INTRODUCTION

This section has the description and operation for the

HGF Hydraguide steering control unit made by Ross
Gear. The disassembly and assembly procedure is for 15
making repairs. A Troubleshooting chart is at the end of
the section.

DESCRIPTION 14

The steering control unit has two sections: a fluid con-

trol valve and a fluid metering section. The two sections
are connected hydraulically and mechanically inside of
the housing.

Control Valve Section

12

The open center control valve is a rotating valve plate.

The control valve controls the pressure and flow of the 6 13
hydraulic oil to the steering cylinder. The valve plate is 11
held in its center position by two sets of three coil
springs. When the valve plate is in the center position, 5
hydraulic oil flows from the hydraulic pump, through
10 4
the steering control unit, and returns to the hydraulic
tank. When the valve plate is moved from its center po- 8
sition by the steering wheel, a port is opened in the isola- 9
tor manifold and hydraulic pressure is sent to the meter- 3
ing section.
2
Metering Section
1

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

FIGURE 2. PARTS FOR THE STEERING CONTROL UNIT

2
 Components with alignment grooves must be
assembled as shown in the illustration. The
alignment grooves make sure that the parts are in
the correct position.
Make a note of the contact brush assembly. The
position of the hole from the alignment grooves
must be the same when the steering control unit is
assembled.
FIGURE 3. ILLUSTRATION FOR COMPONENT
GROOVE ALIGNMENT
The procedures and illustrations in this section are
supplied by the Ross Gear Division of TRW.
DISASSEMBLY AND INSPECTION
WARNING
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.
Make sure you understand the procedures described in
this section before you begin disassembly and repair.
Keep a clean area for the parts and assemblies. The parts
are machined to small tolerances. Use minimum force
and carefully disassemble and assemble the parts. Do
not permit damage to occur from small scratches, dam-
age, and dirt. Use a petroleum solvent to clean the parts.
Dry the parts with compressed air.
Some parts are bonded together and must be replaced as
a single part. Disassemble the parts only as described in
this section. Some parts have a special small tolerance
and can be only replaced as an assembly.
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.

FOUR HOLES 3/8 (0.375) DIA. EQUALLY

SPACED ON A 3.25 DIA. CIRCLE
DIMENSIONS SHOWN IN INCHES
0.50 8.00
3.75
0.18 2.00

2.00
0.625

4.00

45 2.00 DIA.
3.25 DIA.

FIGURE 4. SERVICE FIXTURE ASSEMBLY

NOTE: The numbers in parenthesis () in the following

steps are a reference to the parts list in FIGURE 2.

1. Remove the contact brush assembly. Remove the

screws (45) and washers (46), contact brush assembly
(44), and spacer (37) from the upper tube and jacket as-
sembly.

4
2. Loosen the plug (6) assembly in the port cover (2)
for disassembly after the port cover is removed.
3. Remove the four nuts (1) that hold the port cover (2)
to the unit. Do not damage the ports.
CAUTION
The nuts (1) are a special lock nut. Use only approved
parts as replacement nuts.
4. Remove the port cover (2). Discard the four Orings
and the seal ring.
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.
6. Carefully lift the port manifold (8) from the unit
NOTE: The three springs can become disengaged when
the port manifold is removed. Do not permit the loss of
the three springs (9).
Remove the three springs from the port manifold. In-
spect the springs for damage or distortion.
NOTE: Keep the three springs from the port manifold
separate from the three springs you will remove from
the isolator manifold. The three springs in the port man-
ifold are 19 mm (0.75 in) in length. The three springs in
the isolator manifold are 13 mm (0.50 in) in length. If
any of the springs are damaged, the springs in both the
port manifold and the isolator manifold must be re-
placed.
Inspect the port manifold. The rotation of the valve plate
will normally polish a pattern in the port manifold. An
acceptable part can have this pattern if there are not
scratches, grooves, or other damage.
5
7. Remove the valve ring (12). Discard the two seal
rings (3).
8. Remove the valve plate (13). Inspect the edges and
surfaces for wear and damage. The slots must have
sharp edges. The valve ring and valve plate must be re-
placed as a set.
6
9. Remove the three springs from the isolator man-
ifold. See the NOTE about the springs in step 6.
10. Remove the drive assembly (10) from the drive
link. The alignment pin (11) in the drive assembly
must not be worn and must fit the hole tightly. The
sides and slot of the drive assembly must be replaced if
there is wear.
 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.

