mav chopper operator’s manual

TM

MAV Chopper Operator’s Manual

CG001-01_V9_MARCH 2018

TABLE OF CONTENTS

Page

Introduction / Warranty 3 Serial Number 4

Safety 5

Safety Decals 10

Chopper Maintenance / Operation 11 Bushing 12 Rotor Blade / Torque Values 13

Knife Bar 15

Tailboard / Fins 16

Chaffboard 17

ChaffPanExtension/ChaffDoor 18

Combine Specific Operation NEWHOLLAND 19

JOHNDEERE 21 CATLEXION 24

MASSEYFERGUSON 26

CASEIH 27 Troubleshoot 29

FAQ 30

Redekop Manufacturing 2014Box178A,RR#4Hwy16WestSaskatoonSKS7K3J7Ph: 1.306.931.66641.866.REDEKOP(1.866.733.3567)Fax:1.306.933.1088Email:[email protected]

2

WARRANTYRedekop Manufacturing 2014,hereinafterreferredtoas“Manufacturer”,warrantseachnewRedekopStrawChoppersoldbytheManufacturertobefreefromdefectsinmaterialandworkmanship,undernormaluseandservice,foraperiodofone(1)yearafterthedateofdeliverytotheoriginalretailpurchaser.TheManufacturerwill,atitsoption,replaceorrepair,attheManufacturer’sfactory,oratapointdesignatedbytheManufacturer,anypartorpartswhichshallappeartothesatisfactionoftheManufactureruponinspectionatsuchpoint,tohavebeendefectiveinmaterialorworkmanship.ThisWarrantydoesnotobligatetheManufacturertobearanytransportationchargesinconnectionwiththereplacementofdefectiveparts.

ThisWarrantyshallnotapplytoanyupgradewhichshallhavebeeninstalledoroperatedinamannernotrecommendedbytheManufacturer;nortoanyupgradewhichshallhavebeenrepaired,altered,neglectedorusedinanywaywhich,intheManufacturer’sopinion,adverselyaffectsitsperformance;nortoanyupgradeinwhichpartsnotmanufacturedorapprovedbytheManufacturerhavebeenused;nortoanyaccessoriesinstalledontheupgradewheretheaccessorymanufacturerhasitswarranty;nortonormalmaintenanceorreplacementofnormalserviceitems.

Manufacturerreservestherighttomodify,alter,andimproveanyupgradeorpartswithoutincurringanyobligationtoreplaceanyupgradeorpartspreviouslysoldwithsuchmodified,alteredorimprovedupgradeorpart.

THISWARRANTY,ANDTHEMANUFACTURER’SOBLIGATIONHEREUNDER,ISINLIEUOFALLOTHERWARRANTIES,EXPRESSED,IMPLIED,OROFFITNESSFORAPARTICULARPURPOSE,andallotherobligationsorliabilities,includingspecialorconsequentialdamagesorcontingentliabilitiesarisingoutofthefailureofanyupgradeorparttooperateproperly.NopersonisauthorizedtogiveanyotherwarrantyortoassumeanyadditionalobligationontheManufacturer’sbehalfunlessmadeinwritingandsignedbyanofficeroftheManufacturer.

ThisWarrantyiseffectiveonlyfortheoriginalpurchaser.

RedekopManufacturing2014Saskatoon, SK Canada

INTRODUCTIONThankyouforpurchasingaRedekopproduct.Since1985Redekophasbeendevelopingsolutionsformanagingcropresidueandwillcontinuetoengineerhighqualityproductsthatwilloptimizetheperformanceofyourrotaryorwalkercombine.

ReadthismanualcarefullytolearnhowtoproperlymaintainandsafelyoperateyourMAVstrawchopperupgrade.Failuretodosocanresultinpersonalinjuryorequipmentdamage.

32

B

DriveEnd

A

SERIAL NUMBER1.Therotorserialnumber(A)islocatedontherotor,onthedriveend,inlinewiththeshaftkeyway.

2.Thestrawchopperserialnumber(B)islocatedonthechopperwall,onthenon-driveside,justbehindthespeedsensormonitorbracket.

4

0 SAFETY0.1 Introduction

0.1.1IMPORTANT:Readthroughthisinstructionthoroughlyandfamiliarizeyourselfwiththemachinebeforeremovingthesecomponents.Donotskipstepsorperformthemoutoforder.

ThisinstructionmanualexplainstheproperprocedureforpreparingthecombineandremovingtheFactorySpreaderComponentsinordertoinstalltheRedekopMAVChopper

0.2 Recognize Safety Information

0.2.1Thisisasafety-alertsymbol.Whenyouseethissymbolonyourmachineorinthismanual,bealerttothepotentialforpersonalinjury.

