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REDEKOP MAV - 220 Installation Manual

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TM
MAV - 220
Case IH AFX 120, 230, 240 & 250 Series
Model Year 2017 (MY17) - 2021 (MY21)
Field Chopper Installation Guide
CS0297-01_R4_Jan_2021
1

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Summary of Contents for REDEKOP MAV - 220

  • Page 1 MAV - 220 Case IH AFX 120, 230, 240 & 250 Series Model Year 2017 (MY17) - 2021 (MY21) Field Chopper Installation Guide CS0297-01_R4_Jan_2021...

  • Page 2: Table Of Contents

    Case IH AFX 230 & 240 Series Complete Redekop MAV Chopper Installation Manual Table of Contents Section Safety Air Tank DEF Tank Relocation Preparation 230/240S DEF Tank Relocation 230/240S Hydraulic Line Modification Sieve Extension Chaff and Internal Deflectors AFX Ladder...

  • Page 3: Air Tank

    Case IH AFX 230 & 240 Series Complete Redekop MAV Chopper Installation Manual Component Reference 1A. Air Tank - 240S 1B. Air Tank - 230S 2. DEF Tank 4. Hydraulic Lines 5. Sieve Extension 6. Chaff Deflectors 7. AFX Ladder 8.
  • Page 4 Supplies required to assist during the installation procedure: Requirements: Marker Drill Drill bit - 10mm dia or 13/32 in dia. - required for section 3.9.4 Drill bit - 12mm dia or 1/2 in dia. - required for section 3.1.4 Pipe Sealant Tape - required for section 1.4 DEF parts required for 240 Series, section 3.7...
  • Page 5 This instruction manual explains the proper procedure for preparing the combine and removing the Factory Spreader Components in order to install the Redekop MAV Chopper 0.2 Recognize Safety Information 0.2.1 This is a safety-alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury.
  • Page 6 0.5 Safe Operating Practices 0.5.1 DO NOT stand near the straw chopper and Seed Control Unit when combine is running. ALWAYS refer to your Combine Operator’s Manual, and review the Safety section before operating machine. The Combine Operator’s Manual details safe operating practices that must be followed to protect you and others from accidental injury and/or death.
  • Page 7 0.8 Block Wheels 0.8.1 Park the combine on level ground. Always engage the park brake and block the combine wheels prior to working to prevent the combine from moving. 0.9 Practice Safe Maintenance 0.9.1 Understand service procedure before doing work. Keep area clean and dry.
  • Page 8 0.12 Avoid High-Pressure Fluids 0.12.1 Inspect hydraulic hoses periodically - at least once per year - for leakage, kinking, cuts, cracks, abrasion, blisters, corrosion, exposed wire brand or any other signs of wear or damage. Replace worn or damaged hose assemblies immediately. Escaping fluid under pressure can penetrate the skin causing serious injury.
  • Page 9 0.15 Personal Protective Equipment (PPE) 0.15.1 A Qualified Person designated by the employer, who is knowledgeable about and familiar with all relevant specifications and assembly instructions and is capable of identifying existing or potential hazards in surroundings or working conditions which may be hazardous or dangerous to employees shall determine appropriate Personal Protective Equipment required for this assembly.
  • Page 10 0.18 Fire Extinguisher 0.18.1 A 6 kg (15 lb) general-purpose fire extinguisher meeting national certification requirements must be installed on left side of operator’s platform. Maintain fire extinguisher to keep it in operating condition. Make sure that the fire extinguisher is always ready for use.
  • Page 11 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) M10 - flanged 54 / (40) 57 / (42) - non flanged 49 / (36) 70 / (51)
  • Page 12 Master Power 1. Shut off engine, remove keys from the combine cab 2. Block wheels on level ground 3. Lift up the left rear side access panel (A) 4. Turn Master Power Off (B) 1 Air Tank Removal / Relocation - if equipped - 230 Series only 1.1 Drain Air Tank...
  • Page 13 1.3 Remove Air Tank 1.3.1 Remove hardware (B1) from air tank straps (B) x2 holding the air tank (A) in place 1.3.1.1 Remove air tank (A) - to be reinstalled at a different location 1.3.2 Remove hardware (C1) x2 mounting the bottom air tank mounting bracket (C) to combine wall 1.3.3 Remove hardware (D1) x2 mounting the top air tank mounting bracket (D) to combine wall...
