INSTALLATION MANUAL FOR. Mud Hog System II, System III & System IV Rear Wheel Drive

Transcription

1 INSTALLATION MANUAL FOR Mud Hog System II, System III & System IV Rear Wheel Drive FOR Case International 2144, 2166, 2188, 2344, 2366, 2388 COMBINES Mud Hog Model CASE COMBINES For all machines CI /66 GRAIN SYSTEM II CI GRAIN SYSTEM III (8 Stud) CI GRAIN SYSTEM III (10 Stud) For machines manufactured prior to October 2001 CI21682M 66 RICE & 88 SYSTEM II CI21683M 66 RICE & 88 SYSTEM III CI21684M 66 RICE & 88 SYSTEM IV (8 Stud) CI21884M 66 RICE & 88 SYSTEM IV (10 Stud) For machines manufactured October 2001 and later CI RICE & 88 SYSTEM II CI RICE & 88 SYSTEM III TUTHILL Drive Systems Brookston Indiana USA Toll Free Revised 9/2009 P.N

2 TABLE OF CONTENTS DESCRIPTION PAGE # Instructions and Specifications.2 Safety Procedures..3 Removal of Existing Components...4 Adjusting Axle Center Section Endplay...5 Adjusting Steering Axle Pivot Support...6 CI & Mud Hog Axle Center Section Measurements...7 Mud Hog Tread Centers...8 Mount of Mud Hog Kit Component Parts Mounting Sta-Bar Brackets...15 Mounting Sta-Bars...15 Mounting Equa-Trac II Valve Assembly...16 Mounting Wheel Drive Assemblies...17 Mounting Hose Clamp Brackets...18 Mounting Manifold Adapter Block...19 Connecting & Routing Hydraulic Hoses Mounting Steering Cylinder...32 Mounting Tie-Rod Assembly...33 Mounting Wheels & Adjusting Toe-In...34 Mounting of Electrical Components...35 Adjust Steering Stops 36 Pre-Start Procedures Warranty...Back Cover

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 Drive Systems. B 2

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). 3 A

5 REMOVAL OF EXISTING COMPONENTS Park combine in clean working area. Allow adequate room to remove rear axles. Apply "PARK or EMERGENCY BRAKE" and block front wheels to prevent combine from rolling. Using a suitable lift device, jack or hoist, raise rear of combine so that rear tires are several inches off the ground. Place jack stands securely under combine rear frame. Do NOT support combine under axle center section. The axle center section MUST be free to move during the installation procedure. For convenience, remove the shaker shield and straw spreader. Disconnect steering tie-rod assembly from wheel ends. Retain all slotted nuts and cotter pins for later use. 2144, 2166 GRAIN & RICE & 2188 COMBINES WITH " AXLE CENTER SECTIONS ONLY Disconnect hydraulic hoses from steering cylinder and place aside for later connection. Plug hoses and cap cylinder ports. NOTE: Before disconnecting hoses, mark hoses and connectors to aid in correct connection later. If hose connections are switched, rear drive wheel will steer opposite steering wheel. ALL COMBINES Disconnect steering cylinder from wheel end and axle steering bracket. Retain slotted nuts & cotter pins for later use. If combine is equipped with sta-bars, remove sta-bar brackets located on axle center section. Remove all stub axle mounting bolts. Remove stub axles. Retain all mounting bolts for later use. Wheels and tires MAY be removed separately or left attached to stub axles RICE & 2188 COMBINES USING MUD HOG AXLE CENTER SECTION Remove collar retaining the existing axle center section to the pivot support. Remove existing axle center section and thrust washers. Reinstall one thrust washer onto pivot tube of Mud Hog center section and slide tube and center section assembly into pivot support. Use one additional thrust washer at end of pivot tube. Reinstall retaining collar and check the endplay of the center section. Follow instructions on following page for adjusting endplay. 4

