OWNER S MANUAL CRARY WIND SYSTEM (CWS) JOHN DEERE. Manual PN Rev Companion to

Transcription

1 OWNER S MANUAL CRARY WIND SYSTEM (CWS) JOHN DEERE Manual PN Rev Companion to Record Serial number here

2 HOW TO REACH US ADDRESS HOURS TELEPHONE FAX NUMBER INTERNET Crary Industries th St. NW P.O. Box 849 West Fargo, ND Mon. - Fri. 8 A.M to 5 P.M. Central Time For Parts and Service: Fax: For Service: serv@crary.com Visit us on the 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 connection 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 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. Serial number location Always give your authorized Crary dealer the serial number of your machine when ordering parts, requesting service, or any other information. The serial number decal is located on the front, left hand end of the air manifold. Please record the serial number in the space provided on the front cover and on the warranty and registration card. MANUFACTURED BY CRARY INDUSTRIES WEST FARGO, NORTH DAKOTA U.S.A. SERIAL NUMBER XXXXXX MANUFACTURED IN U.S.A. Serial Number Decal 2006, Crary Industries, All rights reserved. Produced and printed in the USA.

3 LIMITED WARRANTY This warranty applies to Bear Cat, Crary, Load-N-Lift, Lockwood and Weed Roller brand products manufactured 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 Industries 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 occur 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. 7. 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 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 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 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 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.

4 TABLE OF CONTENTS DESCRIPTION PAGE DESCRIPTION PAGE INTRODUCTION... 4 safety SAFETY ALERT SYMBOL GENERAL SAFETY OPERATING SAFETY MAINTENANCE SAFETY HYDRAULIC SAFETY PTO SAFETY TRANSPORT SAFETY STORAGE SAFETY ASSEMBLY SAFETY SAFETY DECALS sign-off form safety decals...11 assembly reel arm mount SERIES HEADERS all other headers air tubes , 20, 25, 30 & 35 ft. WITH 12 SPACING all other cws manifold electric actuator HEADER PREPARATION contour master/sidehill HEADERS F Series headers ALL OTHER headers mount plate support Series Headers All other Headers gearbox/fan mount gearbox/fan extension right hand drive kit series right hand drive kit - F series right hand drive kit series, 1-1/8 hex drive shaft right hand drive kit - contour master right hand drive kit - sidehill right hand drive kit - 200,900 series, 1-1/4 round drive shaft electrical wiring flex hose mounted on manifold (header mounted fans) series headers all other headers transition kit (combine mounted fans) series headers Operation new owner or operator information machine components machine break-in new machine inspection After operating for 2 hours After operating for 10 hours DAILY CHECKLIST controls operating hints transporting storage Service & maintenance MAINTENANCE CHECKLIST fluids and lubricants GREASING GEARBOX OIL pto lubrication fan housing and air hose Troubleshooting Specifications hydraulic fitting torque fan performance data bolt torque PN R060506

5 Serial number location Always give your dealer the serial number of your Crary Wind System (CWS) when ordering parts, requesting service or any other information. The serial number decal is located on the front, LH end of the CWS manifold. Please record the serial number in the space provided below and on the warranty and registration card. WARNING 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, adjusting, repairing, or unplugging. MANUFACTURED BY CRARY INDUSTRIES WEST FARGO, NORTH DAKOTA U.S.A. SERIAL NUMBER XXXXXX MANUFACTURED IN U.S.A. Serial Number Decal Serial Number MANIFOLD, CWS SERIAL NUMBER DECAL Serial Number Decal Location REPLACEMENT PARTS Only genuine Crary Industries replacement parts should be used to repair the CWS. Crary Industries replacement parts are available from your Crary Industries dealer. To obtain prompt, efficient service, remember to give the dealer the correct part description and serial number of the CWS. Please be sure to provide the following information: The SERIAL NUMBER of your CWS. The PART NUMBER of the part. The PART DESCRIPTION. The QUANTITY needed. PN R

6 1 Section INTRODUCTION Congratulations on your choice of a new Crary Wind System (CWS) 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 CWS 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 this manual. Check each item referred to and acquaint yourself with the adjustments required to obtain safe, efficient operation. This manual covers all models of the CWS 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 this 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. PN R060506

7 2 Section safety 1 SAFETY ALERT SYMBOL This Safety Alert Symbol means: ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! The Safety Alert symbol identifies important safety messages on the CWS 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. Why is SAFETY important to you? 3 Big Reasons Accidents Disable and Kill Accidents Cost Accidents Can Be Avoided DANGER - Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury. This signal word is to be limited to the most extreme situations, typically for machine components that, for functional purposes, cannot be guarded. SIGNAL WORDS: 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. Note the use of the signal words DANGER, WARNING, CAUTION, IMPORTANT and NOTE with the safety messages. The appropriate signal word for each message has been selected using the following guidelines: 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. PN R

8 Safety 2 GENERAL SAFETY YOU are responsible for the SAFE operation and maintenance of your CWS. You must ensure that you and anyone else who is going to operate, maintain or work around the CWS are familiar with the operating and maintenance procedures 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 CWS. 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 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. CWS owners must give operating instructions to operators or employees before allowing them to operate the machine, and annually thereafter per OSHA (Occupational Safety and Health Administration) regulation 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 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 modification may impair the function and/or safety and could affect the life of the equipment Read and understand the Owner s Manual and all safety decals before operating, maintaining, adjusting or servicing the CWS. Only trained persons shall operate the CWS. 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 machine. 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 during 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 personnel who will be operating or maintaining the CWS. Think SAFETY! Work SAFELY! 6 PN R060506

9 Safety 3 OPERATING SAFETY 4 MAINTENANCE SAFETY 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 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 CWS. 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 disconnected Follow ALL operating, maintenance, and safety information 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 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 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. Think SAFETY! Work SAFELY! PN R060506

10 Safety 5 HYDRAULIC SAFETY 6 PTO 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 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 highpressure 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 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 according 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.` Think SAFETY! Work SAFELY! PN R060506

11 Safety 7 TRANSPORT SAFETY 10 SAFETY DECALS 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 and header for proper transportation. 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. Safety decals are available from your authorized dealer or the factory. 8 STORAGE SAFETY Store the unit in an area away from human activity. Do not permit children to play on or around the stored machine. See the Owner s manual that came with your combine and header for proper storage. How to Install Safety Decals: 7. 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 smaller 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. 9 ASSEMBLY SAFETY 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. Think SAFETY! Work SAFELY! PN R060506

12 Safety 11 sign-off form 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 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 equipment. SIGN - OFF FORM DATE EMPLOYEE SIGNATURE EMPLOYER SIGNATURE 10 PN R060506