  • Page 14 1.4 Air Fitting Relocation 1.4.1 Remove existing fittings (A1 & A2) from air tank (A) 1.4.2 Apply sealant tape (A3) to ends of fittings (A1 & A2) 1.4.3 Reinstall fitting (A1) into end of air tank (A) 1.4.4 Reinstall fitting (A2) into body of air tank (A)
  • Page 15 1.5 Air Tank Mount Bracket Installation Parts List: parts located in CS970S box hardware located in CS510S bag CS862B Air Tank Mount Bracket (B) Qty 2 1.5.1 At right rear corner of combine, remove upper hardware (C1) x2, mounting brace (C) x2 to combine wall 1.5.2 Mount new air tank mount bracket (B) x2 to front side of mounting braces (C) with: - M12 x 25 flanged head bolts and flange nuts (B1) x4...
  • Page 16 1.5.4 Mount air tank (A) into mounting brackets (D) - ensure end with fitting (A1) is facing rearward 1.6 Air Hose Installation Parts List: parts located in CS970S box CS860-01 Air Hose 3/8 x 16ft (E) Qty 1 RP836 Fitting Tee Air Push In .375 (F) Qty 1 RP837 Fitting Air .375 Push In .25 NPT Nip (G) Qty 1...
  • Page 17 1.6.3.1 Run air hose (E) up under top platform over to new location of air tank (A) 1.6.3.2 Connect air fitting (G) to air tank fitting (A1) 1.6.3.3 Connect air hose (E) to air fitting (G) 1.6.4 Secure air hose (E) to combine with tie straps (E1) as required...
  • Page 18 2 Diesel Exhaust Fluid (DEF) Tank Relocation Preparation - 230/240 Series 2.1 Drain DEF Tank 2.1.1 Open drain valve (A1) at bottom of DEF tank (A) 2.1.1.1 Drain fluid into a clean container (A2) 2.2 Remove Top Left Corner Panel 2.2.1 Remove hardware (B1) x2 mounting the top left rear corner panel (B) to the combine top frame - to be reinstalled...
  • Page 19 2.3 Remove Rear Support Arm 2.3.1 Remove hardware (C1) x4 mounting the rear support arm (C) to rear support bracket (E) 2.3.2 Remove pin, spring, rubber stop and hardware (C2) - to be reinstalled - bracket (C) not to be reused 2.4 Remove Rear Support Bracket 2.4.1 Disconnect wire harness connector (D1) from light 2.4.1.1 Tie up wire harness (D1) into corner panel (B)
  • Page 20 2.5.2 Remove hose clamps (F1) from DEF conduit (F) 40 Series has vent line bolted above DEF line which is to be moved and reattached with bracket provided 40 Series DEF lines only 2.5.4 Loosen hose clamp (H1) from DEF fuel fill line (H) 2.5.4.1 Remove DEF fuel fill line (H) from DEF tank inlet (A) 2.5.4.2 Seal (A3) top of DEF fuel tank inlet (A) to...
  • Page 21 2.6 Remove Left Fuel Tank Left fuel tank is standard on the 9240 and an option on the 8240 Required in order to move Def tank back to provide space for the chopper drive system Parts List: parts located in CS971S bag H17-10 Plug, ORFS 1-14 5/8 Tube (201-913) (A) Qty 1 H15-16 Plug, ORB 1-5/16-12 1.0 Tube (273916) (B) Qty 1...
  • Page 22 2.6.1 Disconnect LH Tank Cross-Over LIne 2.6.1.1 Add plug (A) 2.6.2 Remove LH Tank Vent LIne...
  • Page 23 2.6.2.1 Remove Tank Cover Plate 2.6.2.2 Remove hose and tank fitting...
  • Page 24 2.6.2.3 Install plug (B) 2.6.3 Remove fuel tank mounting brackets and fuel tank as required - parts are not to be reused...
  • Page 25 3 Diesel Exhaust Fluid (DEF) Tank Relocation Installation 230/240 Series Parts List: parts located on pallet and in CS917BS and CS970S boxes CS890B Hanger Front DEF AFX (A) CS829B Bracket Rear DEF Hanger (B) Qty 1 Qty 1 CS829_TEMPLATE Bracket Rear DEF Hanger (B1)Qty 1 CS826B Bottom DEF Mount Plate (C) Qty 1 CS891B Bracket Top DEF Guide (E)
  • Page 26 3.1 DEF Tank Installation Parts List: parts located on pallet and in CS917BS box hardware located in CS850S bag CS890B Bracket Front DEF Hanger (A) Qty 1 Bracket Rear DEF Hanger (B) CS829B Qty 1 CS826B Bottom DEF Mount Plate (C) Qty 1 CS829_TEMPLATE Bracket Rear Def Hanger (B1) Qty1 (located in CS970S)
  • Page 27 Not Required for MY17 & Current Machines Holes are in Frame Steps 3.1.2 to 3.1.4.2 3.1.2 Remove hardware (F2) mounting bracket (F1) to top combine frame (F) 3.1.3 Attach template (B1) to top combine frame (F) with mounting bracket (F1) and hardware (F2) Note: Not required for MY17 - holes are in the frame 3.1.4 Mark holes (B3) x2 through holes in template (B1) onto frame (F)
