LEXION 580 R

Operator’s Manual
 77349

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 77350
1

EC declaration of conformity
corresponds to EC directive 98/37/EC
We CLAAS Selbstfahrende Erntemaschinen Gesellschaft mit beschränkter Haftung
(Name of supplier)
Postfach 11 63
D-33426 Harsewinkel
(full address of the manufacturer - an authorised representative established in the Community must also give the business name and the
address of the manufacturer)

declare under our sole responsibility that the product

Combine harvester type:

(Make, model)

to which this declaration relates corresponds to the relevant basic safety and health requirements of the Direc-
tive 98/37/EC Appendix I,
(if applicable)
and to the requirements of the other relevant Directives

89/336/EEC in the version 92/31/EEC.

(Title and/or number and date of issue of the other Directives)

For the relevant implementation of the safety and health requirements mentioned in the Directives, the following
standard(s) and/or technical specification(s) has (have) been respected:

EN 632 - August 1995

(Title and/or number and date of issue of standard(s) and/or technical specification(s))

Technical Management Quality Management

(J.H. Mohr) (U. Krieg)
(Name, function and signature of the authorized person)

Harsewinkel,
(Place and date of issue)

00 0294 347 2 - BA LEXION 580R - 12/09 3

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 77350
1.2

EC Declaration of Conformity
This declaration of conformity is the original declaration of conformity according to
Directive 2006/42/EC
We CLAAS Selbstfahrende Erntemaschinen GmbH
Postfach 11 63, D-33416 Harsewinkel

declare under our sole responsibility, that the product Combine harvester
(type - serial number - trade name)

585 - from 585 00960 - LEXION 580 R

to which this declaration relates corresponds to the relevant basic safety and health requirements of Directive
2006/42/EC Appendix I and to the requirements of the other relevant Directives 2004/108/EC.

For the relevant implementation of the safety and health requirements mentioned in the Directives, the following
standard(s) and/or technical specification(s) has (have) been respected: EN 632 - August 1995

The person responsible for documentation in the European Community is: J.H. Mohr,
CLAAS Selbstfahrende Erntemaschinen GmbH, Postfach 11 63, D-33416 Harsewinkel

Technical Management Quality Management

(J.H. Mohr) (U. Krieg)

Harsewinkel, 01.10.09

4 00 0294 347 2 - BA LEXION 580R - 12/09

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 77349

Contents

1 Introduction
1.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.1.1 How to use this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.1.2 Validity of Operator's manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2 General Information
2.1 Road traffic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.2 Important notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.3 Identification plate / Serial number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.3.1 Identification plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.3.2 Machine serial number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.3.3 Engine serial number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.3.4 Straw chopper identification plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.3.5 Cab serial number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.4 Attachment parts / machine body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.4.1 Access to the workplace and maintenance areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

3 Safety Rules
3.1 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.1.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.1.2 Identification of warning and danger signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.1.3 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.1.4 Reasonable foreseeable misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.1.5 General safety and accident prevention regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.1.6 Transporting passengers, instructor, operating personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.1.7 Driving operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.1.8 Leaving the combine harvester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.1.9 Front attachments (cutterbar etc.) and other components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.1.10 Air conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.1.11 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.1.12 Basic rule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.1.13 Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.1.14 Decommissioning and disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.1.15 Cylinder safety lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.1.16 Fire extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.1.17 Battery isolating switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.1.18 Wheel chocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.1.19 Jack up the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.1.20 Loading and tying down the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.1.21 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.1.22 Danger of injury due to escaping hydraulic liquid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.1.23 Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.1.24 Relieving the concave adjustment accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.2 Safety decals with pictorials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.2.1 General instructions for warning signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.2.2 Safety decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

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 77349

4 Specifications
4.1 LEXION 580R - Type 585 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
4.1.1 Cab / Operator's platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
4.1.2 Cutterbar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
4.1.3 Threshing mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.1.4 Separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.1.5 Cleaning (JET STREAM cleaning system) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4.1.6 Grain delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4.1.7 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.1.8 Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.1.9 Tyres and tyre pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4.1.10 Torque settings of wheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4.1.11 Track width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.1.12 Transport position / Working position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.1.13 Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.1.14 Safety features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

5 Prior to operation
5.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
5.1.1 Initial operation check list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
5.2 Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
5.2.1 Cab with automatic air conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
5.2.2 Automatic air conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
5.2.3 Putting the automatic air conditioner into operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
5.2.4 Setting the cab temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
5.2.5 Manually setting the evaporator blower speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
5.2.6 Activating ECON operating mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
5.2.7 Deactivating ECON operating mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
5.2.8 REHEAT operation (Dehumidify cab windows) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
5.2.9 Displaying the outside temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
5.2.10 Changing the temperature display to °Fahrenheit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
5.2.11 Floor heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
5.2.12 Display of malfunction - Error in thermometer F0 (cab, blue) . . . . . . . . . . . . . . . . . . . . . . . . . 86
5.2.13 Display of malfunction - Error in thermometer F1 (exhaust, yellow) . . . . . . . . . . . . . . . . . . . . 86
5.2.14 Display of malfunction - Error in thermometer F2 (outside, red) . . . . . . . . . . . . . . . . . . . . . . . 86
5.2.15 Problem, possible cause or remedy – air conditioner system . . . . . . . . . . . . . . . . . . . . . . . . . 87
5.2.16 Cooling box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
5.2.17 Ice bucket (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
5.2.18 Windscreen washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
5.2.19 Crop inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
5.2.20 Opening and closing the cab roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
5.2.21 Cab emergency exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
5.2.22 Operator’s platform overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
5.2.23 Control console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
5.2.24 Screen (vehicle information display) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
5.2.25 Screen (harvest display) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
5.2.26 Keys C / Rotary switch D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
5.2.27 Ignition switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

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 77349

5.2.28 Multifunction switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

5.2.29 Vehicle information unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
5.2.30 Multifunction handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
5.2.31 Reel height limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
5.2.32 Steering column adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
5.2.33 Steering wheel height adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
5.2.34 Central terminal compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
5.2.35 Table of contents – Central terminal compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
5.2.36 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
5.2.37 Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
5.2.38 Operator’s seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
5.2.39 Air-suspended driver's seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
5.2.40 Operator's seat, mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
5.3 Lighting and socket outlets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
5.3.1 Headlights, working lights, mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
5.3.2 Sidefinder (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
5.3.3 Pathfinder lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
5.3.4 Socket outlet 12 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
5.3.5 CDS 5000 diagnosis connection socket outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
5.4 Access ladder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
5.4.1 Fitting the front extension and railing (if applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
5.4.2 Rotating the front ladder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
5.4.3 Ladder starting protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
5.4.4 Rear ladder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
5.5 Side panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
5.5.1 Opening and closing the side panels and the tailgate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
5.5.2 Opening the tailgate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
5.5.3 Adjusting the gripping height of the side panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
5.5.4 Adjusting the side panel lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
5.5.5 Tool cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
5.6 Mudguards / side panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
5.6.1 Installing the mudguards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
5.7 Rear axles (JET STREAM cleaning system) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
5.7.1 Overview of rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
5.7.2 Rear drive axle 000 694 820 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
5.7.3 Rear axle 000 768 980 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
5.7.4 Converting the rear drive axle 000 694 960 2/ 000 694 820 1
from transport to working position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
5.7.5 Adjusting the track width of rear drive axle 000 694 960 2/000 694 820 1 . . . . . . . . . . . . . . . 148
5.7.6 Converting the rear axle 000 768 980 1
from transport to working position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
5.7.7 Rear axle 000 768 980 1 – Adjusting the track width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
5.8 Cutterbar hydraulic cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
5.8.1 Cutter bar hydraulic cylinder without springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
5.8.2 Number of cutterbar cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
5.9 Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
5.9.1 Filling the accumulator for CLAAS AUTO CONTOUR II . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
5.9.2 Special tool for filling the CLAAS AUTO CONTOUR II accumulator . . . . . . . . . . . . . . . . . . . 162

