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OWNER’S MANUAL JOHN DEERE 900F REcORD SERiAL NUMbER HERE PN 12068 R060107 Companion to 12085...
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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.
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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.
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iNSPEcTiON AFTER DELivERY Inspect your shipping cartons for damage. If you suspect any damage, contact the carrier (trucking company) right away. Unpack the shipping cartons and compare the contents with the parts listing on the packing slips. If any parts are missing or damaged, contact your local authorized dealer or call the factory for assistance.
This manual covers all models of the Air Reel manufactured by Crary Industries for John Deere 200, 600, 900 and 900F series headers. Differences are explained where appropriate. Use the Table of Contents as a guide to locate required information.
SAFETY Section 2.1 SAFETY ALERT SYMbOL The Safety Alert symbol identifies impor- This Safety Alert Symbol means: tant safety messages on the Air Reel and in the manual. When you see this symbol, be alert to the possibility of personal injury ATTENTiON! bEcOME ALERT! or death.
SAFETY 2.2 GENERAL SAFETY YOU are responsible for the SAFE operation and main- Read and understand the tenance of your Air Reel. You must ensure that you and Owner’s Manual and all anyone else who is going to operate, maintain or work safety decals before operat- around the machine are familiar with the operating and ing, maintaining, adjusting or...
SAFETY 2.3 OPERATiNG SAFETY 2.4 MAiNTENANcE SAFETY Follow ALL operating, maintenance, and safety infor- Read and understand the owner’s manual and all mation in this manual. safety decals before servicing, adjusting or repairing. Support the machine with blocks or safety stands when Install and secure all guards and shields before start- working around it.
SAFETY 2.6 PTO SAFETY 2.5 HYDRAULic SAFETY Keep bystanders, especially children, away from drive Always place all combine hydraulic controls in neutral before disconnecting from combine or working on shafts. hydraulic system. Be extremely careful when working around PTO shafts, Make sure that all components in the hydraulic system drivelines, or other rotating shafts.
SAFETY 2.7 TRANSPORT SAFETY 2.10 SAFETY DEcALS Keep safety decals clean and legible at all times. Make sure you are in compliance with all local regula- tions regarding transporting equipment on public roads Replace safety decals that are missing or have become and highways.
SAFETY 2.11 SiGN-OFF FORM Crary Industries 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.
SAFETY DEcALS Section 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! Figure 1, Decal location PN 11001 - Decal, Caution PN 11002 - Decal, Warning REMEMbER - If safety decals have been damaged, removed or become illegible or parts have been replaced without...
ASSEMbLY Section Read all instructions to become familiar with the parts and procedure used before starting the actual work. You may refer to the parts catalog for additional aid in assembling the Air Reel. 4.1 UNcRATiNG WARNiNG Assemble in an area with sufficient space to handle the largest component and access to all sides of the machine.
ASSEMBLY 4.2 HEADER PREPARATiON 4.2.1 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 5). Open the auger slip clutch shield by removing two bolts (shield is hinged at bottom).
ASSEMBLY 4.2 HEADER PREPARATiON 4.2.3 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’...
ASSEMBLY 4.2 HEADER PREPARATiON 4.2.4 LH DRivE KiT (OPTiONAL, 600 SERiES) Disassembly of existing header components: Remove the LH side end shield. Loosen the chain tensioner (A) and belt tensioner (B) (See Figure 11). Remove the sickle drive pulley, bearing and auger drive sprocket from the shaft.
ASSEMBLY 4.3 MOUNT PLATE SUPPORT (HEADER MOUNTED FAN) 4.3.1 600 SERiES HEADERS Refer to Figure 14 for correct loca- tions and measurements. Mark and drill two 17/32” holes on the top portion of the header for the top of the mount plate support.
ASSEMBLY 4.4 GEARbOX/FAN MOUNT (HEADER MOUNTED FAN) Attach gearbox mounting plates to the mount plate. Refer to Figure 16 during mounting. DO NOT TiGHTEN AT THiS TiME. Check the gearbox and if necessary, fill the gearbox Lift the fan/gearbox into position using a floor jack or with lube before use.
