Model 3240 Chopper. Chopper Drive. Saskatoon, Saskatchewan Phone (306)

Transcription

1 Model 3240 Chopper Case International 1660 and 1666 Chopper Drive Saskatoon, Saskatchewan Phone (306)

2 ITRODUCTIO REDEKOP CHOPPER USERS GUIDE Thankyou for purchasing a Redekop product. Read this manual carefully to learn how to properly install, maintain and safely operate your straw chopper. Failure to do so can result in personal injury or equipmentdamage. Special features ofthe Redekop Chopper: 1) Your new chopper, for the first time, combines a chaff spreader and a straw chopper in one machine, enhancing both. 2) Special hammer configuration: i) All hammers run in pairs to provide twin cutting action providing closer clearance to stationary blades for fine cutting; ii) paddle hammers provide greater airthrustto the extentthat the entire chopper becomes a fan; and iii) paddle hammers are sloped at the ends to create a scissor action with the stationary blades increasing cutting ability in tough straw. 3) A special fin and tail board design concentrates the airflow generated by the Redekop paddle hammers in a narrow, horizontal band which enhances the spreading ability ofthe chopper. 4) With the feed collection option - the spreading unit is replaced with an outlet tube to blow the chopped feed, including the chaff, into a trailing wagon. The Redekop Manufacturing Co. Model 4240 and 4250 Chopper For CaseIH Combines Users Guide Printed Jan 2000 PAGE I

3 SAFETY RECOGIZE SAFETY IFORMATIO REDEKOP CHOPPER USERS GUIDE This is the safety-alert symbol. This symbol alerts you to the potential for perwnal injury. You will see this symbol on your straw chopper and in this manual. A signal word is used with the safety-alert symbol to identify the type of hazard. The meaning of each signal word is given here: ACAUTI~ ~ CAUTIO Understandidentifies be general alert toprecautions the warnings about andthe instructions machine. given with this safety-alert. AWARIG WARIG alerts you to a specific hazard located nearby. A DAGER FOLLOW SAFETY ISTRUCTIOS DAGER alerts you to the most serious hazards. This safetyalert is also located near the specific hazard. Careful read all safety messages in this manual and on your straw chopper safety signs. Keep safety signs in good condition replacing missing or damaged safety signs. Learn how to properly operate, check, maintain and service your straw chopper. Do not let anyone perform these duties without instruction. Keep your straw chopper in proper working condition. Unauthorized modifications to the straw chopper may impair the function and/or safety and affect chopper performance and life. If you have any questions regarding the operation, maintenance, or service of your straw chopper, contact your Redekop dealer or Redekop Industries direct at (306) A CAUTIO To prevent serious injury or machine damage: Read and understand Operator s Manual before using. installing, or working on this machine. Review annually. Stop combine engine, place all controls in neutral, set park brake, remove ignition key, and wait for all moving parts to stop before servicing, adjusting, repairing, unplugging or fitting this machine. Keep hands, feet, hair, and clothing away from moving parts. R12 ISPECT THE STRAW CHOPPER BEFORE YOU OPERATE Inspect the straw chopperfor damage: Check all hammers and stationary blades for excessive metal wear, cracks, or other visible damage. o Checkfor loose, worn, damaged or missing parts. Check and tighten the straw chopper hardware, especially the rotor hammer mount bolts. All guards and shields must be in good condition and fastened in place before operating. Make sure all caution and warning decals are clearly visible and readable. Make sure all safety devices are correctly fitted and operative. The Redekop Manufacturing Co. Model 4240 and 4250 Chopper For CaselH Combines Users Guide Printed Jan 2000 PAGE 2