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5.10 Dual fitments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

5.10.1 Installing the dual wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
5.11 Grain tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
5.11.1 Closing the grain tank drain holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
5.12 Driving the combine with mechanical control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
5.12.1 Driving machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
5.12.2 Ground speed control lever variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
5.12.3 Engine speed rotary switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
5.12.4 Medium engine idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
5.12.5 Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
5.12.6 Forward travel / reverse travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
5.12.7 Gear selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
5.12.8 Setting the ground speed control lever to move easily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
5.12.9 Setting the ground speed control lever to move easily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
5.12.10Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
5.12.11 Machine driving characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
5.12.12Handling with cutterbar trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
5.12.13Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
5.12.14Coupling / decoupling brake pedals of the foot brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
5.12.15Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
5.12.16Stopping the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
5.12.17Engaging/disengaging the CLAAS 4-Trac system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
5.12.18Towing the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
5.12.19Forward towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
5.12.20Reverse towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
5.12.21EHS emergency shifting using the gear pushbutton (from serial no. ...) . . . . . . . . . . . . . . . . 178
5.12.22Emergency operation decal – Electro-hydraulic gearshift (EHS) . . . . . . . . . . . . . . . . . . . . . . 180
5.12.23Engaging the neutral gearbox position mechanically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
5.12.24Restoring the original state (gearbox can again be shifted electro-hydraulically) . . . . . . . . . 182
5.12.25Engaging the neutral gearbox position hydraulically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
5.12.26Engaging the 2nd gear hydraulically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
5.13 CLAAS Autopilot (Maize picker) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
5.13.1 Putting the CLAAS Autopilot into operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
5.14 CLAAS Autopilot (Grain cutterbar) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
5.14.1 Adjusting the directional stability of the combine harvester . . . . . . . . . . . . . . . . . . . . . . . . . . 189
5.14.2 Setting the laser sensor in the field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
5.14.3 Rough adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
5.14.4 Fine adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
5.14.5 Laser sensor (crop edge has moved out of visible range) . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
5.14.6 Adjusting the right laser sensor (accessory) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
5.14.7 Putting the CLAAS Autopilot into operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
5.14.8 Use in rape with left side cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

6 Installing and removing the cutterbar

6.1 Installing the cutterbar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
6.1.1 Tilting the cutterbar from transport position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
6.1.2 Adjusting the cutterbar cross levelling hydraulic cylinder (from serial no. ...) . . . . . . . . . . . . 197
6.1.3 Attaching the front attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

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6.1.4 Locking cutterbars and maize pickers

(Cutterbars without Auto Contour) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
6.1.5 Connecting the universal drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
6.1.6 Mounting the stands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
6.2 Removing the cutterbar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
6.2.1 Removing the universal coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
6.2.2 Removing the universal drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
6.2.3 Opening the cutterbar locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
6.2.4 Laying down the cutterbar on the ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
6.2.5 Placing the cutterbar on the cutterbar trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

7 CEBIS operation (Version 8.23)

7.1 CLAAS CEBIS on-board information system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
7.2 CEBIS monitor and rotary switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
7.2.1 C keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
7.2.2 Rotary switch D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
7.2.3 Flagging Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
7.2.4 Multifunction handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
7.2.5 Monitor areas E (Harvest display) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
7.3 Rotary switch D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
7.4 Prior to initial operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
7.5 Vehicle information display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
7.6 Harvest display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
7.7 Montana control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
7.7.1 Axle control mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
7.7.2 Cutting angle control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
7.7.3 Lateral levelling control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
7.7.4 Montana axle end stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
7.7.5 Cutting angle limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
7.7.6 Lateral levelling limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
7.7.7 Display period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
7.8 CLAAS CRUISE PILOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
7.8.1 Maximum ground speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
7.8.2 Zero throughput . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
7.9 Yield mapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
7.10 Flagging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
7.11 GPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
7.11.1 Mapping ON/OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
7.11.2 Mapping monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
7.11.3 Load GPS data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
7.12 Preset reel values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
7.12.1 Horizontal reel position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
7.12.2 Reel speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
7.12.3 Reel height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
7.13 Preset front attachment values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
7.13.1 Snapping plate clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
7.13.2 Cutterbar table length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
7.13.3 CAC settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
7.13.4 CAC setting for LEXION Montana . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

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7.14 Partial width selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

7.15 Yield meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
7.15.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
7.15.2 Basic settings and calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
7.15.3 Preparations for yield measuring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
7.15.4 Moisture measurement ON/OFF, Moisture correction, Storage moisture . . . . . . . . . . . . . . . 237
7.15.5 A quick way to obtain reasonable measuring data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
7.16 Yield measuring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
7.16.1 Calibration factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
7.16.2 Yield zero point measuring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
7.16.3 Test-weighing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
7.16.4 Weight measured . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
7.16.5 Moisture correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
7.16.6 Moisture measurement ON/OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
7.16.7 Zero angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
7.16.8 Storage moisture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
7.16.9 Display dry yield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
7.17 Crop-dependent settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
7.17.1 List of crops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
7.17.2 Cleaning by blowing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
7.18 Recording . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
7.18.1 Planned records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
7.18.2 Start / Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
7.18.3 Completed records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
7.18.4 Daily recorder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
7.18.5 Total recorder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
7.18.6 Crop recorder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
7.18.7 Copying the chip card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
7.19 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
7.19.1 Cutterbar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
7.19.2 Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
7.19.3 Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
7.19.4 Separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
7.19.5 CEBIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
7.19.6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
7.19.7 Operator's manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
7.19.8 Code protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
7.20 Engine loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
7.20.1 Engine diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
7.21 Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
7.22 Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
7.23 Fault / Remedy - Yield meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
7.24 Guideline values for pulses/100 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279

8 Operation – Basic machine

8.1 HP feed rake conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
8.1.1 Adjusting the height of feeder chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
8.1.2 Setting the cutting angle of HP feed rake conveyor
(optional equipment) to the basic setting (up to serial no. ...) . . . . . . . . . . . . . . . . . . . . . . . . 281

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8.1.3 Setting the cutting angle of HP feed rake conveyor

