Hyster C227 (HR45-31) Diesel Counter Balanced Truck Service Repair Manual

DESCRIPTION

SteeringControlUnitRepair

Thesteeringcontrolunitisahydrostaticunitcontrolledbythesteeringwheel.SeeFigure3.Itis mountedinthesteeringhousing.Thesteeringcontrolunithasashaftassembly,controlsection,anda meteringsection.Thehydraulichosesforthesteeringsystemarefastenedtoamanifoldblock.

Asthesteeringwheelisturned,thespooljustbeginstorotate.Thespringstrytomovethesleeveto keepthe NEUTRAL positionbetweenthespooland sleeve.However,theforcenecessarytoturntherotorisgreaterthanthepressureofthesprings.The springsbegintobend,lettingthespoolmoveasmall amountwithinthesleeve.Thespoolstopsmoving whenittouchesthecenterpin.Inthisposition,the holesinthesleeveandthespoolarealigned.Oilcomingintothecontrolunitflowstothemeteringsection. Morerotationofthesteeringwheelcausesthespool torotatethepin.Thisactioncausestherotationof thesleeveandtherotorinthemeteringsection.The oilthenflowstotheflowamplifierandthentoone sideofthesteeringcylinder.Oilfromtheotherside ofthesteeringcylinderflowsbackthroughtheflow amplifierandthecontrolsectionofthesteeringcontrolunit.

Whenthesteeringwheelstopsmoving,themeteringactioninthemeteringsectionalsostops.The NEUTRAL positionspringsreturnthesleevetothe NEUTRAL position.Whenthisactionoccurs,the pressurestaysinthesteeringcylindertokeepthe tiresinposition.Oilfromthepumpflowsthrough thesteeringcontrolunittothetankorotherpartsof thesystem.Toreturnthetirestothestraightposition,thesteeringwheelmustberotatedintheoppositedirection.Thesteeringcontrolunitwilloperate asdescribed,butallpartswillrotateintheopposite direction.

LOAD-SENSINGSTEERING

OPERATION

Turningthesteeringwheelactuatesthreemain partsofthesteeringcontrolunit(seeFigure3):(1) thespoolforthecontrolsection,(2)thesleevefor thecontrolsection,and(3)therotorinthemetering section.Whenthesteeringwheelisnotmoving,the spoolandsleeveareheldinthe NEUTRAL (center) positionbysprings.Duringthistime,oilflowsfreely throughthesteeringcontrolunit.Theoildoesnot flowtothesteeringcylinder.

Thedemandforsteeringissensedattheload-sensing (LS)portinthesteeringcontrolunit.Thepilotline fromtheLSportisconnectedtothepriorityvalve inthemaincontrolvalve.Whilesteering,aspring andpilotpressurefromtheLSlineholdtheregulator spoolopenforsteering.Whenthereisnopressurein theLSline(nosteering),pilotpressurefromthehydraulicpumpshiftsthespool.Inthisposition,most oftheoilforsteeringsystemgoestothehydraulic system.

Figure3.SteeringControlUnit

REMOVE

1. Removecoverfromsteeringhousing.Puttags onhydrauliclinesatmanifoldblock.Disconnect hydrauliclinesandputcapsonopenings.

2. Removesteeringcolumnfromsteeringcontrol unit.SeeFigure4.Removecapscrewsthatfastensteeringcontrolunittobracketandremove steeringcontrolunit.

1.STEERINGWHEEL 2.STEERINGCOLUMN 3.RUBBER BOOT

4.STEERINGCONTROLUNIT 5.MANIFOLDBLOCK

Figure4.SteeringColumnAssembly

DISASSEMBLE

STEP1. Putthecontrolunitinavisewithsoftjaws.Makean identificationmarkonlengthofcontrolunit.Remove manifoldblock.

1.STEERINGCONTROLUNIT

2.VISE

STEP2. Removecoveronbottomofsteeringcontrolunit.

2.COVER

3.O-RING

1.CAPSCREW

STEP3.

Removespacer,stator,rotor,andportplate.Puta markonstatorsothesamesideistowardbodyof controlunit.RemoveO-rings.Removecentershaft.

STEP4.

Removescrewforcheck ball.Removecheckball.

1.SPACER

2.STATOR

3.ROTOR

4.PORTPLATE

5.O-RING

6.CENTERSHAFT

1.SCREW

STEP5.

Removespoolandsleeveassembly.Removethrustbearingassemblyfromspool.Pushcenterpinfromsleeve. Carefullyremovespoolfromsleeve.(Rotatespoolslowlyduringremoval.)Removeringfromsleeve.Remove NEUTRAL positionspringsfromspool.

