INSTALLATION MANUAL FOR. Mud Hog Front Wheel Drive FOR JOHN DEERE 4-WHEEL 6500 & 6600 SPRAYERS. Mud Hog Model Numbers: JD65004 JD66004 TUTHILL

Transcription

1 INSTALLATION MANUAL FOR Mud Hog Front Wheel Drive FOR JOHN DEERE 4-WHEEL 6500 & 6600 SPRAYERS Mud Hog Model Numbers: JD65004 JD66004 TUTHILL Drive Systems Brookston Indiana USA Revised 8/2010 P.N

2 TABLE OF CONTENTS INSTRUCTIONS AND SPECIFICATIONS... 3 SAFETY PROCEDURES... 4 I. REMOVING WHEEL SHIELD ASSEMBLIES... 5 II. STABILIZING MACHINE... 6 III. REMOVING ORIGINAL AXLES... 6 IV. REMOVING THE SHIELDS... 7 V. REMOVING THE HOOD... 7 VI. REMOVING SCREENS... 7 VII. MODIFYING SHIELDS AND SCREENS... 8 VIII. INSTALLING VALVE... 9 IX. INSTALLING HOSES X. ELECTRICAL INSTALLATIONS XI. RESERVOIR XII. INSTALLING MUD SCRAPERS WARRANTY... Back Cover 2

3 Instructions and Specifications INTRODUCTION This manual provides instructions for installing the Mud Hog Drive System on hydrostatic machines. Various machine options such as rear axle width and front tire size affect Mud Hog adaptation. These differences are specifically referred to in these instructions. Always follow the instructions which refer to the exact option configuration on the machine being converted. A complete pictorial breakdown of all the individual parts in the Mud Hog Drive System can be found in the Mud Hog Parts Catalog. Refer to this catalog for proper identification of parts required for service. GENERAL The terms right and left in these instructions are the same as the operators right and left hand when positioned in the operator s seat facing forward. IMPORTANT: Cleanliness is essential when installing or servicing hydraulic components. When making hydraulic connections, areas surrounding the connection should be steam cleaned or washed with solvent so that contamination will not enter the system. Always keep hoses and connectors and ports suitably capped or covered to keep contamination out of the system. CAUTION: Make sure that system pressure is relieved before disconnecting any lines or connections. Pressurized fluid escaping from the system can cause serious personal injury. TORQUE SPECIFICATIONS RECOMMENDED FOR USE WITH Mud Hog FASTENERS Recheck all bolt & nut torque after 1 hour s use and again after first day of use. Periodically check tightness every 100 hours of use thereafter. Note: bolts that require Loctite should not be re-tightened once Loctite has had time to cure. Note: When using original equipment fasteners, adhere to manufacturers recommended specifications. GRADE 8 (GRADE 10.9 METRIC) BOLTS AND GRADE C LOCKNUTS SIZE BOLT TORQUE[1] LOCKNUT TORQUE[2] (S.A.E.) (ft.lbs.) (ft.lbs.) 1/ / / / / / / / / M M M HYDRAULIC FITTINGS, HOSE ENDS, TUBE NUTS DASH SIZE THREAD SIZE TORQUE[3] (S.A.E.) (S.A.E.) (ft.lbs.) -4 7/ / / / / / [1] Torque to be applied to Grade 8 bolts. [2] Torque to be applied to Grade C locknuts. [3] Torque to be applied to S.A.E. straight thread O-Ring Boss (ORB) fittings/locknuts and 37 degree flared type (J.I.C.) fittings/hose ends and tube nuts. NOTE: Mud Hog and Equa-Trac are registered trademarks of Tuthill Transport Technologies. B