(optional equipment) to the basic setting
(from serial no. ... up to serial no. ...) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
8.1.4 Setting the cutting angle of HP feed rake conveyor
(optional equipment) to the basic setting (from serial no. ...) . . . . . . . . . . . . . . . . . . . . . . . . . 284
8.1.5 Front attachment reverser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
8.1.6 Cutting height indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
8.1.7 Setting the drop rate of the front attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
8.1.8 Engaging the front attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
8.1.9 Disengaging the front attachment on the switch console . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
8.1.10 Disengaging the front attachment on the multifunction handle . . . . . . . . . . . . . . . . . . . . . . . . 287
8.1.11 Adjusting the feeder chain speeds with the front
attachment step drive, step 2 (optional equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
8.2 Standard feed rake conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
8.2.1 Adjusting the height of feeder chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
8.2.2 Feeder chain safety feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
8.2.3 Front attachment reverser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
8.2.4 Cutting height indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
8.2.5 Setting the drop rate of the front attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
8.2.6 Engaging the front attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
8.2.7 Disengaging the front attachment on the switch console . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
8.2.8 Disengaging the front attachment on the multifunction handle . . . . . . . . . . . . . . . . . . . . . . . . 296
8.2.9 Adjusting the feeder chain speeds with the front
attachment step drive, step 2 (optional equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
8.3 Threshing mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
8.3.1 Stone trap (large stone trap) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
8.3.2 Engaging the threshing mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
8.3.3 Disengaging the threshing mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
8.3.4 Threshing drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
8.3.5 Cleaning the threshing mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
8.3.6 Concave setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
8.3.7 Central concave readjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
8.3.8 Readjusting the left concave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
8.3.9 Adjusting the oil pressure of the concave adjustment accumulators . . . . . . . . . . . . . . . . . . . 306
8.3.10 Basic concave setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
8.3.11 Designations and dimensions for grain concave / maize concave . . . . . . . . . . . . . . . . . . . . . 313
8.3.12 Adjusting the concave position sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
8.3.13 Threshing drum speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
8.3.14 Drum drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
8.3.15 Two-step variable-speed drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
8.3.16 Removing and installing the preconcave segments
(large stone trap) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
8.3.17 Concave segment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
8.3.18 Removing a concave segment (large stone trap) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
8.3.19 Installing the concave segment (large stone trap) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
8.3.20 Disawner plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
8.3.21 Unslugging the threshing drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321

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8.4 Universal rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322

8.4.1 Axial rotors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
8.4.2 Axial rotors variable-speed drive (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
8.4.3 Axial rotors step drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
8.4.4 Universal rotors speed table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
8.4.5 Closing the separating grates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
8.4.6 Replacing separating grates by dummy concaves (option) . . . . . . . . . . . . . . . . . . . . . . . . . . 325
8.4.7 Closing the separating grates electrically with flaps (option) . . . . . . . . . . . . . . . . . . . . . . . . . 325
8.4.8 Removing and installing the dummy concaves / separating grates . . . . . . . . . . . . . . . . . . . . 325
8.4.9 Removing the dummy concaves / separating grates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
8.4.10 Installing the dummy concaves / separating grates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
8.4.11 Axial rotor straw blockage warning signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
8.4.12 Rotors performance monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
8.4.13 Rotor sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
8.5 Cleaning (JET STREAM cleaning system) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
8.5.1 Cleaning unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
8.5.2 Preparation floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
8.5.3 Frogmouth sieves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
8.5.4 Electric sieve adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
8.5.5 Removing the sieves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
8.5.6 Installing the sieves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
8.5.7 Tightening torques of axial mountings for the upper and lower sieves . . . . . . . . . . . . . . . . . 336
8.5.8 Sieves – Basic adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
8.5.9 Harvesting without lower sieves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
8.5.10 Covering up the return pan (accessory for maize) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
8.5.11 Cleaning fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
8.5.12 Adjusting the fan speed adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
8.5.13 Fitting the fan speed adjustment for grass seed threshing . . . . . . . . . . . . . . . . . . . . . . . . . . 339
8.5.14 Under-ventilated cleaning step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
8.5.15 3-D cleaning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
8.5.16 Returns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
8.5.17 Inspecting the returns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
8.5.18 Upper sieve performance monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
8.5.19 Sieve pan sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
8.6 Grain delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
8.6.1 Augers and auger troughs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
8.6.2 Elevators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
8.6.3 Grain tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
8.6.4 Grain tank extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
8.6.5 Unloading the grain tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
8.6.6 Emergency unloading grain tank cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
8.6.7 Grain tank unloading aid (accessory) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
8.6.8 Grain tank unloading tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
8.6.9 Swinging the grain tank unloading tube out and in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
8.6.10 Grain tank unloading tube transport position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
8.6.11 Cleaning covers on the grain tank unloading tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
8.6.12 Shear bolt for grain tank unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353

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8.6.13 Engaging and disengaging grain tank unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354

8.6.14 Grain tank access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
8.6.15 Automatic chain lubrication – grain tank unloading (accessory) . . . . . . . . . . . . . . . . . . . . . . . 356
8.6.16 Grain tank fill indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
8.7 Straw chopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
8.7.1 Straw chopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
8.7.2 Before starting the straw chopper, check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
8.7.3 Straw chopper operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
8.7.4 Straw chopper with spreader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
8.7.5 Putting the straw chopper into operation
(swinging the spreader to chopping position) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
8.7.6 Putting the straw chopper out of operation
(swinging the spreader to swathing position) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
8.7.7 Adjusting the straw guide plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
8.7.8 Setting the straw guide plate to chopping position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
8.7.9 Setting the straw guide plate to swathing position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
8.7.10 Adjusting the length of cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
8.7.11 Adjusting the spreading width of the chopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
8.7.12 Reducing the chopper speed (from serial no. ...) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
8.7.13 Reducing the chopper speed (up to serial no. ...) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
8.8 Chaff spreader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
8.8.1 Chaff spreader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
8.8.2 Adjusting the spreading width of chaff spreader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
8.8.3 Folding down the chaff spreader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
8.8.4 Folding up the chaff spreader (working position) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
8.9 Straw spreader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
8.9.1 Straw spreader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
8.9.2 Adjusting the spreading width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
8.9.3 Fitting the spreader blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
8.10 LEXION 580R sieve charts and suggested combine adjustments
(JET STREAM cleaning system) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
8.10.1 LEXION 580R sieve chart (JET STREAM cleaning system) . . . . . . . . . . . . . . . . . . . . . . . . . 373
8.10.2 LEXION 580R suggested combine adjustments
(JET STREAM cleaning system) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
8.11 Disawning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
8.11.1 Disawner plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
8.11.2 Concave segment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
8.11.3 Rotor cover plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
8.12 Problem, cause and / or remedy – Basic machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
8.12.1 Front attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
8.12.2 Threshing mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
8.12.3 Cleaning unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
8.12.4 Grain delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386
8.12.5 Straw / Putting down the material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387

9 Maintenance – Basic machine

9.1 Important maintenance instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388
9.1.1 Important maintenance instructions and safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388
9.1.2 Front attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388

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9.1.3 Correct tension of steel roller chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388

