En 11SR 6127J 01 Direccion

Steering System SR-6127J-01 SR-1
Steering system
 Structure and working principles of steering system SR-2

1. Integrated power steering booster (steering gear)
2. Hydraulic piping system of steering system
 Technical specifications and parameters of steering system SR-4
1. Technical specifications of steering system
2. Related tightening torques
3. Schematic structural and principle diagrams of steering gear
4. Structural features and working principles
 Troubleshooting SR-9
1. Difficulty in operation of steering wheel
2. Deviation of steering wheel
3. Vibration of steering wheel
4. Failure of steering wheel resetting
5. Early abrasion of tyres
6. Floating of steering
7. Abnormal noises of steering gear
8. Analysis of normal troubles of hydraulic elements
 Assembly, disassembly and adjustment of steering system SR-15
1. Steering wheel and steering linkage
2. Steering drag link
3. Steering hydraulic system
4. Disassembly diagram of steering system structure
5. Troubleshooting of steering gear
6. Disassembly and assembly of steering gear
7. Re-assembly, cleaning and inspection of steering gear
SR-2 Steering System SR-6127J-01
 Structure and working principles of steering system
The bus needs to change its traveling direction from time to time. This is done by letting the driver manipulate a
dedicated mechanism to deflect the steering wheels at a certain angle to the longitudinal axis of the bus. In addition, the
bus will be interfered by road conditions during straight traveling and thus the steering wheels may be deviated subject to
external forces so that the bus traveling direction is changed. In this case, this mechanism can help the bus resume its
original straight traveling direction. This mechanism used to change or resume the bus’s traveling direction is called
automobile steering system. XML6127 bus is furnished with a hydraulic power assisted steering system characterized by
an integrated power assisted steering gear.
The steering forces are transmitted from the steering wheel to the hydraulic power assisted steering gear via the steering
shaft. While the mechanical gearing down unit works, the hydraulic power cylinder also starts to work under the control
of the steering valve of the hydraulic system. They turn the lower pitman arm and then directly push the steering drag
link and the steering forces are magnified, boosted and transmitted to the steering knuckle arm in the front axle assembly
to push the deviation of the steering wheels and change the traveling direction of the bus. Even if the hydraulic system is
in trouble and no longer boosts, the mechanical transmission system can still change the traveling direction although the
driver has to turn the steering wheel with greater forces.
The steering system consists of mechanical transmission system and hydraulic power assisted system. The former has the
steering gear as the reference point and is further divided into the steering force input part (steering wheel and steering
linkage) and steering force output part (steering drag link).
1. Integrated power steering booster (steering gear)
1. Steering gear input shaft

2. Steering valve shaft
3. Gear shaft
4. Oil cylinder piston rack
The input shaft (1) of the steering gear is connected to the steering column and fastened in the rotary valve by the torsion
bar. The rotary valve shaft is rotated into the piston with roller threads (2) and moves in the piston in contact with steel
rollers. The rotational movements of the driving shaft will generate a high hydraulic pressure on a particular end of the
piston. Such a pressure will drive the piston to move in the borehole of the steering gear casing. The fan gear shaft (3) is
engaged with the rack (4) mechanically processed on one side of the piston. The movement of the piston rack drives the
fan gear shaft and the pitman arm to turn. When the steering shaft stops turning, the driving valve will return to the
middle position.
2. Hydraulic piping system of steering system
Steering booster oil pump is driven by the engine. The boosting oil pan supplies hydraulic oils via rubber hoses. High-
pressure hydraulic oils pass the oil outlet of the boosting pump and high-pressure oil pipes to enter the steering gear. The
hydraulic oils discharged from the steering gear return to the boosting oil pan via oil pipes.
1 Installation beam
2 Steering boosting oil
can
3 Oil return pipe
assembly, power
steering
4 Power steering oil
inlet pipe assembly
5 Steering pump
 Technical specifications and parameters of steering system
1. Technical specifications of steering system

Item Data
Model: M-100PPW3
Structure type Circulating ball power steering gear
Fluid flow type Normal flow type
Control valve type Rotary valve type, with traveling unloading valve
Front axle load (t) 4.9-6.4
Output torque (N·M)▲ 4844
Output angle (degrees) 95
Transmission ratio 18.9:1
Steering cycle number (cycle) 5.0 (maximum)
Diameter of output shaft (mm) --
Output shaft spline (outside diameter --
X tooth number)
Input shaft spline (outside diameter X --
tooth number)
Flowrate scope (L/min) 11.4~19.3
Rated pressure (bar) 150
Max working temperature 121℃
1.5 turns per second of the steering --
wheel—flowrate of oil pump
Net weight: 75.18lb
▲ The output torque at a 90% efficiency and rated pressure.
2. Related Tightening Torques

Thread Part of use Tightening torque (N.M)
specification
M10X1.5 Check ring of bearing cap 72-85
M14X2 Bearing cap, hydraulic cylinder end cover and sector shaft cap 154-168
Steering rocker arm fastening bolt --
Bolt-steering gear support and beam --
Bolt-steering gear and gear support --
Note: The tightening torques listed in this table are non-lubrication tightening torques.
Small torque values can be measured using small springs.
3. Schematic structure and principle diagrams of steering gear

Schematic structural diagram
1．Input shaft ２．Valve casing assembly ３．Thrust ball bearing ４．Worm shaft ５． Torsion
bar
６．Circulating ball ７．Piston and screw-nut assembly ８．Discharge plug set ９．Sector shaft
10．Sleeve
11．Slide valve 12. Dust cover 13．Bearing 14．Sealing ring

Working principles:
Middle position
进油口 Oil inlet

出油口 Oil outlet
油泵 Oil pump
截面 Section
储液罐 Oil tank
Power steering fluid route diagram for when the vehicle is turning right (the opposite is the case for a left turn)
通向 “R” Leading to “R”

来自“L” Coming from “L”
进 Coming
出 Going out
油泵 Oil pump
截面 Section
储液罐 Storage tank
L 室 Chamber L
R 室 Chamber R
4. Structural Features and Working Principles

 Structural Features
1) Control valve (rotary valve)-which is a control element for realizing steering boosting
2) Precision roller bearing- which is used to improve the efficiency and automatic resetting performance of the
steering gear。
3) Travel unloading valve-which is used to unload the steering system so as to protect the oil pump and the system
linking parts at the specified travel limit position of steering gear (optional).
4) Circulating ball transmission mechanism- which is used to improve the efficiency and keep stable transmission.
5) Dust and water proof sealing-there is a lip seal on both the input and output shafts.
6) Torsion bar-which provides real “road sense” and makes the rotary valve return to the center position.
a) Equal work areas at both ends of piston-which protects the steering stability from the impact of back
pressure.
b) High temperature seals-which are specially developed and can work at inconsecutive high temperatures.
c) Hand steering capability-which is used for mechanical steering in the event that the hydraulic system
fails.
d) Compactness-which enables a light weight and large output torque.
 Working principles of steering