6 ADJUSTING AXLE CENTER SECTION ENDPLAY NOTE: On those combines which require installation of Mud Hog sta-bars, the axle center section MUST be free to move forward and backwards. Pull axle center section rearward tight against retaining collar. At the rear there MUST be a 1/4" gap - MINIMUM- for 2144, 2166 & 2188 combine center sections. See Figure , 2166 & 2188 Figure 1 If there is NOT a 1/4" gap, remove thrust washers as required until a 1/4" gap - MINIMUM - is obtained. See Figure , 2166 & 2188 Figure 2 5

7 ADJUSTING STEERING AXLE PIVOT SUPPORT Because of the large tires in the MUD HOG kit, certain rear tread center/axle pivot support combinations may result in rear tire interference with sheet metal, straw spreaders and guards, or rear fenders. Follow these steps: 1. Measure the frame height from the ground (see diagram above) with machine level. 2. Determine rear tire size and find corresponding static loaded tire rolling radius from table A. Subtract measured frame height from tire rolling radius. Using the resulting difference, go to table B to determine proper pivot support position. Table A Static Loaded Rolling Rear Tire Size Radius 14.9 x 24 R x 24 R x 24 R x 26 R x 26 R x 26 R x 26 R Table B Frame Height Subtracted From Rolling Radius Pivot Support Position With CI Center Section With MH Center Section # or less #3 0 to to 4.00 # to to 6.25 #1 greater than 4.25 greater than 6.25 Example: If the rear tire size if 16.9 x 26 R1, use table A to determine rolling radius of 24.1". Subtracting determined frame height of 22" from the rolling radius gives a result of 2.1". Using this result, go to table B. The result 2.1" falls in the range of 2.00 to This range corresponds with pivot support position #2. Adjust the pivot support to this position. *Some combinations of tread center and pivot support positions may cause tire interference at rear of combines during extreme axle oscillation and steering. Further adjustments may be necessary. Refer to CASE INTERNATIONAL "OPERATOR'S MANUAL" in the section titled "WHEELS, TIRES, AND STEERING" for further instructions on adjustment of the steering axle pivot support. 6

8 CI AND MUD HOG AXLE CENTER SECTION MEASUREMENTS Used on Combine Models: MOUNTING OF MUD HOG KIT COMPONENT PARTS TO COMBINE REAR AXLE CENTER SECTION REFERENCE PAGE NUMBER , 12, 13, 14 MUD HOG MODEL/KIT NUMBER CI21462 ( CI AXLE: 109 TC) CI21663 ( CI AXLE: 121 TC) CI21462 ( CI AXLE: 121 TC) CI21663 ( CI AXLE: 121 TC) CI21682M, CI21683M, CI21684M, CI21884M ( MUD HOG AXLE: ALL TC S) 7

9 MUD HOG TREAD CENTERS (with MH stub axles set in or out) 8

10 NOTE: Angle sta-bar brackets toward the rear corner frame bolts Sta-Bar Bracket NOTE: Mount the support plate brackets with round holes in the upper hole if the axle pivot support position is in the 1 st or 2 nd setting. Mount brackets in the lower hole if the axle pivot support position is in the 3 rd or 4 th setting. Support Brackets 3 rd Hole Original ¾ x5 bolts & locknuts Original ¾ x5 Bolts Hose Guide Supplied ¾ x 5 ¼ Bolt & Nut Original ¾ x 5 Bolt & Nut Supplied ¾ x 6 ½ bolts & Locknuts Steering Cylinder Bracket Torque Locknuts to ft.lbs. Steering Cylinder Bracket (Use When Small Diameter of Ball Joint On Steering Cylinder Is Larger Than 5/8 ) COMPONENT PART MOUNTING 2144, & 2166 GRAIN COMBINES WITH INCH AXLE CENTER SECTION 109 INCH TREAD CENTER SETTING 9

