Claas C490-C370 Operating instructions

C490-C370
Repair manual

44965
Pleasereadandfollowthesafetyinstructions!
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Contents
Introduction
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Using the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Validity of instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Reason of damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Welding Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Tensioning the steel roller chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Taper ring fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Gib head key joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Self-locking bolts with micro-encapsulated adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Liquid locking compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Lock collar bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Adapter sleeve bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Ferrule fittings on hydraulic lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Progressive ring fittings on hydraulic lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Taper fittings on hydraulic lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Hydraulic hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Some advice for speedy and correct repair work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Tightening torques for metric standard threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Tightening torques for metric fine threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Tightening torques for hydraulic screw fittings with ferrule according to DIN 3861 . . . . . . . . . . . . . . . 21
Tightening torques for hydraulic screw fittings and air conditioner fittings
with a sealing cone and O-ring DIN 3865 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Tightening torques for hydraulic male connector DIN 3901 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Tightening torques for direction-adjustable hydraulic male connectors
ISO 6149-2 / ISO 11926-2 (3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Tightening torque for hydraulic swivelling screw fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Tightening torques for hollow screws DIN 7643 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Tightening torques of brake line screw fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Tightening torques for screw thread clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
CCN explanations
CCN (CLAAS Component Number) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Electric system standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Hydraulic system standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
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Safety precautions
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Important notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Identification of warning and danger signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
General safety and accident prevention regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Front attachments and trailers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Adjustment and maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Danger of injury due to escaping hydraulic liquid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
First aid measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Jack up the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Putting the machine out of action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
02 Gearbox / Clutch / Universal drive shaft
02 60 Universal drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Removing and disassembling the universal drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Universal drive shaft overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Assembling and installing the universal drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
08 Drives
08 00 Drive diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Drive diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
08 14 Intermediate drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Removing the intermediate drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Intermediate drive shaft - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Installing the intermediate drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
09 Hydraulic system
09 15 Hydraulic lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Overview of front attachment multi-coupler (8011) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
09 20 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Overview of reel adjustment valve block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
09 20 Special tools for valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Pulling out the valve insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Screwing out the iron core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Dismounting the seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
20 Crop feeding
20 15 Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Removing the reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Installing the reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Removing the reel shaft bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Overview of reel shaft bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Installing the reel shaft bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Overview of reel speed sensor (B017) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Overview of vertical reel position sensor (B039) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Removing the left reel support arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Installing the left reel support arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Removing the right reel support arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Installing the right reel support arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
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Removing the right reel spider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Overview of right reel spider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Installing the right reel spider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Removing the centre reel spider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Overview of centre reel spider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Installing the centre reel spider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Removing the left reel spider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Overview of left reel spider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Installing the left reel spider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Removing the control spider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Overview of control spider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Installing the control spider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Removing the reel tine tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Installing the reel tine tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Removing the reel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Overview of reel drive chain (K9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Installing the reel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Overview of drive sprocket chain (K9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Overview of driven sprocket of chain (K9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Removing the hydraulic fore and aft reel adjustment hydraulic cylinder (3016) . . . . . . . . . . . . . . . . . 86
Overview of hydraulic fore and aft reel adjustment hydraulic cylinder (3016) . . . . . . . . . . . . . . . . . . . 87
Installing the hydraulic fore and aft reel adjustment hydraulic cylinder (3016) . . . . . . . . . . . . . . . . . . 88
Removing the left reel height adjustment hydraulic cylinder (3015) . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Overview of left reel height adjustment hydraulic cylinder (3015) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Installing the left reel height adjustment hydraulic cylinder (3015) . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Removing the right reel height adjustment hydraulic cylinder (3014) . . . . . . . . . . . . . . . . . . . . . . . . . 92
Overview of right reel height adjustment hydraulic cylinder (3014) . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Installing the right reel height adjustment hydraulic cylinder (3014) . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Removing the hydraulic reel drive motor (2012) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Overview of reel drive hydraulic motor (2012) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Installing the hydraulic reel drive motor (2012) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
21 Feeder unit
21 40 Feed roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Removing the feed roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Installing the feed roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Removing the left feed roller bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Overview of left feed roller bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Installing the left feed roller bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Removing the right feed roller bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Installing the right feed roller bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Removing the adjusting shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Overview of adjusting shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Installing the adjusting shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Removing the control shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Overview of control shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Installing the control shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
