Lexion 580-510

LEXION 580 - 510
Fitting and
Operating
Instructions
Folding cutterbar
5.40 m / 4.50 m
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EC Declaration of Conformity
according to Directive 98/37/EC
We
CLAAS Hungaria KFT.
(Name of supplier)
Postaflók 106
H - 5200 Törökszentmiklós
(full address of the manufacturer - authorized representative established in the Community must also
give the business name and address of the manufacturer)
declare under our sole responsibility, that the product
Cutterbar - Type No.:

(Make, model)
to which this declaration relates corresponds to the relevant basic safety and health
requirements of the Directive 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)
(if applicable)
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))
by order of the Technical Management of

CLAAS Selbstfahrende Erntemaschinen GmbH Product management
0187 555.4 - EN - 09.04
(J. H. Mohr) (B. Hoffmann)

(Name, function and signature of the authorized person)
Törökszentmiklós,
(Place and date of issue)
1
Introduction
Introduction
Introduction
INTRODUCTION These instructions describe how to assemble and

operate the folding cutterbar, and how to mount the
necessary accessories on the machine.
The accessory parts for the switching equipment and
the additional driving lights are listed in Group 7.1.
You should explain the function, operation and
maintenance to the customer on the basis of these
instructions.
Please hand over these instructions to the customer
subsequently.
These instructions are only valid when used in
conjunction with the combine harvester operating
instructions.
CLAAS Service Department
000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION 1.1.1

Introduction
1.1.2 ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

2
Table of contents
Table of contents
Table of contents
TABLE OF CONTENTS
1. Introduction Fitting the cutterbar ............................................................... 8.4.1

Introduction ............................................................................ 1.1.1 Tilting the cutterbar from the transport position ............... 8.4.1
Installing and removing the cutterbar .............................. 8.4.2
2. Table of contents Installing the cutterbar when folded in
(cutterbar in the transport position) ................ 8.4.2
Table of contents ................................................................... 2.1.1
Locking the cutterbar at top and bottom on both sides ... 8.4.3
3. General Information Connecting the universal coupling .................................. 8.4.4
Changing the cutterbar from transport position to
Vehicle type approval ............................................................. 3.1.1
working position ..................................................................... 8.5.1
Important information ............................................................. 3.2.1
Fitting the universal drive shafts
Identification plate / Serial number ......................................... 3.3.1
LEXION MONTANA
4. Safety rules (from serial no. 71300231) ............................. 8.5.6
Removing standard universal drive shafts ...................... 8.5.7
Safety rules ............................................................................ 4.1.1
Installing the universal drive shaft for
Safety locks ..................................................................... 4.1.3
LEXION MONTANA ........................................................ 8.5.7
Feed rake safety locks ..................................................... 4.1.3
Changing the cutterbar from working position to
Reel safety lock ............................................................... 4.1.3
transport position ................................................................... 8.6.1
Safety decals with pictorials ................................................... 4.2.1
Aligning the cutterbar / removing the cutterbar ..................... 8.7.1
5. Specifications Aligning the cutterbar
Weights / Dimensions / Safety devices .................................. 5.1.1 (machines without Auto-Contour) .................. 8.7.1
Additional weights ............................................................ 5.1.1 Removing the cutterbar ................................................... 8.7.2
Adjustments on the cutterbar ................................................ 8.8.1
6. Prior to operation Crop dividers ................................................................... 8.8.1
Carry out prior to initial operation ........................................... 6.1.1 Outer deflector ................................................................ 8.8.2
Driving lights / Cutterbar cylinder ........................................... 6.2.1 Adjusting the dividers ...................................................... 8.8.3
Driving lights for road use ................................................ 6.2.1 Crop lifters ....................................................................... 8.8.3
Changing the driving lights Knife ................................................................................ 8.8.4
(up to serial no. ...) ......................................... 6.2.1 Removing the knife ......................................................... 8.8.4
Changing the driving lights Installing the knife ........................................................... 8.8.4
(from serial no. ...) .......................................... 6.2.1 Adjusting the knife height ................................................ 8.8.5
Safety lighting rail on the cutterbar .................................. 6.2.2 Aligning the knife clips ..................................................... 8.8.5
Removing the transport fixtures ....................................... 6.2.2 Spare knife ...................................................................... 8.8.5
Third cutterbar cylinder .................................................... 6.2.2 Reel ................................................................................. 8.8.6
Adjusting the cutterbar floatation springs ........................ 6.2.2 Adjusting the reel height .................................................. 8.8.6
Fine height adjustment of the reel ................................... 8.8.6
7. Accessory equipment Reel drive ........................................................................ 8.8.7
Additional headlights .............................................................. 7.1.1 Reel fore and aft adjustment ........................................... 8.8.7
Fitting the switches and the additional headlights ........... 7.1.2 Feed auger ...................................................................... 8.8.8
Installing the push buttons for switching .......................... 7.1.2 Adjusting the clearance to the cutterbar bottom plate ..... 8.8.8
Mounting the additional headlights on both sides ............ 7.1.2 Height adjustment of the feed auger ............................... 8.8.9
Adjusting the additional headlights .................................. 7.1.6 Adjusting the intake finger position ............................... 8.8.10
Safety feature ................................................................ 8.8.11
8. Operation Cutterbar skids .............................................................. 8.8.11
Cutterbar skids ....................................................................... 8.1.1 Malfunction, possible cause and/or remedy .......................... 8.9.1
Adjusting the cutterbar skids ........................................... 8.1.1
Cutting angle adjustment ....................................................... 8.2.1 9. Maintenance
Adjusting the cutting angle .............................................. 8.2.1 Maintenance schedules and lubricants charts ...................... 9.1.1
Mounting the spacer bar .................................................. 8.2.1 Maintenance schedule .................................................... 9.1.1
Mounting the coupling brackets ....................................... 8.2.2 Lubricants chart ............................................................... 9.1.2
Locking the coupling lug after fitting the cutterbar ........... 8.2.2 Transmissions ....................................................................... 9.2.1
Unlocking the coupling lug before removing Knife drive transmission .................................................. 9.2.1
the cutterbar .................................................................... 8.2.3 Spring-loaded cylinders / Drive chains / Inductive sensors ... 9.3.1
Mounting the shaft extension ................................................. 8.3.1 Adjusting the spring-loaded cylinders for knife drives ..... 9.3.1
Mounting the extension to the intermediate drive shaft Tensioning the drive chains ............................................ 9.3.1
(LEXION 530 – 510) ...................................... 8.3.1 Tensioning the reel drive chain ....................................... 9.3.2
Cleaning the guide rails of the locking cylinder ............... 9.3.2

Table of contents
General .................................................................................. 9.4.1

Aligning the double fingers .............................................. 9.4.1
Adjusting the reel limit switch ........................................... 9.4.1
Adjusting the locking pawl at the centre reel guide .......... 9.4.1
Cleaning the spaces of the supporting arm bearings ...... 9.4.2
Cleaning the coupling lug areas ...................................... 9.4.3
Suggestions for winter storage .............................................. 9.5.1
10. Lubrication chart

Lubricants and notes ............................................................ 10.1.1
11. Index
Index .................................................................................... 11.1.1

3
General Information
General Information
General Information
VEHICLE TYPE APPROVAL Installing the foldable 5.40 m or 4.50 m cutterbar will
invalidate the Vehicle Type Approval of your
combine harvester.
Therefore, it will be necessary to obtain a new Type
Approval for the combine harvester from the
relevant authorities by presenting a certificate
confirming the combine harvester's technical
condition (§ 19, Section 2 of German Regulations
authorizing the Use of Vehicles for Road Traffic).
The new certificate can be issued e.g. by your local
Technical Inspection Association.
On request, and to simplify the certification
procedure, CLAAS can provide a sample certificate
specifying the harvester type, the machine number,
and the year of manufacture or will carry out the
acceptance together with TÜV Hannover e.V.
Specific care must be taken regarding the
necessary counterweights on the steering axle to
prevent lifting while braking. If no counterweights
are fitted, the certificate might not be issued.

