TUTHILL

Drive Systems

TECHNICAL MANUAL

SELECTOR VALVE

FLOW REGULATOR
Patent Pending

D705279
4/06
 Introduction
FORWARD

This component technical manual contains This is the Safety-alert symbol.

necessary instructions to repair Selector When you see this symbol in this
Valves and Flow Regulators. This manual manual, be alert to the potential for
also includes theory of operation and personal injury.
testing procedures.

Use this component technical manual in

conjunction with the machine technical
manual.
MANUAL ORGANIZATION
SECTION 00 INTRODUCTION AND SAFETY SECTION 03 SELECTOR VALVE OPERATION
SECTION 01 GENERAL INFORMATION SECTION 04 FLOW REGULATOR OPERATION
SECTION 02 BILL OF MATERIALS SECTION 05 TROUBLE SHOOTING/TESTS

NOTE: MUD HOG is a Registered Trade Mark of

Tuthill Transport Technologies
 Contents
Page Page
Section 00 Introduction and Safety Section 03 Selector Valve Operation
Introduction 00-1 Low Pressure Shuttle, Forward 03-1
Safety 00-1 Low Pressure Shuttle, Reverse 03-1
Emergencies 00-1 Solenoid Valve 03-2
Lifting Equipment 00-1 Principle of Operation 03-2
Protective Clothing 00-1 Selector Spool, Off 03-3
High-Pressure Fluids 00-2 Selector Spool, On 03-4
Work in Clean Area 00-2
Proper Tools 00-2 Section 04 Flow Regulator Operation
Fluid Disposal 00-2 Regulating Direction 04-1
Flow at Regulated Value 04-2
Section 01 General Information Return Direction 04-2
Selector Valve Identification 01-1
Flow Regulator Identification 01-1 Section 05 Trouble Shooting/Tests
Selector Valve Specifications 01-2 Trouble Shooting Checks 05-1
Flow Regulator Specifications 01-2 Trouble Shooting Chart 05-2
Selector Valve Dimensions 01-3 Trouble Shooting Chart Cont. 05-3
Flow Regulator Dimensions 01-3 Test Procedure #1 05-4
Hydraulic Adapter Torque Values Metric/inch 01-4 Test Procedure #2 05-5
Hydraulic Adapter Torque Values ORFS 01-5 Test Procedure #3 05-6
Test Procedure #4 05-7
Section 02 Bill of Materials
Selector Valve, Bill of Materials 02-1
Selector Valve, Exploded View 02-2
Flow Regulator, Bill of Material 02-3

All information, illustrations and specifications in this manual are based on the latest information available at the
time of publication. The right is reserved to make changes at any time without notice.

I
 Section 00
Introduction and Safety
INTRODUCTION
This Technical Manual covers recommended repair
procedures for Selector Valves and Flow Regulators. Before
beginning repair, thoroughly clean external surfaces of valves
since dirt and foreign material will damage critical surface
finishes and seals if allowed to enter.

Always use clean tools and work in a clean environment.

RECOGNIZE SAFETY INFORMATION

Pay special attention to this symbol. This is the safety alert
symbol. Any time you see this symbol in this manual or on
your machine be alert to the potential for personal injury.

Follow recommended precautions and safe operating practices.

Review the safety precautions. Read and familiarize yourself

with this manual and the procedures involved before starting
work.

EMERGENCIES
Be prepared for emergencies.

Have a first aid kit and fire extinguisher available.

Post emergency numbers near the telephone.

Include numbers for ambulance service, fire
department, hospital, doctor and poison control.

LIFTING EQUIPMENT
Use appropriate equipment to left heavy components to
avoid personal injury and equipment damage.

Follow instructions for attachment and removal of

equipment in manual.

CLOTHING
Wear appropriate clothing and safety equipment for the job.

Protect your ears from loud noises to avoid hearing loss.

00-1
 Introduction and Safety/Avoid High Pressure Fluids

HIGH-PRESSURE FLUIDS
Stay away from high-pressure leaks.
High-pressure leaks can cause serious injury.

Avoid injuries by relieving pressure before disconnecting

hydraulic or other lines. Tighten all connections before
applying pressure.

Use cardboard to check for leaks.

If fluid penetrates your skin, contact a doctor immediately.

Fluid must be removed immediately to avoid gangrene.