  • Page 28 3.1.6 Install rear DEF hanger bracket (B) to the top rail (F) holes (B3) just drilled with: - M12 x 30 flange bolt and flange nut (B4) x2 3.1.7 Assemble CS891B Bracket Top DEF Guide (E) to front DEF hanger bracket (A) with: - M8 x 20 round head bolt and flange nut (B) x2 3.1.8 Install front DEF hanger bracket (A,E) to the top combine rail frame (F2), with existing hardware:...
  • Page 29 3.1.9 Place DEF tank (A2) into place in to hangers (A) and (B) 3.1.10 Connect bottom of hanger brackets (A) and (B) together below DEF tank (A2) with: - M10 x 25 flange bolt (A3) x2 3.1.10.1 Connect bottom of hanger brackets (A) and (B) to bottom DEF tank mount plate (C) with: - M12 x 30 flange bolt and flange nut (C3) x2 3.1.11 Install top DEF mount guide (E) to top of front...
  • Page 30 3.2 Bracket def ventilation mount Installation Parts List: part located in CS917BS box hardware located in CS850S bag CS835B Bracket def vent mount - Black (G) Qty 1 Use on 240 Series only 3.2.1 Mount def vent mount bracket (G) beside air tank (G1) with: M10 x 25 flange bolt (G2) x1, M10 flange Nut (G3) x2 3.2.2 Mount Factory Vent (G4) on the top hole of (G)
  • Page 31 3.4 Bracket Panel Lock Installation Parts List: part located in CS917BS box hardware located in CS850S bag CS786B Bracket Panel Lock - Black (I) Qty 1 3.4.1 Mount Bracket Panel Lock (I) thru the top side holes in the Arm Panel Latch (H) with: M8 x 20 flange bolt and flange nut (H2) x2 3.5 Existing DEF harness re-attacment Parts List:...
  • Page 32 240 Series Only 3.6 Plastic Cable Loom 52 in long Installation Parts List: parts located in CS970BS box RP925 Harness Electric 3W x 7ft AMP - 240S (J) Qty 1 CS905-01 Plastic Cable Loom 52 in long (K) Qty 1 230 Series DEF lines not extended 3.6.1 Connect harness (J) at the top roof of combine to into the socket (J1)
  • Page 33 3.7 240 Series DEF Line Extension - not required for 230 Series 240 Series MY17 - Order DEF Bundle From CNH Service Parts 3.7.1 47776423 DEF Bundle - Tank to Supply Module...
  • Page 34 3.7.1.1 47776423 DEF Bundle - Tank to Supply Module...
  • Page 35 3.7.1.2 47776423 DEF Bundle - Tank to Supply Module 47776423 DEF Bundle can be replaced with 48037151 or extended using procedure below ** Full 750mm extension required ** 9.9.1 47776423 DEF Bundle - Tank to Supply Module...
  • Page 36 3.7.2 Extending DEF Lines 3.7.3 Extending Coolant Lines...
  • Page 37 3.7.4 47776423 DEF Bundle - Tank to Supply Module...
  • Page 38 3.9 DEF Tank Fill Tube Relocation Parts List: parts located in CS917BS box CS805B Bracket Def Fill Tube Mount (J) Qty 1 CS975B Bracket DEF Fill Guard (M) Qty 1 Decal #47692590A (O4) (not supplied) Qty 1 CS805_Template DEF Fill Bracket Template (T) Qty 1 (located in CS970S kit) Note: Template works for MY17 only 3.9.1 Loosen hose clamp (O2) around filler tube (O1) at...
  • Page 39 3.9.3 Reinstall DEF Filler Hose (K) to the DEF Tank (A1) - tighten hose clamp Not Required for MY17 & Current Machines Holes are in Deck Step 3.9.4. 3.9.4 Drill 10mm (13/32in) holes (O3) x4 into the floor to mount filler tube bracket (J) Use CS805_Template (T) Note: Not required for MY17 Machine 3.9.5 Reattach DEF filler hose (K) to the DEF Tank filler...
  • Page 40 3.9.7 Install DEF fill hose guard (M) on upper platform underneath hose to protect from sharp edges, with: - M8 x 20 flange bolt and flange nut (M1) 3.10 Rear Left Light Components Install Parts List: to be re-installed from the factory assembly Rear Left Light (P) Qty 1 Body panel Door Pin (R)
  • Page 41 4 Hydraulic line modifications Not Required for MY17 & Current Machines Hydraulic Line Modified Steps 4.1 to 4.3.9 Reference: A - Pump A1 - Pump Connection B - Hydraulic Steel Tube (to be removed) B1 - Hydraulic Steel Tube Connection C - Hydraulic Steel Tube Clamp D - Hydraulic Hose Return Line Connection...
  • Page 42 4.1 Hydraulic line changes at PTO ** If available - use vacuum at reservoir to reduce oil leakage ** Parts List: parts located in CS970S Field Install box and CS971S bag hardware located in CS839S bag HH112 Hydraulic Hose .625 x 148L (I) Qty 1 H99-12 Hose Clamp .75 (L) Qty 8...
  • Page 43 4.1.4 Remove hose clamps (C) securing hydraulic steel line (B) on outside of left combine wall (drive side). - qty as required 4.1.5 In combine upper access panel - Quickly disconnect hydraulic steel line (B) from fan side hydraulic line (E) at fitting (B2) - have a container ready to catch any fluid that may leak - plug end of steel line removed or drain fluid in line after disconnecting...