General Information

General Information
General Information
IMPORTANT INFORMATION To prevent accidents, 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 particular, you should read the
sections "Safety rules" and "Prior to operation".
The use of spare parts, accessories, and
ancillary equipment that was not originally
manufactured, checked and released by CLAAS
can have a negative effect on specific design
features or functions of the CLAAS machine,
with possible adverse effects on the machine's
active and/or passive driving safety, and on its
working safety (accident prevention).
CLAAS is in no way liable for any damage or
personal injury caused through the use of parts
other than original CLAAS parts, accessories,
and ancillary equipment.
Technical specifications, dimensions, and
weights are understood with the usual
tolerances. CLAAS reserves the right to make
changes subsequently as technical
developments continue. Liability for errors or
omissions not accepted.
Front, rear, right, and left always refer to the
direction of travel.

General Information

General Information
General Information
IDENTIFICATION PLATE / SERIAL NUMBER
The identification plate with the cutterbar serial number

is located at the back on the left-hand side of the
cutterbar crossbeam.
(Fig.1)
When placing orders for spare parts or making

technical inquiries please quote the cutterbar serial
number.
This is necessary in order to ensure correct delivery of
spare parts.

General Information

4
Safety rules
Safety rules
Safety rules
SAFETY RULES The warning and instruction signs attached to the

cutterbar provide important information for safe
Before putting the machine into operation, read the operation. These instructions involve your safety –
operator's manual and follow the safety precautions. observe them at all times.
Identification of warning and danger signs Intended use

All parts of this manual having to do with your safety The folding cutterbar is designed exclusively for
or the safe operation of the machine are marked customary agricultural operations (intended use).
with the following signs. Please pass on all safety
instructions to other users too. Use for any other purpose is considered as
improper use; the manufacturer accepts no liability
for any damage or injury resulting from such
Danger! misuse; the risks are borne solely by the user.
Sign to indicate instructions which must be Compliance and strict adherence to the conditions
observed. Failure to do so would cause of operation, service and repair as specified by the
danger to life and limb of the operator and manufacturer also constitute essential elements of
the people around him. the intended use.
☞ Preventive measures. The folding cutterbar can only be operated,

maintained and repaired by personnel who are
familiar with these tasks and the associated
dangers.
Attention!
The relevant accident prevention regulations, and
Sign to indicate instructions which must be all other generally accepted regulations on working
observed. Failure to do so could result in safety, occupational health, and road traffic
damage to the machine. regulations must be observed at all times.
☞ Measures to prevent damage to the Fitting and retrofitting of ancillary equipment which
machine. is not originally manufactured by CLAAS, and, in
addition, also modifications and changes may only
be carried out with the consent of CLAAS, as any
such actions may have considerable adverse
Caution! effects on the safety and operational function of the
machine.
Sign to indicate instructions to be followed
during disassembly / assembly. Any arbitrary modifications carried out on the
cutterbar will relieve the manufacturer of all liability
for any resulting damage or injury.
Note! General safety and accident prevention

regulations
Sign to indicate instructions for a more
efficient and economic use of the machine. 1. In addition to these operating instructions,
please observe the general safety and accident
prevention regulations.
2. Always comply with local traffic regulations
Environment!
when driving on public roads.
Sign to indicate instructions which must be
3. Before starting work, familiarise yourself with all
observed in order to avoid damage to the
the controls and instruments and their
environment.
functions. During work or road travel it is too
Danger to the environment is caused by irregular late.
handling and incorrect disposal of toxic
4. Before starting work, check the cutterbar for
material (e.g. old oil).
loose parts.
5. When working on or around the cutterbar, stop
the engine and remove the ignition key.
Hydraulic hoses must be depressurised.

Safety rules
6. Only work under the cutterbar and the reel if 19. Nobody must be allowed between the combine
they are securely supported. harvester and cutterbar unless the parking
brake is applied and/or the wheels are chocked
7. On public roads and lanes, the cutterbar must
so that the vehicle cannot start to move on its
always be folded.
own!
The dividers must be folded.
Observe all further safety precautions contained in
Switch the driving lights from the lower to the the Combine Operator’s Manual.
upper headlights.
Attach safety rail with warning plates and
sidelights on the front of the cutterbar, and
connect the lighting.
8. When folding the cutterbar, the machine should
be secured from rolling away (parking brake,
wheel chocks).
9. When actuating the push button for the
cutterbar folding mechanism, nobody should be
standing between the drive wheels and the
cutterbar.
10. When folding the cutterbar nobody should be
standing within the swing area.
11. Removing and fitting knives involves a great
risk of personal injury, particularly if the
cutterbar is misaligned and/or very dirty.
12. Due to their function, knives, cutterbar, intake
auger and reel etc. cannot be completely
shielded by constructional measures. For this
reason, an adequate safety distance must be
maintained to these moving elements during
operation.
13. Never operate universal drive shafts with
damaged or missing guards.
14. When carrying a cutterbar during travel on
public roads and lanes, the finger bar and/or the
crop lifters must be covered.
15. Under no circumstances attempt to service,
lubricate or clean the machine or to remedy any
operational problems unless the drive is
disengaged and the engine stopped. Remove
the ignition key.
16. When working on the electrical equipment
always switch off the battery master switch!
17. Always replace safety guards and shields after
carrying out maintenance work!
18. There are injury hazards when attaching the
cutterbar to the combine.

Safety rules
Safety rules
Safety locks
Danger!
Any work underneath the raised cutterbar or

reel may only be done with the cutterbar
securely supported.
Feed rake safety locks

– Raise the feed rake to the highest position.
– Release latch (R) of the safety lock (S), and fold it
onto the hydraulic ram.
R (Fig. 1, 2)
– Before operating the combine, the safety lock

must be secured with latch (R).
(Fig. 2)
Reel safety lock

For all work underneath the cutterbar, the raised reel
must also be secured by means of the safety lock (S)
on the right-hand side.
– Raise the reel completely, and position the safety
lock.
S
(Fig. 3)

Safety rules
– Before operating the combine, the safety lock

must be folded up and secured in holder (H).
(Fig. 4)

Safety rules
Safety rules
SAFETY DECALS WITH PICTORIALS Danger areas that cannot be shielded adequately by
constructional or protective measures, are marked
with safety decals. These safety decals alert persons
to hazards which can cause personal injury.
The warning decals consist of 2 parts. The 1st part
shows the nature of the possible danger. The 2nd part
shows how accidents and injuries can be avoided by
correct behaviour.
To ensure that the warnings are not
language-dependent, the possible dangers are
represented by means of icons. As far as possible, the
safety decals are located in the immediate vicinity of
the danger area.
Explanations of the safety decals, together with details
of their correct location on the machine are given in the
section "Safety rules" of this manual.
Original CLAAS safety decals are identified by a
CLAAS order no. and their date of issue.
Danger!
Danger area on the machine

Danger to life and limb!
Safety decals that are damaged or cannot be
recognized any more must be replaced
immediately by new ones.
When parts that have decals are replaced,
always make sure to install the relevant new
decals with each new part.

Safety rules
Safety rules
22 31
3
514 824.1 (31)
22 Do not go near feed mechanisms of front-mounted

31 harvesting units before the drive has been disen-
gaged, the engine shut off, the ignition key removed
and battery disconneting switch is off. Wait for all
mechanisms to stop and only then attempt to correct
2 any problems.
(Fig. 1, 2, 3)
4
516 039.0 (22)
Do not attempt to open or remove guard while the
engine is running.
(Fig. 1, 2, 4)

5
Specifications
Specifications
Specifications
WEIGHTS / DIMENSIONS / SAFETY DEVICES

Weights / Dimensions
Cutterbar type Weight Working width Transport width
Cutterbar 5.40 m (18’) 2100 kg 5970 mm 3000 mm
Cutterbar 4.50 m (15’) 1980 kg 5060 mm 3000 mm
Safety feature
Slip clutch settings
Cutterbar type Intake auger Upper shaft of feed rake
Cutterbar 5.40 m (18’) 700 ± 40 Nm 840 ± 40 Nm
Cutterbar 4.50 m (15’) 700 ± 40 Nm 840 ± 40 Nm
Additional weights
For details, see the operator’s manual of the combine harvester

Specifications

6
Prior to operation
Prior to operation
Prior to operation
CARRY OUT PRIOR TO INITIAL OPERATION

1. Take off all wired-on parts and / or extra parts
packages and unpack.
2. Remove the transport brackets from the reel
carrier arms.
3. Check all oil levels in the gearboxes and refill if
necessary.
4. Check all safety guards and correctly position
them, if required.

