12068 0901 preface - crarymanuals.crary.com/manuals/airreel/12068_r0901.pdf · manual pn 12068 rev....

JOHN DEERE 200, 900, 900FOWNER'S MANUAL

Manual PN 12068Rev. 0901

JOHN DEERE200, 900, 900F

DisclaimerThis document is based on information available at the time of its publication. While efforts have been made to be accurate, theinformation contained herein does not purport to cover all details or variations, nor to provide for every possible contingency inconnection with installation, operation, or maintenance. Features may be described herein which are not present in all systems.Crary Company assumes no obligation of notice to holders of this document with respect to changes subsequently made.

The Crary Company assumes no responsibility for the accuracy, completeness, sufficiency, or usefulness of the information con-tained herein.

SPECIFICATIONS AND DESIGN ARE SUBJECT TO CHANGE WITHOUT NOTICE.

The Crary Company is continually making improvements and developing new equipment. In doing so, we reserve the right to makechanges or add improvements to our product without obligation for equipment previously sold.

Because modification to this machine may affect the performance, function, and safety of its operation, no modifications are to bemade without the written permission of the Crary Company. Part replacements should be with original equipment supplied by theCrary Company.

THE CRARY COMPANY STATEMENT OF PRODUCT SAFETY

“As a manufacturer of specialized agricultural equipment, the Crary Company fully recognizes its responsibility of providing itscustomers products that perform their expected use in a reasonably safe manner. Safety considerations shall be an integral and highpriority part of all engineering/design analysis and judgments involving Crary products. It is our stated policy that our products will bemanufactured to comply with the safety standards specified by the American Society of Agricultural Engineers, the National ElectricalCode, The Society of Automotive Engineers, and/or any other applicable recognized standards at the time manufactured. However,this statement should not be construed to mean that our product will safeguard against a customer’s own carelessness or neglect inviolating common safety practices specified in each product’s manual, nor will we be liable for any such act.”

Copyright© 2000, Crary Company. All rights reserved. Produced and printed in the USA.

Trademark Information

Any trademarks not directly mentioned are also acknowledged.

PrefaceThis manual is intended for use with the “Finger Air Reels” for John Deere Headers 200 / 900 / 900F Series

Revision HistoryIssue Date Reasons for Change21517 05/88 Initial Design22113 07/89 Revision (See ECO Info)22480 06/90 Revision (See ECO Info)22761 04/91 Revision (See ECO Info)22761 06/93 Revision (See ECO Info)12068 03/96 Revision (See ECO Info)12068 03/98 Revision (See ECO Info)12068 07/99 Revision (See ECO Info)12068 04/00 Revision (See ECO Info)

Is a trademark of the American So-ciety of Agricultural Engineers(ASAE) and is so acknowledged.

Is a trademark of the OccupationalSafety & Health Administration(OSHA) and is so acknowledged.

Is a trademark of the National FireProtection Association (NFPA) andis so acknowledged.

Is a trademark of the Society of Auto-motive Engineers (SAE) and is so ac-knowledged.

Is a trademark of the American NationalStandards Institute (ANSI) and is so ac-knowledged.

Is a trademark of the National Electricalcode (NEC) and is so acknowledged.

Is a trademark of Deere & Company andis so acknowledged.

Manual Insert

Crary CompanyA Division of TerraMarc Industries

237 12th St. NW • P.O. Box 849West Fargo, ND 58078-0849

(701)282-5520 • FAX: (701)282-9522www.crary.com

Manufactured in theUnited States of

Americaby Crary Company

www.terramarc.com

PRODUCT: AIR REELS

MODEL: ALL MODELS

SUBJECT: SERIAL NUMBER DECALS

MANUAL INSERT

Fig #1, Location of stickers

Two serial number stickers are included with each Air Reel.The decals are located on the Air Reel manifold. One stickeris to be placed on the warranty registration card and mailedback to Crary Company. The second sticker is to be placedin the owners manual for future reference.



(701)282-5520 • FAX: (701)282-9522www.crary.com

��

PRODUCT: FINGER AIR REELS

MODEL: JOHN DEERE 600 SERIES HEADERS

SUBJECT: REEL ARM MOUNT, GEARBOX MOUNT & RH DRIVE KITS

The procedure for mounting the Reel Arm Mount Kit, theGearbox Mount Kit, and the RH Drive Kit on the new JD 600series header has changed as compared to the 200/900 seriesheaders. The following instructions and pictures will illustratethe differences.

Figure #1 JD Reel Arm Yoke

Figure #2 FAR Reel Arm Yoke/Cylinder Safety Stop

Figure #3 Hydraulic Cylinder Lower Pivot

Step 1Replace the JD reel arm yoke (A) (See figure #1) with the CraryFAR reel arm yoke (B) (See figure #2). Reposition the hydrauliclift cylinder by moving the lower pivot pin from the middle holeto the bottom hole (See figure #3). Further adjustment of thereel arm can be made by screwing the reel arm yoke up or downon the cylinder as required. Repeat procedure for opposite endof header. This change is required in order to be able to positionthe FAR closer to the cutterbar.

Steps 1-3 (Reel Arm Mount Kit)

Step 2The cylinder safety stop (C) (See figure #2) will need to beshortened due to the change of the reel arm yoke. Remove 5/8”from the bottom of the stop. Also, the stop latch (D) (See figure#2) will need to be repositioned 5/8” forward on the undersideof the reel arm to support the shortened stop. Remove the latch,drill (2) new holes at 5/8” from existing holes, and reattach tothe reel arm. Repeat for the opposite end of the header.

Step 3

Slide the Reel Arm Mount Assemblies onto the reel arms andattach to the hydraulic fore/aft cylinders. Remove the fore/aftsensor and mount bracket assembly from the JD RH reel mountand bolt to the bracket on the Crary RH reel arm mount assem-bly (See E in figure #4).

Step 4 (Gearbox Mount Kit)

Position the Mount Plate Support (F) (See figure #5) onto theback of the header so that the RH side of the support is 25-3/4”from the inside RH end of the header. Also, position thesupport so that the centers of the top mounting holes are 3/8”above the edge of the metal sheeting (G & H) (See figure #6).Secure top of support to the back of the head with suppliedhardware. To secure the support at the bottom, drill through themiddle set of holes into the back of the header and through therear stripper. Secure with supplied hardware.

Step 5

A support bearing and mount bracket (J) (See figure #8) areprovided to help support the RH drive shaft along with thegearbox. Bolt the mount bracket to the lower part of the firstsupport left of the gearbox at the rear of the head, using theexisting holes in the support. Refer to your FAR owner’s manualfor remainder of RH drive installation.

Figure #4 Reel Arm Mount Assembly (RH side)

Figure #8

Figure #5

Figure #6

IMPORTANTDo not drill through bottom holes of Mount Plate Supportand into round tube at bottom of header. The tube contains ahydraulic accumulator that could be punctured (See figure#7) for hole locations.

Figure #7 Mount Plate Support

LIMITED WARRANTY

This warranty applies to Bear Cat, Crary, Load-N-Lift, Lockwood and Weed Roller brand products manufactured by Crary Company, a division of TerraMarc Industries, henceforth called Crary Company.

Crary Company warrants to the original owner each new Crary Company product to be free from defects in material and workmanship, under normal use and service. The warranty shall extend 1 year from date of delivery for income producing (commercial) applications and 2 years from date of delivery for non-income producing (consumer) use of the product. The product is warranted to the original owner as evidenced by a completed warranty registration on file at Crary Company. Replacement parts are warranted for (90) days from date of installation.

THE WARRANTY REGISTRATION MUST BE COMPLETED AND RETURNED TO CRARY COMPANY WITHIN 10 DAYS OF DELIVERY OF THE PRODUCT TO THE ORIGINAL OWNER OR THE WARRANTY WILL BE VOID.

In the event of a failure, return the product, at your cost, along with proof of purchase to the selling Crary Company dealer. Crary Company will, at its option, repair or replace any parts found to be defective in material or workmanship. Warranty on any repairs will not extend beyond the product warranty. Repair or attempted repair by anyone other than a Crary Company dealer as well as subsequent failure or damage that may occur as a result of that work will not be paid under this warranty. Crary Company does not warrant replacement components not manufactured or sold by Crary Company.

This warranty applies only to parts or components that are defective in material or workmanship.

This warranty does not cover normal wear items including but not limited to bearings, belts, pulleys, filters and chipper knives.

This warranty does not cover normal maintenance, service or adjustments.

This warranty does not cover depreciation or damage due to misuse, negligence, accident or improper maintenance.

This warranty does not cover damage due to improper setup, installation or adjustment.

This warranty does not cover damage due to unauthorized modifications of the product.

Engines are warranted by the respective engine manufacturer and are not covered by this warranty.

Crary Company is not liable for any property damage, personal injury or death resulting from the unauthorized modification or alteration of a Crary product or from the owner’s failure to assemble, install, maintain or operate the product in accordance with the provisions of the Owner’s manual.

Crary Company is not liable for indirect, incidental or consequential damages or injuries including but not limited to loss of crops, loss of profits, rental of substitute equipment or other commercial loss.

This warranty gives you specific legal rights. You may have other rights that may vary from area to area.

Crary Company makes no warranties, representations or promises, expressed or implied as to the performance of its products other than those set forth in this warranty. Neither the dealer nor any other person has any authority to make any representations, warranties or promises on behalf of Crary Company or to modify the terms or limitations of this warranty in any way. Crary Company, at its discretion, may periodically offer limited, written enhancements to this warranty.

CRARY COMPANY RESERVES THE RIGHT TO CHANGE THE DESIGN AND/OR SPECIFICATIONS OF ITS PRODUCTS AT ANY TIME WITHOUT OBLIGATION TO PREVIOUS PURCHASERS OF ITS PRODUCTS.

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Finger Air Reel Owner Operator’s Manualii

¸HOW TO REACH US

Address Hours Te lephone / Fax

Num berE-m ail

In t ernet

Crary Com p any Mon . - Fr i. Fo r Par t s an d Service: Fo r Service: [email protected] m

237 12t h St . NW 8 A.M. t o 5:00 P.M. 1-800-247-7335 For Par t s: [email protected] m

P.O. Bo x 849 Cen t ral Tim e Fax: 1-701-282-9522 Visit us on t h e Web @

West Fargo , ND 58078-0849 w w w .crary.co m

Please Send us your Warranty Card

Please take time to fill in the information requested on the card. When you send in the completedcard to us, we register your Finger Air reel and start coverage under our limited warranty.

Finger Air Reel Owner Operator’s Manual iii

Contents

SERIAL NUMBER LOCATION .................................................................................... 1REPLACEMENT PARTS ............................................................................................ 1

1.0 INTRODUCTION ........................................................................................................ 22.0 SAFETY...................................................................................................................... 3

2.1 GENERAL SAFETY .................................................................................................... 42.2 OPERATING SAFETY ................................................................................................ 52.3 MAINTENANCE SAFETY ........................................................................................... 52.4 HYDRAULIC SAFETY ................................................................................................ 62.5 PTO (POWER TAKE-OFF) SAFETY .......................................................................... 62.6 TRANSPORT SAFETY ............................................................................................... 72.7 STORAGE SAFETY ................................................................................................... 72.8 ASSEMBLY SAFETY .................................................................................................. 72.9 SAFETY DECALS....................................................................................................... 72.10 SIGN-OFF FORM ....................................................................................................... 8

3.0 SAFETY SIGNS.......................................................................................................... 94.0 ASSEMBLY .............................................................................................................. 10

4.1 UNCRATING............................................................................................................. 104.2 ECCENTRIC MOUNT INSTALLATION ..................................................................... 114.3 IDLER GEAR INSTALLATION (BACK SIDE OF MANIFOLD) ................................... 124.4 REEL BAT ARM INSTALLATION .............................................................................. 124.5 IDLER GEAR INSTALLATION (FRONT SIDE OF MANIFOLD) ................................ 134.6 AIR TUBE INSTALLATION ....................................................................................... 134.7 REEL BAT INSTALLATION ....................................................................................... 154.8 HYDRAULIC MOTOR INSTALLATION ..................................................................... 164.9 ECCENTRIC ARM INSTALLATION .......................................................................... 174.10 RIGHT HAND DRIVE KIT INSTALLATION ............................................................... 18

4.10.1 HEADER PREPARATION (ALL EXCLUDING, CONTOUR MASTER,SIDEHILL AND “F” SERIES HEADERS) .................................................................. 18

4.10.2 HEADER PREPARATION CONTOUR MASTER & SIDEHILL .................................. 184.10.3 HEADER PREPARATION “F” SERIES HEADERS ................................................... 194.10.4 FAN / GEARBOX MOUNTING .................................................................................. 204.10.5 RIGHT HAND DRIVE KIT INSTALLATIONS, “F” SERIES HEADERS ...................... 224.10.6 RIGHT HAND DRIVE KIT INSTALLATIONS, 900 SERIES HEADERS WITH

1-1/8” HEX DRIVE SHAFT ....................................................................................... 244.10.7 RIGHT HAND DRIVE KIT INSTALLATIONS, HEADERS FOR CONTOUR

MASTER COMBINES ............................................................................................... 264.10.8 RIGHT HAND DRIVE KIT INSTALLATIONS, HEADERS FOR SIDEHILL

COMBINE MODELS ................................................................................................. 264.10.9 RIGHT HAND KIT INSTALLATIONS, 200 & 900 SERIES HEADERS WITH

1-1/4” ROUND DRIVE SHAFT .................................................................................. 274.11 FAN BUTTERFLY ACTUATOR INSTALLATION ....................................................... 294.12 REEL SUPPORT INSTALLATION (HYDRAULIC FORE AND AFT) ......................... 304.13 REEL SUPPORT INSTALLATION (MANUAL FORE AND AFT) ............................... 314.14 REEL TO HEADER INSTALLATION ......................................................................... 324.15 MANIFOLD TILT INSTALLATION ............................................................................. 334.16 AIR HOSE INSTALLATION ....................................................................................... 344.17 ELECTRICAL WIRING INSTALLATION ................................................................... 35

5.0 OPERATION ............................................................................................................. 365.1 TO THE NEW OPERATOR OR OWNER ................................................................. 365.2 MACHINE COMPONENTS ....................................................................................... 375.3 PRE-OPERATION CHECKLIST ............................................................................... 385.4 MACHINE BREAK-IN ............................................................................................... 38

5.4.1 PRE-START INSPECTION ....................................................................................... 385.4.2 AFTER OPERATING FOR 2 HOURS ....................................................................... 38

SECTION DESCRIPTION PAGE

SECTION DESCRIPTION PAGE

Contents

Finger Air Reel Owner Operator’s Manualiv

5.4.3 AFTER OPERATING FOR 10 HOURS: .................................................................... 385.5 CONTROLS .............................................................................................................. 395.6 INITIAL ADJUSTMENTS .......................................................................................... 41

5.6.1 INITIAL REEL ADJUSTMENT .................................................................................. 415.6.2 TINE PITCH ADJUSTMENT ....................................................................................... 425.6.3 ALLOWING THE TORQUE LIMITER TO SLIP ............................................................ 435.6.4 ADJUSTING THE TORQUE LIMITER ......................................................................... 44

5.7 OPERATING HINTS ................................................................................................... 455.8 OPTIONAL EQUIPMENT ........................................................................................... 46

