INSTALLATION MANUAL FOR Mud Hog Rear Wheel Drive FOR CNH 5088, 6088, 7088 and 5130, 6130, 7130 COMBINES Mud Hog Model Number: CNH42005 A Product of Tuthill Drive Systems P.O. Box 600 Brookston, Indiana 47923 Fax 219-279-2390 1-800-348-2474 www.mudhog.com Revised Jan 2012 P.N. D709351 1
REAR WHEEL ASSIST The purpose of the Rear Wheel Assist Axle is to provide power to the steering wheels for the purpose of increasing total tractive effort and to improve steering in extreme ground conditions. OPERATING PRINCIPLE The Rear Wheel Assist Axle is equipped with dual-displacement motors. When the Rear Wheel Assist is engaged, the amount of wheel torque obtained is strictly a function of hydrostatic pressure. The higher your gear selection, the higher your hydrostatic pressure will be. You will get a higher percentage of Rear Wheel Assist in the higher gear ranges. It is very important to maintain traction with your front wheels. The pressure to develop wheel torque and the flow to synchronize the speed of the rear wheels with the front wheels is obtained from the main hydrostatic transmission. If a front wheel loses traction (spins out), the hydrostatic pressure drops and the amount of power assist from the Rear Wheel Assist is reduced. Shifting to the next higher gear ratio may then be helpful to reduce the amount of torque on the front wheels, or lightly touching the brakes to stop front wheel spin-out. It is recommended that you use your Rear Wheel Assist at all times when working in the field. You gain several advantages, including: You will be operating at lower system pressure, thereby tending to extend the life of your hydrostatic transmission and gear train. Running at lower system pressure will normally lower hydrostatic oil temperature. OPERATION There is a switch located on the control panel in the cab to turn the RWA ON and OFF and to switch the motors displacement. Operating with the switch in the middle position puts the motors in their smaller displacement. This has the effect of still getting some tractive effort from the rear wheels while at the same time allowing greater speed than the fully ON position, which offers the greatest tractive effort from the rear wheels, and the lowest speed. The system can be engaged, on the Go. When the switch is moved to the On position. The combine will slow and the hydrostatic control lever must be moved forward to maintain the same ground speed. With the RWA switch in the On positions, the combine maximum speed will be less than the speed with the switch in the Off position, since the rear wheels take some of the flow from the hydrostatic transmission. This has the effect of a 3-speed device in each gear with more reduction, therefore, less speed and more tractive effort when the RWA is on. When the switch is moved to the Off position, the combine will accelerate. The system can be engaged or disengaged on the Go. However it will extend the life of your hydrostatic system to do so at lower pressures and speeds. WARNING: The RWA should not be engaged or disengaged while traveling at high road speeds since the sudden speed change could cause loss of control and this practice also introduces pressure spikes into the hydrostatic circuit that can be detrimental to the components. PREPARE COMBINE Park combine. Apply parking brake. Disconnect battery terminals, ground cable first. Remove oil, dirt, and crop material form the area where the work is to be done. Lower feeder housing fully to the ground. Drain the hydraulic reservoir. 2
REMOVAL OF ORIGINAL COMPONENTS Using a suitable lift device, jack or hoist, raise rear of machine so that rear tires are several inches off the ground. Place jack stands securely under the machine s rear center section. Remove rear tires. Remove tie rod tapered ball joints from non-powered rear axle assembly. Do not remove ball joints from existing tie rods. Remove all bolts connecting axle extensions and center section. Remove axle extensions from center section. Steering cylinder and tie rods will be re-used and should remain mounted on machine. Remove tie rod ball joint from wheel end on both ends of axle. Remove all bolts and axle extension from both ends of center section. 3
