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HGF Series Service Procedure

Introduction

Service Manual for Model HGF

This service manual has one purpose: to guide you in maintaining, troubleshooting, and servicing the HGF
Hydraguide power steering valve.

Material in this manual is organized so you can work on the HGF and get results without wasting time or being
confused. To get these results, you should read this entire manual before you being any work on the HGF.

The next section of this manual, Design and Operation, treats the major parts of the HGF and explains how they
function together. The knowledge you acquire from reviewing this section should assist you in solving your steering
problem.

This manual also contains troubleshooting information and checklists. With them, you can diagnose a steering
problem without removing the HGF from the vehicle. If you must service the HGF, the checklists will help you to
determine where the problem may be.

The three-column format of the Disassembly and Inspection, and Assembly sections will make it easier for you to
service the HGF. Column 1 gives a brief key for each procedure. Column 2 explains in detail the procedure you
should follow. Column 3 illustrates this procedure with photographs. Pay special attention to the notes, cautions, and
warnings.

A fold-out page with an HGF Hydraguide exploded assembly view is provided in this manual. The component part
names and item numbers assigned on this exploded assembly view correspond with names and item numbers (in
parentheses) used in the disassembly and assembly procedures set forth in this manual. When this exploded
assembly view page is folded out, you can easily identify components and locate their relative position on the
exploded assembly view as you follow the disassembly and assembly procedures.

As you gain experience in servicing the HGF, you may find that some information in this manual could be clearer or
more complete. If so, let us know about it. Don't try to second guess the manual; if you are stuck, contact us.
Servicing the HGF should be a safe and productive procedure, in order for the unit to deliver the reliable, long-life
operation engineered into it.

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Содержание Hydraguide HGF Series

Страница 1: ...Service Manual 2753 HGF Series Service Procedure Hydraulic Pump Motor Division Hydraguide Hydrostatic Steering System Hydraulics ...

Страница 2: ...t Cover Hex Drive Assembly Port Manifold Isolation Manifold Metering Ring Rotor Set Upper Cover Plate Valve Springs Valve Set Drive Link Commutator Set Drive Plate Thrust Bearing Upper Cover Jacket Tube Assembly Set Input Shaft Wheel Tube ...

Страница 3: ...e driven pump a relief valve a cylinder or cylinders a reservoir and filter suitable fluid lines or hoses and the HGF hydrostatic unit The driver has power steering control at all times so long as system components work together system integrity is maintained and adequate fluid is present If there is a failure in the high pressure circuit a loss of power steering will result The HGF however is des...

Страница 4: ... Contents Page Definitions 1 Introduction 2 Design and Operation 3 HGF Hydraguide Steering System 4 Troubleshooting Guide 5 Troubleshooting Checklists 6 Component Alignment Groove Illustration Fold Out 7B Exploded View Fold Out 7C Tools and Material Required for Servicing 8 Torque Chart 8 Disassembly and Inspection 9 Assembly 21 Hydraulic Fluid 36 Filling and Air Bleeding the System 36 Tips for Ma...

Страница 5: ...ult in a properly functioning steering unit If inspection or testing reveals evidence of abnormal wear or damage to the HGF steering unit or if you encounter circumstances not covered in the Manual STOP CONSULT THE VEHICLE MANUFACTURER S SERVICE MANUAL AND WARRANTY DO NOT TRY TO REPAIR OR SERVICE AN HGF STEERING UNIT WHICH HAS BEEN DAMAGED OR INCLUDES ANY PART THAT SHOWS EXCESSIVE WEAR UNLESS THE ...

Страница 6: ...tion and Assembly sections will make it easier for you to service the HGF Column 1 gives a brief key for each procedure Column 2 explains in detail the procedure you should follow Column 3 illustrates this procedure with photographs Pay special attention to the notes cautions and warnings A fold out page with an HGF Hydraguide exploded assembly view is provided in this manual The component part na...