5.8.1 SPEED SENSOR KIT................................................................................................ 465.8.2 AUXILIARY REEL TINE KIT ....................................................................................... 485.8.3 GEARBOX / FAN EXTENSION .................................................................................. 49

5.9 TRANSPORTING ....................................................................................................... 515.10 STORAGE ................................................................................................................. 51

6.0 SERVICE AND MAINTENANCE ................................................................................ 536.1 SERVICE .................................................................................................................. 53

6.1.1 FLUIDS AND LUBRICANTS ....................................................................................... 536.1.2 GREASING ............................................................................................................... 53

6.2 SERVICE RECORD .................................................................................................. 546.3 SERVICE AND MAINTENANCE ................................................................................ 55

6.3.1 CHECKING GEAR BOX OIL LEVEL .......................................................................... 556.3.2 PTO LUBRICATION ................................................................................................... 556.3.3 TENSION OF IDLER GEARS .................................................................................... 566.3.4 PLASTIC ECCENTRIC ROLLERS.............................................................................. 566.3.5 FAN HOUSING AND AIR HOSE ................................................................................ 576.3.6 CHANGING GEAR LUBE .......................................................................................... 586.3.7 FRICTION DISC TORQUE LIMITER (SLIP CLUTCH) .................................................. 58

7.0 TROUBLE SHOOTING .............................................................................................. 598.0 SPECIFICATIONS ..................................................................................................... 60

8.1 REEL SPECS. .......................................................................................................... 608.2 FAN PERFORMANCE DATA ..................................................................................... 608.3 BOLT TORQUE ......................................................................................................... 618.4 HYDRAULIC FITTING TORQUE ................................................................................. 62

BOX 6: AIR MANIFOLD ASSY & BATSMANIFOLD, F.A.R.REEL BAT ASSEMBLIES (6)

BOX 3: FAR BOX OF PARTS 6 BATMOTOR,HYD.GEARFOAM SEALS - AIR TUBEPIVOT STRAP BUSHINGSSHAFT COUPLERAIR TUBE WELDMENTSIDLER GEAR ASSEMBLIESREEL BAT ARM ASSEMBLIES

BOX 1: FAN KIT (PART # 22667 or 22668)GEARBOX/FAN ASSY 8.831:1 or 9.375:1ELECTRIC ACTUATOR MINI W/PLUGSWITCH/MOUNT PLATE ASSYFLEX HOSE CHAIN ASSYELBOW, RUBBER 8” X 90°T-BOLT CLAMPSELBOW, RUBBER-8" X 45°FLEX HOSE / BAND ASSY.TUBE CAPMISC. HARDWARE

BOX 2: REEL ARM MOUNT KIT (P ART # 22255)FAR OWNER’S MANUALFAR PARTS MANUALCARD, AG WARRANTY/REGISTRATIONHARNESS,ACTUATOR SWITCH ADAPTERELECTRIC ACTUATORHOSE CONNECTOR WELDMENTS

BOX 4: GEARBOX MOUNT/DRIVE (PART # 22671)BUSHINGS, SD 1-3/8" (2)ADAPTERS, - 10 MORING / -10MJIC (2)MOUNT PLATE SUPPORTGEAR BOX MOUNT PLATES (2)SHIELD WELDMENTS (2)MISC. HARDWARE

INSPECTION AFTER DELIVERY

Inspect your shipping cartons for damage. If you suspect any damage, contact the carrier (trucking company) right away.Unpack the shipping cartons and compare the contents with the parts listing on the packing slips. If any parts are missingor damaged, contact your local authorized dealer or call the factory for assistance. NOTE: Depending on header varia-tions, you may or may not receive all crates and or boxes listed below.

ADJUST BRKT. WELDMENTS (2)HALF CLAMPS (2)REEL SUPT. PAD-RH & LHASSEMBLY, PIVOT CLAMPREEL SUPPORT ASSY LH & RHMISC. HARDWARET-BOLT CLAMPS

ECCENTRIC ARM ASSY’S (2)DOUBLE AIR TUBE ASSEMBLIES (2)BRACE CLAMP ASSEMBLIES (2)WRENCH, ADJUSTMENTRH & LH ECCEN. MT. ASSEMBLIESMISC. HARDWARE

BOX 5: BOX 2 OF 3DRIVELINE / C-FLANGEASSY.

BOX 5: BOX 3 OF 3GEARBOX DRIVE SHAFTDRIVE SHAFT SHIELD

BOX 5: RH DRIVE SHAFT KITBOX 5: BOX 1 OF 3SLIP CLUTCH SHIELDSHIELD MOUNT PLATE ASSY.DRIVE SHAFT SHIELD-JACKSHAFTBEARING INSERTSCLUTCH SHAFT WELDMENT - HEXSLIP CLUTCH SHIELD WELDMENTSHIELD MOUNT BRACKETS (2)CHAIN COUPLERDRIVE SPROCKETSDRIVELINE SUPPORT BRACKETMISC. HARDWARE

BOX 1 OF 3 BOX 2 OF 3 BOX 3 OF 3

Finger Air Reel Owner Operator’s Manual v

Air Reel Owner Operator’s Manual

SERIAL NUMBER LOCATION

Always give your dealer the serial number of your Crary Air Reel when ordering parts, requesting service or any otherinformation.

The serial number decal is located on the front, left hand end of the Air Reel manifold. Please record the Serial number inthe space provided below and on the warranty and registration card.

REPLACEMENT PARTS

Only genuine Crary Co. replacement parts should be used to repair the machine. Crary Co. replacement parts are availablefrom your Crary Co. Dealer. To obtain prompt, efficient service, remember to give the Dealer the correct part description andserial number of the machine.

Please be sure to provide the following information:

1. The SERIAL NUMBER of your Air Reel.

2. The PART NUMBER of the part.

3. The PART DESCRIPTION.

4. The QUANTITY needed.

Serial Number ________________________

Fig. 2 Serial number decal

YXXXXX

Fig. 1 Serial number decal location

WARNINGPlace all controls in neutral or off, lower header to theground, stop combine engine, set parking brake, chockwheels, remove ignition key, set cylinder stops, andwait for all moving parts to stop, before obtaining serialnumber, servicing, adjusting, repairing or unplugging.


1.0 INTRODUCTION

Congratulations on your choice of a new Crary Air Reel to complement your farming operation. This equipment has beendesigned and manufactured to meet the needs of a discerning Agricultural industry for the efficient harvesting of crops.

Safe, efficient, and trouble free operation of your Air Reel requires that you and anyone else who will be operating ormaintaining the machine, read and understand the Safety, Operation, Maintenance, and Trouble Shooting informationcontained within the Operator’s Manual. Check each item referred to and acquaint yourself with the adjustments requiredto obtain efficient operation.

This manual covers all Models of the Air Reel manufactured by Crary Company for John Deere headers 200/900/900FSeries. Differences are covered and explained where appropriate. Use the Table of Contents as a guide to locate requiredinformation.

Keep this manual handy for frequent reference and to pass on to new operators or owners. Call your Crary Dealer ordistributor if you need assistance, information, or additional copies of the manuals.

Many people have worked on the design, production, and delivery of this machine. They have built into it the highest qualityof materials and workmanship. The information in this manual is based on the knowledge, study, and experience of thesepeople through years of manufacturing specialized farming machinery.

The performance of the machine depends on proper maintenance and adjustment. Even if you are an experienced operatorof this or similar equipment, we ask you to read the operator’s manual before running the machine. Keep the manual handyfor future reference. It has been carefully prepared, organized, and illustrated to assist you in finding the information youneed. Your Crary Dealer will be happy to answer any further questions you may have about the machine.

OPERATOR ORIENTATION - All references to left, right, front and rear of the machine, as mentioned throughout themanual, are determined by standing behind the machine and facing towards the direction of forward travel.


This Safety Alert Symbol meansATTENTION! BECOME ALERT!YOUR SAFETY IS INVOLVED!

The Safety Alert symbol identifies importantsafety messages on the Crary Air Reel and inthe manual. When you see this symbol, bealert to the possibility of personal injury ordeath. Follow the instructions in the safetymessage.

DANGER - Indicates an imminently hazardoussituation that, if not avoided, will re-sult in death or serious injury. Thissignal word is to be limited to the mostextreme situations, typically for ma-chine components that, for functionalpurposes, cannot be guarded.

WARNING - Indicates a potentially hazardous situ-ation that, if not avoided, could resultin death or serious injury, and includeshazards that are exposed whenguards are removed. It may also beused to alert against unsafe practices.

CAUTION - Indicates a potentially hazardous situ-ation that, if not avoided, may result inminor or moderate injury. It may alsobe used to alert against unsafe prac-tices.

IMPORTANT- Instructions that must be followed toensure proper installation/operation ofequipment.

NOTE - General statements to assist thereader

3 Big Reasons

SIGNAL WORDS:

Note the use of the signal words DANGER, WARN-ING, CAUTION, IMPORTANT and NOTE with the safetymessages. The appropriate signal word for each mes-sage has been selected using the following guidelines:

2.0 SAFETYSAFETY ALERT SYMBOL

Why is SAFETY important to you?

Accidents Disable and KillAccidents CostAccidents Can Be Avoided


2.0 SAFETY

YOU are responsible for the SAFE operation and mainte-nance of your Crary Air Reel. YOU must ensure that youand anyone else who is going to operate, maintain or workaround the Crary Air Reel are familiar with the operating andmaintenance procedures and related SAFETY informationcontained in this manual. This manual will alert you to allgood safety practices that should be adhered to while operat-ing the Crary Air Reel.

Remember, YOU are the key to safety. Good safety prac-tices not only protect you but also the people around you.Make these practices a working part of your safety pro-gram. Be certain that EVERYONE operating this equip-ment is familiar with the recommended operating and main-tenance procedures and follows all the safety precautions.Most accidents can be prevented. Do not risk injury ordeath by ignoring good safety practices.

• Crary Air Reel owners must give operating instructionsto operators or employees before allowing them to op-erate the machine, and at least annually thereafter perOSHA (Occupational Safety and Health Administration)regulation 1928.57.

• The most important safety device on this equipment isa SAFE operator. It is the operator’s responsibility toread and understand ALL Safety and Operating instruc-tions in the manual and to follow them. All accidentscan be avoided.

• A person who has not read and understood all operat-ing and safety instructions is not qualified to operatethe machine. An untrained operator exposes himselfand bystanders to possible serious injury or death.

• Do not modify the equipment in anyway. Unauthorizedmodification may impair the function and/or safety andcould affect the life of the equipment.

• Think SAFETY! Work SAFELY!

2.1 GENERAL SAFETY

1. Read and understand theOperator’s Manual and allsafety signs before operat-ing, maintaining, adjusting orservicing the Crary Air Reel.

2. Only trained persons shall operate the Crary Air Reel.An untrained operator is not qualified to operate themachine.

3. Have a first-aid kit available for useshould the need arise and know howto use it.

4. Provide a fire extinguisher for usein case of an accident. Store in a highlyvisible place.

5. Do not allow children, spectators or by-standers within hazard area of ma-chine.

6. Wear appropriate protective gear. Thislist Includes but is not limited to:

- A hard hat- Protective shoes with

slip resistant soles- Protective goggles- Heavy gloves- Hearing protection- Respirator or filter mask

7. Wear suitable ear protectionfor prolonged exposure to ex-cessive noise.

8. Place all controls in neutral or off, lower header to theground, stop combine engine, set parking brake,chock wheels, remove ignition key, wait for all movingparts to stop, before servicing, adjusting, repairing orunplugging.

9. Review safety related items annually with all person-nel who will be operating or maintaining the Crary AirReel.


2.3 MAINTENANCE SAFETY

1. Follow ALL the operating, maintenance, and safety in-formation in the manual.

2. Support the machine with blocks or safety stands whenworking around it.

3. Follow good shop practices:

•Keep service areaclean and dry.•Be sure electricaloutlets and tools areproperly grounded.•Use adequate lightfor the job at hand.

4. Use only tools, jacks andhoists of sufficient capacityfor the job.

5. Place all controls in neutral or off, lower header to theground, stop combine engine, set parking brake, chockwheels, remove ignition key, set cylinder stops, wait forall moving parts to stop, before servicing, adjusting, re-pairing or unplugging.

6. Before resuming work, install and secure all guards whenmaintenance work is completed.

7. Relieve pressure from hydraulic circuit before servicingor disconnecting from combine.

8. Keep hands, feet, hair and clothing away from all mov-ing and/or rotating parts.

9. Clear the area of bystanders, especially small children,when carrying out any maintenance and repairs or mak-ing any adjustments.

10. Keep safety signs clean. Replace any sign that is dam-aged or not clearly visible.

11. First-class maintenance is a prerequisite for the safestoperation of your machine. Maintenance, including lu-brications, should be performed with the machinestopped and locked out.

2.2 OPERATING SAFETY

1. Read and understand the Owner / Operator’s Manualand all safety signs before servicing, adjusting or re-pairing.

2. Install and secure all guards and shields before start-ing or operating.


4. Place all controls in neutral or off, lower header to theground, stop combine engine, set parking brake, chockwheels, remove ignition key, wait for all moving parts tostop, before servicing, adjusting, repairing or unplug-ging.

5. Clear the area of bystanders, especially small children,before starting.

6. Keep all hydraulic lines, fittings, and couplers tight andfree of leaks before and during use.

7. Clean reflectors and lights before transporting.

8. Review safety related items annually with all personnelwho will be operating or maintaining the Crary Air Reel.

9. Shut the combine off when connecting the machinehydraulics.

10. Do not exceed fan speed of 5300 RPM. Check the fanspeed by multiplying the drive shaft speed (RPM) bythe gear ratio of the gearbox.

11. Do not run the fan without back pressure. Close thebutterfly valve on the fan if the flex hose is disconnected.


2.4 HYDRAULIC SAFETY

1. Always place all combine hydraulic controls in neu-tral before disconnecting from combine or working onhydraulic system.

2. Make sure that all components in the hydraulic sys-tem are kept in good condition and are clean.

3. Relieve pressure before working on the hydraulic sys-tem.

4. Replace any worn, cut, abraded, flattened or crimpedhoses.

5. Do not attempt any makeshift repairs to the hydraulicfittings or hoses by using tape, clamps or cements.The hydraulic system operates under extremely high-pressure. Such repairs will fail suddenly and create ahazardous and unsafe condition.

6. Wear proper hand and eye pro-tection when searching for ahigh-pressure hydraulic leak.Use a piece of wood or card-board as a backstop instead ofhands to isolate and identify aleak.

7. If injured by a concentratedhigh-pressure stream of hydrau-lic fluid, seek medical attentionimmediately. Serious infectionor toxic reaction can developfrom hydraulic fluid piercing the skin surface.

8. Before applying pressure to the system, make sureall components are tight and that lines, hoses, andcouplings are not damaged.


2.5 PTO (POWER TAKE-OFF)SAFETY

1. Keep bystanders, especially children, away from driveshafts.

2. Be extremely careful when working around PTOshafts, drivelines, or other rotating shafts.

3. Do not remove or modify protective shields or guards.

4. Do not step across a PTO or driveline or use it as astep.

5. Keep guards and shields in place at all times whileoperating.

6. Replace all damaged or missing parts or shields withthe correct original manufacturer’s parts.

7. Grease, clean, and maintain PTO components ac-cording to original manufacturer’s specifications andinformation in this manual.