Followrecommendedprecautionsandsafeoperatingpractices.

0.3 Understand Signal Words

0.3.1Asignalword-DANGER,WARNING,orCAUTION-isusedwiththesafety-alertsymbol.DANGERidentifiesthemostserioushazards.

WARNINGorCAUTIONsafetysignsarelocatednearspecifichazardsorprecautionaryareasinthismanual.

0.4 Follow Safety Instructions

0.4.1Carefullyreadallsafetymessagesinthismanualandonyourmachine.Keepsafetysignsingoodcondition.Replacemissingordamagedsafetysigns.Besurenewequipmentcomponentsandrepairpartsincludethecurrentsafetysigns.Replacementsafetysignsareavailablefromyourdealer.

Therecanbeadditionalsafetyinformationcontainedonpartsandcomponentssourcedfromsuppliersthatisnotreproducedinthisoperator’smanual.

Learnhowtooperatethemachineandhowtousecontrolsproperly.Donotletanyoneoperatewithoutinstruction.

Keepyourmachineinproperworkingcondition.Unauthorizedmodificationstothemachinemayimpairthefunctionand/orsafetyandaffectmachinelife.

Ifyoudonotunderstandanypartofthismanualandneedassistance,contactyourdealer.

Otherlanguagesareavailableforthismachine.PleasecontactRedekop

54

0.5 Safe Operating Practices

0.5.1DONOTstandnearcombinewhenmachineisrunning.

ALWAYSrefertoyourCombineOperator’sManual,andreviewSafetysectionbeforeoperatingmachine.TheCombineOperator’sManualdetailssafeoperatingpracticesthatmustbefollowedtoprotectyouandothersfromaccidentaldeathand/orinjury.

Operatemachineonlywhenallguardsarecorrectlyinstalled.

Beforemovingaway,alwayscheckimmediatevicinityofmachine(e.g.forchildren).Ensureadequatevisibility.Usethehornasawarningimmediatelybeforemovingaway.

Whenmakingturns,alwaystakeintoconsiderationthewidthoftheattachmentandthefactthattherearendofthemachineswingsout.Attachmentsandgroundconditionsaffectthedrivingcharacteristicsofthecombine.

Neverleavemachineunattendedaslongasengineisrunning.

0.6 Work In Ventilated Area

0.6.1 Engineexhaustfumescancausesicknessordeath.Ifitisnecessarytorunanengineinanenclosedarea,removetheexhaustfumesfromtheareawithanexhaustpipeextension.

Ifyoudonothaveanexhaustpipeextension,openthedoors and get outside air into the area.

0.7 Remove Key from Ignition

0.7.1 ALWAYSshutoffcombineenginepriortoworkingon it.

Applyparkbrake,removekeyandlockoperatorscab.

Ifthecombineisequippedwithanadditionalsafetymasterpowerswitch,turnthistothePowerOFFposition.

6

0.9 Practice Safe Maintenance

0.9.1 Understandserviceprocedurebeforedoingwork.Keepareacleananddry.

Neverlubricate,service,oradjustmachinewhileitismoving.Keephands,feet,andclothingfrompower-drivenparts.Disengageallpowerandoperatecontrolstorelievepressure.Lowerequipmenttotheground.Stoptheengine.Removethekey.Allowmachinetocool.

Securelysupportanymachineelementsthatmustberaisedforservicework.

Keepallpartsingoodconditionandproperlyinstalled.Fixdamageimmediately.Replacewornorbrokenparts.Removeanybuildupofgrease,oil,ordebris.

Onself-propelledequipment,disconnectbatterygroundcable(-)beforemakingadjustmentsonelectricalsystemsorweldingonmachine.

0.8 Block Wheels

0.8.1 Parkthecombineonlevelground.

Alwaysengagetheparkbrakeandblockthecombinewheelspriortoworkingtopreventthecombinefrommoving.

0.10 Avoid Contact With Moving Parts

0.10.1 Keephands,feetandclothingawayfrompowerdrivenparts.Neverclean,lubricateoradjustmachinewhenitisrunning.

76

0.11 Avoid High-Pressure Fluids

0.11.1 Inspecthydraulichosesperiodically–atleastonceperyear–forleakage,kinking,cuts,cracks,abrasion,blisters,corrosion,exposedwirebraidoranyothersignsofwearordamage.

Replacewornordamagedhoseassembliesimmediately.

Escapingfluidunderpressurecanpenetratetheskincausingseriousinjury.

Avoidthehazardbyrelievingpressurebeforedisconnectinghydraulicorotherlines.Tightenallconnectionsbeforeapplyingpressure.

Searchforleakswithapieceofcardboard.Protecthandsandbodyfromhigh-pressurefluids.