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Overview of feed roller drive chain (K6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
Removing the driven sprocket of chain (K6) along with the slip clutch . . . . . . . . . . . . . . . . . . . . . . . .117
Overview of driven sprocket of chain (K6) with slip clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
Installing the driven sprocket of chain (K6) along with the slip clutch . . . . . . . . . . . . . . . . . . . . . . . . 120
21 40 Feed roller special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Removing / installing the feed roller bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Removing / installing the driven sprocket of chain (K6) along with the slip clutch . . . . . . . . . . . . . . 123
23 Mower unit
23 05 Mower head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Removing and disassembling the wobble transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Overview of wobble transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Assembling and installing the wobble transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Overview of knife drive belt (R1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Overview of jockey pulley belt (R1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Overview of guide roller of belt (R1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Removing the driven pulley of belt (R1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Overview of driven pulley of belt (R1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Installing the driven pulley of belt (R1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
21 23 Mower unit special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Disassembling / assembling the wobble transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Installing the guide roller of belt (R1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
26 Ground guidance
26 05 AUTO CONTOUR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Overview of AUTO CONTOUR sensor band sensors (B003 / B004) . . . . . . . . . . . . . . . . . . . . . . . . 145
80 Various components / machine body
80 10 Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Removing the front attachment lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Overview of front attachment lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Installing the front attachment lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
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00 0290 395 0 - RHB C 490-C 370 - 03/09 7
1 Introduction
General Information
44966
Introduction
General Information
87193
Using the manual
This repair manual should help you to maintain ongo-
ing operational capacity. The high value of the
harvesting machine is ensured through careful mainte-
nance and technical monitoring by customer service.
This repair manual is a compilation of our service tech-
nicians' and shop-floor experience.
The image sequence demonstrates the steps in a
repair procedure. The text provides you with the infor-
mation required for making adjustments, using special
tools and further similar information.
Essential repairs are listed in such a way that even
individual and small repairs can be easily found and
followed.
Supplements are added to reflect the ongoing techni-
cal development of the machines and the manual is
thereby continuously being updated as a reference
book.
As a precaution, always compare the setting values
and fill quantities with the most recent operator's man-
ual for the respective machine.
Texts and figures
Pictures and graphics are neutral. Differences are
pointed out by notes beneath the figure.
Texts are short and not machine-specific as far as pos-
sible. Differences are pointed out by intermediate
headings.
Different types of texts can easily be distinguished
from one another by their formats. The following for-
mats are distinguished:
Formatting Meaning Description
Description Text Further information on the subject.
– Instructions Operation Operations which must be carried out one after the
other.
Result Result Consequence of operations carried out.
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8 00 0290 395 0 - RHB C 490-C 370 - 03/09
1 Introduction
General Information
44966
References can easily be distinguished by suitable
symbols. The following symbols are distinguished:
Document structure based on subassemblies
As far as the contents permit, the chapters of this man-
ual are structured according to subassemblies. The
structure of these subassemblies is the same in all
chapters.
Different product groups have different document
structures based on subassemblies. CLAAS always
takes care to keep these document structures based
on subassemblies identical in any documents.
Search and find
The wanted subject can easily be found with the recur-
ring subassembly structure, using the table of contents
or the header line of this manual.
In addition, the index of this manual is a useful tool for
locating a specific subject. The index can be found on
the last pages of this manual.
Directions
Text elements such as front, rear, right and left always
apply to the direction of travel. In figures, the direction
of travel may be indicated by a direction arrow.
Your CLAAS Service Department
Symbol Meaning Description
See index The symbol points out that further information on
this subject-matter can be found in another section of
this manual.
See index of the relevant
Operator's manual
The symbol points out that further information on
this subject-matter can be found in the Operator's
manual of the machine or the implement in question.
See index of the relevant
Technical Systems
documentation
The symbol points out that further information on
this subject-matter can be found in the Technical
Systems documentation of the machine or the imple-
ment in question.
See index of the relevant
repair manual
The symbol points out that further information on
this subject-matter can be found in the repair manual
of the machine or the implement in question.
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00 0290 395 0 - RHB C 490-C 370 - 03/09 9
1 Introduction
General Information
44966
39101
Validity of instructions
The present Manual applies to the following machine /
front attachment:
Designation Type Serial number
from to
C490
C430
C370
527 52700011 ―
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10 00 0290 395 0 - RHB C 490-C 370 - 03/09
1 Introduction
General repair instructions
44966
General repair instructions
2475
Specifications
Technical data, dimensions and weights are given as
an indication only. CLAAS reserves the right to make
changes subsequently as technical developments con-
tinue. Responsibility for errors or omissions not
accepted.
14015
Reason of damage
Identify reason of damage, limit the case of damage
and safeguard the machine.
67982
Spare parts
Use original CLAAS spare parts and the appropriate
special tools.
With all spare part orders and technical questions,
please provide the machine number of the forage har-
vester as well as the corresponding serial numbers for
the diesel engine and the implements. This is required
as otherwise it may result in a delivery of incorrect
spare parts.
Only use original CLAAS spare parts, accessories and
ancillary equipment that have been tested and
approved by CLAAS. This is the only way to ensure
that the design-related characteristics of the harvest-
ing machine as well as its functional efficiency are
maintained. In addition, original CLAAS parts maintain
the active and / or passive driving safety as well as
occupational safety of the machine.
CLAAS is not subject to any liability for damages inso-
far as they were caused through the use of non-
genuine CLAAS parts, CLAAS accessories and
CLAAS ancillary equipment.
14021
Gearboxes
When removing the gearboxes, always drain the gear-
box oil first and then remove the gearbox. Separate
parts which are firmly connected with each other by
means of a soft metal-tip or plastic-tip hammer.
14045
Welding Work
Note!
All information regarding this subject-matter
can be found in the current Operator's manual
of the machine.
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00 0290 395 0 - RHB C 490-C 370 - 03/09 11
1 Introduction
General repair instructions
44966
14025
Tensioning the steel roller chains
Find the centre point in the slack span between
sprockets. With the tight span slightly under load,
push in the centre point of the slack span with the
thumb. The chain tension is correct when its slack
span deflects about 2% of the centre distance
between shafts. Check chain tension more frequently
when using new chains.
Example: Distance between shafts 500 mm = Deflec-
tion of slack span is roughly 10 mm.
14027
Taper ring fasteners
Even when transmitting high forces from the drive ele-
ment to the shaft and vice versa, taper ring
fasteners are a safe joint when properly pre-loaded.
The important point for assembly is that the shaft, hub,
parallel key and tapered rings are thoroughly cleaned,
some semi-fluid lubricant of NLGI class 00, e.g.
CLAAS AGRIGREASE LC 00 / 000, is applied and
tightening is to the specified torque and in the correct
sequence of assembly.
Disassembly:
After loosening the axial clamping, loosen the taper
ring fastener with a sharp blow, using a block-ended
tube.
85677
Gib head key joints
Prior to installation, the shaft, the hub and the keyway
must be cleaned so they are free of grease, paint and
rust.
When delivered as a spare part, the gib head key is in
its raw condition, it is therefore too high and would
stick out too far after arresting it. Consequently the gib
head key must be matched to the component in ques-
tion by milling or grinding of the bottom face so that it
will not stick out more than necessary after arresting,
but can still be dismounted perfectly using the CLAAS
special tools (straight or cranked key extractor). The
conical top face must not be machined. Treatment
with a file is not recommended.
Warning!
Gluing on taper ring fasteners.
–No solid grease must be used when
assembling the parts.
Warning!
Damage to the taper ring fastener.
– The inside diameter of the block-ended
tube must be large enough to extend over
the tapered ring.

