Every one of the 985 pages in this Claas Lexion 480 repair manual PDF (OEM #188 678.1) exists to put your combine harvester back in the field. You get hydraulic repair coverage across the high-pressure circuit, the low-pressure cylinders and the steering hydraulics (removal, bleeding and refitting procedures), plus step-by-step teardown procedures for the threshing drum, axial rotors, final drives, feed rake conveyor, and grain tank unloading system. Drive diagrams map every belt on both sides of the machine, and a full tightening torque section closes out the book. Set the magnetic pick-up clearance to 0.2 plus or minus 0.1 mm, then torque the jockey pulley clamping screw to 130 Nm; the factory numbers are printed right there. Harvest season doesn't wait for parts counter opinions. Bookmarked and keyword-searchable: download it, pull it up in the cab, and get back to cutting.
What's Inside This Claas Lexion 480 Repair Manual
| System | Pages | Key Topics |
|---|---|---|
| Safety, Specifications & General Repair Information | 1-18 | Safety Rules, Specifications, General, General Repair Information, Sectional View of Machine |
| Drives, Axles & Belts | 19-296 | Drive Diagram, Drive Axle, Final Drives, Drive Belts, Left-Hand Drive Belts, Right-Hand Drive Belts, Axial Rotor Drive, Chopper Drive, Cutterbar Drive, Fan Drive, Rocker Arm Drive, Straw Spreader Drive, Uni-Spreader Drive |
| Engine, Electrical & Fuel System | 297-334 | Engine, Engine Electric System, Engine Output, Fuel System |
| Axial Rotors, Brakes & Cooling | 335-386 | Axial Rotors, Brake, Foot Brake, Parking Brake, Cleaning Fan, Cooling System |
| Feed Rake Conveyor & Grain Elevator | 387-444 | Feed Rake Conveyor, Intercepting Piece, Suction Blower, Suction Blower Drive, Top Feed Rake Shaft, Anti-Wrapping Guards, Filler Blocks, Centre Bearing, Mud Guard, Grain Elevator |
| Grain Tank Unloading & Drive | 445-490 | Grain Tank Cross Auger, Vertical Grain Tank Unloading, Horizontal Grain Tank Unloading, Lower Grain Tank Unloading, Upper Grain Tank Unloading, Grain Tank Unloading Drive Chain, Outlet Spout, Conical Graduation Plates, Drive Wheel, Sprocket |
| Hydraulic System | 491-590 | Hydraulic Cylinders – High-Pressure Hydraulic Circuit, Hydraulic Cylinders – Steering Hydraulics, Hydraulic Cylinders for Low-Pressure Hydraulics, Hydraulic Pumps, Maintenance Hydraulic System |
| Hydrostatic Motors, Gearbox & Oil Cooler | 591-650 | Hydrostatic Fixed Displacement Motors, Impeller, Manual Gearbox, Oil Cooler, Preparation Floor |
| Returns Elevator, Rotary Screen & Sieve Pan | 651-720 | Return Pan, Returns Elevator, Rotary Screen, Rotary Screen Drive, Sieve Pan, Sieve Pan Drive |
| Steering & Straw Chopper | 721-791 | Steering, Steering Axle, Straw Chopper |
| Threshing Mechanism | 792-887 | Left-Hand Threshing Mechanism Drive, Right-Hand Threshing Mechanism Drive, Threshing Concave, Threshing Drum, Threshing Drum Reduction Gearbox, Threshing Mechanism Intermediate Drive |
| Uni-Spreader & Valve Combinations | 888-925 | Uni-Spreader, Fan Blade, Fan Blade Bearings, Uni-Spreader Intermediate Drive Belt, Uni-Spreader Drive Belt, Jockey Pulley Arm, Feed Hopper, Safety Frame, Side Panels, V-Belt Pulley, Valve Combinations |
| Sieve Pan Control, Accelerator, Air Conditioner & Tightening Torques | 926-985 | 3-D Sieve Pan Control System, Accelerator, Air Conditioner, Tightening Torques |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Tightening torque for jockey pulley (A) | 130 Nm | p. 62 |
| Spring length for spring-loaded cylinder (F) | 138 mm | p. 62 |
| Washer (G) dimensions | 26 x 42 x 3 mm | p. 66 |
| Tightening torque for clamping screw (B) at the jockey pulley | 130 Nm | p. 88 |
| Magnetic pick-up clearance | 0.2 ± 0.1 mm | p. 370 |
| O-ring 58 x 3 DIN 3771 | 58 x 3 mm | p. 500 |
| O-ring 18 x 2.5 DIN 3771 | 18 x 2.5 mm | p. 984 |
| O-ring 34.2 x 3 DIN 3771 | 34.2 x 3 mm | p. 511 |
| O-ring 22 x 2 - N DIN 3771 | 22 x 2 mm | p. 900 |
| O-ring 40 x 1.5 - N DIN 3771 | 40 x 1.5 mm | p. 900 |
| Hydraulic System Oil Capacity (Oil Change) | 20 litres | p. 5 |
| Hydraulic System Oil Capacity (New System Filling) | 70 litres | p. 5 |
Claas Lexion 480 Common Problems This Manual Covers
Claas Lexion 480 hydraulic oil weeping from relief valve flange and shock valve plugs on the valve block
Drain residual pressure from the system before cracking any fitting. Replace the O-rings on the valve flanges; the valve combinations section starting on page 900 lists the sizes, 22 x 2 mm and 40 x 1.5 mm among them. Retorque fittings from the table on page 983: M 16 x 1.5 gets 29+10 Nm, M 22 x 1.5 gets 67+22 Nm.
