REDEKOP MAV - 220 User manual

1
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

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Case IH AFX 230 & 240 Series
Complete Redekop MAV Chopper Installation Manual
Table of Contents
Section
Safety 0
Air Tank 1
DEF Tank Relocation Preparation 230/240S 2
DEF Tank Relocation 230/240S 3
Hydraulic Line Modication 4
Sieve Extension 5
Cha󰀨 and Internal Deectors 6
AFX Ladder 7
Straw Door 8
Chopper 9
Chopper Drive - 3B Jackshaft 10
Drive Shields 11
Tailboard 12
Hydraulic Oil Level 13
AFX 20S Roof Upgrade 14
Software Update 15

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1A. Air Tank - 240S
1B. Air Tank - 230S
2. DEF Tank
4. Hydraulic Lines
5. Sieve Extension
6. Cha󰀨 Deectors
7. AFX Ladder
8. Straw Door
9. Chopper
10. Chopper Drive - 3B Jackshaft
11. Drive Shields
12. Tailboard
13. Hydraulic Oil Level
Case IH AFX 230 & 240 Series
Complete Redekop MAV Chopper Installation Manual
Component Reference
1A
1B
4
2
9
12
7
13
6
8
11
5
10

4
Supplies required to assist during the installation procedure:
Requirements:
Laser Alignment Tool
Order RP956 if Required
- required for section 10.2.4
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
Decal
- required for section 3.6
- #47692590A Qty 1
Order from Case IH Parts system
Pipe Sealant Tape
- required for section 1.4
DEF parts
required for 240 Series, section 3.7
- 47777353 DEF Line w/ SV246 NG8
Elbow Connector Qty 2
- 47777447 Barbed Connector for DEF Line Qty 4
- 84480613 EPDN Hose 40” Qty 2
- 84480601 Hose Connector for coolant line Qty 4
- 86625022 Hose Clamp Qty 4
- 47655259 Tool Box Qty 1
Required parts will have to be ordered through Case IH
Parts system

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0 Safety
0.1 Introduction
0.1.1 IMPORTANT: Read through this instruction
thoroughly and familiarize yourself with the machine
before removing these components. Do not skip steps or
perform them out of order.
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.
Follow recommended precautions and safe operating
practices.
0.3 Understand Signal Words
0.3.1 A signal word - DANGER, WARNING, or
CAUTION - is used with the safety-alert symbol.
DANGER identies the most serious hazards.
WARNING or CAUTION safety signs are located near
specic hazards or precautionary areas in this manual.
0.4 Follow Safety Instructions
0.4.1 Carefully read all safety messages in this manual
and on your machine. Keep safety signs in good
condition. Replace missing or damaged safety signs. Be
sure new equipment components and repair parts include
the current safety signs. Replacement safety signs are
available from your dealer.
There can be additional safety information contained on
parts and components sourced from suppliers that is not
reproduced in this operator’s manual.
Learn how to operate the machine and how to use
controls properly. Do not let anyone operate without
instruction.
Keep your machine in proper working condition.
Unauthorized modications to the machine may impair
the function and/or safety and a󰀨ect machine life.
If you do not understand any part of this manual and
need assistance, contact your dealer.
Other languages are available for this machine. Please
contact Redekop

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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.
Operate Seed Control Unit only when all guards are
correctly installed.
Before moving away, always check immediate vicinity of
Seed Control Unit (e.g. for children). Ensure adequate
visibility. Use a horn as a warning immediately before
moving away.
When making turns, always take into consideration the
width of the attachment and the fact that the rear end
of the machine swings out. Attachments and ground
conditions a󰀨ect the driving characteristics.
Never leave combine unattended as long as engine is
running.
0.6 Work In Ventilated Area
0.6.1 Engine exhaust fumes can cause sickness or
death. If it is necessary to run an engine in an enclosed
area, remove the exhaust fumes from the area with an
exhaust pipe extension.
If you do not have an exhaust pipe extension, open the
doors and get outside air into the area.
0.7 Remove Key from Ignition
0.7.1 ALWAYS shut o󰀨 combine engine prior to working
on it.
Apply park brake, remove key and lock operators cab.
If the combine is equipped with an additional safety
master power switch, turn this to the Power OFF position.