  • Page 44 4.1.8 Disconnect outter hydraulic steel line (B) from inner hydraulic steel line at fitting (B1) - not to be reused Outter Inner 4.1.9 Rotate inner hydraulic steel line (B) and pull out left side of combine - not to be reused 4.1.10 Place new hydraulic rubber hose (I) from connection (B2) up along upper access edge (J) to the outside thru left combine side wall hole (same direction...
  • Page 45 4.1.12 Connect new hydraulic rubber hose (I) to pump (A) at fitting (A1) - have a container ready to catch any hydraulic fluid that may leak out from the pump (A) 4.1.13 Re-attach factory hose clamp bracket (K) to new hydraulic rubber hose (I) at connection (B2) in upper access 4.1.13.1 Cut plastic (K1) in half from steel line hose...
  • Page 46 4.1.15.1 Install 2 hose clamp assemblies at each corner (J1) 4.1.16 Install hose clamp assembly between (J1) onto hydraulic rubber hose (I) and steel line 4.1.17 Install hose clamp assemlbies x5 1.125 (18) (R) onto hydraulic rubber hose (I) and secure clamp .75 (12) (L) to hydraulic steel lines (E) - ensure clamps are tight and hose is not rubbing on any moving parts...
  • Page 47 4.1.19 Secure PTO Gearbox Return Tube Parts List: parts located in CS825S bag CS874Z Strap AFX Sump Line (M) Qty 1 H99-20 Hose Clamp 1.25 (P) Qty 1 4.1.19.1 Secure PTO Gearbox Return Tube (N1) to combine tensioner bracket (N2) with Strap (M) 4.1.19.2 Ensure PTO Gearbox Return Tube (N1) is 110mm (4 inches) max from PTO Reservoir (N) - tap tube (N1) into PTO Reservoir (N) as required...
  • Page 48 4.1.19.3 Attach strap (M) to bottom of combine tensioner mount bracket (N2) with: - M8 x 25 flange bolt and flange nut (M1) 4.1.19.4 Attach hose clamp 1.25 (-20) (P) to tube (N1) and fasten to clamp (M) with: - M8 x 25 flange bolt and flange nut (M1) View from above - looking down View from below - looking up...
  • Page 49 4.2 Return Line Changes - if equipped with hydraulic knifebar valve (A) ** This procedure is easiest when upper internal access panel is removed ** Parts List: parts located in CS970S field install box and CS971S bag H17-10 Fit Hyd Plug Hex 10 MORFS (B3) Qty 1 H38-1010FFX Fit Hyd 90deg 10 MORFS-10FORFSX (E)
  • Page 50 4.2.3 Disconnect steel hyd line (D) from tee fitting (C) 4.2.4 Remove hose clamp (D1) from steel hyd line (D) 4.2.5 Remove steel hyd line (D) - not to be reused 4.2.6 Disconnect tee fitting (C) from hyd line/fitting (C1) Reference illustrating hydraulic steel tube (D) being removed 4.2.7 Assemble hydraulic fittings into configuration as...
  • Page 51 4.2.9 Connect new hydraulic rubber line (F) to new hydraulic fitting assembly (EA) at end (E2) 4.2.9.1 Connect new hydraulic rubber line (F) to hydraulic knifebar valve (A) - use same routing as hydraulic steel line (D) just removed 4.2.10 Connect hydraulic hose (B) from reservoir tank to new hydraulic fitting assembly (EA) at end (E4) - quickly remove plug (B1) from end of hose (B) and connect to minimize oil leakage...
  • Page 52 4.3 Return Line Changes - if NOT equipped with hydraulic knifebar valve (A) (Relocation of reservour hydraulic line) Parts List: parts located in CS970S field install box and CS971S bag H17-10 Fit Hyd Plug Hex 10 MORFS (B1) Qty 1 H38-1010FFX Fit Hyd 90deg 10 MORFS-10FORFSX (E)
  • Page 53 4.3.5 Connect hydraulic fittings (E)(E1) to tee (J) - rotate fittings down 4.3.6 Connect hydraulic hose (H) to fitting (E) at end (E2) 4.3.7 Ensure all connections are tight 4.3.7.1 Orientate fittings (G) in line with belt (G1) 4.3.8 Secure hydraulic hose (H) - use tie straps and tube clamps 4.3.9 Reinstall upper access panel (F) with existing CASE Hardware...
  • Page 54 5 Sieve Extension Installation 5.1 Sieve Extension Installation Parts List: parts located on pallet CS857BS hardware located in CS625S bag CS1037BA Sieve Extension Assy AFX (A) Qty 1 5.1.1 Remove existing nuts and flat washers (B3) x4 from bottom of grain loss monitor pan (B) 5.1.2 Install sieve extension assembly (A) to the bottom of grain loss monitor pan (B) on to existing bolts (B2) 5.1.3 Mount side of sieve extension assembly (A) to...