8. Clothing worn by operator must be fairly tight. Neverwear loose-fitting jackets, shirts, or pants when work-ing around the drive shafts. Tie long hair back or putunder a cap.

9. Keep hydraulic hoses, electric cords, chains, andother items from contacting the drive shafts.

10. Do not clean, lubricate, or adjust the drive shafts whenthe reel is engaged and the combine is running.`


2.6 TRANSPORT SAFETY

1. Make sure you are in compliance with all local regu-lations regarding transporting equipment on publicroads and highways.

2. It is the responsibility of the owner to know the light-ing and marking requirements of the local highwayauthorities and to install and maintain the equipmentto provide compliance with the regulations. Add ex-tra lights when transporting at night or during periodsof limited visibility.

3. See the Owner Operator’s Manual that came with yourcombine and header for proper transportation.

2.7 STORAGE SAFETY

1. Store the unit in an area away from human activity.

2. Do not permit children to play on or around the storedmachine.

3. See the Owner Operator’s Manual that came with yourcombine and header for proper storage.

2.8 ASSEMBLY SAFETY

1. Assemble in an area with sufficient space to handlethe largest component and access to all sides of themachine

2. Use only lifts, cranes and tools with sufficient capac-ity for the load.

3. When necessary, have someone assist you.

4. Do not allow spectators in the working area.

5. Be sure to read the maintenance safety section

2.9 SAFETY DECALS

1. Keep safety signs clean and legible at all times.

2. Replace safety signs that are missing or have becomeillegible.

3. Replaced parts that displayed a safety sign should alsodisplay the current sign.

4. Decals that need to be replaced, are to be placed backin the original location. (See section 3.0 SAFETYSIGNS, for correct placement of safety decals.

5. Safety signs are available from your authorized dealeror the factory.

How to Install Safety Signs:

• Be sure that the installation area is clean and dry.

• Be sure temperature is above 50°F (10°C).

• Decide on the exact position before you remove thebacking paper.

• Remove the smallest portion of the split backing paper.

• Align the sign over the specified area and carefully pressthe small portion with the exposed sticky backing inplace.

• Slowly peel back the remaining paper and carefullysmooth the remaining portion of the sign in place.

• Small air pockets can be pierced with a pin andsmoothed out using the piece of sign backing paper.


2.10 SIGN-OFF FORM

The Crary Company follows the general Safety Standards specified by the American Society of Agricultural Engineers(ASAE) and the Occupational Safety and Health Administration (OSHA). Anyone who will be operating and/or maintainingthe equipment must read and clearly understand ALL Safety, Operating and Maintenance information presented in thismanual.

Do not operate or allow anyone else to operate this equipment until such information has been reviewed. Annually reviewthis information before the season start-up.

Make these periodic reviews of SAFETY and OPERATION a standard practice for all of your equipment. We feel that anuntrained operator is unqualified to operate this machine.

A sign-off sheet is provided for your record keeping to show that all personnel who will be working with the equipment haveread and understand the information in the Operator’s Manual and have been instructed in the operation of the equipment.

SIGN - OFF FORM

DATE EMPLOYEES SIGNATURE EMPLOYERS SIGNATURE


KEEP HANDSAWAY WHILE UNIT

IS OPERATING

WARNING

3.0 SAFETY SIGNS

The types of safety signs and locations on the equipment are shown in the picture below. Good safety requires that youfamiliarize yourself with the various Safety Signs, the type of warning and the area, or particular function related to that area,that requires your SAFETY AWARENESS.


REMEMBER - If Safety Signs have been damaged, removed, become illegible or parts replaced without safety signs, newsigns must be applied. New safety signs are available from the manufacture or an authorized dealer.

Part # 11001

Part # 11002

A B

Fig. # 3 Decal locations

1. READ AND UNDERSTAND THE OPERATOR'S MANUAL BEFORE OPERATING.2. KEEP ALL SAFETY SHIELDS AND DEVICES IN PLACE.3. MAKE CERTAIN EVERYONE IS CLEAR OF EQUIPMENT BEFORE OPERATING.4. KEEP HANDS, FEET AND CLOTHING AWAY FROM MOVING PARTS.5. SHUT OFF POWER TO ADJUST, SERVICE OR CLEAN.6. FAILURE TO ADHERE TO THESE, AND OTHER SAFETY WARNINGS, MAY CAUSE SERIOUS INJURY.

CRARY CO.-FARGO, ND


4.0 ASSEMBLY

Read all instructions to become familiar with the parts andprocedure used before starting the actual work.You may refer to the Crary Air Reel parts catalog for addi-tional aid in assembling the Air Reel.

4.1 UNCRATING

1. Locate the manifold and bats crate.

2. Cut the metal bands and remove the 2’ X 4’s and saddletops. (See fig. # 4)

3. Remove the bat assemblies from the crate and place tothe side.

ASSEMBLY SAFETY

1. Assemble in an area with sufficient space tohandle the largest component and access to allsides of the machine

2. Use only lifts, cranes and tools with sufficientcapacity for the load.

3. When necessary, have someone assist you.

4. Do not allow spectators in the working area.

5. Be sure to read the maintenance safety section

Fig. # 4 Manifold and bats crate

4. Remove the lag screws from the mounting clamps (asshown in Fig # 5) from all locations.

5. Using an overhead hoist and a nylon strap, sling or chain,connect to the center of the manifold (See Fig. # 6).

6. Remove from crate, and set down on two steel saw-

horses (or equivalent) two to four inches from the endsof the manifold.

A. The sawhorses must be capable of supporting 500pounds each.

B. The sawhorses must be at least 3 feet high.

The sawhorses must be blocked, to keep the manifold fromrolling.



IMPORTANT


4.2 ECCENTRIC MOUNT INSTALLA-TION

1. Open Box # 3 and sort bolts according to their size andlength.

2. Rotate the manifold on the stands so that the drive shaftis at the 12:00 position.

The back side of the manifold is opposite that of the largeAir Reel Decal.

3. Assemble the R.H. & L.H. Eccentric Mount Plates (withthe nylon rollers facing to the center of the manifold) tothe R.H. & L.H. End Clamps using six (Qty. 6) 3/8” X 1”carriage bolts, twelve (Qty. 12) 3/8” SAE flat washersand six (Qty. 6) 3/8” center locknuts. Do not tightenyet. (See Fig. # 7 & 8).

4. Align the 5th tooth on the R.H. & L.H. eccentric mount-ing plate assemblies with the indicator mark on the R.H.& L.H. end clamps.

The default pitch angle is with the 5th tooth on the eccentricmounting plate assembly aligned with the indicator mark onthe R.H. & L.H. End Clamps. (See section 5.6 Initial Ad-justments, for additional information.)

NOTE

NOTE

NOTE

Fig. # 7 R.H. Eccentric mounting plate assy.

R.H. ECCENTRICMT. PLATE

5. Tighten the six (Qty. 6) 3/8” center locknuts to theirspecified torque.

Do not tighten the nuts for the nylon rollers yet. (See Fig. #9)

Fig. # 8 L.H. Eccentric mounting plate assy.

DO NOTTIGHTEN YET

Fig. # 9 Do not tighten nuts yet


4.3 IDLER GEAR INSTALLATION(BACK SIDE OF MANIFOLD)

1. Assemble one (Qty. 1) idler gear assembly each to theR.H. & L.H. end clamps, and to all Idler mount clamps(back side of manifold only) using one (Qty. 1) 3/8” X 2”bolt, three (Qty. 3) 3/8” flat washers and one (Qty. 1) 3/8” center locknut per each idler gear assembly. (SeeFig. # 10 & 11).

2. Tighten the 3/8” center locknuts to their specified torque.

4.4 REEL BAT ARM INSTALLATION

1. Slide the reel bat arm assemblies over the manifoldassembly. Position each assembly onto the pinion gearsand the idler gears of the manifold assembly. (See Fig.# 12)

The outside face of the arms of the reel bat arm assembliesmust face away from the pillowblock

2. Align the reel bat arm assemblies, so that all of thearms are in-line with one another.

IMPORTANT

Fig. # 10 Idler gear assembly to R.H end clamp assembly

Fig. # 11 Idler gear assembly to idler clamp assembly

Fig. # 12 Reel bat arm assembly to manifold


4.5 IDLER GEAR INSTALLATION(FRONT SIDE OF MANIFOLD)

1. Assemble one (Qty. 1) idler gear assembly each to theR.H. & L.H. end clamps, and to all Idler mount clamps(front side of manifold only) using one (Qty. 1) 3/8” X 2”bolt, three (Qty. 3) 3/8” flat washers and one (Qty. 1) 3/8” center locknut per each idler gear assembly. (SeeFig. # 13).

2. Use a small pry bar between the outside wall of themanifold tubing and the idler gears with approx. 5 lbs. offorce. (See Fig. # 14)

Fig. # 14 Tightening locknuts of idler gears


4. Check the alignment of the reel bat arm assembly withthe pinion and idler gears by looking from the front andrear of the manifold.

5. Rotate the reel arm assemblies to ensure they turn freely.

4.6 AIR TUBE INSTALLATION

1. Roll the manifold over so that the air tube holes in thebottom of the manifold are at the 12:00 position.

2. Apply the self adhesive foam seals.

A. Remove and discard the slot and two hole cutoutsfrom the self adhesive foam seal.

B. Remove the self adhesive foam seal from the back-ing.

Fig. # 15 Apply self adhesive foam seals

Fig. # 13 Idler gear assembly to R.H end & idler clamp assembly


FOAM SEAL(1 PER TUBE)

DOUBLE AIR TUBE ASSEMBLY(1 PER EACH END

OF MANIFOLD)

SELF TAPPINGSCREWS (3 PER

AIR TUBE)

AIR TUBEWELDMENT

BACK OFMANIFOLD

NOTE:OPENINGS OF AIR TUBES FACE TOWARDSREAR OF AIR REEL

4.6 AIR TUBE INSTALLATION(CONTD.)

3. Assemble the single air tubes to the manifold.

A. Locate three (Qty. 3) 11/32 X 7/8 self tapping screwsper each air tube.

B. Place an air tube on the manifold, aligning the threesmall holes of the air tube with the manifold.

Make sure that the opening of the single and double airtubes face towards rear of Air Reel. (See Fig. # 17)

C. Drive three (Qty. 3) 11/32 X 7/8 self tapping screwsthrough the air tube into the holes of the manifold.(See Fig. # 16)

You may want to use an impact wrench for this operation.

D. Follow steps A thru. D for the remaining air tubes.

NOTE

IMPORTANT

Fig. # 16 fasten screws

4. Assemble the double air tubes to the manifold.

A. Follow step # 3 A thru. D for installation of the doubleair tubes.

The double air tube assemblies are only installed on theends of the manifold. (One per end) (See Fig. # 17)

NOTE

Fig. # 17 Installation of air tubes


L.H. PIVOTSTRAP

REEL BATASSEMBLY (QTY. 6)

REEL BAT ASSEMBLY(ASSEMBLED INTO POSITION)

5/16 X 2"BOLT

PLASTICBEARING CAP

5/16" CENTERLOCKNUT

1/4" FLATWASHER

BEARINGBASE

R.H. PIVOTSTRAP

Fig. # 19 Install reel bats

4.7 REEL BAT INSTALLATION

1. Remove the plastic bearing caps, by removing one (Qty1) 5/16” X 2” bolt, one (Qty. 1) 5/16” center locknut andtwo (Qty. 2) 1/4” flat washers per each reel arm. (SeeFig. # 18).

Only remove one bolt when removing the plastic bearingcap.

2. Assemble the reel bat assemblies to the reel arms.

A. Determine the correct orientation of the reel bat. Note:The R.H. and L.H. pivot strap points to the rear of theAir Reel. (See Fig. # 19)

B. Position the reel bats into the bearing bases.

C. Reattach the plastic bearing caps, by installing one(Qty 1) 5/16” X 2” bolt, one (Qty. 1) 5/16” center lock-nut and two (Qty. 2) 1/4” flat washers per each reelarm. (See Fig. # 18).

NOTE

D. Tighten the 5/16” X 2” bolts to 100 In. lbs. Note: donot exceed the recommended torque of 100 In.lbs.

3. Continue with steps 1, 2, A, B, C, and D until all six reelbats are installed.

Fig. # 18 Remove plastic bearing caps

5/16" CENTERLOCKNUT

5/16 X 2"BOLT

1/4" FLATWASHER

PLASTICBEARING CAP


4.8 HYDRAULIC MOTOR INSTALLA-TION

1. Determine the drive side of the manifold. (Right Handend for all JD Headers.)

2. Slide the shaft coupler onto the driveline shaft.

3. Insert the roll pin through the shaft coupler and drivelineshaft hole.

Make sure equal amounts of the roll pin are extended pastthe shaft coupler.

4. Tighten the set screw on the driveline shaft side of theshaft coupler.

If you have the speed sensor option proceed to section (5.8.1Speed Sensor Kit) and follow steps 7, 9, 10 and 11.

NOTE

NOTENOTE

ROLL PIN

SHAFT COUPLER

45° ADAPTER (2)

1/2" CENTER LOCKNUT

HYDRAULIC MOTORBRACE CLAMP

ASSEMBLY

1/2" X 1-1/2" BOLT

1/2" FLAT WASHER

KEY

KEYWAY

HYDRAULIC MOTOR MOUNT

Fig. # 20 Hydraulic motor installation

5. Install the hydraulic motor.

A. Line up the key on the shaft of the hydraulic motorwith the key way of the shaft coupler.

It may be necessary to rotate the reel to line up the key ofthe hydraulic motor with the keyway of the shaft coupler.

B. Align the mounting holes of the hydraulic motor withthe mounting holes of the motor mount clamp.

C. Fasten with the supplied (Qty. 2) 1/2” X 1-1/2” bolts,two (Qty. 2) 1/2” flat washers and two (Qty. 2) 1/2”center locknuts.

D. Torque the center locknuts to their specified torque.

6. Slide the brace clamp assemblies onto each end of themanifold and tighten snug.

The brace clamp assemblies will be used during reel toheader assembly.

NOTE


4.9 ECCENTRIC ARM INSTALLATION

1. Slide an eccentric arm assembly over each end of themanifold, making sure that the end shield faces towardsthe outside.

2. Position the pivot straps of the reel bat assemblies, sothat they point at the 10:00 position (when looking fromthe right side of the reel.) (2:00 position from left side.)

3. Press a pivot strap bushing into each plastic bearing onthe reel arms of the eccentric arm assembly.

4. Bolt the eccentric arm assembly to the reel bat assem-blies by inserting a bolt through the end shield and thepivot strap and tighten to specified torque.

5. Adjust each plastic roller against the eccentric ring andtighten to specified torque.

The plastic rollers should turn with the reel.

NOTE

ECCENTRIC ARM ASSEMBLY

1/2" CENTERLOCKNUT

PIVOTSTRAP

1/2" FLATWASHER

PIVOT STRAP BUSHING(6 REQD. PER ECCEN. ASSY.)

1/2" FLATWASHER

1/2" X 2-1/2" BUTTON HEAD BOLT(6 REQD. PER ECCEN. ASSY.)