INSTALLATION OF WHEEL DRIVES AND AXLE EXTENSIONS The powered rear axle is designed to work with different tire options. Some tire options have a different wheel offset, thus different tread widths are achieved with the different tires. Shown below is a list of the tire options, wheel offsets, and available tread widths. NOTE: Not all tires and/or tread widths can be used with every front tire/width combination. Refer to CNH for further information.. Tire Selection Chart for 5088, 6088, & 7088 STEERING TIRES Wheel Dished In Wheel Dished Out Stop Bolt Length * mm (in.) mm (in.) mm (in.) Axle Width Position Tread Width Center/Center 18.4-26 R1 50 (2.0) 13 (0.5) 1 3201 (126.0) 50 (2.0) 13 (0.5) 2 3353 (132.0) 50 (2.0) 13 (0.5) 3 3506 (138.0) 50 (2.0) 13 (0.5) 4 3658 (144.0) 18.4-26 R2 50 (2.0) 13 (0.5) 1 3201 (126.0) 50 (2.0) 13 (0.5) 2 3353 (132.0) 50 (2.0) 13 (0.5) 3 3506 (138.0) 50 (2.0) 13 (0.5) 4 3658 (144.0) 480/70R30 R1W 39 (1.5) 13 (0.5) 2 3175 (125.0) 50 (2.0) 13 (0.5) 2 3353 (132.0) 50 (2.0) 13 (0.5) 4 3658 (144.0) 540/65/R30 R1W 39 (1.5) 13 (0.5) 2 3176 (125.1) 50 (2.0) 13 (0.5) 2 3354 (132.1) 50 (2.0) 13 (0.5) 3 3507 (138.1) 50 (2.0) 13 (0.5) 4 3659 (144.1) 600/65R28 R1W 65 (2.6) 38 (1.5) 2 3383 (133.2) 65 (2.6) 20 (0.8) 3 3535 (139.2) 65 (2.6) 13 (0.5) 4 3687 (145.2) 28L-26 R1 140 (5.5) 63 (2.5) 2 3529 (138.9) 140 (5.5) 23 (0.9) 4 3834 (150.9) 28L-26 R2 140 (5.5) 52 (2.0) 3 3680 (144.9) 140 (5.5) 31 (1.2) 4 3833 (150.9) mm (in.) * - Stop bolt length measured from cast surface to end of socket set screw. Insert supplied Wheel Drive Assemblies into center section. Install wheel drives with hydraulic adapters pointing toward the front side of the axle as shown in below picture. To achieve the Axle Width Position #1, the Wheel Drive should be slid in until the outermost hole of the axle extension is aligned with the outermost hole of the center section. To achieve the Axle Width Position #2, one set of holes should be exposed outside of the center section on each end of the axle. To achieve the Axle Width Position #3, two sets of holes should be exposed outside of the center section on each end of the axle. To achieve the Axle Width Position #4, three sets of holes should be exposed outside of the center section on each end of the axle. Slide axle extensions to tread width desired. NOTE: Rear axle should be installed to keep the rear tire centerline as close as possible to the front tire centerline. Wider tread widths will generally allow greater steering angles as there will be more clearance between the tires and the machine. 4
Shim Axle Width Position #2 shown in picture with one set of holes on axle extension exposed. Insert original shim on rear side of axle extension. Insert original bolts thru center section and each stub axle. Above picture shows the axle extension in the Axle Width Position #2. For the other positions move the axle extension inward or outward from this picture. Install original nuts onto the bolts. Torque all bolts to original specification as noted in CNH manual. Note, axle extension is shown in upper position of center section. It can be placed in lower position if more rear axle height is needed to level machine. If lower position is used, then steering brackets should be removed from wheel motors and swapped side for side, thus turning the taper over and installing the tie rod from the top which will keep the tie rod more level. Apply permanent Loctite #271 to bolts and torque to 300-350 ft.lbs if steering bracket is re-installed. INSTALLATION OF STEERING COMPONENTS With the wheel drive positioned straight forward, remove bolts from tie rod and adjust the inner tie rod to match the axle extension width. NOTE: tie rod in below picture needs to be moved inward one more hole to get wheel drive positioned straight forward for axle width position #2. Install tie rod tapered ball joints into steering brackets on wheel drives. Install original slotted hex nuts and torque to original specification as noted in CNH manual. Install cotter pins. Secure tie rod using original bolts, clamp halves and nuts. Do not torque at this time. This will be done after setting toe-in and the end of the installation. 5
