Caterpillarcombine(no series)
Caterpillar 480
Maintenance schedule, common problems & OEM parts breakdown
The Caterpillar 480 is a large-frame, hybrid rotary combine harvester built on the Claas Lexion 480 platform, badged Cat under the Caterpillar-Claas America joint venture (roughly 1999-2002/2003) and built at the Claas Omaha, Nebraska plant. Cat-badged units run the Cat 3176C ATAAC, a 10.3 L turbocharged, air-to-air aftercooled inline-6 diesel rated 365 gross hp (272 kW); the separate European Claas-branded Lexion 480 built on the same body instead carried Mercedes-Benz power and is a distinct parts and service line. Operating weight spans roughly 14,000-18,000 kg (30,900-39,700 lb) depending on tire/dual/track fitment and header mounted. The 480 was the first model of the Lexion 400 series, introduced in the mid-1990s and produced through 2003, pairing a Claas Accelerated Pre-Separation (APS) threshing cylinder with twin-rotor separation. Cat sold it as a wheeled APS-hybrid combine (serial prefixes 7ZR and 2BZ) and as the 480R twin-rotor-only variant (prefix JAC), with Mobil-Trac rubber-track and dual-wheel options, and it could be run with grain platforms (G22/G25/G30), flex/draper bean heads, row-crop corn heads, or pickup headers.
Caterpillar and Claas jointly marketed the Lexion line in North America starting 1999, opening the Omaha plant in 2001 to build combines under the Cat badge; Caterpillar sold its stake back to Claas around 2002, after which Cat branding wound down and the 480's platform continued on as Claas-only Lexion 400- and 500-series machines. Across the run, Claas refined APS threshing and twin-rotor separation in ways that carried forward into later Lexion generations. In today's used and parts market, the 480 is a scarce, transitional machine: Cat-badged engine and driveline components cross to the wider Cat 3176C parts base, while threshing, rotor, and header components draw on the Claas Lexion parts network. Buyers should confirm serial prefix (7ZR/2BZ standard wheeled vs. JAC twin-rotor 480R) before sourcing rotor, concave, or drive parts, since the 480R does not share those components with the standard APS-hybrid 480.
Below: full specifications, fluids & capacities, the factory service schedule, common service parts, verified fault codes, what owners discuss, attachment guidance, the complete assembly directory, and a serial-number reference. Complete parts lists with full OEM part numbers, exploded diagrams, quantities, and fitment data are available free in Heavy Parts AI.
Caterpillar 480 specifications
Engine
| Engine model (Cat-badged North American 480) | Cat 3176C ATAAC — 6-cylinder inline diesel, electronic unit injection, turbocharged with air-to-air aftercooling |
| Gross power | 272 kW (365 hp) gross |
| Displacement / cylinders | 10.3 L (629 cu in), 6 cylinders |
| Emissions tier | Not published for this combine application — verify certification level with a dealer |
| Alternate powertrain (Lexion 480 CAC / TT / Evolution variants, non-Cat markets) | Mercedes-Benz OM 441 LA, 6-cylinder, 11.0 L, rated 294–305 kW (400–415 hp) depending on variant — this is not the engine used on Cat-branded units; varies by configuration/series |
Weights
| Operating weight | Not separately published for the Cat-badged wheeled 480. Across Lexion 480-family variants (CAC, TT, Evolution) published operating weights range roughly from 14,000 kg (30,900 lb) to 18,000 kg (39,700 lb) — varies by configuration/series |
| Shipping weight | Not published |
| Ground pressure | Not published |
Dimensions
| Transport length | 8.64 m (28 ft 4 in), basic combine without header |
| Transport width | 3.7 m (12 ft 2 in) |
| Transport height | 3.91 m (12 ft 10 in) |
| Threshing cylinder width | 1,700 mm (67 in) |
| Wheelbase / axle track / ground clearance | Not published |
Performance
| Travel speed | Up to approximately 26.5 km/h (16.5 mph) on the wheeled platform — varies by transmission option and configuration |
| Grain tank capacity | Approximately 9,970–10,500 L (280–298 bu) depending on source and configuration |
| Rated grain throughput | Up to 40 tonnes/hour (44 short tons/hour); marketed as the most powerful combine in its class at introduction |
| Separation architecture | Accelerated Pre-Separation (APS) drum feeding a twin-rotor rotary separation system in place of straw walkers |
| Cleaning area | 5.99 m² (9,286 in²) |
| Separating area | 6.22 m² (9,641 in²) |
| Total concave area | 1.73 m² (2,677 in²) |
| Gradeability | Not published |
Service capacities (summary)
| Fuel tank | 650 L (170 US gal) |
| Hydraulic system | Not published |
| Engine oil | Not published |
| Cooling system | Not published |
Values vary by configuration, region, and serial range — confirm against your machine before planning transport or lifts.