9.1.4 Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388
9.1.5 Variable-speed drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
9.1.6 Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
9.1.7 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
9.1.8 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
9.1.9 Wheels / tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391
9.1.10 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392
9.1.11 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
9.1.12 Air conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394
9.1.13 Safety guards / spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
9.1.14 Unbalance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
9.1.15 Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
9.2 Maintenance schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398
9.2.1 Basic machine maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398
9.3 Lubricants charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
9.3.1 Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
9.4 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
9.4.1 Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
9.4.2 Checking the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
9.4.3 Hydraulic oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
9.4.4 Changing the hydraulic oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
9.4.5 Hydraulic oil filter saturation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
9.4.6 Replacing the return flow filter
(up to serial no. ...) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
9.4.7 Replacing the return filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
9.4.8 Filling instructions when replacing the hydraulic oil
(Sauer 90 R 130 / 90 M 100) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
9.4.9 Bleed hydraulic cylinders for cross levelling of cutterbar
(Machines equipped with Auto Contour ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
9.5 Transmission / Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
9.5.1 Manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
9.5.2 Final drives (1-step) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
9.5.3 Threshing drum reduction gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
9.5.4 Engine output transfer gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
9.5.5 Grain tank unloading gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
9.5.6 Rotor gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
9.5.7 Grain tank filling part-turn gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
9.5.8 Foot brake and brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
9.5.9 Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
9.6 HP feed rake conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
9.6.1 Tensioning the feeder chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
9.6.2 Cleaning the suction blower (accessory) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
9.7 Standard feed rake conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
9.7.1 Tensioning the feeder chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
9.7.2 Cleaning the suction blower (accessory) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
9.8 Separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
9.8.1 Cleaning the separating grates flaps linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422

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9.9 Elevator chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423

9.9.1 Tensioning the grain elevator chain (machine without yield meter) . . . . . . . . . . . . . . . . . . . . 423
9.9.2 Tensioning the grain elevator chain (machine with yield meter / without cock) . . . . . . . . . . . 424
9.9.3 Tensioning the grain elevator chain (machine with yield meter / with cock) . . . . . . . . . . . . . . 424
9.9.4 Relieving the tension of the grain elevator chain (machine with yield meter) . . . . . . . . . . . . . 425
9.9.5 Tensioning the returns elevator chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426
9.10 Drive belts / drive chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427
9.10.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427
9.10.2 Drive diagram, left side (LEXION 570 with JET STREAM cleaning system) . . . . . . . . . . . . . 428
9.10.3 Drive diagram, right side (LEXION 570 with JET STREAM cleaning system) . . . . . . . . . . . . 430
9.10.4 Removing the belt (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
9.10.5 Installing the belt (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
9.10.6 Removing the belt (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433
9.10.7 Installing the belt (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
9.10.8 Removing the belt (3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436
9.10.9 Installing the belt (3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
9.10.10Removing the belt (4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439
9.10.11 Installing the belt (4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441
9.10.12Removing the belt (5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442
9.10.13Installing the belt (5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444
9.10.14Removing belt (6) (without torque support) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445
9.10.15Installing belt (6) (without torque support) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446
9.10.16Removing belt (6) (with torque support) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447
9.10.17Installing belt (6) (with torque support) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448
9.10.18Removing the belt (7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449
9.10.19Installing the belt (7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452
9.10.20Removing the belt (8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
9.10.21Installing the belt (8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455
9.10.22Removing the belt (9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456
9.10.23Installing the belt (9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459
9.10.24Removing the belt (10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 461
9.10.25Installing the belt (10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462
9.10.26Removing the chain (11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464
9.10.27Installing the chain (11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465
9.10.28Removing the belt (12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 466
9.10.29Installing the belt (12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 467
9.10.30Removing the belt (13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 469
9.10.31Installing the belt (13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 470
9.10.32Removing the belt (14) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471
9.10.33Installing the belt (14) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 472
9.10.34Removing the belt (17) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 473
9.10.35Installing the belt (17) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474
9.10.36Removing the belt (18) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 476
9.10.37Installing the belt (18) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 478
9.10.38Removing the belt (19) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 479
9.10.39Installing the belt (19) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480
9.10.40Removing the belt (21) (from serial no. ...) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 482

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9.10.41Installing belt (21) (from serial no. ...) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 484

9.10.42Removing the belt (25) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 485
9.10.43Installing the belt (25) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 487
9.10.44Removing the belt (26) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 489
9.10.45Installing the belt (26) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 491
9.10.46Removing the belt (40) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 492
9.10.47Installing the belt (40) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 493
9.10.48Removing the belt (41) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 494
9.10.49Installing the belt (41) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 495
9.10.50Removing the belt (42) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497
9.10.51Installing the belt (42) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 498
9.10.52Removing belt (R47) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 499
9.10.53Installing belt (R47) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500
9.10.54Adjusting belt (R47) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
9.10.55Removing the belt (49) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
9.10.56Installing the belt (49) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
9.10.57Removing the belt (50) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504
9.10.58Installing the belt (50) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505
9.10.59Removing the belt (51) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506
9.10.60Installing the belt (51) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 507
9.10.61Removing the belt (52) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508
9.10.62Installing the belt (52) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510
9.10.63Removing the belt (53) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .511
9.10.64Installing the belt (53) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513
9.10.65Removing the belt (54) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515
9.10.66Installing the belt (54) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 516
9.10.67Removing the chain (55) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517
9.10.68Installing the chain (55) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517
9.10.69Removing the chain (56) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 518
9.10.70Installing the chain (56) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 519
9.10.71Removing the belt (57) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 520
9.10.72Installing the belt (57) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 521
9.10.73Removing and installing belts (58), (60) and (61) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 522
9.10.74Removing the chain (K64) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 522
9.10.75Installing chain (K64) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 523
9.10.76Adjusting chain (K64). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 524
9.11 Cab / air conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 525
9.11.1 Cleaning the cab filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 525
9.11.2 Cleaning the units located in the cab roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 525
9.11.3 Cleaning the windscreen and the side windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 526
9.11.4 Cleaning the condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 527
9.11.5 Checking the refrigerant level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 527
9.11.6 Replacing the filter receiver drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 527
9.11.7 Required refrigerant quantity – refrigerant R 134 a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 528
9.11.8 Oil for the compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 528
9.11.9 Maintenance work before the harvest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 528

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9.12 Fire extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 529

9.12.1 Checking the fire extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 529
9.13 Straw chopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 530
9.13.1 Removing the free-swinging knives for grain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 530
9.13.2 Bolting down the free-swinging knives for grain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 531
9.13.3 Replacing the stationary knives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 532
9.13.4 Checking and replacing the straw chopper knives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 533
9.13.5 Checking the chopper rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 533
9.13.6 Replacing the straw chopper knives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 533
9.14 Winter storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 536
9.14.1 Winter storage instructions for combines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 536

10 Maintenance – Engine
10.1 Important maintenance instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 538
10.1.1 Important maintenance instructions and safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 538
10.1.2 Cooling water and air intake hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 538
10.1.3 Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 538
10.1.4 Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 538
10.1.5 Cleaning the engine compartment and hazard areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 539
10.1.6 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 539
10.1.7 Warranty on non genuine CATERPILLAR products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 539
10.1.8 Approved engine oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 539
10.1.9 Engine oils with dry lubricant additives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 539
10.2 Maintenance schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 540
10.2.1 Maintenance schedule CATERPILLAR C-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 540
10.3 Lubricants charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 542
10.3.1 Lubricants chart of CATERPILLAR C13 engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 542
10.3.2 Lubricants chart of CATERPILLAR C13 cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 543
10.4 Engine overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544
10.4.1 Engine overview CATERPILLAR C-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544
10.5 Fuel system / engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 545
10.5.1 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 545
10.5.2 Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 545
10.5.3 Fuel tank venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 546
10.5.4 Fuel shut-off tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 546
10.5.5 Water separator / fuel prefilter (standard equipment – small version) . . . . . . . . . . . . . . . . . . 546
10.5.6 Water separator / Fuel pre-filter (accessory) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 547
10.5.7 Replacing the fuel filter cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 548
10.5.8 Bleeding the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549
10.5.9 Engine oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549
10.5.10Engine oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549
10.5.11 Draining used oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 550
10.5.12Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 550
10.5.13Topping up engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 551
10.6 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 552
10.6.1 Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 552
10.6.2 Draining coolant from the water radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 552
10.6.3 Topping up coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 553

