INSTALLATION MANUAL INCLUDING SERVICE PART INFORMATION FOR Mud Hog System III & System IV 2-Speed Rear Wheel Drive FOR JOHN DEERE 9560, 9650, 9660 9750, 9760, 9860 STS COMBINES Mud Hog Model Numbers: JD38453 JD38753 Mud Hog System: SYS. IV SYS. III TUTHILL Drive Systems Brookston Indiana USA Revised 5/2008 P.N. D701316-01
Table of Contents General Information 2 Instructions and Specifications 3 Torque Specifications 3 Safety Procedures 4 Removal of Existing Components 5 Tread Center Adjustments 5 Mounting Adapter and Wheel DriveAssemblies 6 Tires and Frame Heights 7 Hose Guide Installation 8 Equa -Trac II Bracket Mounting 9 Connecting and Routing Hoses 10 Equa-Trac II Valve and Displacement Valve Mounting 11 Bulkhead Tee Installation for Flush Hoses 12 Manifold Block Installation 13 Side Hose Installation 14 System III Hose Connections 15 Left Hand Wheel Drive Hose Installations 16 Right Hand Wheel Drive Hose Installations 17 Equa-Trac II Hose Connections 18 Equa-Trac II Wiring 19 Equa-Trac II Wiring for Models Produced after 2000 20 Equa-Trac II Wiring for 2007 Models 21 Flush Installation (2005 Model and Older) 22 Drain Connections (2005 Model and Older) 23 Drain & Flush Connections (2006 Model and Newer) 24 Switch in Cab (2001 Model Year and Newer) 25 2-Speed Switch Installation (2000 Model Year Only) 26 Oscillation Stop Installation 27 Mounting Wheels/Adjusting Toe-In 28 Equa-Trac Valve Base Assembly 29 2-Speed Valve Assembly 30 Wheel Drive Service Parts 31-32 4WD Mud Hog Vinyl Decal Application Inst. - 24 Month Limited Warranty -
General Information Catalogs This parts catalog is provided to aid in the identification of Tuthill Drive Systems components. It contains an illustration, part number, the required quantity, and a description of each part included in the kit. Catalogs may contain information for several different machines, which use similar Tuthill Drive Systems kits. The appropriate machine model and Tuthill Drive Systems base model number should be selected to assure proper part identification. Each Tuthill Drive Systems conversion package contains all or some of the following kits or subassemblies: A-HYDRAULIC ADAPTER KIT (S) B-HYDRAULIC HOSE KIT C-EQUA-TRAC II VALVE BASE ASSEMBLY D-WHEEL DRIVE BASE ASSEMBLY-RIGHT/LEFT HAND E-TIE ROD EXTENSION SUBASSEMBLY F-MOUNTING KIT G-WHEEL AND TIRE KITS We reserve the right to make changes and improvements in design and specifications without notice and without obligation to provide or substitute new design modifications for those Mud Hog systems or components already in service. Replacement Part Ordering and Returned Parts Information Replacement part orders should include the complete Tuthill Drive Systems part number and description, base model number of Tuthill Drive Systems kit, Tuthill Drive Systems serial number (located on the wheel motor mounting frame or wheel drive half yokes), machine model number, method of shipment, and shipping address information. Parts returned for warranty determination should be accompanied by an explanation of the problem and an RGA (Returned Goods Authorization) number. Before returning any parts, contact the Tuthill Drive Systems Customer Service Department to obtain an RGA number. Any material returned to Tuthill Drive Systems without an RGA number properly displayed on the packaging and/or the returned parts, will NOT be processed and will be returned freight collect. NOTE: Mud Hog and Equa-Trac is a registered trademark of Tuthill Drive Systems 2