12. Remove the isolator manifold (15). Inspect the sur-

faces of the isolation manifold. The rotation of the
valve plate will normally polish a pattern in the isola-
tor manifold. A similar pattern will be on the opposite
side of the isolator manifold caused by the commutator 15. Remove the metering ring (17). Discard the two
cover. An acceptable part can have this pattern if there seal rings (3). Inspect the bore of the metering ring for
are not scratches, grooves, or other damage. grooves. Replace a worn metering ring.

7
16. Remove the metering assembly and put it on a
clean surface. DO NOT put the assembly in a vise.

19. Remove the commutator cover (20). Inspect the

commutator cover. The rotation of the commutator
will normally polish a pattern in the commutator cov-
er. An acceptable part can have this pattern if there are
not scratches, grooves, or other damage.

17. Remove and discard the commutator seal (19).

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

21. Remove the commutator from the rotor. Five align-
ment pins hold the commutator to the rotor. Carefully
separate the two parts
22. Remove the five alignment pins.
23. Remove and inspect the drive link spacer (23). Re-
place a worn part.
0.08 mm (0.003 in)
MAXIMUM
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
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.

28. Remove the thrust bearing (28) and the bearing

spacer (27). Inspect the parts for wear and damage.

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.

29. Make a note of the position of the upper cover plate

(32) to the upper cover and jacket assembly (37) so that
27. Remove the seal (29), backup ring (30), and the the parts will be assembled again in the same position.
spacer (31). Discard the seal and backup ring. Keep Remove the upper cover plate and inspect for wear and
the spacer. damage.

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.

33. Remove the snap ring.

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.

35. Remove the tape, horn cable assembly (47), and

contact ring assembly (43) from the input shaft. Re-
place worn or damaged parts. Make a note of the posi-
tion of the contact rings so that they can be assembled
in the same position again.

38. Use a puller to remove the bushing from the tube.

36. Remove the upper cover and jacket tube assembly Discard the bushing.
(37).

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.

2. Use pliers or a punch to bend two small areas of the

tube to lock the bushing in position. Do not use the
original areas that were used as the locks.

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

4. If the horn contact assembly was removed for re-
pairs, install the horn contact assembly (43) on the in-
put shaft. Make sure the position is like unit before it
was disassembled.
6. Apply a small amount of grease to the face of the re-
tainer plate (36) and washer (35). Install the retainer
plate and then the washer. The flange of the retainer
plate must be towards the washer.

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.

7. Install the snap ring.

5. Install the horn cable assembly (47) in the input

shaft. The spade connector must come through the out-
let hole in the input shaft. Connect the spade connector
to the horn contact assembly (43). Put the protective
sleeve on the wire in position so that it protects the wire
from sharp corners in the outlet hole. Fasten the horn
contact assembly in position with the setscrew. Put ap-
proximately 11/2 rotations of electrical insulation tape
around the contact ring to hold the horn wire in posi- 8. Slide the input shaft assembly into the upper cover
tion. and tube assembly.

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.

10. Apply grease to the face of the upper cover plate

and to the end of the input shaft. 12. Install the seal assembly on the upper cover plate.

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.

14. Apply a small amount of grease to the spacer (23)

and install it in the drive slot of the rotor. The purpose
of the grease is to hold the parts in position during as- 16. Install the alignment pins. Make sure that the align-
sembly. ment pins are below the surface of the commutator.