Ifanaccidentoccurs,seeadoctorimmediately.Anyfluidinjectedintotheskinmustbesurgicallyremovedwithinafewhoursorgangrenemayresult.Doctorsunfamiliarwiththistypeofinjuryshouldreferenceaknowledgeablemedicalsource.

0.12 Dispose of Waste Properly

0.12.1 Improperlydisposingofwastecanthreatentheenvironmentandecology.Potentiallyharmfulwasteincludessuchitemsasoil,fuel,coolant,brakefluid,filters,andbatteries.

Useleakproofcontainerswhendrainingfluids.Donotusefoodorbeveragecontainersthatmaymisleadsomeoneintodrinkingfromthem.

Donotpourwasteontotheground,downadrain,orintoanywatersource.

0.13 Use Proper Lifting Equipment

0.13.1 Liftingheavycomponentsincorrectlycancausesevereinjuryormachinedamage.

Followrecommendedprocedureforremovalandinstallationofcomponentsinthemanual.

Ensureliftingequipmentisratedforthejob

Ensureoperatorisappropriatelylicensedtooperateliftingequipment 8

0.14 Personal Protective Equipment (PPE)

0.14.1 AQualifiedPersondesignatedbytheemployer,whoisknowledgeableaboutandfamiliarwithallrelevantspecificationsandassemblyinstructionsandiscapableofidentifyingexistingorpotentialhazardsinsurroundingsorworkingconditionswhichmaybehazardousordangeroustoemployeesshalldetermineappropriatePersonalProtectiveEquipmentrequiredforthisassembly.

PersonalProtectiveEquipment(PPE)aredeviceswornbytheemployeestoprotectagainsthazardsintheenvironment.Examplesincludesafetyglasses,faceshields,respirators,gloves,hardhats,steel-toeshoes,andhearingprotection.

Check all fasteners to ensure they have been properly

tightened

Torque Table

Nominal Size Class 8.8 Class 10.9

Nm / (ft-lbs) Nm / (ft-lbs)

M8 - flanged 27 / (20) 39 / (29) - non flanged 25 / (18) 35 / (26)




98

A

B

C

D

A - Stay clear decalB - Keep away decalC - Moving parts decalD - Shield missing decal

SAFETY DECALS

STAY CLEAR OF CHOPPER DISCHARGE AREA

Lookandlistentoensurethatallmotionhasceasedoncombineandstrawchopperbeforemovinginthevicinityofthestrawchopper,makingadjustmentstothechopperdrive,spreadingfins,cutterbar,oranyothersectionofthecombine.Flyingchaff,strawandotherdebriscancauseseriouspersonalinjury.Keepallpersonsclearofthespreadingorcollectingunitatalltimes.Chaff,strawandotherobjectscanbepropelledtodistancesof50feetormore,andhardobjectslikestonesmuchfurtherstill.See(A).

KEEP HANDS AWAY FROM RUNNING CHOPPER

Keephandsandanyotherobjectsawayfromchopperwhencombineisrunning.Remember,theRedekopchopperrotordrawsalargeamountofairfromthecombineandcouldeasilydrawinahandorotherobjectthatisplacedtooclosetoit’sblades.See(B).

STAY CLEAR OF MOVING PARTS

Keepsafetyshieldprovidedinplaceatalltimes.Contactwitheitherthepulleyorbeltwhilechopperisrunningcancauseseriousinjury.Keephandsandanyotherobjectsawayfromchopperwhencombineisrunning.Makesurethefactorysafetyshieldsarecorrectlyinstalledandwellmaintained.Neverremovetheshieldsfromthestrawchopper.See(C & D).

10

CHOPPER MAINTENANCE / OPERATIONAlthoughlittleactivemaintenanceisrequiredtokeepyourRedekopMAVChopperoperatingsmoothly,itisveryimportantthatthefollowingpreventativemaintenanceschedulebefollowed.Aregularvisualcheckandreplacementofthehighwearcomponentswillpreventlargerscalemaintenanceinthefuture.Thefollowingareasofyourstrawchopperandrotorshouldbecheckedonaregularbasis.

Component / Instructions1. Bearings •DONOTLUBRICATE.Bearingscomepre-greased,thereisnorequirementtogrease

2. Blades •lookforexcessivewearofmetal,cracks,orothervisibledamageandreplaceasnecessary•checkclearancebetweenthebladesandstationarybladestoensurethatthereisadequatespacetooperatewithoutobstruction •thereshouldbenolessthan1/4”ofclearancebetweeneachbladeedgeandtheclosest stationaryblade •clearanceproblemsmayoccurwhenbladesand/orstationarybladesmaybedeformedbyhard objectsthatpassthroughthecombine-checkforandreplacecomponentsasnecessary •repetitivetickingorknockingsoundsemittedfromthechoppermaysignalaminorclearance problem-thechoppershouldbestoppedimmediatelyandexamined

CAUTION! If one blade breaks and the chopper must be operated without a replacement then the damaged blade and the blade directly opposite it must both be removed in order to keep the rotor in balanceCAUTION! Never replace only one blade for wear or breakage. Eight (8) blades MUST be installed to replace one (1) broken blade, or all the blades replaced at on time. This MUST be done to keep vibration to a minimum.

