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DESCRIPTION 14
WARNING
11124
The use of the steering control unit as a pump for
manual steering can damage the unit if the torque on
the steering wheel is greater than 170 N.m (125 lbf ft). 1. PORT COVER 7
2. PORT MANIFOLD
This damage will cause the complete loss of control of
3. ISOLATOR MANIFOLD
the steering system. 4. METERING RING
5. ROTOR ASSEMBLY
6. UPPER COVER PLATE
The metering section has the following three functions:
7. DRIVE ASSEMBLY
8. VALVE SPRINGS
measures the hydraulic oil to the steering cylin- 9. VALVE ASSEMBLY
der 10. DRIVE LINK
11. COMMUTATOR ASSEMBLY
keeps a constant ratio of steering wheel turns to 12. DRIVE PLATE
13. THRUST BEARING
the direction of the steered wheels
14. COVER AND TUBE ASSEMBLY
15. INPUT SHAFT FROM STEERING WHEEL
operates as a pump for manual steering of the lift
FIGURE 1. ROSS HGF STEERING CONTROL
truck if hydraulic pressure is not available from UNIT
the hydraulic pump
1
1. NUT 5/16 x 24 UNF (4) 11. ALIGNMENT PIN (9)
2. PORT COVER 12. VALVE RING
3. SEAL RING 13. VALVE PLATE
4. ORING (4) 14. SPRING 13 mm (0.50 in)
5. BALL 6 mm (7/32 in) 15. ISOLATOR MANIFOLD
6. PLUG 16. DRIVE LINK
7. ORING 17. METERING RING
8. PORT MANIFOLD 18. CAPSCREW, SOCKET HEAD (11)
9. SPRING 19 mm (0.75 in) 19. SEAL, COMMUTATOR
10. DRIVE ASSEMBLY 20. COMMUTATOR COVER
21. COMMUTATOR RING
22. COMMUTATOR
23. SPACER, LINK DRIVE
24. ROTATOR
1 25. STATOR
6 5
2
3
4
17 7 8
3 9
34
18 3
35
19 12
36
20 14
33 43 21 13
22 3
42 11 10
47 23 11
24 15
46 25
37 11
45 26 3
27 16
38
28
44 39 29
30
31
32
40
26. DRIVE PLATE 41
27. SPACER, THRUST BEARING
28. THRUST BEARING
29. FACE SEAL
30. BACKUP RING
31. SEAL SPACER
32. UPPER COVER PLATE
33. INPUT SHAFT
34. RETAINER RING 41. NUT
35. WASHER, RETAINER PLATE 42. SCREW
36. RETAINER PLATE 43. CONTACT RING ASSEMBLY
37. UPPER COVER AND JACKET TUBE 44. CONTACT BRUSH ASSEMBLY
38. BUSHING 45. SCREW AND LOCKWASHER
39. SEAL 46. SPACER
40. SPECIAL BOLT 5/16 x 24 UNF2A (4) 47. HORN WIRE ASSEMBLY
2
Components with alignment grooves must be DISASSEMBLY AND INSPECTION
assembled as shown in the illustration. The
alignment grooves make sure that the parts are in WARNING
the correct position.
Use a work area with good ventilation when solvents
are used. Keep fire and sparks away from the area.
Commercial cleaning solvents may be flammable
and toxic, and can cause severe skin irritation. When
using commercial cleaning solvents, always comply
with the solvent manufacturers recommended
safety precautions.
Wear eye protection when making repairs described
in this section.
Compressed air can move particles so that they
cause injury to the user or to other personnel. Make
sure that the path of the compressed air is away from
all personnel. Wear protective goggles or a face
shield to prevent injury to the eyes.
CAUTION
Use a puller to remove the steering wheel from the in-
put shaft. Do not use a hammer to remove the steer-
ing wheel or the steering control unit can be dam-
aged.
Do not put the steering control unit directly into a
vise. The clamp pressure will cause distortion and
damage. Make a service assembly fixture as shown in
FIGURE 4.
3
Make a holder for the steering control unit as
shown in the illustration. Do not hold the
steering control unit in a vise or the unit can
be damaged from distortion.
