owner's manual - crarymanuals.crary.com/manuals/airreel/12068_r081205.pdf · 2007-03-06 ·...

OWNER'S MANUAL

Manual PN 12068Rev. 081205Companion to 12085

JOHN DEERE 200, 600, 900, 900f

JOHN DEERE

� John Deere Air Reel Owner’s Manual

DisclaimerThis document is based on information available at the time of its publication. While efforts have been made to be accurate, the information contained herein does not purport to cover all details or variations, nor to provide for every possible contingency in connection 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 contained 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 make changes 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 be made without the written permission of the Crary Company. Part replacements should be with original equipment supplied by the Crary Company.

THE CRARy COmPANy STATEmENT OF PRODUCT SAFETy

As a manufacturer of specialized agricultural equipment, the Crary Company fully recognizes its responsibility of providing its customers products that perform their expected use in a reasonably safe manner. Safety considerations shall be an integral and high priority part of all engineering/design analysis and judgments involving Crary products. It is our stated policy that our products will be manufactured to comply with the safety standards specified by the American Society of Agricultural Engineers, the National Electrical Code, 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 in violating common safety practices specified in each product’s manual, nor will we be liable for any such act.

Copyright© 2005, 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, 600, 900, 900F Series

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

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

Is a trademark of the National Fire Protection Association (NFPA) and is so acknowledged.

Is a trademark of the Society of Automotive Engineers (SAE) and is so acknowledged.

Is a trademark of the American National Standards Institute (ANSI) and is so acknowledged.

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

Is a trademark of Deere & Company and is so acknowledged.


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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HOW TO REACH US

Please Send us your Warranty CardPlease take time to fill in the information requested on the card. When you send in the completed card to us, we register your Air Reel and start coverage under our limited warranty.

Two serial number stickers are included with each Air Reel. The decals are in a packing slip pouch attached to the drive shaft. One sticker is to be placed on the warranty registration card and mailed back to Crary Company. The second sticker is to be placed in the owner’s manual for future reference.

ADDRESS HOURS TELEPHONE fAX NUMBER

E-MAIL INTERNET

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

Mon. - Fri.

8 A.M to 5 P.M. Central Time

For Parts and Service: 1-800-247-7335 Fax: 1-701-282-9522

For Service: [email protected] Visit us on the web @ www.terramarc.com


SECTION DESCRIPTION PAGE

CONTENTS

CONTENTSSERIAL NUMBER LOCATION ............................................................................................................................................................. 8REPLACEMENT PARTS ...................................................................................................................................................................... 8

INTRODUCTION ....................................................................................................... 9

SAFETy .................................................................................................................. 102.1 SAFETY ALERT SYMBOL .......................................................................................................................................................... 102.2 GENERAL SAFETY......................................................................................................................................................................112.3 OPERATING SAFETY ................................................................................................................................................................. 122.4 MAINTENANCE SAFETY ........................................................................................................................................................... 122.5 HYDRAULIC SAFETY ................................................................................................................................................................. 132.6 PTO (POWER TAkE-OFF) SAFETY ........................................................................................................................................... 132.7 TRANSPORT SAFETY ................................................................................................................................................................ 142.8 STORAGE SAFETY .................................................................................................................................................................... 142.9 ASSEMBLY SAFETY ................................................................................................................................................................... 142.10 SAFETY DECALS ...................................................................................................................................................................... 142.11 SIGN-OFF FORM ...................................................................................................................................................................... 15

SAFETy DECALS ................................................................................................... 16

ASSEmBLy ............................................................................................................. 174.1 UNCRATING ............................................................................................................................................................................... 174.2 ECCENTRIC MOUNT INSTALLATION ....................................................................................................................................... 184.3 IDLER GEAR INSTALLATION (BACk SIDE OF MANIFOLD) .................................................................................................... 194.4 REEL BAT ARM INSTALLATION ................................................................................................................................................. 194.5 IDLER GEAR INSTALLATION (FRONT SIDE OF MANIFOLD) .................................................................................................. 204.6 AIR TUBE INSTALLATION .......................................................................................................................................................... 214.7 REEL BAT INSTALLATION.......................................................................................................................................................... 224.8 HYDRAULIC MOTOR INSTALLATION ....................................................................................................................................... 234.9 ECCENTRIC ARM INSTALLATION .............................................................................................................................................. 244.10 RIGHT HAND DRIVE kIT INSTALLATION ................................................................................................................................ 25

4.10.1 HEADER PREPARATION (ExCLUDING, CONTOUR MASTER, SIDEHILL AND “F” SERIES HEADERS) ............................................ 254.10.2 HEADER PREPARATION CONTOUR MASTER & SIDEHILL ................................................................................................................ 264.10.3 HEADER PREPARATION “F” SERIES HEADERS .................................................................................................................................. 264.10.4 FAN / GEARBOx MOUNTING ................................................................................................................................................................. 274.10.4 FAN/GEARBOx MOUNTING (CONT’D) ................................................................................................................................................... 284.10.5 RIGHT HAND DRIVE kIT INSTALLATIONS (600 SERIES)..................................................................................................................... 304.10.6 RIGHT HAND DRIVE kIT INSTALLATION (F SERIES) ........................................................................................................................... 324.10.7 RIGHT HAND DRIVE kIT INSTALLATION (900 SERIES W/1-1/8” HEx DRIVE SHAFT) ....................................................................... 344.10.8 RIGHT HAND DRIVE kIT INSTALLATIONS, HEADERS FOR CONTOUR MASTER COMBINES ......................................................... 354.10.9 RIGHT HAND DRIVE kIT INSTALLATION (SIDEHILL) ........................................................................................................................... 364.10.10 RIGHT HAND DRIVE kIT INSTALLATION (200, 900 SERIES, 1-1/4” ROUND DRIVE SHAFT) .......................................................... 38

4.11 REEL SUPPORT INSTALLATION (HYD. FORE AND AFT) (600 SERIES) ............................................................................... 404.11.1 REPLACING THE LIFT CYLINDER YOkE .............................................................................................................................................. 404.11.2 ATTACHING THE REEL SUPPORT ASSEMBLY ..................................................................................................................................... 42

4.12 REEL SUPPORT INSTALLATION (HYD. FORE AND AFT) (200, 900, 900F SERIES) ............................................................ 434.13 REEL SUPPORT INSTALLATION (MANUAL FORE AND AFT) (200, 900, 900F SERIES) ...................................................... 444.14 REEL TO HEADER INSTALLATION ......................................................................................................................................... 454.15 MANIFOLD TILT INSTALLATION .............................................................................................................................................. 464.16 AIR HOSE INSTALLATION ....................................................................................................................................................... 474.17 ELECTRICAL WIRING INSTALLATION .................................................................................................................................... 484.18 OPTIONAL EqUIPMENT .......................................................................................................................................................... 49

4.18.1 SPEED SENSOR kIT............................................................................................................................................................................... 494.18.2 AUxILIARY REEL TINE kIT ..................................................................................................................................................................... 514.18.3 GEARBOx / FAN ExTENSION ................................................................................................................................................................ 52


SECTION DESCRIPTION PAGE

CONTENTS

OPERATION ........................................................................................................... 545.1 TO THE NEW OPERATOR OR OWNER ..................................................................................................................................... 545.2 MACHINE COMPONENTS ......................................................................................................................................................... 555.3 PRE-OPERATION CHECkLIST .................................................................................................................................................. 565.4 MACHINE BREAk-IN .................................................................................................................................................................. 56

5.4.1 PRE-START INSPECTION ........................................................................................................................................................................ 565.4.2 AFTER OPERATING FOR 2 HOURS ........................................................................................................................................................ 565.4.3 AFTER OPERATING FOR 10 HOURS: ..................................................................................................................................................... 56

5.5 CONTROLS.................................................................................................................................................................................. 575.6 INITIAL ADJUSTMENTS ............................................................................................................................................................. 58

5.6.1 INITIAL REEL ADJUSTMENT .................................................................................................................................................................... 585.6.2 TINE PITCH ADJUSTMENT ....................................................................................................................................................................... 59

5.7 OPERATING HINTS .................................................................................................................................................................... 605.8 TRANSPORTING ........................................................................................................................................................................ 605.9 STORAGE ................................................................................................................................................................................... 61

SERvICE & mAINTENANCE .................................................................................. 636.1 SERVICE ..................................................................................................................................................................................... 63

6.1.1 FLUIDS AND LUBRICANTS ...................................................................................................................................................................... 636.1.2 GREASING ................................................................................................................................................................................................ 63

6.2 SERVICE RECORD ................................................................................................................................................................. 646.3 SERVICE AND MAINTENANCE .................................................................................................................................................. 65

6.3.1 CHECkING GEARBOx OIL LEVEL ........................................................................................................................................................... 656.3.2 PTO LUBRICATION ................................................................................................................................................................................... 656.3.3 TENSION OF IDLER GEARS .................................................................................................................................................................... 666.3.4 PLASTIC ECCENTRIC ROLLERS ............................................................................................................................................................. 676.3.5 FAN HOUSING AND AIR HOSE ................................................................................................................................................................. 676.3.6 CHANGING GEAR LUBE ........................................................................................................................................................................... 686.3.7 FRICTION DISC TORqUE LIMITER (SLIP CLUTCH) ............................................................................................................................... 68

TROUBLESHOOTING ............................................................................................ 69

SPECIFICATIONS ................................................................................................... 708.1 REEL SPECS. ............................................................................................................................................................................. 708.2 FAN PERFORMANCE DATA ....................................................................................................................................................... 708.3 BOLT TORqUE ........................................................................................................................................................................... 718.4 HYDRAULIC FITTING TORqUE ................................................................................................................................................ 72


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°

BOX 2: REEL ARm mOUNT KIT (PART # 22255)FAR OWNER’S MANUALFAR PARTS MANUALCARD, AG WARRANTY/REGISTRATIONHARNESS, ACTUATOR SWITCH ADAPTERELECTRIC ACTUATORHOSE CONNECTOR WELDMENTSADJUST BRkT. WELDMENTS (2)

BOX 4: GEARBOX mOUNT/DRIvE (PART # 22671)BUSHINGS, SD 1-3/8” (2) ADAPTERS, - 10 MORING / -10MJIC (2)MOUNT PLATE SUPPORT GEAR BOx MOUNT PLATES (2)SHIELD WELDMENTS (2)MISC. HARDWARE

INSPECTION AFTER DELIvERyInspect 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 missing or damaged, contact your local authorized dealer or call the factory for assistance. NOTE: Depending on header variations, you may or may not receive all crates and or boxes listed below.

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: RH DRIvE SHAFT KIT

SLIP CLUTCH SHIELDSHIELD MOUNT PLATE ASSY.DRIVE SHAFT SHIELD-JACkSHAFTBEARING INSERTSCLUTCH SHAFT WELDMENT - HExSLIP CLUTCH SHIELD WELDMENTSHIELD MOUNT BRACkETS (2)CHAIN COUPLER

BOx 1 OF 3 BOx 2 OF 3 BOx 3 OF 3

T-BOLT CLAMPSELBOW, RUBBER-8” x 45°FLEx HOSE / BAND ASSY.TUBE CAPMISC. HARDWARE

DRIVE SPROCkETSDRIVELINE SUPPORT BRACkETDRIVELINE / C-FLANGE ASSY.GEARBOx DRIVE SHAFT DRIVE SHAFT SHIELDMISC. HARDWARE

THE FOLLOWING PARTS WILL SHIP IN 2 OR 3 BOXES DEPENDING ON THE LENGTH OF THE DRIvESHAFT.


SERIAL NUmBER LOCATIONAlways give your dealer the serial number of your Crary Air Reel when ordering parts, requesting service or any other information.