3.StationaryBlades•checkbladesforexcessivewear,damage,orbreakage •ifastationarybladebreaks,removetherodholdingthebladesinplace,replacethedamaged blade and reinsert the rod4. Belt •ifexcessivebelttemperaturesareevident,orthechopperseemstobelosingexcessiverpmduringoperationintoughorheavyconditions,thebelttensionisnotsufficientandshouldbeadjustedimmediately•lookforcracks,frayededges,oranyimperfectionsthatmayresultinbreakage •ifabeltedgeshowsexcessivewear,checkformis-alignmentofthepulleysandcorrect ifnecessary5.Cosmetic•cleanoffchaffresiduefromtopoftailboardstopreventexcessmoisturefromcollecting•setangleoftailboardsdowntoallowmoisturetorunoffwhencombineisnotinuse

CAUTION: When chopping corn or sunflowers, the knifebar blades MUST BE ALL THE WAY OUT of the chopper housing and ROTOR MUST BE RUN ON SLOW SPEED (800-1200 rpm)

CORN! SUNFLOWERS!

1110

TaperedBushing

Size&ThreadofCapscrew

Ft.-Lbs.ToApplyWith

TorqueWrenchSK 5/16 - 18 15SF 3/8 - 16 30

Screw Tightening InformationStandard Mounting

Fig. 1

BUSHING

IMPORTANT: DO NOT USE LUBRICANTS IN THIS INSTALLATION

To Install Bushing:1.Removeallpaint,oilgrease,etc.fromtaperedsurfaceofbushingandboreofmatingpart.

2. See Standardmountingassembly-Figure1.

NOTE: If bushing does not slide freely on shaft, wedge a screwdriver blade into the saw cut and theflange OD to open the bore of the bushing. Caution: Excessive wedging will split the bushing.

3. Standard Mount –Slidebushingonshaft,flangefirst.Ifusingthesetscrew,snugitagainstthekey.Excessive Torque will cause mating part to be eccentric.Positionmatingpartinplaceonbushingaligningdrilledholesinmatingpartwithtappedholesinbushingflange.Usinglockwashers,installcapscrewsthruthematinghubandintothebushingflange.(Note: SbushingscanonlybeStandardMounted.Besurethethreetappedholesinthematinghubdo notalignnearthebushingsawcut.Iftheydo,rotatethebushing60degrees.).

4. Use A Torque Wrench.Tightenallcapcrewsevenlyandprogressivelyinrotationtothetorquevaluelisted 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.Loosenandremoveallcapscrews.

2. For Standard Mount,threadcapscrewsintotappedholesinmatingparttojackagainstbushingflange.Tightenboltsevenlyandprogressivelyinrotationtoseparatethetwocomponents.

3.Loosensetscrewtoslidebushingfromshaft.

12

Rotor Blade Installation Procedure

E

C

DF

E

D

C

B

A

A

A - Blade directionB - Hex BoltC - WasherD - Rotating BladeE - BushingF - Lock nut

Note:Torquevalueslistedareforchopperbladeinstallationonly,basedonthestrengthofthebolt.DONOTusethesevaluesfordifferentproceduresorapplications.

CAUTION: Always use METRICclass 10.9 bolts and matching class 10 all steel lock nuts when installing blades.

IMPORTANT! The fan 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 and pushes the air.

1 Thebladesforyourchoppermustbeinstalledasoutlined. Note: If blades are installed other than as directed, damage to the chopper may result or performance may be significantly reduced.

1.2 Ifabladebreaksandthechoppermustbeoperatedwithoutareplacement,thenthedamagedbladeandtheonedirectlyoppositeandthecorrespondingbladesontheoppositeendoftherotormustberemovedtomaintainrotorbalance.Atotaloffourbladestoberemoved.

1.3 UseonlyMETRICclass10.9bolts(B)andclass10DIN980Vallsteellocknuts(F)onthechopperrotor.

1.4 Useatorquewrenchtotightenallnutstotherecommendedvalues: M10nutsto40ft-lbsor55Nm M12nutsto50ft-lbsor65Nm

1.5 Alwayscheckforadequateclearancebetweentheinstalledbladesandthestationaryknives.Aminimumof6mmor1/4”isrequired.Checkclearanceofallblades,eventhosethatarenotreplaced.Donotoperatethestrawchopperunlessthisclearanceismaintainedforallblades.

