Great Wall Safe (2006 year). Instruction — part 17
SR-6
Steering System
Steering Column
Dismantle of the steering wheel
1.
Dismantle of the steering wheel;
(a)
Take down the bugle cap;
(b)
Pull down the bugle wire.
(c)
Tear down the fixing nut of steering wheel.
2.
Tear down the combined switch cover;
3.
Tear down the cover at left bottom part.
4.
Tear down the fixing bracket for the left-bottom cover.
5.
Tear down the air passage;
6.
Tear down the combined switch;
7.
Tear down the fixed support seat bolts on front-wall panel;
8.
Tear down the fixing bolts at upper part of steering
column, and
9.
Tear down the connecting bolts of steering column
drive shaft.
10. Pull out the steering column.
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SR-7
Mount of Steering Column
1.
Mount the ignition switch assembly
Fix the ignition switch on the steering column with SST.
2.
Mount the dust cap and fixed support seat of steering
column on the front-wall panel.
3.
Mount the upper part of steering column;
Mount the upper part of steering column on the fixed bracket
with SST.
4.
Connect the upper part of steering column and the
steering drive shaft with the universal cardan joint;
5.
Connect the steering drive shaft and the steering gear;
6.
Mount the combined switch.
Fix the combined switch with SST.
7.
Mount the combined switch cover;
Fix the combined switch cover with SST.
Steering System
Steering Column
SST
SST
SST
SST
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SR-8
8.
Mount the steering wheel:
(a)
Screw up the fixing nuts of steering wheel according to
the specified torque.
Specified torque
Dr SF
(50 5)N.m
SL SK SY SJ
(30 2)Nm
(b) Connect the bugle wire;
(c
Mount the bugle cap.
Steering System
Steering Column
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SR-9
Steering System
Instruction Steering Gear
Instruction steering gear
Disassembly and mount of instruction steering gear
steering drive shaft
instruction steering gear box
swing arm
N
m
specified torque
245
25(Dr)
assembly mark
SST
Points on disassembly and mount
1.
Disassemble the steering drive shaft:
(a)
Loosen the fixing bolts at upper part of steering column;
(b)
Tear down the connecting bolts of steering drive shaft;
(c)
Mark the assembly marks on the steering drive shaft and
worm shaft;
(d)
Slide the shaft backward to tear it down from the worm shaft.
2.
Tear down the swing arm from the steering gear:
(a)
Loosen the fixing nuts of swing arm;
(b)
Tear down the swing arm from the steering gear with SST.
96
10(Dr SL SK SY)
worm shaft
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SR-10
Steering System
Instruction Steering Gear
3.
Connect the swing arm to the steering gear:
(a)
Mount the swing arm on the segmental gear shaft, and
mount the spring washer and steering arm.
(b)
Screw up the swing arm nuts.
Fastening torque
(245 25)Nm(Dr)
4.
Tear down the swing arm from the central transverse
drag rod;
Tear down the swing arm from the central transverse drag rod
with SST.
SST
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SR-11
Steering System
Power Steering (General Introduction)
power steering oil pump
power steering gear
steering drive shaft
oil cup
Power steering
Introduction
Principal of Power Steering
The power steering is a kind of hydraulic device that use
the engine power to steer. The engine drive the power
steering oil pump to generate the hydraulic pressure, which
actuates the piston in steering gear, so that the worm shaft
can provide to the piston with a supplementary force, which
has relation with the pressure actuated on the piston.
Therefore, pressure increase is required if larger steering
force is needed, and the pressure variation is accomplished
through the control valve.
Intermediate position (forward straightly)
The liquid from the power steering oil pump is sent to
the control valve, which, if locates at the intermediate, will
allow the liquid to pass and enter into the drain outlet, finally
return the pump. At this time, it is difficult to increase the
pressure; meanwhile, due to the equal pressures at the both
sides of the power piston, it cannot move toward either side.
Steering time
When the steering drive shaft move toward either side,
the control valve will move together with it, in case one oil
passage is shut off, meanwhile open the other larger, the
liquid flow variation will increase the pressure, as result, the
unequal pressure at both sides of piston will make the piston
move toward the side of smaller pressure, therefore, the
liquid is pressed in the pump through the control valve.
pump
control valve
drain outlet
power cylinde
power piston
segmental gear shaft
worm shaft
steering gear
Pump
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SR-12
Steering System
Power Steering (Introduction)
Suggestion on maintenance
The failure of power steering system usually relates to the
steering difficulty due to lack of supplementary force. In such
case, it is the first to verify the problem is produced by the pump
or steering gear when repairing. In doing so, the problem can be
checked on vehicle with the pressure meter.
On-vehicle Inspection
As the power steering is a hydraulic pressure device, its
trouble usually caused by the lack of specified hydraulic
pressure or the abnormal work of control valve. As a result, it
cannot acquire the moderate hydraulic pressure.
In case the problem is caused by the pump, the steering
wheel will deflect toward right or left. On the other side, if the
problem is caused by control valve, when the steering wheel
rotates to left or right, the steering will become more difficult
due to the unequal supplementary force. However, when there
is wear on the piston sealing ring of power cylinder, it also cause
the hydraulic pressure loss that may lead into steering difficulty
toward right or left.
Before making inspection on vehicle, verify the power
steering system firstly to see whether there is air. If any, the air
volume will increase with the variation of hydraulic pressure,
which will cause the hydraulic pressure fluctuation that makes
the power steering work abnormally. In order to verify whether
there is any air in the system, check whether the liquid level
varies or not when the steering wheel rotates completely toward
the right or left. For instance, if there is air in the system, the air
will be compressed, which will reduce the liquid level
remarkably, when the steering wheel rotating. If there is no air
in system, the liquid level variation is very small even though
the hydraulic pressure increases. This is because the liquid
volume will not varies when being compressed. And the small
liquid level variation is caused by the expansion of hose
between the pump and steering gear when the hydraulic pres-
sure increasing.