ECCENTRICRING

ENDSHIELD

BEARING OF REEL ARM

PLASTICROLLERS

Fig. # 21 Eccentric arm installation


4.10 RIGHT HAND DRIVE KIT INSTAL-LATION

4.10.1 HEADER PREPARATION (ALL EX-CLUDING, CONTOUR MASTER, SIDEHILLAND “F” SERIES HEADERS)

Clearance of 42” is required between the outside edge of theRH tire and the RH inside edge of the header in order tomount the standard fan/gearbox.A fan/gearbox neck extension kit can be purchased for head-ers smaller than 20’ on combines with dual tires. (See sec-tion 5.8 for optional equipment)A support bearing is provided on 25’-30’ headers.

1. Disassembly of existing header components.

A. Remove quick lock pins and remove right-hand sideend shield.

B. Loosen chain tightener (A) and remove chain (B) fromsprockets. (See Fig. # 22)

C. Remove flange lock nut (C) and sprocket (D). Do notdiscard sprocket, it is reused. (See Fig. # 22)

D. Remove bolts (E) securing bracket (F) to angle sup-port and remove bracket and discard. (See Fig. # 23)

E. Remove bolts (G) securing bearing support to angle.Remove drive shaft and bearing support. (925 & 930Only retain bearing support, hardware). (See Fig. #23)

F. Remove clutch from shaft; the clutch will be reused.

G. One support bearing is needed on 25’ and 30’ head-ers. Remove the 1-1/8” hex or 1-1/4” round bearingand flangettes from the bearing mount plate. Thebearing mount plate will be re-used later, for right handdrive installation.

4.10.2 HEADER PREPARATION CONTOURMASTER & SIDEHILL


A. Remove quick lock pins and remove right-hand side

end shield.

B. Loosen chain tightener (A). This is done to ease re-moval of shaft from slip clutch. (See Fig. # 24)

Fig. # 23

Fig. # 22

Fig. # 24


4.10.2 HEADER PREPARATION CONTOURMASTER & SIDEHILL (CONTD.)

C. Open auger slip clutch shield by removing two (2)bolts. (Shield is hinged at bottom) (See Fig. # 25)

D. Remove the bolt and locknut (B). (See Fig. # 25)E. Remove bolts (C), bracket (D) and shaft (E). Bracket,

bearing and shaft will not be used. (See Fig. # 26)

Fig. # 26

4.10.3 HEADER PREPARATION “F” SERIESHEADERS


A. Remove right-hand side end shield.

B. Loosen chain tightener (A), this is done to ease re-moval of shaft from slip clutch. (See Fig. # 27)

C. Open auger slip clutch shield by removing two (2)bolts. (Shield is hinged at bottom) (See Fig. # 25)

D. Remove the bolt and locknut (B). (See Fig. # 25)

E. Remove the three (3) bolts from the flangette and re-move the bearing from the bracket. Then remove shaftfrom back of header. (See Fig. # 28)

F. On 18’ headers, bearing mount bracket must be re-moved from back of header to allow for installation ofmount plate support.

Fig. # 25

Fig. # 27

Fig. # 28


4.10.4 FAN / GEARBOX MOUNTING

1. Support plate location and mounting.

A. Mark and drill the two (2) 17/32” holes on the topportion of the header for the mount plate support ac-cording to the measurements on the diagram below.(See Fig. # 29)

B. Mark and drill the two (2) 27/64” holes, tap to 1/2”-13NC (See Fig. 29).

C. Mark and drill the four (4) 13/32” holes for the shieldmount brackets according to the measurements onthe diagram below. For contour master and “F” se-ries headers, no holes need to be drilled for the shieldmount brackets. The existing plastic clutch shieldwill be used.

Fig. # 29

24.094.25

16.75

5.19

1.13

6.13

Ø13/32" (4X) THRUHOLES FOR SHIELD MOUNT BRACKETS

NOTE: DRILL ONLY IF YOUR SPECIFIC INSTALLATION REQUIRES YOU TO DO SO

THIS LINE REPRESENTS THE BOTTOM OF THE TUBE ON THE UNDERSIDE OF THE HEADER

THIS LINE REPRESENTS THEINSIDE EDGE OF THE RIGHT HAND SIDE OF THE HEADER

22.22

2.19

THIS LINE REPRESENTSTHE BOTTOM OF THE BACKSHEET OF THE HEADER

OPTIONAL HOLES

29.38

23.63

DRILL 27/64 THRU(ONE WALL ONLY)

TAP 1/2" - 13 NC

OPEN SPACE

Ø17/32" THRU(2)

ROUND TUBE


4.10.4 FAN/GEARBOX MOUNTING (CONTD.)

D. Position the mount plate support and tighten the boltsto the specified torque. (See Fig # 30)

The gearbox is shipped dry.

E. Fill the gearbox with lube before use.

Use Mobilube HD SAE 80W-90 Gear lube or equiva-lent with the following specifications:

API Service GL-5MIL-L-2105D Capacity:MACK GO-H 47 oz.

F. Attach gearbox mounting plates to the mount platesupport. (Do not tighten at this time).

G. Skip to section (4.11 FAN BUTTERFLY ACTUATOR

INSTALLATION), to install the fan butterfly actuator,then return to this section and continue on to step H.

H. Lift the fan/gearbox into position using a floor jack oroverhead hoist and secure to the support plate withfour (4) 1/2” bolts and washers (Do not tighten at thistime).

I. Keep fan/gearbox suspended with hoist or jack forthe next part of the installation.

IMPORTANT

GEARBOX MOUNTINGPLATE

MOUNTPLATE

SUPPORT

FAN / GEARBOXASSEMBLY

Fig. # 30


4.10.5 RIGHT HAND DRIVE KIT INSTALLATIONS, “F” SERIES HEADERS

For Right Hand Drive Kit Part #’s :

KIT # 25370 RIGHT HAND DRIVE KIT, 18’ & 20’ (“F” SERIES)KIT # 25371 RIGHT HAND DRIVE KIT, 22’ (“F” SERIES)KIT # 25372 RIGHT HAND DRIVE KIT, 25’ (“F” SERIES)KIT # 25373 RIGHT HAND DRIVE KIT, 30’ (“F” SERIES)

While using the following steps, refer to (Fig. # 31)

1. Remove the three (3) 5/16” X 1-1/2” bolts from the gear-

WARNINGPlace all controls in neutral or off, stop combine en-gine, set parking brake, remove ignition key, set cylin-der stops, wait for all moving parts to stop, then prop-erly block machine before servicing, adjusting, repair-ing, or unplugging.

NOTE

box sleeve on each side of the gearbox. Install two (2)bushings to the gearbox, aligning the keyways of thebushings with each other at the 12:00 position. Installthe three (3) 5/16” X 1-1/2” bolts to the bushings. Donot tighten at this time.

2. Cut driveshaft shield to fit between bushing on right handside of gearbox and auger slip clutch at right hand endof header.

3. Slide the gearbox shaft through bearing mount platewelded to back of header, bushing shield weldment andgearbox from the left hand side, while simultaneouslyinstalling bushing shield weldment and short drive shaftshield over shaft on right hand side of gearbox. The keyfor right hand bushing needs to be installed at this timealso. Insert hex end of gearbox drive shaft into hub onauger slip clutch and secure with 5/16” hardware.

4. Insert key for left hand bushing and tighten bolts in bush-ing on both sides of gearbox to 15 ft. lbs or 180 in. lbs.Tighten set screws over keys at this time.

Fig. # 31

DRIVELINE

SLIP CLUTCH SHIELD

3/8 X 2CARR. BOLT

SHIELD MOUNTPLATE

DRIVESHAFT SHIELD

3/8 SERR.FLANGE NUT1-3/8 BEARING

INSERT

5/16 X 1-1/2KEY

SPACER

DRIVE SHAFTSHIELD

GEARBOXDRIVESHAFT

5/16 SERR.FLANGE NUT

5/16 X 2-1/2 BOLT

5/16 WASHER

5/16 X 3/4BOLT

BUSHINGSHIELDWELDMENT

FLANGETTE

BUSHING


4.10.5 RIGHT HAND DRIVE KIT INSTALLA-TIONS, “F” SERIES HEADERS (CONTD.)

5. Bolt bushing shield weldment to the right hand side ofgearbox using two (2) 1/2” bolts and 1/2” washers.

6. Retighten auger drive chain. (See header owneroperator’s manual for the correct chain tension).

7. Reinstall right hand header shield and secure with lynchpins or quick lock pins.

Steps 8 - 10 only apply to 22’, 25’ and 30’ headers. For allother headers, skip to step # 11.

8. Bolt bushing shield weldment to the left hand side ofgearbox using two (2) 1/2” bolts and 1/2” washers.

9. Measure and cut long drive shaft shield to fit betweenbushing on left hand side of gearbox and bearing mountplate welded on back of header. Slide drive shaft shieldover shaft and through bearing mount plate.

10. Install bearings and flangettes to bearing mount platewelded on back of header.

Correct shaft alignment is critical.

IMPORTANT

NOTE

11. Check for shaft alignment up and down and in and out.Tighten the bolts securing the gearbox mounting plateto the gearbox and the bolts securing the gearbox mount-ing plate to the mount support plate.

12. For 22’, 25’ and 30’ headers, bolt shield mount plate tobearing mount plate with spacers between plate andbearing flangettes. For all other header sizes bolt shieldmount plate directly to left hand side of gearbox.

13. Insert a 5/16” X 1-1/2” key into keyway at the left end ofgearbox shaft. Slide the clutch end of the PTO drivelineonto the gearbox shaft and tighten set screws.

14. Slide the slip clutch shield over the PTO driveline andfasten to the shield mount plate using the 5/16” X 3/4”bolts.


4.10.6 RIGHT HAND DRIVE KIT INSTALLATIONS, 900 SERIES HEADERS WITH 1-1/8” HEXDRIVE SHAFT


Kit # 24173 right hand drive kit, hex shaft (915 header)Kit # 24174 right hand drive kit, hex shaft (18’/20’ header)Kit # 24175 right hand drive kit, hex shaft (22’ header)Kit # 24176 right hand drive kit, hex shaft (25’ header)Kit # 24177 right hand drive kit, hex shaft (30’ header)



NOTE

1. Install the (Crary supplied) hex clutch shaft into the hexbearing through the right hand side sheet of header.Re-install auger drive sprocket onto slip clutch shaftand secure with 3/4” washer, castle nut and cotter pin.

2. Install the slip clutch onto the hex clutch shaft.

3. Remove the three (3) 5/16” X 1-1/2” bolts from the gear-box sleeve on each side of the gearbox. Install two (2)bushings to the gearbox, aligning the keyways of thebushings with each other at the 12:00 position. Installthe three (3) 5/16” X 1-1/2” bolts to the bushings. Donot tighten at this time.

4. Slide the gearbox shaft through the gearbox from theleft side. Insert the 5/16” X 1-1/2” keys into the key-ways of the round shaft and position the right hand endof the gearbox driveshaft within 1-1/2” of the left handend of the clutch shaft.

BRACKET, DRIVELINESUPPORT

3/8WASHER

3/4WASHER

5/32 X 1-1/4COTTER PIN

3/4 CASTLENUT

CLUTCHSHAFT

SHIELDMOUNTBRACKET

DBL. ROLLERCHAIN

DRIVESPROCKET

ROLLPIN

5/16 X 1-1/2KEY

GEARBOXDRIVESHAFT3/8 X 1

BOLT

AUGER SLIP CLUTCH SHIELD

3/8 SERATE FLANGE NUT

1-3/8 BEARINGINSERT

SHIELDMOUNTPLATE

DRIVELINE

5/16 WASHER

DRIVELINE SLIPCLUTCH SHIELD

DRIVESHAFTSHIELD

5/26 X 3/4BOLT

BUSHING

BUSHING

BUSHING SHIELDWELDMENT

BEARINGMOUNTPLATE

Fig. # 32


4.10.6 RIGHT HAND DRIVE KIT INSTALLA-TIONS, 900 SERIES HEADERS WITH 1-1/8”HEX DRIVE SHAFT (CONTD.)

5. Tighten the three (3) bolts on the bushings on each sideof the gearbox to 15 ft. lbs or 180 in. lbs. Tighten the setscrews on the bushings on each side of the gearbox tosecure the 5/16” X 1-1/2” keys into the keyways of thegearbox shaft.

6. Install drive sprocket onto gearbox drive shaft and se-cure with roll pin.

7. Slide the slip clutch assembly along the hex shaft up tothe right hand end of the drive sprocket. Install thedouble roller chain to the drive sprocket and slip clutchsprocket.

8. Attach the two (2) shield mount brackets to the previ-ously drilled Ø13/32” holes, install two (2) 3/8” X 1” boltsand 3/8” serrated flange nuts to lower holes only. At-tach slip clutch shield to top holes of shield mount brack-ets and install 3/8” hardware. Install and tighten re-maining bolts to shield assembly.

9. Reinstall auger drive chain onto sprocket and tighten(See header owner operator’s manual for the correctchain tension)


Steps 11-14 only apply to 25’ and 30’ headers. For all otherheaders, skip to step # 15.

11. Slide the bushing shield weldment over the gearboxdriveshaft and secure to left hand side of gearbox usingtwo (2) 1/2” bolts and 1/2” washers.

12. Install bearings and flangettes to bearing mount plate,slide onto left hand end of gearbox driveshaft and se-cure temporarily to vertical upright on back of header.

13. Measure between bearing and gearbox bushing for cor-rect length, and cut driveshaft shield to measured di-mension.

14. Remove bearing mount plate, slide driveshaft shield ontogearbox driveshaft and reinstall bearing and mount plate.

IMPORTANT

NOTE



16. For 25’ and 30’ headers, bolt shield mount plate to bear-ing mount plate. For all other header sizes bolt shieldmount plate directly to left hand side of gearbox.



19. Install the driveline bracket support to vertical uprightclosest to feeder house using 3/8” X 3/4” carriage bolts.Combine end of driveline will cradle in this bracket.

20. Depending upon combine model it may be necessaryto grind a notch or groove in the feederhouse shaft toaccommodate the quick connect button of the PTO driv-eline. If a notch is necessary grind the notch: 1-3/4”from the end of the shaft, 7/16” wide, and 1/8” deep.This modification is typically needed on JD Ten Seriesand prior combines.


4.10.7 RIGHT HAND DRIVE KIT INSTALLATIONS, HEADERS FOR CONTOUR MASTERCOMBINES


Kit # 24178 right hand drive kit, (18’/20’ Ctr. Master)Kit # 24179 right hand drive kit, (22’ Ctr. Master)Kit # 24180 right hand drive kit, (25’ Ctr. Master)Kit # 24181 right hand drive kit, (30’ Ctr. Master)

For installation of these right hand drive kits, refer to section4.10.5. The only variation between these kits and the “F”Series kits is the style of bearing mount plate. On “F” Se-ries headers, bearing mount plate is welded to back of header,while on contour master headers, bearing mount plate boltsto back of header.