ASSEMBLY 4.5 RiGHT HAND DRivE KiT - 600 SERiES Slide the gearbox shaft through the bearing mount WARNiNG bracket, bushing shield weldment and the gearbox from the LH side. There should be approximately 3” of shaft Place all controls in neutral or off, lower header to the protruding on the LH side of the 1-3/8”...
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ASSEMBLY 4.5 RiGHT HAND DRivE KiT - 600 SERiES Figure 18, Right hand drive kit (600 series) John Deere Air Reel Owner’s Manual...
ASSEMBLY 4.6 LEFT HAND DRivE KiT - 600 SERiES WARNiNG iMPORTANT Place all controls in neutral or off, lower header to the Correct shaft alignment is critical. ground, stop combine engine, set parking brake, re- move ignition key, chock wheels and wait for all moving Check for shaft alignment up &...
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ASSEMBLY 4.6 LEFT HAND DRivE KiT - 600 SERiES Figure 20, Left hand drive kit (600 series) John Deere Air Reel Owner’s Manual...
ASSEMBLY 4.7 RiGHT HAND DRivE KiT - F SERiES Measure and cut long drive shaft shield to fit between WARNiNG bushing on LH side of gearbox and bearing mount plate welded on back of header. Slide drive shaft shield over Place all controls in neutral or off, lower header to the shaft and through bearing mount plate.
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ASSEMBLY 4.7 RiGHT HAND DRivE KiT - F SERiES Figure 21, Right hand drive kit (F series) John Deere Air Reel Owner’s Manual...
Refer to Figure 22 for the following steps: Remove bearing mount plate, slide drive shaft shield Install the (Crary supplied) hex clutch shaft into the hex onto gearbox drive shaft and reinstall bearing and bearing through the RH side sheet of header. Reinstall mount plate.
ASSEMBLY 4.8 RiGHT HAND DRivE KiT - 900 SERiES, 1-1/8” HEX DRivE SHAFT Figure 22, Right hand drive kit (900 series with hex shaft) 4.9 RiGHT HAND DRivE KiT - cONTOUR MASTER For installation of these RH drive kits, refer to Section 4.7. RiGHT HAND DRivE KiT PARTS The only variation between these kits and the “F”...
ASSEMBLY 4.10 RiGHT HAND DRivE KiT - SiDEHiLL Measure and cut long drive shaft shield to fit between WARNiNG bushing on LH side of gearbox and bearing mount plate welded on back of header. Slide drive shaft shield over Place all controls in neutral or off, lower header to the shaft and through bearing mount plate.
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ASSEMBLY 4.10 RiGHT HAND DRivE KiT - SiDEHiLL Figure 23, Right hand drive kit (sidehill) John Deere Air Reel Owner’s Manual...
Refer to Figure 24 for the following steps: dimension. Install the (Crary supplied) round clutch shaft into the Remove bearing mount plate, slide drive shaft shield bearing through the RH side sheet of header. Reinstall...
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ASSEMBLY 4.11 RiGHT HAND DRivE KiT - 200, 900 SERiES, 1-1/4” ROUND DRivE SHAFT Figure 24, Right hand drive kit (200 and 900 series with round shaft) John Deere Air Reel Owner’s Manual...
ASSEMBLY 4.16 Hi-DRivE FAN MOUNTiNG (JD 96/97/9860STS) After cutting the hole, reinstall the front RH shield. WARNiNG Remove the nut and washer from the OEM pulley Place all controls in neutral or off, lower header to the shown in Figure 27. Then, screw the splined adapter ground, stop combine engine, set parking brake, re- shaft onto the pulley and torque to 875 ft-lbs.
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ASSEMBLY 4.16 Hi-DRivE FAN MOUNTiNG (JD 96/97/9860STS) Slide the back end of the fan mount assembly into the cut hole in the front RH shield. Align the holes in the fan mount assembly with the platform holes shown in Figure 29. Attach the fan mount assembly to the plat- form with five 3/8”...
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ASSEMBLY 4.16 Hi-DRivE FAN MOUNTiNG (JD 96/97/9860STS) Install bushing and sheave on the fan shaft. Use a When shaft alignment and distance are correct, straight edge to check the alignment of the front and connect the two shafts with the short double v-joint back fan drive sheaves (Figure 33).