2.00
0.625
4.00
45 2.00 DIA.
3.25 DIA.
4
2. Loosen the plug (6) assembly in the port cover (2)
for disassembly after the port cover is removed. 5. Remove the loosened plug (6) and Oring from the
port cover. Do not lose the steel check ball (5) as it falls
from its cavity. Inspect the port cover for wear and
damage. Replace damaged parts.
3. Remove the four nuts (1) that hold the port cover (2)
to the unit. Do not damage the ports.
CAUTION 6. Carefully lift the port manifold (8) from the unit
The nuts (1) are a special lock nut. Use only approved NOTE: The three springs can become disengaged when
parts as replacement nuts. the port manifold is removed. Do not permit the loss of
the three springs (9).
5
7. Remove the valve ring (12). Discard the two seal
rings (3). 9. Remove the three springs from the isolator man-
ifold. See the NOTE about the springs in step 6.
6
13. Remove the two alignment pins from the metering
ring.
11. Remove the two alignment pins (11) that align the
port manifold, valve ring, and isolator manifold.
14. Remove the drive link (16). Inspect the ends of the
drive link for wear. The four contact surfaces can not
have wear or have grooves. Replace a worn drive link.
7
16. Remove the metering assembly and put it on a
clean surface. DO NOT put the assembly in a vise.
CAUTION
The commutator ring breaks easily.
18. Remove the 11 socket head capscrews that hold the
20. Remove the commutator ring (21). Inspect for
metering assembly together. Use a 3/32 inch allen
cracks and wear.
wrench.
8
23. Remove and inspect the drive link spacer (23). Re-
place a worn part.
24. Inspect the rotor (24) and stator (25) as they are
found on the drive plate (26). The rotor must rotate and
move freely within the stator. Acceptable parts can not
have grooves or damage. The rotor and stator must be
replaced as a unit if they are worn or damaged.
Check the clearance between the rotor and the stator
with a spacer gauge. The pointer in the illustration
shows the position of the rotor when the clearance is
22. Remove the five alignment pins. measured. The maximum clearance is 0.08 mm (0.003
in). Replace a worn rotor and stator.
9
25. Remove the rotor and stator from the drive plate.
Make sure the drive plate does not have wear or dam-
age.
26. Inspect the other side of the drive plate The move-
ment of the rotor will polish a pattern in the drive plate.
Acceptable parts can not have grooves or wear. Make
sure the hole that engages the input shaft is not worn.
10
32. Inspect the input shaft for wear and damage. Check
the horn circuit for an open circuit or a shortcircuit.
Use an ohmmeter. There must be an electrical connec-
tion between the upper terminal of the horn cable as-
sembly (47) and the contact ring (43). There must be
an open circuit between the upper terminal of the horn
cable assembly and any other parts of the input shaft
assembly. If the input shaft and horn circuit, are correct
go to step 37.
30. Slide the seal (39) from the tube. Replace a worn or
damaged seal.
34. Remove the washer (35) and the retainer plate (36).
31. Remove the input shaft assembly (33). Discard the parts if they are worn or damaged.
11
37. If the bushing must be replaced, use pliers to open
the two areas that hold the bushing in the tube.
12
ASSEMBLY
Make sure the parts are clean before they are as-
sembled. Install new Orings and seals when the steer-
ing control unit is assembled.
1. If the bushing (38) was removed from the upper cov- 3. Apply clean grease to the bushing (38) and install
er and jacket tube (37), Install a new bushing. The end the jacket tube assembly (37) on the service assembly
of the bushing with the smaller size goes into the tube fixture. Make sure that the square shoulder of the bolts
first. The bushing must be below the end of the tube. engage the square holes in the upper cover.
13
6. Apply a small amount of grease to the face of the re-
4. If the horn contact assembly was removed for re- tainer plate (36) and washer (35). Install the retainer
pairs, install the horn contact assembly (43) on the in- plate and then the washer. The flange of the retainer
put shaft. Make sure the position is like unit before it plate must be towards the washer.
was disassembled.