CLEAN WORK AREA

Keep work area and machine clean. Have necessary tools and
parts organized and readily available.

Read instructions thoroughly and have instructions within

reach.

TOOLS
Avoid personal injury and damage to tools and parts by
using the correct tool for the task.

FLUID DISPOSAL
Contact your local environmental agency to get
instructions on proper fluid disposal before draining
any fluids.

Do not use food or beverage containers to hold fluids.

Do not pour any fluids into the ground, a drain, lake,

pond, etc.

00-2
 Section 01
General Information
SELECTOR VALVE IDENTIFICATION

Each Selector Valve has a Serial Number and a build

Date stamped in the side of the valve body.

Serial Number Build Date

FLOW REGULATOR IDENTIFICATION

Each Flow Regulator shows the direction of regulated

flow and has a flow rate (gpm) stamped in the outer housing.
(Text may be different than shown)

Direction of Regulated Flow

Flow Rate

01-1
 General Information/Specifications

SELECTOR VALVE SPECIFICATIONS

Type 4-way, 2-position
1 spool, Pilot operated

Flow Rate 63 gpm Nominal

238 lpm

Max. Operating Pressure 6500 psi

450 bar

Cartridge Valve 3-way, 2-position

12 VDC Solenoid

FLOW REGULATOR SPECIFICATIONS

Type Pressure Compensated Flow Control
Free Flow Return

Flow Rate 15 - 40 gpm

57-152 lpm

Max. Operating Pressure 6500 psi

450 bar

01-2
 General Information/ Dimensions

SELECTOR VALVE DIMENSIONS

FLOW REGULATOR DIMENSIONS

01-3
 General Information/Hydraulic Adapter Torque Chart

HYDRAULIC ADAPTER TORQUE VALUES

DO NOT use these values if a different torque or tightening procedure is listed for a specific
application. Torque values listed are for general use only. Make sure adapters are clean and
you properly start threaded engagement. This will prevent them from failing when tightened.

TABLE 1: METRIC PORT THREAD

SAE J2244-2/ISO 6149-2 metric straight thread o-ring port connector recommended torque
levels for use with SAE J1453/ISO 8434-3 ORFS connectors.

Thread Nominal Assembly Torque

Size Tube OD (Into Steel)
mm Nm
M10x1 5 20 - 22
M12x1.5 6 35 - 39
M14x1.5 8 45 - 50
M16x1.5 10 55 - 61
M18x1.5 12 70 - 77
M22x1.5 16 100 - 110
M27x2 20 170 - 187
M30x2 22 215 - 235
M33x2 25 310 - 341
M42x2 32 330 - 363
M48x2 38 420 - 462
M60x2 50 500 - 550

TABLE 2: INCH PORT THREAD

SAE J1926-2 inch straight thread o-ring port connector recommended torque levels for use
with SAE J1453/ISO 8434-3 ORFS connectors.

Thread SAE Dash Assembly Torque

Size Size (Into Steel)
Nm.
3/8-24 -3 10 - 12
7/16-20 -4 20 - 22
-20 -5 25 - 28
9/16-18 -6 33 - 35
-16 -8 68 - 78
7/8-14 -10 98 - 110
1-1/16-12 -12 170 - 183
1-3/16-12 -14 215 - 245
1-5/16-12 -16 270 - 300
1-5/8-12 -20 285 - 380
1-7/8-12 -24 370 -490

01-4
 General Information/Hydraulic Adapter Torque Chart

HYDRAULIC ADAPTER TORQUE VALUES Cont.

TABLE 3: ORFS CONNECTIONS

SAE J1453/ISO 8434-3 o-ring face seal connectors recommended torque levels for ORFS
tube assemblies, hose assemblies and connectors.

English Thread Assembly

Dash Size Torque
Nm
-4 9/16-18 14 16*
-6 11/16-16 24 27*
-8 13/16-16 43 47*
-10 1-14 60 - 68
-12 1-3/16-12 90 - 95
-16 1-7/16-12 125 - 135
-20 1-11/16-12 170 - 190
-24 2-12 200 - 225
* Torque level shown is for maximum pressure rating of 42MPa.

