TM New Holland TR MAV - 100 Complete Chopper Installation Guide CH003-01_SEP_2014
ROTOR BLADE A IMPORTANT! The paddle blades, located on the balance rings inside the chopper, must be installed in the direction shown (A). The straight edge of the blade cuts the air while the paddle trails behind & pushes the air. 1. The blades for your chopper must be installed as outlined. Note: If blades are installed other than as directed, damage to the chopper may result or performance may be significantly reduced. A 1) Always replace blades two pairs at a time, directly opposite each other through the center of the rotor. This should maintain rotor balance. Never 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 opposite it must both be removed to maintain rotor balance. 3) Use only METRIC class 10.9 bolts (B) and class 10.9 DIN980V steel lock nuts (F) on the chopper rotor. 4) Use a torque wrench to tighten all M12 nuts to the recommended 69 ft-lb. 5) Always check for adequate clearance between the installed blades and the stationary knives. A minimum of 1/4 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. C D D E C F 2. Assembly order for blade pairs (B to F). E B A - Blade direction B - Hex cap screw C - Washer D - Blade, straight E - Bushing, straight blade F - Lock nut CAUTION: Always use METRIC class 10.9 bolts and class 10.9 DIN980V steel lock nuts when installing blades. Allowable torque range for blade mount nuts is 69 ft-lb. Torque values listed are for general use only, based on the strength of the bolt. DO NOT use these values if a different torque value or tightening procedure is given for a specific application. For stainless steel fasteners or for nuts on U-bolts, see the tightening instruction for the specific application. Tighten plastic insert or crimped steel type lock nuts by turning the nut to the dry torque shown in the chart, unless different instructions are given for the specific application. Dry means plain or zinc plated without any lubrication. 2
KIT CONTENTS REF ITEM NAME ITEM DESCRIPTION QTY 1 CH410BA Assy TR STD Chopper 1 2 CH191B Shield TR Upper 1 3 CH192B Shield TR Lower 1 4 CH187BA Hood Extension TR 1 5 NH18BA Assy TR Sieve Ext 1 6 NH27BA Assy Belt Guard 1 7 RP166 Sheave SK 3B 18.4 PD 1 CH411BS Box TR Completion: 8 NH504BL Mount Sieve Ext Lt 1 9 NH504BL Mount Sieve Ext Rt 1 10 CH188B Mount TR Upper Shield 1 11 CH189B Bracket Shield Mount 1 12 CH193B Bracket TR shield Mount 1 13 NH501B Idler Assy TR 1 14 NH700B Assy Spring Tension 1 15 NH502B Assy Tension Arm 1 16 RP105 Gas Shock 1 CH415S TR Drive Box: 17 RP733 Sheave TB 3B 6.0 pd 1 18 BE3B218K V Belt 3B 218 Kevlar 1 19 RP160 Idler 10 OD 3.32W.630ID 3 20 RP655 Bushing Taper TB 50mm 1 21 CH472-01 Bushing Taper Rekeyed 1.188 ID 1 1 2 16 3 15 4 21 7 18 14 9 13 12 6 10 19 11 22 17 8 5 Figure 1 3
PRE-INSTALLATION - COMBINE PREPARATION For Combines Equipped with Straw Spreaders 1. Remove the straw spreader and straw spreader drive assembly from the combine. For Combines Equipped with Straw Chopper 1. Remove the entire factory straw chopper roller, and straw chopper drive from the combine. INSTALL CHOPPER BODY 1. Place a second pallet (A) under the MAV bundle and turn 90 degrees. Remove tailboard shipping brackets and rest tailboard against the loader to ensure it does not strike the combine during mounting. 2. Use a loader or forklift with forks under the chopper to lift the Redekop Chopper to the initial position shown in Figure 3. Ensure that at least one person is available to stand beside the loader to ballance the chopper on the loader forks. Fasten chopper to combine with 10 x 25 bolts and M10 flange nuts. All holes at the chopper side wall hangers should match existing holes in the combine body. Figure 2: Chopper body mounting A sixth hole from front of combine angle iron mount (on left side) fuel tank fuel tank support bracket existing bolts Figure 3: Installing the Redekop Chopper on the Model TR 95 Through Model TR 99. 4