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10.6.4 Identify the coolant type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 554

10.6.5 Coolant mixing ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 555
10.6.6 Changing the coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 556
10.6.7 Shut down the overheated engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 557
10.6.8 Rotary chaff screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 558
10.6.9 Cleaning the water cooler (rotary chaff screen) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 560
10.6.10Diesel engine fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 561
10.7 Dry-type air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 562
10.7.1 Dry-type air cleaner in general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 562
10.7.2 Warning device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 563
10.7.3 Cleaning the air filter suction screen (up to serial no. ...) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 564
10.7.4 Cleaning the air filter suction screen (from serial no. ...) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 564
10.7.5 Cleaning the air filter with plastic housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 565
10.7.6 Cleaning the air filter with metal housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 567
10.7.7 Safety filter cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 569
10.7.8 Removing and installing safety cartridge (plastic housing) . . . . . . . . . . . . . . . . . . . . . . . . . . 570
10.7.9 Removing and installing safety cartridge (metal housing) . . . . . . . . . . . . . . . . . . . . . . . . . . . 571
10.8 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 572
10.8.1 Cleaning the alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 572
10.9 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 573
10.9.1 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 573
10.9.2 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 574
10.10Problem, cause and / or remedy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 575
10.10.1Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 575
10.11Winter storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 577
10.11.1 Engine winter storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 577

11 Lubrication chart
11.1 Lubrication points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 578
11.1.1 Greasing cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 578
11.1.2 Lubrication points - 10 h on the left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 581
11.1.3 Lubrication points - 50 h on the left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 582
11.1.4 Lubrication points - 50 h on the right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 583
11.1.5 Lubrication points - 100 h on the left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 584
11.1.6 Lubrication points - 100 h on the right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 587
11.1.7 Lubrication points - 500 h on the left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 589
11.1.8 Lubrication points - 500 h on the right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 590

18 00 0294 347 2 - BA LEXION 580R - 12/09

 1 Introduction
1.1 General Information
77351

1 Introduction
1.1 General Information
102866
1.1.1 How to use this manual
This operator's manual is the original operator's man-
ual. In the following texts, it will be referred to simply as
the operator's manual.
This operator's manual is intended for all users and
provides information on the use, operation, adjust-
ment, maintenance, cleaning and transportation of the
machine.
Provided all instructions regarding proper maintenance
and operation of your machine are followed, you can
count on many years of reliable service.
Failure to perform maintenance or incorrect operation
lead to an increased safety risk, premature wear, a
reduction in performance, loss of earnings and time.
Have the post harvest check / annual check performed
regularly by your CLAAS dealer. A combination of the
prescribed maintenance work with the post harvest
check is recommended.
If you use the latest expertise and experience that
went into this machine, it will render you consistently
excellent service.
There is a separate operator's manual for front attach-
ments and hitched devices.
Texts and figures
Pictures and graphics are neutral. Differences are
pointed out by notes beneath the figure.
Texts are short and not machine-specific as far as pos-
sible. Differences are pointed out by intermediate
headings.
Different types of texts can easily be distinguished
from one another by their formats. The following for-
mats are distinguished:

Formatting Meaning Description

Description Text Further information on the subject.
– Instructions Operation Operations which must be carried out one after the
other.
Result Result Consequence of operations carried out.

00 0294 347 2 - BA LEXION 580R - 12/09 19

1 Introduction
1.1 General Information
77351

References can easily be distinguished by suitable

symbols. The following symbols are distinguished:

Symbol Meaning Description

See index The symbol indicates that further information on
this subject can be found at another point in this
manual.
See index of the relevant The symbol indicates that further information on
Operator's manual this subject can be found in the Operator's manual of
that machine or equipment.

Document structure based on subassemblies

As far as the contents permit, the chapters of this man-
ual are structured according to subassemblies. The
structure of these subassemblies is the same in all
chapters.
Different product groups have different document
structures based on subassemblies. CLAAS always
takes care to keep these document structures based
on subassemblies identical in any documents.
Search and find
The wanted subject can easily be found with the recur-
ring subassembly structure, using the table of contents
or the header line of this manual.
In addition, the index of this manual is a useful tool for
locating a specific subject. The index can be found on
the last pages of this manual.
Directions
Text elements such as front, rear, right and left always
apply to the direction of travel. In figures, the direction
of travel may be indicated by a direction arrow.
Optional equipment and accessories
Optional equipment includes equipment variants of the
machine where different variants are available, but
only one variant can be fitted.
Accessories are equipment items that may be addi-
tionally fitted to the machine, but are not included in
the standard scope of the machine.
Both terms designate possible variants. Standard
scopes and equipment variants may differ in other
countries.
Your CLAAS Service Department

20 00 0294 347 2 - BA LEXION 580R - 12/09

 1 Introduction
1.1 General Information
77351
28063
1.1.2 Validity of Operator's manual
The present Manual applies to the following machine /
front attachment:

Designation Type Machine serial number

from to
LEXION 580 R 585 585 00960 ―

00 0294 347 2 - BA LEXION 580R - 12/09 21

2 General Information
2.1 Road traffic
77352

2 General Information
2.1 Road traffic
In addition to his driving licence, the operator must
always carry the copy of the vehicle type approval reg-
istration issued by the Kraftfahrt-Bundesamt (the
German Federal Motor Vehicle Executive). A warning
triangle and, on machines over 4 t permissible total
weight, at least one wheel chock must always be car-
ried on the combine.
When driving on public roads with the combine har-
vester comply with all the requirements stated under
letter C in the copy of the vehicle type approval regis-
tration (§ 18 Section 5 StVZO) issued by the Kraftfahrt-
Bundesamt.
On machines with excess width (width over the tyres),
a vehicle type approval registration for individual vehi-
cles (single expert opinion) and a special approval in
accordance with § 70, Section 1, clauses 1 and 2 of
the StVZO must be carried instead of the General
Operating Permit. Furthermore, all the requirements
stated in the vehicle type approval registration for indi-
vidual vehicles and in the special approval must be
observed. The issue of a special approval differs from
country to country. The excess width must be marked
in accordance with the regulations for marking of
excess-width road vehicles (e.g. two marker boards at
the front and the rear each, protective bar, two amber
flashing warning beacons).
If any part(s) of the combine harvester is/are subse-
quently modified whose condition is/are prescribed or
the operation of which (after being modified) could rep-
resent a hazard to other road users, then the vehicle
type approval registration shall no longer be valid and
application must be made for a new vehicle type
approval registration. In this case the machine must be
presented to the motor vehicle safety inspection
authority responsible (e.g. TÜV) in order to obtain an
expert opinion certificate (§ 19 section 2 StVZO).
If you are in any doubt as to whether this situation
applies in your case, please contact us as
manufacturers.
If a transport vehicle for front attachments is towed
behind the combine harvester, then the cable for the
lighting system must be connected and the good con-
dition of the lighting system assured.
If the combine is equipped with a maize picker head or
folding cutterbar, the regulations and requirements of
the machine's General Operating Permit must be
observed, in particular the requirements concerning
ballast weights and tyres.