11 NOTE: Angle sta-bar brackets toward the rear corner frame bolts Sta-Bar Bracket NOTE: Mount the support plate brackets with round holes in the upper hole if the axle pivot support position is in the 1 st or 2 nd setting. Mount brackets in the lower hole if the axle pivot support position is in the 3 rd or 4 th setting. Support Brackets 3 rd Hole Original ¾ x5 Bolts Original ¾ x5 Bolts & Locknuts Supplied ¾ x5 ¼ Bolt & Nut Hose Guide Original ¾ x5 Bolt & Nut Supplied ¾ x6 ½ Bolts & Locknuts Torque Locknuts to ft.lbs. Steering Cylinder Bracket Steering Cylinder Bracket (Use When Small Diameter of Ball Joint On Steering Cylinder Is Larger Than 5/8 ) COMPONENT PART MOUNTING 2144, & 2166 GRAIN COMBINES WITH INCH AXLE CENTER SECTION 121 INCH TREAD CENTER SETTING 10

12 Sta-Bar Bracket 2144 & 2166 Combines Only: Mount sta-bar brackets with mounting ears of bracket pointing INWARD 2188 Combines Only: Mount sta-bar brackets with mounting ears of bracket pointing OUTWARD Support Brackets 1 st Hole NOTE: Mount the support plate brackets with round holes in the upper hole if the axle pivot support position is in the 1 st or 2 nd setting. Mount brackets in the lower hole if the axle pivot support position is in the 3 rd or 4 th setting. ¾ x5 Bolt & Nut Hose Guide ¾ x5 ½ Bolt & Nut Steering Cylinder Braacket ¾ x5 Bolt & Nut Torque Locknuts to Ft.Lbs. Right Hand Cylinder Anchor Use Only For CI23682 or CI23683 Longer Mounting Bolts In Kit K COMPONENT PART MOUNTING 2166 RICE & 2188 COMBINES WITH MUD HOG AXLE CENTER SECTION 108 INCH TREAD CENTER SETTING NOTE: MACHINES MANUFACTURED OCTOBER 2001 AND LATER REQUIRE THE HOSE GUIDES TO BE MOUNTED ON THE FRONT SIDE OF THE AXLE DUE TO THE OVERLAP DESIGN OF THE AXLE. 11

13 Sta-Bar Bracket 2144 & 2166 Combines Only: Mount sta-bar brackets with mounting ears of bracket pointing INWARD NOTE: Mount the support plate brackets with round holes in the upper hole if the axle pivot support position is in the 1 st or 2 nd setting. Mount brackets in the lower hole if the axle pivot support position is in the 3 rd or 4 th setting. ¾ x5 ½ Bolt & Nut 2188 Combines Only: Mount sta-bar brackets with mounting ears of bracket pointing OUTWARD Support Brackets 1 st Hole ¾ x5 Bolt & Nut ¾ x4 ½ Bolt & Nut Hose Guide ¾ x5 ½ Bolt & Nut Steering Cylinder Bracket Torque Locknuts to Ft. Lbs. Right Hand Cylinder Anchor Use only for CI23682 or CI23683 Longer Mounting Bolts In Kit K COMPONENT PART MOUNTING 2166 RICE & 2188 COMBINES WITH MUD HOG AXLE CENTER SECTION 120 INCH TREAD CENTER SETTING NOTE: MACHINES MANUFACTURED OCTOBER 2001 AND LATER REQUIRE THE HOSE GUIDES TO BE MOUNTED ON THE FRONT SIDE OF THE AXLE DUE TO THE OVERLAP DESIGN OF THE AXLE. 12