Страница 7: ...ws fluid to flow from the pump to the pressure port through the HGF unit to the return port and back to the reservoir The valve is available in open or closed cylinder configurations each of which brings its own advantages to bear in the hydraulic system Open Cylinder cylinder ports are open to the metering pump allowing road or ground reaction to rotate and recenter the valve as the vehicle s ste...

Страница 8: ...4 HGF Series Service Procedure OPEN CENTER HYDRAGUIDE STEERING POWER BEYOND HYDRAGUIDE STEERING HGF Hydraguide Steering system Return Pressure ...

Страница 9: ...are present check all of them A tight belt could also be glazed and a slipping belt doesn t always squeal In addition the following could also contribute to a steering problem an overloaded vehicle parts damaged from impact not properly repaired or that should have been replaced and improper replacement parts Hydraulic Components If you think the problem is caused by a hydraulic component start by...

Страница 10: ...Different size tires Tire pressure incorrect or unequal left to right Loose or worn steering linkage parts Improperly adjusted or worn wheel bearings In some vehicles front end out of alignment NO RECOVERY FOR OPEN CYLINDER UNIT Tire pressure low Steering linkage parts binding Tight front axle kingpins Steering column binding or misaligned SHIMMY Improperly mounted tire or wheel Components in stee...

Страница 11: ...ERING WHEEL Steering wheel loose on column Components in steering linkage loose or worn HGF unit loose at mounting Air in hydraulic system EXCESSIVE HEAT 200 F MAXIMUM 93 3 Undersized replacement hose or line Kinked or severely bent hose or line Restricted oil coolers Restricted recentering of HGF unit Excessive fluid flow WARNING IF THE HYDRAULIC SYSTEM FLUID BECOMES OVERHEATED IN EXCESS OF 200 F...

Страница 12: ...S MUST BE ASSEMBLED SO THAT THEIR ALIGNMENT GROOVES ARE POSITIONED AS ILLUSTRATED FOR THE UNIT TO FUNCTION CORRECTLY IF THE HGF UNIT BEING DISASSEMBLED HAD A CONTACT BRUSH ASSEMBLY NOTE THE RADIAL POSITION OF IT S HOLE RELATIVE TO ALIGNMENT GROOVED SIDE OF THE UNIT BEFORE DISASSEMBLY AND REASSEMBLE IN THE SAME RADIAL POSITION ...

Страница 13: ...mutator 20 Commutator Cover 21 Commutator Ring 22 Commutator 23 Spacer Drive Link 24 Rotor 25 Stator 26 Drive Plate 27 Spacer Thrust Bearing 28 Thrust Bearing 29 Face Seal 31 Seal Spacer 32 Upper Cover Plate 33 Input Shaft Wheel Tube 34 Retaining Ring 35 Washer Retaining Plate 36 Retaining Plate 37 Upper Cover Jacket Assy 38 Bushing 39 Seal 40 Special Bolt 5 16 24UNF 2A 41 Nut 42 Screw 43 Contact ...

Страница 14: ...lation Manifold HGF 015000 16 Drive Link HGF 013002 19 Seal Commutator 032724 5 Ball 7 32 dia G453569 6 7 Plug and O Ring 415585 A1 9 14 Spring Kit 401443X1 3 401443 3 401608 10 Hex Drive Assy HGF 013001 A1 11 Alignment Pin 040147 X1 12 13 Valve Ring Valve Plate Matched Set HGF 014000 A1 3A Seal Ring White 032832 3 Seal Ring 032755 5 2 8 Port Cover Port Mainfold Kits HGF 016015 X1 5 line HGF 01601...

Страница 15: ...8 inch 22 mm bearing puller Clean grease Light weight oil Torque wrenches 11 13 in lb 25 35 ft lb or Newton Meter Feeler gauge 003 in 08 mm or 005 in 13 mm See disassembly procedure 37 Electrical continuity checking device Torque Chart Exploded View Part Name Item Number Torque Socket Head Cap Screws 18 11 13 in lbs 1 24 1 47 N m Plug and O Ring Ass y 6 7 8 12 ft lbs 11 16 N m Plug and O Ring Ass ...

