Claas CROP TIGER 40 WHEEL User manual

CROP TIGER 40 WHEEL
Operator's Manual

787-001
OriginalOperator'sManual
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787-001
TABLE OF CONTENTS
1 To this operator's manual
1.1 Notes on the manual...................................................................................................................... 5
2Safety
2.1 Safety rules..................................................................................................................................... 8
2.2 Safety decals on the machine....................................................................................................... 20
2.3 Safety devices ................................................................................................................................ 29
3 Machine description
3.1 Overview and method of operation .............................................................................................. 33
3.2 Identification plates and vehicle identification number ............................................................. 41
4 Operating and control elements
4.1 Cab / Operator's platform .............................................................................................................. 44
5 Technical specifications
5.1 CROP TIGER 40 - type 406 ............................................................................................................ 49
6 Machine preparation
6.1 Shutting down and securing the machine................................................................................... 58
6.2 Prior to operation ........................................................................................................................... 59
6.3 Adjusting the machine................................................................................................................... 61
6.4 Loading the machine ..................................................................................................................... 65
6.5 Front attachment............................................................................................................................ 66
6.6 Engine ............................................................................................................................................. 73
6.7 Chassis............................................................................................................................................ 75
6.8 Brake ............................................................................................................................................... 76
6.9 Hitch ................................................................................................................................................ 78
6.10 Electrical / Electronic equipment.................................................................................................. 84
6.11 Feeder unit...................................................................................................................................... 85
6.12 Threshing mechanism ................................................................................................................... 86
6.13 Cleaning system............................................................................................................................. 94
6.14 Grain delivery ................................................................................................................................. 96
6.15 Various components / Machine body...........................................................................................99
7 Operation
7.1 Driving the machine....................................................................................................................... 100
7.2 Engine ............................................................................................................................................. 107
7.3 Chassis............................................................................................................................................ 110
7.4 Grain harvest .................................................................................................................................. 113
7.5 Brake ............................................................................................................................................... 113
7.6 Steering........................................................................................................................................... 118
7.7 Cab / Operator's platform .............................................................................................................. 119
7.8 Mower unit ...................................................................................................................................... 121
7.9 Crop feeding ................................................................................................................................... 124
7.10 Feeder unit...................................................................................................................................... 129
7.11 Threshing mechanism ................................................................................................................... 131
7.12 Cleaning system............................................................................................................................. 148
7.13 Grain delivery ................................................................................................................................. 152
7.14 Loading the front attachment........................................................................................................ 154
8 Faults and remedies
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787-001
8.1 Engine............................................................................................................................................. 158
8.2 Electrical / Electronic equipment ................................................................................................. 164
8.3 Front attachment ........................................................................................................................... 166
8.4 Feeder unit ..................................................................................................................................... 168
8.5 Threshing mechanism................................................................................................................... 169
8.6 Separation ...................................................................................................................................... 171
8.7 Cleaning system............................................................................................................................ 172
8.8 Grain delivery................................................................................................................................. 173
9 Maintenance
9.1 General Information....................................................................................................................... 175
9.2 Operating utilities.......................................................................................................................... 186
9.3 Service intervals............................................................................................................................ 188
9.4 Engine............................................................................................................................................. 192
9.5 Chassis........................................................................................................................................... 207
9.6 Brake............................................................................................................................................... 214
9.7 Drives.............................................................................................................................................. 215
9.8 Hydraulic system........................................................................................................................... 254
9.9 Electrical / Electronic equipment ................................................................................................. 258
9.10 Feeder unit ..................................................................................................................................... 259
9.11 Grain delivery................................................................................................................................. 261
9.12 Various components / Machine body .......................................................................................... 264
9.13 Lubrication chart ........................................................................................................................... 270
10 Placing out of operation and disposal
10.1 General Information....................................................................................................................... 275
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1 To this operator's manual
1.1 Notes on the manual
787-001
1 To this operator's manual
1.1 Notes on the manual
152771-001
1.1.1 Validity of manual
This manual applies to machine / Cutter Bar / Trailer:
152772-001
1.1.2 How to use the Manual
This operator's manual is the original operator's
manual. It is simply referred to as the operator's
manual in the following text.
This operator's manual is intended for all users, and
provides information about the use, operation,
adjustment, maintenance, cleaning and transportation
of the machine.
Provided all instructions regarding proper maintenance
and operation of your machine are followed, you can
count on many years of reliable service.
Omitted maintenance items or erroneous operation will
result in an increased safety risk, premature wear,
reduced performance, less revenue and loss of time.
Have the post harvest check regularly /annual check
carried out by your specialist CLAAS workshop at
regular intervals. A combination of the prescribed
maintenance operations and the post harvest check is
recommended.
If you use the latest expertise and years of experience
that went into this machine, it will render you
consistently excellent service.
Text and figures