  • Page 55: Chaff And Internal Deflectors

    Qty 2 Case IH Internal Chopper INTERNAL DEFLECTOR SETTING The internal deflectors (B) are used to adjust and distribute straw evenly into the Redekop Straw Chopper 6.1.1 Mount baffle mount plates (A) flush with top of pan (C) with: - M10 x 20 flange head bolt and flange nut x4 6.1.2 Mount deflector fins (B) to 2nd inside...
  • Page 56 6.2 Chaff Deflector Installation Parts List: parts located in CS974BS box hardware located in CS625S bag CS599BAL Sieve Ext. Deflector Lt Assy (DL) Qty 1 CS599BAR Sieve Ext. Deflector Rt Assy (DR) Qty 1 6.2.1 Place each deflector (DL & DR) at each end of the sieve (E1) 6.2.2 Attach bottom of deflector (DR) into existing holes with:...
  • Page 57 7 Ladder Installation Kit Overview Parts List: Parts located on pallet and in CS975BS box Plate Ladder Mount Left (AL) CS1008BL Qty 1 CS1008BR Plate Ladder Mount Right (AR) Qty 1 CS811BL Bracket Front Subwall Mount Left (CL) Qty 1 CS811BR Bracket Front Subwall Mount Right (CR) Qty 1 CS669 Belt Roof Seal (Y)
  • Page 58 7 AFX Ladder Installation 7.1 Ladder Mount Installation Parts List: parts located in CS975BS box hardware located in CS859S bag CS1008BL Plate Ladder Mount Left (AL) Qty 1 CS1008BR Plate Ladder Right Right (AR) Qty 1 CS944BL Bracket Top Skin Mount Left (BL) Qty 1 CS944BR Bracket Top Skin Mount Right (BR) Qty 1...
  • Page 59 7.2 Bracket Front Subwall Mount Installation Parts List: parts located in CS975BS box CS811BL Bracket Front Subwall Mount Left (CL) Qty 1 CS811BR Bracket Front Subwall Mount Right (CR) Qty 1 7.2.1 Mount right front subwall bracket (CR) to the right front corner of combine wall, with: - Do Not remove nuts (C1) - loosen nuts (C1) x3 enough to allow bracket to slip in...
  • Page 60 7.3 Ladder lift arm installation Parts List: parts located on pallet hardware located in CS859S bag CS927B Ladder Lift Arm (E) Qty 1 CS934Z Bolt Ladder Skin (F) Qty 2 CS935Z Washer Ladder Frame (G) Qty 2 CS976-01 Ladder Shim Plate (H) Qty 4 Reuse: 87105202 Pivot Tube Blocks (J)
  • Page 61 7.3.3 Ladder lift arm (E) installed view 7.4 Ladder Rail Extension 7.4.1 Ladder Rail Relocate Brackets Installation Parts List: part included in CS812BS box Bracket Ladder Rail Relocate (L) CS836B Qty 2 7.4.1.1 Install extension bracket (L) cup side down, over bottom rail mount tab with existing hardware: - M10 x 25 flange bolt and flange nut (L1) 7.4.1.2 Attach ladder rail (M) to underside of extension...
  • Page 62 7.4.2 Find factory Ladder (E2) from (Section 3.3.2 from Removal Guide) 7.4.3 Bracket Ladder Stop Installation Parts List: parts located in CS975BS box hardware located CS859S bag Top Ladder Step (N) CS1028B Qty 1 Ladder Bumper Spacer (P) CS948Z Qty 2 7.4.4 Assemble bracket ladder stop (N) on the top side of ladder (E2) by re-attaching factory rollers (E3) x4 with existing hardware:...
  • Page 63 7.4.5.1 With a strap (C2) tighten to keep ladder rails (M) aligned - Measure width of Ladder at rollers - Pull the rails slightly narrower than the Ladder width before tightening hardware, so they spring back to Ladder width 7.4.6 If 2nd mounting hole does not exist in ladder rail: Set the center to center rail spacing to 660 mm (26 inches).
  • Page 64 7.4.7 Reinstall existing rubber bumper (R) and new spacer (P) with: - M6 x 70 hex bolt and flange nut (R1) x1 - repeat for other side 7.5 Straw Door Linkage Bracket Installation Parts List: parts and hardware located CS859S bag CS1012Z Straw Door Clevis (S) Qty 1...
  • Page 65 Not Required for MY17 & Current Machines Holes are in Machine 7.5.2 Straw Door Linkage Bracket Installation Parts List: parts and hardware located CS961K 20S Conv Kit 84127251 Straw Door Clevis (T) Qty 1 84127251_TEMPLATE Template- 20s Straw Door Actuator (U) Qty 1 7.5.2.1 Center drill template (U) on the back side of the step mount frame and mark the hole locations (U1)
  • Page 66 7.6 Top Ladder Step Installation Parts List: part included in CS975BS box hardware located in CS859S bag CS1026B Step Top Ladder (V) Qty 1 7.6.1 Ensure ladder (E2) is mounted on ladder rails (M) prior to installing top step (V) 7.6.2 Slide ladder (E2) up until ladder top step is above floor of engine service area, hold or block in place 7.6.3 Install Top Step (V) onto upper flange (W) between...
  • Page 67 7.7 Ladder Connection to Ladder Lift Arm (E) 7.7.1 Reuse and Insert M8 x 90 flange bolts (X1) through the ladder backplate (E2) 7.7.2 Slide one (1) piece of factory pivot blocks (X) (Section 3.3.1 from Removal Guide) on to the bolts (X1) through ladder backplate 7.7.3 Pivot ladder lift arm (E) up to seat into pivot...
  • Page 68 7.8 Gas spring installation Parts List: Reuse Gas Spring from disassembly #47360439 Factory ladder gas spring (strut) (Y) Qty 2 Gas Spring is under load and will extend when released 7.8.1 Compress existing gas springs (Y) to 712mm (28 in.) long Short Stud (B) Longer Stud (C) - Order CS965BA Shock Compressor Tool (D) if required...
  • Page 69 7.8.2 Mount gas spring (N) onto the left side ladder lift arm (E) with: - factory hardware - Gas shock should be mounted rod end down Ensure Short Stud (B) is connected to ladder lift arm (E) Ensure Longer Stud (C) is connected to left ladder mount plate (AL) 7.8.3 Repeat for right side Ensure Short Stud (B) is connected to ladder lift arm (E)
  • Page 70 7.10 Panel Light Ladder Wall Installation Parts List: parts located on pallet hardware located in CS859S bag CS1041BAL Ladder Side Wall Panel Left (SL) Qty 1 CS1041BAR Ladder Side Wall Panel Right (SR) Qty 1 Pivot Tube Block (B) 87105202 Qty 2 (reused from Internal Straw Door) 7.10.1 Reinstall pivot tube block (B) x2 on both sides of...
  • Page 71 7.11 Handle Ladder AFX Assembly Installation Parts List: parts located in CS975BS box hardware located in CS859S bag CS950BA Handle Ladder AFX Assy (D) Qty 1 ** ensure wheels spin freely ** CS949B Ladder Handle Plate (F) Qty 2 CS951BR Ladder Handle Bracket Left (GL) Qty 1 CS951BL Ladder Handle Bracket Right (GR) Qty 1...
  • Page 72 7.11.5 See Pictures for reference Bolt and Hole locations for the Ladder Handle and Glamour Panel Assembly.
  • Page 73 7.11.6 Mount glamour panel (A3) onto factory Ladder when lower ladder (E2) is folded up, with: - M10 x 25 flange bolt and flange nut (G1) x4 7.11.6.1 Adjust bolts (G1) in slots to align the glamour panel with combine rear cowling when ladder is up. 7.11.7 Assembled ladder over view after Chopper has been mounted.