Страница 16: ... cover 49 contact brush cover seal 48 and related screw and lock washers 50 and disconnect any horn wire connection to the HGF unit Next remove nuts from the mounting bolts blow the unit dry and place it on a work bench Components throughout this assembly are stacked on four bolts and held in alignment with alignment pins designed to be a slip fit into the components Use the minimum force necessar...

Страница 17: ...the assembly Also note the jacket tube contact brush cover hole radial position relative to the side of the unit with the alignment grooves The relative alignment groove positions on the components and the jacket tube contact brush cover hole positions must be maintained at reassembly Refer to the alignment groove graphic on fold out NOTE 3 Loosen plug 6 or hex plug 6A assembly in the port cover 2...

Страница 18: ...g 7 assembly from the port cover Be ready to catch the steel check ball 5 as it falls from its cavity Discard o ring 7 See FIGURE 8 Remove plug 6A If included removed the loosened hex plug 6A and o ring 7A from the port cover 2 Discard o ring Remove relief valve cartridge 5A and spring 5B assembly A bent or lost spring 5B can be serviced separately See FIGURE 8A Do not try to disassemble relief va...

Страница 19: ...g 12 discard the two seal rings 3 See FIGURES 10 and 11 The valve ring should be free of nicks and scoring Remove valve ring 13 Remove the valve plate 13 by lifting it from the isolation manifold 15 Remove valve plate 14 Inspect the slot edges and ground surfaces If the valve plate 13 shows nicks or scoring or the edges are not sharp it must be replaced See FIGURE 12 Inspect valve plate NOTE The v...

Страница 20: ...should not show wear and must be firmly pressed in place The sides of the hex and the slot should not have grooves or scoring If the hex drive assembly 10 shows signs of this type of wear it must be replaced Inspect hex drive assembly 19 Remove the two alignment pins 11 that align the port manifold 8 valve ring 12 and isolation manifold 15 See FIGURE 16 Remove alignment pins NOTE A service kit of ...

Страница 21: ...lation manifold metering ring alignment pins 11 See FIGURE 18 Remove alignment pins 23 Remove the drive link 16 from the unit See FIGURE 19 24 Inspect each end of the drive link 16 The four crowned contact surfaces should not be worn or scored Replace if wear or scoring is evident Inspect drive link 25 Remove the metering ring 17 and discard the two seal rings 3 See FIGURE 20 If the metering ring ...

Страница 22: ...t damage and replace as required Remove cap screws 29 Lift the commutator cover 20 from the metering package Remove commutator cover 30 Inspect the ground surfaces of the commutator cover 20 You should notice a normal polished pattern due to the rotation of the commutator 22 If the cover has nicks burrs or scoring it must be replaced See FIGURE 24 Inspect commutator cover 31 Remove commutator ring...

Страница 23: ...tes pinned and bonded together as a permanent assembly and is not subject to further disassembly Inspect the ground surfaces of the commutator The holes and edges should be free of nicks The ground surfaces should be free of scoring The edges should be sharp Inspect commutator NOTE The commutator 22 and commutator ring 21 are a matched set If either is worn or damaged you must replace the set NOTE...

Страница 24: ...25 from the drive plate 26 The drive plate side of the rotor set also must be free of grooves or scoring Remove rotor set NOTE Handle the rotor set carefully to avoid nicks and scratches NOTE 39 The rotor side of the drive plate 26 should show the normal spiral pattern due to rotor movement Inspect the thrust bearing side of the plate for brinelling dents or spalling flaking The flat sides of the ...

Страница 25: ...CAUTION NOTE For reassembly purposes note the radial position of the alignment grooved edge of the upper cover plate 32 relative to the jacket tube contact brush hole if the unit is so equipped NOTE 43 Remove the upper cover plate 32 four plates bonded together Inspect the upper cover plate You should notice some polishing due to the action of the seal The plate should be free of brinnelling dents...