480 fluids & capacities
| System | Capacity | Recommended fluid |
|---|---|---|
| Engine crankcase (with filter) - Cat 3176C ATAAC, 6-cyl turbo-aftercooled diesel, 365 gross hp | approx. 28-34 L (7.4-9.0 US gal), varies by configuration/series - exact figure not confirmed for this serial range | Cat DEO (Diesel Engine Oil) or Cat DEO-ULS, API CG-4/CF-4 class. Viscosity by climate per Cat chart: SAE 15W-40 for temperate/warm operation, SAE 10W-30 for cold starts down to about -18 C, SAE 0W-30/0W-40 for arctic conditions below that. Confirm exact grade split against the OMM viscosity table for your ambient range. |
| Cooling system (radiator, engine jacket, intercooler circuit) | not confirmed for this exact machine/serial range - verify with dealer or OMM; comparable Cat 3176-family industrial cooling systems run in the 40-50 L (10.6-13.2 US gal) range | Cat ELC (Extended Life Coolant) or Cat DEAC (Diesel Engine Antifreeze/Coolant), premix or concentrate to a 1:1 water ratio for standard climates, adjusted for extended cold protection per local ambient minimums. Use only Cat-approved supplemental coolant additive schedule if running DEAC instead of ELC. |
| Fuel tank | 650 L (170 US gal) | No. 2-D diesel fuel meeting Cat's diesel fuel specification; No. 1-D or a winter-blend/No.1-D and No.2-D mix recommended below freezing to control fuel waxing. Biodiesel blends up to the OMM-stated limit are acceptable if the blend meets Cat's biodiesel fuel quality requirements. |
| Ground-drive transmission (main gearbox, chassis-mounted) | 6.5 L (1.7 US gal) on the 20t HD gearbox; 7.0 L (1.8 US gal) on the standard 17t/20t gearbox - depends on chassis/axle rating | Cat TDTO (Multigrade Transmission/Drive Train Oil), SAE 90, meeting API GL-5 performance level. |
| Transfer gearbox (engine output shaft) | 3.0 L (0.8 US gal) | Cat TDTO SAE 90, API GL-4 performance level. |
| Threshing drum reduction gearbox | 1.8 L (0.5 US gal) | Cat TDTO SAE 90, API GL-4 performance level. |
| Rotor drive gearboxes (each of two separator rotors) | 1.75 L (0.46 US gal) each | Cat TDTO SAE 90, API GL-4 performance level. |
| Final drives, each side (hub housing plus planetary reduction) | approx. 13.0 L (3.4 US gal) per side - 8.0 L (2.1 US gal) in the final drive housing plus 5.0 L (1.3 US gal) in the planetary reduction hub | Cat TDTO SAE 90, API GL-5 performance level. Continuous-duty operation favors the upper end of the allowed viscosity band for best oil film thickness. |
| Grain-unloading auger angle drives (upper and lower) | grease-packed, not oil-filled - approx. 270 g at the upper angle drive and 530-900 g at the lower angle drive depending on production change point | NLGI 2 multipurpose rolling-element-bearing grease - Cat Prime Application Grease or an equivalent lithium-complex EP2 grease. |
| Hydraulic system and reservoir (combined working/lift hydraulics and hydrostatic ground-drive circuit, one shared tank) | approx. 70 L (18.5 US gal) total system fill on initial/major service; approx. 20 L (5.3 US gal) at a routine reservoir oil-and-filter change | Cat HYDO Advanced or an equivalent multigrade anti-wear hydraulic oil, ISO VG 46, detergent-type, meeting a DIN 51524 part 3 spec (pour point below -25 C, viscosity index above 170). Factory fill is a standard-temperature-range oil; machines run below about -20 C need the arctic-grade 0W hydraulic oil instead. |
| Foot-brake hydraulic reservoir | small reservoir, no set refill volume - keep topped to the full mark at all times | DOT 4 brake fluid. |
| Grease points, general chassis and driveline (spec only) | n/a - dispensed at zerk fittings per the lubrication schedule, no reservoir capacity | NLGI 2 multipurpose grease - Cat Prime Application Grease (or Cat Advanced 3Moly Grease where a moly-fortified grease is called for) for pins, bushings, and non-sealed bearing points. |
Capacities are refill values from factory literature — always fill to the dipstick/sight gauge, not the number.
Caterpillar 480 maintenance schedule
| Service interval | Tasks |
|---|---|
| Every 10 h |
|
| Every 250 h |
|
| Every 500 h |
|
| Every 1,000 h |
|
| Every 2,000 h |
|
| Every 3,000 h |
|
| Every 4,000 h |
|
Servicing the 480 beyond the schedule
Predictive Maintenance & Fluid Analysis
Run oil sampling on the Cat 3176C ATAAC every 250 hours to catch turbo, injector, or liner wear before it becomes a teardown; trend coolant condition against the Cat ELC service life. Sample rotor gearbox and final drive/wheel-drive oil at 500 to 1000 hour intervals — twin-rotor separation loads these gearboxes hard during long harvest days. Watch fuel filter/water separator restriction closely; the single 650 L (170 gal) tank means a fouled filter shows up as a mid-field power loss.
Corrective & Common Repairs
Straw chopper and chaff spreader knives wear fast in high-volume corn and soybean work and need frequent replacement or rotation. APS drum and twin-rotor cage clearances drift out of adjustment and cause grain loss or cracked kernels if not reset each season. Feederhouse chain stretch and slat wear show up as uneven crop feed. Unloading auger and grain tank sensor faults are common electrical gremlins on these Cat-badged units, and wheel-drive motor leaks are a frequent undercarriage complaint.
Overhaul & Rebuild Points
High-hour 3176C ATAAC engines typically need turbocharger and injector reconditioning, then a top-end or inframe rebuild as compression and blow-by degrade. The APS threshing cylinder and concave wear surfaces, plus the twin-rotor cages and separation grates, are the next major rebuild targets — expect wire/bar replacement on the concave and cage rotation or swap at heavy hours. Wheel-drive final drives and the feederhouse/header gearboxes are the other common rebuild points on machines pushing past 3000-4000 hours.
Seasonal & Environment Servicing
Before harvest, reset APS drum and rotor clearances for the crop on hand and confirm the ATAAC aftercooler core is clean — dusty small-grain harvest loads it fast and cuts engine power if fouled. Clear chaff and residue from the engine bay and rotor housing daily; combine fires start there. At season's end, drain the fuel/water separator, grease all pivot points, and block off intakes and cab vents against rodent nesting during off-season storage.
480 common service parts
| Part number | Part | Notes | |
|---|---|---|---|
| 1R-0762 | Filter As-Fuel | Fuel system service | Check fitment → |
| 111-2645 | Valve-Pump Bypass | Lubrication service | Check fitment → |
| 8M-3182 | Spring,Helical,Comp Engine Oil Filter Assembly | Lubrication service | Check fitment → |
| 1R-0716 | Filter As-Engine Oil | Lubrication service | Check fitment → |
| 119-3025 | Filter | Scheduled service item | Check fitment → |
Always confirm against your machine's serial number — cross-check any part in Heavy Parts AI before ordering.