4 REDEKOP CHOPPER USERS GUIDE STAY CLEAR OF CHOPPER DISCHARGE AREA Look and listen to ensure that all motion has ceased on combine and straw chopper before moving in the vicinity of the straw chopper, making adjustments to the chopper drive, spreading fins, cutter bar, or adjusting the position of the front deflection door. Flying chaff, straw and other debris can cause serious personal injury. Keep all persons clear of the spreading or collecting unit at all times. Chaff and straw can be propelled to distances of 50 feet or more, and hard objects like stones much further still. STAY CLEAR To prevent serious Injury or death from thrown object: Stay away from discharge area while engine is running. Keep others away. Do not point discharge toward people, animals, or buildings when operating. R120 KEEP HADS AWAY FROM RUIG CHOPPER Keep hands and any other objects away from chopper when combine is running. Do not place hands between the chopper and sieve when samples of chaff are to be obtained. The chaff pan can be moved to open a space for the chaff to fall (see operations section of this manual). Then a drop sheet can be used to safely collect a chaff sample. Remember, the Redekop chopper draws a large amount of air from the combine and could easily draw in a hand or other object that is place too close to it s hammers. ROTATIG BLADE HAZARD To prevent serious Injury or death from contact with chopper rotor: Do not adjust chaff or straw deflection panels while chopper rotor is in motion. Keep hands, feet, clothing, and hair out of the R~21 STAY CLEAR OF MOVIG PARTS Keep safety shield provided in place at all times. The Redekop chopper s placement on your combine has it s pulley/belt drive outside of the protection offered by existing combine shields. Contact with either the pulley or belt while chopper is running can cause serious injury. Keep hands and any other objects away from chopper when combine is running. Make sure the two safety shields are correctly installed and well maintained. ever remove the shields from the straw chopper. 1~ DAGER SHIELD MISSIG When this Is visible DO OT OPERATE R125 MOVIG PART HAZARD To prevent serious injury or death from moving parts: Close and secure all guards and shields before dperating, Keep hands, feet, hair, and clothing away from moving parts. Turn off engine and wait for all motion to stop before adjusting or servicing R122 The Redekop Manufacturing Co. Model 4240 and 4250 Chopper For CaseIH Combines Users Guide Printed Jan 2000 PAGE 3

5 REDEKOP CHOPPER USERS GUIDE OPERATE THE STRAW WIDROW DOOR SAFELY Do not operate the straw chopper while the straw wiridrow door is in the closed position. The door obstructs the motion of the chopper rotor when in the closed position. Operating the chopper with the door in this position can result in damage to the door and the rotor blades. When changing the door to the closed position to drop straw, the chopper drive belt must be moved from the chopper driven pulley to the bale idler located nearby so the rotor does not rotate. Turn off the combine ignition and make sure all motion has stopped before the moving the chopper belt. A CAUTIO PARTS ITERFERECE HAZARD To prevent damage to chopper rotor and straw windrow door: Do not operate the chopper while the straw windrow door is in the windrow position. The chopper drive belt must be moved from the chopper rotor pulley to the nearby idler to windrow straw and chaff. R123 STAY OFF THE SPREADIG FI HOOD The spreading fin hood was not designed to support heavy loads structurally or safely. Do not stand on or plate heavy objects on this hood. To avoid inju~ or machine damage:. Do not use this spreading fin hood as a step. Hood may bend or feet may slip causing rn24 The Redekop Manufacturing Co. Model 4240 and 4250 Chopper For CasetH Combines Users Guide Printed Jan 2000 PAGE 4

6 MAI TEACE Although little active maintenance is required to keep your Redekop Chopper operating smoothly, it is very important that the following preventative maintenance schedule be followed. A regular visual check and replacement of the high wear components will prevent larger scale maintenance in the future. The following areas of your straw chopper should be checked on a regular basis. REDEKOP CHOPPER USERS GUIDE Component Instructions i) Bearings grease lightly every 100 hours ii) Hammers look for excessive wear of metal, cracks, or other visible damage and replace as necessary check clearance between the hammers and stationary blades to ensure that there is adequate space to operate without obstruction there should be no less than 1/4 of clearance between each hammer edge and the closest stationary blade clearance problems may occur when hammers and/or stationary blades may be deformed by hard objects that pass through the combine - check for and replace components as necessary repetitive ticking or knocking sounds emitted from the chopper may signal a minor clearance problem - the chopper should be stopped immediately and examined Caution! If one hammer breaks and the chopper must be operated without a replacement then the damaged hammer and the hammer directly opposite it must both be removed in order to keep the rotor in balance Caution! ever replace only one hammer for wear or breakage - always replace hammers in opposite pairs. iii) Stationary check blades for excessive wear, damage, or breakage Blades if a stationary blade breaks, remove the rod holding the blades in place, replace the damaged blade and reinsert the rod iv) Belt if excessive belt temperatures are evident, or the chopper seems to be losing excessive rpm during operation in tough or heavy conditions, the belt tension is not sufficient and should be adjusted immediately look for cracks, frayed edges, or any imperfections that may result in breakage if a belt edge shows excessive wear, check for mis-alignment of the pulleys and correct if necessary The Redekop Manufacturing Co. Model 4240 and 4250 Chopper For CaselH Combines Users Guide Printed Jan 2000 PAGE S