4 ! Safety Procedures 1) READ THESE PROCEDURES COMPLETELY. Make sure you fully understand all controls BEFORE operating the system. 2) The safety information given does not replace safety codes, insurance needs, or federal, state, and local laws. 3) Standard safety procedures should be observed and practiced when operating or servicing the Mud Hog system. CAUTION should be practiced at all times. 4) All components MUST be securely and correctly mounted and connected BEFORE operating the system. 5) In the event of any malfunction in the system, the Mud Hog should be shut OFF immediately and not restarted until the machine is correctly serviced. 6) When raising the machine, make sure that a dependable left device is used to adequate capacity. Use suitable jack stands to support machine. Apply PARK or EMERGENCY BRAKE and block the front wheels to prevent the machine from rolling. 7) DANGER Escaping fluid under pressure can have sufficient force to penetrate the skin, causing serious personal injury. Fluid escaping from a small hole can be almost invisible. Use a piece of cardboard or wood rather than your hands, to search for suspected leaks. 8) DO NOT extend the axles beyond the distance stated in the instructions. 9) DO NOT alter axles in ANY manner alterations may reduce strength resulting in possible damage or personal injury. 10) DO NOT alter any component of the Mud Hog system. Unauthorized modification may result in possible damage or personal injury. 11) DANGER Failure to follow proper procedures when mounting a tire on a wheel or rim can produce an explosion which may result in serious bodily injury. DO NOT attempt to mount a tire unless you have the proper equipment and experience to perform the job safely. 12) WARNING Decals MUST be obeyed completely to prevent possible damage or injury. If decals are destroyed, lost damaged or cannot be read, replace immediately. 13) WARNING Any damaged hi-pressure hose should be replaced with a comparable 4-wire braid hose (DO NOT use a 2 or 3-wire braid hose). A

5 I. REMOVING WHEEL SHIELD ASSEMBLIES A B Remove factory wheel shields. If your sprayer has a non-powered suspension unit on it, the shield supports will have to be changed out. Remove the existing shield supports, and bolt the supplied shield support (501202) in their place. C If the unit does not have a suspension on it, the openings on the wheel shield will have to be enlarged for king pin and bolt clearance. Follow the existing radius, make the opening 7 1/2" wide, leaving 1 1/2" on each side. 5

6 II. STABILIZING MACHINE A. Lift the machine up and block it so the front axle is just off the ground. Remove the 5/8-11 x 2 3/4" bolt from the top of the king pin and the steering casting. NOTE: The king pin may settle down after the bolt is removed. Remove the caps (501191) from the splines of the supplied Mud Hog wheel drives, install the caps onto the exposed splines of the non-powered axle extensions. Use the 5/8-11 x 2 3/4" bolts from the non-powered wheel drives to keep the caps in place. III. REMOVING ORIGINAL AXLES A. Remove 3 or 4 bolts and the shims from the stub axles. Then remove the non-powered axle. Slide the supplied Mud Hog wheel drive into position, install the shims and bolts. Torque bolts to 250 ft. lbs. Install the steering casting and the large flat spacer, place the hose guide (501192) into position with the loop facing the front slightly toward the outside, then install the supplied 5/8-11 x 3" bolt and washer from the Mud Hog wheel drive. Torque to 200 ft. lbs. Strike steering casting several times with a lead hammer and re-torque to 200 ft. lbs. 6

7 IV. REMOVING THE SHIELDS A. Remove the shield on the right side of the reservoir (behind the cab). B. Remove the platform shield (behind the cab). V. REMOVING THE HOOD A. Remove the hood. Take care not to lose the spacers from beneath the hood, they will be needed when the hood is being replaced. VI. REMOVING SCREENS A. Remove screens from both sides of the machine. 7

8 VII. MODIFYING SHIELDS AND SCREENS A. Drill a 3/8" hole in the shield beneath the platform on the left side, in the front of the shield, inline with existing holes in the back. Drill close enough to the edge so you can hold the 5/16" locking flange nut ( ) with your finger when installing the 5/16-18 x 3/4" long bolt ( ) which holds the large coated hose clamp (104659) on. Bolt both clamps so the hoses are away from the main part of the machine. B. Using a 1 1/2" hole saw, drill two holes in the shield in-line with the power steering hoses. Use supplied grommets (400145) to line holes to protect hoses. 8

9 VIII. INSTALLING VALVE A. Lay out and tighten the two flush fittings (200357) and the check valve (104254). The arrow on the check valve should point to the left when you are standing in front of the machine. Put the 3/4" hose ( ) on the right side flush fitting. Do not tighten the 3/4" hose clamp (2016) until the hose configuration is set. Seal off the 1/2" opening on the left fitting so oil will not flow when the hose from the cooler is hooked to it. Using needle nose vise grips, clamp onto the hose at the rear of the oil cooler. Loosen the hose clamp. This hose goes through the predrilled hole in the screen and gets hooked to the left side flushing tee. The 3/4" hose ( ) gets routed back to the oil cooler. Make sure the hoses are not pinched before tightening the hose clamps (2016). NOTE: 6700 model sprayers have a different orientation of the cooler connections than is shown below. For these the upper connection is to be used. 9