14 Sta-Bar Bracket ¾ X5 Bolt & Nut 2144 & 2166 Combines Only: Mount sta-bar brackets with mounting ears of bracket pointing INWARD NOTE: Mount the support plate brackets with round holes in the upper hole if the axle pivot support position is in the 1 st or 2 nd setting. Mount brackets in the lower hole if the axle pivot support position is in the 3 rd or 4 th setting. ¾ x5 ½ Bolt & Nut 2188 Combines Only: Mount sta-bar brackets with mounting ears of bracket pointing OUTWARD Support Brackets 1 st Hole ¾ x4 ½ Bolt & Nut Hose Guide ¾ x5 Bolt & Nut Steering Cylinder Bracket Torque Locknuts to Ft.Lbs. Right Hand Cylinder Anchor Use only for CI23682 or CI23683 Longer Mounting Bolts In Kit K COMPONENT PART MOUNTING 2166 RICE & 2188 COMBINES WITH MUD HOG AXLE CENTER SECTION 132 INCH TREAD CENTER SETTING NOTE: MACHINES MANUFACTURED OCTOBER 2001 AND LATER REQUIRE THE HOSE GUIDES TO BE MOUNTED ON THE FRONT SIDE OF THE AXLE DUE TO THE OVERLAP DESIGN OF THE AXLE. 13

15 Sta-Bar Brackets ¾ x5 Bolt & Nut 2144 & 2166 Combines Only: Mount sta-bar brackets with mounting ears of bracket pointing INWARD NOTE: Mount the support plate brackets with rooung holes in the upper hole if the axle pivot support position is in the 1 st or 2 nd setting. Mount brackets in the lower hole if the axle pivot support pos.ition is in the 3 rd or 4 th setting. ¾ x5 ½ Bolt & Nut 2188 Combines Only: Mount sta-bar brackets with mounting ears of bracket pointing OUTWARDS Support Brackets 1 st Hole ¾ x4 ½ Bolt & Nut Hose Guide ¾ x5 Bolt & Nut Torque Locknuts to Ft.Lbs. Right Hand Cylinder Anchor Use only for CI23682 or CI23683 Longer Mounting Bolts In Kit K COMPONENT PART MOUNTING 2166 RICE & 2188 COMBINES WITH MUD HOG AXLE CENTER SECTION 144 INCH TREAD CENTER SETTING NOTE: MACHINES MANUFACTURED OCTOBER 2001 AND LATER REQUIRE THE HOSE GUIDES TO BE MOUNTED ON THE FRONT SIDE OF THE AXLE DUE TO THE OVERLAP DESIGN OF THE AXLE. 14

16 MOUNTING STA-BAR BRACKETS See Page 5 MOUNTING STA-BARS Pulling rearward tight against retaining collar, place axle center section in level position. Connect stabar to axle bracket with 7/8 x 3" clevis pin (7/8 x 3 1/2" pin for MUD HOG axle). Adjust sta-bar to proper length and connect external threaded end of sta-bar to frame bracket at appropriate mounting hole with 7/8 x 3" clevis pin; keeping sta-bar in a level position. With both sta-bars mounted, oscillate axle to check adjustment. Axle must oscillate freely from stop to stop. If axle binds at any position, adjust sta-bars as necessary. When properly adjusted, lock clevis pins in place with cotter pins. Tighten sta-bar jam nuts. See figure 6. 15

17 MOUNTING EQUA-TRAC II (E-T II) VALVE ASSEMBLY VALVE AND BRACKET ASSEMBLY SHOULD BE POSITIONED SO THAT VALVE IS AT CENTER OF AXLE. USE APPROPRIATE SET OF MOUNTING HOLES TO ATTACH VALVE BRACKET TO SUPPORT BRACKETS. Equa-Trac II Valve Supplied Bulkhead Tee Supplied 3/8x1 Bolt & Locknut Supplied bulkhead Bracket Supplied 3/8x1 ½ Bolt & Locknut Supplied 3/8x1 ½ Bolt & Lockwasher Support Bracket 3/8 Locknut 2144 & 2166 GRAIN COMBINES WITH CENTER SECTION Equa-Trac II Valve Supplied 3/8x1 ½ Bolt with Lockwasher Supplied Bulkhead Tee Supplied 3/8x1 Bolt & Locknut Supplied bulkhead Bracket Supplied 3/8x1 ½ Bolt & Locknut Support Bracket 3/8 Locknut 2166 RICE & 2188 COMBINES WITH " MUD HOG CENTER SECTION Figure 8 16