Instructions and Specifications This manual provides instruction 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 adaption. 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 Systems 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. CAUTIN: 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 (Class 10.9 metric) Bolts and Grade C Locknuts Size S.A.E. Bolt Torque [1] (ft.lbs.) ¼-20 10-13 7-10 5/16-18 18-25 15-18 3/8-16 35-45 30-35 7/16-14 55-70 45-55 ½-13 90-110 60-80 9/16-12 120-150 90-110 5/8-11 180-200 150-170 ¾-10 300-350 250-280 ¾-16 350-400 - 7/8-9 400-450 359-380 M10-1.5 35-45 30-35 M16-2.0 180-200 150-170 M20-2.5 400-450 350-380 Locknut Torque [2] (ft.lbs. Hydraulic Fittings, Hose Ends & Tube Ends Dash Size (S.A.E.) Thread Size (S.A.E.) Torque[3] (ft.lbs.) -4 7/16-20 9-12 -6 9-16-16 21-24 -8 ¾-16 35-40 -10 7/8-14 55-60 -12 1 1/16-12 77-82 -16 1 5/16-12 110-120 [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. fittings/hose ends and tube nuts. 3
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). 4
Removal of Existing Components Park combine in a 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 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. Disconnect and remove tie-rod ball joints from wheel ends. Remove all wheel end mounting bolts. Remove wheel ends. Wheels and tires MAY be removed separately or left attached to wheel ends. Retain all mounting bolts for later use. NOTE: Always refer to John Deere "TECHNICAL MANUAL" when disassembling any J.D. components. Tread Center Adjustments Available tread center settings are A: 122", B: 130", C: 138", D: 146" and E: 154". Tread settings can be adjusted by sliding stub axles inside of center section. The first figure shows the standard rear axle assembly. The second figure shows the axle in high clearance position. Note: 18.4 x 26 or larger tires may require wider tread settings for proper clearance and steering. See John Deere Manual for further information. 5
Mounting Adapter Plates and Wheel Drive Assemblies Permanent Loctite must be used on bolts. Bolts should be thoroughly cleaned before applying Loctite. Use supplied 3/4-16 x 2 1/2 bolts in place of original bolts. NOTE: grade 9 bolts must be used. Torque 3/4-16 bolts to 390-430 ft.lbs. Do not re-torque bolts that have had Loctite applied once Loctite has had time to cure. NOTE: Mounting pins must be in place before assembling adapter plate to stub axle. Failure to do so will void warranty. Adapter plates are painted and coated with a rust preventative. Any paint, rust preventative or foreign material on mounting surface must be removed prior to assembly to ensure proper clamp load is achieved between wheel drives and JD stub axle mounting surfaces. Excess paint/rust must be removed from JD stub axle endplate. Check flatness of JD endplate prior to installation to ensure proper clamp load is achieved. If endplate is not flat, axle must be replaced prior to Mud Hog installation. John Deere Cast stub axle with 5 bolt pattern is required for this installation. 5 Bolt Stub Axle to Adapter Plate Attachment Service Part Information Torque ¾ x 2 1/4 Bolts to 300-350 Foot Pounds. Permanent Loctite must be used on bolts. Bolts should be thoroughly cleaned before applying Loctite. Do not re-torque bolts that have had Loctite applied once Loctite has had time to cure. CAUTION: Wheel drive assemblies are extremely heavy. Use a lift device of adequate capacity. Qty Part Number Description 10 705334-01 Hex Head Bolt ¾-16 x 2 ½ Gr. 9 2 103799 Endplate Adapter 4 106094 Dowel Pin 12 101881-P1 Hex Head Bolt ¾-10 x 2 ¼ Gr. 8 12 103003 Hardened Washer 3/4 6