4.10.8 RIGHT HAND DRIVE KIT INSTALLATIONS, HEADERS FOR SIDEHILLCOMBINE MODELS


Kit # 24185 right hand drive kit, hex shaft (18’/22’ sidehill)Kit # 24186 right hand drive kit, hex shaft (25’ sidehill)Kit # 24187 right hand drive kit, hex shaft (30’ sidehill)

For installation of these right hand drive kits, refer to section4.10.5. The only variation between these kits and the “F”Series kits is the style of bearing mount plate. On “F” Se-ries headers, bearing mount plate is welded to back of header,while on sidehill headers, bearing mount plate bolts to backof header.


4.10.9 RIGHT HAND KIT INSTALLATIONS, 200 & 900 SERIES HEADERS WITH 1-1/4” ROUNDDRIVE SHAFT


Kit # 22738 right hand drive kit, round shaft (215 header)Kit # 22739 right hand drive kit, round shaft (915 header)Kit # 22741 right hand drive kit, round shaft (216 header)Kit # 24051 right hand drive kit, round shaft (18’-20’ header)Kit # 24052 right hand drive kit, round shaft (22’-24’ header)Kit # 24103 right hand drive kit, round shaft (25’ header)Kit # 24053 right hand drive kit, round shaft (30’ header)

BRACKET, DRIVELINESUPPORT

3/8WASHER

3/4WASHER

5/32 X 1-1/4COTTER PIN

3/4 CASTLENUT

SHIELDMOUNTBRACKET

DBL. ROLLERCHAIN

DRIVESPROCKET

ROLLPIN

5/16 X 1-1/2KEY

GEARBOXDRIVESHAFT3/8 X 1

BOLT

AUGER SLIP CLUTCH SHIELD

3/8 SERATE FLANGE NUT

1-3/8 BEARINGINSERT

SHIELDMOUNTPLATE

DRIVELINE

5/16 WASHER

DRIVELINE SLIPCLUTCH SHIELD

DRIVESHAFTSHIELD

5/26 X 3/4BOLT

BUSHING

BUSHING

BUSHING SHIELDWELDMENT

BEARINGMOUNTPLATE

SLIP CLUTCHSHAFT

5/16 X 1-1/2 KEY

3/4 WASHER

Fig. # 33


WARNINGPlace all controls in neutral or off, stop combine en-gine, set parking brake, remove ignition key,set cylin-der stops, wait for all moving parts to stop, then prop-erly block machine before servicing, adjusting, repair-ing, or unplugging.

NOTE

1. Install the (Crary supplied) round clutch shaft into thebearing through the right hand side sheet of header.Reinstall auger drive sprocket onto slip clutch shaft andsecure with 3/4” washer, castle nut and cotter pin.

2. Install the slip clutch onto the round clutch shaft andsecure with 3/4” washer, castle nut and cotter pin.

3. Remove the three (3) 5/16” X 1-1/2” bolts from the gear-box sleeve on each side of the gearbox. Install two (2)bushings to the gearbox, aligning the keyways of thebushings with each other at the 12:00 position. Installthe three (3) 5/16” X 1-1/2” bolts to the bushings. Donot tighten at this time.

4. Slide the gearbox shaft through the gearbox from theleft side. Insert the 5/16” X 1-1/2” keys into the key-ways of the round shaft and position the right hand endof the gearbox driveshaft within 1-1/2” of the left handend of the clutch shaft.


4.10.9 RIGHT HAND KIT INSTALLATIONS, 200& 900 SERIES HEADERS WITH 1-1/4” ROUNDDRIVE SHAFT (CONTD.)

5. Tighten the three (3) bolts on the bushings on each sideof the gearbox to 15 ft. lbs or 180 in. lbs. Tighten the setscrews on the bushings on each side of the gearbox tosecure the 5/16” X 1-1/2” keys into the keyways of thegearbox shaft.

6. Install drive sprocket onto gearbox drive shaft and se-cure with roll pin.

7. Align the slip clutch sprocket and sprocket on gearboxdriveshaft. Install the double roller chain to the drivesprocket and slip clutch sprocket.

8. Attach the two (2) shield mount brackets to the previ-ously drilled Ø13/32” holes, install two (2) 3/8” X 1” boltsand 3/8” serrated flange nuts to lower holes only. At-tach slip clutch shield to top holes of shield mount brack-ets and install 3/8” hardware. Install and tighten re-maining bolts to shield assembly.

9. Reinstall auger drive chain onto sprocket and tighten(See header owner operator’s manual for the correctchain tension)


Steps 11-14 only apply to 25’ and 30’ headers. For all otherheaders, skip to step # 15.

11. Slide the bushing shield weldment over the gearboxdriveshaft and secure to left hand side of gearbox usingtwo (2) 1/2” bolts and 1/2” washers.

12. Install bearings and flangettes to bearing mount plate,slide onto left hand end of gearbox driveshaft and se-cure temporarily to vertical upright on back of header.

13. Measure between bearing and gearbox bushing for cor-rect length, and cut driveshaft shield to measured di-mension.

14. Remove bearing mount plate, slide driveshaft shield ontogearbox driveshaft and reinstall bearing and mount plate.

IMPORTANT

NOTE



16. For 25’ and 30’ headers, bolt shield mount plate to bear-ing mount plate. For all other header sizes bolt shieldmount plate directly to left hand side of gearbox.



19. Install the driveline bracket support to vertical uprightclosest to feeder house using 3/8” X 3/4” carriage bolts.Combine end of driveline will cradle in this bracket.


4.11 FAN BUTTERFLY ACTUATOR INSTAL-LATION

1. Bolt the stationary end of the actuator between the tabsof the clevis on the actuator mount with the 1/4” X 1-1/2”bolt and 1/4” center locknut.


2. Bolt the other end of the actuator to the clevis on thevalve actuator with the 1/4” X 1-1/2” bolt and 1/4” centerlocknut.

3. With the actuator fully extended, position the indicatorweldment so it points opposite of the fan opening.

4. Tighten the bolts as much as possible while still allow-ing the actuator to pivot at the two points.

Fig. # 34

INDICATOR (SHOWN FULLYCLOSED POSITION)

INDICATOR(FULLY OPENPOSITION)

FAN BUTTERFLYACUATOR

BUTTERFLYACUATOR


4.12 REEL SUPPORT INSTALLATION (HY-DRAULIC FORE AND AFT)

1. Insert reel support pad underneath the top of each reelsupport bracket.

2. Slide the RH and LH reel support brackets onto theirrespective reel arms.

3. Pin the end of the hydraulic cylinder into the yoke onboth of the reel support brackets.

4. Insert a stop bolt into the hole at the end of each reelarm.

5. Check clearance of the reel support assembly to headerreel arm components.

WARNINGAvoid crushing injury or death from fall ofraised reel.Before working on or under a raised reel,place all controls in neutral or off, stop com-bine engine, set parking brake, remove ig-nition key, wait for all moving parts to stopand set cylinder stops on both sides of reel

before servicing, adjusting, repairing, or unplugging.

3/8" X 2"BOLT

3/8" CENTERLOCKNUT

REEL SUPPORTASSEMBLY (RH)

REEL SUPPORT PAD

INSTALL STOPBOLT

Fig. # 35 Reel support installation (hydraulic) RH side

REEL SUPPORT PAD

3/8" X 2"BOLT

3/8" CENTERLOCKNUT

REEL SUPPORTASSEMBLY (LH)

INSTALL STOPBOLT

Fig. # 36 reel support installation (hydraulic) LH side


4.13 REEL SUPPORT INSTALLATION(MANUAL FORE AND AFT)

1. Insert reel support pad underneath the top of each reelsupport bracket.

WARNINGAvoid crushing injury or death from fall ofraised reel.Before working on or under a raised reel,place all controls in neutral or off, stop com-bine engine, set parking brake, remove ig-nition key, wait for all moving parts to stopand set cylinder stops on both sides of reel

before servicing, adjusting, repairing, or unplugging.

2. Slide the RH and LH reel support brackets onto theirrespective reel arms.

3. Slide adjustment bracket weldment onto each reel armso that the threaded rod is to the outside of the reelarm.

4. Thread rod of adjustment bracket into the reel supportbrackets approximately halfway down the length of therod.

5. Secure the adjustment bracket to the reel arm usingthe bolts and nuts provided. It is not necessary to drillholes in the arm.

6. Check clearance of the reel support assembly to headerreel arm components.

INSTALLSTOP BOLT

REEL SUPPORTPAD

REEL SUPPORTASSEMBLY (RH)

ADJUSTMENT BRACKETWELDMENT

7/16" SERR.FLANGE NUT

7/16" X 3" BOLT

USE THIS HOLE TO SECURE ADJUSTMENT BRACKET WELDMENT

Fig. # 37 Reel support installation (manual) RH side

REEL SUPPORTPAD

REEL SUPPORTASSEMBLY (LH)

7/16" SERR.FLANGE NUT

ADJUSTMENTBRACKET

WELDMENT

USE THIS HOLE TO SECURE ADJUSTMENT BRACKET WELDMENT

Fig. # 38 Reel support installation (manual) LH side


4.14 REEL TO HEADER INSTALLATION

1. Set assembled reel into the half clamps on reel supportbrackets so the brace clamps are inside of the reel sup-port brackets.

2. Center the reel between the reel arms.

3. Slide the brace clamps out to the reel support bracketsand tighten the bolts and nuts.

4. Bolt the half clamps over manifold ensuring the mani-fold is able to rotate by hand.

Bolt Half-Clamps from the bottom up so the nuts are on top.On certain header sizes, because of limited space between

reel arms, the brace clamp may not be needed on the motorend of the reel.

NOTE

NOTE

REEL SUPPORT ASSEMBLY

3/8" X 1" CARRIAGE BOLT(4 PER END)

3/8" CENTERLOCKNUT(4 PER END)

HALF CLAMP

ASSEMBLED REEL

BRACE CLAMP

Fig. # 39 Reel to header install



4.15 MANIFOLD TILT INSTALLATION

1. Slide the pivot clamp assembly over the manifold endopposite of the hydraulic motor, and position it next tothe reel support bracket. Do not tighten the clamp atthis time.

2. Place the tube cap on the end of the manifold tube andset with the t-bolt clamp.

The pivot clamp assembly may serve as a clamp for thetube cap in some instances, In this case you would not usethe 8-1/4” t-bolt clamp.

NOTE

3. Bolt the stationary end of the electric actuator to theclevis on the reel support bracket.

4. Rotate the manifold so the line of sight along the airtubes is directed just behind the cutterbar. (See sec-tion 5.6 initial adjustments.)

5. Extend the actuator approx. 1/2 the length of the fullextension. (Approx. 2”).

6. Bolt the actuator to the clevis on the pivot clamp as-sembly.

7. Tighten the pivot clamp assembly around the manifoldtube.

Be sure the reel can be rotated by hand before attaching theactuator.

NOTE

Fig. # 40 Manifold tilt installation


1/2" CENTERLOCKNUT (2)

ELECTRICACTUATOR

PIVOT CLAMPASSEMBLY

1/2" X 2-1/2"BOLT (2)

TUBECAP

8-1/4" T-BOLTCLAMP

TO FAN BUTTERFLYACTUATOR

TO MANIFOLD TILT ACTUATOR

RED WIRES- POWER

BLACK WIRE- GROUND ACTUATOR SWITCH HARNESS

(TO COMBINE AUX. POWER PLUG)

SWITCH / MOUNT PLATEASSEMBLY (MOUNT IN CAB)

REEL SUPPORTCLEVIS


4.16 AIR HOSE INSTALLATION


1. For easier installation of hose parts, prepare a mixtureof soapy water in a spray bottle.

2. Install one (1) 8-11/16” t-bolt clamp to the 45° elbow, donot tighten yet. (See Fig. # 41)

3. Spray soapy water to the inside of the 45° elbow andslip onto the fan outlet. Position the 45° elbow so itpoints toward the 2:00 position.

4. Install one (1) 8-11/16” t-bolt clamp to the 90° elbow, donot tighten yet.

5. Spray soapy water to the inside of the 90° elbow andslip onto the right end of the air manifold. Position the90° elbow so it points toward the 9:00 position.

6. Install the hose connector weldment to the reel arm ofthe header using the two (2) 5/16” X 2-1/2” bolts and two(2) 5/16” serrated flange nuts. Tighten to specified torque.

7 Install one (1) 8-11/16” t-bolt clamp to the opposite endof the 90° elbow. Spray soapy water on the inside ofthe 90° elbow.

8. The flex hose/band assembly must be divided into 2pieces at this time. Measure and cut, the length re-quired for flex hose piece 1&2.

9. Install the elbow support band end of the flex hose (piece1) into the end of the 90° elbow and tighten the t-boltclamp.

10. Slide a 8-1/4” t-bolt clamp over the end of the oppositeend of flex hose (piece 1) and slide onto the hose con-nector weldment and tighten the t-bolt clamp.

11. Repeat steps 7-9 for flex hose (piece 2).

12. Wrap flex hose chain assembly around flex hose (piece1) and the reel arm of the header. Clasp ends of chaintogether.

Fig. # 41 Air hose installation


1. Mount the switch plate assembly in a convenient placeinside the cab. (Use either velcro or bolts)

2. Run the red wires with fuse (15 Amp & 6 Amp) to apower source. Use actuator switch harness if providedand combine is equipped with same type of auxiliarypower supply.

3. Run the black wires to a suitable ground or to the ac-

4.17 ELECTRICAL WIRING INSTALLATION


NOTE

tuator switch harness ground wires.

4. Route the long harnesses along the combine and headerto the actuators (15 Amp Manifold Tilt; 6 Amp Air Vol-ume) and plug in.

5. Mount the intermediate harness connectors to a conve-nient location on the combine feederhouse.

Disconnect the intermediate harness connector at thefeederhouse when the header is disconnected from the com-bine.

with same auxiliary power plug)(Red wires to fuse wires/black to ground)

(Used only if combine equippedActuator Switch Harness

(To 15 Amp Harness)Manifold Tilt Actuator

(To 6 Amp Harness)Fan Butterfly Actuator

(Mount Inside Combine Cab)Switch/Mount Plate Assembly

Fig. # 42 Wiring schematic


5.0 OPERATION

OPERATING SAFETY

Follow all safety instructions exactly. Safety is everyone’sbusiness. By following recommended procedures, a safeworking environment is provided for the operator, bystand-ers and the area around the worksite. Untrained operatorsare not qualified to operate the machine.

Many features incorporated into this machine are the resultof suggestions made by customers like you. Read thismanual carefully to learn how to operate the machine safelyand how to set it to provide maximum efficiency. By follow-ing the operating instructions in conjunction with a goodmaintenance program, your Crary Air Reel will provide manyyears of trouble-free service.

The Crary Air Reel is designed to dramatically improve har-vesting efficiency. Power is provided by the combine feederand hydraulics. Be familiar with the machine before start-ing.

It is the responsibility of the owner or operator to read thismanual and to train all other operators before they startworking with the machine. In addition to the design andconfiguration of equipment, hazard control and accident pre-vention are dependent upon the awareness, concern, andprudence of personnel involved in the operation, transport,maintenance and storage of equipment or in the use andmaintenance of facilities.

1. Read and understand the Owner/Operator’s Manualand all safety signs before servicing, adjusting or re-pairing.

2. Install and secure all guards and shields before start-ing or operating.


4. Place all controls in neutral or off, lower header to theground, stop combine engine, set parking brake,chock wheels, remove ignition key, wait for all movingparts to stop, before servicing, adjusting, repairing orunplugging.