  • Page 74: Straw Door

    8 Straw Door Installation Clevis points to bottom of the door 8.1 Straw Door Assembly Installation parts located on pallet hardware located in CS859S bag Parts List: CS1010BA Straw Door Assembly (A) Qty 1 CS937Z Pin AFX Straw Door (C) Qty2 87547587 M10 Locknut (C1)
  • Page 75 8.1.3 Slide the straw door (A) up into the combine and alilgn pins (C) to the pivot tube blocks (B) 8.1.3.1 Slide the Pins (C) into the Pivot Tube Block (B) 8.1.3.2 Secure Pin (C) with existing hardware from 8.1.1: - M8 x 45 hex head bolt and hex nut (C1) - both sides 8.1.4 Straw door (A) installed...
  • Page 76 8.1.6 Case AFX Straw Door Sealing -Raise straw door to rear most position and apply a bead of RTV Silicone between the straw door pipe and roof. -Apply Silicone to any other openings 8.1.6.1 Case AFX Chaff Deflector Sealing - Apply silicone to front and bottom of the chaff deflector against sidewall of chopper...
  • Page 77 8.2 Top Filler Plates Installation Parts List: parts located in CS975BS box hardware located in CS859S bag CS468B Top Filler Plate (G) Qty 2 CS669-01 Roof Belt Seal (V) Qty 2 8.2.1 Install the roof belt seal (V) and plate (G): - first place roof belt seal (V) and then the top filler plate (G) to cover the open areas on the left and right side of combine top panel, with:...
  • Page 78 8.3 Straw Door Adjustment - Mechanical Linkage for Non-Windrow: - Mechanical Linkage for Windrow - order #CS861K - If combine is equipped with electric actuator - see Step 8.3.3 for installation Parts List: - parts located in CS975BS box - hardware located in CS859S bag CS910BA Straw Door Linkage Arm (D) Qty 1...
  • Page 79 8.3.3 Straw Door Adjustment for Electric Actuator: Parts List: - parts located in CS812BS box - hardware located in CS859S bag RP1058 Electric Actuator (E) Qty 1 CS960Z Stop Door Actuator (F) Qty 1 8.3.3.1 Mount base of actuator (E) to top bracket with: - M8 x 50 hex bolt, flat washer and lock nut (E1) 8.3.3.2 Slide arm of actuator (E2) through door actuator stop (F) and mount to plate (A1) on straw door with:...
  • Page 80 9 Chopper Installation 9.1 Remove Left Rear Gusset Support Brace 9.1.1 Check existing left gusset brace (B) on combine, if it only has two (2) holes in plate, replace as per following steps. If it has four (4) holes, skip step 9.1 and installation of new brace 2 Holes 4 Holes...
  • Page 81 9.2 Install Redekop Chopper Parts List: Chopper is located on pallet parts are located in CS970S box CS531BA2 AFX 40S Chopper (A) Qty 1 CS796B Gusset Support Brace (C) Qty 1 This component weighs 1500 lbs / 680 kg Use a forklift with appropriate...
  • Page 82 9.2.1 Install new gusset support brace (C) to left rear side of combine, with existing hardware: - M16 x 40 hex head bolt and washers (B2) x2 - do not tighten - leave loose 9.2.2 Fasten chopper (A) to the combine and gusset support plate (B) - right side, with existing hardware: - M12 x 120 flange bolts and flange nuts (B1) x4 - may have to pry the chopper top side plate to align and...
  • Page 83 9.3 Ladder Proximity Sensor Mount Plate Installation Parts List: part included in CS975BS box hardware located in CS859S CS857B Ladder Proximity Sensor Mount Plate (J) Qty 1 9.3.1 Install proximity sensor mount plate (J) on to upper side wall flange (L) with: - M12 x 25 flange bolt and flange nut (J1) x2 9.3.2 Relocate existing ladder proximity sensor (K) and install on new mount plate (J) in hole (K1)
  • Page 84 9.4 Chaff Deflector Plate Installation Non-Windrow Parts List: parts included in CS975BS box hardware located in CS859S CS1073BAL Chaff Deflector Left (ML) Qty 1 CS1073BAR Chaff Deflector Right (MR) Qty 1 Windrow Parts List: parts included in CS812BS box hardware located in CS859S CS1054BAL Chaff Deflector Left (ML) Qty 1 CS1054BAR Chaff Deflector Right (MR)
  • Page 85 9.6 Sheave AFX PTO 3B Installation Parts List: part located in RP918S box RP918 Sheave AFX PTO 3B (C) Qty 1 9.6.1 Remove the factory sheave (C1) - not to be reused - keep all hardware 9.6.2 Install new 3B Sheave (C) with: - existing hardware Torque to 95-105 N*m - ensure key is in place...
  • Page 86 Chopper Drive 3B Jackshaft Installation Parts List: parts located on pallet and in CS918BS box and CS970BS box hardware located in CS825S bag CS772B Gusset JackShaft Mount (A) Qty 1 CS771BA Jackshaft AFX 3B 230/240S Assy (B) Qty 1 CS883B Gusset JackShaft Mount 20 Series (A) Qty 1 RP918 Sheave AFX PTO 3B (C)
  • Page 87 10.1 Top Jackshaft support gusset installation Parts List: part located in CS918BS box hardware located in CS825S and CS839S bag CS772B Gusset JackShaft Mount (A) Qty 1 CS883B Gusset JackShaft Mount 20 Series (A) Qty 1 10.1.1 Install gusset jackshaft mount (A) on the outside of left combine side wall thru existing holes with: - M12 x 40 flange bolt and flange nut (A1) x2 - M16 x 50 flange bolt and flange nut (A2) x2...
