Steering System – General Information

211-00-1 211-00-1

Section 211-00 Steering System – General Information

Applicable Model: Boomday

CONTENTS PAGE
Specifications
Specifications................................................................................................................................. 211-00-2
Descriptions and Operations
Steering System............................................................................................................................. 211-00-3
Diagnosis and Testing
Steering System............................................................................................................................. 211-00-4
General Procedures
Measurement of the Steering Wheel Free Play............................................................................ 211-00-17
Adjustment of the Steering Wheel Free Play............................................................................... 211-00-18
Alignment of the Steering Wheel.................................................................................................. 211-00-19
Replacement of Power Steering Fluid.......................................................................................... 211-00-20
Evacuation of the Steering System.............................................................................................. 211-00-21
Measurement of the Pressure in the Steering System Pipeline................................................... 211-00-22

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Specifications

Material Specifications

Item Specification
Power steering fluid EZL401(ESSO)

Parameter Specification

Item Specification
Steering gear
Steer gear type Whole body, ball
Speed ratio 22.6
Gear ratio 15.8 : 1
Sector shaft operating angle 94°
Lubricant capacity 1L
Steering wheel
Number of turns of the steering wheel -
Steering wheel free play 10 mm

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Descriptions and Operations

Steering System
Steering system is a generic term referring to
the special mechanism used to change driving
direction.
Steering system consists of:
● Power steering pump
● Steering gear
● Power steering oil pipe
● Oil reservoir
● Steering drive mechanism
● Steering wheel
● Steering shaft
● Steering column switch
● Damper
Refer to section 211-02 for information of power
steering pump, steering gear, power steering oil
pipe, oil reservoir.
Refer to section 211-03 for information of
steering drive mechanism and damper.
Refer to section 211-04 for information of
steering wheel and steering column shaft.
Refer to section 211-05 for information of steering
column switch.

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Diagnosis and Testing

Steering System
Inspection and Confirmation 3. I f obvious cause for fault is identified,
correct it before proceeding.
1. Verify customer’s concern.
4. I f causes are not obvious, identify the
2. Check for obvious mechanical damage from symptom and refer to Symptom list.
the outer appearance.

Mechanical
●  ower steering fluid level
P
● Tire pressure
● A type triangle belt
● Tie rod ball head
● Wheel and tire
● Power steering oil pipe
● Steering gear
● Steering pump
● Steering column shaft
● Damper

Symptom List

Symptoms Possible Causes Measures

Heavy steering ● High oil viscosity; cannot absorb oil ● It’s recommended to use specified hydraulic oil

● Oil level too low in the oil reservoir;

● Timely refill the oil to specified oil level
lack of oil
● Oil pipe or filter element blocked ● Clean pipe and filter element
● Steering system connector unfastened ● Tighten the pipe connector
● Bending radius of the oil pipe too
● Replace oil pipe
small or the pipe is cracked
● Insufficient tire pressure ● Inflate the tire
● Steering gear malfunction ● Repair or replace steering gear
Noise ● Oil filter blocked and oil absorption
● Clean or replace filter element
is not smooth
●  heck for air leakage at oil intake connecting
C
● Air entered into hydraulic system
part. Repair if there’s any leakage.
● Oil intake and out pipe is too thin, ● T hicken and shorten the oil suction pipe,
too long, with too many elbows, so reduce the amount of elbows.
the oil feeding and discharging of ● Oil out pipe is thin, long, with many elbows.
the steering pump is not smooth Make modification and reduce resistance.
● Low oil level ● Timely refill the oil to the specified range
●  teering wheel has been in the ● Avoid the staying of the steering wheel at the
S
steering limit position for a long time steering limit position

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Diagnosis and Testing

Accurate Testing
Accurate testing A: Power steering gear cannot fully function

Testing Conditions Details / Results / Measures

A1: Check power steering

W
 arning: Do not let the steering wheel stay at steering limit position for an extended period
of time; otherwise power steering pump will be damaged. Properly increase engine speed,
and turn the steering wheel left and right to the steering limit position.

Check whether the power steering is normal?

Yes
Go to A2.
No
Repair the power steering gear or replace with a
new one.
A2: Check hose and connector
Check whether there’s leakage at the hose and
connector?
Yes
Tighten the connector and repair steering linkage
as required.
No
Go to A3.
A3: Check steering pump
Check whether steering pump is damaged?
Yes
Replace the steering pump with a new one.
No
Replace the steering gear.