22 00 0294 347 2 - BA LEXION 580R - 12/09

 2 General Information
2.1 Road traffic
77352

Registration
As a self propelled working machine with a maximum
speed of more than 20 km/h, the combine is subject
to registration and needs to have licence plates fitted.
As a self propelled working machine with a maximum
speed of up to 20 km/h, the combine is not subject to
registration and does not need to have licence plates
fitted.
The machine must be clearly and indelibly marked on
the left side with the Christian name and surname of
the owner and his address.
The towing of trailers in the trailer hitch when driving
on public roads is not permitted.
Road traffic regulations may vary between countries.
In case of discrepancies between the instructions pro-
vided by the manufacturer and the traffic regulations of
the relevant countries, the traffic regulations of the
countries concerned apply.

00 0294 347 2 - BA LEXION 580R - 12/09 23

2 General Information
2.2 Important notice
77352

2.2 Important notice

The instructions contained in this manual should be
carefully read and observed by all persons involved
with the operation, maintenance and inspection of this
machine in order to prevent accidents. In particular,
read the section “Safety rules”.
The use of spare parts, accessories and ancillary
equipment other than genuine CLAAS products or
those which have been tested and approved by
CLAAS, may change the specified design characteris-
tics of this CLAAS machine or detract from its
functional performance, with a possible adverse effect
on the active and/or passive operational safety of the
machine and its occupational safety standards (acci-
dent prevention).
CLAAS is in no way liable for any damage or personal
injury caused through the use of other than original or
approved CLAAS parts, accessories and ancillary
equipment.
Technical data, dimensions and weights are given
as an indication only. CLAAS reserves the right to
make changes subsequently as technical develop-
ments continue. Responsibility for errors or omissions
is not accepted.
Front, rear, right and left refer to the direction
of forward travel.

24 00 0294 347 2 - BA LEXION 580R - 12/09

 2 General Information
2.3 Identification plate / Serial number
77352

2.3 Identification plate / Serial number

3903 1

A =
Equipment options
B =
Permissible gross vehicle weight
C =
Type
D =
Identification no. (serial no.)
E =
Permissible front axle load
F =
Year of construction
G =
Rated engine power of combine-harvester
(kW)
H = Permissible rear axle load
I = Approval no. according to ECE-R 24
J = Absorption coefficient according to ECE-R 24

(Fig. 1)

00 0294 347 2 - BA LEXION 580R - 12/09 25

2 General Information
2.3 Identification plate / Serial number
77352

When ordering spare parts and in case of technical

questions, indicate the machine number of the CLAAS
combine and when the engine, front attachments, cut-
terbar and maize picker are concerned, also the
respective serial numbers.
This is necessary as otherwise, incorrect spare part
deliveries may result.
5873
2.3.1 Identification plate
The identification plate of the machine is located on
the right hand side above the rear axle.
(Fig. 2)

2
9502

5874
2.3.2 Machine serial number
The machine serial number is stamped on the engine
frame underneath the operator's platform on the right
hand side of the machine.
(Fig. 3)

3
3907

28069
2.3.3 Engine serial number
CATERPILLAR C-13, exhaust emission level 3a
Engine number: MDB ...
(Fig. 4)

4
4803

26 00 0294 347 2 - BA LEXION 580R - 12/09

 2 General Information
2.3 Identification plate / Serial number
77352
21372
2.3.4 Straw chopper identification plate
The chopper serial number is provided on the right
side panel.
(Fig. 5)

5
8416

5877
2.3.5 Cab serial number
The cab serial number is located at the top of the left
hand side, at the rear of the frame.
(Fig. 6)

6
3910

00 0294 347 2 - BA LEXION 580R - 12/09 27

2 General Information
2.4 Attachment parts / machine body
77352

2.4 Attachment parts / machine body

107774
2.4.1 Access to the workplace and mainte-
nance areas
The operator's workplace / driver's seat (1) is in the
machine cab. The operating elements in the workplace
are used to start or shut down the machine.
The machine maintenance areas allow maintenance
or adjustment work to be performed.

Danger!
Danger of falling!
Death or serious injuries!
– Only enter areas that are designated as
workplaces or maintenance areas
and are secured by railings or similar.
– Other areas must be secured by addi-
tional rails / safety measures before they
are entered.

– Enter the workplace in the cab via the front

ladder (2) and via the maintenance area at the
left-hand operator's platform (3).

1
7
39598

2
8
39599

28 00 0294 347 2 - BA LEXION 580R - 12/09

 2 General Information
2.4 Attachment parts / machine body
77352

– Enter the maintenance area at the left-hand oper-

ator's platform (3) via the front ladder (2) in order
to enter the cab, clean the left-hand cab window,
3 adjust the mirror and remove grain tank samples

1 – Enter the maintenance area at the feeder

housing (1) in order to clean the front cab window
via the maintenance area at the left-hand
operator's platform (3).

2
9
39599

– Enter the maintenance area at the right-hand

operator's platform (1) via the maintenance area
in order to clean the right-hand cab window
2 , to enter the grain tank via the grain tank access
1 and to adjust the mirror at the feeder housing (2)
.

10
39632

3 – Enter the maintenance area at the tank

platform (2) via the rear ladder (1) to refuel the
2 machine and clean the cooling unit.
– Enter the maintenance area at the engine
platform (3) via the engine platform maintenance
area (2) to perform maintenance on the diesel
engine.

11
39609

00 0294 347 2 - BA LEXION 580R - 12/09 29

3 Safety Rules
3.1 Safety rules
77353

3 Safety Rules
3.1 Safety rules
45097
3.1.1 General information
The CE mark and the enclosed declaration of con-
formity document that the self-propelled machine
fulfils the safety regulations of the EC Machinery
Directive.
Before putting the machine into operation, read and
follow the Operator's manual and the safety
instructions!
5957
3.1.2 Identification of warning and danger
signs
All parts of this manual having to do with your safety or
the safe operation of the machine are marked with the
following signs. Please pass all safety instructions on
to other users, too.

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

Attention!
Sign to indicate instructions which must
be observed. Failure to do so could result in
damage to the machine.
– Measures to prevent damage to the
machine.

Note!
Sign to indicate instructions for a more effi-
cient and economic use of the machine.

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

Environment!
Sign to indicate instructions that must be
observed in order to avoid damage to the
environment.
Danger to the environment is caused by irreg-
ular handling and incorrect disposal of toxic
material (e.g. old oil).