10 B. Install the bulkhead branch tee ( P1) onto the valve bracket (501194) so the jam nut is to the back of the machine. Loosen existing nuts from the carriage bolts to the fuel tank. Carefully install the valve bracket. Hold the bolts so they do not fall out. Bolt the valve to the bracket using two 3/8-16 x 1 1/2 long grade 8 bolts ( P1) and 3/8" lock washers ( ). 10

11 C. Using two 1 1/4" coated hose clamps ( P1), two 3/8-16 x 7/8" bolts ( ), two 3/8-16 locknuts ( P1), and two 3/8" flat washers ( P1) bolt the check valve, flush, and drain arrangement to the valve bracket. Arrange clamps so the hoses are straight. Install the two hose guides (501193) using the existing carriage bolts. 11

12 IX. INSTALLING HOSES A. Lay out all hose assemblies from the hose kit. Separate into three groups Sprayer 6600 Sprayer 1. Main forward and reverse: 3249B Quantity 2-162" Hose 3249B Quantity 2-162" Hose Quantity 1-144" Sleeve Quantity 1-144" Sleeve 2. Right hand wheel drive: Quantity 2-88" Hose Quantity 2-81" Hose Quantity 1-94" Hose Quantity 1-87" Hose Quantity 1-90" Hose Quantity 1-82" Hose Quantity 1-80" Sleeve Quantity 1-72" Sleeve 3. Left hand wheel drive: Quantity 2-88" Hose Quantity 2-81" Hose Quantity 2-90" Hose Quantity 2-82" Hose Quantity 1-80" Sleeve Quantity 1-72" Sleeve B. The 06 ends of the flush and drain hoses are to be positioned toward the wheel drives. Slide the hoses from groups 2 and 3 through the cordura. Right side wheel motor port configuration - front to rear: forward, drain, reverse, flush. Left side wheel motor port configuration - front to rear: flush, forward, drain, reverse. C. Hose hook up at the valve: Port A is forward (port closest to the bracket). Port B is reverse. The flushing hoses are hooked up to the bulk head tee. Drain hoses are hooked up to fittings on the left side of the valve. 12

13 D. For 6500 sprayers with serial numbers N0600X or below, see item 1 for the high pressure hose hook up procedure sprayers with serial numbers N0600X or above and all 6600 sprayers, see item 2 for the high pressure hose hook up procedure sprayers with serial numbers N0600X and below: The high pressure hoses get hooked up at the back of the manifold block. Remove the plugs from the ports labeled GA & GB. Install two 08 ORB to 08 ORS (200304) 90 fittings. 2. All 6600 sprayers and 6500 sprayers with serial numbers N0600X and above: The high pressure hoses must be separated on the left side of the tee connection. The 12 ORS swivel run tees (200296) must be installed with the end facing the front and slightly downward. When working with ORS fittings the o-rings should always be checked prior to installation. Each swivel run tee gets a 12 ORS FS to -08 ORS M reducer (200321) installed. 13

14 E. Lay out the wiring harness (450280) along side of one high pressure hose (3249B-1620). The end with the black plastic connector is to be 26" past the 08 ORS straight fitting. Tape the wire to the hose at this point so they will slide through the cordura ( ). After getting this hose and wire through, push the 2nd hose through. Keep the straight ends of both hoses together, mark both ends of one hose. The 90 hose fittings go toward the Mud Hog valve, route the assembly through the two previously located hose clamps on the left side of the machine (see VII. A). Run the hoses along the top of the fuel tank to the Mud Hog Valve. Install the 12 ORB to 08 ORS adapters (200361) in the valve. The forward port is under the solenoid (port C), the reverse port is (port D). Hook up the ring terminal of the wiring harness to solenoid valve. Connect the 90 ends of the hoses to the adapters in ports C & D. Run the straight ends of the hoses up through the plumbing at the rear of the machine to the fittings installed earlier (see either D.1. or D.2.). The forward hose is connected to the top fitting. The reverse hose is connected to the bottom fitting. Connect the wire that was earlier taped to one of the hoses by removing the cap from the double plug under the right side of the reservoir. Make sure you have the double plug that is utilized by the auxiliary hydraulics electrical circuit. Plug in the wiring harness (450280). The wire should be in port A of the pig tail. Route the wire so it will not get damaged, wire tie. (see X.B.) F. The 33" hose with the 90 hose fitting ( ) is the flushing oil supply. It threads onto the bulkhead fitting, loops around the left and slides onto the barbed fitting on the right. It is secured by a 1/2" hose clamp (104545). The 19" hose ( ) is the system drain hose. It threads onto the drain fitting on the right side of the valve. Loop it to slide onto the hose barb on the fitting on the left. Secure with a 1/2 hose clamp (104545). These hoses must not be pinched in any way that would create internal back pressure. 14

