Model 4240 Chopper Case International 1660 and 1666 Chopper Drive Operators Manual A complete line of crop residue management equtpment. Redekop Industries Box 1 78A RR#4 Saskatoon, SIc S7K 3J7 306 931-6664 Fax 306 933-1088 S.
INTRODUC11ON 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 orequipmentdamage. Special features of the 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 hammerconfiguration: i) All hammers run in pairs to provide twin cutting action providing closer clearance to stationary blades forfine cutting; ii) paddle hammers provide greaterairthrustto the extentthatthe entire chopper becomes a fan; and ib) 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. Redekop Industries Model 3240 and 3250 Chopper For CaselH Combines users Guide PAGE I
REDEKOP CHOPPER USERS[GVIbE r SAFETY RECOGNIZE SAFETY INFORMATION This is the safety-alert symbol. This symbol alerts you to the potential for personal 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 signalword is given here: A MITIflKI CAUTION Understand identifies and be general alert to precautions the warnings about and the instructions machine. given with this safety-alert. AWARNING WARNING alerts you to a specific hazard located nearby. a DANGER DANGER alert is also alerts located you nearthe to the most specific serious hazard. hazards. This safety- FOLLOW SAFETY INSTRUCTIONS Careful read all safety messages in this manual and on your straw chopper safety signs. Keep safety signs in good condition replacing missing ordamaged safety signs. Learn how to properly operate, check, maintain and service your straw chopper. Do not let anyone perform these duties without instruction. A CAUTION 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)931-6664. Ta prevent serious injury or machine damage Read and understand Operaturs Manual before using, instaltiug, or working on [kis macbite. Review anooatty. Stop cnmbioe engiun, place all controls in neutral, set park brake, remuve ignilion key, and wait for alt moving parts In stop before servicing, adjusting, repaidog, uoplug~ing or fitting this machine. Keep hauds, feet, hair, aud clutkiug away 1mm moving parts. Avoid unsale operarun or maintenance. 0178 INSPECT THE STRAW CHOPPER BEFORE YOU OPERATE lnspectthe strawchopperfordamage: Check all hammers and stationary blades for excessive metalwear, cracks, orothervisible damage. Checkforloose,worn, damaged ormissing parts. Check and tighten the straw chopper hardware, especially the rotor hammer mount bolts. All guards and shields must be in fastened in place before operating. good condition and Make sure all caution and warning decals are clearly visible and readable. Make sure all safety devices are correctly fitted and operative. Redekop Industries Model 3240 and 3250 Chopper For CaselH Combines users Guide PAGE 2
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 clearof the spreading orcollecting unit at all times. Chaff and straw can be propelled to distances of 50 feetormore, and hard objects like stones much furtherstill. KEEP HANDS AWAY FROM RUNNING 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. STAY CLEAR To prevent serious injany or death from thrown object: Stay away from discharge area while engine is r000iog. Keep others away. Do nut point dischargetoward people, animals, or buildings when operating. R120 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. ROTATING BLADE HAZARD ropruventsenous injuryordeath from coutactwitii chopper rotor: Do nut adjust chaff or straw defteciun panels while chopper rotor is in mo~on. Keep hands, feet, clothing, and hairout of the chopper and Rt2t STAY CLEAR OF MOVING 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. Never remove the shields from the straw chopper. A DANGER SHIELD I~hISSING Wben toils Is visible DO NOT OPERATE 1125 MOVING PART HAZARD To prevent serious injury or deuth from moving parts: Close and secure all guards and shields before operaling. Keep hands, feel, hair, and clothing away from moving parts. Turn off engine and waitfer alt motion to stop before adjusfng or servicing moo Redekop Industries Model 3240 and 3250 Chopper For CaselH Combines Users Guide PAGE 3
