STEERING

Electronic Power Steering System

Electronic Power Steering
System
Electronic Power Steering System
The electronic power steering system consist of a
3-phase AC motor (M4) coupled to the steering gear.
The motor is controlled by ACCESS 5 which is
mounted on the inside wall of the motor compartment.
ACCESS 5 and M4 are protected from over-current by
FU12, located just below ACCESS 5. Steer command
is received via tiller sensor RPS2 and drive tire position
is determined by RPS1.
9. Slide the tiller mount (7) out of the top of the tiller
support (13) taking care not to lose the compres-
sion spring (12) and wear rod (11) that are assem-
bled into the tiller support.
10. To remove the tiller (3) from the tiller mount (7),
remove the two screws (6).
11. Remove the retaining ring (10) from the tiller mount
remove the ball bearing (9) and retaining ring (8).
12. To remove the steer knob (1) from the tiller (3) re-
move the screw (5) and lockwasher (4). Remove
the roll pin (2).

Steer Tiller
The steer tiller allows the operator to interface with the
truck to control truck direction. Steering information is
monitored by ACCESS 5. A rotary position steering
feedback sensor (RPS2) (25) is connected to the tiller
mount (13). The tiller rotates a small magnet (20) which
influences the RPS2 signal. The signal indicates the
operator's steer command to ACCESS 5. RPS2 re-
ceives +5V and BNEG from ACCESS 5 with feedback
from the sensor's two channels communicated back to
ACCESS 5. Refer to Figure 21902.

Steer Tiller Disassembly

1. Key truck OFF.
2. Disconnect battery and chock wheels.
3. Lockout/Tagout truck as described in Control of
Hazardous Energy section.
4. Remove two flatwashers (16), lockwashers (27)
and nuts (28) to remove the tiller support (13) from
the power unit.
5. Remove the screw (17) and flatwasher (16) that at-
tach the brace (18) to the tiller support. Remove
the tiller support assembly from the power unit.
6. Remove the two screws (26) that mount RPS2 (25)
to the sensor mounting plate (22).
7. If further disassembly of the sensor assembly is re-
quired, remove the two flatwashers (23) and
screws (24) that secure the sensor mounting plate
(22) to the bottom of the tiller support (13).
8. From the bottom of the tiller support (13) remove
Figure 21902
the screw (21) that secures the magnet (20) to the
tiller support.
(a) Part of Power Unit

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STEERING
Electronic Power Steering System

Steer Tiller Assembly

1. Slide the retaining ring (8) onto the tiller mount (7).
2. Slide the ball bearing (9) onto the tiller mount (7).
Slide the retaining ring (10) onto the tiller mount
and snap into place.
3. Assemble the steer knob (1) to the tiller (3) using a
roll pin (2), lockwasher (4) and screw (5). Torque
the screw to 33.9 ± 6.8 (25 ± 5 ft lb).
4. Use the two screws (6) to assemble the tiller mount
(7) to the tiller (3).
5. Fit the compression spring (12) and wear rod (11)
into the hole on the tiller support (13).
6. Slide the assembled tiller mount (7) into the tiller
support (13). From the bottom, insert the magnet
(20) into the tiller mount. Using thread locking ad-
hesive, secure with a screw (21).
7. Assemble the sensor mounting plate (22) to the
bottom of the tiller support (13) using two flatwash-
ers (23) and screws (24).
8. Assemble RPS2 (25) to the sensor mounting plate
(22) using two screws (26).

NOTE
RPS2 must be mounted with the potted side away from
the magnet. Failure to do so will affect truck operation
and calibration.
9. Assemble the brace (18), if previously removed, to
the power unit using a screw (14), two flatwashers
(15 and 16), a lockwasher (27) and nut (28).
10. Assemble the tiller support (13) to the brace (18)
using a screw (17) and flatwasher (16).
11. Use two more flatwashers (16), lockwashers (27)
and nuts (28) to assemble the tiller support (13) to Figure 21902
the power unit.
(a) Part of Power Unit

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 STEERING
Electronic Power Steering System