7 REDEKOP CHOPPER USERS GUIDE REPLACEMET OF WEARIG PARTS SECTIO I - ROTOR PARTS QUATITIES 1. Table I breaks down the total quantities of each part required for the 3240 and 3250 chopper rotor. Use this reference when ordering parts. Qty Per Unit 3240 Item ~ mber Description (3250) I 2 H8CZ3&~. HA500L ~ cap screw, 3/8 x 2 1/4 nc gr8 zinc n~j~- ~~ilw/ left hand bend 20 (26) 14(17) 3 4 HA 500R HA 520 hammer, i~. ~ ht hand bend washer, 1 harden~ 14 (17) 40 (52) 5 HA 530 bushing, 1/4 offset 0.19i (34) 6 HA 600 hammer, straight 0.13 thick sharp~ ~ ~ 12 (18) 7 HA 610 bushing, 114 offset flange ) 10 SLCZC38 lock nut, 3/8-16 C lock nut steel zinc 20 6) Table 1: Rotor Parts Breakdown for 3240 and 3250 Chopper. SECTIO 2- REPLACIG KIFE BAR PARTS 1. Remove pin (3) from the knife blade support rod (4) as shown in Figure 3. Slide the support rod out of the knife bar (2) to free the HA 700 knife blades (1). 2. Remove and replace worn knife blades in the knife bar. Insert the support rod back in the knife bar assuring it passes through the two support tubes welded to the knife bar as well as the hole in each knife blade. 3. lnsertthe pin into the support bar and bend overto secure. 1 - Part# HA 700, 26 pcs in complete set. 4 ~ Figure 3: Knife BarAssembly Schematic. The Redekop Manufacturing Co. Model 4240 and 4250 Chopper For CaselH Combines Users Guide Printed Jan 2000 PAGE 6

8 Model 4250 Blade Installation Instructions 1. The paddle blades for your chopper must be installed as outlined in Figure 1. If blades are installed other than as directed, damage to the chopper may result or performance may be significantly reduced. Important Installation Instructions: 1) Always replace blades two pairs at a time, directly opposite each other through the center of the rotor. This should maintain rotor balance. ever replace only one blade for wear or breakage. You do not need to replace the corresponding two pairs on the other end of the rotor. 2) If a blade breaks and the chopper must be operated without a replacement then the damaged blade and the one directly apposite it must both be removed to maintain rotor balance. 3) Use only METRIC grade 10.9 bolts and grade 10.9 DI98OV steel lock nuts on the chopper rotor. 4) Use a torque wrench to tighten all nuts to the recommended range of 45 ft-lb to 65 ft-lb. 5) Always check for adequate clearance between the installed blades and the stationary knives. A minimum of 3/8 is required. Check clearance of all blades, even those that are not replaced. Do not operate the straw chopper unless this clearance is maintained for all blades. Figure 1: Blade Installation Details 2. The correct assembly for the paddled blade pairs is shown in Figure 2. 2.~ CAUTIO: Always use ~ 6 METRIC grade 10,9 bolts and grade 10.9 DI98OV 4~ ~ steel installing lock hammers. nuts when Allowable torque range for 5 hammer mount nuts is 5 45ft-Ib to 65ff-lb. Figure 2: Paddle BladeAssembly Schematic. 3. Table I breaks down the total quantities of each part required for the 4240 and 4250 chopper rotors. Use this reference when ordering parts. 1I~~ Part umber Description 4240 QtylUnit 4250 QtylUnit I RHI 00 hex cap screw, MI 0 x 60 grl 0.9 zinc HA 505L blade, paddle w/ left hand bend HA 505R blade, paddle WI right hand bend HA 520 washer, 1~ hardened HA 535 bushing, paddle blade RHIOI lock nut, M10 - DI98OV heavy auto lock Table 1: Rotor Parts Breakdown for 4240 and 4250 Chopper Rotors. The Redekop Manufacturing Co. Model 4240 and 4250 Chopper For CaselH Combines Users Guide Printed Jan 2000 PAGE 7