12 00 0290 395 0 - RHB C 490-C 370 - 03/09
1 Introduction
General repair instructions
44966
Never use force for arresting the gib head key in order
to avoid damage to the components (especially the
brake discs) and to enable loosening with the CLAAS
special tool.
14029
Self-locking bolts with micro-encapsulated
adhesive
Replace self-locking bolts, e.g. Verbus-Plus / Imbus-
Plus upon each assembly. In exceptional cases, they
may be reused up to three times.
Always tighten self-locking bolts with microencapsu-
lated adhesive rapidly to the specified tightening
torque.
Always observe the specified tightening torque.
When removing self-locking bolts, quickly unscrew
them completely. Self-locking bolts must never get in
contact with sealing compound.
Self-locking bolts with microencapsulated adhesive
may be used only where operating temperatures will
not exceed + 90 °C max.
These bolts can be subjected to full stress after
24 hours at +20°C. The complete curing period can
be shortened by heating, e.g. to 15 minutes at +70°C.
In individual cases, bolts with liquid locking compound
can be used instead of self-locking bolts only where
these bolts can be heated up to approx. 200 °C for
removing them. Comply with the specified quality
grade of bolts, e.g. 8.8 or 10.9 here as well.
14031
Liquid locking compound
Use liquid locking compound only where specified
by the manufacturer.
Correct application:
Metal surfaces where liquid locking compound is to
be applied must be absolutely free from grease.
Use the "Activator" included in the workshop package
for cleaning.
Before applying the liquid locking compound, the acti-
vator, i.e. the cleaning agent on the metal surfaces
must have dried. Especially in blind holes, no activator
residues are allowed.
Caution!
Damage to the gib head key joint.
– Arrest the gib head key with a suitable
hammer that is not too heavy and with the
right touch.