STEP6. Remove dustsealfromhousing.

1.HOUSING 2.DUST SEAL

CLEAN

WARNING

Cleaningsolventscanbeflammableandtoxicandcancauseskinirritation.Whenusingcleaning solvents,alwaysfollowthesolventmanufacturer’srecommendedsafetyprecautions.

WARNING

Compressedaircanmoveparticlessotheycauseinjurytotheuserortootherpersonnel.Make surethepathofthecompressedairisawayfromallpersonnel.Wearprotectivegogglesoraface shieldtopreventinjurytotheeyes.

Cleanallpartsinsolvent.Drypartswithcompressedair.Donotdrypartswithacloth.Makesureallsurfaces arefreeofscratchesandsharpedges.

ASSEMBLE

NOTE: Usenewseals,O-rings,and NEUTRAL positionspringsduringassembly.Lubricateallpartswith cleanhydraulicoil.

STEP1. Installnewdustsealinhousing.

STEP2.

Putspoolonworkbench,thenputhousingontospool asshown.InstallguideringwithO-ringontheend ofspool.Putalargethrustwasher(seeSTEP5)on topofguideringandO-ringassembly.Useadeep socketortubetopushonwasher,andinstallO-ring andguideringinhousing.Carefullyremovewasher, tube,andspoolfromhousing.

STEP3.

Carefullyassemblespoolandsleeve.Makesurespool rotatesfreelyinsleeve.

1.O-RING

2.GUIDERING

3.SPOOL

4.WASHER

5.TUBE

6.HOUSING

1.SPOOL

2.SLEEVE

STEP4.

Assemble NEUTRAL positionsprings,thenpushthemintopositioninspool.Makesureflatspringsareinstalledtotheoutsideofcurvedsprings.Installcenterpin.Installringonsleeve(over NEUTRAL position springs).Theringmustturnfreelyonthesleeve.

1.NEUTRALPOSITIONSPRINGS(FLAT)

2.NEUTRALPOSITIONSPRINGS(CURVED)

3.CENTERPIN

4.SPOOL 5.RING

STEP5.

Installthrustwashersandthrustbearingonspool. Makesurechamferoninnerthrustwasheristoward sleeve.Installspoolandsleeveassemblyinhousing. Carefullyrotatespoolandsleeveassemblyduring installationtomakesurespoolfitscorrectlyinseal installedinSTEP2.Makesurecenterpininspool andsleeveassemblyishorizontal(paralleltoport surface).

1.HOUSING

2.SPOOLANDSLEEVEASSEMBLY

3.THRUSTWASHER

4.THRUSTBEARING

5.SPOOL

6.SLEEVE

STEP6.

Installcheckballandsleeve.Makesurethesleeveisevenwithorbelowthesurfaceofthehousing.Lubricate O-ringandinstallO-ringandportplate.Alignholesinportplatewithholesinhousing.

1.CHECKBALLSLEEVE

2.HOUSING

3.O-RING

4.PORTPLATE

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STEP7.

Installcentershaftsoitengageswithcenterpininspoolandsleeveassembly.Makesurethecenterpinis stillparalleltotheportsurface.Installrotoroncentershaft.Makesureavalleyintherotoralignswithslot (centerpin)incentershaft.InstallO-ringandstator.Makesuretoalignthemarksmadeduringdisassembly.

STEP8.

Installspacer.InstallO-ringandcover.Tightencapscrewsforthecover,inthesequenceshown,to17N•m (150lbfin).Thentightenthemto30N•m(265lbfin).Makesurethecapscrewwiththepinfitsintheholefor thecheckball. 1.SPACER

STEP9.

InstallmanifoldblockandO-ringsonsteeringcontrolunit.

INSTALL WARNING

Aftermakingrepairs,donotextendthehands orarmsthroughthecenterofthesteering wheel.Ifthecontrolunitwasnotassembled correctly,orhosesarenotconnectedcorrectly, itcanrotatewithastrongforceandcause

injury.Ifthisactionoccurs,disassemblethe controlunitandcorrecttheproblem.

1. Installcontrolunitonbracket.SeeFigure4. Connectlinesatmanifoldblockandsteeringcontrolunit.

2. Connectsteeringcolumn.Installhousing.

4.CAPSCREW 5.CHECKBALL

DESCRIPTION

Thesteeringaxleassemblyincludesanaxleframe, asteeringcylinder,andtwospindleandhubassemblies.SeeFigure5.Theaxleassemblyisconnected totheframewithtwopivotshafts.Theendsofthe axleandsteerwheelscanmoveupanddownwhen thevehicletravelsoverroughsurfaces.