9 Preparing to Install the Redekop Chopper 1. Remove beaters from combine. 2, Remove the factory sieve pan from the combine and remove the hinge bar section and rubber bumper strip from this sieve pan (see Figure 1(a)). 3. Install the rubber strip, hinge bar, and 4 belting on the replacement sieve pan as shown in Figure 1(b). Use the taller mount brackets supplied with your chopper to install the rubber strip. 4. Reinstall new sieve pan onto combine. ~olt the pieces of 4 belting to the insides of the sieve pan with 1/4 x 3/4 bolts using flat washers on the belting side. Figure 1: Replacing the Factory Sieve Pan, V~, Extended Mount brackets 5. Position chopper mount frame underneath combine frame as shown in Figure Place upper frame members on combine frame and insert 3/4 x 14 bolts upwards through the frame and upper members. Use the grade 8-3/4 nuts (gold) and lockwashers to secure the bolts in place. IMPORTAT! - Ensure that the chopper frame is positioned so that the rearward edge of the combine tie-rod will not be obstructed by the angled section of the frame as shown in Figure 2(b), ~.E ~ 2 ~i (b) Ensure that the chopper frame does not sit further forward than shown so / that the tie rod is free to pivot. rj;;~,~:j~ ~ ~:-~.~.. Figure 2: Installing the Chopper Mount Frame, The Redekop Manufacturing Co. Model 4240 and 4250 Chopper for CaseIH installation Manual Printed Jan 2000

10 Installing the Redekop Chopper 1. Using a loader or forklift lift the Redekop chopper into place as shown in Figure 3. Align the pin sleaves of the hinge bar and chopper frame and insert the hinge pin from the top down through the hinge. 2. Grease the hing~after installation and periodically afterwards to avoid corrosion of the pin. insert hinge pin Lift chopper into place so that the hinge bar and the chopper frame line up as shown. Figure 3: Installing the Redekop Chopper. 3. Install the plastic deflection shields on the chopper as shown in Figure 4. L. _ Attach the 1/S Vlastic shield to chopper with 1/4 x 3/4 bolts, Use washers on the plastic side. Attach 1/4 plastic triangle shields to chopper with 1/4 x 3/4 bolts. Use washers on the plastic side. Figure 4: Installation of the plastic deflectors. 4. Bolt the chopper latch onto the frame using a 5/8 x 2-1/2 bolt and locknut (Figure 5). Tighten until snug but moveable. 5. The overcenter bolt can be turned in or out to adjust the holding tension as nessesary. 6. Install hairpin in the U bracket to prevent latch from opening. Figure 5: Installation of the plastic deflectors. The Redekop Manufacturing Co. Model 4240 and 4250 Chopper for CaselH Installation Manual Printed Jan 2000

11 1. Drill 3/8 holes in combine beater pan to hold fin mounting plates (see Figure 6 for assembly and Figure 7 for placement). Fasten these to the boftom side of the pan with 3/8 x 1 bolts. Fasten deflector fins with 5/16 x 3/4 bolts. 2. Fasten the 1/4 x 1,~1 x 39 plastic deflector to combine with 1/4 self threading bolds on top, and 1/4 x 3/4 bolts on the sides. Side View Combine/ ~ eater - -~-~ l~rili 4 holes in combine pan to mount extension plates of the internal deflectors. TppV~ Heavy concentration of straw Approximate location of fins to create an even feed of straw into chopper. Adjust as necessary. Figure 7: Placement of the internal deflectors. 3. Install the shaft monitor sensor as shown in Figure 8. Attach sensor bracket to one of the four bolts holdin~ the bearing flange in place. l~emove sensor from spreader drive on combine ~ ahdattachtothe ~- supplied sensor bracket as ~hown. Install sensor disk onto chopper shaft to line up witli sensor. Figure 8: Installation of The Redekop Manufacturing Co. Model 4240 and 4250 Chopper for CaselH Installation Manual Printed Jan 2000