13 3 Section safety decals 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. Think SAFETY! Work SAFELY! PN Decal, Warning PN Decal, Danger 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. PN R

14 4 Section assembly 1 reel arm mount SERIES HEADERS WITHOUT A POSITION SENSOR These steps apply to both the RH and LH reel arm mounts. Refer to Figure 1 during assembly. Attach roller to the top side of the reel arm mount using one 1/2 x 3 bolt and 1/2 nylock nut. Slide the reel arm mount onto the JD Reel Arm ensuring the mount pin on the reel arm mount seats into the hole on the JD Reel Arm and the bottom tabs slide inside the JD Reel Arm. Secure the tabs using two 3/8 x 1 bolts and 3/8 nuts. Place the arm mount weldment on top of the reel arm mount, aligning the bushing on the arm mount weldment with the holes on the top of the reel arm mount. Insert a 1/2 x 3 bolt through the holes and bushing. Secure using a 1/2 nylock nut. Do not completely tighten. The arm mount weldment should be able to raise and lower. Align the hole on the adjustment strap with the front hole on the reel arm mount. Place a 1/2 x 3 bolt through the holes and secure with a 1/2 nylock nut. Do not tighten Slide the reel mount assembly into the arm mount weldment, aligning the holes. Rotate the adjustment strap so the slot aligns with the holes. Place a 1/2 x 3 bolt through and secure with a 1/2 nylock nut. Do not tighten. NOTE Do not tighten the bolts on the adjustment strap until the manifold and air tubes have been installed and properly adjusted. The height setting chosen will determine where the manifold sits in relation to the wheel. This setting may need to be adjusted later when the CWS is fully assembled. Repeat these steps to install the other reel arm mount. Take special care to ensure that the height of both reel mount assemblies are the same. Figure 1 - Reel Arm Mount without Position Sensor 12 PN R060506

15 Assembly 1 reel arm mount series headers (con t) WITH POSITION SENSOR Left Hand: The LH reel arm mount is installed the same as for a JD header without a Position Sensor. Use steps 1-8 in the previous section to install the LH Mount. Right Hand: These steps apply to the RH reel arm mount. Due to the existing plastic slide attached to the side of the JD Reel Arm for the Position Sensor (Figure 2), some minor adjustments may be needed to the reel arm mount to ensure a proper fit. Attach roller to the top side of the reel arm mount using one 1/2 x 3 bolt and 1/2 nylock nut. A portion of the bracket may need to be clipped in order for the reel arm mount to slide onto the JD Reel Arm. Clip only enough for the bracket to fit (Figure 3). Slide the reel arm mount onto the JD Reel Arm ensuring the mount pin on the reel arm mount seats into the hole on the JD Reel Arm and the bottom tabs slide inside the JD Reel Arm. Secure the tabs using two 3/8 x 1 bolts and 3/8 nuts. Place the arm mount weldment on top of the reel arm mount, aligning the bushing on the arm mount weldment with the holes on the top of the reel arm mount Insert a 1/2 x 3 bolt through the holes and bushing. Secure using a 1/2 nylock nut. Do not completely tighten. The arm mount weldment should be able to raise and lower. Align the hole on the adjustment strap with the front hole on the reel arm mount. Place a 1/2 x 3 bolt through the holes and secure with a 1/2 nylock nut. Do not tighten. NOTE Do not tighten the bolts on the adjustment strap until the manifold and air tubes have been installed and properly adjusted. Slide the reel mount assembly into the arm mount weldment, aligning the top holes. Rotate the adjustment strap so the slot aligns with the holes. Place a 1/2 x 3 bolt through and secure with a 1/2 nylock nut. Do not tighten. The height setting chosen will determine where the manifold sits in relation to the wheel. This setting may need to be adjusted later when the CWS is fully assembled. Take special care to ensure that the height of both reel mount assemblies are the same. Figure 2 - JD Plastic Slide Figure 3 - Adjustments PN R

16 Assembly 1 reel arm mount 2 all other headers The reel arm mount is held on to the header with two bolts. An existing 1/2 x 1 bolt comes with the JD header that will be used to hold the bracket. Refer to Figures 4 & 5 during assembly. Remove the existing 1/2 x 1 bolt from the LH side of the JD header. Place the reel arm bracket onto the JD header. Insert the removed JD bolt through the corresponding hole in the reel arm bracket. Do not fully tighten. Insert the provided 1/2 x 3 bolt through the hole in the JD header, the reel arm bracket, the arm mount tube and the other side of the reel arm bracket. Insert nut but do not fully tighten. Place the adjustment strap on the reel arm bracket, orientated with the slot facing upwards. Attach with provided 1/2 x 1 bolt and nut. Do not yet fully tighten Place the adjustment strap onto the arm mount tube. At the same time insert the reel mount assembly into the arm mount tube. Using the provided 1/2 x 3 bolt and nut connect the hardware. Place reel mount assembly on and tighten all bolts to torque. The height setting chosen will determine where the manifold sits in relation to the wheel. This setting may need to be adjusted later when the CWS is fully assembled. Repeat procedure for RH reel arm mount. Take special care to ensure that the height of both reel mount assemblies are the same. 3/8" NYLOCK NUT HALF CLAMP 3/8" NYLOCK NUT 3/8" X 1-1/2" CARR BOLT SADDLE GUIDE 1/2" CENTERLOCK NUT 3/8" X 1-1/2" CARR BOLT 3/8" NYLOCK NUT BRACE CLAMP 3/8" NYLOCK NUT PIVOT CLAMP ASSEMBLY 1/2" CENTERLOCK NUT 3/8" X 1" CARR BOLT 3/8" X 1-1/2" CARR BOLT 1/2" F LAT WASHER ADJUSTMENT STRAP 1/2" X 2-1/2" BOLT 1/2" X 2-1/2" BOLT HALF CLAMP 3/8" NYLOCK NUT 1/2" CENTERLOCK NUT ARM MOUNT TUBE RH REEL MOUNT ELECTRIC ACTUATOR SADDLE GUIDE 1/2" X 3" BOLT 3/8" X 1" CARR BOLT 1/2" CENTERLOCK NUT 3/8" NYLOCK NUT 3/8" NYLOCK NUT 1/2" F LAT WASHER 1/2" X 1" BOLT ACTUATOR SWITCH ADAPTER HARNESS LH REEL MOUNT RH REEL ARM BRACKET 1/2" X 3" BOLT 3/8" X 1" CARR BOLT BRACE CLAMP 3/8" X 1-1/2" CARR BOLT Figure 5 - Right Hand Reel Arm Mount ADJUSTMENT STRAP 1/2" X 3" BOLT ARM MOUNT TUBE 1/2" FLAT WASHER 1/2" X 1" BOLT LH REEL ARM BRACKET 1/2" CENTERLOCK NUT 1/2" FLAT WASHER Figure 4 - Left Hand Reel Arm Mount 14 PN R060506

