owner’s manual - crarymanuals.crary.com/manuals/airhead/14462-00_r061906.pdf36’ airhead 25’ &...

Cat LexionCase IH 2388Case IH 8010John Deere Pre-60 SeriesJohn Deere 60 SeriesNew Holland Cr

PN 14462-00 R061906Companion to 14463-00

OWNER’S MANUAL

RECORD SERIAL NUMbER HERE

DISCLAIMER

This 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 con-nection with installation, operation, or maintenance. Features may be described herein which are not present in all systems. Crary Industries assumes no obligation of notice to holders of this document with respect to changes subsequently made.

Crary Industries assumes no responsibility for the accuracy, completeness, sufficiency, or usefulness of the information contained herein.

SPECIFICATIONS AND DESIGN ARE SUbJECT TO CHANGE WITHOUT NOTICE.

Crary Industries 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 Crary Industries. Part replacements should be with original equipment supplied by Crary Industries.

THE CRARY INDUSTRIES STATEMENT OF PRODUCT SAFETY

As a manufacturer of specialized agricultural equipment, Crary Industries 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 prior-ity 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.

SERIAL NUMbER LOCATION

Always give your authorized Crary dealer the serial number of your machine when ordering parts, requesting service, or any other information.

Please record the serial number in the space provided on the front cover and on the warranty and registration card.

© 2006, Crary Industries, All rights reserved. Produced and printed in the USA.

HOW TO REACH US

ADDRESS HOURS TELEPHONE FAX NUMBERE-MAIL

INTERNET

Crary 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.crary.com

MANuFACTuREd BY CRARY INduSTRIES

MANuFACTuREd IN u.S.A.XXXXXX

WEST FARgO, NORTH dAkOTA 58078 u.S.A.SERIAL NuMBER

Serial Number Decal

36’ AirHead

25’ & 30’ AirHead

PN 14462-00 R032206 1

LIMITED WARRANTY

This warranty applies to Bear Cat, Crary, Load-N-Lift, Lockwood and Weed Roller brand products manufac-tured by Crary Industries.

Crary Industries warrants to the original owner each new Crary Industries 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 Industries. Replacement parts are warranted for (90) days from date of installation.

THE WARRANTY REGISTRATION MUST bE COMPLETED AND RETURNED TO CRARY INDUSTRIES 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 In-dustries dealer. Crary Industries 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 Industries dealer as well as subsequent failure or damage that may oc-cur as a result of that work will not be paid under this warranty. Crary Industries does not warrant replacement components not manufactured or sold by Crary Industries.

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 Industries is not liable for any property damage, personal injury or death resulting from the unauthor-ized 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 Industries 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 Industries makes no warranties, representations or promises, expressed or implied as to the perfor-mance 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 Industries or to modify the terms or limitations of this warranty in any way. Crary Industries, at its discretion, may periodically offer limited, written enhancements to this warranty.

CRARY INDUSTRIES 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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PN 14462-00 R0322062

INTRODUCTION ...................................................................... 3

SAFETY ................................................................................... 42.1 SAFETY ALERT SYMBOL ................................................................... 42.2 gENERAL SAFETY.............................................................................. 52.3 OpERATINg SAFETY .......................................................................... 62.4 MAINTENANCE SAFETY .................................................................... 62.5 HYdRAuLIC SAFETY .......................................................................... 72.6 pTO SAFETY ....................................................................................... 72.7 TRANSpORT SAFETY ......................................................................... 82.8 STORAgE SAFETY ............................................................................. 82.9 ASSEMBLY SAFETY ............................................................................ 82.10 SAFETY dECALS .............................................................................. 82.11 SIgN-OFF FORM ............................................................................... 9

SAFETY DECALS .................................................................. 103.1 SAFETY dECALS .............................................................................. 10

ASSEMbLY .............................................................................114.1 STRIppER LOCATION .......................................................................114.2 jd pRE-60 SERIES ............................................................................11

4.2.1 ATTACHINg THE FEEdER HOuSE ........................................114.2.2 CONNECTINg THE HYdRAuLICS ANd ELECTRONICS ......11

4.3 jd 60 SERIES .................................................................................... 124.3.1 ATTACHINg THE FEEdER HOuSE ....................................... 124.3.2 CONNECTINg THE HYdRAuLICS ANd ELECTRONICS ..... 12

4.4 CASE IH 2388 .................................................................................... 134.4.1 ATTACHINg THE FEEdER HOuSE ....................................... 134.4.2 CONNECTINg THE HYdRAuLICS ANd ELECTRONICS ...... 13

4.5 CASE IH 8010 .................................................................................... 144.5.1 ATTACHINg THE FEEdER HOuSE ....................................... 144.5.2 CONNECTINg THE HYdRAuLICS ANd ELECTRONICS ..... 14

4.6 NEW HOLLANd CR ........................................................................... 154.6.1 ATTACHINg THE FEEdER HOuSE ....................................... 154.6.2 CONNECTINg THE HYdRAuLICS ANd ELECTRONICS ..... 15

4.7 CAT / LExION .................................................................................... 164.7.1 ATTACHINg THE FEEdER HOuSE ....................................... 164.7.2 CONNECTINg THE HYdRAuLICS ANd ELECTRONICS ..... 16

4.8 CONNECTINg THE pTO ................................................................... 174.9 MANIFOLd TILT ANd FAN ACTuATOR CONTROLS ....................... 174.10 CALIBRATINg THE HEAdER .......................................................... 18

HEADER SETTINGS ............................................................. 195.1 FLEx MOdE ....................................................................................... 195.2 RIgId MOdE ...................................................................................... 195.3 INITIAL REEL AdjuSTMENT ............................................................ 205.4 TINE pITCH AdjuSTMENT ............................................................... 215.5 AIR REEL HEIgHT AdjuSTMENT .................................................... 225.6 STRIppER AdjuSTMENT ................................................................. 225.7 AugER AdjuSTMENT ...................................................................... 23

5.7.1 HEIgHT AdjuSTMENT (RAISE/LOWER) .............................. 235.7.2 FORE/AFT AdjuSTMENT ...................................................... 23

5.8 CuTTERBAR AdjuSTMENT ............................................................. 245.9 CuTTERBAR dRIvE CASE SuppORT SpRINg AdjuSTMENT ..... 255.10 dIvIdER AdjuSTMENT .................................................................. 25

5.10.1 ATTACHINg THE dIvIdERS ................................................. 255.10.2 AdjuSTINg THE uppER WINg .......................................... 255.10.3 AdjuSTINg THE INNER WINg ............................................ 255.10.4 AdjuSTINg THE OuTER WINg .......................................... 25

5.11 dIvIdER pOINT HEIgHT AdjuSTMENT ........................................ 265.12 dRIvE CHAIN AdjuSTMENT ......................................................... 275.13 AugER FINgER AdjuSTMENT ..................................................... 27

CUTTING SYSTEMS ............................................................. 286.1 dOuBLE dRIvE SICkLE ................................................................... 28

OPERATION .......................................................................... 307.1 NEW OWNER OR OpERATOR INFORMATION ............................... 307.2 MACHINE COMpONENTS ................................................................ 307.3 MACHINE BREAk-IN ......................................................................... 31

7.3.1 NEW MACHINE INSpECTION ................................................ 317.3.2 AFTER OpERATINg FOR 2 HOuRS ...................................... 317.3.3 AFTER OpERATINg FOR 10 HOuRS .................................... 317.3.4 dAILY CHECkLIST .................................................................. 31