12 Installing the Redekop Chopper ISTALLIG SPREADER HOOD 1. Loosen the left spreader hood hinge plate (A) from the sidewall of the Redekop Chopper and insert the spreader hood hinge into the right side hinge plate (ref. Figure 5). Tighten the left hinge plate fixing the spreader hood between the two hinge plates. The spreader hood should move freely in the hinge plates. 2. Attach the left and right mount arms to the chopper sidewalls at (B) with 112 x 1-1/4 bolts, lockwashers and nuts. Do not tighten at this time. 3. Fasten the other end of the mount arms to the spreader hood with 7116 carriage bolts, lockwashers and nuts. Use hole #1 for narrow spread or hole #2 forwide spread (see inset). 4. Tighten all fourfastners to fix the spreader hood in place. B I I piat~ Figure 5: Attaching the Spreader Hood to the Redekop Chopper Body. The Redekopjanufactuñn~ Co. Model 4240 and 4250 Choooer for CasetH Installation Manual Printed Jan 2000

13 ATTACHIG FiS TO SPREADER HOOD 1. Attach the spreader fins to the spreader hood as illustrated in Figure 6. All hardware is 5/16 x 3/4 flange bolts and flange nuts. Use 5/16 flat washers on all slotted holes. 2. For initial setting, n{ove each fin to its most outward position and tighten. 3. Fin settings can be adjusted as required after operation in field. ote: For maximum spreading, fasten the front hole of fins 4 and Stothe innertailboard hole positions as shown here. Installing the Redekop Chopper S 6 / Legend Fin 1-15 Curved Fin 2-15 Curved Fin Curved Fin 4-32 Curved Fin 5-10 Curved Fin 6-13 Straight Bent - ote: the front edge of this fin is positioned outside of the chopper side wall with the top bent edge facing out. Figure 6: Attaching the Fins to the Spreader Hood. The Redekop Manufacturing Co. Model 4240 and 4250 Chopper for Casell-l Installation Manual Printed Jan 2000

14 Installing The Redekop Chopper Drive 1. Remove the main drive pulley from the combine. This pulley and the chopper drive pulley provided with this drive should be taken to a machinest. A groove is then machined in the combine drive pulley to accomodate the chopper drive pulley as shown in Figure Attach the chopper drive pulley to the main drive pulley as shown. rear view of engine comp~rt~ment rotor drive pulley (rearw~rd pulley) rotor drive pulley eupport.et~nd comb~ne side well Main Drive Pulley on Combine t~lj ~emove this riieiii drive pulley en~ have a small groove machined into its face to match the lip on the chopper drive pulley. ~ osition the chopper drive pulley in the rriachinet~ groove of the corn E2ine tlrive pulley and drill through pulley spokes to match holes in chopper for 5/iS ~ olts. Figure 11: Attaching the Chopper Drive Pulley to the Main Drive Pulley. a REdEkop IdUSTRIES CASEIH I 660, 1666 ChoppER MAUAL ChoppER DRIVE

