Cushman HAULER 1200, Руководство по ремонту

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B
SUSPENSION AND S FRONT SUSPENSION AND STEERING
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
93
Repair and Service Manual
653045
ing is turned fully to the right forcing passenger
spindle arm against front axle.
Set the proper rack extension-to-rack and pinion unit
clearance. See Checking/Adjusting Rack Extension-to-
Rack and Pinion Unit Clearance.
Rack and Pinion Unit Replacement
Tool List Quantity
Socket, 13 mm ............................................................ 1
Ratchet ........................................................................ 1
Needle Nose Pliers...................................................... 1
Wrench, 11/16” ............................................................ 1
Ball Joint Separator ..................................................... 1
Plastic Faced Hammer ................................................ 1
Wrench, 5/8”................................................................ 1
Socket, 5/8” ................................................................. 1
Ratchet ........................................................................ 1
Torque Wrench, ft. lbs. ................................................ 1
Socket, 11/16” ............................................................. 1
Torque Wrench, in. lbs................................................. 1
To remove the rack and pinion unit (12) (Figure 14),
loosen the front wheel lug nuts.
Lift and support the front of the vehicle per the SAFETY
section. Remove lug nuts and the front wheels.
Remove bolt (13) and washer (14) securing the interme-
diate shaft (15) to the rack and pinion unit (12).
Remove the cotter pin (2) and loosen the castellated nut
(3) until the rack ball joint (1) threads are protected. Using
a ball joint separator as a lever, apply pressure to the ball
joint and tap the nut with plastic faced hammer to release
the ball joint from the passenger side spindle arm.
Remove the nut from the ball joint and the ball joint from
the spindle arm.
Remove the three lock nuts (18) securing the rack and
pinion unit to the front axle. Discard the nuts.
Remove the rack and pinion unit from the vehicle. Retain
washers (19), spacers (20) and the two bolts (16) for
assembly.
Replace the rack and pinion unit in the reverse order of
removal.
Install the new lock nuts (18) and tighten to the torque
specified below.
Tighten the castellated nut (3) to the torque mentioned
and continue to tighten as needed to insert the new cotter
pin.
Tighten the bolt (13) securing the intermediate shaft to the
pinion to the torque value specified below.
After replacing or servicing steering
components, always verify that a 1/
8” gap exists between large hex of
rack extension and rack and pinion unit when steer-
ing is turned fully to the right forcing passenger
spindle arm against front axle.
Set the proper rack extension-to-rack and pinion unit
clearance. See Checking/Adjusting Rack Extension-to-
Rack and Pinion Unit Clearance.
Install the front wheels per the WHEELS AND TIRES sec-
tion.
Lower the vehicle per the SAFETY section.
Check the front wheel alignment and adjust if necessary.
See Wheel Alignment.
Checking/Adjusting Rack Extension-to-Rack
and Pinion Unit Clearance
Tool List Quantity
Wrench, 11/16”.............................................................1
Wrench, 3/4” ................................................................1
Wrench, 1/2” ................................................................1
Wire Cutter...................................................................1
Washer, 1/8” Thick .......................................................1
Crowfoot Socket, 3/4” ..................................................1
Torque Wrench, ft. lbs..................................................1
Wire Tie, 10" long.........................................................1
Check for proper rack extension-to-rack and pinion unit
clearance by first turning the steering wheel fully to the
right.
The rear spindle arm on the passenger side
must rest
against the front axle (Figure 21).
If it does not, all adjustment is made at the rack ball joint
(6) (Figure 20). Loosen the jam nut (5) at rack the ball
joint and use a wrench to thread the shaft of the rack
extension (7) further into the rack ball joint. This will pro-
vide more travel for the steering wheel to be turned to the
right. Item Torque Specification
18 35 - 50 ft. lbs. (47 - 68 Nm)
Item Torque Specification
3 36 - 50 ft. lbs. (49 - 68 Nm)
13 13 - 18 ft. lbs. (18 - 24 Nm)
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