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

Two serial number stickers are included with each Air Reel. The decals are located on the Air Reel driveshaft. One sticker is to be placed on the warranty registration card and mailed back to Crary Company. The second sticker is to be placed in the owner’s manual for future reference.

Serial Number Decal

WARNINGPLACE ALL CONTROLS IN NEUTRAL OR OFF, LOWER HEADER TO THE GROUND, STOP COmBINE ENGINE, SET PARKING BRAKE, CHOCK WHEELS, REmOvE IGNITION KEy, SET CyLINDER STOPS, AND WAIT FOR ALL mOvING PARTS TO STOP, BEFORE OBTAINING SERIAL NUmBER, SERvICING, ADJUSTING, REPAIRING OR UNPLUGGING.

REPLACEmENT PARTSOnly genuine Crary Co. replacement parts should be used to repair the machine. Crary Co. replacement parts are available from your Crary Co. dealer. To obtain prompt, efficient service, remember to give the dealer the correct part description and serial number of the machine.

Please be sure to provide the following information:The SERIAL NUMBER of your Air Reel.

The PART NUMBER of the part.

The PART DESCRIPTION.

The qUANTITY needed.

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Serial Number ________________________

Serial Number Decal Location

MANUFACTURED BY CRARY INDUSTRIES

MANUFACTURED IN U.S.A.xxxxxx

WEST FARGO, NORTH DAkOTA 58078 U.S.A.SERIAL NUMBER

LOCATION OF ADDITIONAL SERIAL NUMBER STICkERS


Congratulations on your choice of a new Crary Air Reel to complement your farming operation. This equipment has been designed 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 or maintaining the machine, read and understand the Safety, Operation, Maintenance, and Trouble Shooting information contained within the owner’s manual. Check each item referred to and acquaint yourself with the adjustments required to obtain efficient operation.

This manual covers all models of the Air Reel manufactured by Crary Company for John Deere 200, 600, 900 and 900F Series headers. Differences are covered and explained where appropriate. Use the Table of Contents as a guide to locate required information.

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

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

The performance of the machine depends on proper maintenance and adjustment. Even if you are an experienced operator of this or similar equipment, we ask you to read the owner’s manual before operating the machine. keep the manual handy for future reference. It has been carefully prepared, organized, and illustrated to assist you in finding the information you need. 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 the manual, are determined by standing behind the machine and facing the direction of forward travel.

INTRODUCTIONSection1

10 John Deere Air Reel Owner’s Manual

This Safety Alert Symbol means:

ATTENTION! BECOmE ALERT!

yOUR SAFETy IS INvOLvED!

The Safety Alert symbol identifies important safety messages on the Crary Air Reel and in the manual. When you see this symbol, be alert to the possibility of personal injury or death. Follow the instructions in the safety message.

DANGER - Indicates an imminently hazardous situation that, if not avoided, will re-sult in death or serious injury. This signal word is to be limited to the most extreme situations, typically for ma-chine components that, for functional purposes, cannot be guarded.

WARNING - Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury, and includes hazards that are exposed when guards are removed. It may also be used to alert against unsafe practices.

CAUTION - Indicates a potentially hazardous situ-ation that, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices.

ImPORTANT- Instructions that must be followed to ensure proper installation/operation of equipment.

NOTE - General statements to assist the reader.

2.1 SAFETy ALERT SymBOL

Why is SAFETy important to you?

1. Accidents Disable and Kill2. Accidents Cost3. Accidents Can Be Avoided

SIGNAL WORDS:

Note the use of the signal words DANGER, WARNING, CAUTION, ImPORTANT and NOTE with the safety mes-sages. The appropriate signal word for each message has been selected using the following guidelines:

3 Big Reasons

Section SAFETy2

11 John Deere Air Reel Owner’s Manual

2.2 GENERAL SAFETy

yOU are responsible for the SAFE operation and mainte-nance of your Crary Air Reel. yOU must ensure that you and anyone else who is going to operate, maintain or work around the Crary Air Reel are familiar with the operating and maintenance procedures and related SAFETy infor-mation contained in this manual. This manual will alert you to all good safety practices that should be adhered to while operating 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 program. Be certain that EvERyONE operating this equipment is familiar with the recommended operating and maintenance procedures and follows all the safety precautions. Most accidents can be prevented. Do not risk injury or death by ignoring good safety practices.

Crary Air Reel owners must give operating instruc-tions to operators or employees before allowing them to operate the machine, and annually thereafter per OSHA (Occupational Safety and Health Administration) regulation 1928.57.

The most important safety device on this equipment is a SAFE operator. It is the operator’s responsibility to read and understand ALL Safety and Operating instructions in the manual and to follow them. All acci-dents can be avoided.

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

Do not modify the equipment in anyway. Unauthorized modification may impair the function and/or safety and could affect the life of the equipment.

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Read and understand the Operator’s Manual and all safety decals before operat-ing, maintaining, adjusting or servicing the Crary Air Reel.

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

Have a first-aid kit available for use should the need arise and know how to use it.

Provide a fire extinguisher for use in case of an accident. Store in a highly visible place.

Do not allow children, spectators or bystanders within hazard area of ma-chine.

Wear appropriate protective gear. This list 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

Wear suitable ear protection for prolonged exposure to excessive noise.

Place all controls in neutral or off, lower header to the ground, stop combine engine, set parking brake, chock wheels, remove ignition key and wait for all moving parts to stop, before servicing, adjusting, repairing or unplugging.

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

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SAFETy

THINK SAFETy! WORK SAFELy!

1� John Deere Air Reel Owner’s Manual

2.4 mAINTENANCE SAFETy

Follow ALL the operating, maintenance, and safety information in the manual.

Support the machine with blocks or safety stands when working around it.

Follow good shop practices:

keep service area clean and dry.

Be sure electrical out-lets and tools are prop-erly grounded.

Use adequate light for the job at hand.

Use only tools, jacks and hoists of sufficient capacity for the job.

Place all controls in neutral or off, lower header to the ground, stop combine engine, set parking brake, chock wheels, remove ignition key and wait for all moving parts to stop before servicing, adjusting, repairing or unplugging.

When maintenance work is completed, install and secure all guards before resuming work, .

Relieve pressure from hydraulic circuit before servicing or disconnecting from combine.

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

Clear the area of bystanders, especially small children, when carrying out any maintenance and repairs or making any adjustments.

keep safety decals clean. Replace any decal that is damaged or not clearly visible.

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

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2.3 OPERATING SAFETy

Read and understand the Owner / Operator’s Manual and all safety decals before servicing, adjusting or repairing.

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

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

Place all controls in neutral or off, lower header to the ground, stop combine engine, set parking brake, chock wheels, remove ignition key and wait for all moving parts to stop before servicing, adjusting, repairing or unplugging.

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

keep all hydraulic lines, fittings, and couplers tight and free of leaks before and during use.

Clean reflectors and lights before transporting.


Shut the combine off when connecting the machine hydraulics.

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

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

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SAFETy



2.5 HyDRAULIC SAFETy

Always place all combine hydraulic controls in neutral before disconnecting from combine or working on hydraulic system.

Make sure that all components in the hydraulic system are kept in good condition and are clean.

Relieve pressure before working on the hydraulic system.

Replace any worn, cut, abraded, flattened or crimped hoses.

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

Wear proper hand and eye protection when search-ing for a high-pressure hydraulic leak. Use a piece of wood or cardboard as a backstop instead of hands to isolate and identify a leak.

If injured by a concentrated high-pressure stream of hydraulic fluid, seek medical attention im-mediately. Serious infection or toxic reaction can develop from hydraulic fluid piercing the skin surface.

Before applying pressure to the system, make sure all components are tight and that lines, hoses, and couplings are not damaged.

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2.6 PTO (POWER TAKE-OFF) SAFETy

keep bystanders, especially children, away from drive shafts.

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

Do not remove or modify protective shields or guards.

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

keep guards and shields in place at all times while operating.

Replace all damaged or missing parts or shields with the correct original manufacturer’s parts.

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

Clothing worn by the operator must be fairly tight. Never wear loose-fitted jackets, shirts, or pants when working around the drive shafts. Tie long hair back or put under a cap.

keep hydraulic hoses, electrical cords, chains, and other items from contacting the drive shafts.

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

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SAFETy



2.7 TRANSPORT SAFETyMake sure you are in compliance with all local regula-tions regarding transporting equipment on public roads and highways.

It is the responsibility of the owner to know the light-ing and marking requirements of the local highway authorities and to install and maintain the equipment to provide compliance with the regulations. Add extra lights when transporting at night or during periods of limited visibility.

See the Owner/Operator’s manual that came with your combine and header for proper transportation.

2.8 STORAGE SAFETyStore the unit in an area away from human activity.

Do not permit children to play on or around the stored machine.

See the Owner/Operator’s manual that came with your combine and header for proper storage.

2.9 ASSEmBLy SAFETyAssemble in an area with sufficient space to handle the largest component and access to all sides of the machine

Use only lifts, cranes and tools with sufficient capacity for the load.

When necessary, have someone assist you.

Do not allow spectators in the working area.

Be sure to read the Maintenance Safety Section.

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2.10 SAFETy DECALSkeep safety decals clean and legible at all times.

Replace safety decals that are missing or have become illegible.

Replaced parts that displayed a safety decal should also display the current decal.

Decals that need to be replaced, are to be placed back in the original location. See Section 3 for correct placement of safety decals.

Safety decals are available from your authorized dealer or the factory.

HOW TO INSTALL SAFETy DECALS:

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 the backing paper.

Remove the smallest portion of the split backing pa-per.

Align the decal over the specified area and carefully press the small portion with the exposed sticky back-ing in place.

Slowly peel back the remaining paper and carefully smooth the remaining portion of the decal in place.

Small air pockets can be pierced with a pin and smoothed out using the piece of decal backing pa-per.

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7.

SAFETy



2.11 SIGN-OFF FORmCrary 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 maintaining the equipment must read and clearly understand ALL Safety, Operating and Maintenance information presented in this manual.

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

Make these periodic reviews of SAFETY and OPERATION a standard practice for all of your equipment. An untrained 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 have read and understand the information in the owner’s manual and have been instructed in the operation of the equip-ment.

SIGN - OFF FORm

SAFETy

DATE EmPLOyEE SIGNATURE EmPLOyER SIGNATURE


The types of safety decals and locations on the equipment are shown in Figure 3.1. Good safety requires that you familiarize yourself with the various safety decals, the type of warning and the area, or particular function related to that area, that requires your SAFETY AWARENESS.


REMEMBER - If safety decals have been damaged, removed or become illegible or parts have been replaced without safety decals, new decals must be applied. New safety decals are available from the manufacturer or an authorized dealer.

A B

Figure 3.1 - Decal Location

Section SAFETy DECALS3

PN 11001 - Decal, Caution

PN 11002 - Decal, Warning


Read all instructions to become familiar with the parts and procedure used before starting the actual work.

You may refer to the Crary Air Reel parts catalog for ad-ditional aid in assembling the Air Reel.

4.1 UNCRATINGLocate the manifold and bats crate.

Cut the metal bands and remove the 2 x 4’s and saddle tops (Figure 4.1).

Remove the bat assemblies from the crate and place to the side.

Remove the lag screws from the mounting clamps (Figure 4.2).

Using an overhead hoist and a nylon strap, or sling re-move from crate, and set down on two steel sawhorses (or equivalent) positioned two to four inches from the ends of the manifold (Figure 4.3).

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Figure 4.1 - Manifold and Bats Crate



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ImPORTANTThe sawhorses must be capable of supporting 500 pounds each.

The sawhorses must be at least 3 feet high.