REDEKOP CHOPPER USERS GUIDE OPERATE THE STRAW WINDROW DOOR SAFELY Do not operate the straw chopper while the straw windrow 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 damagetothedoorand 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. STAY OFF THE SPREADING FIN 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. A CAUTION PARTS INTERFERENCE HAZARD To prevent damage to chopperrotor and straw windrow door: Do not operate the chopperwhile the straw windrow door is in thewindrow posihon. The chopper drive heft must be moved from the chopper rotor puii~ to the neart~ idler towindrow straw and chaff. To avoid injury or machine damage: Do not use this spreadioglin hood as a step or 7 platform. Flood may bead orient may slip causing serious injury. 0123 0124 Redekop Industries Model 3240 and 3250 Chopper For CaseIH Combines Users Guide PAGE 4
MAINTENANCE 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 H) 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 Cautionl Never 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 Redekop Industries Model 3240 and 3250 Chopper For CaseIH Combines Users Guide PAGE 5
REDEKOP CHOPPER USERS GUIDE REPLACEMENT OF WEARING PARTS SECTION I - ROTOR PARTS QUANTITIES 1. Table 1 breaks down the total quantities of each part required forthe 3240 and 3250 chopper rotor. Use this referencewhen ordering parts. Item Part Number 1 H8CZ382 HA 520 0.191 600 ~.._.~straight0.1 zinc Table 1: Rotor Parts Breakdown f~2~ SECTION 2- REPLACING KNIFE 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 freethe 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 barand bend overtosecure. 1.. Part# HA 700, 26 pcs in complete set. 4 Figure3: Knife BarAssembly Schematic. Redekop Industries Model 3240 and 3250 Chopper For CaseIN Combines Users Guide PAGE 6
REDEKOP CHOPPER USERS GUIDE REPLACEMENT OF WEARING PARTS SECTION 1 - ROTOR PARTS QUANTITIES 1. Table 1 breaks down the total quantities of each part required forthe 4150 and 4250 chopper rotor. Use this reference when ordering parts. i~ii~ Part Number Description Quantity Per Unit I H8CZ38.214 hex cap screw, 3/8 x 2 1/4 nc gr8 zinc 26 2 HA 505L blade, paddle w/ left hand bend 26 3 HA 505R blade, paddle W/ right hand bend 26 4 HA 520 washer, 1 hardened 52 5 HA 535 bushing, paddle blade 52 6 RI ROl drum, 52 rotor i 7 RI R05 shaft, 52 rotor 8 SLCZC38 lock nut, 3/8-16 NC lock nut steel zinc 26 Table 1: Rotor Parts Breakdown for4l 50 Chopper. SECTION 2 - REPLACING ROTOR PARTS 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 hammers two pairs at a time, directly opposite each other on the rotor. This should maintain rotor balance. Never replace only one hammer for wear or breakage. You do not need to replace the corresponding two pairs on the other end of the rotor. 2) If a hammer breaks and the chopper must be operated without a replacement then the damaged hammer and the one directly apposite it must both be removed to maintain rotor balance. 3) Use only grade 8 bolts and 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 55 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. CAUTION: Always use Grade 8 bolts and steel lock - 8 nuts when installing hammers. Allowable torque range for hammer mount nuts is 45ft-lb to 65ft-Ib. Figure 2: Paddle BladeAssembly Schematic.