Photos and graphics have been kept neutral. Notes
beneath the figure will draw your attention to any
differences.
Text is kept as short and neutral as possible.
Subheadings will draw your attention to any
differences.
Text types can be easily distinguished from each other
by corresponding formatting. The following format
types are distinguished:
Designation Type Serial number
From To
CROP TIGER 40 Wheel Domestic 406 406 00001 ―
CROP TIGER 40 Wheel Export 406 406 50001 ―
CUTTER BAR 458 458 10001 458 19999
TRANSPORT TRAILER 459 459 10001 459 19999
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1 To this operator's manual
1.1 Notes on the manual
787-001
References can be easily distinguished from each
other by corresponding symbols. The following
symbols are distinguished:
Layout with assembly group structure
The chapters of this manual are structured into
assembly groups, to the extent that the content allows
this. The structure of these assembly groups is the
same in all chapters.
Different product groups have different assembly
group structures. CLAAS always endeavours to keep
these assembly group structures the same in all
documents.
Search and find
With the help of the recurring assembly group
structure, it is easy to find the corresponding subject
via the table of contents or the header of this manual.
In addition, the manual's index is a useful tool for
finding topics. The index is at the end of the manual.
Direction information
Text information such as front, back, right and left
applies in the direction of travel. In figures, the
direction of travel is indicated by a direction of travel
arrow.
Optional and additional equipment
Optional equipment means variants of components
fitted to a machine where different versions are
available, but only one version can be installed.
Additional equipment means variants of the machine
that can be additionally fitted, but do not reflect the
standard series components of the machine.
Both terms designate possible variants. Components
fitted as series components and equipment variants
may vary in different countries.
Your CLAAS service department
Formatting Meaning Description
Description Descriptive text Further information on the subject.
– Procedure
instructions
Process Processes to be carried out one after the other.
Result Result Result of the processes carried out.
Symbol Meaning Description
See index The symbol indicates that further information on
this subject is available in other sections of this
manual.
See the index of the
Operator's Manual in
question
The symbol indicates that further information on
this subject is available in the Operator's Manual of
the machine or of the implement in question.
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1 To this operator's manual
1.1 Notes on the manual
787-001
152773-001
1.1.3 Symbols and notes
152774-001
1.1.4 Technical data
Technical specifications, dimensions and weights are
non-binding. Changes reflecting the technical
development and errors reserved.
Symbol Meaning
Warnings to be absolutely observed.
Information regarding economical machine use.
Information regarding environmental protection.
Reference to page or documentation containing further information.
* Optional machine equipment.
– Instruction
Apply multi-purpose grease to grease points.
Apply lubricating oil to lubrication points.
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2 Safety
2.1 Safety rules
787-001
2 Safety
2.1 Safety rules
152775-001
2.1.1 General safety warnings
Procedure instructions point to the following general
warnings in the following sections of this chapter.
168-001
863-001
152776-001
2.1.2 General instructions
Read and follow the Operator's Manual and the safety
instructions prior to putting the machine into operation!
152777-001
2.1.3 Important!
The instructions in this operator's manual must be read
and observed, in order to prevent danger to all persons
who operate, maintain, repair and inspect this CLAAS
product.
Please read, in particular, the sections “Safety rules”,
“Before putting into initial operation” and “Before every
operation” in the machine operator's manual.
DANGER!
Always stop the engine before carrying out
any work on the machine.
Moving machine parts and / or unexpected
machine movement.
Death or serious injury.
– Diesel engine OFF.
– Apply parking brake.
– Remove the ignition key.
– Remove key of battery isolating switch.
– Wait for machine parts which run on have
come to a complete halt.
– Secure machine by wheel chocks.
– Ensure that the machine cannot be
started by any third persons.
DANGER!
The front attachment, reel and feeder unit may
drop uncontrolled.
Death or serious injuries!
– Apply safety locks.
– Keep a safe distance from the hazard
area.
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2 Safety
2.1 Safety rules
787-001
The use of spare parts, accessories and ancillary
equipment not originally manufactured by CLAAS and
not checked and approved by CLAAS may change the
specified design characteristics of the CLAAS machine
or may detract from its functional performance, with a
possible adverse effect on the active and/or passive
operational safety of the machine and its occupational
safety standards (accident prevention).
CLAAS is in no way liable for any damage caused
through the use of parts, accessories and ancillary
equipment other than genuine CLAAS parts.
152778-001
2.1.4 Intended use
The CLAAS combine harvester is designed exclusively
for professional use in line with the recognised
regulations of agricultural practices in agricultural
harvesting of grain.
The combine harvester is a self-propelled harvesting
machine with a fitted front attachment (machine),
which is approved by the manufacturer, and is suitable
and intended for harvesting grain in fields during
travel. Grain here refers to cultivated cereal and
legume crops such as wheat, barley, rice, rape seed,
maize, durra, soya beans and sunflowers.
The combine harvester takes the grain from the front
attachment and conveys it via a conveying unit to the
threshing and separating units. There, the grains are
separated from straw and chaff. The straw and chaff
are deposited on the field using the distribution units
behind the combine harvester. The grain is stored
temporarily in the combine harvester's grain tank and
then loaded on a transport vehicle by a conveying unit.
When the combine harvester is driven on public roads,
a front attachment approved by the manufacturer can
be fitted on the front, depending on the applicable
regulations, and driven with the combine harvester, or
a trailer approved by the manufacturer that is loaded
with the front attachment can be coupled to the trailer
hitch and towed.
The machine may only be used, maintained and
serviced by persons who are familiar with the machine
and briefed on the hazards that may arise as a result
of the machine's functions.
Compliance with the conditions of operation,
maintenance and servicing as specified in the
operator's manual and by the manufacturer also
constitute essential elements for the intended use.
The relevant accident prevention regulations, all other
generally recognised regulations on safety and
occupational medicine and the road traffic regulations
must be observed by users and owners at all times.
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2 Safety
2.1 Safety rules
787-001
Any use other than this is considered "unintended",
and the manufacturer is not liable for any resulting
damage. All liability in this case is borne by the user.
For specific details, you may request information on
intended use in exceptional situations from CLAAS.
152779-001
2.1.5 Reasonably foreseeable misuse
Any use outside of the intended use is a use not
planned by the machine manufacturer and therefore
represents a misuse in the sense of the Machinery
Directive. The manufacturer accepts no liability for
damage resulting from this. All liability is borne by the
user.
Misuse of the CLAAS combine harvester includes:
• Use of areas and premises that are not described
in the operator's manual as workplaces
• Performance of adjustment work, cleaning work
and maintenance work against the specifications
in the Operator's Manual
• Performance of fault elimination and servicing
work with drives and/or the diesel engine running
• Non-observance of warning signs on the machine
and in the operator's manual
• Performance of servicing and repair work by
untrained personnel
• Unauthorised modifications to the machine
• Attachment of non-approved additional equipment
• Use of non-original CLAAS spare parts
• Use in a stationary position
• Use to harvest goods that are not classified as
grain
• Use as a carrier vehicle for units not approved by
the manufacturer
• Use as a general towing vehicle / carrier vehicle
• Use for compacting goods and subsurfaces
• People transport
• Goods transport
152781-001
2.1.6 Safety and accident prevention
regulations for combine-harvesters
• Never stand in the slewing range of the unloading
auger tube while the engine is running.
Instruct other persons, too, to leave this area!
152782-001
2.1.7 Prior to putting into operation, general
• Observe the permitted axle loads and the total
weight!
• Before driving off and starting work, adjust the
mirrors so that they enable full view of the road
and of the working area behind the machine!
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2 Safety
2.1 Safety rules
787-001
• Check the brake function and the brake fluid level
at regular intervals every time before driving off!
Use only the specified brake fluid and change it as
specified!
Be careful when handling brake fluid.
Toxic and corrosive!
- Dispose brake fluid properly!
• During road travel, the brake pedals must be
coupled with one another.
• Check the specified tyre pressure of the drive and
rear axle tyres every time before driving off.
152783-001
2.1.8 Identification of warning and danger
signs
In this Operator's Manual, we have marked all points
concerning your safety and the safety of the front
attachment or of the machine with the symbols below.
Please pass all safety precautions on to other users as
well.
9-001
11-001
13-001
16-001
DANGER!
Nature and source of danger
Consequences: death or serious injury
– Countermeasures
WARNING!
Nature and source of danger
Consequences: injuries
– Countermeasures
CAUTION!
Nature and source of danger
Consequences: material damage
– Countermeasures
Note!
Nature and source of information
Consequences: enhanced machine economy
or easy assembly
– Measures