17 Assembly 2 air tubes 1 15, 20, 25, 30 & 35 ft. WITH 12 SPACING Start by placing the manifold on a secure work area, making sure it cannot roll. When installing the air tubes, start working from the LH side (as looking from the combine cab) of the manifold and work to the right. Refer to Figure 6 during assembly. The first air tube installed will be a long air tube. Alternate short and long air tubes the length of the manifold. The end air tubes will be mounted after installing all other air tubes. To connect the air tube, place it on one of the holes in the manifold and point the end towards the direction of the cutterbar. Insert the U-bolt around the manifold and through the holes on the air tube weldment. Attach the air tube with two 5/16 flange nuts and flat washers; tighten to proper torque. Repeat procedure for all air tubes, making sure to alternate long and short air tubes. To mount the end air tubes, two 1-9/16 holes must be drilled on each end of the manifold. Drill the holes as far to the outside of the header as possible, while still providing room to install the air tube. Repeat the steps above to mount the end air tubes. U-BOLT WASHER, 5/16" FLAT SAE NUT, 5/16" SERRATED FLANGE WELDMENT, AIR TUBE 2 all other cws Start by placing the manifold on a secure work area, making sure it cannot roll. When installing the air tubes, start working from the LH side (as looking from the combine cab) of the manifold and work to the right. Refer to Figure 6 during assembly. The first air tube installed will be a long air tube. Alternate short and long air tubes the length of the manifold. To connect the air tube, place it on one of the holes in the manifold and point the end towards the direction of the cutterbar. Insert the U-bolt around the manifold and through the holes on the air tube weldment. Attach the air tube with two 5/16 flange nuts and flat washers; tighten to proper torque. Repeat procedure for all air tubes, making sure to alternate long and short air tubes. manifold length Figure 6 - Air Tube Assembly # of short air tubes # of long air tubes 15 FT. (12 SPACING) (DRILL) FT. (12 SPACING) FT. (12 SPACING) FT. (12 SPACING) (DRILL) FT. (12 SPACING) FT. (12 SPACING (DRILL) FT. (13 5/16 SPACING) FT. (12 SPACING) (DRILL) FT. (13 5/16 SPACING) FT. LONG (12 SPACING) FT. (12 SPACING) (DRILL) PN R

18 Assembly 3 manifold Slide a brace clamp over each end of the manifold. Set the manifold in the reel arm mount assemblies. Adjust the position of the manifold to the left or to the right to center the manifold between the reel mounts. Slide the brace clamps out against the inside of the reel arm mounts and tighten using 3/8 x 1-1/2 bolts and 3/8 nylock nuts. Place the half clamps on top of the manifold and connect to the reel mount assembly with 3/8 x 1 bolts and 3/8 nylock nuts. Slide a tube cap onto the LH end of the manifold and secure with a t-bolt clamp. The flex hose will be mounted on the RH end of the manifold later in Sections 16 or 17. Figure 8 - Mounting the Manifold (Right Hand) Figure 7 - Mounting the Manifold (Left Hand) 4 electric actuator Slide the pivot clamp onto the RH side of the manifold. Loosely tighten the 3/8 x 1-1/2 bolts and 3/8 nylock nuts (Figure 8). Attach the electric actuator to the pivot clamp and the reel arm mount using 1/2 x 2-1/2 bolts and 1/2 nylock nuts (Figure 9). Adjust the manifold so the air tubes point towards the cutterbar. The reel tines should extend past the air tubes. Manually turn the reel to ensure that the tines follow the curve of the air tubes as they rotate downward (Figure 10). Tighten the pivot clamp once the manifold and air tubes are properly positioned. Figure 10 - Air Tube Adjustment Figure 9 - Electric Actuator 16 PN R060506

19 Assembly 5 HEADER PREPARATION 1 contour master/sidehill HEADERS Disassembly of existing header components. Remove the quick lock pins and the RH side end shield. Loosen the chain tightener (A). This is done to ease the removal of the shaft from the slip clutch (Figure 11). Open the auger slip clutch shield by removing two bolts. (shield is hinged at bottom) Remove the bolt and locknut (B) (Figure 12). Remove bolts (C), bracket (D) and shaft (E) (Figure 13). The bracket, bearing and shaft will not be used. 2 F Series headers Disassembly of existing header components. Remove the RH side end shield. Loosen the chain tightener (A), this is done to ease the removal of the shaft from slip the clutch (Figure 11). Open the auger slip clutch shield by removing two bolts (shield is hinged at bottom). Remove the bolt and locknut (B) (Figure 12). Remove the three bolts (F) from the flangette. Remove the bearing (G) from the bracket and remove the shaft from back of header (Figure 14). On 18 headers, the bearing mount bracket must be removed from back of header to allow for installation of the mount plate support. F BRACKET F SHAFT Figure 11 - Loosen Chain Tightener G Figure 14 Figure 12 - Remove Bolt & Locknut Figure 13 - Remove Bolts, Bracket & Shaft PN R

20 Assembly 5 HEADER PREPARATION 3 ALL OTHER headers 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 (Section 9). A support bearing is provided on headers. Disassembly of existing header components. Remove the quick lock pins and the RH side end shield. Loosen the chain tightener (A) and remove the chain (B) from the sprockets (Figure 15) Remove flange lock nut (C) and sprocket (D). Do not discard sprocket, it is reused (Figure 15). Remove the bolts (E) securing the bracket (F) to the angle support; remove the bracket and discard (Figure 16) Remove the bolts (G) securing the bearing support to the angle support. Remove the drive shaft and bearing support (925 & 930 only - retain bearing support and hardware) (Figure 16). Remove clutch from shaft; the clutch will be reused. 7. One support bearing is needed on 25 and 30 headers. 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 RH drive installation. Figure 15 Figure PN R060506