Theendsofthepistonrodextendfrombothendsof thesteeringcylindershell.Tierodsconnectthespin-

dlearmstothecylinderrod.Oilpressureononeside ofthepistonmovesthepistoninthebore.Thepiston pushesanequalamountofoilfromtheoppositeside ofthecylinder.

Areliefvalveinthesteeringsystemcontrolstheoil pressurewhenthepistonreachestheendofthecylinder.

Figure5.SteeringAxleAssembly

REMOVE WARNING

Puttherearofthevehicleonblocks.Follow theproceduresforraisingthevehicleinthe OperatingManualorPeriodicMaintenance section.Thesurfacemustbesolid,even,and level.Makesureanyblocksusedtosupport thevehiclearesolid,onepieceunits.Make suretheliftingdevicesusedduringrepairs canlifttheweightoftheparts.

1. Removecounterweight.[Thecounterweight weighsapproximately17,000kg(37,500lb).] SeeFigure5.Whenremovingaxle,disconnect hydrauliclinesandinstallcapsoncylinderfittings.Thecapswillpreventcylinderrodfrom movingasaxleisremoved.

2. Putaliftingdeviceundertheaxle.Remove platesthatholdpivotpinsinframe.Remove pivotpins.Loweraxlefromframeandremove axle.

INSTALL

1. Wheninstallingaxle,makesurewashersets andbushingareincorrectposition.SeeFigure5.Lubricatebushingsandpivotshaftswith multipurposegrease.Raiseaxleintoframe mounts.Installpivotshaftsandplates.Install counterweight.[Thecounterweightweighsapproximately17,000kg(37,500lb).]

2. Checktheoperationoftheantitippingdeviceas describedinAntitippingDeviceAdjustment.

SteeringCylinderRepair REMOVE

WARNING

Makesuretheliftingdevicesusedduringrepairscanlifttheweightoftheparts.

1. Removecounterweight.[Thecounterweight weighsapproximately17,000kg(37,500lb).] Disconnecthydrauliclinesandinstallcapson cylinder fittings.SeeFigure5.

2. Disconnecttierodsatcylinder.Removecapscrewsthatholdcylindertoaxleframe.Remove cylinder.

CLEANAN DINSPECT

WARNING

Cleaningsolventscanbeflammableandtoxic, andcancauseskinirritation.Whenusing cleaningsolvents,alwaysfollowthesolvent manufacturer’srecommendedsafetyprecautions.

WARNING

Compressedaircanmoveparticlessothey causeinjurytotheuserortootherpersonnel. Makesurethepathofthecompressedairis awayfromallpersonnel.Wearprotectivegogglesor afaceshieldtopreventinjurytothe eyes.

Cleanallpartsinsolvent.Drypartswithcompressed air.Makesureallsurfacesarefreeofscratchesand sharpedges.

1. Inspectpistonrodforgroovesordamage.

2. Inspectbracketsoncylinderforcracks.

ASSEMBLE

1. Repaircylinderasnecessaryusingnewsealsand O-rings.Lubricatepartswithhydraulicoilduringassembly.

2. Installretainersatendsofcylinder.

INSTALL

WARNING

Makesure theliftingdevicesusedduringrepairscanlifttheweightoftheparts.

1. Install hydraulicfittingsoncylinder.Install cylinderandmountingblocksonaxleframe. Tighten capscrewsthatholdcylindertoaxle frameto 500N•m(370lbfft).

2. Connect tierodstocylinder.(SeeFigure5.)

3. Install counterweight.[Thecounterweight weights approximately17,000kg(37,500lb).]

REMOVE

Removehubcover.SeeFigure6.Removeadjustmentnutsandlockring.Removehub.Ifthebearingsorthesealsarereplaced,useabrassdrifttoremoveinnerbearingassemblyfromhub.Checkfor damageorwearonbearings.

CLEAN WARNING

Cleaningsolventscanbeflammableandtoxic andcancauseskinirritation.Whenusing cleaningsolvents,alwaysfollowthesolvent manufactur er’srecommendedsafetyprocedures.

Cleanallpartswithsolvent.Makesurebearingsare clean.

INSTALL

1. Lubricatebearingswithmultipurposegrease. SeeFigure6.Installtheinnerbearingandseal. Installhub,outerbearing,washer,andadjustmentnutonspindle.Tightenadjustmentnut whilerotatinghub.

2. Installlockringagainstadjustmentnut.Tighten adjustingnutasmallamountuntiltabonlock ringalignswithanotchinadjustmentnut.Bend tabonlockringtolockadjustmentnut.

3. Installouteradjustmentnutandtightenit. Bendtabonlockringtolockthenut.

4. Fillhubwithmultipurposegrease.Installhub cover.

Figure6.HubandSpindle