Description

Claas AVERO 240, AVERO 160 2015 Repair Manual

You have a Claas AVERO 240 or AVERO 160 in the shop with a fuel system issue, and the aftermarket CD you bought last year shows a torque spec for the injection pump that is flat wrong. That costs you a blown seal and a redo. This is the 2015 Repair Manual from Claas – full OEM, printed in Stuttgart, scanned at 300 DPI. 1224 pages of factory data, not a reprint of a reprint. If you work on these combine harvesters, this is the document you need on the tablet next to the oil drain pan.

Torque Settings: Over 15 Pages of Specs

Section 3 of the manual covers nothing but torque values. Tightening torques for metric standard threads, metric fine threads, hydraulic screw fittings with ferrule according to DIN 3861, sealing cone fittings, hollow screws DIN 7643, brake line fittings, worm drive hose clamps, and tyre bolts. Every value is in Nm with imperial equivalents. Page 24 starts the tables. You want the right number for the feeder housing safety lock bolts? It is in there. Need the tightening torque for an SDS hydraulic male connector? Page 30. No guesswork.

1224 Pages of OEM Data – No Generic Reprint

Most of the aftermarket “service manuals” for Claas equipment are scanned photocopies of photocopies with blurred diagrams. This file is the original Claas repair manual, Genuine repair manual as printed in 2015. The OCR excerpt shows “1443-001” and the Claas logo. Every page is legible. The table of contents runs 10 pages deep, covering the entire harvester from the diesel engine to the exhaust gas aftertreatment. You get the CCN (CLAAS Component Number) explanation – electric systems standard, hydraulic system standard – which is critical when diagnosing electrical faults using the Claas wiring codes. Manual Transmission details are also covered in the gearbox section.

Engine Overhaul: Step-by-Step from Page 50

Chapter 01 – Engine starts on page 50. Complete component removal and installation of the diesel engine (both AVERO 240 and 160 versions). Work preparation, special tool lists, technical specifications. Then engine suspension, housing, cylinder head, valves, idler gear, injection/fuel system, lubricating oil system, cooling system, exhaust, air intake, engine attachment parts, engine control, and exhaust gas aftertreatment. For example, the fuel cooler removal procedure includes the required special tool part numbers and torque sequence for the hydraulic lines. If you have ever snapped a banjo bolt because you thought 40 Nm was fine – this manual stops that.

General Repair Instructions: More Than Common Sense

The introduction dedicates 15 pages to repair basics specific to Claas equipment. Self-locking bolts: when to replace them. Liquid locking compound: which Loctite grade per application. Steel roller chains: proper tensioning and chain connector installation. Taper ring fasteners: dismounting and installing without damaging the hub. Gib head key joints, lock collar bearings, adapter sleeve bearings, chuck bushings, circlips, ferrule fittings, sealing cone fittings, hydraulic hoses (laying rules), drive belts, alternator, and spare parts identification. This section alone saves you from ordering the wrong part or using a bolt that should have been replaced.

Safety Warnings: Not Just a Formality

Page 44 starts the safety chapter. General information, hazard signs, signal words, combine-harvester specific accident prevention regulations, grain tank procedures, chopper safety, hydraulic accumulator dangers, battery isolating switch operation, feeder housing safety lock, jacking up the machine, welding work precautions. If you are a shop owner, you need this to CYA when a tech gets hurt. Every procedure in the manual references these warnings. The manual is written for technicians who know that hydraulic fluid at 300 bar can kill you. It does not treat safety as an afterthought.

Does this manual cover the AVERO 240 and AVERO 160 simultaneously?

Yes.

What is included in the torque settings section that I won’t find in a generic shop manual?

The manual lists tightening torques for hydraulic screw fittings with ferrule per DIN 3861, sealing cone and O-ring per DIN 3865, SDS and SDE hydraulic male connectors, direction-adjustable SDE connectors, swivel fittings, hollow screws DIN 7643, brake line fittings, tube structures with O-ring, worm drive hose clamps (both standard and spring-loaded), and tyre bolts. These are specific to the Claas hydraulics and brake systems used on the AVERO series. A generic manual will give you a standard M10 bolt torque, but it will not tell you the correct torque for a 24° sealing cone fitting that must be tightened to 65 Nm with a specific angle. That difference is what prevents a leak that costs you a day of downtime. Additionally, the manual includes the tightening sequence for chassis fasteners and the torque for the feeder housing safety lock – critical for safe lifting. The section runs from page 24 to page 36, covering over 20 different fitting types with both metric and imperial values. You also get tightening torques for worm drive hose clamps (page 35) which is something most aftermarket manuals skip entirely.

After you have rebuilt the injection pump using the factory procedure from page 72, and torqued every hydraulic line to the spec on page 30, you will trust the next job more. Manual Transmission removal is covered under gearbox chapter with the same level of detail. If you need manuals for other Claas equipment, check the Claas ROLLANT 66, ROLLANT 46 2002 Repair Manual – Torque Specs & Procedures or the Claas ROLLANT 250 / 250 ROTO CUT Repair Manual – 260 Pages. For larger balers, the Claas QUADRANT 3300 2012 Repair Manual – OEM Factory Specs is also available. Access the Factory Manual and keep it on your shop tablet. No more second-guessing.