In steering, the driver transfers the steering torque to the input shaft of steering gear via the steering wheel. The torsion
bar is connected with the input shaft at one end with pins and with the screw at the other end. The steering torque from
the input shaft is transmitted to the screw via the torsion bar. Due to the function of the circulating ball mechanism, the
screw attempts to make the rack piston move axially along the cylinder hole but the ground resistance from the wheels
restricts the axial movement of the rack piston via the drag link system. As a result, the torsion bar is twisted, leading to
the change of the position of the oil groove of input shaft corresponding to that in the valve sleeve. That is, the control
valve functions and leads the high pressure oil to the designated oil tank, the upper one or lower one, which will produce
a hydraulic force on the end face of the corresponding rack piston, moving the rack piston axially. As a result, the rocker
shaft is rotated to realize the steering of vehicle.
 Impact load on the steering gear

If a ground impact load is exerted on the steering wheel, the impact force will be transmitted to the rack piston via the
rocker shaft and further to the transmission screw. The internal structure of the steering gear makes the rotary valve send
high pressure oil to the corresponding oil cylinder to overcome this impact force. As the hydraulic oil absorbs this impact
force, the steering gear prevents the steering wheel from hitting the hand.
 Travel valve
The steering gear has a travel valve provided on each end of the rack piston. When the steering wheel moves near to the
limit screw, the travel valve restricting the steering boosting towards that direction will be opened and the oil pressure in
the steering gear will be reduced, thus reducing the heat produced by the small oil pump and reducing the load on the
connecting parts of the steering system accordingly.
 Exhaust system
An exhaust screw is provided on the steering gear at the side near to the input shaft, which is used to discharge the air in
the oil cylinder. Air entering the steering gear will affect the boosting effect adversely and cause noise.
 Troubleshooting
The troubles that commonly happen to the steering system include steering instability, excessive clearance, one-sided
steering, loosening of steering wheel, front axle deviation and steering wheel failure.
When the steering wheel turns unstably, use a jack to support the front axle and check with the help of the front wheel on
the ground. If the steering wheel still turns unstably, separate the steering gear and the connecting mechanism at the
pitman arm and check these parts.
The abrasion of the kingpin won’t cause difficulty in the turning of steering wheel normally unless the bus is overloaded.
This has to be considered in case of trouble. Difficulty in the turning of steering wheel during traveling is caused by
improper adjustment of front wheel angle.
The instability in the operation and resetting of the steering wheel arising from improper clearance of the steering gear or
excessive pre-stress can’t be discovered unless the steering gear is disassembled. Gradual occurrence of this problem is
normally caused by improper lubrication of the connecting mechanism.
Failure of steering during traveling is normally caused by road unevenness. In this case, it is necessary to drive the bus
and check the steering conditions on every type of road. Deviation of the steering wheel may be caused by improper
alignment of the front wheels, improper balancing of the tyres and excessive clearance or looseness of the steering
mechanism.
In addition to the troubles of hydraulic elements, it is also necessary to check and analyze the conditions of hydraulic oils
preferentially. If the temperature is too high or too low, system troubles may also be caused. Pollution or excessively
high water and air content of hydraulic oils may also cause troubles to the hydraulic system.
1. Difficulty in operation of steering wheel
Trouble Cause analysis Solution

Difficulty in Steering system
operation of steering
wheel Insufficient oil in the steering gear Replenish with lubricating oils to the
required level
Deterioration of or foreign matter in lubricating oils Replace the lubricating oils
Abrasion of steering system’s connecting points (ball- Replace the ball-headed pins
headed pins, etc)
Front axle
Improper adjustment of toe-in (excessive caster angle) Measure and adjust
Insufficient clearance between kingpin and bushing Check and adjust the clearance
Thrust bearing is installed the wrong way round Correct the assembly
Lack of lubrication of front axle parts Apply lubricating greases on the

front axle
Excessively tight or loose ball joints Check and lubricate the ball-headed
pins
Tyre pressure insufficient Pressurize to the required pressure
Excessive wearing of tyre Replace the tyre

2. Deviation of steering wheel

Difficulty in Steering system
operation of
steering wheel Insufficient oil in the steering gear Replenish with lubricating oils to the
required level
Deterioration of or foreign matter in lubricating oils Replace the lubricating oils
Abrasion of steering system’s connecting points (ball- Replace the ball-headed pins
headed pins, etc)
Front axle
Improper adjustment of toe-in (excessive caster angle) Measure and adjust
Insufficient clearance between kingpin and bushing Check and adjust the clearance
Thrust bearing is installed the wrong way round Correct the assembly
Lack of lubrication of front axle parts Apply lubricating greases on the

front axle
Excessively tight or loose ball joints Check and lubricate the ball-headed
pins
Tyre pressure insufficient Pressurize to the required pressure
Excessive wearing of tyre Replace the tyre

3. Vibration of steering wheel

Vibration of Steering system
steering wheel
Bolts of steering gear casing or supports of steering Fasten to the required torque
column are loose
Steering system’s connecting points are loose Make corrections at the connecting
points
Excessively large clearance of steering gear Clearance adjustment

Front axle
Imbalance or abrasion of wheel rim, spoke and wheel Balance all parts and replace
defected parts
Abrasion of front wheel bearing Replace the bearing
Excessive wear of kingpin and bushing Correct or replace the defected

components
Deformation of steering knuckle Replace the steering knuckle
Improper alignment of wheels Check and adjust wheel alignment

Front leaf spring fatigue, U-bolt looseness or central bolt Replace defective parts
damage
4. Failure of steering wheel resetting

Failure of steering Steering system
wheel resetting
Difficulty in gear engagement Adjust gear engagement
Front axle
Excessively large caster angle of kingpin Check and adjust wheel alignment
5. Early abrasion of tyres

Uneven or early Front axle
tyre abrasion
Improper front wheel alignment Check and adjust wheel alignment
Abrasion or shattering of wheel bearing, bearing nut is Replace the bearing or fasten nuts
loose as required
Ball-headed pin, kingpin and bushing are excessively Correct or replace the defective
tight or loose components if necessary
Tyre
Improper tyre pressure Pressurize to the required pressure
Tyre and wheel are not concentric Replace the tyre or wheel
Others
Troubles arising from sudden start-up or braking of the Correct the driving method
vehicle
Overloading Load the bus as required
6. Floating of steering