21 Assembly 6 mount plate support Series Headers Refer to Figure 18 for correct locations and measurements. Mark and drill two 17/32 holes on the top portion of the header for the top of the mount plate support. Mark and drill two 17/32 holes on the bottom portion of the header for the bottom of the mount plate support (Figure 17). Position the mount plate support and tighten the bolts to the specified torque Ø17/32" THRU (2) THIS LINE REPRESENTS THE INSIDE EDGE OF THE RIGHT HAND SIDE OF THE HEADER DRILL 17/32" THRU THIS LINE REPRESENTS THE BOTTOM OF THE BACK SHEET OF THE HEADER THIS LINE REPRESENTS THE BOTTOM OF THE TUBE ON THE UNDERSIDE OF THE HEADER Figure 17 WARNING 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 26 for correct bottom hole location ROUND TUBE Figure 18 Support Plate Location and Measurements (600 Series) 2 All other Headers Refer to Figure 19 for correct locations and measurements. Mark and drill two 17/32 holes on the top portion of the header for the top of the mount plate support. Mark and drill two 27/64 holes, tap to 1/2-13 NC for the bottom of the mount plate support. Mark and drill four 13/32 holes for the shield mount brackets according to the m e a s u r e m e n t s o n t h e d i a g r a m b e l o w Ø17/32" THRU (2) Ø13/32" (4) THRU HOLES FOR SHIELD MOUNT BRACKETS NOTE: DRILL ONLY IF YOUR SPECIFIC INSTALLATION REQUIRES YOU TO DO SO THIS LINE REPRESENTS THE INSIDE EDGE OF THE RIGHT HAND SIDE OF THE HEADER 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. OPEN SPACE THIS LINE REPRESENTS THE BOTTOM OF THE BACK SHEET OF THE HEADER THIS LINE REPRESENTS THE BOTTOM OF THE TUBE ON THE UNDERSIDE OF THE HEADER DRILL 27/64" THRU (ONE WALL ONLY) TAP 1/2"-13 NC ROUND TUBE Figure 19 Support Plate Locations and Measurements (All Others) PN R

22 Assembly 7 gearbox/fan mount Refer to Figure 20 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-5 MIL-L-2105D Capacity: MACK GO-H 40 oz. Attach gearbox mounting plates to the mount plate. 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. MOUNT PLATE SUPPORT GEARBOX MOUNTING PLATE FAN / GEARBOX ASSEMBLY Figure 20 - Fan/Gearbox Mounting 20 PN R060506

23 Assembly This page intentionally left blank. PN R

24 Assembly 8 gearbox/fan extension The 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 installing the gearbox fan extension kit, follow this procedure. Separate gearbox and fan. Refer to Figure 2 a. b. c. d. e. 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. a. b. c. d. e. f. WARNING Place 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. 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 extension 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. Mount gearbox/fan extension to combine. a. Refer to Section 7 for fan/gearbox installation instructions. b. Select appropriate support bracket for combine model. c. Bolt mounting bracket onto header. d. Remove upper RH bolt on gearbox mount plate. Bolt support bracket in the location bolt was removed using provided 1/2 X 1-1/2 bolt. e. Attach gearbox/fan extension to support bracket with provided u-bolt. f. Operate the CWS as instructed in this manual. 22 PN R060506

25 Assembly Figure 21 - KIT, GEARBOX/FAN EXTENSION OPTION ITEM KIT, GEARBOX/FAN EXTENSION OPTION PART NUMBER DESCRIPTION QTY KEY, 3/16" SQUARE X 1-1/4" PLAIN U-BOLT, 3/8" X 3" X 4", FAN MOUNT ZP BOLT, 3/8" X 1" HHCS GR5 ZP BOLT, 1/2" X 1" HHCS GR5 ZP BOLT, 1/2" X 1-1/2" HHCS GR5 ZP WASHER, 3/8" FLAT ZP NUT, 3/8" HEX NC ZP NUT, 1/2" CENTERLOCK GR8 ZP NUT, 3/8" SERRATED FLANGE NC ZP NUT, 3/4" NF CASTLE ZP WASHER, 1/2" SAE FLAT ZP WASHER, 3/4" SAE FLAT ZP WASHER, 7/8" SAE FLAT ZP SCREW, 1/4"-20 X 1/4" SET 1 ITEM KIT, GEARBOX/FAN EXTENSION OPTION PART NUMBER DESCRIPTION QTY BOLT, 3/8" X 1-1/4" HHCS GR5 ZP ROTOR, FAN, 188" X 5", 7/8"B, CW, HSPD, ALUM " FAN, SIDE W/BUTTERFLY, RIGHT HAND " FAN, SIDE W/BUTTERFLY, LEFT HAND PLATE, LARGE BUTTERFLY WELDMENT, INDICATOR PLATE, BEARING RETAINER BRACKET, EXTENSION SUPPORT BRACKET, EXTENSION SUPPORT BRACKET, EXTENSION SUPPORT ASSEMBLY, EXTENSION SHAFT/HUB 1 1 PN R

26 Assembly 9 right hand drive kit series KIT # RIGHT HAND DRIVE KIT PARTS DESCRIPTION RIGHT HAND DRIVE KIT 30 (600 SERIES) RIGHT HAND DRIVE KIT 25 (600 SERIES) RIGHT HAND DRIVE KIT 20 (600 SERIES) RIGHT HAND DRIVE KIT 22 (600 SERIES) 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 22). WARNING Place all controls in neutral or off, lower header to the ground, stop combine engine, set parking brake, remove ignition key, chock wheels and wait for all moving parts to stop before servicing, adjusting, repairing, or unplugging. 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. Refer to Figure 23 FOR THE FOLLOWING STEPS. 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 bearing mount bracket, bushing shield weldment and the gearbox from the LH side. There should be approximately 3 of shaft protruding on the LH side of the 1-3/8 bearing insert. This is needed to attach the driveline. The key for the LH bushing needs to be installed at this time. Insert the key for the RH 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 RH side of gearbox using two 1/2 bolts and 1/2 washers NOTE Steps 5-7 apply to 22, 25 and 30 headers. For all other headers, skip to Step 8. Bolt bushing shield weldment to the LH side of gearbox using two 1/2 bolts and 1/2 washers. Measure and cut the drive shaft shield to fit between bushing on LH 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. Tighten the bolts securing the gearbox mounting plate to the gearbox and the bolts securing the gearbox mounting plate to the mount support plate. 1/2" X 4 BOLT 1/2" X 1" BOLT MARK AND DRILL THIS HOLE BEARING MOUNT BRACKET 1/2" CENTERLOCK NUT (1/2-13 NYLOCK NUT) 1/2" FLAT WASHER IMPORTANT Correct shaft alignment is critical. 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 LH 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. Figure 22 - Support Bearing Mount Bracket 24 PN R060506

27 Assembly 9 right hand drive kit series 5/16" X 3/4" BOLT DRIVELINE 6/16" WASHER DRIVELINE SUPPORT BRACKET 1/2" FLAT WASHER GEARBOX MOUNT PLATE 3/8" SERR FLANGE NUT FLANGETTE 3/8" X CARR BOLT 3/8" X 1" SCREW SLIP CLUTCH SHIELD SHIELD MOUNT PLATE 1-3/8" BEARING INSERT 1/2" X 4 BOLT 1/2" X 1" BOLT BEARING MOUNT BRACKET 1/2" CENTERLOCK NUT (1/2-13 NYLOCK NUT) GEARBOX DRIVE SHAFT 5/16" X 1-1/2" KEY DRIVESHAFT SHIELD BUSHING SHIELD WELDMENT BUSHING SHIELD WELDMENT Figure 23 - Support Bearing Mount Bracket PN R