Prior to operation

Prior to operation
Prior to operation
DRIVING LIGHTS / CUTTERBAR CYLINDER
Driving lights for road use

The normal front driving lights of the combine
harvester are covered by the cutterbar when it is
folded into transport position.
A A When driving on public roads, the lighting must
therefore be switched to the upper headlights (A).
(Fig. 1)
Changing the driving lights

(up to serial no. ...)
U O – Switch on the driving lights as usual.
– Turn rotary switch (D) to position (O).
The upper driving lights are now switched on, and the
lower lights are off.
O = upper headlights on
D U = lower headlights on
(Fig. 2)
Changing the driving lights

(from serial no. ...)
At the left below the driving cab, there is a connector
plug (S) for switching over the driving lights.
S
Connector position "Cable upwards" = lower
headlights.
Connector position "Cable downwards" = upper
headlights.
Also see adhesive label.
– Switch on the driving lights as usual.
3
(Fig. 3)

Prior to operation
Safety lighting rail on the cutterbar

The safety lighting rail (L) is mounted in front of the
cutterbar and fixed by means of turn lock bolts (B).
– Insert the plug for the lighting at (S).
(Fig. 4)
S L
4
Removing the transport fixtures

Before using the cutterbar for the first time, the
struts (T) and the hexagon-head bolts (S) must be
S
S
removed on both sides.
(Fig. 5)
TT
Third cutterbar cylinder

Machines with a folding 5.40 m cutterbar must always
be fitted with 3 cutterbar cylinders.
Adjusting the cutterbar floatation springs

Note: The cutterbar flotation springs are set ex works.
Check the settings. Readjust, if necessary! Please
refer to "Adjusting the cutterbar flotation springs" in the
combine harvester's operator’s manual.

7
Accessory equipment
Accessory equipment
9
7 6
13
2 3
7
12
1 3
10
8
4
11 5
14
1
ADDITIONAL HEADLIGHTS
Description of parts Quantity
1 Push button green................................................1
2 Push button red....................................................1
3 Light bracket, left..................................................1
Light bracket, right................................................1
4 Hexagon head bolt M 8 x 55 ISO 4014-8.8......... 2
Contact washer A 8............................................. 2
Hexagonal nut M 8 .............................................. 2
5 Hexagonal caps ...................................................4
6 Headlight .............................................................2
7 Cable set ..............................................................2
8 Rubber grommet ..................................................2
9 Cable tie ..............................................................8
10 Rotary switch (selector switch) ............................1
11 Knob.....................................................................1
12 Inlay for knob........................................................1
13 Rocker switch .......................................................1
14 Adhesive label......................................................1
(Fig. 1)

Accessory equipment
Fitting the switches and the additional

headlights
Installing the push buttons for switching
Remove the two blind plugs (B) on the left side.
(Fig. 2)
Screw in the green push button (1) in the upper hole,

and the red push button (2) in the lower hole.
Note the direction of the arrows on the push buttons:
The arrow of the green button must point to the rear,
and the arrow of the red button must point to the front.
1
(Fig. 1, 3)
2
Mounting the additional headlights on both sides

G
Drill a 8.5 mm Ø hole into the rail (G) on both sides.
Dimensions:
Distance (X) from top edge of operator's platform
(perforated plate) to hole in rail (G) is 670 mm.
X (Fig. 4)
Mount the light brackets (3) on the rails (G) on both

sides using hexagon head bolts (4).
Fit the hexagon caps (5) on the hexagon head bolts (4)
and nuts on both sides.
(Fig. 1, 5)
5 3

Accessory equipment
Open the headlight housing (6).

Pull the cable sets (7) through the housings and the
rubber grommets (8). If necessary, use circlip pliers to
expand the grommets.
Fit the connectors to the terminals of the light bulbs.
3 Insert the rubber grommets (8) into the housing
openings.
G
Close the housing.
Run the cable sets (7) along the rail on both sides
down to below the operator's platform, and secure
6 them by means of the cable ties (9).
(Fig. 1, 6)
Connect the cable sets (7) to the existing cables.

(Fig. 7, 8)

Accessory equipment
Release the fixing screws of the shield (B), and pull the
S shield slightly forwards.
Remove the blind plugs (S).
(Fig. 9)
Insert the rotary switch (10) and screw it tight. Connect

the existing cables to the rotary switch (10).
(Fig. 10)
10
10
Replace the shield (B).

Mount the knob (11), and insert the inlay (12).
(Fig. 1, 11)
12
B 11
11
Remove the blind cover (D) on the switch console.

D (Fig. 12)
12

Accessory equipment
Disconnect the existing cables from the blind cover,

and connect them to the rocker switch (13). Mount the
rocker switch (13) in the switch console.
(Fig. 1, 13, 14)
13
13
13
14
Attach the adhesive label (14) on the left side of the

operator's platform.
(Fig. 15)
14
15

Accessory equipment
16
. Adjusting the additional headlights
1. Check the tyres for correct inflation pressure.
2. Position the machine at right angles to a vertical
wall at a distance (X = 15 metres).
3. Adjust the headlights so that the top edge of the
light/dark sections on the wall is at half the height
of the headlights.
S1 = ½ headlight height
S2 = headlight height
L = light beam
W = wall
(Fig. 16)

8
Operation
Operation
Operation
CUTTERBAR SKIDS
Adjusting the cutterbar skids

Before mounting the cutterbar, the skids (K) must be
changed from the transport position to the working
B position, and adjusted.
– Remove the hexagon head bolts at (A and B),
whilst holding the skids.
– Remove the washers at (A).
A
A – Raise the skids, and remount them at (B) using
K the hexagon head bolts and the washers. Hereby,
place the washers on the inner side of the skids.
1 (Fig. 1, 2)
– Mount the skids at (A) and the adjusting levers (D)

using hexagon head bolts (C).
The skids are adjustable in five positions at (C):
D C – Positions 1 – 4 using the adjusting levers (D)

1
– Position 5 without the adjusting levers
2 Always adjust the skids as far out as possible.
3 Position 4 with adjusting lever (D) = biggest setting
4
Position 4 without adjusting lever (D) = smallest setting
3
Note!
For position 4 without adjusting levers (D), the

levers are placed on the inner side of the skids
and fixed together with the skid using hexagon
bolts (A).
(Fig. 1, 2, 3)

Operation

Operation
Operation
CUTTING ANGLE ADJUSTMENT
Adjusting the cutting angle

A
Note!
The cutting angle can only be adjusted with the

cutterbar removed from the machine.
The cutting angle depends on the size of the tyres.

A = Lower the front of the cutterbar with smaller
tyres and possibly on wet ground.
B = Raise the front of the cutterbar with larger tyres.
B
(Fig. 1)
Mounting the spacer bar

S The front and rear surfaces of the spacer bar (D) are
conical to each other.
The narrow side of the spacer bar is identified by the
bevelled edge (S).
D
Machines with small tyres:
(front of the cutterbar lowered)
– Mount the spacer bar (D) at the bottom of the
cutterbar so that the narrow side (S) faces
downwards.
2 – Secure spacer bar at points (K) using linch pins.
Machines with large tyres:
(front of the cutterbar raised)
– Mount the spacer bar (D) at the bottom of the
cutterbar so that the narrow side (S) faces
upwards.
– Secure spacer bar at points (K) using linch pins.
(Fig. 1, 2, 3)
K
D
K
3

Operation
Mounting the coupling brackets

H T – Position the coupling bracket (F).
M Machines with small tyres:
(front of the cutterbar lowered)
– Position the coupling brackets (F) in the
F L supports (M) on the cutterbar.
– Insert the pins (L) in the holes at (T), and secure
with linch pins (N).
Machines with large tyres:
(front of the cutterbar raised)
4
– Position the coupling brackets (F) in the
supports (M) on the cutterbar.
– Insert the pins (L) in the holes at (H), and secure
with linch pins (N).
(Fig. 4, 5)
Locking the coupling lug after fitting the cutterbar

