Model 3250 Chopper

Transcript

Model 3250 Chopper Case International 168O~ 1688 Chopper Drive Manual 1998 Saskatoon, Saskatchewan Phone (306) 931-6664 REDEKOP CHOPPER USERS GUIDE INTRODUCTION 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 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 air thrust to the extent that 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 of the 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 CaseIH Combines Users Guide PAGE I REDEKOP CHOPPER USERS GUIDE 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 signal word is given here: A~aITInM CAUTION about machine. Understandidentifies and be general alert to precautions the warnings andthe instructions ‘.“~“ ‘ “ given with this safety-alert. AWARNING WARNING alerts you to a specific hazard located nearby. A DANGER DANGER younear to the serious hazards. This safetyalert is alsoalerts located themost specific hazard. 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. A CAUTION i~L 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)9316664. To prevent sedous injury or machine damage: • Read and understand Operators Manual before using, installing, or working no this machine. Review annually. • Stop combine engine, place all controls in neutral, set park brake, remove ignition key, and wait fur all moving parts to stop befure servicing, adjusting, repairing, unplugging or fitting this machine. • Keep hands, feet, hair, and clothing away from moving parts. • Avoid unsafe operation or maintenance. Rl28 — INSPECT THE STRAW CHOPPER BEFORE YOU OPERATE Inspect the straw chopperfordamage: • Check all hammers and stationary blades for excessive metal wear, cracks, or othervisible damage. • Check for loose, worn, damaged or missing parts. • Check and tighten the straw chopper hardware, especially the rotor hammer mount bolts. o 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. Redekop Industries Model 3240 and 3250 Chopper For CaseIH 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 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. Cu not point discharge toward people, animals, or buildings when operating. R120 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. 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 To prevent serious njur~’ or death from contact with chopper rotor: • Do not adjust chaff or straw deflection panels while chopper rotor is in mnbun. • Keep hands, feet, clothing, and hair oot of the chopper and 0121 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. MOVING PART HAZARD A DANGER SHIELD MISSING When this is visible DO NOT OPERATE Redekop Industries Ta prevent serious injury or death from moving parts: • Close and secure all guards and shields before operating. • Keep hands, feet, hair, and clothing away from mnving parts. • Turnoff engine and wait for all motion to stop before adjusting or servicing 0125 Model 3240 and 3250 Chopper For CaseiH Combines Users Guide 0122 PAGE 3 REDEKOP CHOPPER USERS GUIDE OPERATE THE STRAW WIN DROW 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 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 rotordoes not rotate. Turn off the combine ignition and make sure all motion has stopped before the moving the chopper belt. A CAUTION PARTS INTERFERENCE HAZARD To prevent damage to chopper rotor and straw wiodrow door: Do not operate the chopper white 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 windruw straw and chaff. 0123 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. I To avoid injury or machine damage: • Do not use this spreading fin hood as a step or platform. • Hood may bend or feet may slip causing serioos misTy. R124 Redekop Industries Model 3240 and 3250 Chopper For CaseIH Combines Users Guide PAGE 4 REDEKOP CHOPPER USERS GUIDE 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. 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! Never replace only one hammer for wear or breakage always replace hammers in opposite pairs. - iii) Stationary Blades • check blades for excessive wear, damage, or breakage • 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 CaselH Combines Users Guide PAGE 5 REDEKOP CHOPPER USERS GUIDE REPLACEMENT OF WEARING PARTS SECTION I - ROTOR PARTS QUANTITIES 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. Item I 2 3 4 5 6 7 10 Part Number H8CZ38.214 I-IA 500L I-IA 500R HA 520 HA 530 HA 600 HA 610 SLCZC38 Description hex cap screw, 3/8 x 2 1/4 nc gr8 zinc hammer, flail w/ left hand bend hammer, flail w/ right hand bend washer, 1” hardened bushing, 1/4” offset 0.191” flange hammer, straight 0.13” thick sharpened bushing, 1/4” offset 0.133” flange lock nut, 3/8-16 NC lock nut steel zinc Qty Per Unit 3240 (3250) 20 (26) 14 (17) 14 (17) 40 (52) 28 (34) 12 (18) 12 (18) 20 (26) Table 1: Rotor Parts Breakdown for 3240 and 3250 Chopper. SECTION 2 REPLACING KNIFE BAR PARTS - I. 