480 fault codes & troubleshooting
| Code | Meaning | Likely cause | What to do |
|---|---|---|---|
| CID 100 FMI 01 | Engine Oil Pressure Sensor - data valid but below normal range (low oil pressure signal) | Actual low oil pressure from low oil level, worn pump, or plugged filter, or a failed oil pressure sensor/wiring circuit | Check oil level and filter condition first, then verify sensor signal with Cat ET before condemning the pump |
| CID 110 FMI 00 | Engine Coolant Temperature Sensor - data valid but above normal range (high coolant temperature) | Low coolant level, chaff/debris packed into the radiator or aftercooler core, weak fan drive, or a failed sensor | Clean the cooling package of chaff and check coolant level before further diagnosis |
| CID 168 FMI 01 | Electrical System Voltage - below normal (low system/battery voltage at the ECM) | Weak or discharged batteries, corroded ground straps, or a failing alternator | Load-test the batteries and check ground connections at the ECM and frame |
| CID 190 FMI 08 | Engine Speed/Timing Sensor - abnormal, erratic, or intermittent signal | Damaged timing sensor, worn tone wheel, incorrect sensor air gap, or a chafed harness near the timing gear housing | Inspect sensor mounting and air gap, then check the harness for chafing near the gear housing |
| CID 102 FMI 03 | Boost Pressure Sensor - voltage above normal | Shorted sensor signal wire or a failed sensor | Inspect the sensor connector for moisture or corrosion and check wiring for a short to power before replacing the sensor |
| CID 94 FMI 04 | Fuel Delivery Pressure Sensor - voltage below normal | Open or shorted sensor circuit, failed sensor, or genuinely low fuel supply pressure | Check fuel filters and supply line first, then test sensor wiring continuity |
| CID 91 FMI 13 | Throttle Position Sensor - out of calibration | Sensor or linkage disturbed or replaced without recalibration, or sensor drift | Run the throttle position calibration procedure with Cat ET |
| CID 1 FMI 05 | Cylinder #1 Injector - current below normal (open circuit) | Broken injector solenoid wire, corroded connector, or a failed injector solenoid | Check the injector harness connector and continuity back to the ECM before replacing the injector |
| CAN-BUS WIRES DEFECT (machine isn't supervised anymore - bus error) | Combine control network offline; the body/cab display stops receiving data from CAN-connected sensors, so fuel level, coolant temperature, and hour readings go blank or erratic | Corroded or moisture-damaged CAN harness connector (a known weak point near the chopper/left-side subframe routing) or a shorted node module | Cycle the master power switch off for several minutes to reset the bus, then inspect CAN harness connectors and grounds for corrosion; if the fault returns, unplug modules one at a time to isolate the shorted node |
| Lateral angle sensor defective | Header/feederhouse lateral tilt (float or leveling) sensor circuit fault | Damaged, disconnected, or corroded tilt sensor at the feederhouse lift cylinder linkage, or harness damage in that area | Locate and inspect the tilt sensor bracket and connector at the feederhouse lift linkage, and check wiring continuity before replacing the sensor |
Codes and remedies are general guidance for this model family — always confirm with diagnostic tooling and your dealer before major repairs.
480 attachments & work tools
Grain platform (auger head)
G-series rigid auger platforms are the standard small-grain header for this size class, offered in 6.7 m, 7.5 m and 9 m (22 ft, 25 ft and 30 ft) widths. They mount to the feederhouse on a single-point hookup with header-side hydraulic control valves rather than combine-mounted valves.
Flex/draper platform (bean head)
A flex-cutterbar platform (F30 designation) is offered for beans and low-growing crops on the 400-series feederhouse, with full-finger auger and lateral flotation to follow ground contour. Later flex heads sized for the 500-series (F530/F535 and similar) use a different feederhouse geometry and are not a direct fit for the 480 without an adapter.
Corn head (row-crop head)
A row-crop corn head is offered for this platform, commonly referenced by a naming convention indicating row count and spacing (twelve rows on 76 cm/30 in spacing being typical for this size class); exact row count/spacing varies by configuration and year, verify with dealer records for the specific unit. Deck plates and a horizontal stalk chopper are standard features of these heads.
Pickup header (windrow attachment)
A pickup header is offered for harvesting small grains previously cut and left in a windrow, mounting to the same feederhouse coupling as the grain platform. Owners note this configuration paired with a straight-cut header covers most small-grain harvest needs for this model.
Feederhouse coupler and hydraulics
Headers attach to a single feederhouse mount with hydraulic control valves and manifolds located on the header itself, fed by multiple hoses running from the combine rather than combine-side valve banks. The feederhouse and header drive can be run in reverse from the cab to clear plugs without dismounting.
Aftermarket header adapters
Adapter kits (shell, driveshaft and hydraulics) exist to mount non-factory headers, including MacDon draper platforms and Case IH/New Holland/John Deere heads, to the Lexion/Cat 400-series feederhouse. These are aftermarket conversions, not factory-cataloged work tools, and fitment/electrical compatibility should be confirmed before purchase.
Straw chopper and chaff spreader
An optional four-row straw chopper can be engaged or disengaged from the cab to switch between windrowing residue and chopping/spreading chaff and straw across the cutterbar width. Chaff spreading is selectable between a standard vaned deflector hood or a mechanically driven, counter-rotating dual-rotor power spreader; some configurations add cab-controlled hydraulic adjustment of chopper rotor settings.
Cleaning-fan wind reduction kit
Shutter-plate kits are available to reduce turbine fan air-intake area when harvesting light crops, helping tune cleaning airflow without swapping fan hardware.
Tire, dual-wheel and track configurations
Factory wheel options include standard, wide and dual-tire Michelin fitments plus Firestone duals, in bar-tread or standard-tread patterns; large floater tires are also used in the field. A Mobil-Trac rubber-belt flotation undercarriage, derived from Caterpillar Challenger belt technology, was offered as an alternative to wheels for flotation and traction.
All 480 assemblies by section
Every catalogued assembly group for the Caterpillar 480. Open an assembly to preview the parts inside — full OEM part numbers are available in Heavy Parts AI.