– Remove the linch pins from pin (E), and pull them
C
out completely.
– Rotate stops (R) manually towards the coupling
F R lugs and push pins (E) back in.
– Secure the pins (E) with the spring clips (C).
F = coupling bracket
E Note!
6 The stops (R) can only be rotated when the
cutterbar has only light contact with the ground
or is slightly raised.
If necessary, use a tool (screwdriver or round
bar) that can be inserted into the holes
of stops (R).
(Fig. 6)

Operation
Unlocking the coupling lug before removing the

C cutterbar
– Remove the spring clips from pin (E), and pull
them out completely.
R
F – Rotate stops (R) manually to the front, and push
pins (E) back in.
– Secure the pins (E) with the spring clips (C).
F = coupling bracket
(Fig. 7)
E
7

Operation

Operation
Operation
MOUNTING THE SHAFT EXTENSION
Mounting the extension to the intermediate

drive shaft
(LEXION 530 – 510)
Danger!
Stop the engine and switch off the battery

isolating switch!
– Remove the universal coupling (K) and put it

aside.
K
– Remove protective covers (A, B, and C).
(Fig. 1)
B A
– Push the extension (W) onto the shaft until the

hole in shaft extension is aligned with the notch on
the shaft.
W – Screw in a hexagon bolt and tighten it at 80 Nm.
(Fig. 2)
– Loosely mount flange (F) to the guard plate.

– Mark the positions of the two missing holes at
(E) and (T) respectively.
E
– Remove the flange, and drill two 9 mm Ø holes.
– Mount the flange using four M 8 x 16 hex. bolts,
A 8 contact washers, and M 8 nuts.
T (Fig. 3)
F

Operation
– Reinstall the protective cover (A) and the universal

K coupling (K).
– Reinstall the protective covers (B) and (C) on
flange (F) using the existing screws.
(Fig. 4)
B
A
F
C
4
up to serial no. ...:

– Remove protective covers (T) and (S).
– Cut off the stud (Z), if present.
S (Fig. 5)
T
– Push the extension (V) onto the shaft until the hole
in shaft extension is aligned with the notch on the
shaft.
V – Screw in a hexagon bolt and tighten it at 80 Nm.
(Fig. 6)
– Mount protective device (E) to cover (T) using

M 6 x 12 hex. bolts.
– On machines up to serial no. ..., align the
protective device (E), and drill the holes.
(Fig. 7)
T

Operation
– Replace the cover (T).
S – Reinstall the protective cover (S) using the

existing screws.
T
(Fig. 8)
from serial no. ...

– Remove protective cover (S).
(Fig. 9)
– Push the extension (V) onto the shaft until the hole
in shaft extension is aligned with the notch on the
shaft.
v
– Screw in a hexagon bolt and tighten it at 80 Nm.
(Fig. 10)
10
– Remove cover (K).

– Cut cover (K) at the notch (in direction of arrows).
– Smooth the cut edge.
(Fig. 11, 12)
K
11

Operation
12
– Mount cover (K) and holder (H) to protective cover

(S) using the existing screws.
(Fig. 13)
K
S
13
– Mount cover (T) using M 8 x 20 hexagon bolts and

T Vm 8 self-locking nut.
(Fig. 14)
14
– Reinstall protective cover (S).

(Fig. 15)
15

Operation
Operation
FITTING THE CUTTERBAR
Tilting the cutterbar from the transport

position
Danger!
When fitting front attachments, there is a risk

of injury!
No persons are permitted in the danger area!
Before operating the cutterbar for the first time, it

should be tilted from the vertical to the horizontal
1
position (if necessary).
– Lift the cutterbar by means of the transport
support using a suitable lifting device.
At the same time, hold the cutterbar in place on
the opposite side with a suitable lifting device
(fork-lift truck or similar).
Protect the forks with a pallet or similar to ensure
that the cutterbar is not damaged.
If there is no suitable lifting device available on site,
large tyres can be used instead.
(Fig. 1, 2)

Operation
Installing and removing the cutterbar

The cutterbar can be installed / removed in both the
transport position (cutterbar folded) and in the working
position (cutterbar unfolded).
We will show you both versions.
Installing the cutterbar when folded in

(cutterbar in the transport position)
Danger!
When installing front attachments on the

combine harvester (cutterbar etc.) there is
danger of injury!
Danger!
When installing the cutterbar, there is danger

of injury. Nobody must stand between
combine harvester and cutterbar.
– Before installing the cutterbar, make sure that the

upper and lower couplings are open.
– Remove the locking pins (V) on both sides.
(Fig. 3)
V
3
– Drive the combine harvester up to the cutterbar

until the coupling lugs (F) of the hydraulic
cylinders on the feeder housing are located under
the locating holes of the upper cutterbar beam.
– Raise the cutterbar by actuating the hydraulic
control unit.
– Stop the engine and switch off the battery
isolating switch!
F (Fig. 4)

Operation
Locking the cutterbar at top and bottom on both

sides
Upper locks:
– see page 8.2.2, Locking the coupling lug after fitting
the cutterbar
Lower locks:
– Push the locking pins (V) inwards, and secure
them with linch pins.
(Fig. 5)
V
5
– Drive the combine harvester up to the cutterbar

until the coupling lugs on the feeder housing are
located under the coupling brackets of the upper
cutterbar beam.
– Slightly raise the cutterbar by actuating the
hydraulic control unit.
Danger!

isolating switch!
– Pull out the pins (E), and rotate the locks to the
rear.
– Reinstall the pins (E), and secure them.
– see Cutting angle adjustment on page 8.2.1.
– Lock the cutterbar at the bottom on both sides.
Push the locking pins (V) inwards, and secure
them with linch pins.
(Fig. 5, 6, 7)
E

Operation
Connecting the universal coupling

– Remove the dust cover (T) from the cutterbar.
– Remove the universal coupling (K) from the feeder
housing, and mount it on the cutterbar.
– Replace the dust cover (T) on the feeder housing.
K – Tighten the universal coupling (K) securely by
means of the handwheel (M).
T (Fig. 8, 9)
M
9
Caution!
H Do not hook chain (A) over lever (H).
This is only necessary on Vario and standard
A cutterbars.
(Fig. 10)
10

Operation
Operation
CHANGING THE CUTTERBAR FROM

TRANSPORT POSITION TO WORKING
POSITION
– Start the engine, and actuate the safety switch.
Danger!
Put drive into neutral!
– Briefly actuate switch "Reel reverse" (horizontal

B
reel adjustment) and switch "Lower reel". This
must be done after road travel in transport
position.
S L
– Remove crop lifter guard and knife guard.
1
– Remove the safety lighting bar (L). To do this,
remove the connector (S), and loosen both turn
lock bolts (B).
– Unfold the cutterbar to the working position.
Attention!
2 Avoid jerkily raising and lowering with the

cutterbar halfway folded.
Danger!
2
When unfolding the cutterbar nobody should
be within the danger area. Secure the
machine against rolling away (parking brake,
wheel chocks).
– Press the push button (2) until the cutterbar has

been fully unfolded.
Attention!
The machine may only be moved if the

cutterbar has been fully folded out and
locked.
(Fig. 1, 2)

Operation
– Install the right-hand universal drive shaft.
Caution!
(Fitting the universal drive shaft for LEXION

MONTANA machines will be shown later on)
Danger!
Never operate universal drive shafts with

damaged or missing guards.
Folding cutterbar 4.50 m:

LEXION 530 – 510
– Open guard (D) on the feeder housing.
G – Open universal drive shaft retainer (G) and take

out universal drive shaft.
– Push in the locking pin (1) of the universal drive
shaft.
– Push the drive shaft onto the transmission shaft,
and make sure that the locking pin engages
securely.
3
– Close the guard (D).
(Fig. 3, 4)
1 D

Operation
– Folding cutterbar 5.40 m:

1
D – Fold up the guard (D).
– Open universal drive shaft retainer (G) and take
shaft.
securely.
5
– Close the guard (D).
(Fig. 3, 5, 6)
– Fold out right-hand crop divider.

To do this, retract the lock (R) and swing out the
crop divider to the end positions.
Caution!
In the end position, the lock must be engaged

securely.
R
(Fig. 7)
– Fold out left-hand crop divider.