28 Assembly 10 right hand drive kit - F series WARNING Place all controls in neutral or off, lower header to the ground, stop combine engine, set parking brake, remove ignition key, chock wheels and wait for all moving parts to stop before servicing, adjusting, repairing, or unplugging. RIGHT HAND DRIVE KIT PARTS KIT # DESCRIPTION RIGHT HAND DRIVE KIT, 18 & 20 ( F SERIES) RIGHT HAND DRIVE KIT, 22 ( F SERIES) RIGHT HAND DRIVE KIT, 25 ( F SERIES) RIGHT HAND DRIVE KIT, 30 ( F SERIES) Refer to Figure 24 FOR THE FOLLOWING STEPS. 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. Cut driveshaft shield to fit between bushing on RH side of gearbox and auger slip clutch at RH end of header. Slide the gearbox shaft through bearing mount plate welded to back of header, bushing shield weldment and gearbox from the LH side while simultaneously installing bushing shield weldment and short drive shaft shield over shaft on RH side of gearbox. The key for RH 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 LH 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. Bolt bushing shield weldment to the RH side of gearbox using two 1/2 bolts and 1/2 washers. Retighten auger drive chain (see header owner/operator s manual for the correct chain tension). 7. Reinstall RH header shield and secure with lynch pins or quick lock pins NOTE Steps 8-10 apply to 22, 25 and 30 headers. For all other headers, skip to Step 1 Bolt bushing shield weldment to the LH side of gearbox using two 1/2 bolts and 1/2 washers. Measure and cut long drive shaft shield to fit between bushing on LH 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. Tighten the bolts securing the gearbox mounting plate to the gearbox and the bolts securing the gearbox mounting plates to the mount plate support. IMPORTANT Correct shaft alignment is critical. 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 LH 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. 26 PN R060506

29 Assembly 10 right hand drive kit - f series 5/16 X 3/4 BOLT 5/16 WASHER SPACER 5/16 X 1-1/2 KEY DRIVELINE SLIP CLUTCH SHIELD 3/8 X 2 CARR. BOLT SHIELD MOUNT PLATE 5/16 X 2-1/2 BOLT DRIVE SHAFT SHIELD 1-3/8 BEARING INSERT FLANGETTE 3/8 SERR. FLANGE NUT DRIVE SHAFT SHIELD 5/16 SERR. FLANGE NUT GEARBOX DRIVESHAFT BUSHING BUSHING SHIELD WELDMENT Figure 24- F Series RH Drive Kit Installation PN R

30 Assembly 11 right hand drive kit series, 1-1/8 hex drive shaft WARNING Place all controls in neutral or off, lower header to the ground, stop combine engine, set parking brake, remove ignition key, chock wheels and wait for all moving parts to stop before servicing, adjusting, repairing, or unplugging. RIGHT HAND DRIVE KIT PARTS KIT # DESCRIPTION RIGHT HAND DRIVE KIT, HEX SHAFT (915 HEADER) RIGHT HAND DRIVE KIT, HEX SHAFT (18 /20 HEADER) RIGHT HAND DRIVE KIT, HEX SHAFT (22 HEADER) RIGHT HAND DRIVE KIT, HEX SHAFT (25 HEADER) RIGHT HAND DRIVE KIT, HEX SHAFT (30 HEADER) Refer to Figure 25 FOR THE FOLLOWING STEPS. Install the (Crary supplied) hex clutch shaft into the hex bearing through the RH 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 RH end of the gearbox driveshaft within 1-1/2 of the LH 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 RH end of the gearbox drive shaft and secure with the roll pin. 7. Slide the slip clutch assembly along the hex shaft up to the RH end of the drive sprocket. Install the double roller chain to the drive sprocket and slip clutch sprocket. 8. 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). Reinstall RH header shield and secure with lynch pins or quick lock pins. NOTE Steps apply to 25 and 30 headers. For all other headers, skip to Step 1 Slide the bushing shield weldment over the gearbox driveshaft and secure to LH side of gearbox using two 1/2 bolts and 1/2 washers. Install bearings and flangettes to bearing mount plate, slide onto LH 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. IMPORTANT Correct shaft alignment is critical. For 25 and 30 headers, bolt shield mount plate to bearing mount plate. For all other header sizes bolt shield mount plate directly to LH 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. 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 necessary 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. 28 PN R060506

31 Assembly 11 right hand drive kit series, 1-1/8 hex drive shaft 5/26 X 3/4 BOLT BRACKET, DRIVELINE SUPPORT 3/8 WASHER BEARING MOUNT PLATE DRIVELINE 5/16 WASHER DRIVELINE SLIP CLUTCH SHIELD 3/4 WASHER DRIVE SHAFT SHIELD SHIELD MOUNT PLATE BUSHING SHIELD WELDMENT 5/32 X 1-1/4 COTTER PIN 3/4 CASTLE NUT 1-3/8 BEARING INSERT BUSHING DRIVE SPROCKET SHIELD MOUNT BRACKET AUGER SLIP CLUTCH SHIELD 3/8 SERATE FLANGE NUT 3/8 X 1 BOLT BUSHING 5/16 X 1-1/2 KEY GEARBOX DRIVE SHAFT DBL. ROLLER CHAIN ROLL PIN CLUTCH SHAFT Figure Series Drive Kit Installation 12 right hand drive kit - contour master RIGHT HAND DRIVE KIT PARTS KIT # DESCRIPTION RIGHT HAND DRIVE KIT, (18 /20 CTR MASTER) RIGHT HAND DRIVE KIT, (22 CTR MASTER) RIGHT HAND DRIVE KIT, (25 CTR MASTER) RIGHT HAND DRIVE KIT, (30 CTR MASTER) For installation of these RH drive kits, refer to Section 1 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. PN R