01-5
 Section 02
Bill of Materials
Parts List for Selector Valve Assembly

Item Qty Description

1 1 Solenoid, 12V W/wire Leads
2 1 Connector
3 2 Pin, Terminal
4 5 Plug, 02 ORB-M Hex Socket Head
5 3 Plug, 04 ORB M Hex Socket Head
6 2 Seal
7 1 Forward Adapter
8 1 Drain Adapter
9 1 Plug, M33
10 2 Check Ball
11 2 Roll Pin
12 1 Spool
13 1 Valve Body, Machined
14 1 Spring
15 1 Reverse Adapter
16 1 Dowel Pin
17 4 Flow Regulator
18 1 Seal Kit

02-1
 Bill of Material/Selector Valve

Selector Valve

02-2
 Bill of Material/Flow Regulator

Parts List for Flow Regulator Assembly

Item Qty Description

1 1 Body, Flow Regulator, M33
2 1 Baffle, Flow Regulator
3 1 Piston, Flow Regulator
4 1 O-Ring M33 Boss
5 1 Spring
6 1 Washer, Hardened
7 1 Adapter, M33

Flow Limiter

02-3
 Section 03
Selector Valve Principle of Operation

LOW PRESSURE SHUTTLE (FORWARD)

The low-pressure shuttle system of the Selector valve is
a combination of two check valves between the forward
and reverse sides of the hydrostatic circuit, ahead of the PF
selector spool. The shuttle system provides pilot
(control) pressure oil to passage A at all times; even
when the MUD HOG is off. Passage A feeds to the
solenoid cartridge valve which directs charge pressure oil B
to engage the selector spool. There is always charge
pressure on the return side of the hydrostatic circuit; for
example, in the forward operating mode there is system Dowel
pressure oil in the pump forward (PF) cavity and charge Pin
pressure oil in the pump reverse (PR) cavity. In this
situation, the system pressure will be higher than the A
charge pressure. In forward operation system pressure
oil will close off check ball B. When B closes off, check C
ball C will open up due to the dowel pin between balls B
and C. This pin will not allow both balls to seat at the PR
same time. When check ball C opens, this allows charge
pressure oil to flow from the return (reverse) side of the
circuit, past the check ball C, past the spacer and into System Pressure
passage A.
Charge Pressure

LOW PRESSURE SHUTTLE (REVERSE)

In the reverse operating mode there is system pressure oil in PF
the pump reverse (PR) cavity and charge pressure oil in the
pump forward (PF) cavity. System pressure oil will close off
check ball C. When C closes off, check ball B will open up
due to the dowel pin between balls B and C. This pin will not B
allow both balls to seat at the same time. When check ball B
opens, this allows charge pressure oil to flow from the
forward side of the circuit, past the check ball B, past the
spacer and into passage A.

PR

System Pressure

Charge Pressure

03-1
 Selector Valve Operation/Solenoid Valve

To Tank
SOLENOID VALVE Charge Pressure From Low Pressure Shuttle

The solenoid valve is a 3-way valve that takes the charge

pressure oil and directs it to passage S of the selector
spool when the MUD HOG is turned ON. When the
MUD HOG is turned off the charge pressure is blocked
internally in the solenoid valve and cavity S of the S
selector spool is connected to tank. Drain

Charge Pressure

Selector Spool In Off Position

To Tank
Charge Pressure From Low Pressure Shuttle

S
Drain

Charge Pressure
Selector Spool In On Position

The MUD HOG High Capacity Selector valve is Spool in On

designed for use on machines having nominal flow rates
greater than 60 gpm to the rear wheel assist drives. The
Position
valve is a spool type valve incorporating ON-OFF control
of the assist axle and can be equipped with optional flow
regulators for improved traction control when required.

An ON-OFF switch in the operators cab activates the

electric solenoid valve. The solenoid valve directs pilot
pressure to move the selector spool. This movement of
the spool opens up internal passages within the valve to
permit high system pressure oil to flow to the wheel
motors. The oil flow is split between the wheel motors.
Spool in Off
When the selector valve solenoid is not activated, high- Position
pressure oil flow is blocked and all motor and valve
cavities are connected to tank.

For better control of the high-pressure oil flow, optional

flow regulators can be installed.