To do this, retract the lock (R) and swing out the
crop divider to the end positions.
Caution!
In the end position, the lock must be engaged

securely.
R
(Fig. 8)
4. Install left-hand universal drive shaft.

Operation
Caution!
(Fitting the universal drive shaft for LEXION

MONTANA machines will be shown later on)
Danger!
Never operate universal drive shafts with

damaged or missing guards!

LEXION 530 – 510
G
shaft.
securely.
9
– Close guard (B).
(Fig. 9, 10)
B
10

Operation

– Open guard (B) on the feeder housing.
B 1
shaft.
securely.
11
(Fig. 9, 11, 12)
12
– Move the reel forward from the driver's seat.

The cutterbar is now ready for operation.

Operation
Fitting the universal drive shafts

LEXION MONTANA
(from serial no. 71300231)
When putting the cutterbar into operation for the first

time, convert the universal drive shafts from standard
to Montana version.
Fit the universal drive shaft retainers on both sides of
the cutterbar as follows:
A D C
– Drill holes according to the specified dimensions.
– Drill the front 9 mm Ø hole at the bolt height (D).
B – Drill the holes (F and G) after mounting the
retainers (H and I).
– Mount the retainer (H) using M 8 x 25 hexagon
13 bolts, A 8 contact washers, and M 8 nuts.
– Mount the retainer (I) using M 8 x 16 mushroom
G head screws, A 8 contact washers, and M 8
hexagon nuts.
I Dimensions:
A = 40 mm from the centre of bolt to centre of hole
F B = 940 mm
H C = 80 mm
(Fig. 13, 14)
14
– Before transport, push the universal drive shaft

halves onto retainers (H) and place them in
retainers (I).
(Fig. 15)
15

Operation
Removing standard universal drive shafts

– Remove cover (K).
(Fig. 16)
16
– Remove locking screw (S).

Rotate guard tube (R) through 60° against the
conical guard.
S
– Remove guard tube (R) from the universal drive
shaft.
(Fig. 17)
17
– Use a slightly bent length of round steel (Ø 8 x

280 mm, self-made) to drive the expansion pins
out of the drive shafts (W).
– Remove drive shaft halves.
Note: To make assembly easier, the covers (D) on
the inside of the cutterbar may be removed.
D (Fig. 18)
18
Installing the universal drive shaft for LEXION

MONTANA
– Release drive shaft guard, rotate it, and remove it
from the drive shaft.
(Fig. 19)
19

Operation
– Push drive shaft (E) onto the transmission shaft,

and secure it with an expansion pin.
(Fig. 20)
20
– Mount and secure the drive shaft guard tube.

(Fig. 21)
21
– Place drive shaft into the retainer (L), and secure.

– Mount cover (K), and hang in chain at (A).
A
(Fig. 22)
L
K
22

Operation
Connecting the universal drive shafts:

– Remove universal drive shaft half (H) from the
retainer, and push it onto the universal drive shaft
of the cutterbar.
(Fig. 23, 24)
H
23
24
– Open guard (B) on the feeder housing.

B shaft.
1 – Push the drive shaft onto the transmission shaft,

securely.
(Fig. 25, 26)
25
– Repeat the procedure on the other side.

(Fig. 26)
26

Operation

Operation
Operation
CHANGING THE CUTTERBAR FROM

WORKING POSITION TO TRANSPORT
POSITION
– Start the engine, and actuate the safety switch.

– From the driver's seat, raise the reel, retract it fully,
and lower it onto the support.
– With the reel in the rearmost position, lower it
briefly one more time.
– On cutterbar with Auto-Contour, raise cutterbar so
that the sensing bands no longer touch the
ground.
K
Danger!
1
Put drive into neutral, and secure the
Cutterbar 4.50 m standard
machine against rolling away!
B
– Remove left universal drive shaft from the
transmission shaft in the feeder housing.
– To do this, push in the locking pin (1), and pull off
the drive shaft.
– Place the universal drive shaft in the retainer (G),
1 and secure it.
(Fig. 1, 2, 3, 4, 5)
2
Cutterbar 5.40 m standard

Operation
Cutterbar 5.40 m / 4.50 m LEXION MONTANA
4
Cutterbar 5.40 m / 4.50 m standard
– With LEXION Montana, remove the outer drive

shaft half (H), and place it on the cutterbar.
(Fig. 6, 7)

Operation
– Place the universal drive shaft on the cutterbar

side into the retainer (K) and secure it.
(Fig. 8)
– Fold in the left-hand crop divider.

For this, pull out the locking pin (R), and let it
engage again when the crop divider is in the
folded end position.
(Fig. 9)
– Remove the outer deflector (A) on the right side,

and stow it inside the cutterbar.
– Fold in the right-hand crop divider.
For this, pull out the locking pin (R), and let it
engage again when the crop divider is in the
folded end position.
(Fig. 10, 11)
A
10
11

Operation
Cutterbar 4.50 m
– Remove right universal drive shaft from the
transmission shaft in the feeder housing.
To do this, push in the locking pin (1), and pull off
the drive shaft.
1
Place the universal drive shaft in the retainer (G),
and secure it.
(Fig. 12, 13, 14)
12
Cutterbar 5.40 m
13
14
– With LEXION MONTANA, push in the locking

pin (1), and pull off the universal drive shaft.
– Stow the drive shaft in the same way as on the
left-hand side.
1 (Fig. 15)
15

Operation
5. Fold the cutterbar to the transport position.

Press the push button (1) until the cutterbar has
been fully folded into the transport position.
1 Caution!
Raise the cutterbar until the Auto-Contour

sensing bands are sufficiently free of the
ground. If the cutterbar is raised too high, the
folding procedure will be hampered.
16
(Fig. 16)
– Mount the guards on crop lifter and knife.

– Mount the safety lighting bar (L), and secure by
means of turn lock bolts (B).
– Plug in the connector (S).
– The cutterbar is now ready for transport.
(Fig. 17)
B
S L
17

Operation

Operation
Operation
ALIGNING THE CUTTERBAR / REMOVING

THE CUTTERBAR
Aligning the cutterbar

F (machines without Auto-Contour)
R Before using the combine harvester for the first time,
check horizontal alignment of the cutterbar.
If necessary, the cutterbar position can be modified by
E relocating the washers (E) beneath the coupling lugs.
Ex-works, two washers (43 x 53 x 3) are provided for
each side.
– Drive the combine harvester and cutterbar onto a
flat, level surface.
24021 1
– Lower the cutterbar to the ground.
– First, remove the washers beneath the coupling
lug (F) on the higher side. To do this, unscrew the
hexagon bolt (R), and slightly raise the coupling
lug.
– After removing the washers, retighten the coupling
lug and install the cutterbar.
Should this prove to be insufficient, the removed
washers can be added on the opposite side.
(Fig. 1)

Operation
Removing the cutterbar

Note: The cutterbar can be removed in the transport
position and in the working position. The procedure is
the same in both cases.
Removing the cutterbar:
Danger!

isolating switch.
– Remove the right-hand universal drive shaft from

the intermediate drive shaft in the feeder housing,
and
place it in the retainer on the cutterbar.
– Open the lower lock on the right-hand side.
– Open the lock for the cutting angle adjustment at
the top right-hand side. To do this, lower the
cutterbar until it just touches the ground.
– Fold in both crop dividers (if necessary).
– Unscrew quick-release coupling from the
cutterbar, and attach it to feeder housing. Fit dust
guard on the cutterbar coupling.
– Remove the left-hand universal drive shaft from
the transmission shaft in the feeder housing, and
place it in the retainer on the cutterbar.
– Open the lock for the cutting angle adjustment at
the top left-hand side.
– Open the lower lock on the left-hand side.
– Start the engine, and fully lower the cutterbar.
– Reverse the machine.
While reversing, ensure that the coupling lugs do
not catch in the coupling holes or in the coupling
brackets.