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ASSEMBLY THiS PAGE iNTENTiONALLY LEFT bLANK John Deere Air Reel Owner’s Manual...
ASSEMBLY 4.13 EccENTRic MOUNT iNSTALLATiON Open Box #3 and sort bolts according to their size and length. Rotate the manifold on its saw horses so that the drive shaft is facing upward. NOTE The back side of the manifold is opposite that of the large Air Reel decal.
ASSEMBLY 4.14 REEL bAT ARM iNSTALLATiON 4.14.2 iNSTALLiNG THE REEL bAT ARMS 4.14.3 iNSTALLiNG THE FRONT iDLER GEAR Assemble one front idler gear assembly each to the RH Slide the reel bat arm assemblies over the manifold & LH end clamps and to all idler mount clamps (front assembly.
ASSEMBLY 4.15 AiR TUbES Roll the manifold over so that the air tube holes in the bottom of the manifold are facing upwards. Apply the self adhesive foam seals (Figure 43). Remove and discard the slot and two hole cutouts from the self adhesive foam seal. Remove the self adhesive foam seal from the backing and apply foam seal to manifold.
ASSEMBLY 4.16 REEL bATS Remove the plastic bearing caps from the reel mount arms by removing one 5/16” x 2” bolt, one 5/16” center locknut and two 1/4” flat washers per each reel arm (Figure 46). Assemble the reel bat assemblies to the reel arms. Determine the correct orientation of the reel bat.
ASSEMBLY 4.17 HYDRAULic MOTOR Slide the shaft coupler onto the driveline shaft (right Align the mounting holes of the hydraulic motor hand end). with the holes of the motor mount. Insert the 5/16” bolts through the shaft coupler and Fasten with the supplied 1/2” x 1-1/2” bolts, two 1/2”...
ASSEMBLY 4.18 EccENTRic ARM Slide an eccentric arm assembly over each end of Bolt the eccentric arm assembly to the reel bat as- semblies with a 1/2” x 2-1/2” button head bolt through each manifold, making sure that the end shield faces towards the outside (Figure 49).
The cylinder shown has already been cut (Figure 51). Thread the new yoke onto the cylinder rod (Figure 52). Figure 52, Crary reel arm yoke Figure 50, Removing the OEM reel lift cylinder John Deere Air Reel Owner’s Manual...
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ASSEMBLY 4.19 REEL SUPPORT iNSTALLATiON (HYD. FORE AND AFT) (600 SERiES) The cylinder safety lock must be shortened (Figure 53). Remove the safety lock from the reel arm mount. Measure 17.44” from the center of the pivot bolt towards the bottom end and mark. Cut the safety lock and reinstall onto the reel arm mount.
Remove the fore/aft sensor and mount bracket assem- bly from the JD RH reel support and bolt to the bracket on the Crary RH reel support assembly (Figure 59). Check clearance of the reel support assembly to header reel arm components.
ASSEMBLY 4.20 REEL SUPPORT iNSTALLATiON (HYD. FORE AND AFT) (200, 900, 900F SERiES) Insert the reel support pad underneath the top of each WARNiNG reel support bracket. Slide the RH and LH reel support brackets onto their Avoid crushing injury or death from fall of raised reel. respective reel arms (Figure 60 &...
ASSEMBLY 4.21 REEL SUPPORT iNSTALLATiON (MANUAL FORE AND AFT) (200, 900, 900F SERiES) Slide adjustment bracket weldment onto each reel WARNiNG arm so that the threaded rod is to the outside of the reel arm. Avoid crushing injury or death from fall of raised reel. Before working on or under a raised reel, place all con- Thread adjustment bracket rod into the reel support trols in neutral or off, stop combine engine, set parking...
ASSEMBLY 4.22 REEL TO HEADER iNSTALLATiON Slide the brace clamps out to the reel support brackets WARNiNG and tighten the bolts and nuts. Place all controls in neutral or off, stop combine engine, Bolt the half clamps over manifold, ensuring the mani- set parking brake, remove ignition key, set cylinder fold is able to rotate by hand.