Страница 26: ... assembly 47 to the contact ring of the contact ring assembly 43 There must not be any electrical continuity connection from horn cable assembly terminal or contact ring assembly to the input shaft wheel tube 33 or other components NOTE 47 Using appropriate external retaining ring pliers remove the retaining ring 34 from the input shaft wheel tube 33 See FIGURE 37 Discard if deformed or broken Rem...

Страница 27: ...38 is to be replaced place the upper cover and jacket tube assembly 37 in a vise with the vise jaws clamping firmly on the jacket tube without deforming the jacket tube Using an appropriate type of pliers uncrimp or relieve the two crimped areas on the bushing end of the jacket tube Remove the bushing using a bearing or seal type puller and discard the bushing Set the upper cover and jacket tube a...

Страница 28: ...acilitate stacking of components See FIGURE 46 Place bolts into fixture 2 If the bushing 38 was removed from the upper cover and jacket tube 37 for replacement press a new bushing 38 into the upper end of the jacket tube with the end of the bushing that has recesses toward the jacket tube This may be done using an arbor press or clamping on the jacket tube per disassembly step 52 and using the woo...

Страница 29: ...rminal connector Be sure it is a good firm connection Position the horn cable protector sleeve so that it protects the horn cable from any sharp corner where it exits the horn cable outlet hole Position and fasten the contact ring assembly 43 with screw 42 Use about 1 1 2 turns of tape around the input shaft wheel tube horn cable and contact ring to hold the horn cable in place See FIGURE 51 Check...

Страница 30: ...iner plate Install retaining plate and washer 7 Install retaining ring 34 onto input shaft wheel tube 33 using the appropriate external retaining ring pliers See FIGURE 53 Install retaining ring 8 Slide input shaft wheel tube 33 assembly into upper cover end of upper cover and jacket tube assembly 37 and through the bushing 38 until the retaining ring 34 bottoms against washer 35 which bottoms aga...

Страница 31: ...l and spacer 31 assembly over end of input shaft wheel tube 33 onto upper cover plate 32 See FIGURE 57 Install face seal 12 Place the drive plate 26 on a clean lint free surface with the eleven tapped holes facing up Place the rotor set 24 25 on top of the drive plate with the five pin holes facing up Rotate the stator 25 until the eleven hex socket head screw relief slots are aligned with the tap...

Страница 32: ...bly procedures Install spacer 14 Place the commutator 22 on top of the rotor 24 Be sure the correct surface shown in FIGURE 60 is toward the rotor Align the five holes and press the five alignment pins 11 in place See FIGURE 61 Install commutator CAUTION Make sure the five alignment pins are pressed below the surface of the commutator 22 CAUTION 15 Place a few drops of oil into each recess in the ...

Страница 33: ...rews 18 loosely into metering package See FIGURE 65 Install cap screws NOTE The commutator ring 21 must be concentric with drive plate 26 within 005 inch 127 mm total indicator reading after tightening the eleven hex socket head cap screws 18 The next two procedures are a method of achieving the concentricity NOTE 19 Place the metering ring 17 on a hard flat surface Place the assembled metering pa...

Страница 34: ...kage as a unit on the flat surface Push down on the metering package until the drive plate is on the flat surface Be sure the cap screws 18 are loose enough to allow the commutator ring 21 and drive plate 26 to align themselves concentrically in the metering ring bore Gradually tighten the eleven cap screws following the sequence shown in FIGURE 70 at least twice until a final torque of 11 13 inch...

Страница 35: ...t pin holes Stack the metering ring 17 into place over the four bolts 40 with the seal ring towards the upper cover plate 32 and an alignment pin hole on the metering ring in line with and on the same side as the alignment groove on the side of the upper cover plate See FIGURE 72 This is required so that the other components can be aligned correctly Install metering ring CAUTION Be sure the seal r...