The sawhorses must be blocked to keep the manifold from rolling.

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3.

Assemble in an area with sufficient space to handle the largest component and access to all sides of the machine

Use only lifts, cranes and tools with sufficient capacity for the load.

When necessary, have someone assist you.

Do not allow spectators in the working area.

Be sure to read the maintenance safety section

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•

•

•

•

Assembly Safety


4.2 ECCENTRIC mOUNT INSTALLATION

Open Box 3 and sort bolts according to their size and length.

Rotate the manifold on the stands so that the driveshaft is at the 12:00 position.

Assemble the RH. & LH. Eccentric Mount Plates (with the nylon rollers facing to the center of the manifold) to the RH & LH End Clamps using six 3/8” x 1” carriage bolts, twelve 3/8” SAE flat washers and six 3/8” center locknuts. Do not tighten yet. (Figure 4.4 & 4.5).

Align the 5th tooth on the RH & LH eccentric mounting plate assemblies with the indicator mark on the RH & LH end clamps.

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

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NOTEThe back side of the manifold is opposite that of the large Air Reel Decal.

NOTEThe default pitch angle is with the 5th tooth on the eccentric mounting plate assembly aligned with the indicator mark on the RH & LH End Clamps. See Section 5.6 for additional information.

NOTEDo not tighten the nuts for the nylon rollers yet (Figure 4.6).

Figure 4.6 - Do Not Tighten Nuts Yet

Figure 4.4 - LH Eccentric Mounting Plate Assembly.

Figure 4.5 - RH Eccentric Mounting Plate Assembly.


4.3 IDLER GEAR INSTALLATION (BACK SIDE OF mANIFOLD)

Assemble one idler gear assembly each to the RH & LH end clamps and to all idler mount clamps (back side of manifold only) using one 3/8” x 2” bolt, three 3/8” flat washers and one 3/8” center locknut per each idler gear assembly (Figure 4.7 & 4.8).

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

1.

2.

4.4 REEL BAT ARm INSTALLATIONSlide the reel bat arm assemblies over the manifold assembly. Position each assembly onto the pinion gears and the idler gears of the manifold assembly (Figure 4.9).

Align the reel bat arm assemblies so all of the arms are in-line with one another.

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NOTEThe outside face of the arms of the reel bat arm as-semblies must face away from the pillowblock.

Figure 4.7 - Idler Gear Assembly to RH End Clamp Assembly

Figure 4.9 - Reel Bat Arm Assembly to Manifold

Figure 4.8 - Idler Gear Assembly to Idler Clamp Assembly

�0 John Deere Air Reel Owner’s Manual

Figure 4.11 - Tightening Locknuts of Idler Gears

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4.5 IDLER GEAR INSTALLATION (FRONT SIDE OF mANIFOLD)

Assemble one idler gear assembly each to the RH & LH end clamps and to all idler mount clamps (front side of manifold only) using one 3/8” x 2” bolt, three 3/8” flat washers and one 3/8” center locknut per each idler gear assembly (Figure 4.10).

Insert a small pry bar between the outside wall of the manifold tubing and the idler gears. Apply approxi-mately 5 lbs. of force to slide the gear away from the manifold (Figure 4.11).

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

Check the alignment of the reel bat arm assembly with the pinion and idler gears by looking from the front and rear of the manifold.

Rotate the reel arm assemblies to ensure they turn freely.

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Figure 4.10Idler Gear Assembly to RH End & Idler Clamp Assembly


Figure 4.12 - Apply Self Adhesive Foam Seals

Figure 4.13 - Fasten Screws

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4.6 AIR TUBE INSTALLATIONRoll the manifold over so that the air tube holes in the bottom of the manifold are at the 12:00 position.

Apply the self adhesive foam seals (Figure 4.12).

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

B. Remove the self adhesive foam seal from the backing, align with the airtube hole and press firmly onto the manifold.

Assemble the single air tubes to the manifold.

A. Locate three 11/32” x 7/8” self tapping screws per each air tube.

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

C. Drive three 11/32” x 7/8” self tapping screws through the air tube into the holes of the mani-fold (Figure 4.13).

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

Assemble the double air tubes to the ends of the mani-fold (one per end).

A. Follow Step 3 (A thru C) for installation of the double air tubes.

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4.

NOTEMake sure that the opening of the single and double air tubes face towards rear of Air Reel (Figure 4.14).

NOTEYou may want to use an impact wrench for this opera-tion. Do not exceed 18 Ft-lbs. torque.

Figure 4.14 - Installation of Air Tubes

�� John Deere Air Reel Owner’s Manual

4.7 REEL BAT INSTALLATIONRemove the plastic bearing caps by removing one 5/16” x 2” bolt, one 5/16” center locknut and two 1/4” flat washers per each reel arm (Figure 4.15).

Assemble the reel bat assemblies to the reel arms.

Determine the correct orientation of the reel bat. Note: The RH and LH pivot strap points to the rear of the Air Reel (Figure 4.16)

Position the reel bats into the bearing bases.

Reattach the plastic bearing caps, by installing one 5/16” x 2” bolt, one 5/16” center locknut and two 1/4” flat washers per each reel arm (Figure 4.15).

Tighten the 5/16” x 2” bolts to 100 In-lbs. Note: Do not exceed the recommended torque of 100 In-lbs.

Continue with steps 1, & 2 until all six reel bats are installed.

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3.

NOTEOnly remove one bolt when removing the plastic bear-ing cap.

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Figure 4.15 - Remove Plastic Bearing Caps

Figure 4.16 - Install Reel Bats


B. Align the mounting holes of the hydraulic motor with the mounting holes of the hydraulic motor mount.

C. Fasten with the supplied 1/2” x 1-1/2” bolts, two 1/2” flat washers and two 1/2” center lock-nuts. Tighten coupler onto the motor shaft and the manifold drive shaft.

D. Torque the 1/2” centerlock nuts to their speci-fied torque.

Slide the brace clamp assemblies onto each end of the manifold. DO NOT TIGHTEN AT THIS TIME.

6.

Refer to Figure 4.17 during installation.

Determine the drive side of the manifold (right hand end for all JD Headers).

Slide the shaft coupler onto the driveline shaft.

Install the hydraulic motor.

A. Line up the key on the shaft of the hydraulic motor with the keyway of the shaft coupler.

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3.

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NOTEIf you have the speed sensor option proceed to Section 4.18.1 and follow Steps 5, 8, 9 and 10.

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

NOTEThe brace clamp assemblies will be used during reel to header assembly.

Figure 4.17 - Hydraulic Motor Installation

4.8 HyDRAULIC mOTOR INSTALLATION


4.9 ECCENTRIC ARm INSTALLATIONRefer to Figure 4.18 during installation.

Slide an eccentric arm assembly over each end of the manifold making sure that the end shield faces towards the outside.

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

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

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

Adjust each plastic roller against the eccentric ring and tighten to specified torque.

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NOTEThe plastic rollers should turn with the reel.

Figure 4.18 - Eccentric Arm Installation


Clearance of 42” is required between the outside edge of the RH tire and the RH inside edge of the header in order to mount the standard fan/gearbox.

A fan/gearbox neck extension kit can be purchased for headers smaller than 20’ on combines with dual tires (see Section 4-18).

A support bearing is provided on 25’-30’ headers.

Disassembly of existing header components.

Remove quick lock pins and the right-hand side end shield.

Loosen chain tightener (A) and remove chain (B) from sprockets (Figure 4.19)

Remove flange lock nut (C) and sprocket (D). Do not discard sprocket, it is reused (Figure 4.19).

Remove bolts (E) securing bracket (F) to angle support; remove bracket and discard (Figure 4.20)

Remove bolts (G) securing bearing support to angle. Remove drive shaft and bearing support. (925 & 930 only - retain bearing support and hardware) (Figure 4.20)

Remove clutch from shaft; the clutch will be reused.

One support bearing is needed on 25’ and 30’ head-ers. Remove the 1-1/8” hex or 1-1/4” round bearing and flangettes from the bearing mount plate. The bearing mount plate will be reused for the right hand drive installation.

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7.

Figure 4.20

Figure 4.19

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4.10 RIGHT HAND DRIvE KIT INSTALLATION

4.10.1 HEADER PREPARATION (EXCLUDING, CONTOUR mASTER, SIDEHILL AND “F” SERIES HEADERS)


Figure 4.23

4.10.3 HEADER PREPARATION “F” SERIES HEADERSDisassembly of existing header components.

Remove right-hand side end shield.

Loosen chain tightener (A), this is done to ease removal of shaft from slip clutch (Figure 4.24).

Open auger slip clutch shield by removing two bolts (shield is hinged at bottom) (Figure 4.22).

Remove the bolt and locknut (B) (Figure 4.22).

Remove the three bolts from the flangette. Remove the bearing from the bracket and remove the shaft from back of header (Figure 4.25).

On 18’ headers, the bearing mount bracket must be removed from back of header to allow for installation of the mount plate support.

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Figure 4.22

Figure 4.24

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Figure 4.25

4.10.2 HEADER PREPARATION CONTOUR mASTER & SIDEHILL Disassembly of existing header components.

Remove quick lock pins and the right-hand side end shield.

Loosen chain tightener (A). This is done to ease re-moval of shaft from slip clutch (Figure 4.21).

Open auger slip clutch shield by removing two bolts. (shield is hinged at bottom) (Figure 4.22).

Remove the bolt and locknut (B) (Figure 4.22).

Remove bolts (C), bracket (D) and shaft (E). The bracket, bearing and shaft will not be used (Figure 4.23).

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Figure 4.21


mOUNT PLATE SUPPORT LOCATION 600 SERIES HEADERS

Refer to Figure 4.27 for correct locations and measurements.

Mark and drill the two 17/32” holes on the top por-tion of the header for the top of the mount plate support.

Mark and drill the two 17/32” holes on the bottom portion of the header for the bottom of the mount plate support (Figure 4.26).

Position the mount plate support and tighten the bolts to the specified torque.

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Figure 4.28 Support Plate Locations and Measurements (All Other Headers)

ROUND TUBE

OPEN SPACE

Ø17/32" THRU(2)

THIS LINE REPRESENTS THEINSIDE EDGE OF THE RIGHT

HAND SIDE OF THE HEADER

Ø13/32" (4) THRUHOLES FOR SHIELD MOUNT BRACKETSNOTE: DRILL ONLY IF YOUR SPECIFICINSTALLATION REQUIRES YOU TO DO SO

THIS LINE REPRESENTSTHE BOTTOM OF THE BACKSHEET OF THE HEADER

THIS LINE REPRESENTS THEBOTTOM OF THE TUBE ON THEUNDERSIDE OF THE HEADER

DRILL 27/64" THRU(ONE WALL ONLY)

TAP 1/2"-13 NC

24.094.25

16.75

5.19

1.13

6.13 22.22

2.1929.38

23.63

4.10.4 FAN / GEARBOX mOUNTING

ROUND TUBE

Ø17/32" THRU(2)

THIS LINE REPRESENTS THEINSIDE EDGE OF THE RIGHT

HAND SIDE OF THE HEADER

THIS LINE REPRESENTSTHE BOTTOM OF THE BACKSHEET OF THE HEADER

THIS LINE REPRESENTS THEBOTTOM OF THE TUBE ON THEUNDERSIDE OF THE HEADER

DRILL 17/32" THRU

28.844.25

6.13 26.97

23.63 24.25

Figure 4.27 Support Plate Location and Measurements (600 Series Headers)

ALL OTHER HEADERS

Refer to Figure 4.28 for correct locations and measurements.

Mark and drill the two 17/32” holes on the top portion of the header for the top of the mount plate support.