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2 Safety
2.1 Safety rules
787-001
18-001
152784-001
2.1.9 Road traffic
The provisions of road traffic regulations in the various
countries may differ. In case of discrepancies between
the instructions provided by the manufacturer and the
traffic regulations of the relevant countries, the traffic
regulations of the countries concerned apply.
This self-propelled machine usually requires an
operating permit and an exceptional approval for
driving on public roads.
When travelling on public roads and lanes with this
self-propelled machine, all conditions imposed in the
operating permit and the exceptional approval must be
met.
Documents to be carried on the machine
Besides the driver's licence, the driver must
permanently carry the original of the operating permit
and of the exceptional approval.
Objects to be carried on the machine
A warning triangle must be carried on all self-propelled
machines.
A warning triangle, a warning light and a first-aid box
must be carried on all commercially used machines.
Excess-width machines
In case of excess-width self-propelled machines (width
exceeding 3 m across tyres), an individual operating
permit based on a specific certificate, an exceptional
approval according to country traffic rules are
required.Road traffic regulations may vary between
countries.
All conditions imposed there must be met and all
information observed. Especially the information
regarding the marking of excess-width road vehicles
must be followed. (two red/white striped warning plates
each at the front and the rear, two yellow warning
beacons).
The granting of the exceptional approval and the
exceptional permit follows different rules in the various
countries. Information can usually be obtained from
the road traffic departments in charge.
Environment!
Nature and source of danger
Consequences: damage to the environment
– Countermeasures