Accurate testing B: Steering wheel free play too large

Testing Conditions Details / Results / Measures

B1: Check steering gear free play
Check whether steering gear free play is excessive?
Yes
Adjust it.
No
Go to B2.

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Diagnosis and Testing

Testing Conditions Details / Results / Measures

B2: Check the steering gear
Check whether the steering gear is loosened or
damaged.
Yes
Repair or replace it.
No
Go to B3.
B3: Check the steering linkage
Check whether the steering linkage is loosened or
damaged?
Yes
Repair or replace it.
No
Go to B4.
B4: Check the wheel bearing
Check whether the wheel bearing is worn or damaged?
Yes
Replace it.
No
Check for other possible causes.
Check whether the wheel bearing clearance is
excessive?
Yes
Adjust it.
No
Check for other possible causes.

Accurate testing C: Steering wheel vibration

Testing Conditions Details / Results / Measures

ATTENTION:
1. In most cases, steering vibration can be eliminated through inspection and correction of the
assembly of the wheels and tires. The radial runout of the wheels and tires shall be carefully
adjusted.
2. Steering wheel is shimmy and the clutch vibrates strongly when starting the vehicle. This may
be caused by vibration of the steering gear.
3. Yawing is very likely to happen when driving at a high speed.
4. In case of steering vibration at a speed range of 40 kg/h to 60 kg/h, most of the time the faults
are caused by radial runout or uneven tread of tires.

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Diagnosis and Testing

Testing Conditions Details / Results / Measures

C1: C
 heck whether the vehicle yaws when coasting

Yes
Go to C2.
No
Check other phenomenon.

C2: Check radial runout of tires

Check whether the radial runout of tire is within the
specified range?
Yes
Go to C3.
No
Replace the tire.
C3: C
 heck radial runout and out-of-round of the wheel rim
Check whether the radial run-out and out-of-round
of the wheel rim is within the specified range?
Yes
Go to C4.
No
Replace it.
C4: Check dynamic balancing of wheels and tires
Check whether the dynamic balancing of wheels
and tires is normal?
Yes
Check whether the engine mounting bracket is
cracked or damaged.
No
Correct dynamic balancing.

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Diagnosis and Testing

Accurate testing D: Steering wheel shimmy

Testing Conditions Details / Results / Measures

ATTENTION:
1. The so-called “steering wheel shimmy” is a fault that can be eliminated through balancing of
the wheel and tire assembly. If “steering wheel shimmy” still cannot be eliminated through
correction of radial runout and balancing, continue to check the next cause.
1 R
 adial vibration and imbalance of the wheel still exists.
2 E
 xcessive clearance of the connector or linkage, incorrect wheel alignment or insufficient
linkage rigidity.
2. “Steering wheel shimmy” may be caused by the design of linkage, inappropriate adjustment
or repair of suspension system.
3. The following faults are often misunderstood as steering wheel shimmy:
1 The Vibration of steering gear.
2 The rumbling sound which occurs with vibration at a low speed.
3 Body runout.
D1: C
 heck steering wheel when coasting
Check whether the steering wheel is shimmy when
coasting?
Yes
Proceed to D2.
No
Check malfunction phenomenon.
D2: Check wheels and tires

Check whether the wheels and tires are unbalanced?

Yes
Replace it.
No
Go to D3.

D3: C
 heck the steering linkage

Check whether the steering linkage operates

normally?
Yes
Go to D4.
No
Repair or replace it.

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Diagnosis and Testing

Testing Conditions Details / Results / Measures

D4: C
 heck the wheel bearing

Check whether the wheel bearing operates normally?

Yes
Go to D5.
No
Repair or replace it.

D5: Check the shock absorber

Check whether the shock absorber operates
normally?
Yes
Go to D6.
No
Replace it.
CD6: C
 heck four wheel alignment
Check whether the four wheel alignment is normal?
Yes
Go to D7.
No
Perform alignment.
D7: Check tire wear and inflation pressure

Check whether the tire wear and inflation pressure

is normal?
Yes.
Check for other possible causes.
No.
Replace or adjust it.

Accurate testing E: Difficult steering

Testing Conditions Details / Results / Measures

E1: C
 heck oil pressure of the steering system

Check whether the oil pressure of the steering

system is normal?
Please to this section for more information.
Yes
Go to E2.
No
Repair or replace it.