Mark and drill the two 27/64” holes, tap to 1/2”-13 NC for the bottom of the mount plate support.

Mark and drill the four 13/32” holes for the shield mount brackets according to the measurements on the diagram below. For contour master and “F” series headers: No holes need to be drilled for the shield mount brackets. The existing plastic clutch shield will be used.

Position the mount plate support and tighten the bolts to the specified torque.

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4.

WARNINGFor 600 Series headers, do not drill through the bottom holes of the mount plate support and into the round tube at the bottom of header. The tube contains a hydraulic accumulator that could be punctured. See Figure 4.28 for correct bottom hole location.

Figure 4.26 - 600 Series Bottom Mounting Holes Location.


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Figure 4.29 - Fan/Gearbox Mounting

FAN/GEARBOX mOUNTING600 SERIES HEADERS

Refer to Figure 4.28 during mounting.

Check the gearbox and if necessary, fill the gearbox with lube before use.

Use Mobilube HD SAE 75W-90 Gear lube or equivalent with the following specifications:

API Service GL-5MIL-L-2105D Capacity:MACk GO-H 40 oz.

Attach gearbox mounting plates to the mount plate support. DO NOT TIGHTEN AT THIS TImE.

Lift the fan/gearbox into position using a floor jack or overhead hoist and secure to the mounting plates with four 1/2” bolts and washers. DO NOT TIGHTEN AT THIS TImE.

keep fan/gearbox suspended with hoist or jack for the next part of the installation.

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4.

ALL OTHER HEADERS

Refer to Figure 4.29 during mounting.

Check the gearbox and if necessary, fill the gearbox with lube before use.

Use Mobilube HD SAE 75W-90 Gear lube or equivalent with the following specifications:

API Service GL-5MIL-L-2105D Capacity:MACk GO-H 40 oz.

Attach gearbox mounting plates to the mounting plates. DO NOT TIGHTEN AT THIS TImE.

Lift the fan/gearbox into position using a floor jack or overhead hoist and secure to the mount plate support with four 1/2” bolts and washers. DO NOT TIGHTEN AT THIS TImE.

keep fan/gearbox suspended with hoist or jack for the next part of the installation.

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4.

4.10.4 FAN/GEARBOX mOUNTING (CONT’D)

WARNINGFor 600 Series headers, do not drill through the bottom holes of the mount plate support and into the round tube at the bottom of header. The tube contains a hydraulic accumulator that could be punctured. See Figure 4.28 for correct bottom hole location.


TEXT PLACEHOLDER

THIS PAGE INTENTIONALLy LEFT BLANK.


4.10.5 RIGHT HAND DRIvE KIT INSTALLATIONS (600 SERIES)

WARNINGPlace all controls in neutral or off, stop combine engine, set parking brake, remove ignition key, set cylinder stops, wait for all moving parts to stop, then properly block machine before servicing, adjusting, repairing, or unplugging.

RIGHT HAND DRIvE KIT PARTSKIT # DESCRIPTION26152 RIGHT HAND DRIVE kIT 30’ (600 SERIES)26174 RIGHT HAND DRIVE kIT 25’ (600 SERIES)26297 RIGHT HAND DRIVE kIT 20’ (600 SERIES)26298 RIGHT HAND DRIVE kIT 22’ (600 SERIES)27241 RIGHT HAND DRIVE kIT 35’ (600 SERIES)

INSTALLING THE SUPPORT BEARING mOUNT BRACKET

The bearing mount bracket is mounted to the first support left of the gearbox (Figure 4.30).

Align the bearing mount bracket to the existing holes on the support. Mark and drill a hole on the front of the support.

Bolt the bearing mount bracket to the support (Figure 4.30).

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Figure 4.30 - Support Bearing Mount Bracket

REFER TO FIGURE 4.31 FOR THE FOLLOWING STEPS.

Remove the three 5/16” x 1-1/2” bolts from the gear-box sleeve on each side of the gearbox. Install two bushings to the gearbox, aligning the keyways of the bushings with each other at the 12:00 position. Install the three 5/16” x 1-1/2” bolts to the bushings. Do not tighten at this time.

Slide the gearbox shaft through the bearing mount bracket, bushing shield weldment and the gearbox from the left hand side. There should be approximately 3” of shaft protruding on the left hand side of the 1-3/8” bearing insert. This is needed to attach the driveline. The key for the left hand bushing needs to be installed at this time.

Insert the key for the right hand bushing and tighten bolts in the bushing on both sides of gearbox to 15 Ft-lbs. or 180 In-lbs. Tighten set screws over keys at this time.

Bolt bushing shield weldment to the right hand side of gearbox using two 1/2” bolts and 1/2” washers.

Bolt bushing shield weldment to the left hand side of gearbox using two 1/2” bolts and 1/2” washers.

Measure and cut the drive shaft shield to fit between bushing on left hand side of gearbox and bearing mount plate welded on back of header. Slide drive shaft shield over shaft and through bearing mount plate.

Install bearings and flangettes to bearing mount plate welded on back of header.

Check for shaft alignment up & down and front & back.

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8.

NOTESteps 5-7 apply to 22’, 25’ and 30’ headers. For all other headers, skip to Step 8.

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ImPORTANTCorrect shaft alignment is critical.

Tighten the bolts securing the gearbox mounting plate to the gearbox and the bolts securing the gearbox mounting plate to the mount support plate.

For 22’, 25’ and 30’ headers, bolt shield mount plate to bearing mount plate. For all other header sizes bolt shield mount plate directly to left hand side of gearbox.

Insert a 5/16” x 1-1/2” key into keyway at the left end of gearbox shaft. Slide the clutch end of the PTO driveline onto the gearbox shaft and tighten set screws.

Slide the slip clutch shield over the PTO driveline and fasten to the shield mount plate using the 5/16” x 3/4” bolts.

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11.

Figure 4.31 - Support Bearing Mount Bracket

4.10.5 RIGHT HAND DRIvE KIT INSTALLATIONS (600 SERIES) (CON’T)

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4.10.6 RIGHT HAND DRIvE KIT INSTALLATION (F SERIES)



Cut driveshaft shield to fit between bushing on right hand side of gearbox and auger slip clutch at right hand end of header.

Slide the gearbox shaft through bearing mount plate welded to back of header, bushing shield weldment and gearbox from the left hand side while simultaneously installing bushing shield weldment and short drive shaft shield over shaft on right hand side of gearbox. The key for right hand bushing needs to be installed at this time also. Insert hex end of gearbox drive shaft into hub on auger slip clutch and secure with 5/16” hardware.

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


Retighten auger drive chain (see header owner/oper-ator’s manual for the correct chain tension).

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2.

3.

4.

5.

6.


RIGHT HAND DRIvE KIT PARTSKIT # DESCRIPTION25370 RIGHT HAND DRIVE kIT, 18’ & 20’ (“F” SERIES)25371 RIGHT HAND DRIVE kIT, 22’ (“F” SERIES)25372 RIGHT HAND DRIVE kIT, 25’ (“F” SERIES)25373 RIGHT HAND DRIVE kIT, 30’ (“F” SERIES)

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


Measure and cut long drive shaft shield to fit between bushing on left hand side of gearbox and bearing mount plate welded on back of header. Slide drive shaft shield over shaft and through bearing mount plate.


Check for shaft alignment up & down and front & back. Tighten the bolts securing the gearbox mounting plate to the gearbox and the bolts securing the gearbox mounting plates to the mount plate support.

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



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4.10.6 RIGHT HAND DRIvE KIT INSTALLATION (F SERIES) (CON’T)

Figure 4.32 - F Series Right Hand Drive Kit Installation

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4.10.7 RIGHT HAND DRIvE KIT INSTALLATION (900 SERIES W/1-1/8” HEX DRIvE SHAFT)


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

Install the slip clutch onto the hex clutch shaft.

Remove the three 5/16” x 1-1/2” bolts from the gearbox sleeve on each side of the gearbox. Install two bushings to the gearbox, aligning the keyways of the bushings with each other at the 12:00 position. Install the three 5/16” x 1-1/2” bolts to the bushings. Do not tighten at this time.

Slide the gearbox shaft through the gearbox from the left side. Insert the 5/16” x 1-1/2” keys into the keyways of the round shaft and position the right hand end of the gearbox driveshaft within 1-1/2” of the left hand end of the clutch shaft.

Tighten the three bolts on the bushings on each side of the gearbox to 15 Ft-lbs. or 180 In-lbs. Tighten the set screws on the bushings on each side of the gearbox to secure the 5/16” x 1-1/2” keys into the keyways of the gearbox shaft.

Install the drive sprocket onto the right hand end of the gearbox drive shaft and secure with the roll pin.

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

Attach the two shield mount brackets to the previously drilled Ø13/32” holes, install two 3/8” x 1” bolts and 3/8” serrated flange nuts to lower holes only. Attach slip clutch shield to top holes of shield mount brackets and install 3/8” hardware. Install and tighten remaining bolts to shield assembly.

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RIGHT HAND DRIvE KIT PARTSKIT # DESCRIPTION24173 RIGHT HAND DRIVE kIT, HEx SHAFT (915 HEADER)

24174 RIGHT HAND DRIVE kIT, HEx SHAFT (18’/20’ HEADER)

24175 RIGHT HAND DRIVE kIT, HEx SHAFT (22’ HEADER)



Reinstall auger drive chain onto sprocket and tighten (see header owner/operator’s manual for the correct chain tension).


Slide the bushing shield weldment over the gearbox driveshaft and secure to left hand side of gearbox using two 1/2” bolts and 1/2” washers.

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

Measure between bearing and gearbox bushing for correct length, and cut driveshaft shield to measured dimension.

Remove bearing mount plate, slide driveshaft shield onto gearbox driveshaft and reinstall bearing and mount plate.

Check for shaft alignment up & down and front & back. Tighten the bolts securing the gearbox mounting plate to the gearbox and the bolts securing the gearbox mounting plate to the mount plate support.

For 25’ and 30’ headers, bolt shield mount plate to bearing mount plate. For all other header sizes bolt shield mount plate directly to left hand side of gearbox.



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

Depending upon the combine model it may be neces-sary to grind a notch or groove in the feederhouse shaft to accommodate the quick connect button of the PTO driveline. 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 Series and prior combines.

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20.

NOTESteps 11-14 apply to 25’ and 30’ headers. For all other headers, skip to Step 15.


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4.10.7 RIGHT HAND DRIvE KIT INSTALLATIONS (900 SERIES W/1-1/8” HEX DRIvE SHAFT)

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Figure 4.33 - 900 Series Drive Kit Installation

4.10.8 RIGHT HAND DRIvE KIT INSTALLATIONS, HEADERS FOR CONTOUR mASTER COmBINES

For installation of these right hand drive kits, refer to Sec-tion 4.10.6. The only variation between these kits and the “F” Series kits is the style of bearing mount plate. On “F” Series headers, the bearing mount plate is welded to back of header, while on contour master headers, the bearing mount plate bolts to back of header.

RIGHT HAND DRIvE KIT PARTSKIT # DESCRIPTION24178 RIGHT HAND DRIVE kIT, (18’/20’ CTR MASTER)

24179 RIGHT HAND DRIVE kIT, (22’ CTR MASTER)




4.10.9 RIGHT HAND DRIvE KIT INSTALLATION (SIDEHILL)

RIGHT HAND DRIvE KIT PARTSKIT # DESCRIPTION25466 RIGHT HAND DRIVE kIT, HEx SHAFT (18’, 20’ SIDEHILL)

25967 RIGHT HAND DRIVE kIT, HEx SHAFT (22’ SIDEHILL)



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Cut driveshaft shield to fit between bushing on right hand side of gearbox and auger slip clutch at right hand end of header.