Tires and Frame Heights John Deere STS Combine DRIVE AXLE Tire Size SLR Frt Frame Ht 35.5L-32 R2 36.8 26.1 76x50-32 HF3 36.1 25.4 20.8R-42 R2 36.0 25.3 800/70R38 R1W 35.5 24.8 900/65R32 R2 34.8 24.1 20.8R-42 R1 34.2 23.5 520/85R38 32.5 21.8 18.4R-42 R1 32.3 21.6 20.8R-38 R1 32.2 21.5 800/65R32 R1W 31.8 21.1 30.5LR-32 R1 31.0 20.3 STEERING AXLE Stub Axle Bottom Holes 103799 *Adapter Plate bottom holes Stub Axle Bottom Holes 103799 Adapter Plate top holes Stub Axle Top Holes 103799 Adapter Plate top holes Tire Size SLR Rear Frame Ht Rear Frame Ht Rear Frame Ht 28L-26 R2 28.5 27.4 24.4 22.0 28L-26 R1 28.3 27.2 24.2 21.8 18.4-30 R2 28.2 27.1 24.1 21.7 18.4-30 R1 27.0 25.9 22.9 20.5 600/65R28 R1W 26.4 25.3 22.3 19.9 18.4R-26 R1 25.1 24.0 21.0 18.7 *John Deere cast stub axle with 5 mounting holes, spacers, locating pins and Grade 9 bolts are required when wheel drives are mounted in lower holes of adapter plates. Static Loaded Radius (SLR) and Frame Heights are in inches and for reference only. Front Frame Height is measured from bottom of frame to ground directly behind the front axle. Rear Frame Height is measured from bottom of frame to ground at rear jack point on frame in front of rear axle. 7
Hose Guide Installation Hose Guide (700902-01) Service Part Information: Qty Part Number Description 2 700902-01 Hose Guide 8
Equa-Trac II Bracket Mounting Use Existing Holes to Mount Valve Sub-Assembly Mount Equa-Trac II valve sub-assembly, using supplied ½ bolts, nuts and washers on LH side of frame. Service Part Information: Qty Part Number Description 2 118 Flat Washer 1/2 2 309 Flange Head Bolt ½-13 x 1 ¼ Gr.8 4 8103323 Lock Washer 1/2 2 89422301 Lock Nut ½-13 Gr.8 9
Connecting and Routing Hoses Before connecting hoses to E-T II valve and wheel drives, match straight ends of the two 109" hoses with the 45 end of the 113" case drain hose. Slide the large diameter 88" long cordura (nylon) sleeve over these hoses. Match the small -06 end of the 90" flush hose with the 90 elbow end of the 83.5" 2-speed hose. Route these hoses thru one of the 80" small diameter cordura sleeves. These two sets are to be used for connections on the right-hand side. Match the straight ends of the two 143" hoses with the 45 elbow end of the 149" case drain hose. Slide the large diameter 140" long cordura sleeve over the hoses. Match the small -06 end of the 110" flush hose with the 90 elbow end of the 104" 2-speed hose. Route these hoses thru one of the 80" small diameter cordura sleeves. These two sets are to be used for connections of the left-hand side. Route sleeved hoses through hose guides on axle center section. The right hand hoses will be routed thru the one supplied and one existing hose guide, above the center A-frame section and to the valve. The left hand hoses will be routed thru the one supplied and one existing hose guide, next to the frame crossmember and looped back to the front side of the valve. NOTE: For 2-speed units, refer to the next 3 pages for proper connections. The flush hoses connect to the bulkhead tee located beside E-T II valve. The straight ends of the 2-speed hoses connect to the tee on the 2-speed valve. Check that hoses are routed smoothly, free of kinks and clear of moving parts. Torque all hose ends and hose clamp bolts to specification. CASE DRAIN HOSE TO RESERVOIR CASE DRAIN HOSE TO WHEEL MOTOR CASE DRAIN HOSE TO WHEEL MOTOR FORWARD PRESSURE HOSE TO WHEEL MOTOR DRAIN FROM 2-SPEED VALVE FORWARD PRESSURE HOSE TO PUMP REVERSE PRESSURE HOSE TO WHEEL MOTOR PRESSURE TO 2-SPEED VALVE REVERSE PRESSURE HOSE TO PUMP 10
Equa-Trac II Valve and Displacement Valve Mounting 2-Speed Valve 701290-01 Equa-Trac II Valve 700901-01 Drain Hose 32516-1490 High Pressure Hose 32411-1430 2-Speed Hose 31012-0835 High Pressure Hose 32414-1090 11