Air Inlet And Exhaust System
4p-2881 Cartridge Gp-Turbocharger
| 11***30 | Nut-Compressor | 1 |
| 11***46 | Shaft As-Turbine | 1 |
| 4P***81 | Cartridge Group-Turbocharger | 1 |
117-2755 Manifold Gp-Exhaust
| 10***13 | Gasket | 6 |
| 11***15 | Stud-Taperlock; (M10x85-mm Oal) | 12 |
| 11***55 | Manifold Group-Exhaust | 1 |
116-5405 Manifold Gp-Inlet
| 11***05 | Manifold Group-Inlet | 1 |
| 11***06 | Manifold; (Inlet) | 1 |
| 3J***07 | Seal Valve Assembly To; Seal- Tube Assembly To Logic Valve | 1 |
133-7027 Turbocharger Gp
| 13***27 | Turbocharger Group | 1 |
| 13***35 | Turbocharger Group | 1 |
| 1P***51 | Gasket; (Turbocharger) | 1 |
136-4835 Turbocharger Gp
| 10***28 | Cover-Compressor | 1 |
| 10***79 | Housing-Turbine | 1 |
| 13***35 | Turbocharger Group | 1 |
Basic Engine
115-9382 Camshaft Gp
| 11***82 | Camshaft Group | 1 |
| 11***59 | Cover | 1 |
| 12***11 | Journal | 1 |
117-2791 Cover Gp-Air Compressor
| 11***18 | Cover | 1 |
| 11***19 | Gasket | 1 |
| 11***91 | Cover Group-Air Compressor | 1 |
115-2985 Cover Gp-Cylinder Block
| 11***85 | Cover Group-Cylinder Block | 1 |
| 4P***87 | Cover | 1 |
| 6V***50 | Seal-O-Ring (Id=39.34mm) | 1 |
136-4307 Cover Gp-Front Housing
| 13***07 | Cover Group-Front Housing; -Hydraulic Pump Drive | 1 |
| 1H***39 | Packing,Preformed Cover Part Of Kit P/N 4j***80 | 1 |
| 4P***50 | Cover | 1 |
117-2743 Crankshaft Gp
| 11***07 | Plate; (Thrust) | 2 |
| 11***08 | Bearing-Main; (Standard) | 4 |
| 11***09 | Bearing-Main; (Standard) | 3 |
128-0407 Cylinder Block As
| 11***66 | Cap; (Bearing) | 7 |
| 12***07 | Cylinder Block As | 1 |
| 12***16 | Bearing; (Sleeve) | 5 |
148-2062 Cylinder Block As
| 11***66 | Cap; (Bearing) | 7 |
| 12***16 | Bearing; (Sleeve) | 5 |
| 12***17 | Bearing-Sleeve; (Narrow) | 1 |
148-2095 Cylinder Block As
| 10***60 | Seal; (Liner) | 6 |
| 14***62 | Cylinder Block As | 1 |
| 14***95 | Cylinder Block As | 1 |
200-2054 Cylinder Block As
| 11***66 | Cap; (Bearing) | 7 |
| 17***54 | Bolt-Hex Head; (M16x160mm) | 14 |
| 20***54 | Cylinder Block As | 1 |
204-3450 Cylinder Block As
| 10***60 | Seal; (Liner) | 6 |
| 14***25 | Liner-Cylinder Block | 6 |
| 16***63 | Shim-Liner; -Cylinder | 0 |
144-2958 Cylinder Block As
| 10***60 | Seal; (Liner) | 6 |
| 12***07 | Cylinder Block As | 1 |
| 14***58 | Cylinder Block As | 1 |
115-2982 Cylinder Block Gp
| 11***82 | Cylinder Block Group | 1 |
| 14***95 | Cylinder Block As | 1 |
| 1N***99 | Plug-O-Ring; (Straight Thread) | 2 |
144-2950 Cylinder Head As
| 11***02 | Sleeve; (Injector) | 6 |
| 13***97 | Insert-Valve Seat; (Exhaust) | 12 |
| 13***06 | Insert-Valve Seat; (Inlet)(Standard) | 12 |
179-9459 Cylinder Head As
| 11***02 | Sleeve; (Injector) | 6 |
| 13***06 | Insert-Valve Seat; (Inlet)(Standard) | 12 |
| 17***53 | Insert-Valve Seat; (Exhaust)(Standard) | 12 |
148-2150 Cylinder Head As
| 11***02 | Sleeve; (Injector) | 6 |
| 13***97 | Insert-Valve Seat; (Exhaust) | 12 |
| 13***06 | Insert-Valve Seat; (Inlet)(Standard) | 12 |
148-2149 Cylinder Head Gp
| 10***50 | Guide-Valve; (Standard) | 24 |
| 13***29 | Valve; (Exhaust) | 12 |
| 14***49 | Cylinder Head Group | 1 |
116-1085 Cylinder Head Gp
| 11***85 | Cylinder Head Group | 1 |
| 14***67 | Cylinder Head Group | 1 |
| 16***86 | Gasket As-Cylinder Head | 1 |
144-2967 Cylinder Head Gp
| 10***50 | Guide-Valve; (Standard) | 24 |
| 12***93 | Valve-Exhaust | 12 |
| 14***50 | Cylinder Head As | 1 |
117-2766 Damper Gp
| 11***66 | Damper Group | 1 |
| 13***83 | Bolt-12 Point Head; (M10x1.5x30-mm) | 8 |
| 16***25 | Damper Assem. | 1 |
116-1083 Fastener Gp-Cylinder Head
| 11***83 | Fastener Group-Cylinder Head; (Cylinder Head) | 1 |
| 12***84 | Bolt; (Hex Head) (M16x2x160mm) | 26 |
| 2S***58 | Washer-Hard; (17x29x3-mm Thk)(Engine Brake) | 26 |
117-2792 Fastener Gp-Oil Cooler
| 11***92 | Fastener Group-Oil Cooler; -Engine | 1 |
| 6V***17 | Bolt; (M8x1.25x30-mm)(Location Z) | 1 |
| 9M***74 | Washer-Hard; (8.8x16x2-mm Thk)(Hard) | 1 |
145-9112 Flywheel Gp
| 14***53 | Flywheel As | 1 |
| 14***12 | Flywheel Group | 1 |
| 4N***14 | Gear; (113-Teeth)(Flywheel Starter) | 1 |
117-2750 Gear Gp-Front
| 11***50 | Gear Group-Front | 1 |
| 13***83 | Shaft | 1 |
| 13***86 | Gear As; (Idler) (71 Teeth) | 1 |
145-8287 Housing Gp-Flywheel
| 06***55 | Seal-O-Ring (Id=47.22mm) | 1 |
| 14***57 | Housing-Flywheel | 1 |
| 14***87 | Housing Group-Flywheel | 1 |
115-3006 Housing Gp-Front
| 11***06 | Housing Group-Front; (Front) | 1 |
| 11***24 | Gear; (Pump Drive) (34 Teeth) | 1 |
| 13***96 | Housing As; (Front) | 1 |