INSTALLATION OF VALVE Install a long and short 90 12 ORB x 12 ORS elbow into valve as shown below. Orientate elbows to point to the LH side of machine as shown. Locate existing holes in frame on front side of rear axle. See picture below. Install Valve Bracket using supplied 5/16-18 x 1 bolts, flat washers and lock nuts. Torque bolts to 18-25 ft.lbs. Install Valve Assembly and Bulkhead Bracket and Bulkhead Tee onto valve bracket using supplied 3/8-16 x 1 ½ bolts and lock washers. Torque bolts to 35-45 ft.lbs. Short elbow Long elbow Existing holes 5/16 x 1 bolts, flat washers and nuts Valve Bracket 3/8 x 1 ½ bolts and lock washers (also install bulkhead bracket and tee shown in next picture) Bulkhead Bracket and Tee INSTALLATION OF HOSE GUIDES Install supplied hose guide as shown below using supplied M8-1.25 x 20mm bolts and nut inserts that fit into hex shaped holes in machine frame. NOTE: any of the 3 sets of holes can be used for the hose guide. For narrow axle width positions, use the holes located further forward. For wider axle positions, use the holes toward the rear. Install the other supplied hose guide on RH side of machine. Torque to 18-25 ft.lbs. 6
INSTALLATION OF HOSES AND WIRE HARNESS FROM MOTORS TO VALVE Install hoses as shown below. Forward/Reverse pressure hoses are 4-wire braid and 61 long with a 45 fitting on one end and a straight fitting on the other end. Drain hoses are 63 long. Locate the supplied wire harness that has two 69 long lengths teeing into an 11 long length. Bundle together the straight ends of two of the For/Rev hoses and one of the drain hoses and the end of one 69 long length of wire harness and slide thru each of the supplied pieces of cordura sleeving. Slide the bundles thru the previously installed hose guides toward the wheel drives. The 45 end of the For/Rev hoses will go toward the valve under the center of the machine. Connect 45 ends of forward and reverse hoses and straight end of drain hoses to valve. Connect straight ends of forward and reverse hoses and drain hose to wheel drives. See 4 pictures below. Wire Harness Rear fitting connect to top fitting at valve Drain (middle) connect to bulkhead tee at valve Front fitting connect to top fitting at valve Left hand wheel drive Drain (middle) connect to bulkhead tee at valve Front fitting connect to bottom fitting at valve Right hand wheel drive Wire Harness Rear fitting connect to bottom fitting at valve On the left hand side of the axle, shown in left picture above, connect one high-pressure hose to front fitting on the wheel motor and to the bottom fitting at the valve. Connect the other high-pressure hose to rear fitting on the wheel motor and to the top fitting at the valve. Connect the drain hose to the center fitting on the wheel motor and to the bulkhead tee under the valve. Connect the wire harness to the wire harness at the wheel motor and use a supplied tie strap to secure the harness to a hose. On the right hand side of the axle, shown in right picture above, connect one high-pressure hose to front fitting on the wheel motor and to the top fitting at the valve. Connect the other high-pressure hose to rear fitting on the wheel motor and to the bottom fitting at the valve. Connect the drain hose to the center fitting on the wheel motor and to the bulkhead tee under the valve. Connect the wire harness to the wire harness at the wheel motor and use a supplied tie strap to secure the harness to a hose. Note: as noted above, the high-pressure hoses on the RH wheel drive should be connected opposite the hoses on the LH side. The front port on the RH side has Reverse pressure while the rear port on the LH side is Reverse. Opposite ports are Forward pressures. See next page for more connection details at the valve. Torque 08 JIC hose connections to 37-42 ft.lbs. 7
Hose from rear at LH wheel drive. Hose from front at LH wheel drive. Hose from center at LH wheel drive Two-speed wire harness coming from wheel motors. Hose from front at RH wheel drive. Hose from rear at RH wheel drive. Hose from center at RH wheel drive 8
INSTALLATION OF HOSES FROM COMBINE TO VALVE The hydrostatic oil may be drained at this time. Install supplied 12 ORB x 12 ORS 90 fitting into both of the manifold adapter blocks. Do NOT tighten at this time. Remove the flange connections on the hydrostatic pump located on the LH side of the machine. Install the long manifold adapter block between the pump and the flange connection on the bottom of the pump with four supplied 7/16 x 5 ½" bolts. Install the short manifold adapter block between the pump and the flange connection on the top of the pump with four supplied 7/16 x 3 ¼ bolts. Torque bolts to original specification as noted in CNH manual. Manifold block 90 fitting Connect hose to long elbow on valve Middle of machine Manifold block 90 fitting Connect hose to short elbow on valve Rear of machine 9