7.4 CONTROLS........................................................................................ 327.4.1 REEL ARM SAFETY STOp ...................................................... 327.4.2 MANIFOLd TILT ...................................................................... 327.4.3 FAN ACTUATOR ...................................................................... 327.4.4 HYdRAuLIC FORE/AFT ......................................................... 327.4.5 LIgHTS 33

7.5 FIELd OpERATION ........................................................................... 337.6 OpERATINg SpEEdS ....................................................................... 347.7 OpERATINg HINTS ........................................................................... 34

7.7.1 LIgHT CROpS ......................................................................... 347.7.2 HEAvY CROpS ....................................................................... 347.7.3 dOWN, TANgLEd CROpS ..................................................... 34

TRANSPORTING & STORAGE ............................................ 358.1 TRANSpORTINg ............................................................................... 358.2 STORAgE .......................................................................................... 35

SERvICE & MAINTENANCE ................................................. 379.1 MAINTENANCE CHECkLIST ............................................................ 379.2 FLuIdS ANd LuBRICANTS............................................................... 389.3 gREASINg......................................................................................... 389.4 BLEEdINg THE HYdRAuLIC SYSTEM ............................................ 389.5 gEARBOx OIL ................................................................................... 399.6 pTO LuBRICATION ........................................................................... 409.7 IdLER gEAR TENSION ..................................................................... 409.8 ECCENTRIC ROLLERS ..................................................................... 419.9 jAMMEd CuTTERBAR ..................................................................... 429.10 FAN HOuSINg ANd AIR HOSE ...................................................... 429.11 SICkLE dRIvE OIL COOLER .......................................................... 429.12 REpLACINg AugER FINgERS ...................................................... 43

TROUbLESHOOTING ........................................................... 44

SPECIFICATIONS .................................................................. 4811.1 REEL SpECIFICATIONS .................................................................. 4811.2 AIRHEAd SpECIFICATIONS ........................................................... 4811.3 FAN pERFORMANCE dATA ............................................................ 4811.4 HYdRAuLIC MOTOR dATA ............................................................. 4911.3 SENSOR vALuES ............................................................................ 5011.6 BOLT TORquE ................................................................................ 5211.7 HYdRAuLIC FITTINg TORquE ...................................................... 53

TABLE OF CONTENTS

DESCRIPTION PAGE DESCRIPTION PAGE

PN 14462-00 R032206 3

Congratulations on your choice of a new Crary AirHead 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 AirHead requires that you and anyone else who will be operating or maintaining the machine, read and understand the Safety, Operation, Maintenance, and Troubleshooting 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 AirHead manufactured by Crary Industries. use the table of contents as a guide to locate re-quired 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 manuals.

Many people have worked on the design, production, and delivery of this machine. They have built into it the highest quality of ma-terials 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 refer-ence. 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 towards the direction of forward travel.

Section INTRODUCTION1

PN 14462-00 R0322064

2.1 SAFETY ALERT SYMbOL

Section SAFETy2

This Safety Alert Symbol means:

ATTENTION! bECOME ALERT!YOUR SAFETY IS INvOLvED!

The Safety Alert symbol identifies impor-tant safety messages on the Crary AirHead and in the manual. When you see this sym-bol, 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 result in death or serious injury. This sig-nal word is to be limited to the most extreme situations, typi-cally for machine 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 in-cludes hazards that are exposed when guards are removed. It may also be used to alert against unsafe practices.

CAUTION - Indicates a potentially hazardous situation 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

Why is SAFETY important to you?

Accidents Disable and KillAccidents CostAccidents Can be Avoided

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SIGNAL WORDS:

Note the use of the signal words DANGER, WARN-ING, CAUTION, IMPORTANT and NOTE with the safety messages. The appropriate signal word for each message has been selected using the follow-ing guidelines:

3 big Reasons

PN 14462-00 R032206 5

YOU are responsible for the SAFE operation and maintenance of your Crary AirHead. You must ensure that you and anyone else who is going to operate, maintain or work around the Crary AirHead are familiar with the operating and maintenance proce-dures and related safety information contained in this manual. This manual will alert you to all good safety practices that should be adhered to while operating the Crary AirHead.

Remember, YOU are the key to safety. good safety practices 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 recom-mended 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 AirHead owners must give operating instructions to operators or employees before allowing them to operate the machine, and at least 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 under-stand all safety and Operating instructions in the manual and to follow them. All accidents can be avoided.A person who has not read and understood all operating 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 modi-fication may impair the function and/or safety and could affect the life of the equipment.

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Read and understand the Owner ’s Manual and all safety signs before oper-ating, maintaining, adjusting or servicing the AirHead.Only trained persons shall operate the AirHead. 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 bystand-ers within hazard area of machine.Wear appropriate protective gear. This list Includes but is not limited to:

A hard hatProtective shoes with slip resistant solesProtective gogglesHeavy glovesHearing protectionRespirator 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 en-gine, set parking brake, chock wheels, remove ignition key and wait for all moving parts to come to a complete stop, before servicing, adjusting, repairing or unplugging.Review safety related items annually with all personnel who will be operating or maintaining the AirHead.

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THINK SAFETY! WORK SAFELY!

2.2 GENERAL SAFETY

SAFETY

PN 14462-00 R0322066

Follow ALL the operating, maintenance, and safety informa-tion in this 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 ground-ed.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 come to a complete stop, before servicing, adjusting, 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 signs clean. Replace any sign that is damaged or not clearly visible.First-class maintenance is a prerequisite for the safest operation of your machine. Maintenance, including lubrica-tions, should be performed with the machine stopped and locked out.

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Read and understand the Owner’s Manual and all safety decals before servicing, adjusting or repairing.Install and secure all guards and shields before starting 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 and wait for all moving parts to come to a complete 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.Review safety related items annually with all personnel who will be operating or maintaining the AirHead.Shut the combine off when connecting the machine hy-draulics.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 disconnected.

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2.3 OPERATING SAFETY 2.4 MAINTENANCE SAFETY

SAFETY

PN 14462-00 R032206 7

Always place all combine hydraulic controls in neutral be-fore 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 re-pairs will fail suddenly and create a hazardous and unsafe condition.Wear proper hand and eye protection when searching 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 immediately. 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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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 or driveline or use it as a step.keep guards and shields in place at all times while operat-ing. Replace all damaged or missing parts or shields with the correct original manufacturer’s parts.grease, clean, and maintain pTO components according to original manufacturer’s specifications and information in this manual.Clothing worn by operator must be fairly tight. Never wear loose-fitting jackets, shirts, or pants when working around the drive shafts. Tie long hair back or put under a cap.

keep hydraulic hoses, electric 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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2.5 HYDRAULIC SAFETY 2.6 PTO SAFETY

SAFETY

PN 14462-00 R0322068

Make 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 regulations. Add extra lights when transporting at night or during periods of limited visibility.See the Owner’s Manual that came with your combine for additional transportation information.

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keep 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 3.0 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 back-ing paper.Remove the smallest portion of the split backing paper.Align the decal over the specified area and carefully press the small portion with the exposed sticky backing 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 paper.

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2.7 TRANSPORT SAFETY

2.8 STORAGE SAFETY

2.9 ASSEMbLY SAFETY

2.10 SAFETY DECALS

Store the unit in an area away from human activity.Do not permit children to play on or around the stored ma-chine.See the Owner’s Manual that came with your combine for additional storage information.