Bulkhead Tee Installation for Flush Hoses 90 Elbow 08 JIC 208149-P1 Bulkhead Tee 08 JIC 200140-P1 Flush Hose 32518-1200 Flush Hose 32215-1100 Flush Hose 32215-0900 Service Part Information Qty Part Number Description 1 200140-P1 Bulkhead Tee 08 JIC 1 208149-P1 90 Elbow 08 JIC 1 32518-1200 Flush Hose 120 1 32215-0900 Flush Hose 90 1 32215-1100 Flush Hose 110 Service Part Information for Previous Page Qty Part Number Description 1 700901-01 Equa-Trac II Valve Assembly * 2 100270-P1 Hex Head Bolt 3/8-16x1 ½ Gr.8 4 8120382 Lock Washer 3/8 1 701290-01 2-Speed Valve Assembly* 2 100581-P1 Hex Head Bolt 3/8-16x1 ¼ Gr.8 2 31012-0180 2-Speed Hose 18 1 31012-1040 2-Speed Hose 104 LH Motor 1 31012-0835 2-Speed Hose 83.5 RH Motor 2 32411-1430 High Pressure Hose LH Motor 2 32414-1090 High Pressure Hose RH Motor *See end of manual for assembly breakdowns 12
Manifold Block Installation Service Part Information Qty Part Number Description 4 8454797 Hex Head Bolt 7/16-14 x 3 ½ 1 212125-P1 45 Elbow 12 ORB x 12 JIC 1 104629 Manifold Block short 1 30111-0960 Reverse Pressure Hose 1 102244-P1 O-ring Service Part Information Qty Part Number Description 1 708559-01 Manifold Block long 1 212129-P1 90 Elbow 12 ORB x 12 JIC 4 708560-01 Hex Head Bolt 7/16-14 x 5 1 30111-0780 Forward Pressure Hose 1 102244-P1 O-ring Install manifold blocks as shown above. The long block, o-ring, 90' elbow and 7/16-14 x 5 bolts go on the bottom (forward) side of the pump and the short block, o-ring, 45' elbow and 7/16-14 x 3 1/2 bolts go on the top (reverse) side of the pump. 13
Side Hose Installation Flush Tee 200140-P1 Flush Hose 32518-1200 Hose Clamp Assy. 101702-P1 101754-P1 89422275 101335-P1 Drain Hose 3251B-1000 30111-0960 Reverse HP 30111-0780 Forward HP Attach the hose clamp assembly, as shown above, using supplied 5/16 bolt and nut. Route the forward and reverse hoses through the two pieces of cordura along with the flush and drain lines. The drain line can be tied to an existing tube and routed to the reservoir. Service Part Information: Qty Part Number Description 1 101702-P1 Hose Clamp 1 101754-P1 Clamp Plate 1 101335-P1 Hex Head Bolt 5/16-18x3 ¼ Gr.8 1 89422275 Lock Nut 5/16-18 1 30111-0780 Forward Pressure Hose 78 1 30111-0960 Reverse Pressure Hose 93 1 32518-1200 Flush Hose 120 1 3251B-1000 Drain Hose 100 2 103379-0620 Cordura Sleeve 62 1 200140-P1 Bulkhead Tee 08 JIC 14
System III Hose Connections 15
Left Hand Wheel Drive Hose Installation Drain Hose 32516-1130 Reverse Pressure Hose 32414-1090 Forward Pressure Hose 32414-1090 2-speed Hose 31012-0835 Flush Hose 32215-0900 SERVICE PART INFORMATION: QTY PART NUMBER DESCRIPTION 1 31012-0835 2-Speed Hose 83.5 1 32215-0900 Flush Hose 90 2 32414-1090 High Pressure Hose 109 1 32516-1130 Drain Hose 113 1 101700-0900 Cordura Small Diameter 90 1 103379-0880 Cordura Large Diameter 88 16
Right Hand Wheel Drive Hose Installation Reverse Pressure Hose 32411-1430 Forward Pressure Hose 32411-1430 Drain Hose 32516-1490 Flush Hose 32215-1100 2-speed Hose 31012-1040 SERVICE PART INFORMATION: QTY PART NUMBER DESCRIPTION 1 31012-1040 2-Speed Hose 104 1 32215-1100 Flush Hose 110 2 32411-1430 High Pressure Hose 143 1 32516-1490 Drain Hose 149 1 101700-0900 Cordura Small Diameter 90 1 103379-1400 Cordura Large Diameter 140 17