32 Assembly 13 right hand drive kit - sidehill KIT # WARNING Place all controls in neutral or off, lower header to the ground, stop combine engine, set parking brake, remove ignition key, chock wheels and wait for all moving parts to stop before servicing, adjusting, repairing, or unplugging. RIGHT HAND DRIVE KIT PARTS DESCRIPTION RIGHT HAND DRIVE KIT, HEX SHAFT (18, 20 SIDEHILL) RIGHT HAND DRIVE KIT, HEX SHAFT (22 SIDEHILL) RIGHT HAND DRIVE KIT, HEX SHAFT (25 SIDEHILL) RIGHT HAND DRIVE KIT, HEX SHAFT (30 SIDEHILL) Refer to Figure 26 FOR THE FOLLOWING STEPS. 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. Cut driveshaft shield to fit between bushing on RH side of gearbox and auger slip clutch at RH end of header. Slide the gearbox shaft through bearing mount plate welded to back of header, bushing shield weldment and gearbox from the LH side while simultaneously installing bushing shield weldment and short drive shaft shield over shaft on RH side of gearbox. The key for RH 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 LH 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. Bolt bushing shield weldment to the RH side of gearbox using two 1/2 bolts and 1/2 washers. Retighten auger drive chain (see header owner/operator s manual for the correct chain tension). 7. Reinstall RH header shield and secure with lynch pins or quick lock pins NOTE Steps 8-10 apply to 22, 25 and 30 headers. For all other headers, skip to Step 1 Bolt bushing shield weldment to the LH side of gearbox using two 1/2 bolts and 1/2 washers. Measure and cut long drive shaft shield to fit between bushing on LH 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. Tighten the bolts securing the gearbox mounting plate to the gearbox and the bolts securing the gearbox mounting plates to the mount plate support. IMPORTANT Correct shaft alignment is critical. 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 LH 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. 30 PN R060506

33 Assembly 13 right hand drive kit - sidehill NUT, 1/2" CENTERLOCK WASHER, 1/2" WELDMENT, HUB SLIP CLUTCH SPRING, 1/2" X 1" X 1" SCREW, SET 3/8" X 1-1/2" SCREW, SET 3/8" X 1" HUB, SLIP CLUTCH PLATE, PRESSURE CLUTCH BOLT, 1/2" X 3-1/4" SLIP CLUTCH ADAPTER, SHAFT ROUNG/HEX BRACKET, DRIVELINE SUPPORT DISC, FIBER FRICTION KEY, 5/16" BEARING, 1-3/8" BOLT, 5/16" X 3/4" NUT, 5/16" CARRIAGE BOLT, 3/8" X 1" SLIP CLUTCH SHIELD DRIVE SHAFT SHIELD 5/16" X 2-1/2" BOLT, WASHER, 3/4" NUT, 5/16" TINNERMAN U-TYPE SHIELD MOUNT PLATE ASSEMBLY FLANGETTE BEARING MOUNT PLATE DRIVE SHAFT SHIELD, JACKSHAFT SHAFT, GEARBOX DRIVE NUT, 5/16" SERRATED FLANGE WELDMENT, CLUTCH SHAFT CASTLE NUT, 3/4" COTTER PIN, 5/32" X 1-1/4" Figure 26- Sidehill Combines, Drive Kit Installation PN R

34 Assembly 14 right hand drive kit - 200,900 series, 1-1/4 round drive shaft KIT # WARNING Place all controls in neutral or off, lower header to the ground, stop combine engine, set parking brake, remove ignition key, chock wheels and wait for all moving parts to stop before servicing, adjusting, repairing, or unplugging. RIGHT HAND DRIVE KIT PARTS DESCRIPTION RIGHT HAND DRIVE KIT, ROUND SHAFT (215 HEADER) RIGHT HAND DRIVE KIT, ROUND SHAFT (915 HEADER) RIGHT HAND DRIVE KIT, ROUND SHAFT (216 HEADER) RIGHT HAND DRIVE KIT, ROUND SHAFT (18-20 ) RIGHT HAND DRIVE KIT, ROUND SHAFT (22-24 ) RIGHT HAND DRIVE KIT, ROUND SHAFT (25 ) RIGHT HAND DRIVE KIT, ROUND SHAFT (30 ) Refer to Figure 27 FOR THE FOLLOWING STEPS. Install the (Crary supplied) round clutch shaft into the bearing through the RH 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. 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 RH end of the gearbox driveshaft within 1-1/2 of the LH 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 RH end of the gearbox drive shaft and secure with roll pin. 7. Align the slip clutch sprocket and sprocket on gearbox driveshaft. Install the double roller chain to the drive sprocket and slip clutch sprocket. 8. 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. 9. Reinstall auger drive chain onto sprocket and tighten (see header owner/operator s manual for the correct chain tension) Reinstall RH header shield and secure with lynch pins or quick lock pins. NOTE Steps apply to 25 and 30 headers. For all other headers, skip to Step 1 Slide the bushing shield weldment over the gearbox driveshaft and secure to LH side of gearbox using two 1/2 bolts and 1/2 washers. Install bearings and flangettes to bearing mount plate, slide onto LH 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. IMPORTANT Correct shaft alignment is critical. For 25 and 30 headers, bolt shield mount plate to bearing mount plate. For all other header sizes bolt shield mount plate directly to LH 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. 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. 32 PN R060506

35 Assembly 14 right hand drive kit - 200,900 series, 1-1/4 round drive shaft 5/26 X 3/4 BOLT BRACKET, DRIVELINE SUPPORT 3/8 WASHER BEARING MOUNT PLATE DRIVELINE 5/16 WASHER DRIVELINE SLIP CLUTCH SHIELD 3/4 WASHER DRIVE SHAFT SHIELD SHIELD MOUNT PLATE BUSHING SHIELD WELDMENT 3/4 WASHER 5/32 X 1-1/4 COTTER PIN 3/4 CASTLE NUT 1-3/8 BEARING INSERT BUSHING AUGER SLIP CLUTCH SHIELD 3/8 SERATE FLANGE NUT 3/8 X 1 BOLT BUSHING 5/16 X 1-1/2 KEY GEARBOX DRIVE SHAFT DRIVE SPROCKET DBL. ROLLER CHAIN ROLL PIN SHIELD MOUNT BRACKET SLIP CLUTCH SHAFT 5/16 X 1-1/2 KEY Figure & 900 Series 1-1/4 Round Drive Shaft RH Drive Kit Installation PN R

36 Assembly 15 electrical wiring WARNING Place all controls in neutral or off, lower header to the ground, stop combine engine, set parking brake, remove ignition key, chock wheels and wait for all moving parts to stop before servicing, adjusting, repairing, or unplugging. NOTE Disconnect the intermediate harness connector at the feederhouse when the header is disconnected from the combine. Refer to Figure 28 during assembly. 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. 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 convenient location on the combine feederhouse. MANIFOLD TILT ACTUATOR (TO 15 AMP HARNESS) ACTUATOR SWITCH HARNESS (USED ONLY IF COMBINE IS EQUIPPED WITH SAME AUXILIARY POWER PLUG) (RED WIRES TO FUSE WIRES/BLACK TO GROUND) FAN BUTTERFLY ACTUATOR (TO 6 AMP HARNESS) SWITCH/MOUNT PLATE ASSEMBLY (MOUNT INSIDE COMBINE CAB) Figure 28 - Wiring Schematic 34 PN R060506