CAUTION
Make electrical checks with an ohmmeter. Make
sure there is an electric connection between the up-
per terminal of the horn wire and the contact ring on
the contact ring assembly. There must not be an elec-
tric connection to any other part. The repair of the
horn wire and connections requires the complete dis-
assembly of the steering control unit.
14
9. Install the upper cover plate (32). The finished sur-
face must be towards the metering section. Make the
11. Assemble the backup ring (30) and seal (29) on
identification groove and the hole for the horn contact
the seal spacer (31).
assembly are in the correct positions. See also
FIGURE 3.
15
13. Assemble the metering assembly. Put the drive
plate (26) on a clean surface. Put the rotor assembly on
the drive plate. Align the 11 slots with the threaded
holes in the drive plate. 15. Put the commutator (22) on top of the rotor. Align
the five holes for the alignment pins.
16
17. Lubricate the commutator. Put some drops of oil in
the spaces in the commutator.
19. Put the commutator cover (20) on top of the com-
mutator ring. The flat surface is towards the commuta-
tor. Align the holes for the capscrews.
18. Put the commutator ring (21) on the stator. Both 20. Install the 11 socket head capscrews. Do not tight-
sides of the ring are the same. Align the slots for the en with a wrench. The parts of the metering section
capscrews. must be made concentric in the next two steps before
the capscrews are tightened.
17
21. Put the metering ring (17) on a clean flat surface. 23. Put the metering section in position so that the
Put the metering section in the metering ring with drive plate is on the work surface. Make sure that the
commutator cover towards the surface. Use a spacer to drive plate and the metering ring are touching the work
hold the metering section above the surface of the me- surface. Make sure that the socket head capscrews are
tering ring. loose enough so that the commutator ring and the drive
plate are aligned in the bore of the metering ring.
1
10 3
8 5
18
WARNING
Wear eye protection to remove the shims.
Push the metering assembly and the shims from the me-
tering ring.
19
31. Install the metering assembly into the metering
ring. Make sure that the drive plate correctly engages
the end of the input shaft. The drive plate will ride on
29. Apply grease to the roller thrust bearing and install the thrust roller bearing.
it inside the bearing spacer.
20
33. Apply grease to the seal ring (3) and install it into
the groove of the metering ring.
36. Install two alignment pins into the holes in the iso-
lator manifold.
37. Put the three 13 mm (1/2 in) springs into the spring
35. Install the isolator manifold (15) on the metering pockets of the isolator manifold.
ring. Make sure that the alignment grooves on the side
of the isolator manifold are in the correct position.
21
38. Apply grease to a seal ring (3) and install the seal
ring in the groove of the valve ring (12). Install the
valve ring with the seal ring against the isolator man-
ifold.
39. Put the drive assembly (10) through the hole in the
isolator manifold. The slot in the drive assembly must 40. The valve plate must be installed in the correct po-
engage with the smaller end of the drive link. Turn the sition as shown in the illustrations. Make sure the posi-
input shaft for assistance to engage the drive link. If the tion of the alignment grooves on the outside of the
drive assembly will not engage the drive link, check housing and the position of the valve plate is correct as
that the larger and smaller ends of the drive link are in shown in the illustrations. The pointer points to one of
the correct position. the small cavities that is next to the words PORT
SIDE. Makes sure that the spring slots are also
aligned as shown in the illustration.
22
41. Apply grease to a seal ring (3) and install the seal
43. Apply a few drops of oil to the surface of the valve
ring in the valve ring.
plate. Install the port manifold. Make sure the position
slots are correct. Do not damage one of the springs dur-
ing installation.
44. Install a new Oring (7) on the plug (6). Install the
42. Install the three 19 mm (3/4 in) springs in the spring
check ball in the port of the port cover. Install the plug.
pockets of the port manifold.
23
45. Apply a thin layer of grease to the Orings and the
seal ring and install them in their positions in the port 48. Tighten the plug to 11 to 16 N.m (8 to12 lbf ft).
cover.
46. Install the port cover. Make sure the position slots
are correct.
49. Apply a thin layer of grease to the dirt and water
seal (39). Install the seal on the jacket tube.
4 1
2 3
24
TROUBLESHOOTING
25