2 Assemblebladepairsasperordershown(BtoF)

IMPORTANT! Chopper balance MUST be maintained.

1.1 Replace BOTH blades on single support and BOTH blades opposite support (180 deg). Also, replace the four at the other end of the rotor, at the same axial distance from the balance ring.

Eight blades MUST be installed to replace one broken blade, or all the blades can be replaced at one time. This MUST be done to keep vibration to a minimum.

Never replace only one blade for wear or breakage

1312

Row2

Row4

Row1

StationaryBlades

(AlignedwithKeyway)

Tailboard

Row3

Row1

Row2

RotationDirection

Wide MAV Blade Replacement (67” wide chopper)Thecentersectionofthechoppercontainssomepaddlebladestocreateanincreasedairflowinthemiddleoftherotor.1.Paycloseattentiontotheexistingpatternortotheillustrationbelowtoensurethatthispatternismaintainedwhenreplacingblades.Notethatwhereverapaddlebladeisplaced,thestationaryknifehasbeenremoved.

2.Todeterminelocationdonotcountblades,rathercountthenumberofslotsinthefloororknifebar,startingfromthenon-driveside.Seeillustrationsbelow.Whencountingrowsnotethatrow1isinlinewiththekeywayontherotorshaft.2006modelchoppershavenotchesintheknifebarmarkingwhichbladesareremoved.

3.ThepaddlebladesusedareHA505LandHA505R(Carbiderecommended).Makesurethepaddlebladesareinstalledwiththepaddlefacingoutfromthemountbracketaswellastheblademusthavethecuttingedgemovinginfrontasthepaddlefollowsbehind.Seebottomrightillustration.ThetorquevaluefortheM12boltandnutusedtosecurethebladestotherotoris50ft-lbs.

Note:Checkallfastenerstoensuretheyhavebeenproperlytightened.Rotatechopperrotormanuallytoensureclearanceofallblades.Whenstartingchopper,besureallpeopleareclearoftherearofthecombine.

Startthreshingmoduleinlowspeed&listenforclearanceproblems.Ifaknockingnoiseisheardstopmachineimmediately!Fixproblem&repeatprocedure.Progresstofullpowerwheneverythingisrunningsmoothlyatlowerspeeds.

14

A

B

KNIFE BAR ADJUSTMENT1.Toadjustangleofstationarybladesloosenboltsonbothsidesoftheknifebarandusethehandletopositionaccordingly.

2.Pullhandleup(A)toplacestationarybladesintothechopperhousingasfaraspossibletogetthefinestcut.

3.Pushhandledown(B)toplacestationarybladesoutsidethechopperhousingifanextrafinecutisnotneeded.

Start with the knives completely out or only partially inserted. For an extra fine cut move your knives in farther. More horsepower is needed by the chopper to achieve the finest cut possible. Adjust to suit the desired cut.

4.Beforetighteningknifebarbesurethestationarybladesarecenteredintheslotsinthechopperfloor.

5.Checkforclearanceoftherotorbladeswiththestationarybladesbyrotatingrotorbladesthroughthestationaryblades.

CAUTION: When chopping corn or sunflowers, the knifebar blades MUST BE ALL THE WAY OUT of the chopper housing and ROTOR MUST BE RUN ON SLOW SPEED (800-1200 rpm)

CORN! SUNFLOWERS!

1514

A

B

D

E

C

G

G

F

H

TAILBOARD / FINS ADJUSTMENTPositiontailboard(A)tosuitspreadingrequirements.Pullpin(B)torotatetailboardtoanyofthesixpositionsavailable.

Tailboard Position to chop straw (Fig C): Adjustangleto1ofthe5upperpositions. Positionfinsintheoutermostedgeoftheslotfor thewidestspreadandevendistributionacross thewidthofthecutterbar(D).

Ifanarrowwidthisrequiredpullallfinstotheir narrowestposition(E).Repositionthefrontof the3outerfinstothesquareholes(F)andpull thebackofthefinsasfarinaspossible.

Tailboard position to windrow straw (Fig G): Settailboardatit’slowestpositionifyour combineallowsthestrawtowindrowoverthe topofthechopper. Movethe2outerfins,onbothsides,togainthe bestchaffspreadingdistancewhilewindrowing straw(H).

16

C

D

B

A

CHAFFBOARD ADJUSTMENT - if equippedAvailable for NH and CAT CombinesPositionchaffboard(A)tosuit.TheMAVkitisshippedwiththefinsupwardtoavoiddamage.Pullpin(B)torotateboard.

Chaffboard position to chop straw (C): Placefinsinthedownwardposition.