Slide the gearbox shaft through bearing mount plate welded to back of header, bushing shield weldment and gearbox from the left hand side while simultaneously installing bushing shield weldment and short drive shaft shield over shaft on right hand side of gearbox. The key for right hand bushing needs to be installed at this time also. Insert hex end of gearbox drive shaft into hub on auger slip clutch and secure with 5/16” hardware.

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


Retighten auger drive chain (see header owner/oper-ator’s manual for the correct chain tension).

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2.

3.

4.

5.

6.




Measure and cut long drive shaft shield to fit between bushing on left hand side of gearbox and bearing mount plate welded on back of header. Slide drive shaft shield over shaft and through bearing mount plate.


Check for shaft alignment up & down and front & back. Tighten the bolts securing the gearbox mounting plate to the gearbox and the bolts securing the gearbox mounting plates to the mount plate support.

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

Insert a 5/16” x 1-1/2” key into keyway at the left end of gearbox shaft. Slide the slip clutch assembly onto the gearbox shaft and tighten set screws.

Insert the round end of the round/hex shaft adapter into the slip clutch hub and tighten set screws.

Slide the OEM driveline onto the hex end of the round/hex shaft adapter.

Slide the slip clutch shield over the OEM driveline and slip clutch assembly. Fasten to the shield mount plate using the 5/16” x 3/4” bolts.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.




4.10.9 RIGHT HAND DRIvE KIT INSTALLATION (SIDEHILL) (CON’T)

Figure 4.34 - Sidehill Combines, Drive Kit Installation

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RIGHT HAND DRIvE KIT PARTSKIT # DESCRIPTION22738 RIGHT HAND DRIVE kIT, ROUND SHAFT (215 HEADER)

22739 RIGHT HAND DRIVE kIT, ROUND SHAFT (915 HEADER)

22741 RIGHT HAND DRIVE kIT, ROUND SHAFT (216 HEADER)

24051 RIGHT HAND DRIVE kIT, ROUND SHAFT (18”-20”)

24052 RIGHT HAND DRIVE kIT, ROUND SHAFT (22”-24”)

24103 RIGHT HAND DRIVE kIT, ROUND SHAFT (25”)

24053 RIGHT HAND DRIVE kIT, ROUND SHAFT (30”)



4.10.10 RIGHT HAND DRIvE KIT INSTALLATION (200, 900 SERIES, 1-1/4” ROUND DRIvE SHAFT)

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

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


Slide the gearbox shaft through the gearbox from the left side. Insert the 5/16” x 1-1/2” keys into the keyways of the round shaft and position the right hand end of the gearbox driveshaft within 1-1/2” of the left hand end of the clutch shaft.

Tighten the three bolts on the bushings on each side of the gearbox to 15 Ft-lbs. or 180 In-lbs. Tighten the set screws on the bushings on each side of the gearbox to secure the 5/16” x 1-1/2” keys into the keyways of the gearbox shaft.

Install the drive sprocket onto the right hand end of the gearbox drive shaft and secure with roll pin.

Align the slip clutch sprocket and sprocket on gearbox driveshaft. Install the double roller chain to the drive sprocket and slip clutch sprocket.

1.

2.

3.

4.

5.

6.

7.

Attach the two shield mount brackets to the previously drilled Ø13/32” holes, install two 3/8” x 1” bolts and 3/8” serrated flange nuts to lower holes only. Attach slip clutch shield to top holes of shield mount brackets and install 3/8” hardware. Install and tighten remaining bolts to shield assembly.

Reinstall auger drive chain onto sprocket and tighten (see header owner/operator’s manual for the correct chain tension).


STEPS 11-14 ONLy APPLy TO 25’ AND 30’ HEADERS. FOR ALL OTHER HEADERS, SKIP TO STEP # 15.

Slide the bushing shield weldment over the gearbox driveshaft and secure to left hand side of gearbox using two 1/2” bolts and 1/2” washers.

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

Measure between bearing and gearbox bushing for correct length, and cut driveshaft shield to measured dimension.

Remove bearing mount plate, slide driveshaft shield onto gearbox driveshaft and reinstall bearing and mount plate.

Check for shaft alignment up & down and front & back. Tighten the bolts securing the gearbox mounting plate to the gearbox and the bolts securing the gearbox mounting plate to the mount plate support.

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



Install the driveline bracket support to vertical upright closest to feeder house using 3/8” x 3/4” carriage bolts. The combine end of driveline will cradle in this bracket.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.



4.10.10 RIGHT HAND DRIvE KIT INSTALLATION (200, 900 SERIES, 1-1/4” ROUND DRIvE SHAFT)

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Figure 4.35 - 200 & 900 Series 1-1/4” Round Drive Shaft Right Hand Drive Kit Installation


4.11 REEL SUPPORT INSTALLATION (HyD. FORE AND AFT) (600 SERIES)

Avoid crushing injury or death from fall of raised reel.

Before working on or under a raised reel, place all controls in neutral or off, stop combine engine, set parking brake, remove ignition key, wait for all moving parts to stop and set cylinder stops on both sides of reel before servicing, ad-justing, repairing, or unplugging.

WARNING

Figure 4.36

Figure 4.37

Figure 4.38

4.11.1 REPLACING THE LIFT CyLINDER yOKE

Support the reel with a hoist so the hydraulic cylinder can be removed.

Remove the reel lift cylinder (Figure 4.36).

Remove the OEM cylinder yoke (Figure 4.36).

With the jam nut turned down completely, mark the cylinder so there is 2” of thread above the nut. Cut off at the mark. The cylinder shown has already been cut (Figure 4.37).

Thread the new yoke onto the cyl inder rod (Figure 4.38).

1.

2.

3.

4.

5.

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4.11.1 REPLACING THE LIFT CyLINDER yOKE (CON’T)

Figure 4.40

Figure 4.42

The cylinder safety lock must be shortened (Figure 4.39).

Remove the safety lock from the reel arm mount.

Measure 17.44” from the center of the pivot bolt towards the bottom end and mark.

Cut the safety lock and reinstall onto the reel arm mount.

Install the cylinder onto the head with the taper on the yoke to the rear (Figure 4.40). Install the lower pivot pin into the bottom hole (Figure 4.41).

Reposition the stop latch -1-1/4” forward on the under-side of the reel arm (Figure 4.42).

Remove the latch.

Drill two new holes 1-1/4” from the existing holes.

Reattach the stop latch.

6.

A.

B.

C.

7.

8.

A.

B.

C.

Figure 4.39

Figure 4.41


Figure 4.43 - Reel Support Installation LH Side

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

Slide the RH and LH reel support brackets onto their respective reel arms (Figure 4.44 & 4.45) and attach to the hydraulic cylinders

Remove the fore/aft sensor and mount bracket as-sembly from the JD RH reel support and bolt to the bracket on the Crary RH reel support assembly (Figure 4.43).

Check clearance of the reel support assembly to header reel arm components.

Bleed air from the lift cylinders.

1.

2.

3.

4.

5.

4.11.2 ATTACHING THE REEL SUPPORT ASSEmBLy



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4.12 REEL SUPPORT INSTALLATION (HyD. FORE AND AFT) (200, 900, 900F SERIES)

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

Slide the RH and LH reel support brackets onto their respective reel arms (Figure 4.46 & 4.47).

Pin the end of the hydraulic cylinder into the yoke on both of the reel support brackets.


Install the stop bolt at the front of each reel arm.

1.

2.

3.

4.

5.



WARNING

Figure 4.47 - Reel Support Installation (Hydraulic) LH Side

Figure 4.46 - Reel Support Installation (Hydraulic) RH Side

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4.13 REEL SUPPORT INSTALLATION (mANUAL FORE AND AFT) (200, 900, 900F SERIES)Insert the reel support pad underneath the top of each reel support bracket.

Slide the RH and LH reel support brackets onto their respective reel arms.\ (Figure 4.48 & 4.49).

Slide adjustment bracket weldment onto each reel arm so that the threaded rod is to the outside of the reel arm.

Thread rod of adjustment bracket into the reel sup-port brackets approximately halfway down the length of the rod.

Secure the adjustment bracket to the reel arm using the bolts and nuts provided. It is not necessary to drill holes in the arm.


Install the stop bolt at the front of each reel arm.

1.

2.

3.

4.

5.

6.

7.



WARNING

Figure 4.49 - Reel Support Installation (Manual) LH Side

Figure 4.48 - Reel Support Installation (Manual) RH Side

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4.14 REEL TO HEADER INSTALLATION

While performing the following steps, refer to Figure 4.50.

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

Center the reel between the reel arms.

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

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

1.

2.

3.

4.


NOTEBolt 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 motor end of the reel.

Figure 4.50 - Reel to Header Install

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4.15 mANIFOLD TILT INSTALLATION


Slide the pivot clamp assembly over the manifold end opposite of the hydraulic motor and position it next to the reel support bracket. Do not tighten the clamp at this time.

1.


Place the tube cap on the end of the manifold tube and set with the t-bolt clamp.

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

Rotate the manifold so the line of sight along the air tubes is directed just behind the cutterbar (see Sec-tion 5.6)

Extend the actuator approximately 1/2 the length of the full extension (approx. 2”).

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

Tighten the pivot clamp assembly around the manifold tube.

2.

3.

4.

5.

6.

7.

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

NOTEBe sure the reel can be rotated by hand before attach-ing the actuator.

Figure 4.51 - Manifold Tilt Installation

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4.16 AIR HOSE INSTALLATION

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

Install one 8-11/16” t-bolt clamp to the 45° elbow, do not tighten yet (Figure 4.52).

Spray soapy water to the inside of the 45° elbow and slip onto the fan outlet. Position the 45° elbow so it points toward the 2:00 position.

Install one 8-11/16” t-bolt clamp to the 90° elbow, do not tighten yet.

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

1.

2.

3.

4.

5.


Install the hose connector weldment to the reel arm of the header using the two 5/16” x 2-1/2” bolts and two 5/16” serrated flange nuts. Tighten to specified torque.

Install one 8-11/16” t-bolt clamp to the opposite end of the 90° elbow. Spray soapy water on the inside of the 90° elbow.

The flex hose/band assembly must be divided into 2 pieces at this time. The hose lengths must allow for the complete movement up & down and fore & aft of the reel. Measure and cut the length required for flex hose piece 1 & 2.

Install the elbow support band end of the flex hose (piece 1) into the end of the 90° elbow and tighten the t-bolt clamp.

Slide a 8-1/4” t-bolt clamp over the opposite end of flex hose (piece 1) and slide onto the hose connector weldment. Tighten the t-bolt clamp.

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

Wrap the flex hose chain assembly around flex hose (piece 1) and the reel arm of the header. Clasp ends of chain together.

6.

7.

8.

9.

10.

11.

12.

Figure 4.52 - Air Hose Installation

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4.17 ELECTRICAL WIRING INSTALLATION


Mount the switch plate assembly in a convenient place inside the cab (use either velcro or bolts).

Run the red wires with fuse (15 Amp & 6 Amp) to a power source. Use the actuator switch harness if provided and the combine is equipped with the same type of auxiliary power supply.

1.

2.


Run the black wires to a suitable ground or to the actuator switch harness ground wires.

Route the long harnesses along the combine and header to the actuators (15 Amp Manifold Tilt; 6 Amp Air Volume) and plug in.

Mount the intermediate harness connectors to a con-venient location on the combine feederhouse.

3.

4.

5.

NOTEDisconnect the intermediate harness connector at the feederhouse when the header is disconnected from the combine.

Figure 4.53 - Wiring Schematic

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4.18 OPTIONAL EqUIPmENTOptional equipment is available for your Crary Air Reel. Call your nearest dealer for availability information.