115-9386 Lifter Gp-Valve
| 0T***00 | Plug (.5625" Diameter) | 2 |
| 11***86 | Lifter Group-Valve; -Mechanism | 1 |
| 11***91 | Shaft As; (Lifter) | 1 |
148-2063 Lifter Gp-Valve
| 0T***00 | Plug (.5625" Diameter) | 2 |
| 11***91 | Shaft As; (Lifter) | 1 |
| 14***63 | Lifter Group-Valve; -Mechanism | 1 |
117-2748 Lifting Gp-Engine
| 11***05 | Plate; (Lifting Eye) | 2 |
| 11***48 | Lifting Group-Engine | 1 |
| 5P***45 | Washer-Hard; (13.5x25.5x3-mm Thk)(Turbocharger Blanking Plate) | 6 |
196-1329 Lifting Gp-Engine
| 19***31 | Plate-Lifting | 2 |
| 19***29 | Lifting Group-Engine | 1 |
| 5P***45 | Washer-Hard; (13.5x25.5x3-mm Thk)(Turbocharger Blanking Plate) | 6 |
138-2550 Mounting Gp-Fan Drive
| 12***64 | Stud; (M12x1.75x86.3-mm Oal) | 2 |
| 13***50 | Mounting Group-Fan Drive; (Short) | 1 |
| 5R***37 | Washer; (Seal) (1.27mm Thk) | 2 |
116-5408 Mounting Gp-Valve Mechanism
| 11***83 | Fastener Group-Cylinder Head; (Cylinder Head) | 1 |
| 11***08 | Mounting Group-Valve Mechanism | 1 |
| 17***68 | Bridge As-Valve; (Intake) | 12 |
126-0144 Pan Gp-Oil
| 06***58 | Seal-O-Ring; (Oil Pan Drain Plug) | 2 |
| 10***08 | Gasket; (Oil Pan) | 1 |
| 12***57 | Bell As; (Suction) | 1 |
116-5371 Piston & Rod Gp
| 10***42 | Skirt; (Piston) | 1 |
| 10***19 | Ring; (Piston) (Intermediate) | 1 |
| 11***71 | Piston & Rod Group | 1 |
138-2028 Plug Gp-Cylinder Block
| 13***28 | Plug Group-Cylinder Block | 1 |
| 3J***07 | Seal Valve Assembly To; Seal- Tube Assembly To Logic Valve | 1 |
| 6V***48 | Seal--O-Ring--To Governor Drive Housing | 1 |
117-0185 Plug Gp-Cylinder Block
| 11***85 | Plug Group-Cylinder Block; (Cylinder Block) | 1 |
| 6V***89 | Seal-O-Ring (Id=19.18mm) | 1 |
| 9S***06 | Plug (Front 5 Stem Main Control Valve) | 1 |
117-0165 Plug Gp-Cylinder Block
| 11***65 | Plug Group-Cylinder Block; -Oil Gallery, End | 1 |
| 3B***23 | Core Plug--Flywheel Housing Pinion Shaft Hole | 1 |
116-5452 Plug Gp-Front Housing
| 11***52 | Plug Group-Front Housing; (Front Housing) | 1 |
| 8L***86 | Seal-O-Ring (Id=16.36mm); (16.36-mm Id) | 1 |
| 9S***05 | Plug-O-Ring; (Straight Thread O-Ring) | 1 |
148-0772 Pulley Gp-Auxiliary Drive
| 14***72 | Pulley Group-Auxiliary Drive | 1 |
| 14***55 | Pulley | 1 |
| 8T***07 | Bolt; (M16x2.0x100mm) | 6 |
116-5444 Pulley Gp-Crankshaft
| 11***44 | Pulley Group-Crankshaft | 1 |
| 13***62 | Pulley | 1 |
115-9397 Rocker Arm Gp
| 09***14 | Pin; (Spring) | 1 |
| 11***97 | Rocker Arm Group | 1 |
| 11***98 | Arm; (Valve Rocker) (Exhaust) | 2 |
116-1091 Seal Gp-Crankshaft -Single Lip
| 10***80 | Seal-O-Ring (Id=177.17mm) | 1 |
| 11***91 | Seal Group-Crankshaft; -Single Lip | 1 |
| 16***23 | Cover | 1 |
129-2910 Support Gp-Engine
| 12***10 | Support Group-Engine | 1 |
| 17***27 | Support As-Front | 1 |
| 5P***45 | Washer-Hard; (13.5x25.5x3-mm Thk)(Turbocharger Blanking Plate) | 8 |
170-1094 Support Gp-Engine
| 13***32 | Support As-Engine | 1 |
| 17***94 | Support Group-Engine | 1 |
| 5P***45 | Washer-Hard; (13.5x25.5x3-mm Thk)(Turbocharger Blanking Plate) | 8 |
117-2749 Valve Mechanism Gp
| 10***42 | Base-Valve Mechanism Cover | 1 |
| 10***67 | Pushrod; (Valve) | 12 |
| 10***68 | Pushrod-Injector | 6 |
Cooling System
115-2990 Cooler Gp-Engine Oil
| 06***40 | Seal-O-Ring (Id=37.69mm) | 2 |
| 10***25 | Gasket | 1 |
| 11***90 | Cooler Group-Engine Oil; (Engine Oil) | 1 |
131-6642 Housing & Regulator Gp
| 13***42 | Housing & Regulator Group; -Engine Coolant Temperature | 1 |
| 13***43 | Housing As-Regulator | 1 |
| 3S***43 | Seal-Lip Type; (Water Temperature Regulator) | 1 |
116-5460 Lines Gp-Water
| 10***08 | Flange | 1 |
| 10***95 | Tube | 1 |
| 11***60 | Lines Group-Water; -Bypass | 1 |
131-6644 Lines Gp-Water
| 11***97 | Gasket | 4 |
| 13***42 | Housing & Regulator Group; -Engine Coolant Temperature | 1 |
| 13***44 | Lines Group-Water; -Single Thermostat | 1 |
116-5446 Lines Gp-Water
| 10***35 | Gasket | 1 |
| 11***46 | Lines Group-Water; -Water Pump Inlet Elbow | 1 |
| 11***57 | Elbow-Water Pump | 1 |
117-2789 Plug Gp-Water Lines
| 11***89 | Plug Group-Water Lines; -Engine Oil Cooler | 1 |
| 6V***27 | Seal-O-Ring (Id=8.92mm) | 1 |
| 8T***67 | Plug-Pipe; (Oil Cooler Bonnet Drain) | 1 |
117-2674 Pump Gp-Water
| 11***74 | Pump Group-Water | 1 |
| 17***00 | Pump Group-Water | 1 |
| 6V***21 | Bolt; (M8x1.25x80-mm) | 2 |
176-7000 Pump Gp-Water
| 10***10 | Gasket | 1 |
| 14***88 | Seal As; (Water Pump) | 1 |
| 17***94 | Washer | 1 |
100-6944 Pump Gp-Water
| 10***44 | Pump Group-Water | 1 |
| 10***09 | Impeller; (Pump) | 1 |