Equa-Trac II Hose Connections Drain Hose 3251B-1000 2-Speed Hose 31012-0180 Drain Hose 32516-1130 Drain Hose 32516-1490 hidden from view above valve Forward Pressure Hose 32414-1090 Reverse Pressure Hose 32414-1090 2-Speed Hose 31012-0180 Forward Pressure Hose 32411-1430 Reverse Pressure Hose 32411-1430 SERVICE PART INFORMATION: QTY PART NUMBER DESCRIPTION 2 31012-0180 2-Speed Hose 18 2 32411-1430 High Pressure Hose LH Motor 143 2 32414-1090 High Pressure Hose RH Motor 109 1 32516-1490 Drain Hose LH Motor 149 1 32516-1130 Drain Hose RH Motor 113 18
Equa-Trac II Wiring 2-speed wire assy. (701289-01) (Hi/Lo) Existing wiring harness on machine Wiring connection from ETII valve (On/Off) SERVICE PART INFORMATION: QTY PART NUMBER DESCRIPTION 1 701289-01 2-Speed Wire Assembly (for 2000 models only) For models produced after 2000, the 2-speed harness is already on the machine. Some machines will have a 2-way connector for the 2-speed that will connect directly to the 2- speed displacement control valve. Other models will have a 3-way connector for 2-speed and the supplied jumper harness will need to be used to adapt the 3-way connector to the 2-way connector on the 2-speed displacement control valve. See the next page for more information. 19
Equa Trac II Wiring For models produced after 2000: Later model combines have a 2-speed harness already on the machine. Some models will have a 2-way connector and others will have a 3-way connector for the 2-speed. The harness in the above picture has a 2-way connector that is to be attached to the Equa-Trac II valve to turn the Mud Hog on and off. The 3-way connector shown in the picture is for 2-speed and can be used with the supplied jumper harness to adapt the 3-way connector to the 2-way connector that is on the 2-speed displacement control valve. SERVICE PART INFORMATION: QTY PART NUMBER DESCRIPTION 1 704502-01 Jumper Wire Assembly (for later models only) 20
Equa Trac II Wiring For 2007 models: 3-Way Connector to 2 Speed Solenoid 2-Way Connector to Equa Trac II Solenoid Later model combines have a 2-speed harness already on the machine. Some models will have a 2-way connector and others will have a 3-way connector for the 2-speed. The harness in the above picture has a 2-way connector that is to be attached to the Equa-Trac II valve to turn the Mud Hog on and off. The 3-way connector shown in the picture is for 2-speed and can be used with the supplied jumper harness to adapt the 3-way connector to the 2-way connector that is on the 2-speed displacement control valve. See Jumper Wire Assembly on page 20. 2008 and newer 9770 models have a 4 way connector and need the wire harness in the kit with the 4 way connector. 21
Flush Installation (2005 Model and Older) Disconnect hose and install flush fitting as shown below 105284 Tube ¾ Connect 120 inch flush hose 200231 Reducer Reconnect hose from combine Connect this end of tube to elbow on reservoir 104977 Check Valve 200296 Swivel Run Tee With hydraulic system drained, disconnect existing hose from elbow in reservoir. Install supplied ¾ inch tube assembly to reservoir elbow. Install check valve, arrow on check valve must point toward reservoir. Install tee to check valve and reducer to tee. Install supplied 120 inch flush hose to reducer. Reconnect hose from combine to tee. SERVICE PART INFORMATION: QTY PART NUMBER DESCRIPTION 1 200296 Swivel Run Tee 12 ORS 1 200321 Reducer 12 ORS-F x 08 ORS-M 1 32518-1200 Flush Hose 120 1 104977 Check Valve 1 105284 Tube Assembly 3/4 22
Drain Connections (2005 Model and Older) 200321 Reducer 3251B-1000 Drain hose 200296 Tee Use the supplied tee and reducer to connect the drain hose to the reservoir as shown. SERVICE PART INFORMATION: QTY PART NUMBER DESCRIPTION 1 200296 Swivel Run Tee 12 ORS 1 200321 Reducer 12 ORS-F x 08 ORS-M 1 3251B-1000 Drain Hose 100 23