18 MOUNTING WHEEL DRIVE ASSEMBLIES CAUTION: Wheel drive assemblies are extremely heavy. Use a lift device of adequate capacity. Stub Axle End Plate Wheel Drive Assembly (Left Hand Shown) Supplied ¾ Hardened Flat Washer Qty 6 per Side Rear of Machine Supplied 3/4x2 ¼ Hex Head Bolt Qty 6 per Side TORQUE 3/4" BOLTS TO FOOT POUNDS Figure 9 17

19 MOUNTING HOSE CLAMP BRACKETS 18

20 MOUNTING MANIFOLD ADAPTER BLOCK NOTE: The hydrostatic system oil may be drained at this time. Many of the following procedures require removal and replacement of various hydraulic fittings and connectors in the hydrostatic system. Oil within the system will leak from these connections as the procedures are performed. Refer to CASE INTERNATIONAL Specifications and recommended procedures for servicing the hydrostatic system. Always keep in mind cleanliness and safety precautions. Remove all hydraulic hoses attached to relief manifold block on hydrostatic motor. See figure 12. CAREFULLY remove relief manifold block from hydrostatic motor. Do NOT drop or abusively handle manifold block. The mated sealing surface must NOT be warped or scratched. Replace sealing o-rings in relief manifold block with new o-rings and back-up washers supplied in kit. Apply grease to hold o-rings in place. Install supplied 3/8 x 5 3/4" bolts through mounting holes of relief manifold block. Slide adapter manifold block onto mounting bolts. Figure 12 Secure entire assembly to hydrostatic motor. CAREFULLY and firmly hold manifold block against hydrostatic motor during assembly to keep o-rings in position. NOTE: If o-rings slip out of place, resulting oil leaks must be repaired. Reconnect all fluid lines to relief manifold block. Torque to specification. 19

21 CONNECTING & ROUTING HYDRAULIC HOSES NOTE: Torque hose ends to specification ONLY after both ends are connected. When tightening hose ends do NOT allow hose to twist. Twisting hose contributes to hose failure. Over-tightening can damage fittings. Refer to torque specifications at the front of this manual. A. MANIFOLD ADAPTER BLOCK TO EQUA-TRAC II VALVE 1.Slide a small diameter 48" cordura (nylon) sleeve over each 162" and 169" high pressure hose. 2. Route hoses over fan housing and through opening above frame. Position cordura sleeves at frame opening to prevent hose abrasion. NOTE: On late model machines, hoses can not be routed through opening above frame. Route hoses through opening in cage shield and down to manifold pump. See figure or 169 Reverse 151 or 162 Forward 20

22 CONNECTING & ROUTING HOSES A. CONTINUED: REAR TUBE CLAMP Supplied 5/8 square x 1 ½ tapped spacer 3/8 flat washer Hose Clamp Existing 3/8 bolt Supplied 3/8 x 7/8 bolt MANIFOLD ADAPTER BLOCK 21

23 CONNECTING & ROUTING HOSES A. CONTINUED: Route hoses secured at the rear tube clamp behind steel hard line tubes. Slide a 48" large diameter cordura sleeve over the unconnected end of the upper (reverse) large diameter hose. Loosely insert 126" x 1/2" diameter drain hose inside large sleeve. Slide another 48" large diameter sleeve over the unconnected end of the lower (forward) large diameter hose. Secure hoses to rear hose clamp bracket with double hose clamp. Fasten with hose clamp plate 5/16 x 3 1/4" bolt and locknut; Do NOT tighten at this time. Route hoses toward E-T II valve for connection. See Figure 21. NOTE: Double clamp holds ONLY two large diameter (forward & reverse) hoses. Position 126" drain hose in the upper sleeve loosely OUTSIDE the clamp. 22