Operation
Operation
ADJUSTMENTS ON THE CUTTERBAR
Danger!
Due to their function, knives, cutterbar,

intake auger and reel etc. cannot be
completely shielded by constructional
measures.
For this reason, an adequate safety distance
must be maintained to these moving
elements during operation!
For all work underneath the raised cutterbar,
the raised reel or the feeder housing, the
safety locks on the reel cylinders and the
cutterbar cylinders must be in place.
Crop dividers
The crop dividers consist of divider plates (A) and
inner deflectors (B). Additionally, an outer deflector
plate (C) may be fitted.
A
– If required, mount the crop dividers on stud (P)
using hexagon bolts (S), contact washer (C) and
three Belleville spring washers (T).
The crop divider is foldable, and can remain mounted
B also in the transport position.
(Fig. 1, 2, 3)
1
S = Hexagon bolt M 12 x 35 ISO 4017-8.8

C = Contact washer B 12
D = Spacer
T = Spring washers (3 per side)
O = Divider support tube
P S P = Stud
(Fig. 2)
C
D
T
O

Operation
Outer deflector
Mounting the outer deflector:
A – Push the adjusting pins (A) of the adjusting tubes
into the holes of the cutterbar uprights (see arrow)
B up to the stop.
C
– Mount the outer deflector (C), and adjust.
(Fig. 3, 4)
6 5
Adjusting the outer deflector:

– Adjust the height of outer deflector (C) after
releasing the toggle bolt (5) and the turn lock (6)
so that the stalks are pushed into the standing
A crop.
(Fig. 3)
– To remove the adjusting tube, retract the clip (K),

and pull out the connecting pins (A).
(Fig. 5)
A
K

Operation
Adjusting the dividers

– Push the divider plates (A) as close as possible to
the reel, after releasing the bolts (2).
Caution: Make sure that the reel does not collide.
– Position left-hand divider plate (A) in the middle of
3 the slot.
– Push the right-hand divider plate (A) completely to
1 the right-hand side.
L = Left-hand crop divider
6 R = Right-hand crop divider

– Adjust the inner deflectors (B) so that the reel
shafts do not wind, and the reel does not collide.
L R – Adjust the height of the crop divider with the
adjusting slider (1) after releasing the screws (3)
so that the points of the crop divider do not
continuously scrape on the ground, and do not dig
into uneven ground.
(Fig. 3, 6, 7)
2 2
37341 7
Crop lifters
The number of crop lifters to be fitted depends on the
condition of the crop.
For down crops and weed growth, attach a crop lifter
to every fourth to sixth finger, and closer together for
short, upright crops with ears hanging downwards.
(Fig. 8)
Fitting the crop lifter:

– Loosen nut (M).
– Push the crop lifter between the washer and the
top nut, and at the same time place pocket (T) on
T the finger tip.
– Tighten the nut.
Do not fit a lifter on the first three fingers from either
end of the cutterbar.
M
(Fig. 9)

Operation
Knife
Danger!
Always wear gloves to avoid injuries when

removing and installing the knife.
Use particular care when pulling out the
knife, if the finger bar is bent or very dirty.
Removing the knife

– Move the knife to the outside dead centre.
– Remove the hexagon bolts (N), and pull out the
knife.
N (Fig. 10, 11)
10
11
Installing the knife

– Push the knife into the finger bar, and secure with
hexagon bolts (N).
Make sure that the recess (M) has been cleaned
and that the drive key is fully engaged.
(Fig. 10)

Operation
Adjusting the knife height

– After loosening the clamping bolt (K), adjust the
lever (G) so that a clearance of 0.5 to 1.0 mm is
provided between the first knife blades and the
double finger supports.
G – Retighten the clamping bolt after adjustment.

(Fig. 12)
K
12
Aligning the knife clips

– By adding or removing equalizing washers, align
the knife clips (D) so that the cutting knife runs
D
smoothly.
There should be about 1.5 mm clearance between the
knife blade and the knife clips.
(Fig. 13)
13
Spare knife
A spare knife can be stowed in the holders (H) on each
side of the cutterbar.
– Secure the knives on both sides with
the latches (R).
(Fig. 14)
R
H
14

Operation
Reel
Adjusting the reel height
The reel height can be adjusted by means of a
solenoid valve actuated by the pushbuttons
(2a and 2b) on the multifunction handle.
2a
Lower the reel for down crops, and use a higher
setting when harvesting standing crop.
2b
2a = lowering the reel
2b = raising the reel
(Fig. 15)
15
Fine height adjustment of the reel

If the reel tines come into contact with the knife when
B the reel is in the lowest position, the distance to the
K knife can be increased by unscrewing the eye
bolts (B).
– To adjust, loosen lock nut (K) and rotate the
hydraulic piston accordingly.
– After adjustment, retighten the lock nut.
When adjusting the eyebolts, the internal lock nuts (D)
must also be adjusted accordingly.
16 (Fig. 16, 17)
17

Operation
Reel tines:
B
A vertical setting of reel teeth, or slightly forward is
best in normal harvesting conditions.
C In heavy down grain or with very short-stalked crops,

the reel tines should be set backward to grip position
by relocating lever (B) in the perforated segment (C).
Note!
Adjusting the tines of the reel too much to the

rear causes the reel to wrap.
18
(Fig. 18)
Reel drive
The reel is driven by hydraulic motor (M), roller
M chain (R) and sprockets.
The reel speed is infinitely adjustable. Also refer to the
operating manual of the combine harvester.
R
(Fig. 19)
19
Reel fore and aft adjustment

By actuating the pushbuttons (2c and 2d) on the
multifunction handle, the reel can be adjusted forward
and backward by means of the horizontal,
H
double-acting hydraulic cylinders (H).
2c = horizontal reel adjustment, backwards
2d = horizontal reel adjustment, forwards
(Fig. 20, 21)
20

Operation
2d
2c
21
Feed auger
Adjusting the clearance to the cutterbar bottom
S plate
S
The basic auger setting has a gap of approx. 15 mm
F between auger flights (S) and bottom of cutterbar
trough.
Raise the feed auger setting when taking in very heavy
swaths or bulky or brittle crops.
Also refer to the "threshing table" in the combine
harvester's operating manual.
22 The crops conveyed to the centre by the auger spirals
are pulled under the feed auger to the feed rake by the
controlled fingers (F).
Damaged fingers should be replaced immediately.
(Fig. 22)

Operation
Height adjustment of the feed auger

C
After loosening the clamping bolts (4), the feed auger
adjustment can be changed with the setscrew (C) on
each side and the centre of the cutterbar.
4 Adjust both sides and the centre by equal amounts.
After adjusting, retighten all bolts.
4
(Fig. 23, 24)
23
24

Operation
25
Adjusting the intake finger position
The position of the intake fingers (F) can be adjusted
by rotating the plate (T) after removing the screws (3).
T T
A = right-hand feed auger
B = left-hand feed auger
G = direction of travel
3 With identical intake finger settings, the locations of

3 the stamped identification letters (L and R) are
opposite between the two feed augers.
M = middle position
26
Caution!
Do not use the position (L) on the right-hand

feed auger (A) and do not use the position (R)
on the left-hand intake auger (B)!
#
27

Operation
Danger!
Risk of injury when rotating the plate (T).

Steady the plate (T) with a spanner.
Replace and retighten the screws after adjustment.

Adjustment can only be done with the cutterbar in the
transport position.
(Fig. 25, 26, 27)
Safety feature
The feed augers are protected from overload by slip
clutches (R).
Attention!
Do not adjust the slip clutches so tightly that

R they block and fail to provide a safety
function.
See Specifications for the slip clutch torque settings.

28
(Fig. 28)
Cutterbar skids
Cutterbar skids (K) are height-adjustable.
S
Proper adjustment of skids depends on the tyre size.
F
Extend the skids as far out as possible.
L
Working in grass:
K If necessary, the skids can be retracted completely, for
example on lodged grass.
To do this, proceed as follows:
– Unbolt the flat bars (F).
29
– Fully raise the skids.
– Place flat bars (F) into the skids.
– Reattach skids in holes (L) using bolts (S) and flat
bars (F).
Extend the skids again as soon as possible.
(Fig. 29)

Operation

Operation
Operation
MALFUNCTION, POSSIBLE CAUSE AND/OR REMEDY
Malfunction Possible cause and/or remedy
Cutterbar cannot be folded 1. Limit switch (interlock) faulty.