INSTALLATION OF GAS SHOCKS Mount gas shocks (B) on both sides of the chopper. (See Appendix 1 for Hardwared Definitions) 2 - Shock, Gas 4 - Bolt, Flg M8 x 16 B Figure 4: Gas Shock mounting ATTACH CHOPPER TO NH STRAW DEFLECTOR SHIELD 1. Install the Interface plate on the Redekop Chopper rotor cover plate as shown in Figure 6. 2. Move the NH deflector shield from its original position to the new position shown in Figure 6. The top of the shield should fit against the combine ceiling between the longitudinal support braces and the angle support brace of the combine. Fasten the bottom of the shield to the interface plate as shown and drill 5/16 holes in the combine walls to fasten the shield s side with original M8 bolts. B Figure 4 longitudinal support members NH deflector shield new position drill through side walls and use original bolts angle support on combine NH deflector shield original position interface plate use top holes in deflector interface plate 5/16"x3/4" bolts 1/4"x3/4" bolts Figure 6: Installing the interface plate and moving the Internal Straw Deflector. 5
ATTACHING SIEVE EXTENSION TO COMBINE SHOE 1. Remove the two bolts at Position (A) from both sides of the combine shoe (see Figure 7). Attach the left sieve extension on mount bracket to the shoe at (A) with the original bolts as shown. Note: The Stub shaft welded to the left mount bracket should point in ward when mounted on the left side of the combine. 2. Slide the left side of the sieve extension pipe over the left mount bracket stub shaft. Slide the right mount bracket into the right side of the sieve extension pipe and fasten the right mount bracket to the shoe as at Figure 2. 3. Drill a 5/16 hole through each side of the combine shoe at Position (B) and fasten the bracket to the shoe with M8 x 45 bolts. 4. Attach an eyebolt and spring between the sieve extension and the mount brackets on both ends of the extension. Tighten the tension on the springs so that sieve extension pan remains firmly in position, but still allows for motion of the sieve extension pan between the horizontal and vertical positions. Side View grain loss monitor Redekop sieve extension A B spring eye bolt sieve extension mount bracket belting chopper chaffpan grain loss monitor combine sieve extension Top View Figure 7: Installing the Sieve Extension. ATTACH BELT GUARD TO COMBINE WALL 1. ATTACHING Fasten the belt guard BELTto GUARD the combine TO with COMBINE two M8 x 20 flange WALL bolts and M8 Nuts. The guard fastens to existing holes in the straw chopper mount rail as shown in Figure 8. This guard prevents chaff from building up on the drive belt. Attach the belt guard at these belt Figure 8: Attaching the belt guard to the combine side wall. 6
INSTALL THE CHOPPER DRIVE 1. Refer to Figure 9 for all drive mounting instructions below. Step 1 Step 3 Step 2 Step 4 Step 5 Figure 9: Chopper Drive Assermbly View. Step 1 - Installing the Drive Pulley 1. Remove the factory installed chopper drive pulley from the beater shaft if it exists. Remove all paint, oil, grease, etc. from the shaft. 2. Install the 18.4 pulley (3B18.4 SK Wood s sheave) on the beater shaft with the 1-3/16 Sk Wood s bushing and the 5/16 x 1-1/4 woodruff key supplied in the chopper bolt kit. Note that bushing capscrews require 15 ft-lbs of torque. For Bushing installation Instruction please see Appendix: 2. 7
Step 2 - Installing The Idler Assembly 1. Assemble the idler unit as shown in Figure 10: Assemble in order as numbered. Item Descrioption: 1 2 3 attach to combine 1 idler swing arm bracket 2 10 triple B width idler 3 5/8 x 5 hex cap screw 4 M16 lock washer 5 M16 hex nut 6 M16 flat washer 7 M16 lock washer 8 M16x150 hex cap screw 9 idler hinge insert bushing 10 M16 flat washer (2 pcs) 11 10 triple B width idler 12 M16 ID x M30 OD x M16 spacer 5 4 8 Figure 10: Idler Assembly. 