24 FOR COMBINES MANUFACTURED OCTOBER 1996 AND LATER: 44 & 66 CORN & GRAIN Drain Connection Upper Manifold Block (Reverse) Flush Connection Lower Manifold Block (Forward) Forward Drain Flush Reverse 23

25 24 Forward

26 FOR COMBINES MANUFACTURED OCTOBER 1996 AND LATE: 88 RICE Drain Connection Lower Manifold Block (Forward) Upper Manifold Block (Reverse) Flush Connection See Detail A See Detail B Forward Drain Flush Reverse 25

27 CONNECTING & ROUTING HOSES A. CONTINUED: HOSE CONNECTIONS AT EQUA-TRAC II VALVE 151 FORWARD (2144) 162 FORWARD (2166, 2188) 169 REVERSE (2166, 2188) 155 REVERSE (2144) Figure 22 NOTE: Position cordura sleeves at point of contact with steel hard-line tube assemblies leading to hydrostatic pump to prevent hose abrasion. Route hoses clear of shaker shield. Tie-strap hose together. *DO NOT tighten hose connections at this time* 26

28 B: CASE DRAIN AND MOTOR FLUSH HOSES: RESERVOIR TO ET-II VALVE VIEW A (from rear of combine) FLUSH LINE CONNECTION VIEW B VIEW A Bulkhead Tee Bracket VIEW B Install the bulkhead tee bracket using the existing valve bracket mounting bolts. Connect the two flush lines from the motors to the bulkhead tee. The 3/8" fitting attaches to the motors and the 1/2" fitting attaches to the bulkhead tee. Use the hose with a 90' 08 JIC fitting on one end and 06 ORS fitting on the other end, and connect the 90' fitting to the bulkhead tee. Route this hose through cordura with a high pressure line and connect it to the supplied orificed elbow at hydrostatic pump (see Figure 24). The case drain hose with a 90' fitting on one end and no fitting on the other end connects to the supplied hose barb fitting at hydrostatic pump and to the ET-II valve as shown in Figures 23 &

29 CONNECTING & ROUTING HOSES B. CONTINUED: Figure 23 Check that hoses are routed smoothly, free of kinks and clear of moving parts. Torque all hose ends, reservoir fittings and hose clamp bolts to specification. 28

30 B: CONTINUED: Remove plug from block located in bottom right corner of Figure 24 and install supplied 06 ORB x 08 hose barb fitting. Connect blank end of drain hose from ET II valve. Use supplied hose clamp to secure. GRAIN MACHINES Remove plug and install supplied 04 ORB-M x 06 ORS-M orificed elbow as shown in center of Figure 24. Connect 06 ORS end of hose from bulkhead tee to elbow. RICE MACHINES Remove plug from bottom of charge pump and install supplied 10 ORB-M x 04 ORB-F reducer and 04 ORB-M x 06 ORS-M orificed elbow as shown in Figure 24A. Connect 06 ORS end of hose from bulkhead tee to elbow. Figure 24 Figure 24A Reducer and Elbow 29

31 CONNECTING & ROUTING HOSES C. MOTOR HOSES: EQUA-TRAC II VALVE TO WHEEL DRIVES Match straight ends of two 57" hoses (69" for 2166R, & 2188) with 45 degree elbow end of a 61" (73" for 2166R & 2188) case drain hose. Slide a large diameter 48" long cordura (nylon) sleeve over these hoses; to be used for connections on the right-hand side. Match straight ends of remaining two 57" hoses (69" for 2166R & 2188) with 45 degree elbow end of remaining 67" (79" for 2166R & 2188) case drain hose. Slide another large diameter 48" long cordura sleeve over these hoses; to be used for connections on the left-hand side. Route sleeved hoses through hose guides on axle center section. See Figures 25 & 26. Figure 25 FORWARD & REVERSE MOTOR AND CASE DRAIN HOSE CONNECTIONS AT E-T VALVE NOTE: Loose drain hose connection fittings and adjust to enable smooth routing of drain hoses to wheel drives. 30