Страница 36: ... 26 engages the end of the input shaft and the drive plate is seated on the thrust bearing 28 When properly seated the metering package will be below the surface of the metering ring See FIGURES 75 and 76 Install commutator seal 27 Grease the new commutator seal 19 and place it into the commutator cover 20 seal groove The rubber portion the softer side of the seal with the yellow mark must be plac...

Страница 37: ...late 32 and the alignment pin holes with the alignment pins in the metering ring The isolation manifold surface without the recessed slots must be placed toward the metering ring See FIGURE 80 Install two alignment pins 31 Install two alignment pins 11 into the isolation manifold 15 See FIGURE 81 Install 1 2 inch springs 32 Place the three 1 2 inch 13 mm springs 14 into the spring pockets of the i...

Страница 38: ...efully study FIGURES 85 and 86 for positioning of the valve plate 13 spring slots and its other cavities in relation to the spring and spring recesses on the isolation manifold 15 Be sure to use the alignment grooves on the side of the isolation manifold for orientation Place the valve plate 13 with the surface that reads shaft side down over the hex drive assembly 10 aligning the three spring slo...

Страница 39: ...e Install three 3 4 inch 19 mm springs 9 into the spring pockets See FIGURE 88 Install check ball 39 Install new O ring 7 on plug 6 insert check ball 5 into check ball hole in port cover 2 Be sure ball 5 is seated in bottom of check ball hole Turn plug assembly 6 7 into port cover 2 until ball 5 is retained See FIGURE 90 Install port manifold 38 Apply a few drops of oil to the valve plate 13 Align...

Страница 40: ...e it in hole in the port manifold 8 Install port cover 42 Align a groove on the side of the port cover 2 with the grooves on the side of the port manifold 8 and place the port cover 2 into position See FIGURE 92 Install nuts 43 Install nuts 1 onto bolts 40 Tighten each one gradually until resistance is felt Torque to 18 22 ft lbs 24 30 N m in sequence shown See FIGURES 93 and 94 Torque plug 6 to 8...

Страница 41: ... to the fixture and remove the unit Make sure shaft rotates by hand See FIGURE 97 Assemble contact brush and related parts 46 Place HGF unit on a clean working surface If required assemble spacer 51 for 1 1 2 inch 38 mm jacket tube only contact brush assembly 44 washer 46 for 1 3 4 inch 44 mm jacket only and screw and lock washers 45 See FIGURES 98 99 and 100 Check for the required electrical cont...

Страница 42: ...100 CAUTION IF THE INSTALLATION APPLICATION HAS A JACKET TUBE COLUMN SUPPORT CLAMP IT IS EXTREMELY IMPORTANT THAT THE UPPER COVER AND JACKET TUBE ASSEMBLY ALIGN WITH THIS CLAMP IN THE FREE STATE IF MISALIGNMENT IS EVIDENT THE HGF UNIT MUST BE SHIMMED AT THE MOUNTING SURFACE TO ELIMINATE THIS MISALIGNMENT OR DAMAGE TO THE HGF UNIT MAY RESULT Figure 99 TYPICAL 7 8 22 mm Input Shaft Wheel Tube 1 1 2 ...

Страница 43: ...g and Air Bleeding the System NOTE For steps 1 and 2 do not turn the steering wheel 1 Fill the reservoir nearly full Crank the engine for 10 seconds without if possible allowing the engine to start If the engine does start shut it off immediately Do this procedure 3 times each time checking and refilling the reservoir CAUTION Do not allow fluid to drop significantly or to run out of the reservoir ...

Страница 44: ...rattle shimmy or other unusual occurrence in the steering system Remove cause of steering column misalignment Encourage all drivers or operators to report any malfunction or accident that may have damaged a steering system part Do not attempt to weld any broken steering component Replace the component with original equipment only Do not cold straighten hot straighten or bend any steering part Prev...

Страница 45: ...HGF Series Service Procedure Notes ...

Страница 46: ...HGF Series Service Procedure Ross Operations 2745 Snapps Ferry Road Greeneville TN 37745 USA Phone 423 639 8151 Fax 423 787 2418 b b 962252 25 11 96 ...

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