4.18.1 SPEED SENSOR KITThe Crary Speed Sensor Gear kit (as an option) is needed on the Air Reel to use the automatic reel speed to ground speed option provided on some late model John Deere combines.

Relieve pressure from the hydraulic system.

Loosen and remove the 1/2” x 1-1/2” bolts from the hydraulic motor (Figure 4.56).

Loosen clamp screws on the shaft coupler.

Remove the shaft coupler and hydraulic motor.

Simultaneously slide the shaft coupler onto the driveline and the sensor gear weldment onto the shaft coupler. Do not tighten the set screw yet (Figure 4.54).

Install the hydraulic motor.

A. Line up the key on the shaft of the hydraulic motor with the keyway of the shaft coupler.

B. Align the mounting holes of the hydraulic motor with the mounting holes of the hydraulic motor mount.

1.

2.

3.

4.

5.

6.


WARNINGRelieve pressure before working on or near the hy-draulic system. Escaping pressurized hydraulic fluid can have sufficient force to penetrate your skin causing serious injury.

WARNINGThis representation may not reflect all models of header hydraulic systems.

C. Fasten with the supplied 1/2” x 1-1/2” bolts, two 1/2” flat washers and two 1/2” center lock-nuts. Tighten coupler onto the motor shaft and the manifold drive shaft.

D. Torque the 1/2” centerlock nuts to their speci-fied torque.

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

Bolt the sensor mount bracket to the outside of the hydraulic motor mount with the 3/8” x 3/4” Bolt, 3/8” flat washer and 3/8” nut. Do not tighten yet.

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 and gear. (0.020” is approximately 1/2 turn out from sensor bottoming out on gear. Some additional gap adjustment may be needed according to the sensor’s sensitivity.) Control of reel speed and display should function the same as the original equipment.

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

INSTALLING THE HyDRAULIC RELIEF vALvE (200 AND 900 SERIES ONLy).

Disconnect the 45° fitting from the steel return line for the reel drive motor.

Remove the bracket securing the top coupler from the back of header (two 1/4” bolts).

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

Install the 45° fitting into the straight fitting on relief valve.

Using the existing valve strap, bolt the relief valve to the location where the coupler was removed in Step 2.

7.

8.

9.

10.

1.

2.

3.

4.

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

NOTEThe brace clamp assemblies will be used during reel to header assembly.

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Reconnect the steel line to the 45° fitting.

Screw the return coupler onto the 90° fitting on the relief valve.

Run the system and check all lines for leaks.

6.

7.

8.

Figure 4.56 - Removing Hydraulic Motor

Figure 4.55 - Installing Speed Sensor

WARNINGBefore applying pressure to the system, make sure all components are tight and that lines, hoses and couplings are not damaged.

WARNINGWear proper hand and eye protection when search-ing for a high-pressure hydraulic leak. Use a piece of wood or cardboard as a backstop instead of hands to isolate and identify a leak.

Figure 4.57 - Installing Hydraulic Relief Valve

Figure 4.54 - Speed Sensor Installed

4.18.1 SPEED SENSOR KIT

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4.18.2 AUXILIARy REEL TINE KITThe Crary Auxiliary Reel Tine kit is recommended for crops that do not move easily from the knife to the auger at the ends of the header.

Remove one 1/2” x 2-1/2” button head bolt, two 1/2” flat washers, one pivot strap bushing and one 1/2” center locknut (Figure 4.58).

Simultaneously assemble the auxiliary reel tine as-sembly with the two steel machine bushings as shown in (Figure 4.59).

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

Insert the 3/8” x 2-1/2” carriage bolt through the square hole of the auxiliary reel tine assembly and fasten the 3/8” flat washer and 3/8” centerlock nut.

Tighten the 3/8” centerlock nut to the specified torque.

Repeat Steps 1 - 5 for each auxiliary reel tine assembly being installed.

1.

2.

3.

4.

5.

6.


NOTEMake sure the pitch of the plastic reel tine lines up with the existing reel tines.

Figure 4.58 - Loosen and Remove 1/2” Hardware and Bushing

Figure 4.59 - Assemble Auxiliary Reel Tine Kit

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4.18.3 GEARBOX / FAN EXTENSIONThe gearbox/fan extension option is designed to extend the fan up to eliminate clearance problems with headers smaller than 20’ and combines with dual tires. When install-ing the gearbox fan extension kit, follow this procedure.

Separate gearbox and fan. Refer to Figure 4.60.

Loosen the set screw securing the indicator weldment and remove from butterfly shaft.

Remove 3/8” x 1-1/4” bolts connecting fan housings and separate.

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

Remove fan rotor and spacer washers.

Remove bolts connecting lower fan housing to gearbox flange.

Attach extension shaft/hub assembly.

Bolt extension shaft/hub assembly to gearbox flange with 1/2” x 1” bolts. Rotate extension shaft so the key in the coupler at the bottom of the shaft lines up with the keyway on the gearbox shaft.

Place bearing retainer plate and washers onto end of extension shaft/hub assembly.

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

Attach spacer washers and fan rotor to exten-sion shaft and secure with washer and 3/4” castle nut.

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

Reinstall indicator weldment onto butterfly shaft and tighten set screw.

1.

a.

b.

c.

d.

e.

2.

a.

b.

c.

d.

e.

f.


Mount gearbox/fan extension to combine.

Refer to Section 4.10.4 for fan/gearbox instal-lation instructions.

Select appropriate support bracket for com-bine model.

Bolt mounting bracket onto header.

Remove upper right hand bolt on gearbox mount plate. Bolt support bracket in the loca-tion bolt was removed using provided 1/2” x 1-1/2” bolt.

Attach gearbox/fan extension to support bracket with provided u-bolt.

Operate the Air Reel as instructed in this manual.

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b.

c.

d.

e.

f.

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FIGURE 4.60 - KIT, GEARBOX/FAN EXTENSION OPTION

KIT, GEARBOX/FAN EXTENSION OPTION

ITEm PART NUmBER DESCRIPTION qTy

1 7022 kEY, 3/16" SqUARE x 1-1/4" PLAIN 12 13014 U-BOLT, 3/8" x 3" x 4", FAN MOUNT ZP 13 15006 BOLT, 3/8" x 1" HHCS GR5 ZP 14 15012 BOLT, 1/2" x 1" HHCS GR5 ZP 15 15014 BOLT, 1/2" x 1-1/2" HHCS GR5 ZP 86 15031 WASHER, 3/8" FLAT ZP 27 15042 NUT, 3/8" HEx NC ZP 28 15049 NUT, 1/2" CENTERLOCk GR8 ZP 89 15051 NUT, 3/8" SERRATED FLANGE NC ZP 12

10 15055 NUT, 3/4" NF CASTLE ZP 111 15097 WASHER, 1/2" SAE FLAT ZP 812 15098 WASHER, 3/4" SAE FLAT ZP 113 15099 WASHER, 7/8" SAE FLAT ZP 214 15332 SCREW, 1/4"-20 x 1/4" SET 1

KIT, GEARBOX/FAN EXTENSION OPTION

ITEm PART NUmBER DESCRIPTION qTy

15 15364 BOLT, 3/8" x 1-1/4" HHCS GR5 ZP 12

16 16466 ROTOR, FAN, 12.88" x 2.5", 7/8"B, CW, HSPD, ALUM 1

17 21193 8" FAN, SIDE W/BUTTERFLY, RIGHT HAND 1

18 21194 8" FAN, SIDE W/BUTTERFLY, LEFT HAND 1

19 21444 PLATE, LARGE BUTTERFLY 120 22344 WELDMENT, INDICATOR 121 24510-12 PLATE, BEARING RETAINER 122 24639-12 BRACkET, ExTENSION SUPPORT 123 24640-12 BRACkET, ExTENSION SUPPORT 124 24641-12 BRACkET, ExTENSION SUPPORT 125 24643 ASSEMBLY, ExTENSION SHAFT/HUB 1

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The Crary Air Reel is designed to dramatically improve harvesting efficiency. Power is provided by the combine feeder and hydraulics. Be familiar with the machine before starting.

It is the responsibility of the owner or operator to read this manual and to train all other operators before they start working with the machine. In addition to the design and configuration of equipment, hazard control and accident prevention are dependent upon the awareness, concern, and prudence of personnel involved in the operation, trans-port, maintenance and storage of equipment or in the use and maintenance of facilities.

5.1 TO THE NEW OPERATOR OR OWNER

OPERATING SAFETy

Read and understand the Owner/Operator’s Manual and all safety decals before servicing, adjusting or repairing.

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

keep hands, feet, hair and clothing away from all moving and/or rotating parts.

Place all controls in neutral or off, lower header to the ground, stop combine engine, set parking brake, chock wheels, remove ignition key, wait for all moving parts to stop, before servicing, adjusting, repairing or unplugging.

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

1.

2.

3.

4.

5.

keep all hydraulic lines, fittings, and couplers tight and free of leaks before and during use.

Clean reflectors and lights before transporting.


Shut the combine off when connecting the machine hydraulics.

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

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

6.

7.

8.

9.

10.

11.

Follow all safety instructions exactly. Safety is everyone’s business. By following recommended procedures, a safe working environment is provided for the operator, bystand-ers and the area around the work site. Untrained operators are not qualified to operate the machine.

Many features incorporated into this machine are the result of suggestions made by customers like you. Read this manual carefully to learn how to operate the machine safely and how to set it to provide maximum efficiency. By following the operating instructions in conjunction with a good maintenance program, your Crary Air Reel will provide many years of trouble-free service.

Section OPERATION5


5.2 mACHINE COmPONENTSThe Crary Air Reel is designed to handle all types of beans and small grains such as wheat and barley.

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

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

Figure 5.1 - Machine Components

Air ManifoldDrive ShaftReel Bat Arm Assy.Air TubeReel Bat Assy.Reel TineHydraulic MotorEccentric Arm Assy.Gear BoxFan Fan HosePTO Driveline

A.B.C.D.E.F.G.H.I.J.k.L.

OPERATION


5.3 PRE-OPERATION CHECKLISTEfficient and safe operation of the Crary Air Reel requires that each operator reads and understands the operating procedures and all related safety precautions outlined in this section. A pre-operation checklist is provided for the operator. It is important for both personal safety and maintaining the good mechanical condition of the Air Reel that this checklist is followed.

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

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

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

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

Ensure that the machine is properly attached to the header and that mechanical retainers, such as quick pins are installed.

Check the cutterbar, reel area and drives for entangled material.

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

Visually inspect the hydraulic system for leakage, loose fittings, and damaged hoses. Tighten fittings, replace damaged components and wipe up leaked or excess hydraulic fluid.

Check condition of slip clutch friction discs. If install-ing replacement discs, adjust spring height to original height (See chart in section 8.3). Deviation from original setting may be needed depending upon disc wear.

5.4 mACHINE BREAK-INAlthough there are no operational restrictions on the Crary Air Reel when used for the first time, it is recommended that the following mechanical items be checked:

5.4.1 PRE-START INSPECTIONRead the owner’s Manual.

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

Check that all guards are installed and secured.

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

1.

2.

3.

4.

5.

6.

7.

8.

1.

2.

3.

4.

5.4.2 AFTER OPERATING FOR 2 HOURSRetorque fasteners and hardware.

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

Check that hydraulic hoses are not being pinched, crimped, or rubbing. Reroute as required.

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

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

The gearbox will generate heat. The typical operating temperature of the gearbox is 180° F to 220° F.

5.4.3 AFTER OPERATING FOR 10 HOURS:Retorque fasteners and hardware.

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

Check safety decals. Install new ones if required.