| 10***10 | Gasket | 1 |
153-8053 Pump Gp-Water
| 10***09 | Impeller; (Pump) | 1 |
| 10***10 | Gasket | 1 |
| 10***12 | Shaft; (Water Pump) | 1 |
Electrical And Starting System
124-2673 Control & Mtg Gp-Engine Elek
| 11***55 | Control Group-Engine Electronic; (Engine Electronic) | 1 |
| 12***73 | Control & Mtg Group-Engine Elek; (Engine Elek) | 1 |
| 5P***70 | Nut-Hard; (M8 X 1.25) | 1 |
145-1232 Control Gp-Eng Ratings Elek
| 14***32 | Control Group-Eng Ratings Elek | 1 |
115-3055 Control Gp-Engine Electronic
| 11***55 | Control Group-Engine Electronic; (Engine Electronic) | 1 |
| 12***74 | Screw-Pan Head; (8-32x9.52-mm) | 1 |
| 21***50 | Control Group-Engine Electronic | 1 |
117-2763 Harness As-Engine
| 10***02 | Kit-Receptacle; (2-Pin)(Engine Sensor Wiring Harness) | 1 |
| 10***03 | Kit; (Receptacle) (3-Pin) (Includes Receptacle As & Wedge) | 4 |
| 11***63 | Harness As-Engine; -Electronic Control | 1 |
117-2785 Sensor Gp-Engine
| 10***40 | Sensor Group-Temperature; -Output Transfer Gear Oil | 2 |
| 10***03 | Kit; (Receptacle) (3-Pin) (Includes Receptacle As & Wedge) | 1 |
| 10***08 | Kit; (Connecting Plug) (3 Pin) (Includes Plug As And Wedge) | 1 |
129-6628 Sensor Gp-Speed -Engine Speed/Timing
| 10***13 | Seal; (3 Pin Plug) | 1 |
| 12***28 | Sensor Group-Speed; -Engine Speed/Timing | 1 |
| 15***60 | Kit-Connecting Plug; (3-Pin)(Engine Sensor Wiring Harness) | 1 |
207-1524 Starting Motor Gp-Electric
| 03***23 | Bolt; (1/4-28x1-In) | 5 |
| 20***89 | Kit-Solenoid; (12-Volt)(Starting Motor) | 1 |
| 20***24 | Starting Motor Group-Electric | 1 |
101-8936 Starting Motor Gp-Electric
| 10***36 | Starting Motor Group-Electric | 1 |
| 15***25 | Gasket | 1 |
| 20***24 | Starting Motor Group-Electric | 1 |
148-0769 Switch Gp-Pressure
| 14***69 | Switch Group-Pressure | 1 |
| 6T***52 | Switch As-Pressure; (Engine Oil) | 1 |
| 6V***49 | Seal-O-Ring (Id=11.89mm); (11.89-mm Id) | 3 |
156-9792 Wiring Gp-Electronic Control
| 11***63 | Harness As-Engine; -Electronic Control | 1 |
| 15***92 | Wiring Group-Electronic Control | 1 |
| 3S***93 | Strap-Cable-To Tie Harnesses Together | 1 |
117-2759 Wiring Gp-Electronic Control
| 11***59 | Wiring Group-Electronic Control; (Electronic Control) | 1 |
| 11***63 | Harness As-Engine; -Electronic Control | 1 |
| 3S***93 | Strap-Cable-To Tie Harnesses Together | 1 |
117-2760 Wiring Gp-Unit Injector
| 11***60 | Wiring Group-Unit Injector | 1 |
| 2V***16 | Clip; (9.52mm Id) | 4 |
| 4P***37 | Harness Assembly-Wiring; (Unit Injector) | 1 |
Engine Arrangement
148-1330 Engine Ar-Complete
| 10***36 | Starting Motor Group-Electric | 1 |
| 11***85 | Cover Group-Cylinder Block | 1 |
| 11***90 | Cooler Group-Engine Oil; (Engine Oil) | 1 |
148-0770 Engine Ar-Core
| 11***82 | Cylinder Block Group | 1 |
| 11***06 | Housing Group-Front; (Front) | 1 |
| 11***82 | Camshaft Group | 1 |
Fuel System
116-5436 Filter Gp-Fuel
| 11***36 | Filter Group-Fuel; -Secondary | 1 |
| 1R***62 | Filter As-Fuel; (Advanced Efficiency)(Secondary) | 1 |
116-5434 Fitting Gp-Fuel Lines
| 11***34 | Fitting Group-Fuel Lines | 1 |
| 11***35 | Connector | 1 |
| 3J***07 | Seal Valve Assembly To; Seal- Tube Assembly To Logic Valve | 1 |
159-0645 Fitting Gp-Fuel Return
| 15***45 | Fitting Group-Fuel Return | 1 |
| 2R***06 | Connector Valve Assembly To; Connector- Tube Assembly To Logic Valve | 1 |
| 3J***07 | Seal Valve Assembly To; Seal- Tube Assembly To Logic Valve | 1 |
117-0183 Fitting Gp-Fuel Supply
| 11***83 | Fitting Group-Fuel Supply; (Supply)(Supply) | 1 |
| 3K***60 | Seal Pilot Manifold On; Seal To Boom Check Valve Drain | 1 |
| 9X***50 | Connector-O-Ring; (O-Ring Port) | 1 |
148-0791 Lines Gp-Fuel Injection
| 11***18 | Hose As | 1 |
| 12***79 | Manifold; (Fuel) | 1 |
| 13***88 | Clip-Loop | 2 |
197-5965 Lines Gp-Fuel Injection
| 03***47 | Elbow-Filtered Fuel From Based Assembly | 1 |
| 03***62 | Elbow, Swivel Nut 45 Degrees (-6) | 1 |
| 11***04 | Hose As. | 1 |
123-0782 Plug Gp-Fuel Lines
| 12***82 | Plug Group-Fuel Lines | 1 |
| 3J***07 | Seal Valve Assembly To; Seal- Tube Assembly To Logic Valve | 1 |
| 9S***04 | Plug-O-Ring; (Straight Thread O-Ring) | 1 |
116-5428 Pump & Mtg Gp-Fuel Transfer
| 09***70 | Washer-Sealing | 2 |
| 11***17 | Tube As; (Fuel Supply) | 1 |
| 11***28 | Pump & Mtg Group-Fuel Transfer; (Fuel Transfer) | 1 |
116-5415 Pump Gp-Fuel Injection
| 11***15 | Pump Group-Fuel Injection | 1 |
| 11***84 | Seal-O-Ring; (32.99mm Id) | 1 |
| 15***01 | Bolt; (8x1.25x7-mm)(M8x1.25x70mm) | 1 |
116-5411 Pump Gp-Fuel Priming