00 0290 395 0 - RHB C 490-C 370 - 03/09 13
1 Introduction
General repair instructions
44966
In threaded assemblies, apply the liquid locking com-
pound only to the internal thread of the nut in drops if
possible. In blind holes only wet approx. 1d (d = nomi-
nal Ø of bolt) at the thread bottom. The same applies
to any extra-long female threads. When applying the
liquid locking compound to the bolt or at the top end of
a female thread, the liquid locking compound will
spread over the entire thread length when screwing
the bolt in. As a result, too much break-away torque is
required to remove the bolt – Danger of breaking!
Threaded assemblies secured with liquid locking com-
pound can be easily unscrewed by heating them up to
approx. 200 °C.
14033
Lock collar bearing
Lock collar bearings are arrested on the shaft by twist-
ing the eccentric ring over the inside bearing race.
Before inserting, it is useful to apply some semi-fluid
lubricant of NLGI class 00, e.g.
CLAAS AGRIGREASE LC 00 / 000 to the inner race
and the shaft to enable easier dismounting of bearings
at a later date.
Always arrest the eccentric ring moderately in direction
of rotation of the shaft and lock it with a set screw. To
loosen the bearing, drive off the eccentric ring against
the sense of rotation of the shaft.
14035
Adapter sleeve bearing
Adapter sleeve bearings do not require a specially
machined bearing seat. They may be mounted on any
drawn or scalped shaft. This is an advantage because
it allows the shaft to be axially moved as required to
obtain correct alignment.
Always install adapter sleeve bearings according to
the conical inside ring. Clean the taper lock adapter
sleeve and the shaft and check that the sleeve nut
runs easily so the taper lock adapter sleeve will not
turn on the shaft when tightening.
Tightening the bearing:
First tighten the sleeve nut to the point where the taper
lock adapter sleeve has no more play and is under
slight preload. Now tighten the nut by approx. 90° and
continue turning until the next nearest slot fits the tab.
Secure sleeve nut with the tab.
Loosening the bearing:
Loosen the unlocked sleeve nut only by a few turns for
the time being. The thread must still carry the full load.
Loosen the taper lock adapter sleeve with a sharp
blow, using a block-ended tube.