Floating of steering Steering system components are loose or worn out; Adjust or replace
Steering gear screws are loose; Fasten
Improper adjustment of steering gear Adjust the steering gear
Overpressure of tyre or uneven pressures of left and right Adjust tyre pressure
tyres
7. Abnormal noises of steering gear

Sizzling of steering Sizzling sound of power steering system is normal and Slight sizzling sound is normal and
gear occurs most overtly during parking. This sound has won’t affect the steering
nothing to do with steering performance; When the performance
steering wheel is at the limit position or turned slowly
when the bus remains standstill, such sizzling would take
place.
Clattering of Steering gear and bracket are loose Check the bolts of steering gear
steering gear and fasten them with a torque of 90
to 110Nm;
Steering linkage is loose Check if the link joints are worn

out and replace them if necessary;
Pressure hose touches other parts Adjust the position of the hose;
Steering rocker arm is loose. Fasten the rocker arm nuts with the
required torque.
8. Analysis of normal troubles of hydraulic elements
Hydraulic Trouble Cause

pump Insufficient flowrate or pressure The pump is worn out or leaks internally and pipe
resistance is too high
Big noises Insufficient oil suction and loosening of fittings
High oil temperature Excessive leakage and unsatisfactory oil viscosity
No oil drainage Transmission system components are damaged
Hydraulic Interrupted and uneven operations Air ingress; poor coaxiality of piston and piston rod
cylinder Impacts during operation Excessive clearance between piston and cylinder
barrel and failure of throttle valve
Uneven operation Excessive engagement clearance so that the high-
pressure and low-pressure chambers are connected
Leakage of hydraulic oils O-ring is damaged and piston rod surface is damaged
Hydraulic Valve core is stuck Polluted hydraulic oils and damaged core surface
valve Failure to work or excessive sensitivity Spring is too soft or broken
Too much leakage Excessive wear and tear
Noises and vibrations Air ingress in oil outlet pipe so that resonance with
the pump occurs
 Assembly, disassembly and adjustment of steering system
1. Steering wheel and steering linkage

 Removal of the steering wheel
1) Remove the horn button cover;
2) Remove the earth contact plate assembly;
3) Disconnect the horn wires, nuts and washers;
4) Take off the steering wheel;
 Removal of combined switch

1) Remove the screws and switch cover;
2) Remove the combined switch assembly;
3) Remove the starting switch assembly;
4) Remove the wire clamping board, steering column's sealing jacket and steering column's protective cover;
 Removal of the steering column and steering transmission shaft assembly

1) Remove the screws of steering column;
2) Use a copper hammer to strike the head of the steering shaft to separate the steering shaft and the steering
column pipe;
3) Remove the steering shaft and steering slide fork assembly;
4) Make a mark on the spline shaft and steering slide fork shaft sleeve;
5) Use a copper hammer to tap the tail of the universal joint fork lightly and then remove it from the steering
gear.
Assembly of the universal joint fork with spline shaft
 Disassembly of transmission shaft assembly of the steering system

1) Use long-nose pliers to take out the elastic retainer ring of the shaft;
Caution: take protective measures for the threads at the head of the steering shaft.
2) Use a copper hammer or wooden hammer to strike as indicated in the Figure until the cross shaft and the
bearing are detached from the
bearing hole.
3) Remove the bearing from the steering shaft;

Note: If the parts are found to be undamaged and rotate flexibly, there is no need to disassemble the
bearing.
 Inspection
1) Clearance between cross shaft needle bearing and shaft journal:
2) Clearance between steering shaft bushing hole and shaft journal
3) Clearance between slide fork key and key groove:
 Installation of steering universal knuckle with spline shaft assembly

Install the universal knuckle with spline shaft assembly onto the steering gear’s input shaft;
 Install the steering column pipe and steering shaft

1) Install the steering column pipe, steering shaft and sealing jacket;
2) Install the steering column onto the pedal bracket;
3) Install the wire clipping board

1. Screw
2. Wire clipping board
 Install the combined switch

1) Install the starting switch assembly and the wire connectors;
2) Install the combined switch assembly and the wire connectors;
1. Combined switch
2. Screw
3) Install the steering column protective cover;
4) Install the combined switch protective cover;
Caution: ensure that the switch cover does not interfere with the adjusting nuts, key switches and combined
switches.
 Install the steering wheel

1) Turn the steering gear to the middle position (maintain straight travel), put on the steering wheel as shown in
the figureand insert it into the spline;
2) Install the toothed washer and nut and fasten the nut.
3) With the front wheels being in the position they would be in straight travel, turn the steering wheel slightly to
inspect its free gap;
4) Connect the lead wires of the horn brush and install the horn button cover;
5) In trial runs, ensure that the steering wheel operates normally without swinging, steering difficulty
or deviation.
 Caution:
1) ·Apply a coat of lubricating greases on the inner surface of the bearing during installation of needle bearing;
2) ·Install the elastic retainer ring inside the snap groove and the components should rotate flexibly after
assembly;
3) The grease nozzle of the cross shaft should be assembled in the same direction;
4) The inner surface of the steering shaft bushing and the surface of bearing's ball raceway should be applied
with a coat of lubricating greases before assembly;
5) After installation of the steering transmission shaft assembly, please fully add lubricating greases into the
grease nozzle;
2. Steering drag link

 Removal of tie-rod and drag link
1) Remove the split pins at the front and rear ends of drag link and take off the slotted nut,
and now the drag link assembly can be taken off.
Note: The drag link assembly is non-detachable and if the ball-head is loose, the drag
link assembly has to be changed.
2) Remove the split pins of the left and right joints of the
tie-rod, loosen the slotted nut, and now,
the tie-rod assembly can be taken off.
 Inspection
Abrasion of ball-headed pins of tie-rod and drag link
 Reinstallation of tie-rod and drag link

Reinstall them in the reversed sequence of installation.
Note: In the assembly reinstallation, apply lubricating grease
to the ball-headed pins and ball cup surface;
When the assembly has been reinstalled, add the grease to
the grease nozzles of the two assemblies (two for each).
 Adjust
1) When installing the tie-rod and drag link assemblies on to the vehicle, tighten the slotted thin nut and strike the
joint arm with a hand hammer.
Screw in the nut by split pin
2) The link length shall be adjusted to satisfy the requirements on the position of lower pitman arm and the status
of the steering wheels.
Caution: Do not loosen the nuts in order to align the split pins.
3. Steering hydraulic system

 Precautions for the installation and removal of hydraulic pipelines
1) Collect working oils with a container to avoid pollutions;
2) Take care to prevent pollutions during removal of pipe elements;
3) Make necessary marks;
4) Carefully check the abrasion conditions of main components and decide if they should be replaced or not;
5) Confirm the cleanness of elements and clean them if polluted.
6) For the sake of installation, please check the marks made during removal.
7) Do not damage the contact surfaces of oil seals;
8) Take care to fasten various elements with the required torque;
 Adjustment of hydraulic pipelines

1) Inject new working oils after assembly of the hydraulic system
2) Discharge the air inside;
Support the front wheels above the ground, run the engine at idle speed, turn the steering wheel left and right
and add oils if necessary;
When the oil level remains stable in the tank, increase the working speed of the engine and keep turning the
steering wheel until no air bubble pops up in the oil tank;
3) Check if there is any oil leakage;
4) Lower down the front wheels and carry out necessary inspections on the steering system.
4. Disassembly diagram of steering system structure

1 Rear drag link assembly 31 COMBINED PEDAL, 2ND 44 Locking hand wheel (right)
2 Front drag link assembly 32 Assembly of steering 45 Rear shield of the decoration cover
transmission device of steering column
7 Middle rocker arm w/ bushing 33 Combination switch assembly, 46 Front shield of the decoration cover
assembly new of steering column
9 Middle rocker shaft 34 Assembly of the steering 47 Lower shield of the decoration
column body cover of steering column
10 Middle rocker arm seat 35 Retarder switch 48 Compression ring, dust boot
21 Steering gear 36 Decoration cover of steering 49 Horn button switch
column
22 Plumbing arm 37 Ignition switch 50 Tie rod ball
29 Bracket, steering gear 39 Dust boot, rubber 51 Tie rod ball
30 Steering wheel 43 Locking hand wheel (left) 52 Tie rod ball
5. Troubleshooting of steering gear
 Problem diagnosis of steering system

Initial inspection
With respect to the steering problem, if you (service man) can confirm what users are actually relaying and ensure you
are discussing a same issue with them, you will save a lot of time in handling problems. For example, if the customer
tells you that steering is difficult, you should ascertain the specifics: is it left steering difficulty, right steering difficulty,
pivot steering difficulty, intermittent steering difficulty or no boosting at all.
If any one of these problems is possible and under the condition of safety, drive the vehicle yourself. If you are not
familiar with driving, ask the customer to drive the vehicle and sit beside him, with your hand on the steering wheel so as
to gain a direct understanding of the problem. As the customer generally drives the vehicle with a load, you may load the
vehicle if necessary in searching for the cause. Once you have confirmed what has really been reflected by the customer,
do not hurry to remove the steering gear or oil pump. In fact, in most cases, there are many other parts in the steering
system that may cause a steering fault. Inspect these parts first before inspecting the steering gear.
Check the steering wheels first. Find out if the tyres have proper and balanced pressure, suitable size, and if they are
seriously worn or damaged.
Then check the front wheel alignment (kingpin caster, inclination, camber and toe-in) and the tightness of steering tie-
rod, ball joint and kingpin. If the customer has replaced the oil pipe, the oil pipe may be wrongly installed, be too small
in small diameter, or may be blocked, twisted or bent too much, leading to unsmooth oil flow or insufficient flowrate. Oil
pipes not conforming to requirements should be replaced.
Now check the power steering oil tank. Make sure the oil reaches the specified level. If the pump adopts a belt
transmission, check if the belt is slipping. The belt may be tight but may also be slipping due to wear. A slipping belt
does not always screech. Please adjust the belt according to the technical specifications.
The above is only part of the inspection to be made before inspecting the steering gear or oil pump. “Fault Analysis”
suggests how to make a diagnosis of some special faults. It will save a lot of time and avoid unnecessary repair and costs
if you perform the diagnosis according to the suggestions listed in the table.
Hydraulic test
If no problem is found in the above inspection, the steering fault may be due to insufficient pressure or flowrate. In this
case, a more careful inspection should be made, including a hydraulic test.
Preparation for hydraulic test
For the following hydraulic test, first install a flowmeter, pressure gauge and stop valve at a suitable position of the
hydraulic piping as shown in the figure. The three devices (comprising an oil-line fault detector) are used in combination
to check the hydraulic and flow conditions in the steering system. Set a thermometer in the oil tank to ensure the
accuracy of the hydraulic test.
Start the engine to warm-up the hydraulic system. When the temperature rises to between 51.7℃and 57.2℃, open the
stop valve. Now the warm-up is completed, the test can begin.
Caution:
The stop valve cannot be Off. Otherwise, the oil pump may be damaged. The oil temperature is prohibited to exceed and
all test steps should be made with a scope of
Pressure test of oil pump
Set the engine at idle speed, turn off the stop valve and read the pressure gauge. If the reading of the pressure gauge is
smaller than the specified minimum value of , the oil pump should be repaired or replaced.
The stop valve can not be closed for more than 5 seconds to avoid damaging the oil pump. When the stop valve is turned
off, the oil pump will overflow and the oil temperature will rise rapidly. Other tests should be made when the oil
temperature has dropped to
Flowrate test of oil pump
When the engine is at idle speed and the oil fluid temperature is at 51.7-57℃, check the flowrate of oil pump and
compare the flowmeter reading with the specified flowrate.
Fully turn off the stop valve till the pressure gauge reflects the pressure that means the oil pump is overflowing. When
the oil pump overflows, the flowrate should be zero. Now, immediately turn on the stop valve and the flowrate should
immediately return to the original reading value. If the flowrate cannot immediately return to the original value, it means
that the oil pump is not working properly, which may lead to boosting failure for a short instant or interruption.
Now, adjust the engine to a rotating speed that is three times the idle speed and repeat the above test. If the oil flowrate
cannot immediately return to the original value, it means that the oil pump is not working properly, which may lead to
boosting failure for a short instant or interruption
Caution:
1) Carry out the flowrate test of the oil pump when the engine is at the idle speed and at a speed three times the idle
speed respectively.
2) The oil temperature is not allowed to be higher than 82.2℃ and should be at 51.7-57.2℃during the test.
3) The maximum permissible flowrate of IPS series steering gears is 22.7lL/min, which can not be exceeded. Too high a
flowrate may cause damage to the internal parts of steering gear, leading to a failure of steering boosting.
Internal leakage test of steering gear

To detect the leakage, the travel valve should not act so that the maximum pressure can be formed in the oil pump. To
avoid the action of the travel valve, put a non-quenched steel pad (that has a thickness of about 25 mm and length that
can ensure the safety of the fingers) between the limit screw of steering wheel and limit lug boss
When the oil temperature is between
pad.
Caution:
1) When performing this test, the retaining time for the steering wheel at the limit position should not exceed 5 seconds
so as to avoid the oil pump damage.

2) In this test, the fingers should be kept away from the contact between the lug boss and the steel pad and the
steel pad should be in straight contact with the limit boss. Otherwise,
the limit lug boss may break or collapse due to the squeeze or the steel pad may be squeezed out, causing a hazard.
Caution:
When the hydraulic test is completed and the oil piping is reconnected, check the oil level in the tank and discharge the
air in the system (refer to “Oiling and discharge of steering system”).
Symptoms Possible causes Repair/preventive measures

No hydraulic The vane of hydraulic pump can Instantly increase the engine speed to throw out the vane
boosting at a cold not freely extend out (vane pump by its high speed rotation so as to start the oil pump (for
start only). a seldom and short time case, there is no need to check
the oil pump.)
No or instable Oil pump failure Repair or replace the oil pump.
hydraulic boosting A. Belt transmission: the Tension the belt or replace the belt
transmission belt of oil pump is
loose or broken.
B. Gear transmission: the gear or Replace the gear.
the key is damaged.
Damaged pressure safety valve of Replace the pressure safety valve of oil pump or change
oil pump or dirt in oil lead to poor the oil and clean the valve.
performance.
Damaged flowrate control valve of Replace the flowrate control valve of oil pump or change
oil pump or dirt in oil lead to poor the oil and clean the valve.
performance
Difficulty in Front axle overload Reduce the front load.
steering Bent or damaged kingpin or tie-rod Repair or replace the damaged part.
Improper kingpin caster Adjust the kingpin caster as specified.
Oil too hot with reduced viscosity Locate the cause of heat and address.
Seriously worn oil pump and Replace the oil pump.
internal leakage
Unqualified, deteriorated or low Change the oil with appropriate oil.
viscosity oil
Internal leakage of the pressure Replace or clean the pressure safety valve of oil pump
safety valve of oil pump
Deviation of steering Align the front axle and adjust the front wheels
Insufficient oil or air trapped in the Locate and remove the cause and add sufficient oil and
oil of hydraulic system discharge the air
Dirt in the travel limit safety valve Check the travel limit safety valve and clean it.
of steering gear (at one end or both
ends)
Difficult steering Loose transmission belt of oil Tension the transmission belt (or repair the transmission
when the steering pump (or transmission gear fault) gear).
wheel is turned Insufficient oil in oil tank or air Locate the cause, remove the fault, add sufficient oil and
violently. absorption of oil pump discharge air.
Blocked filter of oil tank Clean, replace the filter and change the oil.
Blocked or seriously deformed oil Eliminate the blockage and then repair or replace the oil
pipe pipe.
Steering becomes Incorrect adjustment of the Make a correct adjustment of the unloading plunger
difficult when the unloading plunger lever of steering lever.
steering wheel is gear (one end or both ends).
not turned to the
limit position.
Floating in high Overloading Reduce the load.
speed drive Loose or worn steering parts of Check, repair or replace the worn parts.
front axle
Ball pin joint of tie rod or drag link Check the rotating torque.
too tight
Incorrect alignment Check and correctly adjust the front axle and kingpin
caster.
Rear axle and front axle not parallel Check and adjust the front and rear axles.
Air in the steering gear Air exhaust
Oil flowrate too high Adjust the flowrate control valve of oil pump or change
oil pump for a suitable one.
Too great spare Worn pin and joint in steering Check and replace the worn parts;
travel of steering column universal joint and
wheel damaged universal joint
Loose universal joint sleeve Repair or replace the worn parts.
Looseness between the steering Check, repair or replace the damaged parts and tighten
gear support and the vehicle frame the assembling bolts to the required torque.
or between the steering gear and its
support
The ball pin seat and ball pin of Replace the ball pin seat and the ball pin.
drag link or tie rod are worn or
have too large a gap.
Difficult resetting Jammed ball hinge of tie rod or Check or replace the worn part.
of steering wheel drag link
Jammed kingpin of steering Check or replace the damaged part.
knuckle
Small kingpin caster of steering Adjust the kingpin caster to the required value.
knuckle
Jammed steering column Locate the cause and repair or replace the damaged part.
Improper oil flowrate Check and correct the oil pump.
Deformed installation of steering Adjust the steering gear installation by adding shims to
gear leads to restricted piston allow the piston move freely.
movement
Instable steering Worn universal joint of steering Check and replace the universal joint.
input column
Incorrect positioning of universal Readjust the positioning of steering column.
joint
Low oil flowrate Tension the belt of the oil pump till it does not slip at a
low or idle speed operation, or repair the oil pump.
Insufficient oil or air absorption of Locate the cause, remove the fault, add sufficient oil and
oil pump. discharge the air.
Overheat Locate and remove the cause.
Hydraulic system Restricted oil flow and large energy Check the oil return pressure and clear the restriction or
temperature too consumption replace the oil pipe.
high Flowrate of oil too high Check the max. flowrate, adjust the flowrate control
valve of oil pump or replace oil pump with a suitable
one.
Incorrect adjustment of the Make a correct adjustment of the unloading plunger
unloading plunger lever of travel lever.
limit
Color or odor Too long a usage period Change the oil as required.
change of oil Unsuitable oil or mixed use of oil Change for a suitable oil.
Over high work temperature Locate the cause of overheating and remove it.
Water entry into the oil via the Change the oil and replace the cover set of oil tank.
venting system of oil tank.
Oil leakage of Worn or damaged sealing elements Replace the seals.
steering gear after long use
Worn or damaged sector shaft or Replace the steering gear.
input shaft
Overhaul
1．Housing 2．End cover of hydraulic cylinder 3 ． Input shaft, rotary valve, bearing
cover and lead screw components
4．Sector shaft cover 5．Sector shaft 6．Piston, circulating ball, nut and rack
components
7．Integrated safety valve 8．Locking device of steering rocker arm 9．Steering rocker arm
10．Sealing components of input shaft 11． Sealing components of sector shaft
12．Set of unloading plunger lever of cylinder end cover
13． Set of unloading plunger lever of bearing cover 14．Set of bleed screw 15．Retaining
ring of bearing cover
Oil filling and air discharge of steering system
The power steering system adopts

Caution: A steering gear can only be filled with single brand of oil. Any mixed oil or unauthorized oil may damage the
oil seal and cause oil leakage, leading to the loss of steering boosting.
Oil filling of steering system
Before starting the engine, the hydraulic oil of steering must be sufficiently filled. Otherwise, the steering oil pump will
be damaged. Oil filling should be performed according to the following procedure:
a) Stop the vehicle on clean flat ground, set the gear lever in the neutral position, use the hand brake, block the
rear wheels and use a jack to lift the tyres from the ground at the front axle.
b) Fill the oil into the tank up to the mark, start the engine at idle speed, check the oil level and supplement the
oil.
c) Turn the steering wheel from the left to the right till the limit position several times. Now, recheck the oil level
of the tank and add oil if necessary.
d) Let the engine work at high speed for ten minutes and then check if the oil pump works normally and the
whole steering hydraulic system has neither oil leakage nor seepage. Repeat high speed engine operation several
times and make sure that the whole system has no oil leakage or seepageNow, release the jack and let the front axle
tyres set on the ground.
Air discharge of steering hydraulic system
Air in the hydraulic system will seriously affect the normal operation of the system and therefore, air discharge must be
performed after oil filling or change.
Release the steering rocker arm from the steering drag link and let the engine run at high idle speed. Turn the steering
wheel from the left to the right till the limit position and then turn it back to the left limit position as a cycle. Perform
three full cycles as such to fully exhaust the air from the system. If the oil level in the tank falls, add sufficient oil. Then
connect the steering rocker arm with the drag link and lock the ball joint well.
6. Disassembly and assembly of steering gear

 Read the following before disassembly and assembly
1) All functional parts must be cleaned. Blow out the dirt with compressed air and use volatile metal detergent for
cleaning. Never use brushes or cloths for the cleaning.
2) The rubber components and seals must be kept clean. Immediately replace the worn parts if any.
Volatile metal detergent may damage rubber components and therefore, can not be used on them. They should be
cleaned with oil.
3) Only specified oil can be used in the disassembly or assembly.
4) Though common standard tools can also be used in the disassembly or assembly, dedicated tools are required.
Use the dedicated tools carefully according to the instructions and don’t use standard tools instead of dedicated ones.
 Disassemble the steering rocker arm
1) Stop the vehicle on flat ground, put the brakes on and lock the wheels.
2) Remove the lock nut of drag link ball and take off the drag link from the plumbing arm.
3) Use a small punch and the projecting tongue of lock washers to bend out of the positioning pin.
4) Use a small punch and ball-head hammer to bend the two projecting tongues of the lock washer out of the
positioning pins.
Now, the positioner can be taken off.
Caution:
The project tongue can’t be bent into the plumbing arm
groove.
5) Use a 5/8” or 3/4” Allen wrench and safety pole to remove the lock pin of the projecting tongue.
6) Use a 3-claw detacher to remove the plumbing arm, with three pads for the arm against the three claws.
Caution:
The plumbing arm should be very robust. Knocking or heating can not be applied to the arm and welding can
not be made on the arm or the sector shaft.
Remove the rubber sleeve of sector shaft.

Take off the bolts of the assembly support and separate the support from the steering gear (if there is one).
The steering gear will use a precision dust shield and now take it off.
Use a punch to make two reference marks on the bearing cover and also corresponding marks on the housing.
Make a single mark on the cylinder head and a corresponding one on the housing.
In this way, after reassembly the gear will resemble its original appearance.
Take off the safety valve plungers from both ends of the steering gear, which will play a role of protection in repair.
Remove the bolts connecting the housing with the sector shaft
washer.
Use a soft hammer to slightly strike the end of sector shaft to loosen the washer.
Carefully slide the sector shaft and washer from the housing.
Slide the washer from the sector shaft.
Take off and throw away the O-seal and sector shaft seal or 3 piece set of seal (if there is one)..
Caution:
In the sector shaft washer, there may be seal device. Use a screwdriver to get it out.
Remove the cylinder head and throw away the seal ring and rectangular seal ring.
Take off the end-face seal device from the input shaft.
Remove the bolts from the bearing cover. Turn the input shaft to separate the bearing cover component from the
housing.
Caution:
Keep the shaft stable after the bearing cover is taken off from the housing. Otherwise, the shaft may be
damaged.
Carefully slide the piston and bearing cover component out the internal chamber of housing until the guide ring of
ball guide is out.
Caution:
The ball guide must be held. Otherwise, the guide and steel balls will come off from the component and the
steel ball may be lost.
Screw a small fast screw into the ball guide by 2-3 turns and use flat nose pliers to remove the ball guide from the
piston.
Different pistons:
Some steering gears have a bolt provided on the ball guide.

Caution:
The baffle is provided with a bolt. Take off the assembling bolt and ball guide and remove the seal from the
baffle and discard it.
Now, you can’t move the piston and let it remain in the housing while the ball guide is exposed.
Take off the ball guide and the balls will roll out of the guide and roll into the piston.
Caution:
It is necessary to slightly rotate the shaft out and in so as move all the steel balls.
There are 24 steel balls in the piston, which must be all taken out before the input shaft is moved out of the
bearing cover.
After taking out the 24 balls, it is time to remove the input shaft and bearing cover component set.
Now, the seal and rectangular seal can be taken out and discarded.
Carefully slide the piston out of the housing.
Take off and discard the sector shaft seal.
Now, the steering gear has been disassembled and the replacement of parts can be performed.
 Replace the sector shaft seal

Remove the six inner hexagonal bolts from the fixing rings.
Take out the three fixing rings and draw out the washer of sector shaft from the housing.
Remove and replace the washer and the oil seal of housing, with the blue side of the seal facing outwards.
Caution:
The sector shaft has two seal rings, which may have to be bent in installation by hand.
Install the washer into the housing, which must be level with or lower than the bottom of the convex translot of the
fixing ring.
Install the fixing ring in the convex slot and make sure the installation hole of the ring aligns with that of the
washer.
Tighten the assembling bolt. In tightening the bolt, the washer has to be fixed till the fixing ring is well tightened.
Replace the seal sleeve.
 Assembly of integrated safety valve

M-100P1 steering gear provides an optional integrated pressure safety valve.
The valve seat is in the bearing cover and the valve restricts the maximum operation pressure. In most cases, the
hydraulic pump will produce a max pressure higher than that controlled by the integrated safety valve. When the
steering system reaches the maximum safety pressure, the surplus pressure will be released. When the oil pressure
exceeds the max safety pressure, the valve will open and the surplus pressure will come into the oil circuit via the
return hole of steering gear.
The safety valve seat can be taken off for cleaning and inspection. Take off the nut and seat of the safety valve and
meanwhile clean and inspect the filter.
Caution:
The safety valve seat can’t be disassembled and should be replaced if damaged. The O-seal and filter are
replaceable.
Caution:
Don’t use old seal set or O-seal. Use a complete set of seals when installing the safety valve seat in the
bearing cover.
Insert the seat component into the safety valve chamber and turn the nut with a torque of 35ft/lbs.
压力安全阀组件 Components of pressure safety valve

零件序号 Part No.
颜色 Color
棕色 Brown
绿 Green
棕色 Brown
黄 Yellow
黑 Black
蓝 Blue
红 Red
桔黄 Orange
白 White
灰 Grey
 Replace the seal of rotary valve
Generally, there is no need to replace the seal and O-type high pressure seal of rotary valve.
Unless the seals are damaged, the replacement of seals can’t be made without a seal-pressing tool.
Ensure the work area is clean and dust-free so as to prevent any foreign matter from entering the rotary valve seals.
The replacement procedure is as follows:
1) Take off the seals and high pressure O-seals of rotary valve.
2) Make sure the groove of rotary valve is clean and has no burrs or cracks.
3) Install three high pressure seals in the groove of rotary valve.
Caution:
These high pressure rings may be pulled out of the rotary valve. Be careful to prevent the high pressure
rings from twisting in the valve chamber.
4) Carefully pull the seals of rotary valve to the outer side of the high pressure O rings.
Caution:
You may use a small-sized flat handle to pull out the seal from the inner side of high pressure O ring.
Sharp metal items cannot be used.
5) Use No.3563972 tool to press the rotary valve to facilitate the installation of valve shaft.
Caution:
The seal rings may be damaged if a compression tool is not used in installing the valve shaft component into
the bearing cover.
7. Reassembly, cleaning and inspection of steering gear

 Parts cleaning
Cleaning is very important. Dust and foreign matter getting into the steering system during the repair may cause part
damage and possible steering malfunction. In consideration of possible small tolerance between mating members, it is
best that all parts are at the same temperature during the reassembly.
In cleaning the parts, collisions between the parts should be avoided. Use clean solution to wash the parts and dry using
compressed air. Use a hand stone for fine grinding to eliminate the cracks or burrs and coat the parts with clean lubricant.
All hose connectors and steering oil tanks should be cleaned and filter units changed before the reinstallation or repair of
the steering gear or after pump replacement.
Inspection
Make careful inspection of all steering gear parts and replace the worn ones.
Caution:
Steering gears that have caused an accident must be replaced. As the impact load transmitted to the steering gear via the
rear steering link of front axle in the accident would compress the parts, it will be unsafe in the future use. The steering
gear components and the plumbing arm must be replaced. Bent plumbing arm, twisted sector shaft and worn rack and
driving gear all suggest that the parts are damaged. The damaged installation frame must also be changed.
Inspection of the steering gear parts can reveal some problems in the steering system. To avoid the occurrence of similar
problems, all parts should be carefully checked. The following are some very common problems that ask for earnest
consideration during repair.
Inspection item Cause Inspection item Cause

Faded parts 1． Over high operation Sector shaft 1． Improper lubricant
(Blue) temperature (bearing wear) 2． Over high temperature
2． Jammed steering 3． Overloaded axle
wheel column 4． Foreign matter in the
3． Malfunction of lubricant
hydraulic pump 5． Impact damage
Steering shaft Impact damage
(Hardened or concave
ball thread)
damaged steering shaft 1． Improper lubricant Scratches on the housing 1． Foreign substances
thread 2． Overloading or piston 2． Serious overload
3． Insufficient operating 3． Improper use of
pressure lubricant
4． Insufficient oil 4． Exceeding the normal
flowrate temperature (>250℃)
5． Continuous operation 5． Damaged pump
at high temperature
Worn out housing Accidental damage Thrust bearing (rusty) 1． Entry of foreign matter
into the system
2． Overloading
Broken piston ring that is 1． Incorrect installation 3．
clamped, sheared or 2． Incorrect assembly
damaged
Caution:
Small scratches on the steering gear housing and piston are normal. In operation at high pressure or flowrate, they will
not affect the safety of steering gear. They should be removed by a hand stone for fine grinding.
The internal chamber of hydraulic cylinder can not be ground or be enlarged by boring, which may increase internal
seepage.
 Reinstall
M100-P1 power steering gear uses a seal at the end of its power piston.
Set a O-seal retaining ring in the piston groove and add a square section seal on its outer layer for installing a new seal
device.
Caution:
When inserting the seal ring into the groove, the seal ring will be elongated.
If the piston is fixed, it will become very easy to install the seal ring into the piston chamber.
Use a ring compressor to avoid damaging the piston ring.
Install a new sector shaft seal
Important:
When installing the sector shaft seal, make sure that the seal lip faces the housing while the blue side of seal faces the
operator.
Caution:
There is an inclined slot at both ends of piston housing. The piston will be installed via the end of housing.
Now, you can begin to reassemble the steering gear. Before installing the piston into the piston chamber in the housing,
check if there is any burrs on the piston or the piston chamber.
If there are any burrs, they must be removed.
Use light color machine oil to coat the piston or chamber housing. Carefully insert the piston into the piston chamber and
make sure the ball guide cavity is exposed.
Caution:
Care must be taken when installing the piston into the housing. Fine tolerance will make the piston retarded in the
housing.
Any attempt to press the piston will produce scratches in the housing chamber.
Install a new seal ring on the bearing cover and steering shaft component.
Caution:
Coat a layer of grease on the new seal ring to make it remain in place in the installation process.
Insert the bearing cover and steering shaft component in the piston.
Caution:
Do not insert the bearing cover component fully into the piston keep it no more than
Install the ball guide into the ball guide chamber.
Caution:
Make sure the ball guide has been pushed into the chamber. Otherwise, it will be pushed out of the piston and the
balls will derail.
Place 24 steel balls into the ball guide while using your hand to support the bearing cover component
Slowly turn inwardly the bearing cover component and meanwhile, add the balls into the ball guide till all balls are
installed.
Caution:
During this process, do not pull out the steering shaft from the piston. Otherwise, the balls may be jammed in the
steering shaft, damaging the shaft.
When the balls have been installed, the two halves of the ball guide must be held to avoid the balls coming out of the
track.
Fit a new O-seal ring on the locating pin of the ball guide. Coat a little grease on the upper part of the ball return guide.
Insert a locating pin at the guide groove.
It is necessary to use a soft hammer to strike the locating pin of ball guide till it is in place.
Caution:
When correctly installed, the locating pin will be level with the outer contour of piston.
 Changes of early products