03-2
 Selector Valve Operation/Solenoid Valve

SELECTOR SPOOL (OFF POSITION)

With the MUD HOG system off, charge pressure oil in
the Selector valve is blocked at the solenoid valve.
Cavity S is exposed to tank through the solenoid
cartridge. The spring pressure in cavity D holds the
spool in the OFF position. The spool prevents system
pressure oil from entering both the forward or reverse
inlet port and the rest of the valve; therefore no high-
pressure oil is delivered to the wheel motors.

In the off position the spool cavities PF and PR are Drain

closed off from motor cavities MF and MR. Cavities PF
and PR are the forward and reverse pressure inlet
cavities; they will always be exposed to either system System Pressure
pressure or return (charge) pressure oil depending on
direction of the machine. Cavity MF opens an oil flow Charge Pressure
path to the forward pressure ports of the wheel motors.
Cavity MR similarly opens an oil flow path to the
reverse pressure ports of the motors. Spool In Off
S
Position

PF

MF

MR

PR

Spring

03-3
 Selector Valve Operation/Selector Spool

SELECTOR SPOOL (ON POSITION)

When the switch in the cab is in the ON position, the coil

within the solenoid valve is energized. Passages in the
solenoid valve cartridge are opened and charge
pressure oil is delivered to cavity S and shifts the spool,
compressing the spring in cavity D. When the spool
arrives at its full ON position, passage PF is open to
passage MF, which provides forward system pressure to
the forward pressure inlet ports of the motors. Passage
MR is open to passage PR, which allows return flow (at
charge pressure) to come from the motors and back to Drain
the return side of the hydrostatic circuit. In the reverse
operation mode, the process is switched; where System Pressure
passages MR and PR are open to each other to provide
reverse system pressure to the reverse pressure inlet
ports of the motor. Passages PF and MF allow return Charge Pressure
flow to come from the motors.
Spool In On Position S

PF

MF

MR

PR

03-4
 Section 04
Flow Regulator Operation

FLOW REGULATOR *

The Flow Regulator purpose is to limit maximum flow to

a wheel drive motor due to the loss of traction. The
normal result of losing traction is wheel spin out at the
affected wheel. The effect of this is that the speed of the
spinning motor can increase to the limit of available
system flow. The torque is lost at other wheels due to
pressure reduction in the system. The Flow Regulator
mounts in the hydraulic line to a wheel motor, and
controls only the flow to that motor or axle in one
direction of rotation. Free flow is permitted in the
opposite direction, and allows a second regulator valve
to separately control flow in the opposite direction.

*Patent Pending

Flow Regulator in normal operating mode at a flow level below regulated value.

OIL TO MOTOR

OIL FROM PUMP

The space between mating

edges of spool and baffle Fixed reference
comprise a variable orifice orifice in end of
sliding spool

REGULATED DIRECTION (FORWARD) SHOWN;

REVERSE OPPOSITE

04-1
 Flow Regulator Operation

Flow at Regulated Value As flow rate through the valve approaches

controlled value, the spool and baffle
compress the spring reducing the flow path
to control the flow rate. The valve
constantly modulates to maintain constant
flow at the design reference value.

Return Direction When flow returns in the reverse

direction, the spool slides freely
to the right. The spool will
extend past the end of the body
and allows for additional orifices
to open. This allows for free flow
return through the flow regulator.

04-2
 Section 05
Trouble Shooting/Tests
Trouble Shooting Checks
With the engine of the machine shut off, check for
evidence of external oil leakage around seals, housing
or hose connections. Also check for pinched or kinked
hoses and steel lines that could restrict oil flow and
cause excessive heat build-up in the hydraulic oil.

Check hydraulic oil level in reservoir and add the correct

amount and type of hydraulic oil, if necessary.

Check the quality of the oil; change if milky, dirty or

discolored. Also smell the oil. A burned odor indicates
excessive heat that can destroy the lubricating qualities
of the oil. Again, the oil should be changed if this
condition is found. Determine the cause of the
excessive heat and correct it.

Determine if the hydrostatic filter is plugged or damaged.

A filter that has failed will permit oil to bypass the
system, affecting system operation and tests.

Check the maintenance records with the machine to

determine if the recommended service procedures have
been made at the proper intervals. Check for previous
reports of unusual, frequent or similar failures
.

05-1
 Trouble Shooting/Tests/Test Procedure #1

Trouble Shooting
PROBLEM POSSIBLE CAUSE REMEDY
1) Performance of RWD is A) Operating with transmission System is more effective in
sluggish (poor) gearing too low higher gear.