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2 Safety
2.1 Safety rules
787-001
Additional weights
Self-propelled machines with a rear steering axle and
with front attachments fitted that are approved by
CLAAS must be equipped with additional weights
acting on the rear axle when driving on public roads.
This is required to ensure that the machine will not lift
off at the rear and remain steerable when braking and
travelling on slopes.
The required additional weights can be implements,
rear-axle weights and liquid filling of the rear axle
wheels.
Depending on the type of front attachment and the
components fitted on the machine, additional weights
must be added at the rear of the self-propelled
machines.
Specific relevant information and tables can be
requested from CLAAS.
Changes on the machine
When subsequently modifying machine parts whose
condition is prescribed or fitting parts that may cause a
hazard to other road users when in operation, the
operating permit (individual operating permit) and the
exceptional approval shall cease to be valid.
Obtaining a new individual operating permit requires
that the machine be presented to the technical
inspection agency in order to prepare a specific
certificate according to Regulations Authorizing the
Use of Vehicles for Road Traffic, which may vary in
different countries.
If in doubt whether this is the case, please contact
CLAAS as the manufacturer.
Carrying a transport trailer
A transport carriage for front attachments may be
carried only when not exceeding the permitted trailing
capacity.
When trailing a transport carriage behind the machine,
the lighting cable must be connected and the proper
condition of the entire lighting equipment must be
checked.
Moreover, proper hitching of the trailer must be
ensured.
Carrying other trailers in the trailer hitch is not allowed
to self-propelled combine-harvesters when travelling
on public roads.
Registration
Registration plate fitted on the machine varies in
different countries as per their Traffic Rules.As a self-
propelled machine with an allowed top speed of up to
20 km/h.