5. Clear the area of bystanders, especially small chil-dren, before starting.

5.1 TO THE NEW OPERATOR OR OWNER

6. Keep all hydraulic lines, fittings, and couplers tightand free of leaks before and during use.

7. Clean reflectors and lights before transporting.

8. Review safety related items annually with all person-nel who will be operating or maintaining the Crary AirReel.

9. Shut the combine off when connecting the machinehydraulics.

10. Do not exceed fan speed of 5300 RPM. Check thefan speed by multiplying the drive shaft speed (RPM)by the gear ratio of the gearbox.

11. Do not run the fan without back pressure. Close thebutterfly valve on the fan if the flex hose is discon-nected.


A

B

C

D

G

F

E

K

H

Fig # 43 Machine Components

5.2 MACHINE COMPONENTS

The Crary Air Reel is designed to handle all types of beans and small grains such as wheat and oats.

The Air Reel stationary air tubes deliver a constant stream of high velocity air pressure which firmly pushes the crop off thecutterbar, over the platform and into the auger. To generate the high velocity air, power is provided by the combine feedershaft and transmitted via the PTO driveline to the gearbox driveshaft. The gearbox provides rotational power to the highpressure fan.

The hydraulically driven reel, lifts and directs the crop over the cutterbar and delivers it to the combine feeder in a smoothand even flow. Hydraulic power is provided by the combine hydraulics.

A. Air ManifoldB. Drive ShaftC. Reel Bat Arm Assy.D. Air TubeE. Reel Bat Assy.F. Reel TineG. Hydraulic MotorH. Eccentric Arm Assy.I. Gear BoxJ. FanK. Fan HoseL. PTO Driveline


5.3 PRE-OPERATION CHECKLIST

Efficient and safe operation of the Crary Air Reel requiresthat each operator reads and understands the operating pro-cedures and all related safety precautions outlined in thissection. A pre-operation checklist is provided for the opera-tor. It is important for both the personal safety and main-taining the good mechanical condition of the Air Reel thatthis checklist is followed.

Before operating the Air Reel and each time thereafter, thefollowing areas should be checked off:

1. Service the machine per the schedule outlined in theService Record.

2. Use only a Combine of adequate power and specifica-tions to operate the Air Reel.

3. Check that all guards are installed, secured and func-tioning as intended. Do not operate with missing or dam-aged shields.

4. Ensure that the machine is properly attached to the headerand that mechanical retainers, such as quick pins areinstalled.

5. Check the cutterbar, reel area and drives for entangledmaterial.

6. Check the chains and sprockets for proper tension andalignment. Adjust as required.

7. Visually inspect the hydraulic system for leakage, loosefittings, and damaged hoses. Tighten fittings, replacedamaged components and wipe up leaked or excesshydraulic fluid.

8. Check condition of slip clutch friction discs. If installingreplacement discs, adjust spring height to original height(See chart in section 8.3) Deviation from original settingmay be needed depending upon disc wear.

5.4 MACHINE BREAK-IN

Although there are no operational restrictions on the CraryAir Reel when used for the first time, it is recommended thatthe following mechanical items be checked:

5.4.1 PRE-START INSPECTION

1. Read the Operator’s Manual.

2. Check that the hydraulic lines and electrical harnessesare routed where they will not contact moving parts.Be sure all components are clipped, taped or tiedsecurely in place.

3. Check that all guards are installed and secured.

4. Check that all required nuts and bolts are installedand tightened to their specified torque.

5. Adjust the torque limiter following specifications inthe Initial Adjustments section of this manual.

5.4.2 AFTER OPERATING FOR 2 HOURS

1. Re-torque fasteners and hardware.

2. Check that all safety decals are installed and legible.Apply new decals if required.

3. Check that no Hydraulic hoses are being pinched,crimped, or are rubbing. Reroute as required.

4. Check that the wiring harness is not being pinched,crimped, or rubbing. Reroute as required.

5. Check the tension and alignment of all drive chains.Adjust as required.

6. The gearbox will generate heat. The typical operatingtemperature of the gearbox is 180° F.

5.4.3 AFTER OPERATING FOR 10 HOURS:

1. Re-torque fasteners and hardware.

2. Check that all guards are installed, secured and func-tioning as intended. Do not operate with missing ordamaged shields.

3. Check safety decals. Install new ones if required.

4. Check the routing of hydraulic lines and the wiringharness. Reroute as required to prevent pinching,crimping, binding, or rubbing.

5. Check the plastic eccentric rollers for uneven wear.

6. Refer to the normal servicing and maintenance sched-ule as defined in the Service Record.


5.5 CONTROLS

Before starting to work, all operators should familiarize them-selves with the location and function of the controls andsafety devices. Some machines may vary due to differentmodels of combines and headers.

1. Manifold Tilt:

A. Moving the toggle switch to the “Fore ” position (SeeFig. # 44 and 45) extends the shaft of the electricactuator forward, which rotates the manifold CCW,which directs the air tubes towards the back of theheader. (See section 5.6 Initial adjustments for thecenter stroke position which points the air tubes di-rectly behind the cutterbar).

B. Moving the toggle switch to the “AFT” position (SeeFig. # 44 and 45) retracts the shaft of the electricactuator backward which rotates the manifold CWwhich directs the air tubes towards the front of theheader.

AIR TUBE AIR MOVEMENT

CUTTERBAR

MOVING TOGGLE TO "FORE" POSITION, DIRECTS AIR TUBES TOWARDS BACK OF HEADER

MOVING TOGGLE TO "AFT" POSITION, DIRECTS AIR TUBES TOWARDS FRONT OF HEADER

Fig. # 45 Manifold tilt & fan air volume toggle switch

MANIFOLDTILTTOGGLE SWITCH

FAN AIR VOLUME TOGGLE SWITCH

Fig. # 44 Manifold tilt & fan air volume toggle switch

ELECTRICACTUATOR

Fig. # 46 Manifold tilt electric actuator


3. Reel Lift:

A. Consult your owner operator’s manual that came withyour header.

4. Hydraulic Reel Fore And Aft Adjustment:

A. Consult your owner operator’s manual that came withyour header.

5. Manual Reel Fore & Aft Adjustment :

A. Turn the adjustment bolt CW to pull the reel forward.

B. Turn the adjustment bolt CCW to push the reel back-ward.

C. Adjust both sides evenly.

5.5 CONTROLS (CONTD.)

2. Fan Air Volume Actuator:

A. Move the toggle to the open position (See Fig. # 47and 48) to open the butterfly plate which increases airvolume to the air tubes.

B. Move the toggle to the closed position (See Fig. # 47and 48) to close the butterfly plate which decreasesair volume to the air tubes.

FORE

CCW

ADJUSTMENTBOLT

CW

AFT

Fig. # 49 Right side, manual reel fore and aft adjustment

INDICATOR (SHOWN FULLYCLOSED POSITION)

INDICATOR(FULLY OPENPOSITION)

FAN BUTTERFLYACUATOR

BUTTERFLYACUATOR

Fig. # 47 Butterfly indicator

MANIFOLDTILTTOGGLE SWITCH

FAN AIR VOLUME TOGGLE SWITCH

Fig. # 48 Fan air volume toggle switch


5.6 INITIAL ADJUSTMENTS

Since all applications of the Air Reel are not the same, basedon header and combine variations, some initial adjustmentsmust be made to achieve peak performance of your Air Reel.

Adjustments are needed for best feeding as crop conditionschange. Refer to (Section 5.7 operating hints) for sugges-tions.

5.6.1 INITIAL REEL ADJUSTMENT

1. Rest the header on the ground and lower the reel so thereel tines clear the cutterbar by at least one (1) inch.

2. Position the reel so that the reel tines sweep over thecutter bar and begin their lift just behind it.

NOTE

3. Rotate the manifold so the line of sight along the airtubes is directed just behind the cutterbar.

4. Turn adjustable air tubes at each end approximately900 so they direct air into the corners of the header.

5. Open fan butterfly to fully open position.

Use the electric actuators to adjust air flow direction and airvolume.WARNING

Place all controls in neutral or off, stop combine en-gine, set parking brake, remove ignition key, set cylin-der stops, wait for all moving parts to stop, then prop-erly block machine before servicing, adjusting, repair-ing, or unplugging.

LINE OFSIGHT

AIR TUBE

1.00" MIN.

Fig # 50 Initial reel adjustment


5.6.2 TINE PITCH ADJUSTMENT

1. From the right side of the Air Reel loosen the three(Qty. 3) 3/8” X 1” carriage bolts securing the eccentricmount plate assembly to the R.H. End Clamp. (SeeFig. # 51)

2. Insert the Tine Pitch Adjustment wrench into the

shaped cutout on the side of the eccen-

tric mount plate assembly (as shown in Fig. # 51).The default pitch angle is with the 5th tooth (middle tooth)

on the eccentric mount plate assembly aligned with the in-dicator mark on the R.H. & L.H. End Clamps. (See Fig. # 51& 52)

NOTE

3. From the R.H. side of the Air Reel, move the Tine PitchAdjustment wrench CCW to change the tine pitch for-ward. Move the Tine Pitch Adjustment wrench CW tochange the tine pitch backward. (See Fig. # 51)

4. Tighten the three (Qty. 3) 3/8” X 1” carriage bolts to theirspecified torque.

5. From the L.H. side of the Air Reel, follow steps 1 & 2,then move the Tine Pitch Adjustment wrench CCW tochange the tine pitch backward. Move the Tine PitchAdjustment wrench CW to change the tine pitch for-ward. (See Fig. # 51)

6. Tighten the three (Qty. 3) 3/8” X 1” carriage bolts to theirspecified torque.

Although the adjustment can be made anywhere along theadjustment slot, aligning the teeth tips with the indicatorpoint, allow you to better identify the position of the reel tineadjustment for both sides. (See Fig. # 52)

NOTE

TIP OFINDICATOR POINT

TIP OFTEETH

Fig. # 52 Reel tine adjustment teeth


Fig. # 51 Tine pitch adjustment

INDICATORMARK

RIGHT SIDE

TINE PITCH

FORWARDBACKWARD

5TH TOOTH (MIDDLE TOOTH)

(DEFAULT POSITION)TINE PITCHADJUSTMENT WRENCH(PART # 24913-12)

FRONT OF MANIFOLD

CW

CCW

LOOSEN THE THREE 3/8" X 1"

CARRIAGE BOLTS

ECCENTRIC MOUNTINGPLATE ASSEMBLY


Fig. #532, Allowing the Torque Limiter to Slip

BONDIOLI DRIVELINES

WALTERSCHEID DRIVELINES

FULLY LOOSEN (QTY. 4)SOCKET HEAD SCREWS

AFTER SLIPPING CLUTCH

ADJUST (QTY. 8)CENTER LOCK NUTS


5.6.2 SLIP CLUTCH ADJUSTMENT


The Crary Air Reel comes equipped with a Walterscheid orBondioli torque limiter (slip clutch) on the main drive of theair reel. From the factory the Bondioli torque limiter is set ata slip position. The Walterscheid torque limiter is set in theengaged position. Before use each model must be slippedand adjusted to ensure proper function.

5.6.3 ALLOWING THE TORQUE LIMITER TOSLIP

BONDIOLI MODELS:Before use, the torque limiter must also be allowed to slip toensure it will work when needed. Before starting make surethe socket head screws are fully extended and relieving pres-sure on the pressure plates.

1. With the combine engine at idle speed, engage the PTOfor 2-3 seconds to make the torque limiter slip. The torquelimiter is shipped in the slip position so it should readilyspin. Do not allow the torque limiter to slip for morethan 2-3 seconds at a time to prevent damage to thelinings .

2. If the torque limiter does not slip repeat the procedure 2or 3 times. If it still doesn’t slip, check that the sockethead screws are fully extended and relieving pressure onthe pressure plates.

3. After the torque limiter has slipped, fully loosen all 4 ofthe socket head screws, using the hex wrench provided.The socket head screws are to be torqued all of the wayout while in operation -- they will not screw out of theclutch. This will restore pressure on the linings for properoperation.

WALTERSCHEID MODELS:Before use the torque limiter must be allowed to slip to en-sure it will slip when needed.

1. Loosen the center lock nuts on the torque limiter so thatthe pressure is relieved from the pressure plates.

2. With the combine engine at idle speed, engage the PTOfor 2-3 seconds to make the torque limiter slip. Do notallow the torque limiter to slip for more than 2-3seconds at a time to prevent damage to the linings .

3. If the torque limiter does not slip repeat the procedure 2or 3 times. If it still doesn’t slip check that all the centerlock nuts are loosened and not placing tension on thepressure plates.

4. After the torque limiter has slipped, refer to the adjust-ment section for instructions on how to reset the torquelimiter.

IMPORTANTTo prevent burn-up of slip disks the torque limiter (SlipClutch) must be adjusted prior to use.


5.6.4 ADJUSTING THE TORQUE LIMITER

BONDIOLI AND WALTERSCHEID MODELS:

NOTEAt the end of the season, or before any long period ofnon-use, loosen the center locknuts on Walterscheidmodels to relieve the pressure on the linings.


Fig. #54, Adjusting the Torque Limiter


After the torque limiter has slipped it must be adjusted tothe tension required to operate the header. The goal of thisprocedure is to have the torque limiter slip momentarily uponinitial startup and then operate normally.

1. If using a Bondioli clutch make sure that the socket headscrews are disengaged from the spring.

2. Slowly engage the PTO with the engine running at idlespeed.

3. If the torque limiter does not slip, shut off machine andloosen the center locknuts in 1/4 turn increments until itslips momentarily when the header is engaged. If thetorque limiter slips, tighten the center locknuts in 1/4turn increments until it slips momentarily when the headeris engaged.

4. The torque limiter is ready for use.


5.7 OPERATING HINTS

The following are recommended adjustments the operatorcan make based on crop conditions. (Any adjustmentsthat involves the operator leaving the combine cab shouldheed the warning instructions listed below.)

Light Crops:

• Adjust the reel back and down.

• The reel tines must clear the divider points and be ad-justed perpendicular to the cutterbar.

• Use only enough air to move the crop to the auger.

It is recommended that the cutterbar be adjusted to thefully extended position for cutting short, thin crops.

Heavy Crops:

• Adjust the reel forward and higher than in short crops.

• Use the air to bend the crop over the cutterbar, not toforce it into the header.

• Direct the air just below the head of the plant. This willallow the heads to feed into the auger first.

It is recommended that the cutterbar be adjusted to themiddle position when cutting good, heavy standing crops.


Down, Tangled Crops:

• Adjust the reel forward and lower so the reel tines areclose to the cutterbar.

• Tilt the tines back for maximum pitch so the crop islifted as much as possible.

• The reel tines should lift the crop high enough to passover the guards for easier cutting.

• Adjust the air direction as low as possible, with thenozzles at a 90° angle to the down crop.

It is recommended that the cutterbar be adjusted to theretracted position when cutting down, tangled crops.

• Adjustments are needed for best feeding as crop condi-tions change.


5.8 OPTIONAL EQUIPMENT

Optional equipment is available for your Crary Air Reel, callyour nearest dealer for availability information.

5.8.1 SPEED SENSOR KIT

The Crary Speed Sensor Gear Kit (as an option) is neededon the Air Reel to use the automatic reel speed to groundspeed option provided on some late model John Deere com-bines.