7 6 9 10 11 12 2. Fasten the assembled idler assembly to the combine as shown in Figure 10 with the 5/8 x 6 hex cap screw (item 8 in Figure 10). fasten idler swing arm to the tapped stubshaft on the combine - this was the mount location for the NH factory straw chopper combine outer shield support members located on the left hand side of combine near the end of the shoe combine side Figure 11: Placement of the idler Assembly on the Combine. Step 3 - Installing the Quick Release belt Tightener 1. Attach the belt tightener assembly to the combine frame as shown in Figure 11. The connector plate fits over the hook on the idler assembly swing arm. bolt tightener to combine with a 3/8" M10 x 1-1/4" x 30 bolt, locknut and nut 81/4 " from combine wall drill 13/32" hole in frame member 5/8" from the top of the combine outer shield support members located on the left hand side of combine near the end of the shoe combine side fit over hook on idler swing Figure 12: Placement of the belt Tightener Assembly on the Combine. 8
Step 4 - Installing The Driven Pulley and Windrow Idler 1. Remove all paint, grease, ect. from the chopper shaft. 2. Attach the 10 triple B width idler to the windrow idler bracket located above the shaft on the straw chopper (see item 1 in Figure 13). Use M16 x 80 bolts, 1.125 OD x 0.625 L Spacer and M16 locknuts to secure this bracket. 3. Install the shaft speed monitor sensor wheel on the chopper shaft (see item 2 in Figure 13). Attach the angle bracket supplied in the drive kit to one of the four bolts on the bearing block (see in Figure 14). Install the NH factory straw chopper sensor to this bracket. 4. Install the 6 pulley (3B6.0 SD sheave) on the chopper shaft with the 50mm SD bushing and the s14 x 9 x 50mm key included in the drive hardware box. Follow the installation instructions given in Appendix 2 with the following exception - the bushing capscrews require only 9 ft-lbs of torque. 1 Speed Sensor Detail Redekop sensor bracket NH factory chopper speed sensor Redekop sensor disk 4 3 2 Figure 13: Installing the Driven Pulley and Widrow Idler. Figure 14: Speed Sensor Detail. Step 5 - Installing The Driven Belt 1. Remove the pin in the quick release belt tightener and pull the tightener handle to allow the belt to be installed (see in Figure 15). Istall the 3B218 belt on the combine as shown in Figure 16. Tighten the belt by closing the tightener handle and replacing the pin. Adjust the belt tension by tightening or loosening the belt tightener spring as nessesary. 2. Chack to ensure that all pulleys and idlers are aligned and that the belt runs straight between them. Make adjustments to pulley positions are required. Belt Tension Release release tension by removing pin and pulling handle as 3B218 Figure 15 Figure 16: Belt Installation Schematic. 9
Step 6 - Installation of Drive Shield Mount bracket (A) & (B) to chopper sidewall. See Figure 18 for placement and use following hardware: A 2 - Bolt, Crg M8 x 20 2 - Nut, Flg M8 B Figure 17 A B Figure 18 Mount front shield (C) as shown in Figure 19 by using: D 1 - Bolt M10 x 130 - Replaces 3/8 x 4 hydraulic hose clamp bolt on combine (D) 3 - Bolt, Flg M8 x 20 1 - Nut, Flg M8 C Figure 19 10
Mount hinges (A) as shown in Figure 20 by using: 4 - Bolt, Crg M8 x 20 4 - Nut, Flg M8 A Mount end shield (B) as shown in Figure 21 by using: 1 - Bolt, Flg M8 x 20 (C) 4 - Bolt, Crg M8 x 20 4 - Nut, Flg M8 Figure 20 B C Note: Check all fasteners to ensure they have been properly tightened. When starting chopper, be sure all people are clear of the rear of the combine. Figure 21 Start threshing module in low speed & listen for clearance problems. If a knocking noise is heard stop machine immediately! Fix problem & repeat procedure. Progress to full power when everything is running smoothly at lower speeds. 11
