Claas LEXION 510, LEXION 580, LEXION 500 Technical Manual

If you are chasing a hydraulic leak on a Claas LEXION 510, LEXION 580, LEXION 500 Technical Manual and relying on a third-party reprint, you are losing money and risking a fire. I have been turning wrenches for 28 years, and the first thing I do when a combine comes in with a dead steering or a concave that won’t move is pull the factory hydraulic circuit diagram. You cannot diagnose a valve stack without knowing which line goes where and at what pressure. This OEM manual gives you that – 532 pages of Claas engineering, not some aftermarket guess.

Every circuit diagram in this book is stamped with the serial number break points. For a LEXION 580 rotor machine up to serial 586 00336, the overall hydraulic system is on one page; from 586 00337 it changes. That level of detail matters when you are swapping a Valve insert and need to know which port feeds the tank. You get the whole system: oil tank (1.1.1), hydraulic pumps, motors, and those valve inserts that always give trouble. Section 1.2 lists eight separate circuit diagrams for rotor and straw walker machines, each with its own key. If you are working on a LEXION 500 series, the low-pressure system section (Chapter 4) covers the charge pump and filter location.

Hydraulic System General – 1.1 Oil Tank, Pumps, Motors, Valve Inserts

Section 1.1 breaks down the general layout. You get the oil tank capacity and the pump drive details – no guessing which pulley drives the gear pump. The valve inserts subsection (1.1.4) shows the cross-section and the O-ring locations. Use a torque wrench on those retaining bolts; the manual gives the spec in Nm. If you are used to lb-ft, convert it – do not guess. The manual also lists the hydraulic motor identification for the rotor drive and the feeder house. That alone can save you an hour of tracing lines.

Steering Hydraulics and AUTOPILOT – Circuit Diagrams by Serial Number

Chapter 2 is steering. Three circuit diagrams: with AUTOPILOT and filling valve (for LEXION 580/570), without filling valve (for 560-510), and without AUTOPILOT. Each diagram has the exact port labeling for the Orbitrol units. If the steering drifts, you need to check the double-stage Orbitrol function in 2.2.2. The manual explains the pressure drop across the priority valve. I have seen guys replace a steering cylinder because they skipped checking the AUTOPILOT solenoid – the manual tells you to test that first.

Working Hydraulics – Main Valve and Concave Adjustment

Chapter 3 runs 11 sub-sections of working hydraulics circuit diagrams. The main valve (3.2) is the heart of the system. Concave adjustment (3.3) differs between the 580/570 hydro-pneumatic system and the 560-510 hydraulic system. The filling valve is a common failure point – the manual gives the pressure test port location and the spec. Rotor speed control (3.7) and front attachment quick stop (3.8) are also here. Every valve stack is mapped, including the individual solenoid functions.

If you need the low-pressure system (charge pressure, filter bypass), turn to Chapter 4. The manual also covers the Electro-hydraulic Gearshift (EHS) in Chapter 5, straw and chaff spreading (Chapter 6), radiator cleaning (Chapter 7), ground drive (Chapter 8), and axle hydraulics for Montana models (Chapter 9). This is not a general repair guide – it is a Technical Manual for the hydraulic system only, which means every page is relevant.

532 Pages of Factory Specs – What You Actually Get

The Table of Contents lists 14 chapters plus a component grid and index. You get the overall circuit diagrams, steering, working hydraulics, low-pressure, EHS, spreading, radiator cleaning, ground drive, Montana axle, multi-coupling, and cutterbar sections (standard, Vario, folding, Conspeed maize picker). Page 2 shows the LEXION 500 TIC hydraulic system identifier. That means the manual applies to the entire LEXION 500 series including the 510, 580, and 500. The component grid at the back locates every hydraulic component on the machine – useful when the decals are worn off.

FAQs – Four Questions Before You Download

Does this manual cover the LEXION 500 with a different engine?

The engine itself is not detailed, but all hydraulic interfaces are identical across the 500 series (510, 580, 500). If the hydraulic pump is belt-driven from the engine, the manual shows the drive layout and pump specs.

Are torque values given in both metric and imperial?

No. The manual provides OEM torque specs in Nm. You will need to convert to lb-ft if that is your preference. Do not skip converting – a stripped valve body costs more than the manual.

What about serial number breaks – are they accurate?

Yes. The manual lists exact serial number ranges for each circuit diagram (e.g., LEXION 580 up to 586 00336 and from 586 00337). If your machine falls in between, you have the correct diagram.

Can I use this manual for troubleshooting the AUTOPILOT system?

Absolutely. Section 2.3 covers the AUTOPILOT right/left function and the associated steering hydraulics diagram. It shows the solenoid valve and the pressure line routing.

Related Manuals:

• CLAAS LEXION 500 Series Operators Manual CEBIS”>CLAAS LEXION 500 Series Operators Manual CEBIS
• Claas ROLLANT 160 Technical Manual – Factory Electric & Hydraulic Specs”>Claas ROLLANT 160 Technical Manual – Factory Electric & Hydraulic Specs
• CLAAS Jaguar II Speedstar Technical Systems Training”>CLAAS Jaguar II Speedstar Technical Systems Training

For background on transmission theory, refer to Manual Transmission”>Manual Transmission on Wikipedia. Also see Manual Transmission”>Manual Transmission for additional details.

That part is not in the manual. Do not rely on memory for hydraulic fittings – get the factory wiring and plumbing straight. I have had to re-do jobs because a guy used an aftermarket diagram that swapped two pressure lines. This manual is the same one the Claas dealer uses. Download the Factory Manual and keep it in a dry binder next to your workbench. You will reference it more than any other book in the shop.