Chaffboard position to windrow straw (D): Placefinsintheupwardposition.

1716

B

A

DA

CSTRAW& CHAFF

D

A

E

STRAW& CHAFF

CHAFF PAN EXTENSION / CHAFF DOORPositionchaffpanextension(A)intheupperpositiontoguidethechaffintothechopper.Besurethebelting(B)isupandoverthechaffdoor.Pullthechaffpandownandoutofthewaywhenwindrowingstraw(E). Pan position to chop straw (Fig C): 1.Placechaffdoor(D)downandlockinplace. 2.Placesieveextensionpanbeltingontopof chaffdoor.

Pan position to windrow straw (Fig E): 1.Chaffdoor(D)isupandlocked. 2.Sieveextensionpan(A)isdown.

18

A

CB

DF

E

E

B

C

G

FD

STRAW

CHAFF

STRAW

CHAFF

COMBINE SPECIFIC OPERATION

For combines equipped with a windrow straw chopper.Windrowstraw(FigA)overthebackofthechopper.Openthestrawdoor(B)withtheleverarm(C)orthefactoryelectricactuator,dropthetailboard(D),flipthechaffboard(E)andengagethehydraulicdrivenroller(F)thatallowsthestrawtomovesmoothlyoverthebackwallofthechopper.Onboththeleftandrighttailboardsrepositionthefrontofthe2outerfinsintowardthemiddleinordertoredirectmorechaffforspreading.Boltinplaceusingtheprecutsquareholes.Proceedtooperatecombine.

Chopstraw(FigG).Strawdoorforward,hydraulicrolleroff,chaffboardfinsdown,tailboardup,outer2finsbacktooriginalposition.

Access&AdjustSieves.Toaccessyoursievesrotatethechaffdoorupusingthehandleonthesideofthechopper,pullthespringloadedchaffpanextensiondown,standupinfrontofthechopperandadjustwhereneeded.Placeallpanelsbacktotheiroriginalpositiontocloseoffaccesstothesieves.

1918

B

D

C

G

C

A

B

EF

D

For combines NOT equipped with a windrow strawchopper.Windrowstrawinfrontofthechopper(FigA).Positionthestrawdoor(B)withthemanualarm(C)andlockinpositioninthemostforwardposition(D).Rotatethechaffdoor(E)upwiththehandleontheotherside,dropthechaffpanextension(F)andallowstrawandchafftodropinfrontofthechopper.

Chopstraw(FigG).Strawdoorback,chaffdoordown,andchaffpanextensionup.

20

A

Beater

Beater Shelf

Isometric View

B

For all upgrade rotors.Aftertighteninglockcollars,recheckeachindividualbladetoensurethatthereisadequateclearance(A)betweenitandthestationaryblades.Thedoublebeltdrive,suppliedwithyourkit,providessufficienttractioninthetoughestconditions.

For complete choppers.OntheSTScombinebesuretoadjusttheinternalfins(B)todistributethestrawevenlyacrossthewidthofthechopper.Failuretodosowillcausetheresiduetorowinbehindthechopper.

2120

E

D

Besuretoadjustthestrawdoor(D)andthechaffdoor(E)whenchoppingorwindrowingstraw.

For chopping straw (Fig A): Lockthestrawdoor(D)intheuppermost positionwiththehandle, lockthechaffdoor(E)intoplace

For windrowing straw (Fig B): Positionthestrawdoor(D)downvertically withthehandle,unlockthechaffdoor(E) tohangvertically.

For chopping CORN (Fig C): Positionthestrawdoor(D)downvertically withthehandle, lockthechaffdoor(E)intoplace

A

C

E

D

E

D

B

CAUTION: When chopping corn or sunflowers the knifebar blades MUST BE ALL THE WAY OUT of the chopper housing and ROTOR MUST BE RUN ON SLOW SPEED (800-1200 rpm)

CORN! SUNFLOWERS!

John Deere S-Series

OperateinsamemanorasOEMchopper,pleaserefertocombinemanual

John Deere STS

CAUTION: When chopping corn or sunflowers the knifebar blades MUST BE ALL THE WAY OUT of the chopper housing and ROTOR MUST BE RUN ON SLOW SPEED (800-1200 rpm)

CORN! SUNFLOWERS!

22

COMBINE MAINTENANCE

John Deere STS - Remove Sieves

NOTE: Remove sieves easily by pivoting the chopper rearward.For more information review your John Deere manual.

John Deere S-Series - Remove Sieves

1-Slidechopperback2-Removeknifebar(B)3-Removeandreplacecombinesievesthroughopeninginfrontofchopper4-Replaceknifebaraftermainenanceiscompleteandadjustallpanelstotheiroriginalpositionsforchopping

Remove Seive

Pivot chopper up

Remove Seive

BRemove Knifebar

2322

Chopper

Windrow

A

B

D

BC

400 SeriesWindrowstrawinfrontofthechopperwiththeMAV-400kit(FigA).Adjustdoorpositioningplatestofinetunestrawdoorplacement.