37 Assembly 16 flex hose mounted on manifold (header mounted fans) series headers NOTE Do not torque any parts until unit is fully assembled. Cut the 8 x 8 flex hose into two 4 ft. sections. Mount two tube mounts in the existing holes on the JD reel arm (Figure 29). Insert the end manifold into the tube mounts. Position the end manifold so there is approximately 2 of manifold extending past the upper tube mount. Secure using two U-bolts, 5/16 washers and 5/16 nuts. Slide the 45 rubber elbow onto the lower end of the end manifold; secure using an 8-11/16 t-bolt clamp (Figure 30) Using one 4 ft. flex hose, attach the end with the elbow support band to the 45 rubber elbow using an 8-11/16 t-bolt clamp. Attach the other end of the flex hose to the gearbox/fan assembly using an 8-1/4 t-bolt clamp. Attach the manifold elbow to the CWS manifold using the 8-1/4 t-bolt clamp on the CWS manifold (Figure 31). Using the other 4 ft. flex hose, attach the end with the elbow support band to the manifold elbow with an 8-11/16 t-bolt clamp. Attach the other end of the flex hose to the end manifold and secure using an 8-1/4 t-bolt clamp. Figure 30 - End Manifold Figure 29 - End Manifold Figure 31 - End Manifold PN R

38 assembly 16 flex hose mounted on manifold (header mounted fans) 12 all other headers NOTE Do not torque any parts until unit is fully assembled. Refer to Figure 32 during assembly. Install the manifold elbow onto the RH end of the CWS manifold with a t-bolt clam. Insert the elbow support band into the other end of the manifold elbow and attach with a t-bolt clamp. Attach 8 x 8 flex hose onto the elbow support band. Secure with a t-bolt clamp. Insert the other elbow support band into the opposite end of the flex hose and secure with a t-bolt clamp Attach rubber elbow onto the elbow support band and secure with a t-bolt clamp. Mount the rubber elbow to the fan with the t-bolt clamp. Attach the flex hose chain assembly to the flex hose and the header, finding a mounting location that gives the flex hose the most support. Tighten hardware to the proper torque. In the combine cab, find a suitable location for mounting the switch mount plate. Drill holes and install with 1/4 x 1 bolts and nuts. Attach the switch mount plate to a power source, the electric actuator located on the fan, and the electric actuator located on the manifold. 8" MANIFOLD ELBOW 8-11/16" T-BOLT CLAMP ELBOW SUPPORT BAND FLEX HOSE CHAIN 5/16" X 8.19" X 59" U-BOLT 8-1/4" T-BOLT CLAMP GEARBOX/FAN ASSEMBLY 5/16" FLAT WASHER 5/16" FLANGE NUT 5/16" FLAT WASHER 5/16" X 2" BOLT 5/16" FLAT WASHER 8-1/4" T-BOLT CLAMP 8" X 4' FLEX HOSE FLEX HOSE SUPPORT BAND ASSEMBLY 8-11/16" T-BOLT CLAMP TUBE MOUNT WELDMENT 5/16" FLANGE NUT 8-1/4" T-BOLT CLAMP 8" X 4' FLEX HOSE RUBBER ELBOW 8-11/16" T-BOLT CLAMP Figure 32 - Flex Hose Mounting - All Other Headers 36 PN R060506

39 assembly 17 transition kit (combine mounted fans) series headers 7. Refer to Figure 33 during assembly. Cut the 8 x 8 flex hose into two 4 ft.. sections. Mount two tube mounts in the existing holes on the JD reel arm. NOTE Do not torque any parts until unit is fully assembled. The lower tube mount is mounted, with the cradle facing down, using the same hole as the hydraulic hoses. The upper tube mount is mounted with the cradle facing up. Insert the end manifold into the tube clamps. Position the end manifold so there is approximately 2 of manifold extending past the upper tube mount. Secure using two U-bolts, 5/16 washers and 5/16 nuts. Attach the manifold elbow to the CWS manifold using the 8-1/4 t-bolt clamp on the CWS manifold. Using a 4 ft.. flex hose, attach the end with the elbow support band to the manifold elbow with an 8-11/16 t-bolt clamp. Attach the other end of the flex hose to the end manifold and secure using an 8-1/4 t-bolt clamp. Slide a 90 rubber elbow onto the lower end of the end manifold; secure using an 8-11/16 t-bolt clamp Install two tube clamps onto the rear LH side of the header. Space the clamps evenly to best support the weight of the manifold. Insert the end of the header manifold into the manifold elbow and secure using a 8-11/16 t-bolt clamp. Place the header manifold onto the tube clamps and secure using two U-bolts, 5/16 washers and 5/16 nuts. Attach two tube clamps onto header beam on the head. Space the clamps evenly to best support the weight of the feederhouse manifold. Place the feederhouse manifold onto the clamps making sure it is centered over the feederhouse opening on the header. Secure using two U-bolts, 5/16 washers and 5/16 nuts. Attach a manifold elbow to the RH end of the feederhouse manifold using an 8-11/16 t-bolt clamp. Insert an elbow support band into the other end of the manifold elbow and secure using an 8-11/16 t-bolt clamp. Attach the 8 x 6 flex hose to the elbow support with an 8-1/4 t-bolt clamp. Attach the connector band to the flex hose using an 8-1/4 t-bolt clamp. PN R

40 Assembly 17 transition kit (combine mounted fans) 8" MANIFOLD ELBOW ELBOW SUPPORT BAND 8-1/4" T-BOLT CLAMP 8" X 8' FLEX HOSE 8-11/16" T-BOLT CLAMP 5/16" X 8.19" X 59" U-BOLT 8-1/4" T-BOLT CLAMP FT HEADER/END 8-11/16" T-BOLT CLAMP 8" MANIFOLD ELBOW 5/16" FLAT WASHER 5/16 SERR. FLANGE NUT 5/16 SERR. FLANGE NUT TUBE MOUNT WELDMENT TUBE CLAMP WELDMENT 5/16" X 1" BOLT 8-11/16" T-BOLT CLAMP HEADER MANIFOLD 8-1/4" T-BOLT CLAMP 8-1/4" T-BOLT CLAMP 5/16" X 8.19" X 59" U-BOLT 5/16" X 8.19" X 59" U-BOLT DIRECTION OF TRAVEL FEEDERHOUSE MANIFOLD CUT SHORT SECTION OF HOSE FROM 8" X 8' FLEX HOSE. TUBE CLAMP WELDMENT 5/16" FLAT WASHER 5/16 SERR. FLANGE NUT 3/8" NYLOCK NUT 3/8" X 1" BOLT 3/8" FLAT WASHER 8-11/16" T-BOLT CLAMP 8" MANIFOLD ELBOW 8-11/16" T-BOLT CLAMP ELBOW SUPPORT BAND 8-1/4" T-BOLT CLAMP 8-1/4" T-BOLT CLAMP ELBOW SUPPORT BAND 8" X 6' FLEX HOSE Figure 33 - Transition Kit 38 PN R060506