15 X. ELECTRICAL INSTALLATIONS A. Loosen the six bolts that hold the top console in place. Lift up and use a flat screwdriver to remove the blank plate beneath "auxiliary hydraulics". Locate the female receptacle that has a white tag on it labeled "auxiliary hydraulics". Plug into the rocker switch (400135). Install the fuse, 10 amp 6m blade type (400133) in the bottom fuse block (2nd place up on the left). Use a test light to make sure the circuit is completed when the rocker switch is rocked forward turning the unit on. A clicking noise should be heard in the solenoid on the Mud Hog valve. Push the rocker into the blank space. Install the decal (104959) on rocker switch. Bolt the top of the console back into the proper position. B. If the auxiliary hydraulic circuit is already utilized then an electrical kit will have to be ordered from Tuthill. The kit will consist of several parts needed to complete to electrical system for the Mud Hog. The instructions for installing will be included with the electrical kit. XI. RESERVOIR A. Fill the oil reservoir with hi-grade viscosity oil. Test run the unit to check for leaks at low pressure and proper rotation of the wheel motors. Refill the reservoir. See start-up procedure at the end of this manual. 15

16 XII. INSTALLING MUD SCRAPERS A. Install the mud scrapers to wheel drives (501203/501204), each side will use 4-3/8 flat washers ( P1), 2-3/8-16 x 7/8" grade 8 bolts ( ), 2-3/8" locking nuts ( P1), 2-3/8 lock washers ( ), and 2 3/ /4" grade 8 bolt ( P1). Install tires. NOTE: Older units, made in 2001 or earlier, have a 2-piece nut. The torque specification for this type of nut is 125 ft.lbs. During 2001, the style of nut changed to a 1-piece nut and the torque specification for this type of nut is 147 ft.lbs. NOTE: Lug nuts should periodically be checked and re-torqued. Toe-in should be checked at this time. Measure across from tire to tire, halfway up on the front and rear sides of the tires. The measurement on the front side should be 1/8" to 3/8" less than the measurement on the rear side. Adjust if necessary. Install the front wheel shields. Torque the bolt at the top of the shield support to ft. lbs. The two inside plates should be reversed and installed upside down. This will allow more room for the hoses going to the wheel drives. Install the two shields in back. Put side screens and hood back on. The two long screws in the kit (192) are to be installed in the two rear positions on the left side. The back screw uses the two original spacers under the hood. The second screw uses the supplied spacer (105556), this allows the hood to lay more natural around the high pressure hoses. All spacers and screws should be started before any are tightened. 16

17 NOTE: The sprayer cannot be towed any faster than it travels under its own power. If this speed is exceeded severe damage to the wheel motors may be experienced, and the Fluidrive warranty would be void. See decal shown above. Decal (105503) should be installed near the tow valve. See the bottom picture on page 9. NOTE: Wheel shield damage is not warranted by Tuthill Transport Technologies. 17

18 4WD Mud Hog Vinyl Decal Application Instructions To apply your decal, please follow the instructions below: 1. Clean area above rear wheel on ladder side of machine to remove dirt and grime. 2. Without removing the paper backing, position decal on surface exactly where you want it. 3. Once the decal is in position, place a piece of masking tape along the top edge to hold the decal in place. 4. The decal should be sitting on the surface like a flap. Lift up the decal and remove the paper backing. 5. With the backing paper completely removed from the decal & transfer tape, gently lower the decal with the transfer tape back down to the surface and rub it down lightly with your hand. 6. The transfer tape should still be on the side of the decal facing you. This allows you to rub the decal without scratching or damaging the decal. Take a squeegee or credit card and firmly rub the transfer tape and thus the decal until it is firmly adhered to the surface. 7. Finally, peel off the transfer tape and masking tape gently. The decal will adhere to the surface much more aggressively than the transfer tape. The transfer tape should lift easily leaving behind no sticky residue. 8. Your decal installation is complete. If there are bubbles present under the decal that cannot be removed by working them to edge, a small needle or pin can be used to puncture the bubble and remove the air. A small pin hole will not be seen after the air bubble has been worked out.