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0.9 Practice Safe Maintenance
0.9.1 Understand service procedure before doing work.
Keep area clean and dry.
Never lubricate, service, or adjust Seed Control Unit
while it is moving. Disengage all power and operate
controls to relieve pressure. Lower equipment to the
ground. Stop the engine. Remove the key. Allow machine
to cool.
Keep hands, feet and clothing away from power-driven
parts. Tie long hair behind your head. Do not wear rings,
jewelry, a necklace, a necktie, scarf, or loose clothing
when you work near machine or moving parts. If these
items were to get caught, severe injury could result.
Securely support any Seed Control Unit elements that
must be raised for service work.
Keep all parts in good condition and properly installed.
Fix damage immediately. Replace worn or broken parts.
Remove any buildup of grease, oil, or debris.
On self-propelled equipment, disconnect battery ground
cable (-) before making adjustments on electrical systems
or welding on Seed Control Unit.
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.
0.11 Avoid Contact With Moving Parts
0.11.1 Keep hands, feet and clothing away from power
driven parts. Never clean, lubricate or adjust machine
when it is running.
Never attempt to clear obstructions from machine unless
it is disengaged, engine shut o󰀨 and key removed.
0.10 Guards and Shields
0.10.1 Keep guards and shields in place at all times.
Ensure that they are serviceable and maintained
correctly.

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0.14 Use Proper Lifting Equipment
0.14.1 Lifting heavy components incorrectly can cause
severe injury or Seed Control Unit damage.
Follow recommended procedure for removal and
installation of components in the manual.
Ensure lifting equipment is rated for the job
Ensure operator is appropriately licensed to operate
lifting equipment
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 uid under pressure can penetrate the skin
causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten all
connections before applying pressure.
Search for leaks with a piece of cardboard. Protect hands
and body from high-pressure uids.
If an accident occurs, see a doctor immediately. Any uid
injected into the skin must be surgically removed within
a few hours or gangrene may result. Doctors unfamiliar
with this type of injury should reference a knowledgeable
medical source.
0.13 Dispose of Waste Properly
0.13.1 Improperly disposing of waste can threaten the
environment and ecology. Potentially harmful waste
includes such items as oil, fuel, coolant, brake uid, lters
and batteries.
Use appropriate tools and personal protective equipment
such as clothing, gloves, face shields or glasses, during
the removal or handling of objects and materials.
Use leakproof containers when draining uids. Do not
use food or beverage containers that may mislead
someone into drinking from them.
Do not pour waste onto the ground, down a drain, or into
any water source.

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0.15 Personal Protective Equipment (PPE)
0.15.1 A Qualied Person designated by the employer,
who is knowledgeable about and familiar with all
relevant specications 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.
Personal Protective Equipment (PPE) are devices worn
by the employees to protect against hazards in the
environment. Examples include safety glasses, face
shields, respirators, gloves, hard hats, steel-toe shoes,
and hearing protection. Wear close tting clothing and
safety equipment appropriate for the job.
Operating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones
while operating machine.
0.16 Sound Level
0.16.1 This product produces sound pressure levels in
excess of 90 dB within 10m of discharge area.
Hearing protection is required!
Interference with speech communication, acoustic signals
is possible.
0.17 Prepare for Emergencies
0.17.1 Be prepared if a re starts.
Keep a rst aid kit and re extinguisher handy.
Keep emergency numbers for doctors, ambulance
service, hospital and re department near your
telephone.

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0.19 Remove Accumulated Crop Debris
0.19.1 The build up of cha󰀨 and crop debris in the
engine compartment, on the engine, and near moving
parts is a re hazard. Check and clean these areas
frequently.
0.20 In the Event of Fire
0.20.1 Stop work immediately at rst sign of re. This
may be the smell of smoke or the sight of smoke or
ames.
If a re can be safely extinguished, procedd carefully and
follow these guidlines:
1. Remove re extinguisher from bracket and carry it to
the area of re.
2. Approach area of re wind to your back.
3. Pull the safety pin out of actuating lever.
4. Hold extinguisher upright and aim hose at base of
ames.
5. Squeeze lever to discharge re extinguisher.
6. Move hose to cover the source of the re evely with
extinguishing agent.
CAUTION: Do not risk personal injurty. If a
re is too far advanced, do not try to extinguish it.
0.18 Fire Extinguisher
0.18.1 A 6 kg (15 lb) general-purpose re extinguisher
meeting national certication requirements must be
installed on left side of operator’s platform.
Maintain re extinguisher to keep it in operating condition.
Make sure that the re extinguisher is always ready for
use. Refer to the re extingisher’s manual for instructions
on how to operate it. Once extinguisher is operated - no
matter how long - it must be recharged.
Keep the engine clean and free of dust, cha󰀨 and straw
to prevent the possibility of re.