| 10***08 | Pump As; (Fuel Priming) | 1 |
| 11***11 | Pump Group-Fuel Priming; -Hand | 1 |
| 1P***36 | Gasket; (Fuel Priming Pump)(Fuel Priming Pump) | 1 |
Lubrication System
166-1329 Base Gp-Oil Filter
| 11***45 | Valve-Pump Bypass; (Engine Oil Filter) | 1 |
| 16***28 | Base Assem. | 1 |
| 16***29 | Base Group-Oil Filter; -Engine | 1 |
122-0725 Base Gp-Oil Filter
| 11***45 | Valve-Pump Bypass; (Engine Oil Filter) | 1 |
| 12***25 | Base Group-Oil Filter; -Engine | 1 |
| 12***26 | Base As; (Oil Filter) | 1 |
117-2786 Cover Gp-Oil Filter Base
| 11***86 | Cover Group-Oil Filter Base; -Engine | 1 |
| 5S***34 | Seal-O-Ring; (97.79mm Id) | 1 |
| 7C***42 | Cover; (Filter Base) | 1 |
156-6352 Filler Gp-Engine Oil
| 06***55 | Seal-O-Ring (Id=47.22mm) | 3 |
| 15***52 | Filler Group-Engine Oil | 1 |
| 15***53 | Tube As-Oil Filler | 1 |
117-2751 Filter Gp-Engine Oil
| 11***51 | Filter Group-Engine Oil | 1 |
| 13***45 | Bolt-Hex Head; (M10x1.50x30) | 6 |
| 16***29 | Base Group-Oil Filter; -Engine | 1 |
161-6303 Gauge Gp-Oil Level (Dipstick)
| 03***28 | Clip; (31.8mm Id) | 1 |
| 13***30 | Gauge As-Oil Level; (Dipstick)(Engine) | 1 |
| 13***31 | Tube As-Gauge Guide | 1 |
129-2855 Lines Gp-Turbocharger Oil
| 11***87 | Seal-O-Ring (23.16 mm Id) | 1 |
| 11***42 | Adapter | 1 |
| 12***55 | Lines Group-Turbocharger Oil | 1 |
117-2746 Pump Gp-Engine Oil
| 06***61 | Seal-O-Ring (Id=40.87mm) | 1 |
| 11***03 | Tube Assem. | 1 |
| 11***46 | Pump Group-Engine Oil | 1 |
9y-8073 Pump Gp-Engine Oil
| 6D***46 | Seal-O-Ring (Id=101.27mm) | 1 |
| 6V***17 | Bolt; (M8x1.25x30-mm)(Location Z) | 4 |
| 9M***74 | Washer-Hard; (8.8x16x2-mm Thk)(Hard) | 4 |
Steering System
156-5783 Valve Gp-Check
| 03***33 | Seal-O-Ring; (12.42mm Id) | 1 |
| 15***83 | Valve Group-Check; -Fuel | 1 |
| 6V***23 | Ring; (Backup) (13.16mm Id) | 1 |
480 serial number reference
On these Caterpillar-badged Lexion combines the machine ID/serial plate is riveted to the main frame, typically accessed from the operator's platform/ladder area rather than a body panel. The serial reads as a 3-character alpha prefix (identifies the specific model/production block, e.g. 480 vs 480R) followed by a numeric sequence for that block. Match the prefix to the model before ordering parts - 480, 480R and 485 share a lot of common componentry and sometimes turn up bundled in the same manual set, but serial-specific parts differ between blocks.
| Prefix | Identifies | Notes |
|---|---|---|
| 7ZR | Lexion 480 (wheeled, APS drum + twin-rotor RotoPlus separation) | Earlier serial block for the Cat-badged Lexion 480, per the factory parts-manual scope (7ZR1170-Up), superseded later by the 2BZ block. Built at the Caterpillar-Claas America joint-venture plant in Omaha, Nebraska (JV formed 1997, Cat-badged production from 1999); Caterpillar exited the combine business in 2001/2002 and Claas took full ownership of the plant in 2002. Runs the Cat 3176C ATAAC engine per Caterpillar's own equipment spec sheet, rated 272 kW (365 hp) gross, roughly 10.3 L displacement. Separation is an APS threshing drum plus a twin-rotor (RotoPlus) unit, not straw walkers - the 480 replaced walkers versus earlier Lexion models, it is not the walker version relative to the 480R. |
| 2BZ | Lexion 480 (wheeled, APS drum + twin-rotor RotoPlus separation) | Main/later serial block for the Cat-badged Lexion 480 (2BZ1-Up), confirmed in the factory parts-manual scope and cross-checked against real machine listings titled Lexion 480. Same Omaha-built, Cat 3176C ATAAC configuration as the 7ZR block - treat 7ZR and 2BZ as sequential serial ranges of the same base model, not distinct configurations. |
| JAC | Lexion 480R | Cited as the serial start point in the factory parts-manual scope for the 480R (JAC1-Up, alongside an earlier non-alpha numeric block starting near 8661). The 480R is catalogued by Caterpillar as a separate model from the base 480 (separate manual, separate serial block), but the exact technical difference from the standard 480 - which already runs twin-rotor separation itself - is not clearly documented in public sources; do not assume it is a walkers-to-rotors distinction. Engine fitment varies across the 480R's production run: used-parts listings show both the Cat 3176 (10.3 L) and the larger Cat C12 (12.0 L) tied specifically to this model. Thin sourcing on the exact JAC cutoff and the precise 480-vs-480R distinction - confirm with dealer. |
Frequently asked questions
What engine powers the Caterpillar 480 combine?