ASSEMBLY 4.23 MANiFOLD TiLT Slide the pivot clamp assembly over the LH end of WARNiNG the manifold, and position it next to the reel support bracket. Do not tighten the clamp at this time. Place all controls in neutral or off, stop combine engine, set parking brake, remove ignition key, set cylinder If using a left hand drive kit, skip to Step 3.
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ASSEMBLY THiS PAGE iNTENTiONALLY LEFT bLANK John Deere Air Reel Owner’s Manual...
ASSEMBLY 4.24 TRANSiTiON KiT (cOMbiNE MOUNTED FANS) Insert the end of the header manifold into the manifold NOTE elbow and secure using an 8-11/16” t-bolt clamp. Place the header manifold onto the tube clamps and Do not torque any parts until unit is fully assembled. secure using two U-bolts, 5/16”...
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ASSEMBLY 4.24 TRANSiTiON KiT (cOMbiNE MOUNTED FANS) Figure 66, Transition kit John Deere Air Reel Owner’s Manual...
ASSEMBLY 4.25 AiR HOSE Install the hose connector weldment to the reel arm of WARNiNG the header using the two 5/16” X 2-1/2” bolts and two 5/16” serrated flange nuts. Tighten to 17 ft-lbs. Place all controls in neutral or off, stop combine engine, set parking brake, remove ignition key, set cylinder The flex hose/band assembly must be divided into 2 stops, wait for all moving parts to stop, then properly...
ASSEMBLY 4.26 ELEcTRicAL WiRiNG Run the black wires to a suitable ground or to the WARNiNG actuator switch harness ground wires. Place all controls in neutral or off, stop combine engine, Route the long harnesses along the combine and set parking brake, remove ignition key, set cylinder header to the actuators (15 Amp Manifold Tilt;...
4.27.1 SPEED SENSOR KiT The Crary Speed Sensor Gear Kit (as an option) is needed on the Air Reel to use the automatic reel speed to ground speed option provided on some late model John Deere combines.
Figure 72, Loosen and remove hardware and bushing Figure 71, Installing hydraulic relief valve 4.27.2 AUXiLiARY REEL TiNE KiT The Crary Auxiliary Reel Tine Kit is recommended for crops that do not move easily from the knife to the auger at the ends of the header.
ASSEMBLY 4.27 OPTiONAL EqUiPMENT 4.27.3 GEARbOX/FAN EXTENSiON Mount gearbox/fan extension to combine. Refer to Section 4.4 for fan/gearbox installa- The gearbox/fan extension option is designed to extend tion instructions. the fan up to eliminate clearance problems with headers smaller than 20’ and combines with dual tires. When in- Select appropriate support bracket for com- stalling the gearbox fan extension kit, follow this proce- bine model.
ASSEMBLY Figure 74, Gearbox/fan extension KiT, GEARbOX/FAN EXTENSiON OPTiON KiT, GEARbOX/FAN EXTENSiON OPTiON PART PART iTEM DEScRiPTiON iTEM DEScRiPTiON NUMbER NUMbER BOLT, 3/8" X 1-1/4" HHCS GR5 ZP KEY, 3/16" SqUARE X 1-1/4" PLAIN 15364 7022 U-BOLT, 3/8" X 3" X 4", FAN MOUNT ZP ROTOR, FAN, 12.88"...
OPERATiON Section WARNiNG Keep all hydraulic lines, fittings, and couplers tight Read and understand the owner’s manual and all and free of leaks before and during use. safety signs before servicing, adjusting or repair- ing. Clean reflectors and lights before transporting. Install and secure all guards and shields before Review safety related items annually with all per- starting or operating.
OPERATION 5.1 MAcHiNE cOMPONENTS Your Air Reel incorporates the superior feeding performance of an adjustable tine pitch pickup reel and an adjustable air system. The combination of these two systems results in superior harvesting efficiency. Please take the time to fa- miliarize yourself with the proper adjustment and operation of your Air Reel.
OPERATION 5.2 PRE-OPERATiON cHEcKLiST 5.3 MAcHiNE bREAK-iN Efficient and safe operation of the Air Reel requires that 5.3.1 PRE-START iNSPEcTiON each operator reads and understands the operating pro- Read the owner’s manual. cedures and all related safety precautions outlined in this Check that the hydraulic lines and electrical harnesses section.