Drain and Flush Connections (2006 Model and Newer) Cooler Return Line Flush 200296 Tee 200321 Reducer Drain 200296 Tee 200321 Reducer Swivel Adapter 706906-01 Check Valve 104977 Flush Hose 32518-1200 To Bulkhead Tee Drain Hose 3251B-1000 To ET II Valve With hydraulic system drained disconnect cooler return line and remove adapter from reservoir. Install the supplied tees, check valve and swivel adapter between existing cooler return line and reservoir. Arrow on check valve must point toward reservoir. Use supplied reducers to connect drain and flush hoses as shown. Connect opposite end of drain and flush hose to valve. See page 11 for bulkhead tee installation for flush hose and page 18 for Equa-Trac II hose connections. SERVICE PART INFORMATION: QTY PART NUMBER DESCRIPTION 2 200296 Swivel Run tee 12 ORS 2 200321 Reducer 12 ORS-F X 08 ORS-M 1 3251B-1000 Drain Hose 100 1 32518-1200 Flush Hose 120 1 104977 Check Valve 1 706906-01 Swivel Adapter 12 ORB/120RS 24
Switch in Cab (2001 Model Year and Newer) Remove switch cover on console, switch and wiring already exist on combine. 25
2-Speed Switch Installation (2000 Model Year Only) Mounting location for supplied 2-speed toggle switch (400007-P1) and decal (105077). Mounting location for Fuse Holder assy. (700899-01). For 2-speed control, you will need to drill holes in your console and mount the supplied toggle switch and fuse holder. One lead on the fuse holder connects to a hot source that is only hot when the key is ON. The other lead on the fuse holder connects to the toggle switch. Use the supplied wire and female slides to connect the toggle switch to the displacement control valve. You will need to route the wire from the cab back to the valve. Use the supplied tie straps to keep wire out of any moving parts. Use supplied "HI/LO" label for toggle. 26
Oscillation Stop Installation To order oscillation stops shown below, call Mud Hog Customer Service 1-800- 348-2474 and order K708042, Oscillation Stop Kit. Socket head cap screw (701777-01) Oscillation stop (700903-01,-02) SERVICE PART INFORMATION: QTY PART NUMBER DESCRIPTION 1 700903-01 Oscillation Stop LH 1 700903-02 Oscillation Stop RH 4 701777-01 Bolt M10-1.5 x 40mm full thread If oscillation stop looks like this no change is necessary. 27
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. NOTE: the wheel for a 28L-26 tire will likely have the center disc inverted from the position found in most other wheels. This wheel should be mounted as shown in order to keep the center of the wheel in-board of the wheel motor mounting flange. 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. Make sure that the steering cylinder rod is centered in the cylinder housing and mount tapered studs of tie-rod ends into tie-rod brackets or ears on wheel motor drive assemblies. Install slotted hex nuts. Torque hex nuts to 150-170 ft. lbs. and insert cotter pins. Place both wheel motor drive assemblies in straight ahead position. Set toe-in 1/4 to 3/8" closer together 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. If necessary, loosen tie-rod clamp, and remove bolts from adjustable tie-rod and turn outer tie-rod tube to adjust toe-in. Replace bolts and remeasure toe-in. NOTE: Attempt to maintain equal amounts of exposed threads on both tie-rods. PRE-START PROCEDURES ADJUSTING 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. 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 ignition 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 John Deere specifications and recommendations concerning hydrostatic fluid and the servicing of filters. SEE START-UP PROCEDURE AT END OF TROUBLESHOOTING MANUAL 28