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2 Safety
2.1 Safety rules
787-001
Work lights
The work lights must absolutely be switched off when
travelling on public roads and lanes.
152785-001
2.1.10 General driving operation
• When travelling on roads with the front attachment
must be raised.
• Never leave the operator's platform while driving!
• The machine is allowed to travel on public roads
and lanes only with an empty grain tank.
• When travelling on public roads and lanes, the
finger bars, crop lifters or divider points of front
attachments must be covered up.
• The driving properties of the machine are
influenced e.g. by the road surface and by
vehicle-mounted implements. The way of driving
must therefore be adapted to the terrain and
ground conditions. Be particularly careful when
working and turning on slopes and with a filled
grain tank. – Never shift gears when driving
downhill!
• The ground speed must be adapted to road and
traffic conditions in public road traffic so that no
persons will be endangered or hindered more
than can be avoided.
• The operator must be familiar with the driving
properties of the machine and adapt the ground
speed to his/her abilities at all times.
• When the diesel engine is Off or when the
hydraulic steering force is not available, steering
requires a considerably higher effort.
• Stop the machine immediately when detecting any
malfunction on the steering or the brake systems.
Have faults removed without delay!
153923-001
2.1.11 Combine harvester driving operation
• When travelling on public roads swing over the
grain tank unloading tube all the way.
• When travelling on public roads swing over the
grain tank cover all the way.
• Existing traffic regulations must be observed.
152786-001
2.1.12 Driving on slopes
• When travelling downhill with a slope of more than
7%, always shift one gear down (braking effect of
diesel engine)!
• Never exceed the permitted ground speed when
travelling downhill.

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2 Safety
2.1 Safety rules
787-001
152787-001
2.1.13 Transporting persons
• Only persons who are instructing the driver of the
machine should be transported.
• Otherwise, it is not permissible to transport
persons on the machine!
152788-001
2.1.14 Leaving the machine
• Secure machine against rolling away when
leaving it (parking brake, wheel chocks). Stop the
engine, remove the ignition key.
• When shutting down the machine for an extended
period, disconnect the battery isolating switch.
• Never leave the machine unattended as long as
the engine is running!
• Lower the front attachment fully to the ground
before leaving the machine!
152789-001
2.1.15 Diesel engine
Absolutely follow the safety measures listed below in
order to avoid damage to the engine, components and
wiring looms and to prevent personal injuries that may
result from the above conditions.
• Start the engine only with the batteries firmly
connected.
• Do not disconnect the batteries while the engine is
running.
152790-001
2.1.16 Hints regarding the diesel engine
88736-002
152791-001
2.1.17 Anti-freeze
Anti-freeze is highly flammable!
Note!
Operation of diesel engine under unsuitable
operating conditions.
Increased fuel consumption.
Increased diesel engine wear.
– Do not let the diesel engine warm up at
idle speed.
– Stop the diesel engine during operational
waiting times.
– Check fuel consumption at regular
intervals.
– Carry out the specified maintenance work
at regular intervals.

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2 Safety
2.1 Safety rules
787-001
Keep anti-freeze out of reach of children!
Vapours could cause tiredness and lethargy.
Repeated contact can cause brittle or cracked skin.
The following problems can occur:
• Irritation of the eyes
• Irritation of the airways
• Headache
• Dizziness
Influences on the central nervous system with high
doses:
• Breathlessness
• Unconsciousness
Swallowing:
• Nausea
• Vomiting
• Liver damage
Do not release anti-freeze into the environment.
– Collect in a suitable container.
– Dispose of properly!
152792-001
2.1.18 Risk of injury by hydraulic liquid
4167-001
1
740-001
DANGER!
Liquids under high pressure.
Liquids penetrate the skin and cause serious
injuries.
– Work on the hydraulic system may only
be carried out by authorised specialist
workshops.
– Check hoses regularly.
– Check for leaks with a piece of wood or
cardboard.
– Ensure that the flow of oil is not diverted
towards the body.
– Replace damaged hoses.
– Replace hoses at the latest 6 years after
the date of manufacture.