Appendix: 1 - Hardware Classification B## Bolt - Imperial B##M Bolt - Metric HEX Bolt Hex Head HEX Bolt Hex Head FLG Bolt Hex Flange Head FLG Bolt Hex Flange Head RH Bolt Round Head, Carriage RH Bolt Round Head Carriage CS Bolt Countersunk CS Bolt Countersunk N## Nut - Imperial N##M Nut - Metric JAM Nut, Jam JAM Nut, Jam LOCK Nut, Lock LOCK Nut, Lock P## Pin - Imperial P##M Pin - Metric ROLL Pin, Roll ROLL Pin, Roll COT Pin, Cotter COT Pin, Cotter HITCH Pin, Hitch Clip HITCH Pin, Hitch Clip LYNCH Pin, Lynch LYNCH Pin, Lynch CLEVIS Pin, Clevis CLEVIS Pin, Clevis SPIROL Pin, Spirol SPIROL Pin, Spirol W## Washer - Imperial W##M Washer - Metric FLAT Flat FLAT Flat LOCK Helical Lock LOCK Helical Lock FEN Fender Washer FEN Fender Washer Description: BOLT HEX.5 X 1 GR5 UNC Description: BOLT HEX M8 X 40 C8.8 Type = Hex Imperial Spec = GR5 UNC Type = Hex Metric Spec = C8.8 Diameter = 0.5 inch Length = 1 inch Diameter = 8mm Length = 40mm Hardware Diameter Wrench Size Hardware Diameter Wrench Size 1/4in Hardware 7/16in M6 Hardware 10mm 5/16 Hardware 1/2in M8 Hardware 13mm 3/8 Hardware 9/16in M10 Hardware 15mm or 16mm 1/2 Hardware 3/4in M12 Hardware 18mm or 19mm 5/8 Hardware 15/16in M16 Hardware 24mm 12
Appendix 2 - Bushings IMPORTANT: DO NOT USE LUBRICANTS IN THIS INSTALLATION To Install Bushing: 1. Remove all paint, oil grease, etc. from tapered surface of bushing and bore of mating part. 2. See Standard mounting assembly - Figure 1. NOTE: If bushing does not slide freely on shaft, wedge a screwdriver blade into the saw cut and the flange OD to open the bore of the bushing. Caution: Excessive wedging will split the bushing. 3. Standard Mount Slide bushing on shaft, flange first. If using the setscrew, snug it against the key. Excessive Torque will cause mating part to be eccentric. Position mating part in place on bushing aligning drilled holes in mating part with tapped holes in bushing flange. Using lockwashers, install capscrews thru the mating hub and into the bushing flange. (Note: S bushings can only be Standard Mounted. Be sure the three tapped holes in the mating hub do not align near the bushing saw cut. If they do, rotate the bushing 60 degrees.). 4. Use A Torque Wrench. Tighten all capcrews evenly and progressively in rotation to the torque value listed in the table. Excessive wrench torque, closing the gap between the bushing flange and mating hub, or the use of lubricants will break the mating hub. To Remove Bushing: 1. Loosen and remove all capscrews. 2. For Standard Mount, thread capscrews into tapped holes in mating part to jack against bushing flange. Tighten bolts evenly and progressively in rotation to separate the two components. 3. Loosen setscrew to slide bushing from shaft. Standard Mounting Screw Tightening Information Tapered Bushing Size & Thread of Capscrew Ft.-Lbs. To Apply With Torque Wrench SK 5/16-18 15 SF 3/8-16 30 Fig. 1 13
WARRANTY Redekop Manufacturing Co., hereinafter referred to as Manufacturer, warrants each new Redekop Upgrade sold by the Manufacturer to be free from defects in material and workmanship, under normal use and service, 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, or at a point designated 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 connection with the replacement of defective parts. This Warranty shall not apply to any rotor which shall have been installed or operated in a manner not recommended by the Manufacturer; nor to any rotor 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 rotor in which parts not manufactured or approved by the Manufacturer have been used; nor to any accessories installed on the rotor where the accessory manufacturer has its warranty; nor to normal maintenance or replacement of normal service items. Manufacturer reserves the right to modify, alter, and improve any rotor or parts without incurring any obligation to replace any rotor or parts previously sold with such modified, altered or improved rotor or part. THIS WARRANTY, AND THE MANUFACTURER S OB- LIGATION HEREUNDER, IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED, IMPLIED, OR OF FIT- NESS FOR A PARTICULAR PURPOSE, and all other obligations or liabilities, including special or consequential damages or contingent liabilities arising out of the failure of any rotor 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. Redekop Manufacturing Co. Saskatoon, SK Canada 14