32 CONNECTING & ROUTING HOSES FORWARD & REVERSE HI-PRESSURE AND CASE DRAIN HOSE CONNECTIONS AT WHEEL MOTOR DRIVES Figure 27 Torque all hose ends and fittings at E-T II valve and wheel motor drives to specification. Turn wheel motor drives from stop to stop. Check that hoses do NOT kink, twist or bind. Make any necessary adjustments to clamps or fittings. 31

33 MOUNTING STEERING CYLINDER 2144, 2166 & ALL TREAD CENTERS Attach axle anchor end of steering cylinder to axle steering bracket. Secure tapered stud with original slotted nut. Torque to specification and insert cotter pin. 108", 109", 120", 121", 132", & 144" TREAD CENTERS WITH " CI CENTER SECTIONS - OR MUD HOG CENTER SECTION Connect 18" steering extension hoses to steering cylinder ports. Connect extension hoses to earlier marked steering cylinder hoses. Torque extension hoses to specification. See figure & 2166 GRAIN COMBINES WITH " AXLE CENTER SECTIONS ONLY Install supplied steering cylinder ball socket rod end using original bolt and locknut from previously removed rod end. Do NOT tighten at this time. Mount rod end of steering cylinder to lower ear on wheel motor drive. If necessary, loosen clamp on cylinder end or rod end to adjust to proper length. Secure tapered stud with original slotted nut. Torque to specification and insert cotter pin. TREAD CENTERS USING STEERING CYLINDER EXTENSION HOSES: Secure steering hoses in a supplied clamp. Mount hose clamp on rear left-hand side of axle center section at an available hole. Use 1/2 x 4 1/2" bolt, three flat washers and locknut. Install one flat washer between locknut and axle center section; one between axle center section and hose clamp; and one between hose clamp and bolt head. See Figure 31. Figure 31 ALL KITS Torque all steering cylinder hose ends to specification. 32

34 MOUNTING TIE-ROD ASSEMBLY Install supplied tie-rod inner tubes with tie-rod ends into supplied tie-rod outer tube. Remove cotter pins, slotted hex nuts and washers from tapered studs of inner tie-rod ends. Mount tapered studs of tie-rod ends into upper ears on wheel motor drives. Install slotted hex nuts and torque to ft. lbs. If slot in hex nut does not align with hole in taper stud, continue tightening nut until slot and hole align. Lock nuts in position with cotter pins. Place both wheel motor drive assemblies in straight ahead position. Slide tie-rod outer tube to the center of combine. At one end of tie-rod ONLY, align nearest set of holes in outer and inner tube. Install round spacer in each top hole. Secure outer tie-rod tube to inner tie-rod tube using 2 supplied 1/2 x 3 1/2" bolts, 2 supplied tie-rod clamp halves and 2 1/2" locknuts. Remaining side of tie-rod should be left UNSECURED in order to adjust toe-in. Torque locknuts to ft. lbs. See Figure