For chopping straw: Strawdoor(B)isupagainstthefrontwall(C) mountedinsidethecombine

For windrowing straw: Strawdoor(B)isupagainsttheupperrearseal(D)

Access & Adjust SievesToaccessyoursieves:-rotatethechaffdoorupusingthehandleonthesideofthechopper-pullthespringloadedchaffpanextensiondown-standupinfrontofthechopperandadjustwhereneeded.-placeallpanelsbacktotheiroriginalpositiontocloseoffaccesstothesieves.

24

E

EF

G

CAT LEXION 500 - 700 Series

Windrowstrawinfrontofthechopper

For chopping straw: Strawdoor(E)isupagainsttherearwall insidethecombine

For windrowing straw: Rotatestrawdoor(E)downagainsttheupper chaffpanel(F) Rotatetailboard(G)down

2524

A

DCF

B

E

H

J

K

G

STRAW& CHAFF

STRAW& CHAFF

8000 - 9000 Series

Adjustlinkage(A)locatedonthedrivesidetopositionthestrawdoor(B).Notetheangleofthechaffdoor(C)isalignedwiththeadjustmenthandle(D).

For chopping straw (Fig E): Positionthestrawdoor(B)upagainsttheupper hoodofthecombine,rotatethechaffdoor(C) downandlock,andthechaffpanextension up(F).Placeoverhangingmaterialontopof chaffdoor.

For windrowing straw (Fig G): Positionthestrawdoor(H)downoverlappingthe chaffdoor(J),lockinplace.Rotatethechaffpan extensiondown(K).

Access&AdjustSieves.Toaccessyoursievesrotatethechaffdoorupusingthehandleonthesideofthechopper,pullthespringloadedchaffpanextensiondown,standupinfrontofthechopper

26

F

E

G

CD

A

1. Using a loader or forklift, lift the Redekop chopper into place as shown in Figure 3. Align thepin sleaves of the hinge bar and chopper frame and insert the hinge pin from the top downthrough the hinge.

2. Grease the hinge after installation and periodically afterwards to avoid corrosion of the pin.

Lift chopper into place so thatthe hinge bar and the chopperframe line up as shown.

Installing the Redekop Chopper

Figure 3: Installing the Redekop Chopper.

inserthingepin

2

Figure 4: Installation of the plastic deflectors.

3. Bolt the chopper latch onto the frame using a 5/8" x 2-1/2" bolt and locknut (Figure 4).Tighten until snug but moveable.

4. The overcenter bolt can be turned in or out to adjust the holding tension as nessesary.

5. Install hairpin in the U bracket to prevent latch from opening.

B

A 1480 - 2588 Havethechoppermountedonthecombineframeextensionwhenreadytochopstraw(A).

Remove the MAV chopper in order to windrow straw. Thechoppercanbeliftedfromunderneathwithafrontendloaderorforkliftorcanbeliftedoffbyhookingintotheuppersideplates(B).RemovethepinontheRHside,removethechopperandbelt,placeonapalletreadyfornextinstallation.

Toaccessthesievesunlatchthepin(C)onthenon-drivesideofthechopperandpullbacktheover-centerlockingarm(D).Be sure the access ladder (E) is in the upper most position.AlwayshavetheRedekopchopperintheopenposition,whenusingtheladder,toavoidanydamagetothechoppertailboard.Pullthechopperopenasmuchasneeded(F).

Besuretheinternalfins(G)areinstalledtodistributetheresidueevenlyaccrossthewidthofthechopper.Thiseliminatesthepotentialofrowingbehindthechopper.Seeyourinstallationguideforplacement.

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B

D

C

G

C

A

B

EF

D

AFX-8010, 7010, 9120, 8120, 7120Windrowstrawinfrontofthechopper(FigA).Positionthestrawdoor(B)withthemanualarm(C)andlockinpositioninthemostforwardposition(D).Rotatethechaffdoorup(E)withthehandleontheotherside,dropthechaffpanextension(F)andallowstrawandchafftodropinfrontofthechopper.

Chopstraw(FigG).Strawdoorback,chaffdoordown,andchaffpanextensionup.

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TROUBLESHOOT1. Broken blade?Ifabladebreaksduetoaforeignobjectcomingthroughthechopper,alwaysreplacebladesfourpairatatime.Refertosection1.1forreplacementbladeprocedure.Never replace only one blade for wear or breakage.