19 LIMITED WARRANTY Tuthill Drive Systems ( Tuthill ) warrants Mud Hog drive systems and components to be free from defects in material and workmanship under normal use and service as shown in the chart below from the date of shipment from Tuthill. Installed By: Warranty Period Tuthill Drive Systems Mud Hog 24 months parts and 12 months labor for the Mud Hog kit & Installation. Authorized Mud Hog Dealer 24 months parts and 12 months labor for the Mud Hog kit. Note: Any defects resulting from installation errors are covered by the installer. Warranty period start date is determined by ship date from Tuthill Drive Systems. Normal use and service means that the product will be installed by a qualified mechanic, operated, inspected and maintained in accordance with the applicable Mud Hog manual or instructions and any applicable vehicle manufacturer s manual or instructions. Tuthill is not liable for any printing errors contained within manuals. THE ABOVE WARRANTY IS EXCLUSIVE. TUTHILL MAKES NO OTHER REPRESENTATIONS OR WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE. No agent, distributor, dealer or employee of Tuthill has authority to extend the scope of this warranty. This warranty applies only to products which are sold and used only in the United States, Canada and Mexico. [Tuthill does not itself warrant components which bear the name or trademark of another manufacturer. Any warranty or remedy for such parts is limited to the extent of any warranty provided by the manufacturer to Tuthill.] No warranty applies in the event of replacement of parts with parts not obtained from or approved by Tuthill which do not meet Tuthill quality and performance specifications, improper installation, maintenance, repair, misuse or abuse, or unauthorized alteration or modification. Wheel motor warranty will be denied if the motor is disassembled and or serviced by anyone other than an authorized Tuthill service center within the warranty period. Tuthill reserves the right to make changes and improvements in design, specifications or instructions without notice and without obligation to provide or to substitute new design modifications for those Mud Hog systems or components already in service. Tuthill will at its option refund the purchase price of, or repair or replace without charge for parts, any Mud Hog product determined by Tuthill to be defective in material or workmanship during the applicable warranty period. Labor allowance, if applicable, will be determined in accordance with Tuthill s warranty labor rate and time allowances established from time to time. These remedies are exclusive. In no event shall Tuthill s liability exceed the purchase price for the Mud Hog product when sold by Tuthill to the first buyer. Tuthill shall not be liable for any incidental or consequential damage or expense resulting from any product defect, including but not limited to loss of profits, loss of use of equipment, increased costs or other expenses. This warranty shall become effective only when the Warranty Certificate has been returned to Tuthill and validated by same. INSTALLER AND OWNER RESPONSIBILITIES The installer is responsible for installing the product according to Tuthill s approved procedures, for providing a copy of Tuthill s warranty and installation/parts manual to the owner, and for advising the owner of proper use, service, and maintenance required for the product. The owner is responsible for operation, inspecting and maintaining the product according to the instructions in the installation/parts manual and any applicable vehicle manufacturer s owner s manual, and for properly instructing all operators and maintenance personnel. ADJUSTMENTS When adjustment is sought under this warranty, a claim should be made as follows: A. Tuthill must be notified in writing promptly upon discovery of a claimed defect. B. If the product was installed by the vehicle manufacturer (or it s dealer), follow the manufacturer s procedures for warranty claims; or If the product was purchased from Tuthill through a distributor of Mud Hog products, have the distributor write or phone the Tuthill Customer Service Department and ask for a Returned Goods Authorization Number (RGA#). A warranty claim form will be submitted with information including: The RGA#, Tuthill axle serial #, retail sales date, machine hours and a description of the failure. C. Components requested by Tuthill must be returned freight prepaid and accompanied by a properly completed warranty claim form. Tuthill will specify the ship-to address at time of return approval W. 800 S., Brookston, IN 47923, Tel: / Fax: tdswebinquiries@tuthill.com Web: