HQS SENIOR

TECHNICIAN COURSE
STEERING SYSTEM
STEERING SYSTEM
1) OUTLINE AND STRUCTURE

STEERIG
MECHANISM

STEERIG
STEERIG LINKAGE
GEAR
MECHANISM

MECHANICAL STEERING SYSTEM

 INTEGRAL POWER STEERIG
STEERIG GEAR BOX SHAFT

OIL RESERVOIR TANK

OIL PUMP

PITMAN ARM

DRAG LINK
KNUCKLE ARM

INTEGRAL TYPE POWER STEERING

 POWER
SYLINDER

LINKAGE TYPE POWER STEERING

 WORM SHAFT
TAPERED ROLLER BEARING
BEARING OUTER RACE
SECTOR SHAFT

BOLL- NUT

HOUSING

SHIM

LOWER COVER DRAIN PLUG

BOLL- NUT TYPE STEERING GEAR BOX

 STEERING GEAR RATIO
Unit:(angle)
STEERING
Steering wheel
movement "A" "A"
GEAR
RATIO = Pit-man arm
movement "B"

"B"
AT STEERING WHEEL WHEN TRAVERING
MAXIMUM TURNING ANGLE STRAIGHT AHEAD

SECTOR GEAR

VARIABLE GEAR RATIO

(Boll-not type Steering Gear)
 Table of steering gear ratio

Model Power steering Gear ratio

FB2W Without 26~30:1
FB2W With 18.85:1
FF1J With 22:1
FS1K With 20.48:1

Variable gear ratio

2) Operation of integral type power steering for medium-duty
vehicle

TO RESERVOIR FROM PUMP VALVE PIN

CENTERING
SPRING
REACTION
CHAMBER CENTERING
BOLT

VALVE PISTON

POWER
TOP COVER PISTON

SLEEVE

SECTOR
Construction SHAFT BOLL
Drawing HOUSING NUT
 CENTERING CENTERING
BOLT SPRING

REACTION
CHAMBER
BOLL
NUT

POWER
TOP COVER PISTON

VALVE PIN
SLEEVE
VALVE PISTON

SECTOR
SHAFT
HOUSING

Construction Drawing
 TO RESERVOIR FROM PUMP

KETIKA BERJALAN
LURUS KE DEPAN
 TO RESERVOIR FROM PUMP
VALVE PIN
VALVE PISTON
REACTION
CHAMBER

Valve piston during right turn

 TO RESERVOIR FROM PUMP

KETIKA KEMUDI
DIPUTAR KEKANAN
 TO RESERVOIR FROM PUMP

When steering wheel

is turned to the left
(3) Integral type power steering for heavy-duty vehicle

SPOOL
TORSION BAR VALVE WORM
PISTON SHAFT
STUB
CYLINDER SHAFT
CHAMBER

VALVE
SECTOR SHAFT HOUSING

Integral type power steering unit

 WORM
SHAFT

SECTOR SHAFT

PISTON
 WORM
SHAFT
TORSION
BAR
SECTOR
SHAFT
STUB
SHAFT

SLEEVE

SPOOL
VALVE

VALVE
HOUSING
GEAR
HOUSING
PISTON
Saat berjalan
lurus
Posisi spool valve Saat
YOKE (STUB SHAFT)
berjalan lurus

KE RESERVOIR SPOOL VALVE

TORSION BAR

GEAR CASE

SECTOR SHAFT

KE CYLINDER CHAMBER
BAWAH CYLINDER CHAMBER ATAS
DARI RESERVOIR
Saat belok kanan
 KE RESERVOIR
SPOOL VALVE

TORSION BAR

KE CYLINDER CHAMBER BAWAH CYLINDER CHAMBER ATAS

DARI RESERVOIR
KETIKA BERJALAN LURUS KE DEPAN
KETIKA KEMUDI DIPUTAR KE KANAN

R
 KETIKA KEMUDI DIPUTAR KE KIRI

From
pump To tank
To L To L
To tank From R
From pump
From
R ToRtank
 SPOOL VALVE OPERATION

BERGERAK KE DEPAN
(NETRAL) BELOK KANAN

FROM FROM
PUMP SLEEVE PUMP
TO TO TO
RESERVOIR RESERVOIR RESERVOIR

SPOO
L
VALVE

PISTO
N
TORSION BAR

Reactive force ( Steering feel )

 WORM
SHAFT

STUB
SHAFT

A-A SECTION

Valve stopper
(4) Power steering pump

MAX.SPECIFIED
MODEL
PRESSURE
FC4J 85kgf/cm2
FF1J 130kgf/cm2
FS1K 130kgf/cm2

Power steering pump

 FLOW
BEARING RELIEF VALVE CONTROL
VALVE

CAM
RING

SHAFT

VANE

OIL SEAL ROTOR

O-RING
Power steering pump
 POWER STEERING OIL PUMP OPERATION

Neutral (flow control valve & relief valve Ketika RELIEF

saat tidak bekerja) VALVE bekerja

CAM RING FROM PUMP TO RESERVOIR

FROM
ROTOR GEAR
BOX

TO
GEAR FLOW CONTROL VALVE
BOX OPERATION
VANE
FROM PUMP
ORIFICE

RELIEF VALVE
FLOW CONTROL VALVE
(5)Steering wheel play ( gear backlash ) adjustment

15~35mm

Adjusting backlash
INSTALLATION OF DIALGAUGE
(6) Air bleeding procedure

(1) Jack up the front wheels.

(2) Supply oil to the oil reservoir until the oil level does not drop.
(3) Gently turn the steering wheel 6-7 times or more from lock position to lock
position. If the oil level in the reservoir drops at this time, replenish oil to
the prescribed level.
(4) Idle the engine and repeat step (3).
(5) Slowly depress the accelerator pedal while turning the steering wheel
as far as it will turn, and check steering wheel play, pipe vibration, and
pump noise.
(6) Stop the engine and make sure the oil level has not changed. If anything is
unusual, idle the engine for about ten minutes and repeat steps (4) and (6).
(7) Oil pressure check PRESSURE GAUGE

STOP VALVE

ENGINE

OIL PUMP

STEERING GEAR BOX

RESERVIOR TANK
Power steering performance check circuit
 (A)Preparation prior to check

(1)Fully clean the power steering piping installation parts,

remove the inlet-side joint, and arrange an oil pressure
measuring gauge as shown in the figure above.
(2)Check the oil quantity in the oil reservoir, and replenish
the oil if necessary.
Bleed air out of the system at this time.
(3)Idle the engine and turn the steering wheel back
and forth. Run the engine until the oil temperature
in the oil reservoir is 50 ~ 60ºC .
(B) Measuring back-pressure ( pipe resistance )

The oil pressure ( pipe resistance ) with the engine

idling and the steering wheel released is normally
below 0.98Mpa (10kgf/cm²). If the measured value is
greater than 0.98Mpa (10kgf/ cm² ), check for clogging
of the power steering control valve, piping, and other
parts.

engine

below 10kgf/ cm²

(C) Measuring relief pressure

(1) Measuring procedure

Raise the engine speed to about 1,500rpm and
gradually tighten the cock, mindful of the rising
pressure on the gauge.
Measure the maximum pressure ( relief valve control
pressure ) under these conditions.
(2) Determination
Refer to the workshop manual for the control
pressure values for each model.
Example:
FC4J:85kgf/ cm², FF1J:130kgf/ cm², FS1K:130kgf/ cm²
If the measured value deviates from the stipulated
value, the pump is out of order. ( Repair or replace
the oil pump. )
NOTE: For protection of the pump and piping, take
at least 15 seconds to fully close the cocks.
This also applies to the following checks.
(D) Checking the flow control valve

(1) Measuring procedure

1) Idle the engine and gradually close the cock,
setting the oil pressure to 4.90MPa( 50kgf/ cm² )
2)Raise speed to about 1,500rpm and then lower it
rapidly.
Quickly read the drop in oil pressure.
Repeat this step once or twice more.
(1) Determination
1) Set pressure return quickly ……..Normal.
2) Pressure drops below set pressure and does not
quickly return to set pressure……Faulty.
3) Pressure drops below set pressure and remain
there……..Faulty.
If results are faulty, repair or replace the oil pump.

(E) Checking the power steering gearbox

Conform that the oil pump is operating normally and

then take the following measurements.
< With the front wheels jacked up >

(1) Measuring procedure

1) Jack up the front wheels.

2) Fully open the cock.
3) Measure the oil pressure with the steering wheel
turned fully to the right and left until the knuckle
stopper is contacted.
 (2) Determination

Refer to the Workshop Manual for the control pressure values for each
model.
Example: FC4J 85kg/cm², FF1J 130kg/cm²
FS1K 130kg/cm²

If the measured value deviates from the stipulated value,

the power steering gearbox is out of order.
( Repair or replace the power steering gearbox. )
< With the front wheels on the ground >

(1) Measuring procedure

1)Lower the front wheels to the ground.

2)Fully open the cock.
3)Stabilize the engine speed at 1,000 ~1,500 rpm,
and turn the steering wheel until the gauge is
indicating 4.90MPa { 50kgf/cm2 }.
Release the steering wheel and read the oil pressure
drop. Repeat this procedure at least five times.
4)Change the set pressure to 3.92, 2.94, 1.96, 0.98Mpa
{ 40, 30, 20, 10kgf/cm2 }, and take the same
measurement at each pressure.
(2) Determination

1) Set pressure returns quickly to piping resistance

< 0.98Mpa { 10kgf/cm2 } maximum >……...Normal
2) Pressure stays at normal steering oil pressure…
Power steering gear is faulty, provided column
and foot areas are normal.
3) Pressure only returns to an oil pressure higher
than the piping resistance…… Same as 2).
If results are faulty, repair or replace necessary
parts.
(3) Running test

Perform every type of steering operation,

and if a fault is discovered, repair or replace
the necessary part.
2)SERVICE POINTS: Steering system
Mechanical type steering gearbox
(1) Clean the air breather,
because a clogged breather
will cause oil leakage.

AIR BREATHER
(2) Measure the gear backlash at the end, with the
pit-man arm in neutral.
(3) The tapered roller bearing pre-load is adjusted with
the worm shaft and shims..

SHIM
(4) Do not disassemble the worm shaft and ball nut.
If either is defective, replace the Assy.

WORM SHAFT

BALL NUT
(5) Use gear oil for the gearbox oil.
PS type steering gearbox

(1) During gearbox disassembly or assembly the entry

of dirt into the system must be avoided at all cost.
(2) Make sure sealing materials for pipe and joints
do not enter into the piping.
(3) Check for crushed pipes or twisted hoses.
(1)What trouble will occur if the worm shaft pre-load
in a mechanical type steering gearbox is too large
or too small?

WORM SHAFT PRE-LOAD

Steering play, bearing wear, heavy steering wheel or lock.
(2) What might cause
the power steering oil RESERVOIR TANK
to blow out
of the reservoir?
Oil blown out by heat expansion due to overfilling.
(3) What trouble might occur if dirt or foreign substances
enter the piping?

Heavy steering, different left/right operating forces,

faulty self return.
(4) If the prescribed value is not reached when the oil
pump oil pressure is measured, what do you think
might cause this?

Distortion relief valve spring, faulty check ball contact,

vane wear or seizing, relief valve wear.