2.Nosparebladereplacementavailable?Ifabladebreaksandthechoppermustbeoperatedwithoutareplacement,thenthedamagedbladeandtheonedirectlyoppositeandthepairontheoppositeendmustberemovedtomaintainrotorbalance.

3.Isaknockingsoundheardwhenstartingupthechopper?Checkforadequateclearancebetweentheinstalledbladesandthestationaryblades.Aminimumof6mmor1/4”isrequired.Checkclearanceofallblades,eventhosethatarenotreplaced.Donotoperatethestrawchopperunlessthisclearanceismaintainedforallblades.

4.Insufficientclearanceofrotorbladespastthestationaryblades?Checkthatthestationarybladesarecenteredinthemiddleoftheslotsinthechopperfloor.Iftheyarenottheknifebarmustbemovedover.

5.Stillinsufficientbladeclearance?Ifyoudonothavesufficientclearanceandthestationarybladesareinthepositionspecifiedinpoint#4,therotormustbemovedover.Removeallshieldstoaccesstherotorbearingsandloosenbolts.Shifttherotoroverslightlyandcheckforbladeclearance.Retightenboltsmakingsuretherotordoesnotgetpulledovertoonesideintheprocess.Retorqueboltstospecifications.

6.Notcuttingproperly?Checkyourrotorbladesandfliporreplacethemifnecessary.Toughconditionswillalsoplayafactorinhowwellthechopperisorisn’tcuttingsufficiently.

7.Isthererowingbehindyourchopper?Adjustthetailboardfins.Checkthattheinternaldeflectorfinsarepositionedcorrectlysothatallresiduewillbeevenlydistributedacrossthewidthofthechopper.Singlerotarycombinesmusthavethestrawredirectedbeforeitreachesthechoppertoaccomplishevenspread.Inmostcases,rowingresultsbecausethestrawfromthe2ndand3rdfinfromtheoutside,laysstrawontopofthatfromtheoutsidefin.Adjustthesefinsinward.

8.Areyourdrivebeltsslipping?Makesurethedrivesheavesarealignedandcheckthetensionofyourbelt.Ifthebeltsaretoolooseyou’llgetinsufficienttractionandwearthebelts;ifthebeltsaretootighttherewillbeexcesswearonthebeltandonthesheave;checkforsheavewear.Ifthesheavesarealignedandthebeltsarenotworn,checkforwearonthesheaveasthenextpossibility.

9.Istherechaff/grainembeddedinthedrivebelt?Determinewherethechaffiscomingfromandredirectchaffflowawayfromthebelt.

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FAQQ1.Howmuchhoresepowerdoesthechopperneedtorun?A1.HPrequirementisrelatedtotypeandvolumeofstraw,aswellasmoistureconditions.Asaresultitwillvarycontinually.Onanygivendaythesamechoppercouldrequireaslittleas20hporupwardsof60hp.

Q2.Howmuchdoesthechopperspread?A2.TheMAVchoppercanspreadasnarrowas20-25feet.Toaccomplishthisthetailboardshouldbeloweredconsiderably.Underidealconditionsthechopperwillspread45feet.Toaccomplishthis,thechoppermustbeadjustedtocutmediumlengthstraw,itmustberunningfull,anditmustbefeduniformly,especiallytotheoutsides.

Q3.Howlongdothebladeslast?A3:Itvariesdrasticallyduetocuttingconditions,cropconditions,soiltypes,etc..Thetypicallifeofaheattreatedbladeisapproximately350hours.Thecarbidecoatedbladehasalifeapproximately1.5xthelifeofthe heat treated blade.

Q4.Doesthechopperneedtoberebalancedeachtimeyouneedtoreplaceblades?A4.No,byreplacingALLthebladestherotorshouldbefullybalanced.

Q5.Howdoesthechopperperforminflaxandsoybean?A5:Thebladeswillwearfasterinthesecrops,butwithcarbidecoated-selfsharpeningblades,theywillholdtheiredgelongerandcutmoreeffectively.

Q6.Anyspecialrequirementsforchoppingcorn?A6:Yes,thechopper must run at a slower speed(800-1200rpm)andthestationary blades must be pulled completely out of the chopper housing.

Q7.CanIspreadthechaffwiththestraw?A7.Yes,withstrawandchaffmodelchoppers.CustomersorderingaMAVstrawonlychopperdoesnottakethechaffintothechoppertobespread.Inthosecasesthefactorychaffspreadersystemsmustremainintact.MostrotarytypecombinescanbefittedtotakeinbothstrawandchaffwithoneofournewMAVchoppers.

Q8.DotheRedekopbladesfitintoallchoppers?A8.No,youmusthaveaRedekopChopperoraRedekopUpgradeRotortousetheRedekopblades.

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mav chopper operator’s manual

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