14 00 0290 395 0 - RHB C 490-C 370 - 03/09
1 Introduction
General repair instructions
44966
14037
Ferrule fittings on hydraulic lines
When pre-assembling the unit and for pre-assembled
factory-delivered ferrule fittings, the following applies:
installation is in the associated, well-oiled threaded
joint with half a turn of the union nut beyond the point
where resistance is felt.
Pre-assembly:
– Cut off the tube at right angles.
Do not use a pipe cutter! This will slant the tube
wall, causing heavy inside and outside burrs.
– Slightly deburr the inside and outside tube ends.
Do not chamfer!
– Clean the tube end.
In case of tube bends, the straight tube end up to
where the bending radius starts must be at least twice
the height of the union nut.
– Push the union nut and the ferrule on the tube.
– Push the tube against the stop in the union and
tighten the union nut until the ferrule catches the
tube.
The tube must not rotate. This point can be felt
because increased power is needed from here.
– Tighten the union nut half a turn beyond the point
where resistance is felt.
– Check the cut produced by the cutting edge.
A visible collar must fill up the space ahead of the
ferrule face. The ferrule may rotate, but axial dis-
placement must not be possible.
Final assembly
– Insert the pre-assembled tube into the well-oiled
screw fitting.
– Tighten the union nut until considerably more
force is needed.
– Then add another half a turn.
Repeated assembly
– Every time the ferrule fitting has been loosened,
retighten the union nut without using increased
force.
Ferrule fitting leaks
– If a fitting leaks, first loosen the union nut until
some oil escapes.
– Then tighten the union nut as specified.
14039
Progressive ring fittings on hydraulic lines
When pre-assembling the unit and for pre-assembled
factory-delivered profiled ring fittings, the following
applies: installation is in the associated, well-oiled
threaded joint with half a turn of the union nut beyond
the point where resistance is clearly felt.

00 0290 395 0 - RHB C 490-C 370 - 03/09 15
1 Introduction
General repair instructions
44966
Pre-assembly
– Cut off the tube at right angles.
Do not use a pipe cutter! This will slant the tube
wall, causing heavy inside and outside burrs.
– Slightly deburr the inside and outside tube ends.
Do not chamfer!
– Clean the tube end.
In case of tube bends, the straight tube end up to
where the bending radius starts must be at least twice
the height of the union nut.
– Push the union nut and the profiled ring on
the tube.
– Push the tube against the stop in the union and
tighten the union nut until the profiled ring catches
the tube.
The tube must not rotate.
This point can be felt because increased power is
needed from here.
– Tighten the union nut half a turn beyond the point
where resistance is felt.
– Check the cut produced by the cutting edge:
A visible collar must fill up the space ahead of the
profiled ring face. The profiled ring may rotate, but
axial displacement must not be possible.
Final assembly
– Insert the pre-assembled tube into the well-oiled
screw fitting.
– Tighten the union nut until considerably more
force is needed and then add another half a turn.
Important: Back up the threaded joint with
a spanner!
Repeated assembly
– Every time the profiled ring fitting has been loos-
ened, retighten the union nut until resistance is
felt and then continue for half a turn beyond that
point.
Important: Back up the threaded joint with
a spanner!
Profiled ring fitting leaks
If a fitting leaks, first loosen the union nut until some oil
escapes and then tighten it as specified.
Any deviating tightening torques reduce the rated
pressure resistance and the service life of the screw
fitting. This results in leaks and the tube slipping out.

16 00 0290 395 0 - RHB C 490-C 370 - 03/09
1 Introduction
General repair instructions
44966
14041
Taper fittings on hydraulic lines
Installation:
– Oil the O-ring on the sealing cone. Tighten the
union nut a third of a turn beyond the point where
resistance is felt.
Important: Back up the threaded joint with
a spanner!
Any deviating tightening torques reduce the rated
pressure resistance and the service life of the screw
fitting. This results in leaks and the tube slipping out.
49921
Hydraulic hoses
Hydraulic fittings:
Observe the final assembly instructions:
– For ferrule fittings on hydraulic lines see above.
For progressive ring screw fittings on hydraulic
lines see above. For sealing cone screw fittings on
hydraulic lines see above.
Laying the hoses:
Observe the information provided with the five figures
below.
– Avoid twisting the hoses during installation.
A = incorrect installation
B = correct installation
– Hoses must be installed in such a way that neither
tensile loads will occur in any operating condition
nor compression loads on short hose lines.
C = incorrect installation
D = correct installation
– As a guideline, the total play of the hose should be
1 cm min. when moving the hose back and forth in
the middle between two holders/connectors
(e.g. clamps).
1
5728
2
5727
Warning!
Hoses laid in a straight line become shorter
due to the internal hydraulic pressure.
Fittings may be torn out.
– Always install hoses with a slight sag.
Even in static positions.