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. Insert the pin into the support bar and bend overto secure. I - Part# HA 700, 26 pcs in complete set. Figure 3: Knife BarAssembly Schematic. Redekop Industries Model 3240 and 3250 Chopper For CaselH Combines Users Guide PAGE 6 REDEKOP CHOPPER USERS GUIDE SECTION 3- REPLACING ROTOR PARTS 1. The bent flail and straight hammers for your chopper must be installed in the pattern shown in Figure 2. Changing the hammer pattern can significantly reduce the performance of the chopper. Model 3240 HA500L HA 530 HA 610 //HA600 Important Installation Instructions: ~ HA 50CR Row I Row 2 Row 3 Row 4 HA500L HA 530 HA 50CR RowI Row2 Row3 Row4 Hi ft nftft ft rlftn ft 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. Model 3250 HA 610 ~ ~//~600~ ft ft ft ~ ft ft ft H. fl ft ft ft 11fl ~ ft 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. Figure 2: Hammer Installation Patterns for 3150 Chopper. 2. The correct assembly for the paddled and straight blade hammers is shown in Figure 3. CAUTION: Always use ~ IV Grade 8 bolts and steel lock nuts when Allowable installing torque hammers. range for hammer mount nuts is 45ft-Ib to 55ft-lb. Figure 3: Paddle and Straight Blade HammerAssembly Schematic. Redekop Industries Model 3240 and 3250 Chopper For CaseIH Combines Users Guide PAGE 7 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. l3olt the pieces of 4” belting to the insit~es of the sieve pen with 1/4 x ~/4’ bolts using fist weshers 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. - IMPORTANT! 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). - (b) Ensure thet the chopper freme does not sitfurtherforwerel then shown so thet the tie rod is free to pivot. Angled E’ectiori Figure 2: Installing the Chopper Mount Frame. Redekop Industries Model 3240 and 3250 CaselH 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. 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’ rlastic 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 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 plasfic deflectors, Redekoc Industries Model 3240 and 3250 CaselH Chooier 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 boffom 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 11 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 Coml~ine 6e~ter ~‘—~ Drill 4 holes in combine pan to mount extension plated of the internal deflectors, Top View Heavy concentration of straw Approximate location of fins to create an even feed of straw into chopper. Adjust as necessary. 36 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 holding the bearing flange in place. — _— ~emove sensor from spreader drive on combine ahdattachtothe supplied sensor bracket asdhown, Install sensor disk onto chopper shaft to line up with sensor. Figure 8: Installation of shaft monitor sensor. Redekoo Industries Model 3240 and 3250 caselH Cho~~er Manual Generic Installation Instructions Installing the Redekop Chopper 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 not tighten at this 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 narrow spread, hole #2 for medium spread, or hole #3 forwide spread (see inset). 4. Tighten all fourfastners to fix the spreader hood in place. sprc~der I - hood Narrow Spread 2 Medium Spread 3 Wide Spread - - Figure 5: Attaching the Spreader Hood to the Redekop Chopper Body. Redekop Industries Model 3240 and 3250 CaselH Chooper Manual Generic 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 flatwashers on all slotted holes. 2. For initial setting, move each fin to its most outward position and tighten. 3. Fin settings can be adjusted as required after operation infield. Note: For maximum spreading, fasten the front hole of fins 4 and 5 to the inner tailboard hole positions as shown here. Fin 1-15”Curved Fin 2-15” Curved Fin 3-21.5” Curved Fin 4-32” Curved Fin 5 13” Straight Note: 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 Finstothe Spreader Hood. Redeko~ industries Model 3240 end 3250 CoseiR Choeeer Manual Generic installation Instructions 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 Main Drive Pulley on Combine combinc side wall Remove this main drive pulley and have a small groove machined into its face to match the lip on the chopper drive pulley. Q~E~J 