B) Incorrectly plumbed main high Refer to MUD HOG

pressure lines (For. & Rev) Installation/Operation Manual for
correct plumbing procedure.
C) Weak high pressure relief Refer to machine service manual
valve for proper setting.
D) Excessive case leakage from See test Procedure # 1, page
MUD HOG system: 05-4
1) From wheel motor(s)
2) From selector valve
E) Inadequate charge pressure See Test Procedure # 1 page
05-4
2) RWD operates in Forward but A) Excessive Case See Test Procedure # 1 page
not in Reverse OR operates in Leakage 05-4
Reverse but not in Forward B) Electrical circuit
malfunction
C) Stuck spool in selector
valve

05-2
 Trouble Shooting/Tests/Test Procedure #2 & #3
Trouble Shooting, Cont.
PROBLEM
3) One wheel on RWD is
dragging or locked up
4) RWD is not functioning.
POSSIBLE CAUSE REMEDY
A) Incorrectly mounted high Refer to MUD HOG
pressure hoses on hydraulic Installation/Operation Manual for
wheel motors proper hose routing.
B) Hydraulic wheel motor is With the MUD HOG system
locked up due to internal OFF (no Forward or Reverse
component failure. system pressure) and with the
tire off the ground, rotate tire by
hand, if the tire will not rotate,
then the wheel motor is locked
up. Service or replace wheel
motor.
A) Blown fuse. Replace fuse.
B) ON-OFF switch shorted Replace switch.
out.
C) Disconnected or broken Reconnect or replace with16
electrical wire. gauge wire.
D) Solenoid valve in See Test Procedure # 2
selector valve not page 05-5
working due to:
1) Solenoid valve
spool not
shifting.
2) Coil inside
solenoid valve
shorted out.
3) Lose wire
connections(s)
4) Improper
grounding.
E) Main spool in selector See Test Procedure # 3 page
valve not shifting. 05-6
F) Excessive motor
leakage.
G) Low hydrostatic fluid
level.
05-3
 Trouble Shooting/Tests/Test Procedure #2

Test Procedure #1
Problem/Cause Rear Wheel Drive Sluggish/Excessive Leakage/Inadequate Charge Pressure

Make sure that the outside of the Selector valve is free

from any dirt or grease. Dirt must NOT be allowed to
enter the valve when removing any of the valve
components.

CAUTION The following steps require removal

of hydraulic hoses and fittings. Be sure to relieve
pressure from system prior to loosening any Charge Pressure
connections. Test Ports

Install 7500 psi (or greater) pressure gauges in both the

forward and reverse inlet hoses to the valve.

Install 500 psi (or greater) pressure gauge in charge

pressure port and drain test port.

With Rear Wheel Drive ON, record pressure readings

with machine moving in forward and then reverse.
Sluggish (poor) performance of machine may be caused
when charge pressure drops below 100 psi, when this
happens system pressure is not allowed to increase high
enough to keep the machine moving.

Leakage from the selector valve should not exceed 2

gallons per minute (gpm) with the machine moving at
system pressure.
1) Disconnect hose end from bottom fitting on
valve. Drain Test Port
2) Plug hose Pressure should be zero at
3) Measure leakage from bottom fitting. this port. (Pressure may
Note: Flow may pulse when shifting valve. pulse when shifting). If
Leakage from the wheel motors will vary depending on pressure doesnt drop to
the size and type of motor. In general, leakage should zero drain hose or passage
not exceed 2.0 gpm from each motor. If excessive may be obstructed.
leakage exists, refer to the appropriate motor technical
manual for your machine. If leakage is within
specification, then components with the hydrostatic Disconnect and
transmission of the machine may have excessive
leakage; refer to the service manual for the machine. plug hose

05-4
 Trouble Shooting/Tests/Test Procedure #2

Test Procedure #2
Problem/Cause Rear Wheel Drive NOT Functioning/Solenoid Valve Not Working

Turn Ignition switch to ON position or machine

configuration that allows signal voltage to the rear wheel Wire Connector
drive without starting engine.
Pin Terminals
Have assistant operate the ON-OFF Rear Wheel Drive Seals
switch. A distinct click should be heard at the solenoid,
indicating that the solenoid valve spool is shifting
properly. If click is not heard, check for possible loose
wire connections at the solenoid, switch in the cab and
all other connections for rear wheel assist harness. Wire Leads
from Coil
If no problems are found, perform an electrical
resistance check on the solenoid valve coil to determine
if the coil is defective. Coil resistance should be 7 - 9 Solenoid Coil
ohms.