Manual Section: Valve combinations.PDF (p.900-925) p. 900Header lift slow and spongy after hose repair, concave adjustment drifts, functions need repeated cycling
Check hydraulic oil level first; the system holds 20 litres on a change and 70 litres from dry, per the specs on page 5. Bleed the concave adjustment cylinder by running it to both stops several times as described on page 542, then cycle the cutterbar cross levelling cylinders the same way. Verify lifting pressure reaches 175+15 bar.
Manual Section: Concave Adjustment Hydraulic Cylinder Bleeding p. 542Sieve pan drive belt squealing and slipping under load, needs retensioning every few days
Measure the tension spring instead of guessing: the sieve pan drive belt spring should sit at 125 mm (page 91), the intermediate drive belt spring at 131 mm (page 88). If the belt still slips at correct spring length, replace it and inspect the jockey pulley bearing for roughness. Torque the jockey pulley clamping bolt to 130 Nm when finished.
Manual Section: Drives, Axles, Drive Diagram, belts.pdf (p.19-296) p. 91Steering feels slow and wanders, oil seeping from the orbitrol unit under the cab floor
Check the failure chart on page 721 to separate external leaks from internal bypass before pulling the unit. Test steering circuit pressure against the 150+15 bar set pressure listed on page 6. After replacing seals, bleed the steering hydraulics completely and recheck play at the steering wheel before any road travel.
Manual Section: Orbitrol Steering Unit Failures p. 721Cleaning fan speed reads zero or erratic on the display after variable speed drive repair
Adjust the magnetic pick-up clearance to 0.2 ± 0.1 mm as specified on page 370; too wide a gap kills the signal. Clean metal filings off the sensor tip and check the connector for corrosion. If the drive was apart, pre-tighten the face-end slotted nut M 40 x 1.5 to 20 Nm before final assembly.
Manual Section: Cleaning fan.PDF (p.367-380) p. 370Frequently Asked Questions
What is the tightening torque for the M 20 bolts on the drive axle?
When installing the drive axle, the M 20 bolts must be tightened to a torque of 410 Nm. p. 24
What is the tightening torque for the castellated nut on the final drive gearbox?
The castellated nut (K) on the final drive gearbox must be tightened to a torque of 600 Nm. p. 28
What is the capacity of the hydraulic system oil tank?
The hydraulic system requires approximately 20 litres for an oil change and approximately 70 litres for a new system filling. p. 5
What is the tightening torque for the M 16 bolt used to secure the reduction gearbox to the machine?
The M 16 bolt used to secure the reduction gearbox to the machine is tightened to 120 Nm. p. 881
What do I get after purchasing this Claas Lexion 480 manual?
You download the Repair Manual yourself: 985 pages, searchable PDF, available immediately. Keep a copy on every device you use.
Can I print a copy of this Claas Lexion 480 Repair Manual for the shop?
Yes, print as many copies as you want, and there are no restrictions. Many mechanics print the section they need and bring it to the shop floor.
Does this manual cover the hydraulic system?
Yes. It covers the high-pressure hydraulic circuit and the low-pressure hydraulic cylinders, plus the steering hydraulics, with removal, bleeding, refitting and oil-change procedures, and the fill capacities (approx. 20 litres for an oil change, approx. 70 litres for a new fill, page 5). It does not contain hydraulic circuit schematics.
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