Cat-badged 480 units run the Cat 3176C ATAAC, a 10.3 L inline-6 turbocharged, air-to-air aftercooled diesel rated at 365 gross hp (272 kW). The separate European Claas-branded Lexion 480 built on the same body used Mercedes-Benz power instead — don't mix parts or service specs between the two.
What is the operating weight of the Caterpillar 480?
Operating weight runs roughly 14,000-18,000 kg (30,900-39,700 lb) depending on tire, dual, or Mobil-Trac track configuration, header mounted, and grain tank load. Check the serial plate on your specific unit to confirm.
What replaced the Caterpillar 480?
The Cat-badged joint venture wound down around 2002-2003 when Caterpillar sold its stake in Claas Omaha back to Claas. The 480's platform continued as Claas-only Lexion combines, with the Lexion 500 series (built 2003-2010) as the direct successor lineage.
What 480 owners discuss
Why do some Cat 480 / Lexion 480 combines develop a pulsing or surging feel in the hydraulic controls?
Owners describe a repeating pulse or surge through the solenoid-operated hydraulic valve bank on the left side of the machine, most noticeable in header and reel response. Field diagnosis on multiple machines traced it to an intermittent electrical fault rather than a hydraulic pump or valve defect - a flow control solenoid or shaft-speed sensor input feeding false signals through the control module, not worn pump components. Chasing the wiring, sensor gaps, and control modules one at a time is the common troubleshooting path; some owners resolved it by isolating a single pin on the speed control module tied to the CAN input from the cab display. Because a stuck-energized solenoid can move a header or reel unexpectedly, have your dealer verify the fix with a full CAN diagnostic before returning the machine to field work.
What engine problems come up most with the 480's Cat 3176C ATAAC diesel?
The 3176C in the 480 is generally rated as a solid, if unspectacular, engine when maintenance is kept current - owners report 3000-plus hours with minimal repair work. Two age-related patterns show up repeatedly. Early-production 3176 blocks used an aluminum spacer between block and head that can start weeping coolant after repeated heat cycling; later production dropped that spacer. At higher hours, worn or failing cam followers can take the camshaft lobes with them, showing up first as a rough idle or a developing miss - a rebuild at that point should replace the cam and followers together rather than just the followers. Occasional coolant loss and injector cup weeping after high hours are also mentioned, consistent with any high-hour turbocharged diesel of this era. Have your dealer verify cam and follower condition with a compression or oil-analysis check before committing to a top-end rebuild.
What wears out first on a 480 with age, aside from the engine?
The rotor drive line and the cleaning shoe are the two areas owners flag most. A splined coupler between the rotor gearboxes takes the shock load of rotor start-up and slugging through wet or tangled material and wears with age - a knocking or rattling on rotor engagement is the usual tell. In the sieve and grain pan area, the rubber isolation bushings have a service life around 1500 hours regardless of how well the rest of the machine has been kept, and should be inspected as a set once a machine is well past that mark. Feeder house chain and front drum bearings are another wear point, with reports of chains jumping the sprocket as bearings and tensioners age; aftermarket chain with plastic slats has a reputation for not holding up as well as OEM-spec chain in this application.
Why does one sensor fault sometimes disable the whole machine's speed monitoring?
Most of the machine's speed sensors - feeder chain, elevators, cleaning fan, rotor, ground speed, and others - share a single fused 12-volt supply from the main panel. When one sensor circuit shorts, that fuse blows and every sensor on the circuit reports a fault at once, which reads to the operator like a total electrical failure rather than one bad sensor. The recurring root cause is chafed wire insulation inside the hard-plastic protective loom near the rotor speed sensor, where a downward bend in the harness routing lets the wires rub through with vibration over time. Tracing it means pulling the loom apart at that bend and checking for bare copper before replacing the fuse again. Because a false rotor-stopped or feeder-stopped signal can trigger an automatic shutdown mid-field, have your dealer verify the harness repair and fuse rating before extended use.
What should a buyer check before purchasing a used Cat 480?
Check both engine hours and rotor (separator) hours separately - the two numbers can diverge meaningfully depending on how much time the machine spent idling on the road or in transport versus actually threshing. Ask about crop history: machines with prior rice service may still carry heavier-duty concaves, preconcaves, and rotor grates suited to rice rather than corn or soybeans, and swapping those over is a real cost if the machine is going into row crops. Sealed bearings throughout the machine hold up well for several seasons, but owners note a machine can run clean for years and then show its age all at once as multiple bearings reach end of life together, so budget for that regardless of how good the machine looks on a walk-around. Given the belt and chain count on this platform compared with simpler competing machines, a pre-purchase inspection by an independent technician is worth the cost before agreeing on a price.
Does the 480 handle high-moisture or leafy crops like alfalfa and canola as well as newer combines?
The 480's twin-rotor separation system threshes and separates well ahead of older straw-walker designs, but its sieve cleaning airflow is lower than the jet-stream cleaning fans used on later Lexion generations. In tough or leafy material like alfalfa, that shows up as more material loading onto the sieves than a newer machine would carry, and operators running high-moisture or high-trash crops report needing rotor covers and careful fan and sieve setting to keep sample quality up. Grain tank capacity is also on the smaller side next to newer combines in its class, which owners weigh against the machine's low used-market price and strong threshing capacity in corn and soybeans.
What's the overall reputation of the 480 among long-term owners?
The consensus leans positive for a machine of its age: several owners report running one for a decade or more into the low thousands of hours with only routine wear-item replacement, and rate it as one of the more reliable combines they've owned. The tradeoff most often cited is maintenance complexity - the platform runs a noticeably higher count of belts and chains than some competing brands, so annual service and belt or chain replacement cost more in both parts and labor. Parts availability is generally described as manageable given the machine's age, aided by decent aftermarket support for the Cat engine specifically, though header and some Lexion-specific parts can take longer to source than mainstream domestic-brand combines.
Compiled from owner and technician discussions across the industry — experiences vary by serial range and machine history.
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