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.
Put the metering section in the metering ring with
commutator cover towards the surface. Use a spacer to
hold the metering section above the surface of the me-
tering ring.
22. Use 0.18 mm (0.007 in) shim material. Use six
pieces approximately 13 mm x 38 mm (0.5 x 1.5 in).
Install three pieces of shim material at equal distances
on the circumference between the drive plate and the
metering ring. Put another piece of shim material be-
tween the drive plate and each of the other shim pieces
already in position. Remove the spacer from under the
metering assembly and push the metering assembly
into the metering ring. The metering assembly and the
shims must be even with the surface of the metering
ring.
18
23. Put the metering section in position so that the
drive plate is on the work surface. Make sure that the
drive plate and the metering ring are touching the work
surface. Make sure that the socket head capscrews are
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
6 7
4 9
2 11
24. Tighten the socket head capscrews in stages ac-
cording to the sequence diagram. Tighten the socket
head capscrews to a final torque of 1.24 to 1.47 N.m
(11 to 13 lbf in).
 WARNING
Wear eye protection to remove the shims.
Push the metering assembly and the shims from the me-
tering ring.
25. Install the larger end of the drive link (16) into the
slot in the rotor.
26. Rotate the drive link and metering assembly with
your hand to make sure that the parts move smoothly.
If the parts do not move smoothly, disassemble the me-
tering assembly and make repairs before you assemble
the steering control unit.
27. Use grease to hold the seal ring in the metering
ring. The seal ring is installed in the opposite side from
the holes for the alignment pins. Install the metering
ring with seal ring on the upper cover plate. Make sure
that one of the holes for the alignment pins is aligned
with the alignment groove on the side of the upper cov-
er plate. Make sure that the seal ring stays in position in
the metering ring.
28. Install the bearing spacer (27) on the upper cover
plate.
19

29. Apply grease to the roller thrust bearing and install
it inside the bearing spacer.
30. Make sure the face of the drive plate is clean. Ap-
ply a thin layer of grease to the surface of the drive
plate on the metering assembly.
20
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
the thrust roller bearing.
32. Apply grease to a new commutator seal (19) and
install it into the seal groove in the commutator cover.
The side of the seal with the yellow mark (softer rub-
ber) must be put into the seal groove.
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.

34. Install two alignment pins into the metering ring.

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
engage with the smaller end of the drive link. Turn the
input shaft for assistance to engage the drive link. If the
drive assembly will not engage the drive link, check
that the larger and smaller ends of the drive link are in
the correct position.
40. The valve plate must be installed in the correct po-
sition as shown in the illustrations. Make sure the posi-
tion of the alignment grooves on the outside of the
housing and the position of the valve plate is correct as
shown in the illustrations. The pointer points to one of
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

47. Install the special lock nuts on the through bolts.

Tighten the nuts in steps in the sequence shown in the
illustration. Tighten the lock nuts to 27 to 33 N.m (20 50. Install the electric connection for the horn.
to 24 lbf ft).

24
 TROUBLESHOOTING

NOTE: This Troubleshooting is only for the steering

CAUTION control unit and does not include the steering system.
Temperatures greater than 93C (200F) will cause Make sure the steering system is correct before doing
damage to the seals and cause leaks. the troubleshooting for the steering control unit.

TROUBLE POSSIBLE CAUSE PROCEDURE OR ACTION

The steering wheels do not move
when the steering wheel is turned.
Slow or difficult steering.
Steering wheel turns the tires in the
wrong direction.
Steering function continues after the The steering control unit is as-
steering wheel stops.
The steering operation is not
smooth.
The oil level is low or there is no oil
in the tank.
The steering control unit is dam-
aged.
No oil flow from the steering control
unit to the steering cylinder.
The sleeve and spool in the control
unit will not move.
Hydraulic hoses not connected or
have damage.
Relief valve for the steering system
is not adjusted correctly.
Low oil pressure from the hydraulic
pump.
Seal in the steering cylinder has a
leak.
Hydraulic lines are too small or
have restrictions.
Steering control unit is worn, not as- Repair or install new control unit.
sembled correctly or has dam-
age.
The hydraulic lines are not con-
nected correctly at the steering
cylinder or at the steering con-
trol unit.
sembled wrong or has damage.
The oil level in the tank is low.
Air was not removed after repair to
the hydraulic system.
The steering control unit is as-
sembled wrong or has damage.
The hydraulic pump has a leak at
the inlet.
Fill tank to the correct level. Check
for leaks.
Repair or install new control unit.
Repair or install new components.
Check for leaks.
Install new components.
Check for leaks. Tighten connec-
tions. Install new components
as necessary.
Adjust or install new relief valve.
Check for restrictions. See Trouble-
shooting Chart, Hydraulic Sys-
tem.
Repair cylinder. Install new seal or
new cylinder.
Remove restrictions. Install larger or
new hydraulic lines.
Connect lines correctly. Remove air
from the system.
Repair or install new control unit.
Fill tank. Check for leaks.
Remove air from the system.
Repair or install new control unit.
Fix leaks. Remove air from the sys-
tem.

25