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. Doltthe 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. 5. Position chopper mount frame underneath combine frame as shown in Figure 2. 6. 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. 1MPORTANfl - Ensure that the chopper frame is positioned so that the rearward edge of the combine tie-rod ~ll not be obstructed by the angled section of the frame as shown In Figure 2(b), (b) Ensure that the chopper frame does not sit further forward than shown so that the tie rod is free to pivot. Figure 2: InstallIng the Chopper Mount Frame. Angled Section Redekop ndusfrles ModolaaselH Chopper Manual Generic Installation Instructions
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 hinge after installation and periodically afterwards to avoid corrosion of the pin. insert hinge pin V 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. Attach the 1/8 plastic shield to chopper with 1/4~ x 3/4 bolts. Use washers on the plastic side. Figure 4: Attach 1/4 plastic triangle shields to chopper with 1/4 x 3/4 bolts. Use washers on the plastic side. Installation of the plastic deflectors. 4. Bolt the chopper latch onto the frame Tighten until snug but moveable. using a 5/8 x 2-1/2 bolt and locknut (Figure 5). 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, Redekoo IndustrIes ModelcaselH chonoer Manual Generic Installation Instructions
Installing the Redekop Chopper 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 bottom side of the pan with 3/8 x 1 1 bolts. Fasten deflector fins with 5/1 6 x 3/4 bolts. 2. Fasten the and 1/4 x 3/4 1/4 x 11 bolts on the sides. x 39 plastic deflector to combine with 1/4 self threading bolds on top, Side View Combine 8eater PrilI 4 holes in combine pan to mount extension piate~ Top View 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 thefour bolts holding the bearing flange n place. ~emove sensor from spreader drive on combine. ahdattachtothe ~ supplied sensor bracket as ~hown. Install sensordisk onto chopper shaft to line up with sensor. Figure 8: Installation of shaft monitor sensor. Redekop Industries Model ~aseih Cho~~er Manual Generic Installation Instructions
REDEKOP CHOPPER INSTALLATION INStRUCTIONS INSTALUNG 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 1/2 x 1-1/4 bolts, lockwashers and nuts. Do nottighten atthis time. 3. Fasten the other end of the mount arms to the spreader hood with 7/16 carriage bolts, lockwashers and nuts. Use hole# 1 for narrowspread, hole # 2forwide spread (see inset). 4. Tighten all four fastners to fix the spreader hood in place. 0 S S plate pread FigureS: Attaching the Spreader Hood to the Redekop Chopper Body.
REDEKOP CHOPPER INSTALLATION INSTRUCTIONS ATTACHING FINS 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. Forinitial selling, move each fin to its most outward position and tighten. 3. Fin settings can be adjusted as required after operation in field. Note: For maximum spreading, fasten the front hole of fins 4 and 5 to the innertailboard hole positions as shown here. C 5 Figure6: Attachingthe FinstothespreaderHood. / 4 Le~end Fin 1-15 Curved Fin 2-15 Curved Fin 3-21.5 Curved Fin 4-32 Curved Fin 5-1O Curved 6 Fin 6-13 Straight Bent - Note: the front edge of this fin is positioned outside of the chopper sidewall with the top bent edge facing out.
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 11. 2. Attach the chopper drive pulley to the main drive pulley as shown. rear view of engine Compartment combine side wall Chopper Drive Pulley Main Drive Pulley on Combine geniove this main drive pulley and have a small groove machined into its face to match the lip on the chopper drive pulley. U Figure 11: Attaching the Position the chopper drive pulley in the machined groove of the combine drive pulley and drill through pulley spokes to match holes in chopper for 5/10 bolts. Chopper Drive Pulley to the Main Drive Pulley: REdEkop k.dusrnis ~AsEIH 1660, 1666 ChoppER M*no.~I dioppu DRIVE
Insta IlingIbe ed~kop;c pper Drive 1. Remove the four bolt and support brace from the combine and attach the gear box frame in place using the original bolts as shown in Figure 12. Do not tighten these bolts fully at this time. IMPORTANT: 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 ~Fiji gear box with oil before operating! Note: The gear box manufacturer recommends the use of high quality synthetic gear oil in this gear box. This gear box is equipped with two fill level plugs. Use the upper plug to check the fluid level of the gearbox in this drive. CanM,. ~j~e.tor This brace should be refastened on top of gear box frame. Attach the gear box frame to the combine using the top four bolts on the side of the conibiries main drive unit Do not tighten at this time, Figure 12: Right Side View of Gear Box Mount. 2. Attach the gear box idler bracket and idler on the x~ar side of the Figure 13. gear box frame as shown in 3. Tighten the spring until the washer touches the metal sleave sunounding the bolt. Fasten idler mount with 1/4 bolt and Fender washer. S Figure 13: Upper Chopper Drive REdzkop lndusrpics ~s~lh 1660, 666 Tightener Installation. MANuAl 6 double belt idler. Attach to bracket with 5/3 x 3.1/211 bolt and 5/3 washers as spacers. clopprrouvf I