Connect end of 111 long hose to elbow on top manifold. Route hose down LH side of machine and thru hole as shown below. Route hose over to valve and connect to short elbow on valve. Connect end of 96 long hose to elbow on bottom manifold. Route hose to valve and connect to long elbow on valve. Route hoses thru hole Connect hose from top manifold Connect hose from bottom manifold 10
Install the supplied 06 ORB x 08 JIC adapter in block on top of pump. See below picture. Connect straight end of 126 drain hose to adapter. Route hose down LH side of machine with other hoses and over to valve. Connect 90 end of hose to bulkhead tee at valve. Do not tighten hose ends at this time. Install 06 ORB x 08 JIC adapter and connect drain hose. Connect supplied 65 long wire harness to valve. Connect 126 drain hose to bulkhead tee under valve. 11
Splice the hose on the LH side of machine noted in below picture. Install supplied hose barb tee. Connect blank end of 124 drain hose to tee. Route hose down LH side of machine with other hoses and over to valve. Connect 90 end of hose to drain adapter on valve. See 2 nd picture below. Do not tighten hose ends at this time. Splice this hose. Install tee and clamps. Install blank end of 124 hose here. Connect 90 end of 124 hose here. 12
Connect supplied 65 long wire harness to valve connector (see 3rd picture above) and route with hoses to LH side of machine and connect to existing wire harness with black #328 wire and white #63 wire (see below picture). Install supplied hose guide into existing hole on side of machine using two supplied M10-1.5 nuts. Existing wire harness on machine. Hose guide Install supplied wire harness that has one 10 length with a ring terminal and one very long length of wire with no terminal. Connect ring terminal at valve to one of the valve mounting bolts. Connect 2-way connector to wire harness coming from wheel motors. See below picture. Ring Terminal 2-way connector Route supplied wire harness from valve with hoses to LH side of machine. This long length of wire will later be routed up the LH side of the machine to the cab. Secure the hoses and wire harnesses using tie straps. Locate away from contact with any moving parts or places of abrasion. Torque all 12 hose ends and manifold adapters to 77-82 ft.lbs, -08 hose ends and drain fitting at pump to 37-42 ft.lbs. 13
ELECTRICAL INSTALLATION Locate supplied wire harness with long length of wire that was previously connected to valve mount bolt and to 2-speed harness from motors and route up LH side of machine along with other wiring on machine to RH console in cab. Drill a 1/8 diameter hole in existing grommet under LH side of cab and insert wire thru drilled hole. Drill 1/8 diameter hole thru here under left side of cab. Route wire across the cab behind the seat with other wiring to RH console. Wire routing LH side of cab RH console In cab, on right console, remove a blank in location for Rear Wheel Drive. Locate connector #X060 with white #63 wire and beige #65 wire for RWD. See picture below. Position for rocker switch 14
To get wiring to work with supplied 3-position rocker, the wiring locations in the connector will need to be modified. Install female spade onto supplied wire harness that was routed from rear axle into cab. Insert female spade into location #6 on connector to match up with correct spade on rocker switch that will be hot when the rocker is only in the middle position and NOT hot in either of the other positions. This wire will control the solenoids on the wheel motors that control the displacement of the wheel motors. When the wire is hot, the RWD wheel motors will be in minor displacement and allow greater speed and less torque than when you have the rocker switch turned all the way on into the last position on the rocker. The existing wire (white in picture) in position 1 of the existing connector needs to be moved to position 3. This wire should be hot when the ignition key is on. Using supplied small length of wire, female spade, and splice, connect to position 1 or 2 and splice to beige wire installed into position 5. These wires should be hot when the rocker is in both the middle position and the furthest position from off. This is the wire that activates the valve to turn the RWD on and off. Location #6 Long wire routed from rear axle. Beige wire, leave in position 5. Move white wire from position 1 to 3. Install short wire into position 1 or 2 and splice to beige wire in position 5. RWD connector #X060 Install supplied yellow lens with combine image into supplied rocker switch. Position connector in opening from removed blank and install the supplied rocker switch. Slide switch into its position. Tie strap harness to prevent contact with moving parts and plants. Installed rocker 15