35 MOUNTING WHEELS/ADJUSTING TOE-IN Mount the wheels onto the wheel motor hub flanges with the center of the wheel in-board of the wheel motor flange. NOTE: Installing the wheels dished-out with the center of the wheel outside of the mounting flange on the motors will VOID your warranty. Install the lug nuts and torque to proper specification. NOTE: Older axles, made in 2002 or earlier have a 2-piece nut. The torque specification for this type of nut is 369 ft.lbs. During 2002, the style of nut changed to a 1-piece nut and the torque specification for this type of nut is 442 ft.lbs. NOTE: Check tire pressure. Place both wheels in a straight ahead position. Set toe-in 1/4 to 3/8" closer in the front than in the rear. Measure toe-in from center of tire to center of tire, preferably at the height of wheel center, at the same height from the ground in the front and in the rear. See Figure 33. Figure 33 Loosen both tie-rod jam nuts. Turn adjustable inner tubes as necessary to align a set of holes in the unbolted end of the outer tube. NOTE: Attempt to maintain equal amounts of exposed threads on both tie-rod ends. Install supplied round spacer in each remaining top hole. Secure outer tie-rod tube to inner tie-rod tubes using 2 supplied 1/2 x 3 1/2" bolts, 2 supplied tie-rod clamp halves and 2 1/2" locknuts. Torque locknuts ft. lbs. 34

36 MOUNTING OF ELECTRICAL COMPONENTS Remove access panel to right hand console panel. Install supplied rocker switch in right hand console. There should be a knock-out in the console that the rocker switch will fit into. Locate wiring harness with red wire with light green stripe and light green wire with red stripe. Plug into rocker switch. Locate wiring harness on left hand side of machine. Connect supplied wire to light green wire in harness. Connect the ring terminal end of supplied wire to the threaded terminal post on the solenoid valve at the Equa-Trac II Valve. Secure with provided nut (already on terminal post). Check wiring. Turn ignition switch "ON" and "OFF". Listen for a soft "clicking" sound at the solenoid valve to insure proper wiring function. Use the provided tie straps as necessary to secure the wire to the sleeved hoses alongside the machine clear of moving parts. Reattach console panels and secure with original fasteners COMBINES: Install supplied microswitch and two #6 x 1 1/4 screws & nuts into console panel containing gear selector lever. Drill holes to mount microswitch such that switch is activated when lever is in 3rd gear. Mount switch underneath panel. Connect existing wires to microswitch. Connect to "COMMON" and "NORMALLY CLOSED" connections. The microswitch will disenable the Mud Hog in 3rd gear. 35

37 PRE-START PROCEDURES ADJUST STEERING STOPS: Locate steering stop bolts at top left and right of king pin housing (bolted to axle endplate). Loosen jam nuts and screw all 4 stop bolts completely in. Turn steering wheel a full right-hand turn. Adjust left rear and right front stop bolts to touch edge of wheel motor frame. Tighten jam nuts. Turn steering wheel a full left-hand turn. Adjust right rear and left front stop bolts to touch wheel motor frame. Tighten jam nuts. Check for tire clearance with narrow tread center settings and extreme axle oscillation,; with wheels fully turned both directions. Make any necessary adjustments. Return wheels to straight ahead position. See Figure 39. Check that all bolts, nuts and hydraulic connections are torqued to specification. Check that all hoses and wires are properly routed, free and clear of moving parts and suitably secured. Check wiring. Turn ignitions switch "ON". Do NOT start engine. Operate MUD HOG toggle switch "ON" and "OFF". Listen for a soft clicking sound at the E-T II valve solenoid to insure proper wiring function. Fill hydrostatic reservoir. Follow CASE INTERNATIONAL specifications and recommendations concerning hydrostatic fluid and the servicing of filters. SEE START-UP PROCEDURE AT END OF TROUBLESHOOTING MANUAL. 36

38 24 MONTH 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 for 24 months from the date of shipment from Tuthill. Normal use and service means that the product will be installed, operated, inspected and maintained in accordance with the applicable Mud Hog manual or instructions and any applicable vehicle manufacturer s manual or instructions. 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 and Canada. [Tuthill does not itself warrant components which bear the name or trademark of another manufacturer. [Such components include but or not limited to ] 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. Tuthill reserves the right to make changes and improvements in design or specifications 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. 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 owner s 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 owner s 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. 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. TUTHILL Drive Systems 9098 West 800 South, P.O. Box 600 Brookston, Indiana USA Tel Fax Toll Free: B