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Assemble in an area with sufficient space to handle the larg-est component and access to all sides of the machineUse 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.

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SAFETY

PN 14462-00 R032206 9

Crary Company follows the general Safety Standards specified by the American Society of Agricultural Engineers (ASAE) and the Occupational Safety and Health Administration (OSHA). Anyone who will be operating and/or 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 infor-mation before the season start-up.

Make these periodic reviews of SAFETY and OpERATION a standard practice for all of your equipment. We feel that 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 equipment.

SIGN-OFF FORMDATE EMPLOYEE’S SIGNATURE EMPLOYER’S SIGNATURE

2.11 SIGN-OFF FORM

SAFETY

PN 14462-00 R03220610

good safety requires that you familiarize yourself with the various Safety decals and the type of warning or particular function related to the areas that require your SAFETY AWARENESS.

Section SAFETy DECALS3

AIRHEAD DECALSITEM PART NUMbER DESCRIPTION

1 0732-0093-00 dECAL, REFLECTOR REd 2” x 9”

2 0732-0512-00 dECAL, WARNINg dRIvES

3 0732-0575-00 dECAL, CAuTION dRIvES

4 14429-00 dECAL, dRIvELINE dANgER

5 14430-00 dECAL, REEL WARNINg

6 14431-00 dECAL, pLATFORM CAuTION

7 14432-00 dECAL, REFLECTIvE ORANgE 9” x 2”

0732-0093-001

0732-0512-002

0732-0575-003

14429-004

14430-005

14431-006

14432-007

3.1 SAFETY DECALS

PN 14462-00 R032206 11

Figure 4.2 - Attaching the Feeder House.

4.2.1 ATTACHING THE FEEDER HOUSEMake sure that the combine is sitting square with the mount-ing location of the header.Move the combine into the header opening and insert the pivot blocks on the feeder house into the header beam (3) on the header (Figure 4.2). Raise the feeder house and header to the fully raised po-sition. Ensure the header beam is secured by the feeder house pivots.Lock out the hydraulics on the feeder house with the safety lock located on the feederhouse lift cylinders.Manually insert the lock pins on the feeder house into the latch plates (1)(2) on the header and lock into position (Figure 4.2). The lock pins must extend through the latch plate. Toler-ances may require the latch plates to be installed differently on the left and right hand sides.

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Section ASSEMBLy4

4.2.2 CONNECTING THE HYDRAULICS AND ELECTRONICSAfter connecting the feeder house to the header, hook the hy-draulics and electronics to the machine.

On the combine: connect the Reel drive Return Line (2), Reel drive Supply Line (3), Fore/Aft Line (4) Wiring Harness (5), 12 pin connector from the switch mount plate (6), Reel Lift Line (7) and the Reel Fore/Aft Return (8) (Figures 4.3 & 4.4).

Figure 4.3 - Connecting the Hydraulics/Electronics.


The adjustable strippers are provided in 3 different lengths. Depending on the size of the combine, the strippers may need to be changed. Prior to attaching the feeder house, verify that the correct length strippers are installed.

Measure the combine feeder house opening.Measure the distance between the inner ends of the strippers (Figure 4.1). The distance between the strippers should match or be slightly smaller than the measurement of the feeder house opening.Change the strippers (if needed) by removing the screws. Install the proper length stripper and reinstall the screws.

The adjustable stripper bar is reversible. This provides additional wear life.

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Figure 4.1 - Inner End Measurement

4.1 STRIPPER LOCATION

4.2 JD PRE-60 SERIES

The header may detach from the combine if the latch plates are not in place.

WARNING

The AirHead is equipped with hydraulics, electronics and an adapter designed specifically for each brand of combine. prior to mount-ing, verify that the AirHead is properly equipped with the correct hydraulics, electronics and adapter for your combine.

PN 14462-00 R03220612

ASSEMBLY

4.3.2 CONNECTING THE HYDRAULICS AND ELECTRONICS

Open the quick connect handle (1) on the header and remove the quick connect coupler (2) (Figures 4.6 & 4.7).Install the quick connect coupler onto the combine feeder house and close the handle (3).The lock pins on the feeder house will be inserted and locked into position in the latch plates (1)(2) when the quick connect coupler is attached to the combine feeder house. Verify that the lock pins extend through the latch plates. Tolerances may require the latch plates to be installed differently on the left and right hand sides.

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4.3.1 ATTACHING THE FEEDER HOUSEThe AirHead comes ready to attach to the feeder house.

Make sure that the combine is sitting square with the mounting location of the header.Move the combine into the header opening and insert the pivot blocks on the feeder house into the header beam (3) (Figure 4.5). Raise the feeder house and header to the fully raised posi-tion. Ensure the header beam is secured by the feeder house pivots.Lock out the hydraulics on the feeder house with the safety lock located on the feederhouse lift cylinders.The lock pins on the feeder house will be inserted and locked into position in the latch plates (1)(2) when the quick connect coupler is attached to the combine feeder house in the next section (Figure 4.5). The lock pins must extend through the latch plate. Tolerances may require the latch plates to be installed differently on the left and right hand sides.

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4.3 JD 60 SERIES

The header may detach from the combine if the latch plates are not in place.

WARNING




PN 14462-00 R032206 13

ASSEMBLY


On the combine: connect the Auto Header Height Control (1), Reel drive Supply Line (2), Reel Lift Line (3), Fore/Aft Line (4) and the Field Tracker harness (5) (if applicable) (Figure 4.11)On the head: Connect the Reel drive Return Line (6), Fore/Aft Line (7) and the Electrical plug (8) (Figure 4.12).

1.

2.


Make sure that the combine is sitting square with the mounting location of the header.Ensure that the top of the feeder house saddle (1) is clear of debris (Figure 4.8).Move the combine into the header opening until the feeder house saddle is aligned with the header beam.Raise the feeder house and header to the fully raised posi-tion. Ensure the header beam is seated in the feeder house saddle.Lock out the hydraulics on the feeder house with the safety lock located on the feederhouse lift cylinders.Reach under the feeder house to slide the bolts (2) or (3) on the header until they fully engage the feeder house (Figures 4.9 & 4.10). Ensure the bolts are seated properly to secure the header to the feeder house.

1.

2.

3.

4.

5.

6.



Figure 4.9 - Engage Bolt - w/o Field Tracker..

Figure 4.8 - Clearing Feederhouse Saddle.

4.4 CASE IH 2388

Figure 4.10 - Engage Bolt - with Field Tracker.


PN 14462-00 R03220614

ASSEMBLY


4.5 CASE IH 8010

4.5.1 ATTACHING THE FEEDER HOUSEThe AirHead comes ready to attach to the combine feeder house.

Make sure that the combine is sitting square with the mount-ing location of the header.Ensure that the top of the feeder house cradle is clear of debris (Figure 4.13).Move the combine into the header opening until the feeder house cradle is aligned with the header beam and the front prong on the feeder house cradle is positioned on the front side of the header beam.

Raise the feeder house and header to the fully raised posi-tion. Ensure the rear prong (2) on the feeder house cradle is properly seated in the back edge of the header beam (1).Lock out the hydraulics on the feeder house with the safety lock located on the feederhouse lift cylinders.Move the quick-attach lever (3) to rotate the hooks (4) until they are in full contact with the pins. If the hooks don’t fully contact the pins, adjust the lever with the bolts (5) so that some resistance is felt when the latch (6) is over the quick attach lever.

1.

2.

3.

4.

5.

6.


Rotate handle (2) upward to gain access to the quick coupler (Figure 4.14) Connect the hydraulic block (1) to the quick coupler.Lower the handle (2) until the lock (3) seats into its security groove.Connect the electrical plug (4).

1.

2.3.

4.


Do not insert the front prong on the feeder house cradle into the back edge of the header beam (1). Ensure that the front prong on the feeder house cradle is positioned on the front side of the header beam. Failure to do so could damage the adapter and/or combine feeder house.

WARNING


PN 14462-00 R032206 15

4.6 NEW HOLLAND CR


Rotate handle (2) upward to gain access to the quick coupler (Figure 4.17).Connect the hydraulic block (1) to the quick coupler.Lower the handle (2) until the lock (3) seats into its security groove.Connect the electrical plug (4).

1.

2.3.

4.


4.6.1 ATTACHING THE FEEDER HOUSEThe AirHead comes ready to attach to the combine feeder house.

Make sure that the combine is sitting square with the mount-ing location of the header.Ensure that the top of the feeder house cradle is clear of debris.Move the combine into the header opening until the feeder house cradle is aligned with the header beam.Raise the feeder house and header to the fully raised posi-tion. Ensure the header beam is seated in the feeder house cradle.Lock out the hydraulics on the feeder house with the safety lock located on the feederhouse lift cylinders.Move the quick-attach lever to rotate the hooks (1) until they are in full contact with the pins (Figure 4.15). If the hooks don’t fully contact the pins, adjust the lever with the bolts (2) so that some resistance is felt when the latch (3) is over the quick attach lever (Figure 4.16).

1.

2.

3.

4.

5.

6.



ASSEMBLY


PN 14462-00 R03220616


Make sure that the combine is sitting square with the mount-ing location of the header.Move the combine into the header opening and insert the pivot blocks (1) on the feeder house into the header beam (Figure 4.18).Raise the feeder house and header to the fully raised posi-tion. Ensure the header beam is secured by the feeder house pivot blocks.Lock out the hydraulics on the feeder house with the safety lock located on the feederhouse lift cylinders.Manually slide the pins (2) on the header into the holes (3) on the feeder house. Make sure the bolts fully engage the holes on the feeder house.

1.

2.

3.

4.

5.


Connect the single point connector (4) on the combine to the single point coupler (6) on the header (Figures 4.18 & 4.19).Disconnect the hydraulic hoses (5) and connect to the male (8) and female (7) quick attach couplers located on the header.

1.

2.

4.7 CAT / LExION



ASSEMBLY


PN 14462-00 R032206 17

ASSEMBLY

Using the quick connect, attach the left and right side PTO drivelines on the header (Figures 4.20 and 4.21) with the left (2) and right (1) hand PTO splines on the combine (Figure 4.22).Unlock the feeder house safety lock.

1.

2.

Figure 4.20 - Left Side PTO. Figure 4.21 - Right Side PTO. Figure 4.22 - Left and Right Hand Splines.

4.8 CONNECTING THE PTO

Mount the switch plate assembly (Figure 4.25) in a conve-nient place inside the combine cab. (Use either velcro or bolts)Connect the orange wires on the switch plate assembly to the orange (jd) or red (CASE IH 2388) wires on the actuator switch adapter (if applicable) (Figures 4.23 & 4.24). Other-wise, route the orange wires on the switch plate assembly to the auxiliary 12 Volt power supply. Connect the black wires on the switch plate assembly to the black wires on the actuator switch adapter (if applicable). Otherwise route the black wire on the switch plate assembly to the ground.Attach the unconnected end of the actuator switch adapter to the auxiliary power panel (if applicable).Route the long harnesses along the combine and header to the 12 pin connector located on the main wiring harness of the AirHead.Mount the connector to a convenient location on the combine feeder house.

1.

2.

3.

4.

5.

6.

4.9 MANIFOLD TILT AND FAN ACTUATOR CONTROLS

Place all controls in neutral or off, stop combine engine, set parking brake, remove ignition key, wait for all moving parts to stop, then properly block machine before servicing, ad-justing, repairing, or unplugging.

WARNING

For adapters for all other combine models, contact your combine dealer for availability.

NOTE

Figure 4.25 - Switch Plate Assembly.

Figure 4.23 - CASE IH 2388, Actuator Switch Adapter.

Figure 4.24 - JD 50 Series, Actuator Switch Adapter.

PN 14462-00 R03220618

When using the AirHead on combines in the flex orientation, you must calibrate the header to the combine. The header calibration must be performed when the header is first used with a combine or when any of the sensors are replaced or adjusted.

Follow the calibration instructions in the combine owner’s manual to calibrate the AirHead. The AirHead will operate in the same manner as an OEM header.

READING THE SENSOR OUTPUT vALUES

See Section 11.3 for a complete listing of sensor values.

The sensor output values can be checked in the cab on the following combine models:

CASE 8010

JD 60 Series

NH CR

For all other combines, the sensor output values can be checked at the sensors using a volt meter.

•

•

•

ASSEMBLY

4.10 CALIbRATING THE HEADER

PN 14462-00 R032206 19

Adjust header angle so the header contacts the ground on center of skid plates.Raise header and install the safety stops located on the lift cylinders.Unscrew the nut and washer (1) (Figure 5.1) from underneath the header for each flex head bar. Pull out the corresponding bolt (2) (Figure 5.2) for each section.Remove safety stops from the lift cylinders.place a 4” block under center of cutting bar and lower head to the ground.Adjust the reel height to achieve reel tine to sickle clearance of 1” minimum.Set cylinder stops at this position.Calibrate header height controls following the combine owner’s manual.

1.

2.

3.

4.

5.6.

7.

8.9.

Raise header and install the safety stops located on the lift cylinders.Starting form the LH side, place a bolt (2) (Figure 5.2) into each hole corresponding to each flex head bar section.Once the bolt goes completely through the hole, place the washer and nut (1) (Figure 5.1) onto the bolt.Tighten the bolt until the washer is snug against the bottom of the header.

1.

2.

3.

4.

Figure 5.1 - Flex Head Lock-up Nut and Washer.

Figure 5.2 - Flex Head Lock-up Bolts.

5.1 FLEx MODE 5.2 RIGID MODE

Since all applications of the AirHead are not the same, some initial adjustments must be made to achieve peak performance of your AirHead. Adjustments are needed for best feeding as crop conditions change. Refer to Section 7.6 & 7.7 for operating hints.

Section HEADER SETTINgS5


WARNING

Make sure each bolt is taken from its respective section. Fail-ure to pull all bolts could damage the machine and/or create problems while harvesting.

NOTE

Make sure each flex head bar section has a bolt, washer and nut assembly placed in it. Failure to do so could dam-age the machine and/or create problems while harvesting.

NOTE

Always lower the safety stop when working under the plat-form.

CAUTION

PN 14462-00 R03220620

Lower 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.Rotate the manifold so the line of sight along the air tubes is directed just behind the cutterbar (Figure 5.3).

1.2.

3.

Turn the adjustable air tubes at each end approximately 45° - 60° so they direct air into the corners of the header.Adjust the minimum reel height so the reel tines clear the knife by 1 inch (Section 5.5). Position the reel so that the reel tines sweep over the cutter bar and begin their lift just behind it (Section 5.4).

4.

5.

Figure 5.3 - Initial Reel Adjustment.

5.3 INITIAL REEL ADJUSTMENT

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

NOTE

hEAdEr SETTiNgS

PN 14462-00 R032206 21

From the RH side of the AirHead loosen the three 3/8” x 1” carriage bolts securing the eccentric mount plate assembly to the RH End Clamp. (Figure 5.4)

Insert the Tine Pitch Adjustment wrench into the shaped cutout on the side of the eccentric mount plate as-sembly (Figure 5.4)

Move the Tine Pitch Adjustment wrench CCW to change the tine pitch forward. Move the Tine Pitch Adjustment wrench CW to change the tine pitch backward. (Figure 5.4)

Tighten the three 3/8” x 1” carriage bolts to their specified torque.

From the LH side of the AirHead, 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 5.4)

Tighten the three 3/8” x 1” carriage bolts to their specified torque.

1.

2.

3.

4.

5.

6.

Figure 5.4 - Tine Pitch Adjustment.

Figure 5.5 - Reel Tine Adjustment Teeth.

5.4 TINE PITCH ADJUSTMENT


WARNING

The default pitch angle is with the 5th tooth (Figure 5.5) on the eccentric mount plate assembly aligned with the indicator mark on the RH & LH End Clamps.

NOTE

Although the adjustment can be made anywhere along the adjustment slot, aligning the teeth tips with the indicator point will allow you to better identify the position of the reel tine adjustment for both sides.

NOTE

hEAdEr SETTiNgS

PN 14462-00 R03220622

Figure 5.9 - Adjustable Stripper Clearance.

FIxED STRIPPER

To achieve the proper clearance between the auger and the fixed stripper, adjust the auger until it clears the floor of the plat-form by 1/2” - 5/8” (Figure 5.8). See Section 5.7 for information on adjusting the auger.

hEAdEr SETTiNgS

Figure 5.8 - Fixed Stripper Clearance.

5.6 STRIPPER ADJUSTMENT

ADJUSTAbLE STRIPPER

Loosen the screws (2) and slide the stripper (1) until there is 1/8” - 3/16” clearance between the adjustable stripper and the auger (3). Rotate the auger by hand to check the clearance as the screws are tightened (Figure 5.9). See Section 5.7 for informa-tion on adjusting the auger.

To raise or lower the minimum height of the air reel:Collapse the reel lift cylinders.Locate the adjustment bolts on the left (2), right (2) and center (3) reel lift arms (Figure 5.6 and 5.7).Pull the pin (1) to allow the bolt to move.Adjust the bolt to correspond to the height you want to place the air reel (1” above cutter bar). Repeat steps for all three bolts (left, right, and center).When completed, place the pins back into their respective holes to lock bolts in place.

1.2.3.4.5.6.

Figure 5.6 - Adjustment Bolt. Figure 5.7 - Center Adjustment Bolt.

5.5 AIR REEL HEIGHT ADJUSTMENT

Adjust the stripper clearance with the platform fully raised.

NOTEIf the auger is too far from the strippers, material could be car-ried around the auger and will not feed evenly into the feeder house. The auger must feed evenly to prevent the material from wrapping inside of the feeder house.

PN 14462-00 R032206 23

5.7.1 HEIGHT ADJUSTMENT (RAISE/LOWER)Left side of Header (Figure 5.10) - Loosen nuts (1) (2) and (4). Adjust the top and bottom nuts (3) on the I-bolt until the auger is in the desired position. Retighten nuts (1) (2) and (4).

Center of Header (Figure 5.12) - Loosen nuts (11) and (13). Adjust the top and bottom nuts (16) (17) and (18) on bolts (14) (15) until the auger is in desired position. Retighten nuts (11) and (13).

Right side of Header (Figure 5.11) - Loosen nuts (5) (6) (9) (10). Adjust the top and bottom nuts (8) on the I-bolt until auger is in desired position. Retighten nuts (5) (6) (9) (10).

hEAdEr SETTiNgS

5.7.2 FORE/AFT ADJUSTMENTLeft side of header (Figure 5.10) - Loosen nuts (1) (2) and (4). Push or pull the auger until in desired position. Retighten nuts (1) (2) and (4).

Center of header (Figure 5.12) - Loosen nuts (11) and (13). Loosen the bottom nuts only (17) on bolts (14) (15). Adjust the left and right nuts (12) on I-bolt until the auger is in the desired position. Retighten nuts (11) (13) and (17).

Right side of header (Figure 5.11) - Loosen nuts (5) (6) (9) (10). Adjust the left and right nuts (7) on the I-bolt until the auger is in desired position. Retighten nuts (5) (6) (9) (10).

5.7 AUGER ADJUSTMENTPerform auger adjustments with the header mounted on the combine and locked in rigid mode. Refer to Section 5.6 for proper strip-per/auger clearance.

Figure 5.10 - Left Side of Header

Figure 5.11 - Right Side of Header.Figure 5.12 - Center of Header.

PN 14462-00 R03220624

hEAdEr SETTiNgS

LEvEL THE CUTTER bAR:Adjust the LH and RH tilt channels until there is 19 mm (3/4”) of bolt showing in the gap between the nut and the bottom of the tilt pin (Figure 5.15). Hold the nut and tighten the bolt.Run a string from both ends of the platform, along the tips of the cutter bar guardsAdjust the center tilt channel bolts to align the guards.Hold the nut and tighten the adjusting bolts.Once the cutter bar is level, the angle should be adjusted to match the tire size and expected ground conditions.

FOR DRY CONDITIONS: Turn the adjusting bolt (1) CW to lower the front and raise the rear (tilt downward) (Figure 5.13).

FOR SOFT OR WET CONDITIONS: Turn the adjust-ing bolt (2) CCW to raise the front and lower the rear (tilt upward) (Figure 5.14).

Calibrate the head (refer to the combine owner’s manual).Adjust the reel for 1” minimum clearance with the cutterbar (Section 5.5).For the flex position, remove the lockout washers and bolts.

1.

2.

3.4.5.

6.7.

8.

Figure 5.15 - Adjusting the Tilt Pin.

5.8 CUTTERbAR ADJUSTMENT

Figure 5.13 - Dry Conditions.

1

Figure 5.14 - Soft or Wet Conditions.

2

Lower the feeder house cylinder safety stop when working under the platform. Set the parking brake, shut off the engine and remove the key.

CAUTION

If a change to the cutterbar angle is required after making these initial adjustments, locking out the cutterbar will not be required as long as all the tilt channel bolts are turned an equal amount.

IMPORTANT

Readjust the auger finger timing and reel. Check the auger height and divider point float height.

IMPORTANT

The platform must be on the combine before adjusting the cutterbar angle, leveling the cutterbar, adjusting the range in-dicator (if equipped) and adjusting the reel to cutterbar clear-ance.

IMPORTANT

ADJUST THE CUTTER bAR ANGLE:

The AirHead is equipped with the ability to adjust the cutterbar angle up to 9 degrees.

The angle adjustment is made for platform/cutterbar/skid plate to ground relationship. It is made to compensate for tire size and other variables but MUST be used to make the cutterbar straight.

Check the LH and RH side tire pressure or tire rim height; they should be equal and at the correct pressure.Be certain the platform is level (refer to the combine Owner’s Manual).Lock the flex cutterbar in rigid mode (Section 5.2).Loosen the top nut (1) upward to allow upward/downward movement of the bolt (2) (Figure 5.15). To tilt the cutterbar upward, tighten the bolt (2). To tilt the cutterbar downward, loosen the bolt (2).To secure the placement of the cutterbar, retighten the nut (1) to protect the bolt (2) from slipping.Check reel to cutterbar clearance and adjust if needed (Section 5.3)

1.

2.

3.4.

5.

6.

7.

PN 14462-00 R032206 25

hEAdEr SETTiNgS

The drive case support spring must be set to the lowest possible weight that allows the cutterbar to drop to the bottom of flex when the dividers are installed.

Place the header in flex mode.Tighten or loosen spring (1) on both the LEFT and RIgHT HANd ends of the cutterbar until the springs are set to the lowest possible weight that allows the cutterbar to drop to the bottom of flex when the dividers are installed. A typical adjustment (2) will range from 185-215 mm (7-1/4 - 8-1/2”) (Figure 5.16).Readjust every time the cutterbar tilt is changed signifi-cantly.

1.2.

3.

Figure 5.16 - Cutterbar Drive Case Support Spring.

5.9 CUTTERbAR DRIvE CASE SUPPORT SPRING ADJUSTMENT

The Crary AirHead is equipped with dividers that lift and separate the crop in front of the cutter bar. proper adjustment will assure the crop is directed gently into the header and around the end of the header. The dividers can be removed for transport, and reinstalled after transporting (Figures 5.17 & 5.18).

5.10.1 ATTACHING THE DIvIDERSPlace the divider into the square divider mounting tube.Place a bolt (7) through the square divider mounting tube to lock the attachment in place (8).Tighten bolt to proper torque. To remove the dividers, reverse process.

1.2.

3.4.

5.10.2 ADJUSTING THE UPPER WINGThe upper wing is used for lifting down or leaning crops to pro-vide a smooth flow to the cutter bar.

Loosen the upper wing adjustment bolt (2) to slide the upper wing (1) up or down. Tighten the bolt to the proper torque once the adjustment is made.

5.10.3 ADJUSTING THE INNER WINGThe inner wing is used to direct the crop to the inside of the header.

Loosen the inner wing adjustment clamp (4) to slide the inner wing (3) in/out or up/down. Tighten the bolt to the proper torque once the adjustment is made.

5.10.4 ADJUSTING THE OUTER WINGThe outer wing is used to direct the crop around the outside of the header.

Loosen the outer wing adjustment clamp (6) to slide the outer wing (5) in/out or up/down. Tighten the bolt to the proper torque once the adjustment is made. Figure 5.18 - Adjusting the AirHead Dividers.

Figure 5.17 - Adjusting the AirHead Dividers.

5.10 DIvIDER ADJUSTMENT

PN 14462-00 R03220626

hEAdEr SETTiNgS

Adjust the cutterbar angle (Section 5.8).Lower the platform to the ground.Loosen the nut (1) (Figure 5.19).Turn the divider stop (2) until the desired height is ob-tained.Tighten the nut (1).

1.2.3.4.

5.

5.11 DIvIDER POINT HEIGHT ADJUSTMENT

Repeat for the other divider point.Start the combine engine and raise the platform.Set the parking brake, shut off engine, remove the key and lower the safety stop.Turn the spring adjusting bolt (3) IN until the divider point can be pushed upward easily and still return to the lower position when released.Repeat for the other divider point.

6.7.8.

9.

10.

Figure 5.19 - Divider Point Height.

1 2

3

In softer ground, the divider may need to be adjusted upward and the spring lift force increased to avoid plowing.

NOTEAlways lower the safety stop when working under the plat-form. Set the parking brake, shut off the engine and remove the key.

CAUTION

PN 14462-00 R032206 27

Figure 5.20 - Auger Chain Assembly.

Loosen nuts (1) and (3). Move the tightener (2) down to tighten the chain (Figure 5.20) . Tighten nuts to proper torque. The chain should have about 1/8” - 1/4” deflection.

1.

2.

5.12 DRIvE CHAIN ADJUSTMENT


WARNING

5.13 AUGER FINGER ADJUSTMENT

The AirHead is equipped with auger fingers which enhance the feeding of crop into the feeder house. Proper adjustment will ensure the crop is directed gently beneath the auger and into the feeder house.

Feeding can sometimes be improved by adjusting the auger fin-ger timing.

Loosen nuts (1) (Figure 5.21).Rotate the casting (2) counterclockwise to extend the fingers to a minimum of 1” from the platform floor.Tighten nuts (1).Manually rotate the auger to check clearances.

1.2.

3.4.

To avoid damage to the platform floor or fingers, maintain a minimum of 1” clearance between the fingers and the plat-form floor.

IMPORTANT

hEAdEr SETTiNgS

Figure 5.21 - Auger Finger Adjustment.

PN 14462-00 R03220628

Section CUTTINg SySTEMS6

Refer to Figure 6.2 and the parts manual during installa-tion:

At the center of the double drive cutting system, the left hand side of the sickle is designed to move beneath the right hand side. To accomplish this, the left hand side of the sickle uses offset wear plates, thicker wear pads and shims (used to lower the guards). Refer to the parts manual when installing the cut-ting system to ensure the correct placement of parts.

SICKLES: Attach the L-RH sickle to the Left Hand sickle. Attach the R-LH sickle to the Right Hand sickle.GUARDS: Starting on the left hand side of sickle, install the guards. Note: The center and left hand side have shim spacers installed between the guards and the cutterbar.WEAR PLATES: Install the wear plates (with the curled edge turned downward) on alternating guards beginning with the second full guard from the sickle head. Note: The right hand side has standard wear plates (Figure 6.2) and the left hand side has offset wear plates installed (Figure 6.3). In the center, where the knifebacks overlap, there is one standard wear plate and one offset wear plate installed.

1.

2.

3.

HOLD DOWNS: Attach hold downs above the wear plates starting with the head hold down and continuing with spring loaded hold downs. Do not tighten at this time. Use shims to adjust the rear wear pad until the clearance between the top of the sections and the bottom of the wear pads is between .010” and .020” (Figure 6.1).Bolt knifeback to the knifehead (one each on the right and left hand sickles). Recommended torque is 50-60 In-lbs.Slide the left hand sickle into the guards from the left side and slide the right hand sickle into the guards from the right side making sure the knifeback of the right hand sickle is on top of the knifeback of the left hand sickle.Adjust wear plates snugly against the back of the knifeback.Tighten guard bolts securely (bolt torque should be 30 Ft-lbs.).Using the adjustment bolts, adjust the heads of the hold downs to obtain .020” clearance between the top of the sections and the bottom of the wear pads (Figure 6.1). In hard cutting conditions the hold downs can be adjusted down to .005”.

4.

5.

6.

7.

8.

9.

6.1 DOUbLE DRIvE SICKLE

Figure 6.1 - Wear Pad Clearance.


WARNING

Figure 6.2 - Standard Wear Plate (PN 17329).

Figure 6.2 - Offset Wear Plate (PN 24261).

PN 14462-00 R032206 29

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PN 14462-00 R03220630

Follow all safety instructions exactly. Safety is everyone’s busi-ness. By following recommended procedures, a safe working environment is provided for the operator, bystanders 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 AirHead will provide many years of trouble-free ser-

The Crary AirHead is designed to dramatically improve harvest-ing efficiency. power is provided by the combine feeder, elec-tronics, 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 depen-dent upon the awareness, concern, and prudence of personnel involved in the operation, transportation, maintenance and stor-age of equipment or in the use and maintenance of facilities.

Section OPERATION7

Figure 5.1 - Machine Components

Your Crary Air Head incorporates an adjustable tine pitch pickup reel, an adjustable air system and a dual hydraulic driven Crary cutting system. The combination of these systems results in one of the most efficient flex headers in the industry. please take the time to familiarize yourself with the proper adjustment and operation of your Crary Air Head. You will be well rewarded for your time in increased performance and crop yields.

The finger reel is designed to support and direct the crop during the cutting process and subsequent transfer to the header auger. Air is used to enhance the performance of your finger reel by moving the cut crop off the sickle towards the header auger.

The Crary cutting system, whether gold’N Cut or kingkut, utilizes the patented Crary 4 in 1 guard to give the ultimate in cutting performance and efficiency. The dual hydraulic drive provides a system that can operate faster and smoother than similar size me-chanical drive systems.

ITEM DESCRIPTION1 Auger Drive (N/S)2 Reel3 Cutterbar4 Auger5 Divider6 Reel Support Arm7 knife drive (not shown)

7.1 NEW OWNER OR OPERATOR INFORMATION

7.2 MACHINE COMPONENTS

PN 14462-00 R032206 31

7.3.1 NEW MACHINE INSPECTIONRead and understand all sections in 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 the proper torque.Check the level of the gearbox lube in the gearboxes.Check the drive chain(s) for proper tension.Verify that the slip clutches are not slipping.

7.3.2 AFTER OPERATING FOR 2 HOURSRetorque all fasteners and hardware.Check that all safety decals are installed and legible. Apply new decals if required.Visually inspect the hydraulic system for leakage, loose fit-tings, and damaged hoses. Tighten fittings, replace damaged components and wipe up leaked or excess hydraulic fluid.Check the routing of hydraulic lines and the wiring harness. Reroute as required to prevent leaking, pinching, crimping, binding, or rubbing.Check the tension and alignment of all drive chains. Adjust as required.The gearbox will generate heat. The typical operating tem-perature of the gearbox is 200° F.Check the drives for proper tension.

7.3.3 AFTER OPERATING FOR 10 HOURSRetorque all fasteners and hardware.Check that all guards are installed, secured and function-ing as intended. Do not operate with missing or damaged shields.Check that all safety decals are installed and legible. Apply new decals if required.Check the routing of hydraulic lines and the wiring harness. Reroute as required to prevent leaking, pinching, crimping, binding, or rubbing.Check the plastic eccentric rollers for uneven wear.Refer to the normal servicing and maintenance schedule as defined in the Service Record.

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OPErATiON

7.3.4 DAILY CHECKLISTBefore operating the AirHead and each time thereafter, the fol-lowing areas should be checked.

Service the AirHead per the schedule outlined in the Main-tenance Checklist (Section 9).Use a combine of adequate power and specifications to operate the AirHead.Check that all guards are installed, secured and function-ing as intended. Do not operate with missing or damaged shields.Ensure that the combine is properly attached to the header and that mechanical retainers are properly installed.Check the cutterbar, reel area, sensor linkages and drives for entangled material.Check the chains and sprockets for proper tension and align-ment. Adjust as required.Visually inspect the hydraulic system for leakage, loose fit-tings, and damaged hoses. Tighten fittings, replace damaged components and wipe up leaked or excess hydraulic fluid.Place the header on the ground and visually check the hy-draulic sight glass on the hydraulic reservoir to ensure the hydraulic fluid is at the proper level.Visually inspect the electrical system for damaged wires or cracked insulation. Repair or replace as needed.Check the condition of the driveline slip clutch friction discs. If installing replacement discs, adjust the spring height to its original height. Deviation from original setting may be needed depending upon disc wear.

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7.3 MACHINE bREAK-IN

Efficient and safe operation of the Crary AirHead requires that each operator reads and understands the operating procedures and all related safety precautions outlined in this section. It is important for the personal safety of the operator and maintaining the good mechanical condition of the AirHead that the following checklists are followed.

PN 14462-00 R03220632

7.4.1 REEL ARM SAFETY STOPTo lock the reel, raise the reel to an upright position. Lower the safety stop onto the cylinder piston rod on both ends of the header (Figure 7.1).

7.4.2 MANIFOLD TILTMoving the toggle switch to the FORE position (Figure 7.2) extends the shaft of the electric actuator forward, which ro-tates the manifold CCW, directing the air tubes toward the rear of the header. Moving the toggle switch to the AFT position (Figure 7.2) retracts the shaft of the electric actuator backward, which rotates the manifold CW, directing the air tubes toward the front of the header.

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OPErATiON

Figure 7.2 - Switch Plate Assembly.

Figure 7.1 - Reel Arm Safety Stop.

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

WARNING

7.4 CONTROLS

7.4.3 FAN ACTUATOR

25’ & 30’ AirHeads come equipped with one fan. 36’ AirHeads are equipped with two fans. Each fan is controlled separately. The switch mount plate holds both controls.

Moving the toggle switch to the OpEN position extends the shaft of the electric actuator forward and increases the flow of air to the air tubes (Figures 7.3).Moving the toggle switch to the CLOSEd position retracts the shaft of the electric actuator and decreases the flow of air to the air tubes (Figures 7.3).

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Figure 7.3 - Fan Actuator.

Do not operate the fans with the hose detached.

WARNING

7.4.4 HYDRAULIC FORE/AFTThe hydraulic fore/aft moves the reel forward and backward on the AirHead. The fore/aft uses a hydraulic system which the op-erator controls within the combine

The hydraulic fore/aft cylinders are located on the left and right sides of the header and on the center arm (Figure 7.4).

Figure 7.4 - Hydraulic Fore/Aft.

For 36’ AirHeads, do not leave the reel in the raised position for extended periods of time. Doing so can cause the auger to sag which may damage the auger and other components of the AirHead.

IMPORTANT

PN 14462-00 R032206 33

7.4.5 LIGHTSThe AirHead lights turn on when the combine lights are turned on. Make sure the lights are working properly at all times (Fig-ures 7.5 and 7.6).

Figure 7.5 - Stubble Light.

Figure 7.6 - Signal Light.

OPErATiON

7.5 FIELD OPERATION

Adjust header height control for desired cutting height per combine manufacturer’s instructions.Begin operation at desired ground speed.Adjust height control and sensitivity for flex operations per combine manufacturer’s instructions.Adjust reel speed to slightly faster (5% to 10%) than ground speed.gradually lower reel speed until crop head is slightly tipped towards header and appears to be held stationary when cut.gradually adjust reel height just low enough to tip crop to-wards head without wrapping.Increase air to maximum.Move tilt control until air is directed at back of sickle bar with reel feeding properly.gradually reduce air until crop is no longer moving smoothly across sickle.gradually increase air until smooth crop flow across the sickle is achieved.Remember: more air uses more horsepower.gradually adjust air position fore and aft until optimum crop flow is achieved.gradually reduce air further until minimum air is used to

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DO use the reel to bring the crop into the header.

DO operate reel as slow as possible.

DO operate reel as close to auger as possible.

DO keep tines as perpendicular to sickle as possible.

DO use air to feed crop across the sickle.

DO adjust air tube angle to maximize crop flow across the sickle.

DO make adjustments gradually.

DO verify proper air tube position whenever adjusting reel height or fore and aft position.

DO SHUT OFF AIR IMMEDIATELY IF THE AIR HOSE SHOULD FAIL. FAILURE TO DO SO MAY RESULT IN GEARbOx FAILURE.

DO follow troubleshooting guide one step at a time.

DO NOT operate reel lower than needed.

DO NOT operate with tines striking the ground or sickle.

DO NOT use more air than needed.

DO NOT operate with plugged air tubes.

7.4 CONTROLS

PN 14462-00 R03220634

The AirHead is equipped with the proper gear ratios to optimally run at the following speeds on a given machine.

MODEL FAN RPMAUGER

RPMHEADER

SHAFT SPEEDCat Lexion 4660 174 641JD 50/60 Series 4592 141 520CIH 2388 4685 135 500CIH 8010 4811 154 570NH CR/Cx 4811 154 570

*ALL vALuES ARE ESTIMATES

7.6 OPERATING SPEEDS

Exceeding recommended speeds may cause excessive vi-bration which could cause damage to header equipment

WARNING 7.7.1 LIGHT CROPSAdjust the reel back and down.The reel tines must clear the divider points and be adjusted perpendicular to the cutterbar.Use only enough air to move the crop to the auger.

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7.7 OPERATING HINTS

7.7.2 HEAvY CROPSAdjust 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. The air will allow the heads to feed into the auger first.

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7.7.3 DOWN, TANGLED CROPSAdjust the reel forward and lower so the reel tines are close to the cutter bar.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.

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As crop conditions change, make adjustments for best

feeding results.

OPErATiON

PN 14462-00 R032206 35

Never secure the header by strapping down over the hydrau-lic lines. This can cause damage to the hydraulic lines.Make sure you are in compliance with all local regulations regarding transporting equipment on public roads and highways.

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Clear the area of bystanders, especially small children.Thoroughly wash the entire machine using a pressure washer to remove all dirt, mud, debris or residue.Check the following systems and components:

PTO DRIvELINE COMPONENTS:Check the condition and operation of the friction disc torque limiter (slip clutch). (See the mainte-nance section). 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 reroute to prevent damage in the future.

HYDRAULIC SYSTEM:Check all hydraulic lines for damage, replace as required.Tighten all hydraulic connections and mounts, replace o-rings, fittings, or connectors subject to leaking.

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Section TRANSPORTINg & STORAgE8

REEL COMPONENTS:Air Tubes: Check for bent or damaged air tubes. Repair or replace as required.Plastic Tines: Check for bent or damaged plastic tines. Repair or replace as required.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.Check idler gears and bearing components, pinion gears and internal gear sections for worn or dam-aged components. Replace/adjust as required.Plastic eccentric rollers: Check for uneven wear. Replace as required.Auger Fingers: Check for broken/loose auger fin-gers. Replace/adjust as required.

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8.1 TRANSPORTING

The Crary AirHead is designed to be easily and conveniently moved from location to location. When transporting the machine, review and follow these safety instructions:

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 regulations. Add extra lights when transporting at night or during periods of limited visibility.See the Owner’s Manual that came with your combine for additional transportation information.

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8.2 STORAGE

After the season’s use, thoroughly inspect the machine and prepare 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, follow this procedure when preparing the unit for storage:

PN 14462-00 R03220636

TrANSPOrTiNg ANd STOrAgE

RIGHT HAND DRIvE COMPONENTS:Roller chain, sprockets and bearings: Check for wear, replace as required.Visually inspect fan rotor for wear or buildup.Check the condition of the rotary screen bear-ings.Check the condition of the drive shaft and bear-ings.Inspect the oil cooler; clean out any debris that has accumulated.

LEFT HAND FAN (36’):Visually inspect fan rotor for wear or buildup.Check the condition of the rotary screen bear-ings.

Make a list of all parts needed for repairs and order them im-mediately. Repairs can be done when time permits and pre-vent unnecessary down time at the start of next season.Lubricate all grease points to remove any water residue 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.Change gearbox oil: use Mobilube SHC 75W-90 synthetic gear lube or equivalent with the following specifications:

ApI Service gL-5/MT.1MIL-L-2105dMACk gO-j pLuSSAE j2360Capacity: 40 oz.

Change hydraulic oil: use Texaco Rando Hd 46 or equivalent hydraulic oil. Capacity 20 gal. Check the cutterbar, reel area, sensor linkages 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.Store with the reel in the down position.If you cannot store the machine inside, cover with a water-proof tarpaulin and tie securely in place.Store out of the way of human activity.Do not allow children to play on or around the stored unit.

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REMOvING FROM STORAGE / PRESEASON MAINTE-NANCE:

Clear the area of bystanders, especially small children.Remove the tarpaulin from the machine (if covered). Clean off accumulated trash and dirt.Check the 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 proper 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 7.3).Review and follow all items on the Daily Checklist before starting (Section 7.3). Install all safety shields and review precautions with operators and other personnel involved in the operation.Inspect the PTO friction disc torque limiter. (See the main-tenance section).

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8.2 STORAGE

PN 14462-00 R032206 37

Section SERvICE & MAINTENANCE9

These service recommendations are based on normal operating conditions. Severe or unusual conditions may require more frequent attention. Copy this page to continue record.

ACTION COdE: √ = CHECk OR INSpECT CL = CLEAN L = LuBRICATE C = CHANgE

HOURS

SERvICED bY

DAILY

√ SICkLE dRIvE OIL COOLER

L pTO CROSS jOuRNAL ZERkS

√ HYdRAuLIC OIL LEvEL

16 HOURS

√ gEARBOx OIL LEvEL (CHECk FOR LEAkS)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

√ AugER CLuTCH

√ WOBBLE BOxES

√ OvERRuN CLuTCH

YEARLY

C gEARBOx LuBE

√ CONDITION OF FRICTION DISC TORquE LIMITER (SLIp CLuTCH)

√ AugER dRIvE CHAIN TENSION ANd ALIgNMENT

C HYdRAuLIC OIL

9.1 MAINTENANCE CHECKLIST

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GREASE: use an SAE multipurpose high temperature grease with extreme pressure (Ep) performance meeting or exceeding the NLgI #2 rating for all requirements. Also acceptable is an SAE multipurpose lithium based grease.

GEARbOx LUbE: use Mobilube SHC 75W-90 synthetic gear lube or equivalent with the following specifications:

ApI Service gL-5/MT.1MIL-L-2105dMACk gO-j pLuSSAE j2360Capacity: 40 oz.

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Use 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.

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9.2 FLUIDS AND LUbRICANTS

Along with a servicing interval, perform a visual inspection. Maintenance personnel can often detect potential problems from any unusual sounds made by such components as shafts, bearings and drives.

HYDRAULIC OIL: Texaco Rando Hd 46 or equivalent hy-draulic oil. Capacity 20 gal. CHAIN LUbRICANT: use a spray chain lubricant or SAE 30 engine oil.STORING LUbRICANTS: Your machine can operate at top efficiency only if clean lubricants are used. Use clean contain-ers to handle all lubricants. Store them in an area protected from dust, moisture and other contaminants.

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9.3 GREASING

Replace and repair broken fittings immediately.If fittings will not take grease, remove and clean thoroughly. Also clean lubricant passageway. Replace fitting if neces-sary.

4.5.

SErViCE & MAiNTENANCE

Open the bleed plug (1) in

owner’s manual - crarymanuals.crary.com/manuals/airhead/14462-00_r061906.pdf36’ airhead 25’ &...

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