Use this kit in conjunction with and not as a substitute forthe reel speed to ground speed option provided by the origi-nal manufacturer.

1. Relieve pressure from the hydraulic system.

2. Loosen and remove the 1/2” X 1-1/2” bolts from the hy-draulic motor.

NOTE


WARNINGRelieve pressure before working on or near the hydrau-lic system. Escaping pressurized hydraulic fluid canhave sufficient force to penetrate your skin causing se-rious injury.

3. Loosen and remove the set screw on the hydraulic mo-tor side of the shaft coupler.

4. Loosen the set screw on the driveline side of the shaftcoupler.

5. Remove roll pin.

6. Remove shaft coupler and hydraulic motor.

7. Simultaneously slide the shaft coupler onto the driv-eline and sensor gear weldment onto the shaft coupler.Do not tighten the set screw yet.

8. Follow steps in # 3 thru. # 6 in section 4.7 HYDRAULICMOTOR INSTALLATION

9. Bolt the sensor mount bracket to the outside of thehydraulic motor mount with the 3/8” X 3/4” Bolt, 3/8” flatwasher and 3/8” nut. Do not tighten yet.

10. Install the existing (customer supplied) speed sensor(OEM Part) into the sensor mount bracket and adjust

to approximately 0.020" air gap between the sensor andgear. (0.020" is approximately 1/2 turn out from sensorbottoming out on gear. Some additional gap adjustmentmay be needed according to the sensor's sensitivity.)Control of reel speed and display should function thesame as the original equipment.

5.8.1 SPEED SENSOR KIT (CONTD.)

11. Tighten the 3/8 hardware to their specified torque.

ROLLPIN

SHAFTCOUPLER HYDRAULIC

MOTOR1/2" BOLT

DRIVELINESIDE

Fig. # 55 Removing hydraulic motor

SENSOR GEAR

HYDRAULIC

3/8" X 3/4" BOLT

OEM PICKUPSENSOR

SENSOR MOUNTBRACKET 3/8" NUT

3/8" FLAT

WELDMENT

MOTOR

WASHER

Fig. # 56 Installing speed sensor


12. Install the Hydraulic Relief Cartridge to the Header ReelDrive Coupler Connection. (See Fig. 58)

A. Disconnect the 45° fitting from the steel return line for

the reel drive motor.

B. Remove the bracket securing the top coupler fromthe back of header (two 1/4" bolts).

C. Remove 45° fitting from back of the return coupler.

D. Install the 45° fitting into the straight fitting on reliefvalve.

E. Using the existing valve strap, bolt the relief valve tothe location where the coupler was removed from instep B.

F. Reconnect the steel line to the 45° fitting.

G. Screw the return coupler onto the 90° fitting on therelief valve.

WARNINGBefore applying pressure to the system, make sure allcomponents are tight and that lines, hoses, and cou-plings are not damaged.

Wear proper hand and eye protection when searchingfor a high-pressure hydraulic leak. Use a piece of woodor cardboard as a backstop instead of hands to isolateand identify a leak.

WARNING

This representation may not reflect all models of headerhydraulic systems.

NOTE

Fig. # 57 Speed sensor installed

H. Run the system and check all lines for leaks.

Fig. # 58 Installing hydraulic relief valve

BACK OF HEADER

RETURNCOUPLER

STEELRETURNLINE

45° FITTING

BRACKET

RELIEF VALVE

90° FITTING

STRAIGHTFITTING


5.8.2 AUXILIARY REEL TINE KIT

The Crary Auxiliary Reel Tine Kit is recommended for cropsthat do not move easily from the knife to the auger at theends of the header.

1. Loosen and remove one (Qty. 1) 1/2” X 1-1/2” hex bolt,two (Qty. 2) 1/2” flat washers, one (Qty. 1) pivot strapbushing and one (Qty. 1) 1/2” center locknut. (See Fig.# 59)

NOTE


1/2" X 2-1/2"HEX SKT BOLT

1/2" FLATWASHER

PIVOTSTRAPBUSHING

1/2" FLATWASHER

1/2" CENTERLOCKNUT

Fig. # 59 Loosen and remove 1/2” hardware and bushing

2. Simultaneously assemble the auxiliary reel tine assem-bly with the two (Qty. 2) steel machine bushings asshown in (Fig. # 60)

3. Rotate the auxiliary reel tine assembly until the squareend sets into the square hole of the pivot strap.

Fig. # 60 Assemble auxiliary reel tine kit

AUXILIARY REEL TINEASSEMBLY (LH SHOWN)

7/8" MACHINERYBUSHING

3/8" X 2-1/2"CARRIAGE BOLT

7/8" MACHINERYBUSHING

3/8" FLATWASHER

3/8" CENTERLOCKNUT

PIVOT STRAP

SQUARE END

Make sure the pitch of the plastic reel tine lines up with theexisting reel tines.

4. Insert the 3/8” X 2-1/2” carriage bolt through the squarehole of the auxiliary reel tine assembly and fasten the3/8” flat washer and 3/8” center locknut.

5. Tighten the 3/8” center locknut to the specified torque.

6. Repeat steps # 1 - # 5 for each auxiliary reel tine as-sembly being installed.


5.8.3 GEARBOX / FAN EXTENSION

The gearbox/fan extension option is designed to extend thefan up to eliminate clearance problems with headers smallerthan 20’ and combines with dual tires. When installing thegearbox fan extension kit, follow this procedure.

1. Separate gearbox and fan. (Refer to drawing on thefollowing page for identification of parts.)

A. Loosen set screw securing the indicator weldmentand remove from butterfly shaft. (See Fig. # 61)

B. Remove 3/8” x 1-1/4” bolts connecting fan housingsand separate.

C. Loosen 3/4” castle nut and remove washer and nutfrom gearbox shaft.

D. Remove fan rotor and spacer washers.

E. Remove bolts connecting lower fan housing to gear-box flange.

2. Attach extension shaft/hub assembly.

A. Bolt extension shaft/hub assembly to gearbox flangewith 1/2” x 1” bolts. Rotate extension shaft so thekey in the coupler at the bottom of the shaft lines upwith the keyway on the gearbox shaft.

B. Place bearing retainer plate and washers onto end ofextension shaft/hub assembly.

C. Bolt lower fan housing to extension flange with 1/2 x1” bolts.

D. Attach spacer washers and fan rotor to extension shaftand secure with washer and 3/4” castle nut.

E. Bolt upper fan housing to lower fan housing with 3/8”x 1-1/4” bolts.

F. Reinstall indicator weldment onto butterfly shaft andtighten set screw.


3. Mount gearbox/fan extension to combine.

A. Refer to owners manual for fan/gearbox installationinstructions.

B. Select appropriate support bracket for combine model.Refer to drawing on next page for assistance.

C. Bolt mounting bracket onto header. Refer to diagramson next page.

D. Remove upper right hand bolt on gearbox mount plate.Bolt support bracket in the location bolt was removedusing provided 1/2” X 1-1/2” bolt.

4. Attach gearbox/fan extension to support bracket withprovided u-bolt.

5. Operate the Air Reel as instructed and cautioned in thismanual.

Fig. # 61 Bolt mounting bracket onto header


KIT, GEARBOX/FAN EXTENSION OPTIONPARTS LIST

ITEM # PART # DESCRIPTION QTY

1 24643 ASSY., EXTENSION SHAFT/HUB 1

2 15014 BOLT 1/2" X 1-1/2" GR5 HEX CAPSW ZP 4

3 15012 BOLT 1/2" X 1" GR5 HEX CPSCREW ZP 2

4 15097 WASHER 1/2" SAE FLAT ZP (56PC/LB) 4

5 15049 NUT 1/2 CENTER LOCKNUT ZP 4

6 24510-12 PLATE, BEARING RETAINER 1

7 24638-12 BRACKET, EXTENSION SUPPORT 1


8 24640-12 BRACKET, EXTENSION SUPPORT - JD 1


10 13014 U-BOLT, FAN MOUNT 3/8 X 3" X 4" ZP 1

11 15006 BOLT 3/8 X 1 GR5 HEX CAPSCREW ZP 2

12 15031 WASHER, 3/8" FLAT ZP (67PCS/LB) 2

13 15042 NUT 3/8 HEX NUT NC ZP 4


5.9 TRANSPORTING

The Crary Air Reel is designed to be easily and convenientlymoved from location to location. When transporting the ma-chine, review and follow these safety instructions:

TRANSPORT SAFETY

1. Make sure you are in compliance with all localregulations regarding transporting equipment onpublic roads and highways.

2. It is the responsibility of the owner to know thelighting and marking requirements of the localhighway authorities and to install and maintainthe equipment to provide compliance with theregulations. Add extra lights when transportingat night or during periods of limited visibility.

3. See the Owner Operator’s Manual that came withyour combine and header for proper transporta-tion.

1. Store the unit in an area away from human activ-ity.

2. Do not permit children to play on or around thestored machine.

3. See the Owner Operator’s Manual that came withyour combine and header for proper storage.

STORAGE SAFETY

5.10 STORAGE

After the season's use, the machine should be thoroughlyinspected and prepared for storage. Repair or replace anyworn or damaged components to prevent any unnecessarydown time at the start of next season. To insure a long,trouble free life, this procedure should be followed when pre-paring the unit for storage:

1. Clear the area of bystanders, especially small children.

2. Thoroughly wash the entire machine using a pressurewasher to remove all dirt, mud, debris or residue.

3. Inspect the following components:

PTO Driveline Components:

A. Check the condition and operation of the friction disctorque limiter (slipclutch). (See the maintenance sec-tion).

B. Store in a dry place.

Electrical system:

A. Check the wiring harness and all wiring componentsfor damaged or worn areas. Check for cracked orworn insulation. Replace any components that havecome in contact with moving parts and re-route toprevent damage in the future.

Hydraulic system:

A. Check all hydraulic lines for damage, replace as re-quired.

Air Reel components:

A. Air tubes bent or damaged: repair or replace as re-quired.

B. Plastic tines bent or damaged: repair or replace asrequired.

C. Manifold driveshaft bearings. Driveshaft bearings aresealed bearings, and do not need lubrication. If wornor damaged replace as required.

D. Bat splice and plastic reel arm bearings. Check forwear and replace as required.

E. Idler gears and bearing components within, piniongears and bearing components within and internal gearsections. Check gears for wear, check for worn ordamaged bearings and replace as required.

F. Plastic eccentric rollers. Check for uneven wear, re-place as required.

Right Hand drive components:

A. Double roller chain, sprockets and bearings. Checkfor wear, replace as required.

B. Visually inspect fan rotor for wear or buildup.

C. Check condition of the rotary screen bearings.


REMOVING FROM STORAGE / PRE-SEASON MAINTE-NANCE:

When removing from storage and preparing to use, followthis procedure:

1. Clear the area of bystanders, especially small chil-dren.

2. Remove the tarpaulin from the machine if it was cov-ered.

3. Clean off accumulated trash and dirt.

4. Check:

A. Routing and securing of all hydraulic linesand wiring harness, adjust as required.

5. Rotate all components and systems by hand to seethat none are seized. Loosen any seized compo-nents with penetrating oil before starting.

6. Retighten any loose bolts to their specified torque.

7. Lubricate all grease points and shaft surfaces.

8. Check for excessive wear on all moving parts.

9. Tighten all hydraulic connections and mounts, replaceo-rings, fittings, or connectors subject to leaking.

10. Review machine break-in (See section 5.4).

11. Review and follow all items on the Pre-OperationChecklist before starting. (See section 5.3)

12. Install all safety shields and review precautions withoperators and other personnel involved in the opera-tion.

13. Inspect the PTO friction disc torque limiter. (See themaintenance section).

5.10 STORAGE (CONTD.)

4. Make a list of all parts needed for repairs and orderthem immediately. Repairs can then be done whentime permits and prevent unnecessary down time atthe start of next season.

5. Lubricate all grease points to remove any water resi-due from the washing and prevent rusting during thestorage period. Rotate all moving parts to distributelubricant to all surfaces.

6. Apply a light coat of grease on the shafts.

7. Check the cutterbar, reel area and drives for entangledmaterial.

8. Touch up all paint nicks and scratches to prevent rust-ing.

9. Move the machine to its storage area.

10. Select an area that is dry, level, and free of debris.

11. If the machine cannot be stored inside, cover with awaterproof tarpaulin and tie securely in place.

12. Store out of the way of human activity.

13. Do not allow children to play on or around stored unit.


1. Follow ALL the operating, maintenance, and safetyinformation in the manual.

2. Support the machine with blocks or safety standswhen working around it.

3. Follow good shop practices:

•Keep service area clean and dry.•Be sure electrical outlets and tools are

properly grounded.•Use adequate light for the job at hand.

4. Use only tools, jacks and hoists of sufficient ca-pacity for the job.

5. Place all controls in neutral or off, lower header tothe ground, stop combine engine, set parking brake,chock wheels, remove ignition key, wait for all mov-ing parts to stop, before servicing, adjusting, repair-ing or unplugging.

6. Before resuming work, install and secure all guardswhen maintenance work is completed.

7. Relieve pressure from hydraulic circuit before ser-vicing or disconnecting from combine.

8. Keep hands, feet, hair and clothing away from allmoving and/or rotating parts.

9. Clear the area of bystanders, especially small chil-dren, when carrying out any maintenance and re-pairs or making any adjustments.

10. Keep safety signs clean. Replace any sign that isdamaged or not clearly visible.

11. First-class maintenance is a prerequisite for thesafest operation of your machine. Maintenance,including lubrications, should be performed with themachine stopped and locked out.

6.0 SERVICE AND MAINTENANCE

MAINTENANCE SAFETY

6.1 SERVICE

Along with a servicing interval, a visual inspection shouldalso be performed. Maintenance personnel can often de-tect potential problems from any unusual sounds made bysuch components as shafts, bearings and drives.

6.1.1 FLUIDS AND LUBRICANTS1. Grease

Use an SAE multi-purpose high temperature greasewith extreme pressure (EP) performance meeting orexceeding the NLGI #2 rating for all requirements.Also acceptable is an SAE multi-purpose lithiumbased grease.

2. Gearbox LubeUse Mobilube HD SAE 80W-90 Gear lube or equiva-lent with the following specifications:API Service GL-5MIL-L-2105D Capacity:MACK GO-H 47 oz.

3. Roller chain lubricating oil.* Stamped on chain link side plate.

4. Storing LubricantsYour machine can operate at top efficiency only ifclean lubricants are used. Use clean containers tohandle all lubricants. Store them in an area protectedfrom dust, moisture and other contaminants.

6.1.2 GREASING

Use the Maintenance Checklist provided to keep a record ofall scheduled maintenance.

1. Use a hand-held grease gun for all greasing.

2. Wipe grease fitting with a clean cloth before greas-ing, to avoid injecting dirt and grit.

3. Replace and repair broken fittings immediately.

4. If fittings will not take grease, remove and clean thor-oughly. Also clean lubricant passageway. Replacefitting if necessary.

AMBIENT TEMPARATURE RANGE

14°F - 32°F 32°F - 104°F 104°F - 122°F

RS-50 - LESS SAE 10 SAE 20 SAE 30

RS-60 / RS-80 SAE 20 SAE 30 SAE 40

RS-100 SAE 20 SAE 30 SAE 40

RS120 / MORE SAE 30 SAE 40 SAE 40

CHAIN TYPE *


6.2 SERVICE RECORD

See Lubrication and Maintenance sections for details of service. Copy this page to continue record.