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Diagnosis and Testing

Testing Conditions Details / Results / Measures

E2: Check tire inflation pressure
Check whether the tire inflation pressure is normal?
Yes
Go to E3.
No
Adjust it.
E3: Check front wheel alignment

Check whether the front wheel alignment is correct?

Yes
Go to E4.
No
Adjust it.
E4: Check the front shock absorber
Check whether the front shock absorber operates
normally?
Yes
Go to E5.
No
Replace it.
E5: Check the steering linkage
heck whether the steering linkage operates
normally?
Yes
Check for other possible causes.
No
Replace it.

Accurate testing F: Steering system hesitating

Testing Conditions Details / Results / Measures

F1: Check whether the components of the body or frame are distorted.
Yes
Repair it.
No
Go to F2.

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Diagnosis and Testing

Testing Conditions Details / Results / Measures

F2: Check the wheel bearing clearance
Check whether the bearing clearance is excessive?
Yes
Adjust the bearing clearance.
No
Go to F3.
Check whether the bearing is malfunctioning?
Yes
Replace the bearing.
No
Go to F3.
F3: Check the steering linkage
Check whether the connector clearance is
excessive or the fixing part is not tightened?
Yes
Adjust the connector clearance or tighten the fixing
part.
No
Go to F4.
Check whether the steering linkage is damaged?
Yes
Replace it.
No
Go to F4.
F4: Check the front suspension
Check whether the front suspension operates
normally?
Yes
Go to F5.
No
Repair or replace it.
F5: Check the power steering pump
Check whether the power steering pump operates
normally?
Yes
Check other possible problems in the system.
No
Replace the power steering pump.

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Diagnosis and Testing

Accurate testing G: Steering oil pump noise

Testing Conditions Details / Results / Measures

G1: Check whether the steering oil level is normal
Yes
Go to G2.
No
Add specified steering oil to the level within a proper
range.

G2: Check operating conditions of the steering gear

 ARNING: Do not let the steering wheel stay at the steering limit position for an extended
W
period of time; otherwise, the power steering pump will be damaged. Properly increase
engine speed, and turn the steering wheel left and right to the steering limit position.

Check whether the oil pump generates noise at a

raised temperature?
Yes
Repair it or replace with a new steering pump.
No
Go to G3.
G3: Check whether there is air in the hydraulic loop
Yes
Discharge the air in the circuit.
No
Go to G4.
G4: Check whether the outlet pipe or the filter is blocked
Yes
Clean or replace it.
No
Go to G5.
G5: Check whether the steering pump is intact
Yes
Check the steering pump.
No
Replace or repair steering pump.

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Diagnosis and Testing

Accurate testing H: Poor returnability of the steering wheel

Testing Conditions Details / Results / Measures

H1: Check tire pressure

Check whether the tire pressure is norma?

Yes
Go to H2.
No
Adjust it.

H2: Check the front wheel alignment

Check whether the front wheel alignment is normal?

Yes
Go to H3.
No
Adjust it.

H3: Check the stabilizer bar

Check whether the stabilizer bar operates normally?

Yes
Go to H4.
No
Replace it.

H4: Check the lubrication of the steering system

Check whether the lubrication of the steering
system is normal?
Yes
Go to H5.
No
Refill grease.
H5: Check the relay lever

Check whether the relay lever operates normally?

Yes
Go to H6.
No
Repair or replace it.

H6: Check the suspension system

Check whether the suspension system operates
normally?
Yes
Check other possible causes.
No
Repair or replace it.

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Diagnosis and Testing

Accurate testing J: Steering is deviated to one side

Testing Conditions Details / Results / Measures

J1: Check the tire pressure and dynamic balance

Check whether the tire pressure and dynamic

balance is normal?
Yes
Go to J2.
No
Replace it.

J2: Check the front axle and the rear axle (4WD)
Check whether the front axle is parallel to the rear
axle (4WD)?
Yes
Go to J3.
No
Perform a repair
J3: Check the brake

Check whether the brake operates normal?

Yes
Go to J4.
No
Repair or replace it.

J4: Check the bearing preload

Check whether the bearing preload is damaged
and correct?
Yes
Go to J5.
No
Repair or replace it.
J5: Check the front wheel alignment
Check whether the front wheel alignment is
normal?
Yes
Go to J6.
No
Repair it.
J6: Check the axle
Check whether the axle operates normally?
Yes
Check other possible causes.
No
Repair or replace it.