30 00 0294 347 2 - BA LEXION 580R - 12/09

 3 Safety Rules
3.1 Safety rules
77353

The warning and instruction signs placed on the com-

bine provide important recommendations for safe
operation. These instructions involve your safety –
observe them at all times!
106459
3.1.3 Intended use
The CLAAS combine harvester is designed exclusively
for professional use in line with the recognised regula-
tions of agricultural practices in agricultural harvesting
of grain.
The combine harvester is a self-propelled harvesting
machine with a fitted front attachment (machine),
which is approved by the manufacturer, and is suitable
and intended for harvesting grain in fields during
travel. Grain here refers to cultivated cereal and leg-
ume crops such as wheat, rye, barley, oats, rice, rape
seed, maize, durra, soya beans and sunflowers.
The combine harvester takes the grain from the front
attachment and conveys it via a conveying unit to the
threshing and separating units. There, the grains are
separated from straw and chaff. The straw and chaff
are deposited on the field using the distribution units
behind the combine harvester. The grain is stored tem-
porarily in the combine harvester's grain tank and then
loaded on a transport vehicle by a conveying unit.
When the combine harvester is driven on public roads,
a front attachment approved by the manufacturer can
be fitted on the front, depending on the applicable reg-
ulations, and driven with the combine harvester, or a
trailer approved by the manufacturer that is loaded
with the front attachment can be coupled to the trailer
hitch and towed.
The machine may only be used, maintained and serv-
iced by persons who are familiar with the machine and
briefed on the hazards that may arise as a result of the
machine's functions.
Compliance with the conditions of operation, mainte-
nance and servicing as specified in the operator's
manual and by the manufacturer also constitute
essential elements for the intended use.
The relevant accident prevention regulations, all other
generally recognised regulations on safety and occu-
pational medicine and the road traffic regulations must
be observed by users and owners at all times.
Any use other than this is considered "unintended",
and the manufacturer is not liable for any resulting
damage. All liability in this case is borne by the user.
For specific details, you may request information on
intended use in exceptional situations from CLAAS.

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3 Safety Rules
3.1 Safety rules
77353
106464
3.1.4 Reasonable foreseeable misuse
Use outside of intended use constitutes use not
intended by the manufacturer of the machine and
therefore amounts to misuse for the purposes of the
machinery directive. The manufacturer accepts no lia-
bility for damage resulting from this. All liability is borne
by the user.
Misuse of the CLAAS combine harvester includes:
• Use of areas and premises that are not described
in the operator's manual as workplaces
• Performance of adjustment work, cleaning work
and maintenance work against the specifications
in the operator's manual
• Performance of fault elimination and servicing
work with drives and/or the diesel engine running
• Nonobservance of warning signs on the machine
and in the operator's manual
• Performance of servicing and repair work by
untrained personnel
• Unauthorised modifications to the machine
• Attachment of non-approved additional equipment
• Use of non-original CLAAS spare parts
• Use in a stationary position
• Use to harvest goods that are not classified as
grain
• Use as a carrier vehicle for units not approved by
the manufacturer
• Use as a general towing vehicle / carrier vehicle
• Use for compacting goods and subsurfaces
• People transport
• Goods transport
5959
3.1.5 General safety and accident prevention
regulations
• In addition to the instructions contained in this
operator's manual, also observe the general
safety and accident preventive regulations.
• Always comply with local traffic regulations when
driving on public roads.
• Before starting work, familiarise yourself with all
the controls and instruments and their functions.
During work or road travel it is too late!
• Before starting the engine ensure that all guards
are installed and in their correct position.
• Start the engine only from the operator's seat.
Never attempt to start the engine by shortening
across the starting motor terminals as the
machine may immediately start to move.
• Before moving away, always check the immediate
vicinity of the machine (e.g. for children). Ensure
adequate visibility. For a warning, always blow the
horn before starting up!

32 00 0294 347 2 - BA LEXION 580R - 12/09

 3 Safety Rules
3.1 Safety rules
77353

• Never run the engine in a closed building!

• Clothing worn by the operator must be close-fit-
ting. Avoid wearing loose jackets, shirts or ties.
• Handle fuel with care. – It is highly flammable.
Never refuel the machine in the vicinity of naked
flames or sparks. Do not smoke during refuelling.
• Always stop the engine and remove the ignition
key before refuelling. Fill the fuel tank outdoors.
Clean up any spilled fuel immediately!
• Prevent fires by keeping the machine clean!
• Take care when handling brake fluid and battery
acid (toxic and corrosive)!
• Always blow the horn before starting the engine
and engaging the threshing mechanism – watch
for children.
5961
3.1.6 Transporting passengers, instructor,
operating personnel
• Only such persons may be transported on the
instructor's seat who instruct the driver and/or pro-
vide instructions regarding the machine.
• The carrying of passengers is otherwise not
permitted!
5962
3.1.7 Driving operations
• Observe the maximum permissible axle loads and
total weights!
• The operating, steering and braking behaviour of
the combine will be affected, e.g. by the road sur-
face and by attaching implements. Therefore, the
handling of the machine must be adapted
to existing terrain and ground conditions. Take
particular care when operating or turning on a
slope and with a full grain tank. Never take the
transmission out of gear when driving on a slope
or on uneven terrain!
• The grain tank must be empty when driving
on public roads and lanes.
• Never leave the operator's platform when driving.
• Stay a safe distance away from low overhead
power lines (watch radio and CB radio antennas, if
installed)!
• For road travel with a raised front attachment the
safety switch must be switched off.
• Before driving the machine and before starting
fieldwork adjust the mirrors to give full view of the
road or lane and working area behind.
• Be particularly careful when crossing level cross-
ings. When a level crossing cannot be crossed
quickly and without stopping due to road traffic or
an obstacle, stop in front of the St. Andrew's
cross. In all other cases, cross a level crossing
without stopping and standstill.

00 0294 347 2 - BA LEXION 580R - 12/09 33

3 Safety Rules
3.1 Safety rules
77353
5963
3.1.8 Leaving the combine harvester
• When leaving the combine harvester, ensure that
it will not roll away (apply parking brake, chock
blocks). Shut off the engine, remove the main
switch key (ignition key) and lock the operator’s
cab!
• If the combine harvester is shut down for an
extended period, turn off the battery isolating
switch.
• Never leave the combine unattended as long
as the engine is still running!
• Lower front attachments (cutterbars, maize picker
head etc.) fully to the ground before leaving the
machine!
5964
3.1.9 Front attachments (cutterbar etc.) and
other components
• Work under raised front attachments (cutterbar
etc.) only when you are sure that the front attach-
ment is safely supported!
• Particular care must be taken when attaching front
attachments (cutterbar etc.) or when coupling a
trailer to the combine!
• Knives, the cutterbar, intake auger and reel etc.
cannot be completely shielded by constructional
measures due to their function. For this reason, an
adequate safety distance must be maintained to
these moving elements during operation!
• Feeder chains and snapping rolls of the maize
head (maize picker head) cannot be completely
shielded by constructional measures due to their
function. For this reason, an adequate safety dis-
tance must be maintained to these moving
elements during operation. These instructions
apply analogously for all other attachments!
• The straw chopper has safety guards surrounding
dangerous rotating knives which continue to rotate
for a while after the drive has been disengaged.
Therefore, always stay a safe distance away from
the chopping unit!
• The augers located inside the grain tank
cannot be shielded completely against accidental
contact due to their function.
• Before mounting or entering the grain tank, make
sure that no other person can restart the engine.
• To enter the grain tank, use only the openings pro-
vided for this purpose.
• When carrying a cutterbar along during travel on
public roads and lanes, the finger bar and/or the
crop lifters must be covered.