If using a locating pin with bolts, you will have to change the seal ring of locating pin and install it in the piston chamber.
Install the assembling bolt.
Caution:
The internal tooth lock seal must be installed on the assembling bolt.
When installing the piston, carefully move the piston ring over the sector shaft opening in the cylinder chamber.
Press the piston seal ring into the groove while keeping the piston end pressure. Now, the piston will continue to slide
into the chamber till the piston ring has passed the sector shaft opening.
Install a new quadrilateral seal ring on the bearing cover component and connect the bearing cover and the housing.
Caution:
Coat a little grease on the quadrilateral seal to keep it in place.
Use 4 longest assembling bolts to secure the bearing and housing with required torque
Caution:
If the bearing cover is not level with the housing, check if the
bearing cover seal or quadrilateral seal are out of place.
Make a mark on the piston rack and turn the steering shaft to make
the mark reach the center of the pinion chamber of housing.
Install the sector shaft on the piston rack.

Caution:
The single mark on the sector shaft should be aligned with the two
marks on the piston rack.
It is necessary to use a soft hammer to tap the end of sector shaft to

ensure a full engagement of the rack with the driving gear.
Install a new sector shaft seal on the sector shaft washer and install the sector shaft washer and assembly bolt with
required torque.
Caution:
Coat light color oil on both the sector shaft seal and the seal ring to facilitate the installation.
Fit new seals and quadrilateral seal rings on the cylinder end cover.
Caution:
Coat the seals with a layer of light color grease for fixing.
Use the rest 4 bolts to connect the cylinder end cover and housing with required torque.
Install the safety plunger in the cylinder head and bearing cover. Screw the screw into the safety plunger till 1/8” from
the end cover.
When installing the dust shield by adhesion, it is very important to use a proper solvent to thoroughly clean the housing.
Apply a room-temperature- vulcanizing thin coating on the edge of the dust shield, put the shield on the end of sector
gear and allow it sufficient time to solidify.
Use connecting bolts to connect the installation support and the steering housing with required torque.。
Use the grease to coat the sector shaft sleeve opening and set it on the sector shaft.
Install rubber sleeves on the input shaft and lubrication parts.
If your steering gear has a compressed seal device, use grease to coat the seal lip.
Slide the seal device on the sector shaft, with the seal lip facing outwards. Use a 2¼” sealing tool to press the seal device
into the washer.
Clean the sector shaft spline before the installation of the plumbing arm. You may reinstall the steering gear by following
the procedure.
 Replacement of sector shaft seal

Remove the 6 square-head bolts from the fixing rings.
Take off the three fixing rings. Pull out the sector shaft washers from the
housing.
Remove and replace the washer and the oil seal in the housing, with the blue side of seal facing the outer side of housing
or washer.
Caution:
The sector shaft sealing adopts a 2 piece seal, which can be bent and installed into the sector shaft.
Once the seal has entered the housing, use your finger or a blunt flat pint to position properly. Carefully press the
seal ring body not the edge.
Install the washer in the housing, with the washer surface

Level with or lower than the fixing ring groove
Install the fixing ring into the four grooves, with the installation hole of the ring aligning with that of washer.
Tighten the assembly bolts and at the same time fix the washer. You may turn the washer till the fixing ring is tightened.
Replace the sleeve or seal device.

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En 11SR 6127J 01 Direccion

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Steering System SR-6127J-01 SR-1

 Structure and working principles of steering system SR-2

 Structure and working principles of steering system

1. Integrated power steering booster (steering gear)

1. Steering gear input shaft

2. Hydraulic piping system of steering system

 Technical specifications and parameters of steering system

1. Technical specifications of steering system

▲ The output torque at a 90% efficiency and rated pressure.

2. Related Tightening Torques

3. Schematic structure and principle diagrams of steering gear

11．Slide valve 12. Dust cover 13．Bearing 14．Sealing ring

进油口 Oil inlet

通向 “R” Leading to “R”

4. Structural Features and Working Principles

 Working principles of steering

 Impact load on the steering gear

1. Difficulty in operation of steering wheel

Trouble Cause analysis Solution

Deterioration of or foreign matter in lubricating oils Replace the lubricating oils

Improper adjustment of toe-in (excessive caster angle) Measure and adjust

Lack of lubrication of front axle parts Apply lubricating greases on the

Tyre pressure insufficient Pressurize to the required pressure

Excessive wearing of tyre Replace the tyre

2. Deviation of steering wheel

Trouble Cause analysis Solution

Deterioration of or foreign matter in lubricating oils Replace the lubricating oils

Improper adjustment of toe-in (excessive caster angle) Measure and adjust

Lack of lubrication of front axle parts Apply lubricating greases on the

Tyre pressure insufficient Pressurize to the required pressure

Excessive wearing of tyre Replace the tyre

3. Vibration of steering wheel

Trouble Cause analysis Solution

Excessively large clearance of steering gear Clearance adjustment

Abrasion of front wheel bearing Replace the bearing

Excessive wear of kingpin and bushing Correct or replace the defected

Deformation of steering knuckle Replace the steering knuckle

Improper alignment of wheels Check and adjust wheel alignment

4. Failure of steering wheel resetting

Trouble Cause analysis Solution

5. Early abrasion of tyres

Trouble Cause analysis Solution

Improper tyre pressure Pressurize to the required pressure

Trouble Cause analysis Solution

Steering gear screws are loose; Fasten

Improper adjustment of steering gear Adjust the steering gear

7. Abnormal noises of steering gear

Trouble Cause analysis Solution

Steering linkage is loose Check if the link joints are worn

8. Analysis of normal troubles of hydraulic elements

Hydraulic Trouble Cause

 Assembly, disassembly and adjustment of steering system

1. Steering wheel and steering linkage

 Removal of combined switch

 Removal of the steering column and steering transmission shaft assembly

 Disassembly of transmission shaft assembly of the steering system

3) Remove the bearing from the steering shaft;

2) Clearance between steering shaft bushing hole and shaft journal

3) Clearance between slide fork key and key groove:

 Installation of steering universal knuckle with spline shaft assembly

 Install the steering column pipe and steering shaft

3) Install the wire clipping board

 Install the combined switch