If all electrical connections are good and coil resistance

is good, replacement of the solenoid valve is necessary.

05-5
 Trouble Shooting/Tests/Test Procedure #3

Test Procedure #3
Problem/Cause Rear Wheel Drive NOT Functioning/Selector Spool NOT Shifting

Make sure that the outside of the Selector valve is free

from any dirt or grease. Dirt must NOT be allowed to
enter the valve when removing any of the valve Charge Pressure
components. Test Ports

Caution The following steps require removal of

hydraulic hoses and fittings. Be sure to relieve pressure
from system prior to loosening any connections. Drain
Test Port
Install 7500 psi (or greater) pressure gauges in the
forward and reverse inlet lines to the valve and forward
and reverse lines between the Selector valve and the
wheel motors.

Install 500 psi (or greater) pressure gauges in the charge

pressure port and drain test port.

With Rear Wheel Drive ON, record pressure readings

with machine moving in forward and then reverse.

With Rear Wheel Drive OFF, record pressure readings

with machine moving in forward and then reverse.

If pilot pressure reading is NOT correct, (machine charge

pressure) then check solenoid valve to be sure that the
valve is shifting properly (See Test Procedure #2).

If pilot pressure reading is correct, but the forward and

reverse line pressures to the wheel motors are NOT
correct, then the main spool in the Selector valve is not
shifting. Forward and reverse pressures will be the
same as the machine system pressure and machine
charge pressure.

To prevent siphoning of the oil reservoir, loosen and

remove the bottom hose connection from the valve. Spool
Plug the hose to prevent draining the reservoir.

Remove bottom fitting from Selector valve. Spring

Check for free movement of Selector spool in the bore.

If spool does not move freely, remove spool from bore Fitting
and check for excessive wear on the spool and the bore.

Reinstall spool in bore and check again for free Disconnect

movement. and plug hose

If spool continues to stick, replacement of the complete

Selector valve is necessary.

05-6
 Trouble Shooting/Tests/Test Procedure #4

Test Procedure #4 (For optional Flow Regulators)

Problem/Cause Rear Wheel Drive is Sluggish

Make sure that the outside of the Selector valve and Flow
Regulators are free from any dirt or grease. Dirt must NOT Charge Pressure
be allowed to enter the system when removing any of the Test Ports
valve/flow regulator components.

Caution The following steps require removal of

hydraulic hoses and fittings. Be sure to relieve pressure from Drain
system prior to loosening any connections. Test Port

Install 7500 psi (or greater) pressure gauges in the forward

and reverse inlet lines to the valve and forward and reverse
lines between the Selector valve and the wheel motors.

Install 500 psi (or greater) pressure gauges in the charge

pressure port and drain test port.

With Rear Wheel Drive ON, record pressure readings with

machine moving in forward and reverse.

With Rear Wheel Drive OFF, record pressure readings with

machine moving in forward and then reverse.

If pilot pressure reading is NOT correct, (machine charge Disconnect

pressure) check solenoid valve to be sure that the valve is and plug
shifting properly (See Test Procedure #2, page 05-5). hose

If pilot pressure reading is correct, but the forward and

reverse line pressures to the wheel motors are NOT correct,
check the selector spool to be sure that the spool is shifting
properly (See Test Procedure #3, page 05-6).

If the solenoid valve and the spool are shifting properly, then Adapter
the flow regulators may not be functioning properly.
Baffle
To prevent siphoning of the oil reservoir, loosen and remove
the bottom hose connection from the valve. Plug the hose to Spring
prevent draining the reservoir.
Washer
Remove the hoses from the flow regulators and the flow
regulators from the Selector valve. Piston

Check for free movement of piston in the bore of the flow

regulator. If piston does not move freely, remove piston,
spring, washer and baffle from flow regulator by removing
hydraulic adapter.

Check all parts and bore for excessive wear. Body

Reinstall spool in bore and check again for free movement. If O-Ring
spool continues to stick, replacement of the Flow Regulator is
necessary.

05-7