34 00 0294 347 2 - BA LEXION 580R - 12/09

 3 Safety Rules
3.1 Safety rules
77353
2422
3.1.10 Air conditioner
• The air conditioning system is filled with
CFC refrigerant. CFC refrigerants must not be
allowed to escape into the atmosphere.
- Therefore, please take appropriate precautions
when working on the air conditioner.
• Maintenance and repair work may only be carried
out by specialised air conditioning system service
workshops. Refrigerant must always be sucked
out and disposed of for recycling.
5965
3.1.11 Maintenance
• Repair, service and cleaning work and the elimi-
nation of malfunctions should only be performed
with the drive and the engine switched off –
remove the ignition key and turn off the battery
isolating switch!
• Escaping fluid (fuel or hydraulic oil) under high
pressure can penetrate the skin and cause seri-
ous injuries. If any fluid is injected into the skin,
consult a doctor immediately as otherwise serious
infections may result!
• Be careful when opening the radiator cap. The
radiator is under pressure when the engine is hot!
• Dispose of oil, fuel and filters in a way that is
harmless to the environment and in accordance
with existing anti-pollution regulations!
• Do not attempt to mount a tyre unless you
have the proper equipment and experience
to perform the job safely!
• Retighten the wheel nuts and wheel bolts
regularly!
• Only have qualified workshops carry out repair
work on the hydraulic system.
5966
3.1.12 Basic rule
• Always check the operational safety and road
safety of the combine before starting the engine!
5968
3.1.13 Accumulators
• Be especially careful when working on the accu-
mulators! Accumulators are under high pressure!
• With valve-controlled hydraulic accumulators – as
for example on the CLAAS Autopilot – first
slacken the short-circuit bolt before carrying out
any repair work at the hydraulic accumulator. This
is necessary to relieve the hydraulic pressure.

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3 Safety Rules
3.1 Safety rules
77353
107360
3.1.14 Decommissioning and disposal
When the machine (or its components) reaches the
end of its useful life and is surrendered as scrap, the
components must be disposed of in the correct man-
ner. The regulations of the local authorities responsible
must be observed.
The operating materials in the machine require special
disposal and must not be released into the environ-
ment. More information on disposal can be obtained
from the local authorities responsible, your CLAAS
dealer or the CLAAS service department.
– Do not dispose of products marked with the
symbol (1) in your domestic waste at the end of
their service life.

1
39207

– Recycle used materials marked with the

symbol (2) in accordance with their labelling.
– Recycle packaging material, do not dispose of it in
domestic waste.
– Recycle plastics that are labelled with material
information, e.g. PP TV 20, do not dispose of
them in domestic waste.
– Used batteries contain hazardous substances and
must be taken back by the distributor, disposed of
correctly or delivered to a collection point. Do not
dispose of used batteries in domestic waste.
2 – Operating materials, such as oils, hydraulic fluids,
7761 brake fluids or fuels, must be treated as hazard-
ous waste and disposed of correctly.
– Have refrigerants disposed of only by specialist
companies with experienced personnel and the
necessary technical equipment. Refrigerants must
never be released into the atmosphere. Have
refrigerants disposed of by your CLAAS dealer.
Observe country-specific regulations.
– Follow the regulations of the local authorities
responsible.

36 00 0294 347 2 - BA LEXION 580R - 12/09

 3 Safety Rules
3.1 Safety rules
77353
5970
3.1.15 Cylinder safety lock

Danger!
Work under raised front attachment (cutterbar,
maize picker head etc.) only when you are
sure that the front attachment is safely
supported!

– Completely raise the feed rake conveyor.

– Release safety lock (S) at latch (R) and fold onto
the hydraulic ram.
– Then lower the feed rake conveyor onto the
S R applied cutterbar cylinder safety lock.
(Fig. 3)

3
2755

– During combine operation, the safety lock (S)

must be secured with latch (R).
(Fig. 4)
S
R

4
2756

5971
3.1.16 Fire extinguisher
– The agent for the fire extinguisher manufacturer
should check the extinguisher (F) at least every
other year.
The date of manufacture or the date last checked
is shown on the extinguisher.
– Prior to putting the machine into operation, the fire
extinguisher must be installed on the left side of
the operator's platform, next to the cab.
(Fig. 5)
F

5
2733

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3 Safety Rules
3.1 Safety rules
77353
5972
3.1.17 Battery isolating switch
The battery isolating switch (H) can cut the entire
power supply of the machine.

A Designation
A OFF (switch off by turning anticlockwise)
H
B ON (switch on by turning clockwise)

– In case of emergency and for maintenance work,

B disconnect the battery isolating switch.

6 Attention!
2548 Do not turn off the battery isolating switch
while the engine is running.

(Fig. 6)
5973
3.1.18 Wheel chocks
(not for all countries)
The combine is equipped with two wheel chocks from
the factory.
The brackets holding the wheel chocks are located on
the left machine side behind the fan guard.
– The wheel chocks must be carried on the machine
at all times.
– When leaving the machine on uneven ground,
both wheel chocks must always be placed under
the traction wheels.
7 (Fig. 7)
2731

Positioning the wheel chocks

– Always position the wheel chocks in front of or
behind the traction wheels (depending on the
slope of the ground) on both sides of the machine.
– Always position the wheel chocks so that the
machine cannot roll away.
– Completely open the wheel chocks and place as
close to the traction wheels as possible.
(Fig. 8)

8
2732

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 3 Safety Rules
3.1 Safety rules
77353
11229
3.1.19 Jack up the machine

Danger!
Jacking up the machine.
Death or serious injury.
– Use jack / jack stand with sufficient
1 capacity.
– Use reliable jack / jack stand.
– Use jack / jack stand on solid and level
ground.
– Apply the jack / jack stand at the position
614659 9 of the machine intended for this purpose.
5298
The jacking points / supporting points are marked by
symbol (1) on the axles.
(Fig. 9)
34639
3.1.20 Loading and tying down the machine
The safety decal (1) shows all permitted tie-down
points on the machine.
(Fig. 10)

10
12786

00 0294 347 2 - BA LEXION 580R - 12/09 39

3 Safety Rules
3.1 Safety rules
77353

The lifting points are marked by the hazard warning

sign (1) on the machine.
The tie-down points are marked by the safety decal (2)
on the machine.

Danger!
Hazard points on the machine.
1 Death or serious injury!
– Hazard warning signs / safety decals that
are damaged or unrecognisable must be
11 replaced immediately by new ones.
65
– When parts that have hazard warning
signs / safety decals are replaced, always
make sure to attach the relevant new haz-
ard warning signs / safety decals to
each new part.

Moreover, the following instructions must be observed

while loading and tying down machines:
1 Improper lifting or tying-down may relocate the
2 machine and cause injuries or damage.
2 Before bending or tying-down the machine, apply
the parking brake.
12
3 The feed rake conveyor must be fully raised
9602
before bending or tying-down. Before standing
beneath the feed rake conveyor, its support fitted
to the raise cylinders must be installed.
4 For lifting the machine, use lift eyes and/or a car-
rying beam at the front. If such equipment is not
available, please contact your CLAAS dealer.
5 Use only flawless and sufficiently dimensioned lift-
ing devices for lifting the machine.
6 Protect your lifting device against sharp corners
and edges, e.g. by using edge protectors.
(Fig. 11, 12)
5975
3.1.21 Hydraulic system

Danger!
Only have qualified workshops carry out repair
work on the hydraulic system.

40 00 0294 347 2 - BA LEXION 580R - 12/09

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