  • Page 88 10.2.2 Secure top jackshaft mount bracket (J1) to the gusset jackshaft mount (A) with: - M12 x 30 flange bolt and flange nut (B1) x2 10.2.3 Mount jackshaft assembly (B) in place by attaching lower jackshaft mount bracket (J2) to combine’s replaced gusset with: - M12 x 40 round head bolt and flange nut (B2) x2 Round head bolts (B2) to be...
  • Page 89 - Align the Jackshaft Outter Sheave (J4) to the Combine PTO Sheave (J3) with laser alignment tool. Note: Laser Alignment Kit can be purchased from Redekop if required. Part # RP956. - Alignment can be corrected by moving bottom Gusset CS796B found in step 9.2.1.
  • Page 90 10.4 Spring Tensioner Assembly Installation for Internal High Speed OEM Chopper Belt Parts List: High Speed Tensioner Assembly (G) located in CS918BS CS784B Spring Assy Weld Int Chopper HS (J1) Qty 1 CS797Z Indicator Internal Chopper HS Spring (A4) Qty 1 CS856Z Spacer (A5) Qty1 Washer Flat M12 x 24 x 2.5 Yzd (B1)
  • Page 91 10.5 Re-install Drive Belts Parts List: Belts located in CS771BS Kit BE2B117K VBelt 2B x 117L (J) Qty1 BE3B88K VBelt 3B x 88L (K) Qty 1 VBelt 3B x 135L (L) BE3B135K Qty 1 AFX 120 Series Only Belt Located in CS961K Kit 86976208 VBelt 3B 2720mm (M) Qty 1...
  • Page 92 10.5.3 Install V belt BE3B88K (L) onto the upper sheave (J3), route around idler (L2) and install on to sheave (J5) on jackshaft 10.5.4 Install V-belt BE2B117K (N) onto the upper sheave (J3) outter grooves and to large drive sheave (C) on combine...
  • Page 93 10.5.5 Adjust tension on belts: 10.5.6 To adjust the tension on the belt, the idler needs to be adjusted to apply the correct tension to the belt 10.5.6.1 To apply idler tension (K2, L2, M2), adjust nut (T1) on tension rod (K1, L1, M1) to tighten spring (T2) until it lines up with the spring indicator (T3) - typical for all belts except J 10.5.6.2 To apply idler tension (J2), adjust nut (T1) on...
  • Page 94 10.8.5 Attach CASE IH speed sensor (F3) to existing mount plate (D) with: Note: mount plate (D) is replaced with (D2) on 20S and may have to be replaced with (D2) on pre 40S in order for sensor to read off of alternate tooth pattern CS833Z Speed Sensor Mount Plate Hardware included in CS622BS box - bag CS955S - .5-20 hex jam nut (F6)
  • Page 95 10.10 Windrow Hydraulics Installation - Optional Parts List: parts located in CS919S box: H30-1010MF Fitting Hyd 45 Deg (C) Qty 2 HH115 Hyd. Hose .625 x 61L (D) Qty 2 H28-1012FF Fitting Hyd Str (X) Qty 2 87000151 Hyd Hose Tube Clamp (G) Qty 4 1186005 Hyd Hose Clamp Plate (G1)
  • Page 96 10.10.6 Run hydraulic lines (D) below the def tank, along chopper wall and through the jackshaft frame 10.10.7 Attach hydraulic hoses (D) to chopper wall with: - hose clamps (G) x2 - hose clamp plate (G1) x1 - M8 x 70 hex head bolt and lock nut (G2) 10.10.8 Attach hydraulic hoses (D) to jackshaft frame hose support plate with: - hose clamps (G) x2...
  • Page 97 11 Chopper Drive 3B Jackshaft Shield Installation parts located on pallet hardware located in CS825S and CS625S bags Parts List: RP997 Shield Case AFX MY20 (A) Qty 1 RP998 Vent AFX w/Notch Left (B) Qty 1 RP1001 Vent AFX w/Notch Rightt (C) Qty 1 CS1035Z Vent Pin Mount (D) Qty 4...
  • Page 98 11.3 Install shield latch bracket (G) to jackshaft (B), with - M10 x 25 flange bolt (G1) x2 11.4 Install hose mount bracket (J), upper shield support bracket (H) then belt guide (B1) on jackshaft (B), - M10 x 25 flange bolt (H1) x3 (reuse 2 from belt guide) 11.5 Install shield on to pins and brackets on chopper and jackshaft.
  • Page 99 12 Tailboard Control 12.1 Gas Shock Installataion Parts List: part included in CS974BS box hardware located in CS625S bag RP951A Gas Spring (S) Qty 2 12.1.1 Install gas shock (S) on to chopper and tailboard studs, with: - M8 x 20 flange bolt (S1) x2 - both sides 12.2 If your combine is equipped with electric actuators: Parts List:...
  • Page 100 12.2.1 Install tailboard actuator tube limiter (E) to chopper, with: - M8 x 50 round head bolt, flat washer spacer bushing and flange nut (E1) - both sides Note: Tailboard stop (F) can be adjusted if tailboards do not line up 12.2.2 Install gas shock (S) on to chopper and tailboard studs, with: - M8 x 20 flange bolt (S1) x2...
  • Page 101 Case IH 12.4 If your combine is NOT equipped with electric actuators and you require a mechanical control, order kit #CG314K from Redekop Manual Control 12.4.1 Remove electric actuator mount brackets and tailboard lug stop (D, E & F) from chopper housing - both sides 12.4.2 Install tailboard adjustment lug CG314B (F) to...