SETTING TOE-IN Install the new tire and wheel assemblies using supplied spacers and M20 x 70 lug bolts. Refer to Tire Selection Chart earlier in manual to see if wheels should be dished in or dished out for proper tread width and machine clearance. Apply supplied wheel torque decals to each wheel. Torque lug bolts to 450 ft.lbs. With rear of combine on blocks and steering wheels straight ahead, check steering wheel toe-in by placing a mark at the center of tread at the rear of each tire at the same distance from the ground as the center of the wheel hub. Measure the distance, X, between these two marks. Rotate tires by hand until the two marks are at the same height from the ground at the front of the tires and measure the distance, Y, between the two marks. Dimension X minus dimension Y should be 1/4-3/8", when measured at tire outside diameter. To adjust toe-in, loosen clamp on steering tie rods, remove bolts connecting inner and outer tie rods and twist tie rod to make rod length longer or shorter as required to obtain correct toe-in. Install bolts and nuts connecting inner and outer tie rods. Tighten bolts on clamps. Torque to original specification noted in CNH manual. Bolts Clamp 16
STEERING STOPS The steering stops have been installed on the wheel drives already. Refer to the earlier Tire Selection chart for the suggested stop bolt length for your tire and axle width. However, care must be taken to insure that this setting is correct for your machine. Steering stop length can be adjusted by loosening the jam nut and screwing the setscrew in the axle extension either inward or outward. Set the steering stop to the setting in the chart. Repeat this step for the opposite wheel. On one side of the axle, oscillate the rear axle upward on that side. Steer the rear axle so that the tire rotates forward toward the machine frame until the steering bracket contacts the steering stop bolt on the c-frame. Rotate the tire and make sure that it does not contact anything on the combine. Steer the rear axle so that the tire rotates rearward toward the machine frame until the steering bracket contacts the steering stop bolt on the c-frame. Rotate the tire and make sure that it does not contact anything on the combine. Adjust the steering stop if necessary to limit steering to prevent contact or to allow more steering if available space is present. Pay attention to the hoses to make sure they don t contact the tire during steering. Repeat this step for the opposite wheel. Steering stop PRE-START PROCEDURES 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 "ON". Do NOT start engine. Operate rear axle rocker switch. Listen for a soft clicking sound at the valve solenoid and motor solenoids to insure proper wiring function. When rocker switch is in the OFF position, none of the solenoids at the valve or at each wheel motor should be energized. When the rocker is in the middle position, all of the solenoids should be energized. This is the position where the motors are being operated in their minor displacement, which offers greater speed and some torque to the rear tires. When the rocker is in the fully on position, only the valve solenoid should be energized. This is the position for full torque at the rear tires. Add hydraulic transmission fluid, as required, to fill hydrostatic reservoir. Follow combine's specifications and recommendations concerning hydrostatic fluid and the servicing of filters. Remove blocks from under combine. SEE START-UP PROCEDURE AT END OF TROUBLESHOOTING MANUAL. 17
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. 9098 W. 800 S., Brookston, IN 47923, Tel: 219-279-2801 / 800-348-2474 Fax: 219-279-2390 Email: tdswebinquiries@tuthill.com Web: www.tuthill.com