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

Check the plastic eccentric rollers for uneven wear.

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

1.

2.

3.

4.

5.

6.

1.

2.

3.

4.

5.

6.

OPERATION


5.5 CONTROLSBefore starting to work, all operators should familiarize themselves with the location and function of the controls and safety devices. Some machines may vary due to dif-ferent models of combines and headers.

mANIFOLD TILT:

Moving the toggle switch to the “Fore” position (Figures 5.2 & 5.3) extends the shaft of the electric actuator forward, rotating the manifold CCW and directing the air tubes towards the back of the header See Section 5.6 for the center stroke position which points the air tubes directly behind the cutterbar.

Moving the toggle switch to the “AFT” position (Figures 5.2 & 5.3) retracts the shaft of the electric actuator backward rotating the manifold CW and directing the air tubes towards the front of the header.

1.

a.

b.

Figure 5.2 Manifold Tilt & Fan Air Volume Toggle Switch

OPERATION

Figure 5.3 - Manifold Tilt & Fan Air Volume Toggle Switch

FAN AIR vOLUmE ACTUATOR:

Move the toggle to the open position (Figures 5.4 & 5.2) to open the butterfly plate; this increases air volume to the air tubes.

Move the toggle to the closed position (Figures 5.4 & 5.2) to close the butterfly plate; this decreases air volume to the air tubes.

REEL LIFT:

Consult your owner’s manual that came with your header.

mANUAL REEL FORE & AFT ADJUSTmENT

Turn the adjustment bolt CW to pull the reel forward.

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

Adjust both sides evenly.

2.

a.

b.

3.

a.

4.

a.

b.

c.

INDICATOR (SHOWN FULLYCLOSED POSITION)

INDICATOR(FULLY OPENPOSITION)

FAN BUTTERFLYACUATOR

BUTTERFLYACUATOR

Figure 5.4 - Butterfly Indicator

Figure 5.5 - Right Side, Manual Reel Fore and Aft Adjustment


5.6 INITIAL ADJUSTmENTSSince all applications of the Air Reel are not the same, based on header and combine variations, some initial adjustments must be made to achieve peak performance of your Air Reel.

Adjustments are needed for best feeding as crop conditions change. Refer to Section 5.7 for operating hints.


5.6.1 INITIAL REEL ADJUSTmENTLower the reel until it is in its lowest position

Raise the cutterbar until it is in its highest position. Make sure the cutter bar is flexed to its highest position (or locked up) before setting minimum reel height.

The reel tines must clear the knife by 1 inch. Position the reel so that the reel tines sweep over the cutter bar and begin their lift just behind it.

Rotate the manifold so the line of sight along the air tubes is directed just behind the cutterbar (Figure 5.6).

Turn the adjustable air tubes at each end approxi-mately 900 so they direct air into the corners of the header.

Open the fan butterfly to fully open position.

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6.

NOTEUse the electric actuators to adjust air flow direction and air flow volume.

Figure 5.6 - Initial Reel Adjustment

OPERATION


5.6.2 TINE PITCH ADJUSTmENT

From the right side of the Air Reel loosen the three 3/8” x 1” carriage bolts securing the eccentric mount plate assembly to the RH End Clamp (Figure 5.7)

Insert the Tine Pitch Adjustment wrench into the shaped cutout on the side of the eccentric mount

plate assembly (Figure 5.7).

From the RH side of the Air Reel, move the Tine Pitch Adjustment wrench CCW to change the tine pitch for-ward. Move the Tine Pitch Adjustment wrench CW to change the tine pitch backward (Figure 5.7).

Tighten the three 3/8” x 1” carriage bolts to their speci-fied torque.

From the LH side of the Air Reel, follow Steps 1 & 2, then move the Tine Pitch Adjustment wrench CCW to change the tine pitch backward. Move the Tine Pitch Adjustment wrench CW to change the tine pitch forward (Figure 5.7).

Tighten the three 3/8” x 1” carriage bolts to their speci-fied torque.

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3.

4.

5.

6.

Figure 5.8 - Reel Tine Adjustment Teeth


NOTEThe default pitch angle is with the 5th tooth (middle tooth) on the eccentric mount plate assembly aligned with the indicator mark on the RH & LH end clamps (Figures 5.7 & 5.8).

NOTEAlthough the adjustment can be made anywhere along the adjustment slot, aligning the teeth tips with the indi-cator point allows you to better identify the position of the reel tine adjustment for both sides (Figure 5.10).

Figure 5.7 - Tine Pitch Adjustment

OPERATION


5.7 OPERATING HINTSThe following are recommended adjustments the operator can make based on crop conditions. Any adjustments that involve the operator leaving the combine cab should heed the warning instructions below.

LIGHT CROPS:Adjust the reel back and down.

The reel tines must clear the auger and be adjusted perpendicular to the cutterbar.

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

It is recommended that the cutterbar be adjusted to the fully 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 to force it into the header.

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

It is recommended that the cutterbar be adjusted to the middle position when cutting good, heavy stand-ing crops.

DOWN, TANGLED CROPS:Adjust the reel forward and lower so the reel tines are close to the cutterbar.

Tilt the tines back for maximum pitch so the crop is lifted as much as possible.

The reel tines should lift the crop high enough to pass over the guards for easier cutting.

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

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

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•


OPERATION

5.8 TRANSPORTINGThe Crary Air Reel is designed to be easily and conve-niently moved from location to location. When transporting the machine, review and follow these safety instructions:

TRANSPORT SAFETyMake sure you are in compliance with all local regulations regarding transporting equipment on public roads and highways.

It is the responsibility of the owner to know the lighting and marking requirements of the local highway authorities and to install and maintain the equipment to provide compliance with the regula-tions. Add extra lights when transporting at night or during periods of limited visibility.

See the Owner’s manual that came with your combine and header for proper transportation guidelines.

1.

2.

3.


5.9 STORAGEAfter the season’s use, the machine should be thoroughly inspected and prepared for storage. Repair or replace any worn or damaged components to prevent any unnecessary down time at the start of next season. To insure a long, trouble free life, this procedure should be followed when preparing the unit for storage.

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

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

Inspect the following components:

PTO DRIvELINE COmPONENTS

Check the condition and operation of the friction disc torque limiter (slip clutch) (see the maintenance sec-tion).

Release slip clutch pressure.

Store in a dry place.

ELECTRICAL SySTEm

Check the wiring harness and all wiring components for damaged or worn areas.

Check for cracked or worn insulation.

Replace any components that have come in contact with moving parts and re-route to prevent damage in the future.

HyDRAULIC SySTEm

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

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2.

3.

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B.

C.

A.

B.

C.

A.

STORAGE SAFETyStore the unit in an area away from human activ-ity.

Do not permit children to play on or around the stored machine.

See the Owner’s manual that came with your com-bine and header for proper storage guidelines.

1.

2.

3.

OPERATION

AIR REEL COmPONENTS:

Air Tubes: repair or replace bent or damaged air tubes.

Plastic Tines: repair or replace bent or damaged plastic tines.

manifold Driveshaft Bearings: Driveshaft bearings are sealed bearings and do not need lubrication. If worn or damaged replace as required.

Bat Splice and Plastic Reel Arm Bearings: Check for wear and replace as required.

Idler Gears and Bearing Components, Pinion Gears and Bearing Components and Internal Gear Sections: Check gears for wear; check for worn or damaged bearings and replace as required; adjust gears as required.

Plastic Eccentric Rollers: Check for uneven wear; replace as required.

RIGHT HAND DRIvE COmPONENTS

Roller Chain, Sprockets and Bearings: Check for wear; replace as required.

Visually inspect fan rotor for wear or buildup.

Check condition of the rotary screen bearings.

Make a list of all parts needed for repairs and order them immediately. Repairs can then be done when time permits and prevent unnecessary down time at the start of next season.

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

Apply a light coat of grease on the shafts.

Check the cutterbar, reel area and drives for entangled material.

Touch up all paint nicks and scratches to prevent rusting.

Move the machine to its storage area.

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

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

Store out of the way of human activity.

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

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B.

C.

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E.

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B.

C.

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13.


REmOvING FROm STORAGE / PRE-SEASON mAIN-TENANCE:

When removing from storage and preparing to use, follow this procedure:

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

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

Clean off accumulated trash and dirt.

Check routing and securing of all hydraulic lines and wiring harness; adjust as required.

Rotate all components and systems by hand to see that none are seized. Loosen any seized components with penetrating oil before starting.

Retighten any loose bolts to their specified torque.

Lubricate all grease points and shaft surfaces.

Check for excessive wear on all moving parts.

Tighten all hydraulic connections and mounts; replace o-rings, fittings, or connectors subject to leaking.

Review machine break-in (Section 5.4).

Review and follow all items on the Pre-Operation Checklist before starting (Section 5.3).

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

Inspect the PTO friction disc torque limiter (Section 6).

Drain and refill gearbox.

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4.

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10.

11.

12.

13.

14.

OPERATION


6.1 SERvICEAlong with a servicing interval, a visual inspection should also be performed. Maintenance personnel can often de-tect potential problems from any unusual sounds made by such components as shafts, bearings and drives.

6.1.1 FLUIDS AND LUBRICANTSGREASE: Use an SAE multi-purpose high tempera-ture grease with extreme pressure (EP) performance meeting or exceeding the NLGI #2 rating for all re-quirements. Also acceptable is an SAE multi-purpose lithium based grease.

GEARBOX LUBE: Use Mobilube HD SAE 75W-90 Gear lube or equivalent with the following specifica-tions:

API Service GL-5

mIL-L-2105D Capacity:

mACK GO-H 40 oz.

ROLLER CHAIN LUBRICATING OIL:

* Stamped on chain link side plate.

STORING LUBRICANTS: Your machine can operate at top efficiency only if clean lubricants are used. Use clean containers to handle all lubricants. Store them in an area protected from dust, moisture and other contaminants.

6.1.2 GREASINGUse the Maintenance Checklist provided to keep a record of all scheduled maintenance.

Use a hand-held grease gun for all greasing.

Wipe grease fitting with a clean cloth before greasing to avoid injecting dirt and grit.

Replace and repair broken fittings immediately.

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

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2.

3.

4.

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2.

3.

4.

Follow ALL operating, maintenance and safety information in the manual.

Support the machine with blocks or safety stands when working around it.

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.

Use only tools, jacks and hoists of sufficient capac-ity for the job.

Place all controls in neutral or off, lower header to the ground, stop combine engine, set parking brake, chock wheels, remove ignition key and wait for all moving part to stop before servicing, adjust-ing, repairing or unplugging.

Before resuming work, install and secure all guards when maintenance work is completed.

Relieve pressure from hydraulic circuit before servicing or disconnecting from combine.

keep hands, feet, hair and clothing away from all moving and/or rotating parts.

Clear the area of bystanders, especially small children, when carrying out any maintenance and repairs or making any adjustments.

keep safety decals clean. Replace any decal that is damaged or not clearly visible.

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

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11.

mAINTENANCE SAFETy

CHAIN TyPE*

AmBIENT TEmPERATURE RANGE14° 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

SERvICE & mAINTENANCESection6


6.2 SERvICE RECORDSee 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 conditions may require more frequent attention.

ACTION CODE: √ = CHECk OR INSPECT CL = CLEAN L = 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)

SERvICE & mAINTENANCE


6.3 SERvICE AND mAINTENANCEBy following a service and maintenance program on your machine, you will enjoy many years of trouble-free use.

6.3.1 CHECKING GEARBOX OIL LEvELEvery 8 operating hours the oil level should be checked.

The oil level should be no higher than the bottom of the driveshaft. (Figure 6.1).