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Diagnosis and Testing

Accurate testing K: Steering wheel cannot return to the position which keeps the vehicle moving
in a straight forward direction

Testing Conditions Details / Results / Measures

K1: Check the tire pressure
Check whether the tire pressure is normal?
Yes
Go to K2.
No
Adjust it.
K2: Check the steering linkage
Check whether the steering linkage is normal?
Yes
Go to K3.
No
Repair or replace it.
K3: Check the front wheel alignment
Check whether the front wheel alignment is normal?
Yes
Go to K4.
No
Adjust it.
K4: Check the swinging arm ball joint
Check whether the swinging arm ball joint is
damaged?
Yes
Go to K5.
No
Repair or replace it.
K5: Check the stabilizer bar
Check whether the stabilizer bar operates
normally?
Yes
Check other possible causes.
No
Replace it.

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Diagnosis and Testing
Parts Testing
 TTENTION: If the vehicle is equipped
A smooth, without any unstable signs. Check
with a power steering gear, the engine
must be running while performing the
following operations.
Steering Wheel
1. Check clearance and loosening
1 S et the steering wheel at the straight
forward position. Slightly turn the steering
wheel to the left and right. Before the front
tires move, there should be a clearance of
approximately 10 mm at each direction.
2 F irmly grasp the steering wheel with
both hands. Push and pull upwards and
downwards along the steering column.
There should be no loosening.
3 Turn the steering wheel to the left and
right. Check whether the steering shaft is
loosened. Check whether the connecting
part is loosened.
2. Check the operation condition of the system
Check the following items when driving the
vehicle:
1 W hen driving the vehicle in a straight
forward direction, check the position of the
steering wheel.
2 Verify that the vehicle is not inclined to steer
to the left or right.
3 Steering wheel shall not strongly vibrate.
4 Radically turn the vehicle to the left and right
as much as possible. When the steering
wheel fully turns to the end, check for noise.
Even when fully turning the steering wheel to
the end, steering wheel shall not be operated
heavily. Release the steering wheel, turn the
steering wheel to the original position.
Steering Gear
1. Check for leakage of hydraulic oil
Check for oil leakage of all steering gear parts
(e.g., front cover oil seal, side cover, sector
gear shaft, etc).
2. Check for loosening of assembly
Place the wheel on the ground (vehicle shall
not be jacked up), and ask the assistant to
rotate steering wheel. When he turns the
steering wheel to the left or right, you can
check whether the contacting part between
the steering gear and the frame is loosened
or whether there’re other kinds of faults in the
contacting part.
3. Check the bearing clearance
1 Check the connection between the steering
shaft and the bearing. Axially move the
steering shaft to verify whether a clearance
exists.
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2 R otate the steering shaft. There should be
no abnormal noise. The rotation should be
and verify that there is no abnormal or
excessive abrasion.
4. Check for gear clearance
The front wheel must be in a straight forward
position. Ask the assistant to grip the steering
pitman arm and hold it. Then rotate the
steering wheel. The gear clearance shall not
exceed 1 mm.
5. Check for cracks of sector gear shaft
Remove the steering gear from vehicle and
disassemble it. Carefully check whether there
are cracks or other kinds of damage in the sector
gear shaft.
Levers and Arms
If any of the following faults is identified through
check, it’s required to replace the corresponding part.
1. Check for loosening, clearance and damage
1 P a r k t h e v e h i c l e o n t h e g r o u n d ( t h e
vehicle shall not be jacked up) and ask the
assistant to turn the steering wheel to the
left and right. When the assistant rotates
the steering wheel, carefully check whether
connectors of all parts are loosened or have
clearance or damage.
2 C arefully check whether all lock pins are
broken or damaged.
2. Check for abrasion or other abnormal condition
at couplings.
1 C heck ball joints and rubber bushings.
There should be no abrasion and damage.
Check Steering Column Shaft
If any abrasion, damage or other faults are
identified for the following parts through check,
repair or replace them as necessary.
● Universal joint
● Fork
● Steering shaft
● Column
● Spring
● Bearing
Ball
If any of the following faults is identified through
check, it’s required to replace.
● Check whether the ball sleeve is damaged.
● Check whether the ball rotates smoothly.
 Steering System – General Information
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General Procedures

Measurement of the Steering Wheel Free Play

The steering wheel free play should be measured
when the engine is running. Turn the steering wheel
to the left and right until the tire starts to rotate, in
order to check the steering wheel free play.
Standard range of free play: ≤10 mm.