Replace switch.
2. Reel not fully retracted.
Retract reel completely.
The limit switch must be actuated.
3. Limit switch (rear reel position) faulty.
Replace limit switch.
4. Reel not fully lowered.
Lower the reel completely.
5. Limit switch (bottom reel position) faulty.
Replace limit switch.
6. Limit switch not adjusted correctly.
Adjust limit switch.
7. Pushbutton on machine faulty.
Replace the pushbutton.
8. Reel is askew. Limit switch on left side is not
actuated. Raise reel to its end position. This
restores the reel to the horizontal position.
If this does not help, check for internal leaks of
reel cylinders, and remedy. Also refer to
"Adjusting the reel limit switch", page 9.4.1.

Operation

9
Maintenance
Maintenance
Maintenance
MAINTENANCE SCHEDULES AND LUBRICANTS CHARTS
Maintenance schedule
Maintenance operations Service intervals
working hrs.
After the first Every
As required
Annually =
Before the
Every day
every 500
After the
40 100 50 100 250
harvest
harvest
Working hours Working hours
HYDRAULIC SYSTEM
– Bleed reel cylinders
GEARBOXES
Knife drive gears
– Check oil level
– Change oil
Bottom angle drive (driven via universal drive shaft)
DRIVES
Check and adjust the belts with spring-loaded belt tensioners
– Knife drive
Check chain drives and adjust if necessary

– Intake auger drive
– Reel drive

Maintenance
Lubricants chart
Component Type of lubricant Capacity Viscosity Change Check

intervals
Gearboxes
Knife drive gears Multi-purpose gear 0.85 litres each See See
oil to (MIL-L-2105 B) maintenance maintenance
API-GL-5-90 schedule schedule

Maintenance
Maintenance
TRANSMISSIONS
Knife drive transmission

Oil filling quantity – see page 9.1.2, Lubricants chart
E
Oil type – see page 9.1.2, Lubricants chart
Change oil – see page 9.1.1, Maintenance schedule
Environment!
Dispose of used oil properly!
E = oil filler cap

1 A = oil drain plug
Check the oil level:

– Bring the knife drive transmissions to a horizontal
position by raising the cutterbar.
– Remove the oil filler cap (E) for checking the oil
level.
– The oil level can be checked with a wire.
A Details of the wire:

Overall length approx. 300 mm
Insertion depth approx. 210 mm
2
– Make a slight bend in the wire at approx. 220 mm.
– Insert the wire at an angle to perform the check.
Correct level = 80 mm above the end of the wire.
– Replace the oil filler cap after checking the oil
level.
(Fig. 1, 2)

Maintenance

Maintenance
Maintenance
SPRING-LOADED CYLINDERS / DRIVE

CHAINS / INDUCTIVE SENSORS
Adjusting the spring-loaded cylinders for
knife drives
– Loosen the lock nut (K), and adjust the spring
guide tube so that the end of the gauge rod (D) is
D
flush with the washer (S).
K
– Retighten the lock nut (K).
(Fig. 1)
S
Tensioning the drive chains

The drive chain can be tensioned by means of the
chain tensioner (T).
T – For tensioning, loosen the clamping bolt of the
sprocket.
M – Adjust the chain tensioner (T) with the nuts (M).
– Retighten the clamping bolt after adjustment.
(Fig. 2)

Maintenance
Tensioning the reel drive chain

– Unscrew cover (D).
D – Slightly loosen the bolts (E).

– Tension the chain moderately at the tensioning
bolt (F).
– Retighten the screws (E), and replace the
cover (D).
(Fig. 3, 4)
E
F
Cleaning the guide rails of the locking

cylinder
If possible, clean the guide rails with compressed air
every day.
The guide rails of the rear cylinder at (M) are
accessible in the working position.
The guide rails of the front cylinder at (V) are
accessible in the transport position.
M
(Fig. 5, 6)
V
6

Maintenance
Maintenance
GENERAL
Aligning the double fingers

15 16 17 18 19 20 21 To ensure a perfect overlap of the double fingers
(18 and 19), the double fingers (16 – 18) can be
adjusted in height using the spacer washers
(S, 11 x 21 x 0.5).
S 2 4 6 Numbers 1 – 6 = Number of spacers

1 3 5
When mounting the double fingers (18 and 19), please
note:
– Push the double finger (18) all the way back.
M
– Push the double finger (19) and the mulch
1 finger (M) all the way forward.
(Fig. 1)
Adjusting the reel limit switch
Caution!
To fold the cutterbar, the limit switch (E) must

be actuated by the reel. Otherwise the cutterbar
cannot be folded. Also refer to "Malfunction,
E possible cause and/or remedy", page 8.9.1.
(Fig. 2)
Adjusting the locking pawl at the centre reel

guide
X The basic dimension (X) from flange surface (F) to
behind the bolt head (S) is 38 mm.
The hexagon bolt (S) can also be adjusted while the
S cutterbar is in the working position.

Maintenance
Check with the cutterbar in working position:

Y
The clearance (Y) between the locking pawl (K) and
the locking block (T) should be approx. 3 mm.
T – Adjust accordingly, if necessary.

K
(Fig. 3, 4)
S
Cleaning the spaces of the supporting arm

bearings
Perform cleaning work with the cutterbar in the
working position.
Remove dirt and straw from the free spaces on both
sides of the supporting arm bearings, as necessary
(see arrows).
(Fig. 5, 6)

Maintenance
Cleaning the coupling lug areas

Perform cleaning work with the cutterbar in the
transport position.
Clean the supports in the area of the coupling lugs, as
necessary (see arrows).
(Fig. 7, 8)

Maintenance

Maintenance
Maintenance
SUGGESTIONS FOR WINTER STORAGE

The cutterbar must be prepared for winter after the
harvest so that the machine lasts for as long as
possible. With consistent and conscientious care, as
well as the preventive maintenance of worn and
possibly damaged parts at the same time, both time
and money is saved when using the machine again.
1. Clean the exterior of all bearings of dust and
grease.
2. Thoroughly clean the cutterbar.
3. Preserve the cutterbar by inserting brand name
lubricant in the lubrication points to be maintained,
once a year after the harvest. To ensure the even
distribution of the grease, briefly run the machine
until a small circle of grease has formed on the
outside of the bearings.
Seal off peripheries of slip clutches with paint to
keep moisture out and to keep friction faces from
rusting.
4. Grease all polished parts such as finger bars and
crop lifters.
5. Change the transmission oil.
6. Lower the cutterbar to the ground or remove it in
order to relieve the hydraulic system.
Attention!
If the cutterbar is washed (to be avoided if

possible), all lubrication points must be
greased after washing. Afterwards, allow the
machine to run for a few minutes.
Cavities, such as cable inlets, should not be
washed with water. In some cases the water
can no longer be removed from the hollow
spaces and can lead to rusting.

Maintenance

10
Lubrication chart
Lubrication chart
Lubrication chart
LUBRICANTS AND NOTES
Grease brand name Remove humped cover plate See the lubrication intervals
recommended by the PTO shaft
Examples:
supplier
Manufacturer Description
FINA "Marson EPL 2"
ARAL "Aralub HLP 2"
FUCHS "Renolit EP 2"
SHELL "Retinax EP 2"
or "Alvania G3"
DEA "Glisando EP2"
AVIA "Avilup
Special grease EP"
FAG "Arcanol L 135 V"
SKF "LGEP2"
Every 100 Every 250

working hours working hours
Once per year

(500 operating hours)