Note: These service record recommendations are based on normal operating conditions. Severe or unusual conditionsmay require more frequent attention.

ACTION CODE: √ CHECK OR INSPECT CL CLEANL LUBRICATE C CHANGE

HOURS

MAINTENANCE SERVICED BY

8 HOURS

L PTO CROSS JOURNAL ZERKS

√ GEARBOX OIL LEVEL

16 HOURS

L PTO INNER TUBE

40 HOURS

L PTO SHIELD RETAINING BEARING

L PTO DISCONNECT MECHANISM

√ TENSION OF IDLER GEARS

√ FAN HOUSING AND DUCTWORK

√ PLASTIC ECCENTRIC ROLLERS

YEARLY

C GEARBOX LUBE

√ CONDITION OF FRICTION DISC TORQUE LIMITER (SLIP CLUTCH)


6.3 SERVICE AND MAINTENANCE

By following a service and maintenance program on yourmachine, you will enjoy many years of trouble-free use.


6.3.1 CHECKING GEAR BOX OIL LEVEL

Every 8 operating hours the oil level should be checked.

1. The oil level should be no higher than the bottom of thedriveshaft. (See Fig. # 62)If gearbox oil needs to be added, use the following:

Mobilube HD SAE 80W-90 Gear lube or equivalent withthe following specifications:

API Service GL-5MIL-L-2105DMACK GO-H

406

166

86 86

406

Fig. # 63 Lubricate PTO cross journals.

6.3.2 PTO LUBRICATION

1. Every 8 hours, lubricate PTO cross journals. Make suregrease purges through all four bearings. (See Fig. # 63)

2. Every 16 hours, lubricate PTO inner tubes. Telescopingmembers must have lubrication to operate successfully.Telescoping members without fittings should be pulledapart and grease should be added manually with a brush.(See Fig. # 63)

3. Every 40 hours, lubricate the PTO shield retaining bear-ing. Molded nipples on the guard near each guard bear-ing are intended as grease fittings and should be lubri-cated every 40 hours of operation! (See Fig. # 63)

4. Every 40 hours, lubricate the PTO disconnect mecha-nism. (See Fig. # 62)

Fig. # 64 Grease disconnect mechanism

MAXIMUM GEAR LUBE LEVEL

DRAIN AND FILLWITH 47oz. OF90 WT. GEAR LUBE

SIGHT TUBE

BOTTOM OF DRIVE SHAFT

Fig. # 62 Check oil level


6.3.3 TENSION OF IDLER GEARS

Every 40 hours the tension of the idler gears should bechecked. If the tension between the idler gears and internalgear sections of the reel bat arm assembly has any radialmovement it will be necessary to make adjustments. Whenadjusting the tension of the idler to internal gears, follow thisprocedure.

1. Loosen the 3/8” center locknuts which are on the idlergear assembly on the front side of the manifiold.

2. Use a small pry bar between the outside wall of themanifold tubing and the idler gears with approx. 5 lbs. offorce. (See Fig. # 65)


4. Rotate the reel arm assemblies to ensure they turn freely.Do not grease pinion or idler gears on the reel. Drive shaftbearings on the reel are sealed and do not need lubrication.If worn or damaged, replace as required.

WARNINGPlace all controls in neutral or off, stop combine en-gine, set parking brake, remove ignition key, wait for allmoving parts to stop, then properly block machine be-fore servicing, adjusting, repairing, or unplugging.

Fig. # 65 Tightening locknuts of idler gears

6.3.4 PLASTIC ECCENTRIC ROLLERS

Every 40 hours the plastic eccentric rollers should bechecked. Flat wear spots may show on the plastic eccen-tric rollers if they do not rotate while the reel rotates. If thisoccurs it may be necessary to make adjustments or re-place the roller and or bearings. When adjusting the eccen-tric rollers or replacing rollers or bearings follow this proce-dure.

1. Inspect the eccentric rollers for uneven wear. If no wearis detected proceed to step # 5. (Contd. on next page).

WARNINGPlace all controls in neutral or off, stop combine en-gine, set parking brake, remove ignition key, wait for allmoving parts to stop, then properly block machine be-fore servicing, adjusting, repairing, or unplugging.

Fig. # 66 Inspect plastic rollers for uneven wear

CHECK FORUNEVEN WEAR

IMPORTANT


6.3.4 PLASTIC ECCENTRIC ROLLERS(CONTD.)

2. If uneven wear is detected, loosen and remove eachbolt and hardware for each plastic roller that is defec-tive.

3. Inspect the radial bearings that are seated in the plasticrollers, check to see if they turn freely.

4. If replacement parts are needed, consult your local au-thorized Crary dealer.

5. Reassemble the eccentric roller assembly as shown inFig. #68.

6. Readjust the roller firmly against the eccentric ring andtighten bolts to the specified torque.

The plastic rollers must rotate with the reel.

LOOSEN HARDWARE

PLASTICROLLER

PLASTICROLLER

PLASTICROLLER

Fig. # 67 Loosen and remove hardware for plastic rollers

IMPORTANT

PLATE, ECCENTRIC ROLLER MOUNT

PLASTIC ROLLER

ROLLERBUSHING

3/8" BOLT

3/8" FLATWASHER

5/16" FLATWASHER

RADIALBEARING

3/8" NUT

Fig. # 68 Loosen and remove hardware for plastic rollers

Fig. # 69 Check fan housing and ductwork

6.3.5 FAN HOUSING AND AIR HOSE

Every 40 hours the fan housing and ductwork should bechecked for wear. (See Fig. # 69)


6.3.6 CHANGING GEAR LUBE

Each Air Reel has a high speed fan which is driven by thecombine feeder shaft.Each gearbox is equipped with a drain, level and fillplug.Every 500 operating hours or annually, whichever comesfirst, the oil should be replaced. Check more frequently ifthere are leaks around any of the plugs or shaft seals.When checking or changing the oil, follow this procedure.

1. Loosen the worm clamp on the top of the sight tube.

2. Place a container under the gearbox.

3. Remove the top portion of the sight tube from fitting andflex downward into the container. Allow 10 minutes todrain.

4. Add Gearbox Lube 47 oz. of Mobilube HD SAE 80W-90Gear lube or equivalent with the following specifications:

API Service GL-5MIL-L-2105DMACK GO-H

5. Fill gear lube through site tube, reconnect sight tube tofitting and tighten worm clamp.

6. Check that the air passage through the vent plug isopen.

6. Dispose of the used oil in an environmentally safe man-ner.

Always clean the vent plug if any leaks are noticed aroundshaft seals.

6.3.7 FRICTION DISC TORQUE LIMITER (SLIPCLUTCH)

1. Disconnect the PTO driveline from the implement.

2. Position the driveline on a workbench.

3. Loosen the eight nuts.

4. Remove bolts and disassemble all components.

5. Check the condition of all parts, especially the frictiondiscs.

6. If replacement parts are needed, consult your local au-thorized Crary dealer.

7. Reassemble all components.

6. Tighten nuts following an alternating cross pattern untilreaching the default factory height specified in the torquetable. (See section 8.2 for torque chart.)

IMPORTANT

Fig. # 72 Exploded view of torque limiter

Fig. # 71 Check condition of friction disc torque limiter (slip clutch)

MAXIMUM GEAR LUBE LEVEL

DRAIN AND FILL WITH 47oz. OF 90 WT. GEAR LUBE

SIGHT TUBE

BOTTOM OF DRIVE SHAFT

WORM CLAMP

VENT PLUG

Fig. # 70 Change gear lube yearly


7.0 TROUBLE SHOOTING

In the following section, we have listed many of the problems, causes and solutions to the problems that you may encoun-ter.If you encounter a problem that is difficult to solve, even after having read through this trouble shooting section, please callyour local Crary dealer. Before you call, please have this Operator's Manual and the serial number from your machine ready.

AIR REEL TROUBLE SHOOTING

PROBLEM POSSIBLE CAUSE REMEDY

Shattering of grain ahead of cutter bar. Reel speed not coordinated with ground speed, causing excessive agitation before crop is cut.

Adjust reel speed to coordinate with ground speed so reel will move crop evenly.

Reel is positioned too low. Raise reel.

Ground speed too fast for conditions of crop. Slow down ground speed so reel will not cause shattering.

Cut crop building up and falling from front of cutter bar or loss of grain heads at cutter bar.

Reel not adjusted low enough for proper delivery of cut crop to auger.

Set reel low enough to sweep material from cutter bar.

Insufficient ledge for crop travel. Extend rigid cutter bar.

Auger clearance too high from platform bottom.

Adjust outer ends of auger to 1/2" (13mm) clearance of platform bottom and check finger clearance.

Insufficient airflow or misdirection of airflow from manifold to clean off cutter bar.

Adjust manifold so that air flow is directed more at cutter bar to keep it clean.

Clean debris from rotary screen

Check for and clear obstruction from flex hose or manifold.

Check butterfly position and open to allow more air flow.

Check fan rpm, adjust combine shaft speed and check for proper gear box ratio for combine.

Reel speed too slow. Increase speed of reel.

Reel is positioned too high. Move reel back and then down.

Build up of grain on cutterbar. Lower height of reel and set fore-and-aft position as close as possible to cutter bar and auger.

Uneven or bunched feeding of crop to cylinder.

Feeder chain carrying straw back around and disrupting crop flow to the cylinder.

Extend feederhouse stripper down to stop straw from filtering back out.

Crop "tailing in" to the auger (heads not feeding first).

Rotate manifold so that air flow is directed higher on the crop.

Cutter bar not at recommended speed Check basic speed of combine (see combine operator's manual).

Gear box leaking or overheating Incorrect oil type or level. Check level and replace if necessary.

Breather plugged. Remove breather, clean and reinstall.

Seals are leaking. Install new seal kit.

BEFORE YOU CALLPlease Have the following information available:

Serial # (see page # 1 for location) ______________________________


Efficiency

Pressure

Horsepower

4000300020001000CFM

10

20

30

40

50

4500 RPMFORWARD CURVE8" OUTLET FAN

ROTOR SIZE =16.50" DIA X 3.00" WIDE

ST

AT

IC P

RE

SS

UR

E

HO

RS

EP

OW

ER

& E

FF

ICIE

NC

Y %

10

30

20

40

50

8.0 SPECIFICATIONS

8.1 REEL SPECS.

SPEED OF HYDRAULIC DRIVE .........0 THROUGH 59 RPMDIAMETER (BAT REEL) .............................................. 48”NUMBER OF BATS ....................................................... 6

8.2 FAN PERFORMANCE DATA

Ø48.00"


8.3 BOLT TORQUE

CHECKING BOLT TORQUE:The tables shown below give correct torque values for various bolts and capscrews. Tighten all bolts to the torques specifiedin chart unless otherwise noted. Check tightness of bolts periodically, using bolt torque chart as a guide. Replace hardwarewith the same strength bolt.

ENGLISH TORQUE SPECIFICATIONS

Torque figures indicated above are valid for non-greased or non-oiled threads and heads unless otherwise specified. Therefore, do not grease oroil bolts or capscrews unless otherwise specified in this manual. When using locking elements, increase torque values by 5%.

* Torque value for bolts and capscrews are identified by their head markings.

SAE - 8SAE - 2

A

SAE - 5

SAE 2(N.m) (lb-ft)

Bolt Torque*BoltDiameter

"A"SAE 5

(N.m) (lb-ft)SAE 8

(N.m) (lb-ft)

1/4”5/16”3/8”7/16”1/2”9/16”5/8”3/4”7/8”1”

1-1/8”1-1/4”1-3/8”1-1/2”

7.515274467951352402403605107259501250

5.51120325070100175175270375530700930

9.52544701101552153756259251150165021502850

918335280115160280450675850120015502100

17356310015022530055087513001850260034004550

12.52646751151602254006509751350195025503350

A

METRIC TORQUE SPECIFICATIONS

8.8(N.m) (lb-ft)

Bolt Torque*BoltDiameter

"A" 10.9(N.m) (lb-ft)

M3M4M5M6M8M10M12M14M16M18M20M22M24M27M30M33

---

11285595150240330475650825120016502200

---

8.520407011017525035047560087512001650

---

1740801402253504756759251150170023003150

---

123060105165255350500675850125017002350

12.9(N.m) (lb-ft)

---

19479516526040056080010751350200027003700

---

14.535701201903004105808001000150020002750

4.8(N.m) (lb-ft)

.5356152950801251752403304256258501150

.42.24

4.51121376092125180250310450625850


8.4 HYDRAULIC FITTING TORQUE

TIGHTENING FLARE TYPE TUBE FITTINGS *

1. Check flare and flare seat for defects that mightcause leakage.

2. Align tube with fitting before tightening.

3. Lubricate connection and hand tighten swivel nutuntil snug.

4. To prevent twisting the tube(s), use two wrenches.Place one wrench on the connector body and withthe second tighten the swivel nut to the torqueshown.

* The torque values shown are based on lubricatedconnections as in reassembly.

TIGHTENING O-RING FITTINGS *

1. Inspect O-ring and seat for dirt or obvious defects.

2. On angle fittings, back the lock nut off until washerbottoms out at top of groove.

3. Hand tighten fitting until back-up washer or washerface (if straight fitting) bottoms on face and O-ringis seated.

4. Position angle fittings by unscrewing no more thanone turn.

5. Tighten straight fittings to torque shown.

6. Tighten while holding body of fitting with a wrench.

* The torque values shown are based on lubri-cated connections as in reassembly

Tube Size O.D

Nut Size

AcrossFlats

Torque Value* RecommendedTurns To Tighten

(After Finger Tightening)

(in.) (in.) (N.m) (lb-ft) (Flats) (Turn)3/8 1/2 8 6 2 1/3

7/16 9/16 12 9 2 1/3

1/2 5/8 16 12 2 1/3

9/16 11/16 24 18 2 1/3

3/4 7/8 46 34 2 1/3

7/8 1 62 46 1-1/2 1/4

1-1/16 1-1/4 102 75 1 1/6

1-3/16 1-3/8 122 90 1 1/6

1-5/16 1-1/2 142 105 3/4 1/8

1-5/8 1-7/8 190 140 3/4 1/8

1-7/8 2-1/8 217 160 1/2 1/12

Tube Size O.D

Nut Size

AcrossFlats

Torque Value* RecommendedTurns To Tighten

(After Finger Tightening)

(in.) (in.) (N.m) (lb-ft) (Flats) (Turn)3/16 7/16 8 6 1 1/6

1/4 9/16 12 9 1 1/6

5/16 5/8 16 12 1 1/6

3/8 11/16 24 18 1 1/6

1/2 7/8 46 34 1 1/6

5/8 1 62 46 1 1/6

3/4 1-1/4 102 75 3/4 1/8

7/8 1-3/8 122 90 3/4 1/8

Manufactured in theUnited States of America

by Crary Company



(701)282-5520 • FAX: (701)282-9522www.crary.com

www.terramarc.com

12068 0901 preface - crarymanuals.crary.com/manuals/airreel/12068_r0901.pdf · manual pn 12068 rev....

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