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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 - anged 27 / (20) 39 / (29)
- non anged 25 / (18) 35 / (26)
M10 - anged 54 / (40) 57 / (42)
- non anged 49 / (36) 70 / (51)
M12 - anged 93 / (69) 134 / (98)
- non anged 85 / (63) 121 / (90)
M16 - anged 231 / (171) 331 / (244)
- non anged 210 / (155) 301 / (222)

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Master Power
1. Shut o󰀨 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 O󰀨 (B)
1 Air Tank Removal / Relocation
- if equipped
- 230 Series only
1.1 Drain Air Tank
1.1.1 Open bottom valve (A1) on air tank (A) to release
air pressure
1.2 Disconnect Air Line
1.2.1 Remove bottom air line (A2) from Tee tting (A3)
1.2.2 Disconnect Tee tting (A3) from tting (A4) on air
tank (A)
A
B
A
A1
A
A4
A2
A3
A3
A4
A2

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1.3.2 Remove hardware (C1) x2 mounting the bottom
air tank mounting bracket (C) to combine wall
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 di󰀨erent location
1.3.3 Remove hardware (D1) x2 mounting the top air
tank mounting bracket (D) to combine wall
D1
A
B
B1
B
B1
D
D1
C1
C1 C

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1.4.1 Remove existing ttings (A1 & A2) from air tank (A)
1.4.3 Reinstall tting (A1) into end of air tank (A)
1.4.4 Reinstall tting (A2) into body of air tank (A)
A2
1.4 Air Fitting Relocation
1.4.2 Apply sealant tape (A3) to ends of ttings (A1 & A2)
A1
A
A2
A1
A3
A2 A3
A
A1

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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
B
C1
C1
C
1.5.2 Mount new air tank mount bracket (B) x2 to front
side of mounting braces (C) with:
- M12 x 25 anged head bolts and ange nuts (B1) x4
1.5.3 Mount existing air tank mount bracket (D) x2 to
mounting brackets (B) with:
- existing M12 x 20 anged head bolts and ange nuts
(D1) x4 from step 1.3.1
B1
B
C
D1 D1
D
B

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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
1.5.4 Mount air tank (A) into mounting brackets (D)
- ensure end with tting (A1) is facing rearward
1.6.1 Replace existing air tee tting (A3) with new tee
tting (F)
1.6.2 Insert new air hose (E) into tee tting (F)
1.6.3 Run air hose (E) up under top platform over to
new location of air tank (A) at right rear corner
Previous New
A3
A1
A
D
E
GF
E
F

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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 tting (G) to air tank tting (A1)
1.6.3.3 Connect air hose (E) to air tting (G)
1.6.4 Secure air hose (E) to combine with tie straps (E1)
as required
E
A1
G
E
E
E1
E1
E

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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 uid 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
A
A1
A2
A
B
B
B1

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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
(D)
2.4.1.1 Tie up wire harness (D1) into corner panel (B)
- to be reconnected
2.4.2 Remove hardware (E1) x4 mounting the rear
support bracket (E) to left combine wall and rear corner
panel (B)
2.4.3 Remove light (D) from support bracket (E)
- to be reinstalled
- support bracket (E) not to be reused
- Hoses will now be loose and will be reclampled into
place upon completion of the MAV Chopper
2.5 Prepare DEF Lines
2.5.1 Remove hose clamps (F1) from ground drive
hoses (F)
C2
C2
C
E2
D
C
C1
C1
E
E1
E
D
B
E1
D1
F
F1

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2.5.2 Remove hose clamps (F1) from DEF conduit (F)
A
2.5.4 Loosen hose clamp (H1) from DEF fuel ll line (H)
2.5.4.1 Remove DEF fuel ll line (H) from DEF tank
inlet (A)
40 Series has vent line bolted above DEF line which is to
be moved and reattached with bracket provided
2.5.4.2 Seal (A3) top of DEF fuel tank inlet (A) to
prevent contamination in the tank
DEF Tank relocation installation completed in section 3
40 Series DEF lines only
F
F1
G
G1
H1
H
A
A
A3