Lubrication chart
1 2 3
1 2

Lubrication chart

Lubrication chart

Lubrication chart
1 2
3 4
Standard Montana
1 2
Standard Montana
3 4

Lubrication chart
2 3 4 6 7
1 5
1 2
3 4 5
6 7

11
Index
Index
Index
INDEX
Additional headlights .............................................................. 7.1.1 Introduction ............................................................................ 1.1.1
Additional weights .................................................................. 5.1.1 Knife ...................................................................................... 8.8.4
Adjusting the additional headlights ........................................ 7.1.6 Knife drive transmission ........................................................ 9.2.1
Adjusting the clearance to the cutterbar bottom plate ............ 8.8.8 Locking the coupling lug after fitting the cutterbar ................. 8.2.2
Adjusting the cutterbar floatation springs ............................... 6.2.2 Locking the cutterbar at top and bottom on both sides ......... 8.4.3
Adjusting the cutterbar skids .................................................. 8.1.1 Lubricants and notes ........................................................... 10.1.1
Adjusting the cutting angle ..................................................... 8.2.1 Lubricants chart ..................................................................... 9.1.2
Adjusting the dividers ............................................................. 8.8.3 Maintenance schedule .......................................................... 9.1.1
Adjusting the intake finger position ...................................... 8.8.10 Maintenance schedules and lubricants charts ...................... 9.1.1
Adjusting the knife height ....................................................... 8.8.5 Malfunction, possible cause and/or remedy .......................... 8.9.1
Adjusting the locking pawl at the centre reel guide ................ 9.4.1 Mounting the additional headlights on both sides ................. 7.1.2
Adjusting the reel height ........................................................ 8.8.6 Mounting the coupling brackets ............................................. 8.2.2
Adjusting the reel limit switch ................................................. 9.4.1 Mounting the extension to the intermediate drive shaft
Adjusting the spring-loaded cylinders for knife drives ............ 9.3.1 (LEXION 530 – 510) ............................................ 8.3.1
Adjustments on the cutterbar ................................................. 8.8.1 Mounting the shaft extension ................................................ 8.3.1
Aligning the cutterbar / removing the cutterbar ...................... 8.7.1 Mounting the spacer bar ........................................................ 8.2.1
Aligning the cutterbar Outer deflector ....................................................................... 8.8.2
(machines without Auto-Contour) ....................... 8.7.1 Reel ....................................................................................... 8.8.6
Aligning the double fingers ..................................................... 9.4.1 Reel drive .............................................................................. 8.8.7
Aligning the knife clips ........................................................... 8.8.5 Reel fore and aft adjustment ................................................. 8.8.7
Carry out prior to initial operation ........................................... 6.1.1 Reel safety lock ..................................................................... 4.1.3
Changing the cutterbar from transport position to Removing standard universal drive shafts ............................ 8.5.7
working position ..................................................................... 8.5.1 Removing the cutterbar ......................................................... 8.7.2
Changing the cutterbar from working position to Removing the knife ................................................................ 8.8.4
transport position ................................................................... 8.6.1 Removing the transport fixtures ............................................ 6.2.2
Changing the driving lights Safety decals with pictorials .................................................. 4.2.1
(from serial no. ...) ............................................... 6.2.1 Safety feature ...................................................................... 8.8.11
Changing the driving lights Safety lighting rail on the cutterbar ........................................ 6.2.2
(up to serial no. ...) .............................................. 6.2.1 Safety locks ........................................................................... 4.1.3
Cleaning the coupling lug areas ............................................. 9.4.3 Safety rules ........................................................................... 4.1.1
Cleaning the guide rails of the locking cylinder ...................... 9.3.2 Spare knife ............................................................................ 8.8.5
Cleaning the spaces of the supporting arm bearings ............. 9.4.2 Spring-loaded cylinders / Drive chains / Inductive sensors ... 9.3.1
Connecting the universal coupling ......................................... 8.4.4 Suggestions for winter storage .............................................. 9.5.1
Crop dividers .......................................................................... 8.8.1 Tensioning the drive chains ................................................... 9.3.1
Crop lifters .............................................................................. 8.8.3 Tensioning the reel drive chain ............................................. 9.3.2
Cutterbar skids ....................................................................... 8.1.1 Third cutterbar cylinder .......................................................... 6.2.2
Cutterbar skids ..................................................................... 8.8.11 Tilting the cutterbar from the transport position ..................... 8.4.1
Cutting angle adjustment ....................................................... 8.2.1 Transmissions ....................................................................... 9.2.1
Driving lights / Cutterbar cylinder ........................................... 6.2.1 Unlocking the coupling lug before removing the cutterbar .... 8.2.3
Driving lights for road use ...................................................... 6.2.1 Vehicle type approval ............................................................ 3.1.1
Feed auger ............................................................................ 8.8.8 Weights / Dimensions / Safety devices ................................. 5.1.1
Feed rake safety locks ........................................................... 4.1.3
Fine height adjustment of the reel .......................................... 8.8.6
Fitting the cutterbar ................................................................ 8.4.1
Fitting the switches and the additional headlights .................. 7.1.2
Fitting the universal drive shafts LEXION MONTANA
(from serial no. 71300231) .................................. 8.5.6
General .................................................................................. 9.4.1
Height adjustment of the feed auger ...................................... 8.8.9
Identification plate / Serial number ......................................... 3.3.1
Important information ............................................................. 3.2.1
Installing and removing the cutterbar ..................................... 8.4.2
Installing the cutterbar when folded in
(cutterbar in the transport position) ..................... 8.4.2
Installing the knife .................................................................. 8.8.4
Installing the push buttons for switching ................................ 7.1.2
Installing the universal drive shaft for LEXION MONTANA ... 8.5.7

Index

At CLAAS KGaA mbH we are constantly improving our
products to reflect the latest technological
developments. For this reason, we may from time to
time need to make changes to diagrams and
descriptions in this documentation which do not reflect
products that have already been delivered and which
will not be implemented on these machines.
Technical data, dimensions and weights are given as
an indication only. Responsibility for errors or
omissions not accepted.
Reproduction or translation of this publication, in whole
or part, is not permitted without the written consent of
CLAAS KGaA mbH.
All rights under the provision of the Copyright Act are
reserved.
CLAAS KGaA mbH
33426 HARSEWINKEL
Germany
Our contribution to the environment:

CLAAS have printed this manual on 100 %
chlorine free paper.
CLAAS KGaA mbH
Postfach 1163
33426 Harsewinkel
Tel. +49 (0)5247 12-0
www.claas.com
000 299 846 1

ABA / BA klappb. SW 5.40 m / 4.50 m LEXION
EN - 06/05
Printed in Germany

Lexion 580-510

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LEXION 580 - 510

declare under our sole responsibility, that the product

Cutterbar - Type No.:

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

EN 632 - August 1995

by order of the Technical Management of

(J. H. Mohr) (B. Hoffmann)

INTRODUCTION These instructions describe how to assemble and

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION 1.1.1

1.1.2 ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

1. Introduction Fitting the cutterbar ............................................................... 8.4.1

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION 2.1.1

General .................................................................................. 9.4.1

10. Lubrication chart

2.1.2 ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION 3.1.1

3.1.2 ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

IMPORTANT INFORMATION To prevent accidents, the instructions contained

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION 3.2.1

3.2.2 ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

IDENTIFICATION PLATE / SERIAL NUMBER

The identification plate with the cutterbar serial number

When placing orders for spare parts or making

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION 3.3.1

3.3.2 ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

SAFETY RULES The warning and instruction signs attached to the

Identification of warning and danger signs Intended use

☞ Preventive measures. The folding cutterbar can only be operated,

Note! General safety and accident prevention

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION 4.1.1

4.1.2 ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

Any work underneath the raised cutterbar or

Feed rake safety locks

– Before operating the combine, the safety lock

Reel safety lock

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION 4.1.3

– Before operating the combine, the safety lock

4.1.4 ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

Danger area on the machine

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION 4.2.1

22 Do not go near feed mechanisms of front-mounted

4.2.2 ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

WEIGHTS / DIMENSIONS / SAFETY DEVICES

Cutterbar type Weight Working width Transport width

Cutterbar 5.40 m (18’) 2100 kg 5970 mm 3000 mm

Cutterbar 4.50 m (15’) 1980 kg 5060 mm 3000 mm

Cutterbar type Intake auger Upper shaft of feed rake

Cutterbar 5.40 m (18’) 700 ± 40 Nm 840 ± 40 Nm

Cutterbar 4.50 m (15’) 700 ± 40 Nm 840 ± 40 Nm

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION 5.1.1

5.1.2 ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

CARRY OUT PRIOR TO INITIAL OPERATION

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION 6.1.1

6.1.2 ABA / BA klappb. SW 5.40 m / 4.50 m LEXION - 000 299 846 1

DRIVING LIGHTS / CUTTERBAR CYLINDER

Driving lights for road use

Changing the driving lights

Changing the driving lights

000 299 846 1 - ABA / BA klappb. SW 5.40 m / 4.50 m LEXION 6.2.1

Safety lighting rail on the cutterbar

Removing the transport fixtures

Third cutterbar cylinder

Adjusting the cutterbar floatation springs