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General Procedures

Adjustment of the Steering Wheel Free Play

1. Park the vehicle at a straight forward position.
2. Loosen the locking nut cap of adjusting screw
of the steering gear assembly.
3. Turning the adjusting screw clockwise can
decrease the free play, whereas turning the
adjusting screw counterclockwise can increase
the free play.
4. Tighten the locking nut cap after adjustment.
Tighten to 42 ± 6 Nm during installing.

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General Procedures

Alignment of the Steering Wheel

In case of steering wheel misalignment caused
by replacement of steering gear or other reasons,
align the steering wheel as necessary. The
alignment procedures are as followed:
1. D
 rive the vehicle in a straight forward direction
to align the wheels.
2. R
 emove the steering wheel.
Refer to section 211-04 for more information.
3. P
 lace the steering wheel and keep it centered,
then install it.

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General Procedures

Replacement of Power Steering Fluid

Material

Item Specification
Power steering fluid EZL401(ESSO)

 TTENTION: Do not let the steering wheel

A
stay at the steering limit position for an
extended period of time; otherwise, the
power steering pump will be damaged.
1. Jack up the front wheel, keep the wheels com-
pletely off the ground.
2. Remove the oil pipe between the steering gear
and the oil reservoir to drain oil and use proper
container to collect steering fluid.
 TTENTION: Steering fluid drained from
A
power steering system shall not be rep-
eatedly used.
3. A fter steering fluid is drained out, turn the
steering wheel to the left and right and stop at
the left/right steering limit positions for a while,
thus to drain out the steering fluid remained in
hydraulic loop.

 TTENTION: Do not add excessive amount

A
of steering fluid at a time.
4. After installation of removed oil pump, fill spe-
cified power steering fluid to the power steering
fluid reservoir.
5. Fill power steering fluid to the specified level in
the reservoir, which takes two to three minutes.
Top up the reservoir when refilling, in order to
prevent air entering into the hydraulic loop.
6. Lower the front wheels onto the ground and
start the engine, run the engine at idling speed.
Re-check the fluid level and refill as necessary.
7. Visually check for leakage of power steering
system.

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General Procedures

Evacuation of the Steering System

 TTENTION: If air in power steering
A
system is not properly evacuated, it
will cause the malfunction of the power
steering pump to happen earlier than
usual.

 TTENTION: The purring sound heard

A
from the power steering pump may
caused by air entry into the steering
system. In case of purring sound from
the power steering system, steering fluid
must be mixed with air, and it’s required
to evacuate the steering system.
1. R
 emove the oil reservoir cover of the power
steering pump and check the oil.
2. J ack up front wheel to keep it off ground.
3. S
 tart the engine.

 TTENTION: Do not let the steering wheel

A
stay at the steering limit position for an
extended period of time; otherwise the
power steering pump will be damaged.
4. Turn the steering wheel to the left and right,
until there are no bubbles in the oil reservoir.
5. O
 bserve level change in the oil reservoir. If the
level drops to the lowest level, add steering
fluid to the specified level. After that, repeat
step 4 until there are no bubbles in the steering
oil reservoir, and the steering oil level remains
within the specified range.

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General Procedures
Measurement of the Pressure in the Steering System Pipeline
Special Tools
Connector
From the hydraulic measurement of power
steering system, one can judge whether the oil
pump and power steering gear function normally.
Item Description
1 Power steering pump
2 Fluid reservoir
3 Steering gear
4 Pressure gauge
5 Cut-off valve
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1. Tester installation.
Use testing tools: 5-8840-0135-0, 5-8840-
0136-0.
Connect output end of power steering pump to
the pressure gauge side, and steering gear to
the cut off valve side.
2. Hydraulic measurement.
Accelerate the engine to 1500 rpm, turn the
steering wheel to the left and right, and let
the steering wheel briefly stay at the left/right
steering limit position to measure the hydraulic
value.
 TTENTION: Do not let the steering wheel
A
stay at the steering limit position for an
extended period of time, otherwise the
power steering pump will be damaged.
Specified value: 8.3 ~ 8.8 MPa.
If the measured value is above 8.8 MPa, the
steering gear fails. If the measured value is
below 8.3 MPa, the steering pump fails.