  • Page 102: Hydraulic Oil Level

    13 Hydraulic Oil Level CHECK HYDRAULIC DO NOT RUN THE COMBINE FITTINGS FOR LEAKS WITHOUT HYDRAULIC OIL 13.1 Check the hydraulic oil level before starting and moving the combine. Oil level can be checked through the sight glass (A) located on the top rear deck. The oil level should at a minimum reach the bottom of the sight glass.

  • Page 103: Afx 20S Roof Upgrade

    14 Case AFX 20S Roof Upgrade 14.1 If you have a 20 Series combine and you require a Roof Upgrade, order kit #CS961K from Redekop...

  • Page 104: Software Update

    15 Software Update 30 and 40 Series 15.1 Update software: Use the 240-Series EST to set the new configurations on 230-Series and 240-Series machines. (after the S/N break below) The new cab machines start at S/N YDG218540 Software update required is: UCM1 - V33.33.0.0 or newer, UCM2 - V33.34.0.0 or newer (for S/N above and newer) Display Software (Part # 48109497 Combine Axial Flow) V30.8.0.0 Machines <YDG218540 do not get software update and would require the spreader/chopper speed sensor placed on the 7-tooth target.
  • Page 105 50 Series 15.3 Procedure to configure in cab parameters for Redekop Chopper on AFX 15.3.1 Select Toolbox icon (A) 15.3.1 Select residue tab (B) 15.3.2.1 Select No (C1) 15.3.2 Select in Cab Chopper Speed (C) 15.3.3 Select in Cab Windrow Door (D)
  • Page 106 Scroll Bar 15.3.5 Scroll down the page and select Hood Mounted 15.3.4 Scroll down the page and select Chopper (E) Chopper (F) 15.3.4.1 Select Straw Hood Chopper (E1) 15.3.5.1 Select Yes (F1) 15.3.6 Scroll down the page and select Center Spread Deflector (G) 15.3.6.1 Select No (G1)
  • Page 107 Ensure that the CHECK HYDRAULIC Hydraulic Fittings have been FITTINGS FOR LEAKS tightened DO NOT RUN THE COMBINE WITHOUT HYDRAULIC OIL HYDRAULIC LINES MAY BE UNDER PRESSURE Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines.
  • Page 108 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) M10 - flanged 54 / (40) 57 / (42) - non flanged 49 / (36) 70 / (51)
  • Page 109 WARRANTY CARD Please send this warranty card in to Redekop Manufacturing Fill in when the Straw Chopper has been fully installed and the following items have been checked Email to: warranty@redekopmfg.com Fax to: +1-306-933-1088 Selling Dealer Name and Location: _______________________________________________________________...

This manual is also suitable for:

Case ih afx 120 seriesCase ih afx 230 seriesCase ih afx 240 seriesCase ih afx 250 series