Equa Trac Valve Base Assembly VALVE BASE ASSEMBLY (SERVICE PARTS ONLY) Item QtyPer Part Number Description 1 1 200225 TEE (04 ORB-M x 04 JIC-M x 04 JIC-M) 2 1 200110-P1 CAP (04 JIC-F) 3 1 200083-P1 ADAPTER (06 ORB-M x 08 JIC-M) 4 4 200041-P1 ADAPTER (12 ORB-M x 08 JIC-M) 5 4 200163 HEX SOCKET PLUG (1/4 ORB-M) 6 2 101679-M1 ADAPTER (12 ORB-M x 04 ORB-F) 7 1 704491-01 Solenoid Cartridge Valve with wire connectors 8 1 704492-01 Solenoid Coil with wire connectors 9 1 204041-P1 ADAPTER (04 ORB-M x 04 JIC-M) 10 1 103709 TUBE ASSEMBLY, PILOT PRESSURE NI 1 200040-P1 SWIVEL BRANCH TEE (08 JIC) NI 1 204048-P1 SWIVEL RUN TEE (04 JIC) NI 1 208040-P1 REDUCER (08x04 JIC) NI 1 212129-P1 90 ELBOW (12 ORBxJIC) NI 1 212130-P1 90 ELBOW LONG (12 ORBxJIC) NI 8 5372 BRAIDED LOOM NI 2 5380 SEAL-WEATHERPACK #12010293 NI 1 700904-01 Shroud-Weatherpack #12010973 NI 2 701064-01 Pin, Weatherpack #12124582 NI 1 150346 SEAL KIT - ET-II (ORB O-RINGS) NI = NOT ILLUSTRATED 29
2-Speed Valve Assembly 400155 Pin 5380 Seal 702468-01 Connector 702469-01 Lock 5372 Braided Loom 90 Elbow 204049-P1 Branch Tee 200123-P1 90 Elbow 204049-P1 Solenoid Valve 103123 Valve Block 104707 SERVICE PART INFORMATION: QTY PART NUMBER DESCRIPTION 1 103123 Solenoid Valve 1 104707 Valve Block 1 200123-P1 Branch Tee 04 ORB x JIC x JIC 2 204049-P1 90 Elbow 04 ORB x JIC 2 400155 Pin Metri-Pack 280 8 5372 Braided Loom 2 5380 Seal Weatherpack #12010293 1 702468-01 Connector M 2-Way Metri-Pack 2 702469-01 Lock 2-Way Metri-Pack 280 30
Wheeldrive Service Parts ITEM QTY PART NUMBER DESCRIPTION 1 2 100276-P1 JN 5/8 UNC GR.5 2 2 101345-P1 HHB 5/16-18x2, GR.8 3 1 103640 King Pin Housing 4 1 103675 Kingpin 5 1 103685 Thrust Washer 6 2 103686 Kingpin Bushing@ 7 2 103693 Tube Clamp 8 1 103694 Tube Clamp Plate 9 1 103695 FW 1.9 x 3.23 x.072 10 1 104715 Tube Assy. S11 2 Speed RF/LR 11 1 104716 Tube Assy. S11 2 Speed RR/LF 12 2 103815 Snap Ring 13 10 103864 Lug Nut M20 w/washer 14 1 103958 Set Screw, ½-13 x 1 1/4 15 1 104717 Flush Tube Assy. S11 2 Speed 16 1 104718 Tube Clamp-3/8,.656 Hole 17 1 200020-P1 Adapter, 08 ORB-M x 08 JIC-M 18 2 200041-P1 Adpater, 12 ORB-M x 08 JIC-M 19 1 208063-P1 Adapter, 08 ORB-M x 06 JIC-M 20 1 101671-P1 Hard Washer 5/8 21 2 8103899 Expansion Plug 2.5 NOM 22 2 8120214 SLW 5/16 23 8 8223540 HHB 7/8-9 x 2, GR.8 24 2 8223512 HHB 5/8-11 x 1 ¾, GR.8 25 2 89411032 Grease Fitting, ¼-28 90 26 8 102354-P1 FW 7/8 27 1 104358 Wheel Motor Frame 28 1 105537 ME11 2SP WM LH SAE HP (System IV) 28 1 105536 ME11 2SP WM RH SAE HP (System IV) 28 1 104945 MS11 2SP WM LH SAE HP (System III) 28 1 104944 MS11 2SP WM RH SAE HP (System III) 29 1 200093-P1 Adapter 06 ORB-M x 04 JIC-M NI 4 101407-P1 HHB 5/8-11 x 2 ¼, GR.8 ZN NI 4 101671-P1 Hard Washer 5/8 NI 1 701314-01 Steering Bracket Weldment, LH * NI 1 701314-02 Steering Bracket Weldment, RH * NI 1 708243-01 Steering Bracket Weldment LH * NI 1 708243-02 Steering Bracket Weldment, RH * @ Included with 104358 wheel motor frame. * See page 32 for assembly information 31
Wheeldrive Service Parts Wheel Drives are shipped with 701314-01 & -02 Steering Brackets installed onto wheel motor frames. These are used on STS combines built prior to July 2007. 708243-01 & -02 Steering Brackets are shipped loose in the kit and are used on STS combines from July 2007 and newer. When replacing 701314-01 & -02 with 708243-01 & -02, apply Loctite #271 to bolt threads and torque mount bolts to 180-200 ft.lbs. 32
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.
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 47923 Tel 219 279-2801 Fax 219 279-2390 www.tuthill.com Toll Free: 1-800-348-2474 B