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 5/16” bolts. Figure 11: Attaching the Chopper Drive Pulley to the Main Drive Pulley. Redekop Industries Model 3250 Chopper for CaseiH 1680, 1688 Installation Manual Chopper Diive Installing the Redekop Chopper Drive 1. Remove the four bolt and support brace from the combine and affach the gear box frame in place using the original bolts as shown in Figure 12. Do not lighten these bolts fully at this time. IMPORTANT: Fastening a rope belween 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 _~ ~ ~ I Fill gear box with oil before operating! Note: The gear box manufacturer recommends the use of nigh qua lily 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. 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 combines 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 rear side of the gear box frame as shown in Figure 13. 3. TIghten the spring until the washer touches the metal sleave surrounding the bolt. Fasten idler mount with 1/4 bolt and Fender washer. 0 6” double belt idler. Attach to bracket with 5/6” x ~-1/2” bolt and 5/6” washers as spacers. Figure 13: Upper Chopper Drive Tightener Installation. Redekop Industries Model 3250 Chopper for CoselH 1680, 1688 InstallatIon Manual Chopper Drive a 1 Reinforce the gear box frame by installing the Iwo braces as shown in Figure 14. Adjust brace B so that the gear box frame does not contact the main drive pulley and then tighten the four bolts fastening the gear box frame to the combine, Attach brace to existing bolt on pillowblock mount. Enlarge existing hole on combine to 1/2. IMPO~TAN11 -Mjust brace ~‘ to allow a small clearence between the main tlrive pulley an~ gear box frame before tightening the four gear box frame bolts. Figure 14: Top View of Gear Box Frame. 2. Install the Iwo sheaves on the gear box as shown in Figure 15. To ensure proper drive alignment, the 3B6.6 sheave should be left untightened until the rest of the drive is completed. Caution: Do not overtighten the bushings on the caste sheaves, Excessive tightening can cause the sheave to crack, 3~S.G sheave SD l-~IS bushing 2~9.4 sheave sic 1-3/S bushing Figure 15: Installation of Sheaves on the Gearbox. Redekop Industries Model 3250 Chopper for Caseli-I 1680, 1688 Installation Manual Chopper Drive Installing the Redekop Chopper Drive 1. Move the Iwo speed drive lever to the position shown in Figure 15 by drilling a new hole In its bracket as close to the forward edge as possible. On some combine models this drive lever will still interfere with the top idler pulley after moving it to this position. In this case, the lever can be given a slight bend away from the pulley to give adequate clearance. 2. Attach idler bracket in place on top using the existing bolts on the combine channel Iron. The bracket should line up with the Iwo holes shown in the diagram. Drill out the Iwo bottom holes and fasten using 3/8’ bolts. 3. GrInd or torch off the corner of the radiator bracket shown in Figure 15 to make room for the idler pulley. 4. Install the idler pulley using a 5/8” x 2-1/2” bolt and lockwasher, and the tapered spacer with adjustment arm as a spacer behind the idler. 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. Grind or torch off this corner of the radiator mount to make room for idler. Figure 15: Installation of the Upper Idler Bracket, 5. Install the main idler bracket in place using 7/16” x 1-1/4” bo[ts (see Figure 16). 2. Assemble the Iwo 9” idlers on the lower idler combination using 5/8’ x 4” bolts and the 11/4” spacers in belween the pulleys and bracket, The lower idler also uses a belt guard as shown in the 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. Figure 16: Installalion of the Lower Idler Bracket. Redekop IndustrIes Model 3250 Chopper for CaselH 1680, 1688 InstallatIon Manual Chopper Ddve I REDEIKOP 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 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 the1 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 Chopper which shall have been installed or operated in 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 iñanufacturer has its warranty nor to normal maintenance or replacement of normal service items. Manufacturer reserves the right to modify, alter, 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 WARRANTy, AND THE MANUFACTURER’S OBLIGATION HEREUNDER, IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED, IMPLIED, OR OF FITNESS 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 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. rD~s(O!p IU3~I2’S SS~c4TOO~ ~