15 Installing the Redekop Chopper Drive 1. Remove the four bolt and support brace from the combine and attach the gear box frame in place using the original boils as shown in Figure 12. Do not tighten these bolts fully at this time. IMPORTAT~ Fastening a rope between the gear box frame and some fixed component or brace in the engine component until it is fastened properly will prevent damage or injury caused by dropping the gear box. Special Gear Box Installation and Maintenance Instructions \ ~~~FiH gear box with oil before operating! ote: The gear box manufacturer recommends the use of high quality synthetic gear oil in this gear box. Com~n. s4~atof \ tjthis brace should be ~ refastened on top of gear box frame. This gear box is c~uipped with two fill level plugs. Use the up to check the fluid level o~ ~ gearbox in this drive. Attach the gear box frame to the combine using the top four bolts on the side of the combines main drive unit. Po not tighten at this tame. Figure 12: Right Side View of Gear Box Mount 2. Attach the gear box idler bracket and idler on the rear side of the gear box frame as shown in Figure Tighten the spring until the washer touches the metal sleave surrounding the bolt. Fasten idler mount with 1/4 bolt and Fender washer. ced Figure 13: Upper Chopper Drive Tightener Installation. 6 double belt idler. Attach to bracket with 5/& x 3-1/2 bolt and 5/& washers as spacers. G. REdEkop IdUSTRIES CASEIH 1660, I 666 ChOPPER MAUAL ChOPPER DRIvE

16 Installing the Redekop Chopper Drive 1. Reinforce the gear box frame by installing the two braces as shown in flgure 14. Adjust brace B so that the gear box frame does not contact the main drive pulley and then tighten the four bolis fastening the gear box frame to the combine. Attach brace to existing bolt on pillowbiock mount. Enlarge existing hole on combine to 1/2. IMPORTAT! -Adjust 6race ~ to allow a small clearence between the main drive pulley and gear box frame before tightening the four gear box frame bolts. Figure 14: Top View of Gear Box Frame. 2. Install the two sheaves on the gear box as shown in Figure 15. To ensure proper drive alignment, the sheave should be left untightened until the test of the drive is completed. \\ \~ \ 2~ 6,O sheave Sc S1-3/& 2e~9.4 sheave S~ 1-3/& bushing Figure 15: Installation of Sheaves on the Gearbox. REdEkop IdUSTRiES CASEIH I 660, 1666 C[~oppER MAUAL ChOPPER DRIvE I

17 Installing the Redekop Chopper Drive 1. Attach the top of the idler bracket to the combine channel using 7/16 x 1-1/4 bolts (see Figure 15). Drill out the two bottom holes and fasten the bracket to the combine wall using 3/8 x 1 bolts. 2. Install the upper 9 double idler pulley using a 5/8 x 2 bolt and lockwashei and the tapered spacer with adjustment arm as a spacer behind the idler (see top inset in Figure 15). 3. Assemble the two 9 idlers on the lower idler combination using 5/8 x 4 bolts and the 1-1/4 spacers in between the pulleys and bracket. The lower idler also uses a belt guard as shown in the bottom inset. 3. Assemble spring tension unit and attach to lower idler bracket. The lower idler bracket is then fastened to the main idler bracket using a fender washer and 5/16 x 3/4 bolt. Important: Moving thie a~lju~tment arm changee the allgnment of the upper idler pulley. Adjust as necessary to ensure proper alignment of the idler with th~ rest of the drive. Misaligned idlers can cause premature belt failure. Combine ~adiator PouL le belt Idler pulleys Figure 15: Installation of the Idler Bracket. 1 REdEkop IdUSTRIES Css~lH I 660, 1666, ChoppER MAUAL ChoppER DRIVE

18 Installing the Redekop Chopper Drive 1. Install the chopper sheave and drive belts on the combine as shown in FIgure 17. Install sheave wi St~ 1-1/2 bushing on the chopper shaft. The sheave may rest slightly past the end of the shaft when properly aligned Selt Move adjustable arm to thiø position to otart. ~un the chopper. If the belt does not ride in the center of the idler, stop the combine and adjust this lever as necessary. l~epeat until belt runs in center of the idler. Figure 17: Belt Installation Schematic. 1. Install pulley shield on the chopper as shown in Figure 18. / bolt mounting brackets inside shield as shown and attach to chopper after belt is in place. (Use ~ /& x i~ bolts antl flange nuts) lnst~h belt guards to keep belts on pulley while chopper is swung to the side. Rotate until they ~re ~pproxim~tely l/4~ from the puhey before tightening. Figure 18: Installation of the pulley shield. J REdEkop IdUSTRIES Css~IH Cl~oppe~ MAUAL ChoppER DRIVE