEXION 580/570/560 Terra-Trac

72

5859

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7 Maintenance 7.2 Maintenance schedules 7845 18680

7.2.6 Wheel bolts and mounting bolts - torque settings Guide and drive wheels – Retighten wheel bolts (1) after the first 10 and 100 operating hours.

Hex. bolts M 24 x 70 ISO 4017-10.9 Tightening torque = 1000 Nm (Fig. 33) 1 33 7338

Half-track transmission

2

– Retighten bolts (2) after the first 10 and 100 operating hours.

Hex. bolt M 16 x 1.5 x 65 DIN 961-10.9 Tightening torque = 280 Nm - max. 325 Nm – Retighten bolts (3) after the first 10 and 100 operating hours.

Hex. bolt M 16 x 1.5 x 25 DIN 961-10.9 Tightening torque = 220 Nm

3

(Fig. 34) 34 7338

Centre support wheels – Retighten wheel bolts (4) after the first 10 and 100 operating hours.

Hex. bolt M 12 x 30 ISO 4017-10.9 Tightening torque = 125 Nm

4

(Fig. 35)

35 7339

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7 Maintenance 7.2 Maintenance schedules 7845 18685

7.2.7 Inspection of rubber track / track roller unit The rubber track consists of a number of wire plies.

The wires are similar to those in car tyres. The most important wire ply is about 8 mm (0.3 inch) from the inside of the rubber track. These wires are referred to as the zero degree belt (1). The zero degree belt absorbs the chain tension. Other wire plies are positioned between the zero degree belt and the outer surface of the rubber track. These wires are referred to as the intermediate belt (2). Intermediate belts lie at different angles to provide lateral strength. The intermediate belts also protect the zero degree belt.

36 7588

If a wire is exposed to moisture because of cuts or nicks in the rubber, it can rust. Any wires that are exposed in this way should be repaired as soon as possible. Ask your local dealer for advice.

Any wires from a damaged zero degree belt that protrude from the rubber track must be repaired. To repair the wire, it must be cut off or ground down. It must be cut off or ground down such that it is no longer visible above the surface of the rubber track. This will prevent further damage.

If the rubber track is run in under very damp conditions or dry, clean conditions, rubbing of the rubber may occur. This rubbing can last for up to 400 operating hours. The surfaces of the guide blocks may appear slightly or heavily worn. Material wear may even occur.

Though this rubbing may detract from the appearance of the rubber track, it does not affect the service life of the guide blocks.

If the guide blocks become hot in addition to the rubbing, contact your local dealer.

(Fig. 36)

74

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7 Maintenance 7.2 Maintenance schedules 7845

Cuts, nicks and slight wear of the guide blocks (3) will not cause any operating problems. But if two or more adjacent guide blocks on the rubber track are missing, the track must be replaced. A rubber track with two or more adjacent guide blocks missing can become detached from the machine. This can cause damage to other components of the ground drive.

4 3

37

If parts of the cleats (4) become separated from the track, this will not seriously impair traction. Replace the track when the cleats are less than 13 mm (0.5 inch) high and when the track slippage consistently exceeds 10 percent.

(Fig. 37)

7338

Rubber parts can become detached from the following components of the ground drive: • Guide wheels (5) • Support wheels (6) • Drive wheels (7)

5

6

The rubber can become separated from these parts because stones or foreign bodies get into the ground drive. Replace idler pulleys/middle wheels when they show wear of more than 50 percent.

7 38 7589

Replace the drive wheel (7) when the rubber track starts to slip on the drive wheel because there is not enough rubber to provide proper grip.

(Fig. 38)

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

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8 Lubrication chart 8.1 Lubrication points 7846

8 Lubrication chart 8.1 Lubrication points 18456

8.1.1 Greasing cycles Danger!

Moving machine parts and/or unexpected machine movements.

Death or serious injuries.

– – – –

Diesel engine OFF. Engage the parking brake.

Remove the ignition key.

Remove the key of the battery isolating switch.

Danger!

Front attachment, reel and feeder may drop in an uncontrolled way.

Death or serious injury.

– Fit the safety locks.

– Keep a safe distance from the hazard area.

Lubrication point number

Operating hours 10

50

1

•

2

•

100

3

•

4

•

5

•

6

•

250

Remarks 500

7

•

8

•

Lubricant symbols in figures The following symbols are used in figures:

76

Grease lubrication point with the grease gun.

Lubricate lubrication point with the oil can.

For grease see Lubricants Chart.

For chain oil see Lubricants Chart.

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

8 Lubrication chart 8.1 Lubrication points 7846 18459

8.1.2 Lubrication points - 50 h on the left

1

7516

3757

1

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

77

8 Lubrication chart 8.1 Lubrication points 7846 18460

8.1.3 Lubrication points - 50 h on the right

2

7517

3760

78

2

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

8 Lubrication chart 8.1 Lubrication points 7846 18461

8.1.4 Lubrication points - 100 h on the left

3

4 7516

3761

3

3762

4

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

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8 Lubrication chart 8.1 Lubrication points 7846 18462

8.1.5 Lubrication points - 100 h on the right

5

6 7517

80

3904

5

3905

6

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

8 Lubrication chart 8.1 Lubrication points 7846 18463

8.1.6 Lubrication points - 500 h on the left

7

7516

3911

7

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

81

8 Lubrication chart 8.1 Lubrication points 7846 18464

8.1.7 Lubrication points - 500 h on the right

8

7517

3918

82

8

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

7838

Index F Front ladder Installation ...........................................................42

G Greasing cycles .......................................................76

H How to use this manual ..............................................5

I Identification plate ......................................................6 Important maintenance instructions and safety rules ........................................................54 Inspection of rubber track / track roller unit ..............74

Towing Machine with hydraulic parking brake and defective engine ...........................................52 Track width ...............................................9, 15, 19, 25 Transport position Working position ...............................10, 16, 21, 26 Tyres and tyre pressures .........................8, 14, 18, 24

V Validity of instructions ................................................5

W Warning signs Identification ........................................................29 Working position Transport position .............................10, 16, 21, 26

L Ladder while driving on slopes .................................51 Lubriation points Symbols ..............................................................76 Lubricants ................................................................56 Lubrication points .....................................................76 Lubrication points - 100 h on the left ........................79 Lubrication points - 100 h on the right ......................80 Lubrication points - 50 h on the left ..........................77 Lubrication points - 50 h on the right ........................78 Lubrication points - 500 h on the left ........................81 Lubrication points - 500 h on the right ......................82

M Machine serial number ...............................................5 Maintenance Rubber tracks ......................................................57 Maintenance chart for rubber half-track ...................55

O Oil change / Oil level check ......................................66

R Rubber half-track Fitting ..................................................................34 Rubber half-tracks pack joint ...................................33 Rubber track tension Check ..................................................................51 Rubber tracks Alignment ......................................................46, 57 Tension ...............................................................62

S Safety Proper use ..........................................................28 Warning signs .....................................................29 Safety decals ...........................................................31 Important .............................................................30

T Torque settings of wheel bolts .................8, 14, 19, 24

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

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7838

84

000 294 140 1 - ABA GHR LEX 600-560 Terra Trac - 01/07

7847

Following the policy of CLAAS KGaA mbH to improve their products as technical developments continue, CLAAS reserves 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 translation 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 has printed this manual on 100% chlorine free paper.

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

000 294 140 1 ABA GHR LEX 600-560 Terra Trac EN - 01/07 Printed in Germany