Installing the Redekop Chopper Drive 1. Reinforce the gear box frame by installing the two braces as shown in FIgure 14. Adjust brace B so that the gear box frame does not contact the main drive pulley and then lighten the four bolts fastening the gear box frame to the combine. \ N Attach brace to existing bolt on pillowblock mount. \ I \ NI Enlarge existing hole on combine to 1/2. IMPOKTAN11 -Adjust Srace 8 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 2B6.O sheave should be left untightened until the i~st of the drive is completed. N 2~S.O sheave SPS 1-3/s 289.4 sheave 5K 1-3/3 bushing Figure 15: Installation of Sheaves on the Gearbox. REdEkop lndu5rri~ CASEIH 1660, 1666 ChoppER MANUAl 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 lockwasher, 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. S Important: Moving this adjustment arm changes the alignment of the upper idler pulley. Adjust as necessary to ensure proper alignment of the idler with the rest of the drive. Misaligned idlers can cause premature belt failure. CombIne ~adlator Pouble belt Idler pulleys Figure 15: Installation of the Idler Bracket. RECJEkOp lndunpies CASEIH 660, 666, clwpprr MANUAL ciio~per Dpiv
1. Install the chopper sheave and drive belts on the combine as shown in Figure 17. I 2670 6ej~~~ N /2~ Install 265.8 sheave wi 50 1-1/2 bushing on the chopper shaft. The sheave may rest slightly past the end of the shaft when properly aligned. Figure 17: Belt Installation Schematic. 26240 Selt Move adjustable arm to this sition to start. Run the pper. If the beltdoee not in the center of the idler,. stop the combine and adjust this leveras necessary. Repeat until belt runs in centerof the idler. 1. Install pulley shield on the chopper as shown in Figure 18. / 3olt mounting brackets inside shield as shown and attach to chopper Install belt guards to keep belts on pulley while chopper is Swung to the side. ~otate until they are approximately 1/4 from the pulley before tightening. (Use ~/&U xl bolts and flange nuts) ~ after belt is in place. R cjtlop INduSTRIE5 CASEIN ChoppER MANuAl ChoppER
REDEKQp INDUSTRIES hereinafter referred to as Manufacturer warrants each new Redekop Chopper sold by the Manufacturer to be free from defects in material and workmanship, under normal use and se~ice, For a period of one ~1) year after the date of delivery to the original retail purchaser. The Manufacturer will, at its option, replace or repair, at the Manufacturer s factory, orat a point desi~ated by the Manufacturer, any part or parts which shall appear to the satisfaction of the Manufacturer upon inspection at such point, to have been defective in material or workmanship. This Warranty does not obligate the Manufacturer to bear any transportation charges in corn~ection with the replacement of defective parts. This Warranty shall not apply to any Chopper which shall have been installed or operated th a manner not recommended by the Manufacturer; nor to any Chopper which shall have been repaired, altered, neglected or used in any way which, in the Manufacturer s opinion, adversely affects its performance; nor to any Chopper in which parts not manufactured or approved by the Manufacturer have been used; nor to any accessories installed on the Chopper where the accessory thanufacturer has its warranty nor to normal maintenance or replacement of normal service items. Manufacturer reserves the right to modify, altei~ and improve any Chopper or parts without incurring any obligation to replace any Chopper or parts previously sold with such modified, altered or improved Chopper or part. THIS WAR~NTY, AND THE MANUFACTURER S OBLIGATION HEREUNDER, IS IN LIEU OF ALL OTHER WAR~NTIES EXPRESSED, IMPLIED, OR OF FITNESS FOR A PARTICULAR PURPOSE, and all other obligations or liabilities, including special or consequential damages or contingent liabilities aristhg out of the failure of any Chopper or part to operate properly. No person is authorized to give any other warranty or to assume any additional obligation on the Manufacturer s behalf unless made in writing and signed by an officer of the Manufacturer. This Warranty is effective only for the original purchaser. fl~rs(ofp I9ZJ5ppj~~ S~5~AWo~ S~A~5[EW~...