Removing Steer Motor from Assembly of Steer Motor to Carriage

Carriage Refer to Figure 21933.
Refer to Figure 21933. 1. Lightly lubricate the pinion gear (1).
1. Remove locknuts (10), compression springs (8) 2. From the bottom of the undercarriage, insert the
and flatwashers (9) from threaded shafts (7). Re- pinion gear (1), making sure the teeth align with the
move threaded shafts. teeth on the idler gear (2).
2. Carefully slide the steer motor (6) out of the car- 3. Press the bearing (5) onto the pinion gear, ensur-
riage. ing the bearing is seated on the shoulder of the pin-
ion gear. Install the small retaining ring (3) on the
3. Remove the large retaining ring (4) and bearing
pinion gear.
(5).
4. Secure the assembled parts with large retaining
4. Remove the small retaining ring (3) to remove the
ring (4). Check gear mesh for proper operation.
pinion gear (1).
5. Lubricate the steering gears as required. Refer to
Planned Maintenance for lubricant type and fre-
quency.
6. Install the larger diameter of the threaded shafts
(7) into the counter bored holes (11) of the under-
carriage. Only one side shown. Torque the shaft to
31 ± 1.4 Nm (23.0 ± 1.0 ft lb).
7. Apply a light film of grease to the male and female
splines of the steer motor (6) shaft and pinion gear
(1). Brush the grease into the roots and tips of the
splines.
8. Install the steer motor (6) over the threaded shafts
(7).
9. Place a compression spring (8) and flatwasher (9)
over each of the threaded shafts and secure with
locknuts (10). Torque the locknuts to 31 ± 1.4 Nm
(23.0 ± 1.0 ft lb).

Figure 21933

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STEERING
Electronic Power Steering System

Steering Feedback Gear and Wheel Steering Feedback Gear Alignment

Position Sensor (RPS1) Trucks with 1065 mm (42 in) Power Unit
The steering feedback gear works with the steer wheel 1. Rotate the drive unit clockwise until it hits a hard
position sensor (RPS1) to communicate steering wheel stop.
angle to ACCESS 5. The steering feedback gear as-
sembly rotates a small magnet as it moves. The mag-
net influences the signal that RPS1 provides. The sig-
nal indicates the angle of the steering wheel to
ACCESS 5, which is communicated to ACCESS 1 for
display to the operator or technician. It is important that
the feedback gear is aligned correctly and sensor
bracket is mounted as shown for proper truck function.
Refer to Steer Wheel Position Sensor in this section
and ACCESS 123® Menus for calibration information.

NOTE
RPS1 must be mounted with the potted side away from
the magnet. Failure to do so will affect truck operation
and calibration. Figure 21906

2. Install steering feedback gear assembly, aligning

hole in carriage with hole in feedback gear.

Figure 21907

3. Install retaining rings to hold gear in place.

Figure 22333

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Trucks with 1220 mm (48 in) Power Unit (S Class)
1. Rotate the drive unit counterclockwise until it hits a
hard stop.
Figure 21931
2. Install steering feedback gear assembly, aligning
the hole in the carriage with a hole in the feedback
gear.
Figure 21932
3. Install retaining rings to hold gear in place.
Crown 2009 PF17706-5 Rev. 8/09
STEERING
Electronic Power Steering System
Traction/Steer Tire Alignment and
RPS1 Calibration
Feedback from the wheel position feedback sensor
(RPS1) is used to detect the angle of the traction/steer
tire and reduce the truck's travel speed when turning. It
is critical that the sensor is calibrated correctly and the
traction/steer tire is aligned correctly. There is a
1 degree tolerance.
The C4.1 Wheel Position Sensor submenu provides a
means for ACCESS 5 to monitor the voltage range of
the traction/steer wheel position sensor (RPS1). This
submenu applies only to trucks with electronic power
steering and will only be displayed if F3.7 is set to AC.
Complete the following steps to properly align the trac-
tion/steer tire.
NOTE
A builder's square or similar tool is necessary for
proper traction/steer tire alignment. There is no me-
chanical alignment mark and the software tolerance al-
lows less than 1 degree of error. Splitting the voltage
difference between fully CW and fully CCW is not ac-
curate because the ratio between the drive unit steer-
ing gear and the sprocket on the shaft for the RPS1
sensor magnet is not a 1:1 ratio.
1. Enter the submenu. Use the up and down arrows
to select "SURE?Y". Press enter to confirm choice
(selecting "SURE?N" will return to C4.1). RPS1
voltage is displayed on the lower line of the display
during calibration.
2. ACCESS 1 indicates steer wheel fully CW, press
enter - Turn the tiller to rotate the traction /steer tire
is fully clockwise, then press enter on ACCESS 1.
3. ACCESS 1 indicates steer wheel fully CCW, press
enter - Turn the tiller to rotate the traction/steer tire
fully counterclockwise, then press enter on
ACCESS 1.
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STEERING
Electronic Power Steering System

4. ACCESS 1 indicates center steer wheel, press en-

ter - Turn the tiller to rotate the traction/steer tire to
within one degree of center. This procedure may
require two people to complete. To confirm the
traction/steer tire is centered, use a carpenter's
square, or other right angled tool to align the trac-
tion/steer tire with the truck. Place one edge of the
tool against the back of the traction/steer tire, align-
ing the other edge along the battery box. Turn the
tiller until the traction/steer tire and battery box are
aligned, then press enter. Refer to Figure 21908.
5. "Calibration accepted" or "Calibration failed" will be
displayed. Press the left arrow to return to C4.1. If
necessary, restart the calibration at step one.

Figure 21908

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