41 5 Section Operation OPERATING SAFETY 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, 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. Review safety related items annually with all personnel who will be operating or maintaining the CWS. 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 disconnected. 1 new owner or operator information The CWS 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, transport, maintenance and storage of equipment or in the use and maintenance of facilities. Follow all safety instructions exactly. Safety is everyone s business. 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 CWS will provide many years of trouble-free service. PN R

42 Operation 2 machine components The CWS is designed to handle all types of beans and small grains such as wheat and barley. The CWS 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 1 - Machine Components 40 PN R060506

43 Operation 3 machine break-in Efficient and safe operation of the Crary CWS 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 CWS that the following checklists are followed. 1 new machine inspection Read 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. 2 After operating for 2 hours Retorque 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 fittings, 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 temperature of the gearbox is 200 F. Check the drives for proper tension. 3 After operating for 10 hours Retorque all fasteners and hardware. Check that all guards are installed, secured and functioning 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. 4 DAILY CHECKLIST Before operating the CWS and each time thereafter, the following areas should be checked Service the CWS per the schedule outlined in the Maintenance Checklist (Section 6). Use a combine of adequate power and specifications to operate the CWS. Check that all guards are installed, secured and functioning 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 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. Place the header on the ground and visually check the hydraulic sight glass 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. Check the condition of the auger driveshaft slip clutch friction discs. PN R

44 Operation 4 controls Before 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 different models of combines and headers. a. b. Manifold Tilt: Moving the toggle switch to the FORE position (Figure 2) extends the shaft of the electric actuator forward, rotating the manifold CCW and directing the air tubes towards the back of the header (Figure 3). Moving the toggle switch to the AFT position (Figure 2) retracts the shaft of the electric actuator backward rotating the manifold CW and directing the air tubes towards the front of the header (Figure 3). a. b. a. a. Fan Air Volume Actuator: Move the toggle to the OPEN position (Figures 2 & 4) to open the butterfly plate; this increases air volume to the air tubes. Move the toggle to the CLOSED position (Figures 2 & 4) 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 Consult your owner s manual that came with your header. MANIFOLD TILT TOGGLE SWITCH INDICATOR (FULLY OPEN POSITION) FAN AIR VOLUME TOGGLE SWITCH Figure 2 Manifold Tilt & Fan Air Volume Toggle Switch INDICATOR (SHOWN FULLY CLOSED POSITION) BUTTERFLY ACUATOR FAN BUTTERFLY ACUATOR Figure 4 - Butterfly Indicator MOVING TOGGLE TO "AFT" POSITION, DIRECTS AIR TUBES TOWARDS FRONT OF HEADER. AIR TUBE MOVING TOGGLE TO "FORE" POSITION, DIRECTS AIR TUBES TOWARD BACK OF HEADER. CUTTERBAR AIR MOVEMENT Figure 3 - Manifold Tilt & Fan Air Volume Toggle Switch 42 PN R060506

45 Operation 5 operating hints 6 transporting WARNING Place 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. The 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 above. 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. The CWS is designed to be easily and conveniently moved from location to location. When transporting the machine, review and follow these safety instructions: 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 and header for proper transportation guidelines. 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. 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. PN R

46 Operation 7 storage After 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 children. Thoroughly wash the entire machine using a pressure washer to remove all dirt, mud, debris or residue. Inspect the following components: 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. A. B. C. D. PTO Driveline Components Check the condition and operation of the friction disc torque limiter (slip clutch) (see the maintenance section). 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. CWS Components: Air Tubes: repair or replace bent or damaged air tubes. Fan Components 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 residue from the washing and prevent rusting during the storage period. Rotate all moving parts to distribute lubricant to all surfaces. removing from storage When removing from storage and preparing to use, follow this procedure: Clear the area of bystanders, especially small children. Remove the tarpaulin from the machine if it was covered. 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 and follow all items in the Machine Break-In section before starting (Section 3). Install all safety shields and review precautions with operators and other personnel involved in the operation. 1 Drain and refill gearbox. 44 PN R060506

47 6 Section Service & maintenance 1 MAINTENANCE CHECKLIST 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 DAILY HOURS SERVICED BY L PTO CROSS JOURNAL ZERKS GEARBOX OIL LEVEL 16 HOURS L PTO INNER TUBE 40 HOURS L L PTO SHIELD RETAINING BEARING 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) PN R

48 Service & maintenance 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. 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 HD SAE 75W-90 Gear lube or equivalent with the following specifications: 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. API Service GL-5 MIL-L-2105D MACK GO-H Capacity: 40 oz. 3 GREASING 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. Replace and repair broken fittings immediately. If fittings will not take grease, remove and clean thoroughly. Also clean lubricant passageway. Replace fitting if necessary. 46 PN R060506

49 Service & maintenance 4 GEARBOX OIL CHECKING THE GEARBOX OIL LEVEL Check the gearbox oil level daily. Check more frequently if leaks exist around any of the plugs or shaft seals. The oil level in the gearbox should be no higher than the bottom of the driveshaft (Figure 1). CHANGING THE GEARBOX OIL Each gearbox is equipped with a drain, level and fill plug. Every 500 operating hours or annually, whichever comes first, the oil should be replaced. When changing the oil, follow this procedure: Place a container under the gearbox. Remove the drain plug. Allow 10 minutes to drain. Replace the drain plug. 7. Add 40 oz of Mobilube SHC 75W-90 synthetic gear lube or equivalent with the following specifications: API Service GL-5/MT.1 MIL-L-2105D MACK GO-J PLUS SAE J2360 Capacity: 40 oz. Fill the gearbox oil 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. Figure 1 - Gearbox Oil Level. IMPORTANT Always clean the vent plug if any leaks are noticed around shaft seals. PN R

50 Service & maintenance 5 pto lubrication Daily Lubricate PTO cross journals. Make sure grease purges through all four bearings. Every 16 hours Lubricate PTO inner tubes. Telescoping members must have lubrication to operate successfully. Telescoping members without fittings should be pulled apart and grease should be added manually with a brush. 7. Every 40 hours 8. 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! (See Figure # 39) 9. Lubricate the PTO disconnect mechanism. h 8 h 40 h 40 Figure 2 - Lubricate PTO Cross Journals. h h fan housing and air hose Every 40 hours the fan housing and ductwork should be checked for wear (Figure 10.9). Figure 3 - Check Condition of Slip Clutch 48 PN R060506