OPERATION 5.4 cONTROLS Before starting to work, all operators should familiarize FAN AiR vOLUME AcTUATOR: themselves with the location and function of the controls Move the toggle to the OPEN position (Figure 77) to and safety devices. Some machines may vary due to dif- open the butterfly plate which increases air volume to ferent models of combines and headers.
OPERATION 5.5 iNiTiAL ADJUSTMENTS Since all applications of the Air Reel are not the same, Turn adjustable air tubes at each end approximately 45° - 90° so they direct air into the corners of the based on header and combine variations, some initial ad- justments must be made to achieve peak performance of header.
OPERATION 5.5 iNiTiAL ADJUSTMENTS 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.
OPERATION 5.5 iNiTiAL ADJUSTMENTS (cONT.) 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.
OPERATION Electrical System 5.6 OPERATiNG HiNTS • Check the wiring harness and all wiring components for damaged or worn areas. • The reel tines should lift the crop high enough to pass • Check for cracked or worn insulation. over the guards for easier cutting. •...
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OPERATION 5.8 STORAGE 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.
SERvicE & MAiNTENANcE Section 6.1 MAiNTENANcE cHEcKLiST 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. These service recommendations are based on normal operating conditions. Severe or unusual conditions may require more frequent attention.
SERVICE & MAINTENANCE cHANGiNG THE GEARbOX OiL 6.2 FLUiDS AND LUbRicANTS Each gearbox is equipped with a drain, level and fill plug. Every 500 operating hours or annually, whichever comes GREASE: Use an SAE multi-purpose high tempera- first, the oil should be replaced. When changing the oil, ture grease with extreme pressure (EP) performance follow this procedure: meeting or exceeding the NLGI #2 rating for all re-...
SERVICE & MAINTENANCE 6.5 PTO LUbRicATiON 6.6 iDLER GEAR TENSiON Every 40 hours the tension of the idler gears should be DAiLY checked. If the tension between the idler gears and inter- Lubricate PTO cross journals (Figure 83). Make sure nal gear sections of the reel bat arm assembly has any ra- grease purges through all four bearings.
WARNiNG If replacement parts are needed, consult your local Place all controls in neutral or off, stop combine engine, authorized Crary dealer. set parking brake, remove ignition key, set cylinder Reassemble the eccentric roller assembly as shown stops, wait for all moving parts to stop, then properly in Figure 86.
Check the condition of all parts, especially the friction discs (Figure 89). If replacement parts are needed, consult your local authorized Crary dealer. Reassemble all components. Tighten nuts following an alternating cross pattern until the clutch slips momentarily upon initial startup and then continues to operate normally.
If you encounter a problem that is difficult to solve, even after having read through this troubleshooting section, please call your local Crary dealer. Before you call, please have this manual and the serial number from your machine ready. bEFORE YOU cALL...
SPEciFicATiONS Section 8.1 REEL SPEciFicATiONS SPEED OF HYDRAULIC DRIVE ....0 - 59 RPM DIAMETER (BAT REEL) ........... 48” NUMBER OF BATS ............6 8.2 FAN PERFORMANcE DATA John Deere Air Reel Owner’s Manual...
SPECIFICATIONS 8.3 HYDRAULic FiTTiNG TORqUE TiGHTENiNG FLARE TYPE TUbE FiTTiNGS * FLARE TYPE TUbE FiTTiNGS NUT SiZE REcOMMENDED TURNS TUbE SiZE TORqUE AcROSS TO TiGHTEN Check flare and flare seat for defects that might vALUE * FLATS (AFTER FiNGER TiGHTENiNG) cause leakage.
The table shown below is for reference purposes only and its use by anyone is entirely voluntary, unless otherwise noted. Reliance on its contents for any purpose is at the sole risk of that person. Crary Co. is not responsible for any loss claim or damage arising therefrom.
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237 12th St. NW • P.O. box 849 West Fargo, ND 58078-0849 (701)282-5520 • FAX: (701)282-9522 www.crary.com...
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