00 0290 395 0 - RHB C 490-C 370 - 03/09 17
1 Introduction
General repair instructions
44966
Avoiding external damage:
– Avoid external mechanical effects on hoses
at (G).
– Avoid chafing of hoses against one another or
against components by ensuring useful arrange-
ment and fixing.
– Keep a sufficient clearance from components (H).
– Cover up sharp-edged components permanently.
E = incorrect installation
F = correct installation
Avoiding torsional loads:
– When connecting a hose to moving parts, avoid
twisting the hose, especially when the movement
and the bending occur in the same plane.
K = incorrect installation
L = correct installation
Protection against external temperature effects:
– When major external temperature effects occur,
install hoses at a sufficient distance from heat-
emitting components.
– Or protect hose by a shielding (N).
3
5726
4
5729
5
5730

18 00 0290 395 0 - RHB C 490-C 370 - 03/09
1 Introduction
General repair instructions
44966
14047
Some advice for speedy and correct repair
work
– Mark machine parts prior to disassembly to
ensure their correct left-to-right positions and bal-
ance when reassembled.
– Fit expansion pins with the slot facing the side
under load. When fitted with a quarter turn from
this position, they will get loose, fall out or shear
off.
– Replace split pins, locking wires, locking plates,
tab washers and lock washers when carrying out
repairs.
– Install greasable ball and sliding bearings with the
grease specified for them.
– Align sprockets and V-belt pulleys toward each
other.
– Care for strict cleanliness when working on
hydraulic systems.
– Never mix different oil types.
– Run the machine or operate machine assemblies
at low speed after any repair.

00 0290 395 0 - RHB C 490-C 370 - 03/09 19
1 Introduction
Torque settings
44966
Torque settings
14049
Tightening torques for metric standard
threads
The tightening torques specified below apply only if:
– a coefficient of friction of µ tot = 0.14 is reached in
connection with thread grease.
To achieve this, surface protection such as
A3C+L, Dacromet or Termosil is recommended.
– no other tightening torque is specified in the
descriptive text.
– no additional screw locking such as microencap-
sulated bolts or liquid locking compound is used.
Tightening torque in Nm for a coefficient of friction
µ tot = 0.14
Bolts and nuts
Property class 8.8 10.9 12.9
Dimensions
Hex. bolts
ISO 4014 to ISO 4018
Cheese-head screws
ISO 4762
Hex. nuts
ISO 4032
M 4 2.9 4.3 5
M5 5.8 8.5 10
M 6 10 14.5 17
M8 24.5 36 42
M 10 48.5 71 83.5
M 12 83.5 123 144
M 14 133 196 229
M 16 207 304 355
M 18 296 422 494
M 20 417 594 695
M 22 570 813 951
M 24 718 1022 1196
M 27 1058 1506 1763
M 30 1437 2046 2395
M 33 1944 2770 3240
M 36 2500 3561 4167
M 39 3237 4610 5394

20 00 0290 395 0 - RHB C 490-C 370 - 03/09
1 Introduction
Torque settings
44966
14051
Tightening torques for metric fine threads
The tightening torques specified below apply only if:
– a coefficient of friction of µ tot = 0.14 is reached in
connection with thread grease.
To achieve this, surface protection such as
A3C+L, Dacromet or Termosil is recommended.
– no other tightening torque is specified in the
descriptive text.
– no additional screw locking such as microencap-
sulated bolts or liquid locking compound is used.
Tightening torque in Nm for a coefficient of friction
µ tot = 0.14
Bolts and nuts
Property class 8.8 10.9 12.9
Dimensions
Hex. bolts
ISO 8765, ISO 8876
Hex. nuts
ISO 4032
M8x1 2638.545
M 10 x 1 54 79 92.5
M 10 x 1.25 51 74.5 88
M 12 x 1.25 90.5 134 156
M 12 x 1.5 87 128 150
M 14 x 1.5 143 210 246
M 16 x 1.5 219 323 378
M 18 x 1.5 331 470 551
M 18 x 2 313 446 522
M 20 x 1.5 459 655 766
M 22 x 1.5 622 886 1037
M 24 x 1.5 809 1152 1348
M 24 x 2 778 1108 1297
M 27 x 1.5 1173 1672 1956
M 27 x 2 1135 1617 1892
M 30 x 2 1580 2251 2634
M 33 x 2 2116 3015 3528
M 36 x 2 2773 3951 4623
M 39 x 2 3557 5067 5930