If gearbox oil needs to be added, use the following:

Mobilube HD SAE 75W-90 Gear lube or equivalent with the following specifications:

API Service GL-5

mIL-L-2105D Capacity:

mACK GO-H 40 oz.

6.3.2 PTO LUBRICATION

Every 8 Hours: lubricate the PTO cross journals. Make sure grease purges through all four bearings (Figure 6.2).

Every 16 Hours: lubricate the PTO inner tubes. Tele-scoping members must have lubrication to operate successfully. Telescoping members without fittings should be pulled apart and grease should be added manually with a brush (Figure 6.2).

Every 40 Hours: lubricate the PTO shield retaining bearing. Molded nipples on the guard near each guard bearing are intended as grease fittings and should be lubricated every 40 hours of operation (Figure 6.2).

Every 40 Hours: lubricate the PTO disconnect mecha-nism (Figure 6.3).

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1.

2.

3.

4.

Figure 6.3 - Grease Disconnect Mechanism


Figure 6.1 - Check Oil Level

Figure 6.2 - Lubricate PTO Cross Journals.



6.3.3 TENSION OF IDLER GEARS

Every 40 hours, the tension of the idler gears should be checked. If the tension between the idler gears and internal gear sections of the reel bat arm assembly has any radial movement it will be necessary to make adjustments. When adjusting the tension of the idler to internal gears, follow this procedure:

Loosen the 3/8” centerlock nuts which are on the idler gear assembly on the front side of the manifold.

Insert a small pry bar between the outside wall of the manifold tubing and the idler gears. Apply approxi-mately 5 lbs. of force to slide the gear away from the manifold (Figure 6.4).

Tighten the 3/8” centerlock nuts to their specified torque

Rotate the reel arm assemblies to ensure they turn freely.

Do not grease pinion or idler gears on the reel. Drive shaft bearings on the reel are sealed and do not need lubrication. If worn or damaged, replace as required.

1.

2.

3.

4.

Figure 6.4 - Tightening Locknuts of Idler Gears




Figure 6.8 - Check Fan Housing and Ductwork

6.3.5 FAN HOUSING AND AIR HOSEEvery 40 hours the fan housing and ductwork should be checked for wear (Figure 6.8).

6.3.4 PLASTIC ECCENTRIC ROLLERS

Every 40 hours, the plastic eccentric rollers should be checked. Flat wear spots may show on the plastic ec-centric rollers if they do not rotate while the reel rotates. If this occurs, it may be necessary to make adjustments or replace the roller and/or bearings. When adjusting the eccentric rollers or replacing rollers or bearings, follow this procedure:

Inspect the eccentric rollers for uneven wear (Figure 6.5). If no wear is detected proceed to Step 5.

If uneven wear is detected, loosen and remove each bolt and hardware for each plastic roller that is defec-tive (Figure 6.6).

Inspect the radial bearings that are seated in the plastic rollers. Check to see if they turn freely.

If replacement parts are needed, consult your local authorized Crary dealer.

Reassemble the eccentric roller assembly as shown in Figure 6.7.

Readjust the roller firmly against the eccentric ring and tighten bolts to the specified torque.

1.

2.

3.

4.

5.

6.


Figure 6.5 - Inspect Plastic Rollers for Uneven Wear

Figure 6.6 - Loosen and Remove Hardware for Plastic Rollers

Figure 6.7 - Loosen and Remove Hardware for Plastic Rollers



6.3.6 CHANGING GEAR LUBEEach Air Reel has a high speed fan which is driven by the combine feeder shaft.

Each gearbox is equipped with a drain, level and fillplug. Every 500 operating hours or annually, whichever comes first, the oil should be replaced. Check more frequently if there are leaks around any of the plugs or shaft seals. When checking or changing the oil, follow this proce-dure.

Place a container under the gearbox.

Remove the drain plug. Allow 10 minutes to drain.

Replace the drain plug

Add 40 oz. of Mobilube HD SAE 75W-90 Gear lube or equivalent with the following specifications:

API Service GL-5mIL-L-2105DmACK GO-H

Fill gear lube through the top fill plug.

Check that the air passage through the vent plug is open.

Dispose of the used oil in an environmentally safe manner.

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7.

6.3.7 FRICTION DISC TORqUE LImITER (SLIP CLUTCH)

Disconnect the PTO driveline from the implement.

Position the driveline on a workbench.

Mark the position of the nuts on the bolts.

Loosen the eight nuts.

Remove bolts and disassemble all components.

Check the condition of all parts, especially the friction discs (Figure 6.10).

If replacement parts are needed, consult your local authorized Crary dealer.

Reassemble all components.

Tighten nuts following an alternating cross pattern until reaching the original position (marked in step 3).

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6.

7.

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9.

Figure 6.11 - Exploded View of Torque Limiter

Figure 6.10 - Check Condition of Friction Disc Torque Limiter (slip clutch)

ImPORTANTAlways clean the vent plug if any leaks are noticed around shaft seals.

Figure 6.9 - Change Gear Lube Yearly



In the following section, we have listed many of the problems, causes and solutions to the problems that you may en-counter.

If you encounter a problem that is difficult to solve, even after having read through this trouble shooting section, please call your local Crary dealer. Before you call, please have this Operator’s Manual and the serial number from your ma-chine ready.

PROBLEm POSSIBLE CAUSE REmEDy

Shattering of grain ahead of cutter bar.

Reel speed not coordinated with ground speed causing excessive agitation be-fore crop is cut.

Reel is positioned too low.

Ground speed too fast for conditions of crop.

1.

2.

3.

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

Raise reel.

Slow down ground speed so reel will not cause shattering.

1.

2.

3.

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.

Insufficient ledge for crop travel.

Auger clearance too high from platform bottom.

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

Reel speed too slow.

Reel is positioned too high.

Build up of grain on cutterbar.

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4.

5.

6.

7.

Set reel low enough to sweep material from cutter bar.

Extend rigid cutter bar.

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

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 al-low more air flow.

Check fan RPM, adjust combine shaft speed and check for proper gearbox ratio for combine

Increase speed of reel.

Move reel back and then down.

Lower height of reel and set fore-and-aft position as close as possible to cutter bar and auger.

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7.

Uneven or bunched feeding of crop to cylinder

Feeder chain carrying straw back around and disrupting crop flow to the cylinder.Crop “tailing in” to the auger (heads not feeding first).Cutter bar not at recommended speed.

1.

2.

3.

Extend feederhouse stripper down to stop straw from filtering back out.Rotate manifold so that air flow is directed higher on the crop.Check basic speed of combine (see combine owner’s manual)

1.

2.

3.

Gearbox leaking or overheating.Incorrect oil type or level.Breather plugged.Seals are leaking.

1.2.3.

Check level and replace if necessary.Remove breather, clean and reinstall.Install new seal kit.

1.2.3.

TROUBLESHOOTINGSection7

BEFORE yOU CALLPlease have the following information available:

Serial # (see Page � for location) ______________________________


8.1 REEL SPECS.

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

8.2 FAN PERFORmANCE DATA

Efficiency

Pressure

Horsepower

4000300020001000CFM

10

20

30

40

50

4500 RPMFORWARD CURVE8" OUTLET FAN

ROTOR SIZE =16.50" DIA X 3.00" WIDE

STA

TIC

PR

ES

SU

RE

HO

RS

EP

OW

ER

&E

FFIC

IEN

CY

%

10

30

20

40

50

Section SPECIFICATIONS8


8.3 BOLT TORqUECHECKING BOLT TORqUE:The table shown below is for reference purposes only and its use by anyone is entirely voluntary, unless otherwise noted. Reliance on its contents for any purpose is at the sole risk of that person. Crary Co. is not responsible for any loss claim or damage arising therefrom. In developing these tables, Crary has made a determined effort to present the contents accurately.

Torque figures indicated above are valid for non-greased or non-oiled threads and heads unless otherwise specified. Therefore, do not grease or oil bolts or cap screws 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.

ENGLISH

BOLT DIAmETERBOLT TORqUE *

SAE 2 SAE 5 SAE 8N.m Ft-lb. N.m Ft-lb. N.m Ft-lb.

1/4” 7.5 5.5 11 8 16 125/16” 15 11 23 17 34 253/8” 27 20 41 30 61 45

7/16” 41 30 68 50 95 701/2” 68 50 102 75 149 110

9/16” 97 70 149 110 203 1505/8” 122 90 203 150 312 2303/4” 217 160 353 260 515 3807/8” 230 170 542 400 814 6001” 298 220 786 580 1220 900

1-1/8” 407 300 1085 800 1736 12801-1/4” 570 420 2631 1940 2468 1820

mETRIC

BOLT DIAmETERBOLT TORqUE *

4.8 8.8 10.9 12.9N.m Ft-lb. N.m Ft-lb. N.m Ft-lb. N.m Ft-lb.

M3 0.5 0.4 - - - - - -M4 3 2.2 - - - - - -M5 5 4 - - - - - -M6 6 4.5 11 8.5 17 12 19 14.5M8 15 11 28 20 40 30 47 35

M10 29 21 55 40 80 60 95 70M12 50 37 95 70 140 105 165 120M14 80 60 150 110 225 165 260 190M16 125 92 240 175 350 255 400 300M18 175 125 330 250 475 350 560 410M20 240 180 475 350 675 500 800 580M22 330 250 650 475 925 675 1075 800M24 425 310 825 600 1150 850 1350 1000M27 625 450 1200 875 1700 1250 2000 1500

A

SAE - 2 SAE - 5 SAE - 8

A4.8 8.8 10.9 12.9

SPECIFICATIONS


TIGHTENING FLARE TyPE TUBE FITTINGS *

1. Check flare and flare seat for defects that might cause leakage.

2. Align tube with fitting before tightening.

3. Lubricate connection and hand tighten swivel nut until snug.

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

TIGHTENING O-RING FITTINGS *

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

2. On angle fittings, back the locknut off until washer bottoms out at top of groove.

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

4. Position angle fittings by unscrewing no more than one turn.

5. Tighten straight fittings to torque shown.

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

8.4 HyDRAULIC FITTING TORqUE

FLARE TyPE TUBE FITTINGS

TUBE SIZEO.D

NUT SIZE ACROSS

FLATS

TORqUE vALUE *

RECOmmENDED TURNS TO TIGHTEN

(AFTER FINGER TIGHTENING)(in.) (in.) (N.m) (Ft-lb.) (Flats) (Turn) 1/5 2/5 8 6 1 1/6 1/4 4/7 12 9 1 1/6 1/3 5/8 16 12 1 1/6 3/8 2/3 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

* The torque values shown are based on lubricated connections as in reassembly

O-RING FITTINGS

TUBE SIZEO.D

NUT SIZE ACROSS

FLATS

TORqUE vALUE *

RECOmmENDED TURNS TO TIGHTEN

(AFTER FINGER TIGHTENING)(in.) (in.) (N.m) (Ft-lb.) (Flats) (Turn)3/8 1/2 8 6 2 1/3

7/16 9/16 12 9 2 1/31/2 5/8 16 12 2 1/3

9/16 11/16 24 18 2 1/33/4 7/8 46 34 2 1/37/8 1 62 46 1-1/2 1/4

1-1/16 1-1/4 102 75 1 1/61-3/16 1-3/8 122 90 1 1/61-5/16 1-1/2 142 105 3/4 1/81-5/8 1-7/8 190 140 3/4 1/81-7/8 2-1/8 217 160 1/2 1/12

* The torque values shown are based on lubricated connections as in reassembly

SPECIFICATIONS

manufactured in the United States of America

by Crary Company

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

owner's manual - crarymanuals.crary.com/manuals/airreel/12068_r081205.pdf · 2007-03-06 ·...

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