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2 Safety
2.1 Safety rules
787-001
4186-001
152793-001
2.1.19 Front attachments and trailers
• Only carry out work under raised front
attachments if they are supported safely.
• Particular care should be taken when attaching
front attachments and when connecting a trailer!
• Front attachments and feeder units, such as
conveyors, rollers, chains, augers, reels and
similar cannot be fully secured using integral
design features due to their function. Therefore,
during operation, keep a sufficient safety distance
from the moving parts. The sense of these
instructions applies to all other ancillary
attachments.
• No persons are allowed between the machine and
the front attachment without having secured the
vehicle against rolling away by means of the
parking brake and/or by wheel chocks!
• Attach the trailer carefully. Take particular care
when connecting a trailer!
• Park front attachments in a stable position!
• When attaching front attachment, always ensure
that there is sufficient rear axle load – the
steerability and braking capacity must be retained.
152794-001
2.1.20 Grain delivery
• The grain tank contains feed augers which cannot
be completely secured against contact due to their
function.
• Before mounting the grain tank, please ensure
that other persons cannot restart the machine.
• Only climb into the grain tank through the opening
intended for this purpose.
DANGER!
Incorrect handling of injuries through hydraulic
liquids.
Risk of death or serious injury.
Even a pin prick sized hole can lead to serious
injuries.
– Please seek medical advice immediately
following penetration of hydraulic liquids
into the skin or eyes.

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2.1 Safety rules
787-001
152795-001
2.1.21 Accumulator
Take particular care on hydraulic systems with
pressure accumulators. Hydraulic systems with
pressure accumulator are highly pressurised!
Repair work on the hydraulic system may only be
carried out by specialist workshops.
152796-001
2.1.22 Adjusting and maintenance work
Due to their function, the machine drives are not
secured automatically once the engine stops.
It may also be necessary for the drives to be turned
during adjustment work.
For these reasons the following precautions should be
observed:
• Before carrying out adjustments, cleaning and
maintenance operations as well as removing
malfunctions:
- Switch off the threshing mechanism.
- Switch off the front attachment.
- Switch off the grain tank unloading mechanism.
- Stop the engine.
- Disconnect the battery isolating switch.
• Before adjustment, cleaning and maintenance
operations and before correcting malfunctions at
the hydraulic system, lower the front attachment
all the way.
• When working on the electric system, always
disconnect the battery isolating switch.
• Once the threshing unit has been switched off, the
drives will continue turning for a short period of
time. Always wait for the drives to come to a
complete halt.
• It must be ensured that other persons will not start
the machine or can turn the drives.
• Liquids escaping under high pressure (such as
fuel, hydraulic oil) may penetrate the skin and
cause serious injury, therefore consult a doctor
immediately as otherwise serious infections may
result!
• Repair work on the hydraulic system may only be
carried out by specialist workshops.
2
172258-001

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2 Safety
2.1 Safety rules
787-001
• Be careful when opening the radiator opening.
When the engine is hot, the radiator is under
pressure!
• Mounting of tyres requires sufficient knowledge
and proper fitting tools!
• Dispose of oils, fuels and filters properly!
• Retighten wheel nuts at regular intervals!
152798-001
2.1.23 First aid measures
Inhaling:
– Make the person inhale fresh air and consult a
doctor, depending on the symptoms.
– Remove the person from the hazard area.
Eye contact:
– Thoroughly flush with water for several minutes. If
necessary, consult a doctor.
Skin contact:
– Thoroughly clean with plenty of water and soap
and remove polluted and soaked clothing
immediately, consult a doctor if skin is irritated
(e.g. redness etc.).
Swallowing:
– Do not induce vomiting; consult a doctor
immediately.

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2 Safety
2.2 Safety decals on the machine
787-001
2.2 Safety decals on the machine
152799-001
2.2.1 General information on safety decals
The hazard points on the machine or on the front
attachment which cannot be eliminated by design or
protective measures are marked by safety decals. The
safety decals are intended to help in identifying the
injury hazard.
The safety decals consist of two parts:
– part 1 shows the hazard in a warning triangle,
– part 2 shows how to avoid the injuries and
accidents by proper behaviour.
The pictures on the safety decals are generally
comprehensible pictograms. The safety decals must
be located directly near the hazard point as far as
possible.
Original CLAAS safety decals are provided with the
CLAAS part no. and a date of manufacture.
The meanings of the safety decals and how to locate
them is explained below:
– For ordering, use the 10-digit CLAAS part no.
provided ahead of each safety decal,
– the safety decal no. shown in ( ) shows the correct
position of the safety decals in the associated
figure,
– the safety decal is explained as a text below the
graphic representation.
861-001
DANGER!
Hazard points on the machine.
Death or serious injury!
– Hazard warning signs / safety decals that
are damaged or unrecognisable must be
replaced immediately by new ones.
– When parts that have hazard warning
signs / safety decals are replaced, always
make sure to attach the relevant new
hazard warning signs / safety decals to
each new part.