Meanwhile, the air in system sometimes will cause the
pump or steering gear produce noise when the steering wheel
rotating completely toward a certain direction. After checking
or exchanging the pump or steering gear, the on-vehicle inspec-
tion should be often conducted to guarantee the normal work of
power steering system.
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SR-13
Steering System
Power Steering (On-Vehicle Inspection)
tensioning wheel
power steering oil
pump
crankshaft
On-vehicle inspection
Inspection on tension of driver conveyor
Measure the tension of drive conveyor.
Drive conveyor tension: under the condition of 98 N.
New conveyor: (5-7)mm
Old conveyor:
(7-9)mm
Remark:
ìnew conveyorî means the conveyor that is used on the
machine less than five minutes;
ìold conveyorî means the conveyor that is used on machine
more than five minutes
Check for height of liquid level
1.
Keep the body in horizontal status
2.
Increase the liquid temperature
When the engine runs idly by 1000 r/m or less, rotate the
steering wheel several times from the locking position to the
reverse locking position to increase the liquid temperature.
3.
Check to see whether there is foam or emulsification;
Remark: the foam or emulsification shows there is air in the
system or the liquid level is over-low.
4.
Check the liquid level height in oil cup;
Check the liquid level height and, if needed, add the oil.
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SR-14
Steering System
Power Steering (On-Vehicle Inspection)
Change of power steering liquid
1.
Tear down the oil-returning hose from the oil cup to
drain the liquid into the container;
2.
Run the engine in the idle status, and rotate the
steering wheel toward the max rotating angle for
several times in right or left direction while draining the
liquid, until the oil in steering liquid is drained up.
3.
Turn off the engine.
4.
Connect the oil-returning pipe and inject the new
power steering liquid in the liquid tank;
Hydraulic oil type: No.8 Liquid drive oil (Q/SH003.01.012-88)
5.
Start the engine, and make it running in the idle status.
Rotate the steering wheel to the max rotating angle repeatedly
several times, meanwhile, supplement new power steering
liquid in the liquid tank until there is no foam or turbidities in
the liquid tank, and the oil indicating lamp reaches the marked
range when the engine is turned off.
6.
Tighten the liquid tank cover
7.
Exhaust the air in the power steering system;
Ai-r bleeding in power steering system
1.
Check the liquid level height in the liquid tank
Check the liquid level and, if needed, supplement the liquid.
2.
Start the engine in the idle status and rotate the
steering wheel repeatedly to the max rotating angle
several times.
3.
Turn off the engine and connect the ethane pipe and
bleeding plug.
4.
Start the engine and rotate the steering wheel
repeatedly to the max rotating angle several times.
5.
Locate the steering wheel at the intermediate position.
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SR-15
Steering System
Power Steering (On-Vehicle Inspection)
6.
Exhaust the air in steering system:
(a)
Loosen the bleeding plug;
(b)
Screw up the bleeding plug when there is no air bubble
exhausted from the pipeline.
Notice: take care not let the ethane pipe slide from the
bleeding plug, because the liquid is high in temperature
and pressure.
7.
Check to see whether there is air bubble or turbidities
in the oil cup, and ensure the liquid level will not
exceed the max value when the engine stops,
Measure the liquid height under the condition of engine running,
then turn off the engine and measure the liquid height again.
In case any problem is found, repeat the approaches of (5) and
(6) in Power Steering Liquid Change. If the problem still
exists, repair the power steering oil pump.
RPM
RPM
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SR-16
Steering System
Power Steering (Oil Pump of Power Steering)
Oil Pump of Power Steering
Dismantle and Mount of Oil Pump of Power Steering
Gasoline Engine Series
Diesel Engine Series
power steering oil pump
power steering oil pump bracket
belt pulley
driving belt
LP oil pipe
HP oil pipe
power steering oil pump bracket
HP oil pipe
LP oil pipe
belt pulley
oil cup
power steering oil pump
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SR-17
Steering System
Power Steering (Oil Pump of Power Steering)
Points on disassembly and mount
1.
Disassemble and connect the pressure pipe;
Tear down and mount the pressure pipeline on the power
steering oil pump with SST.
2.
Loosen the belt pulley nuts;
Press the driving belt by hand to fix the belt pulley to immo-
bilize and loosen the belt pulley nut.
3.
Adjust the driving belt tension after mounting the
power steering oil pump;
(See page SR-13)
SST
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SR-18
Steering System
Power Steering Gear
Power steering gear
Disassembly and mount of power steering gear
Dr SF SJ
LP oil pipe
HP oil pipe
steering drive shaft
power steering gear
swing arm
N
m
specified torque
pi=ph=pv
96
10
96
10(Dr)
145
10(SF)
78
10(SJ)
swing arm
245
25
LP oil pipe
HP oil pipe
steering drive shaft(SJ)
power steering gear
steering drag rod
91
10(Dr SF)
steering drive shaft(Dr SF)
245
25
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SR-19
assembly mark
SST
Points on disassembly and mount
1.
Tear down the HP oil pipe and LP oil pipe from the
steering gear;
Tear down the HP oil pipe and LP oil pipe from the steering
gear.
2.
Tear down the steering power shaft
(a)
Make assembly marks on the steering drive shaft and the
worm shaft.
(b)
Tear down the connecting bolts of drive shaft
(c)
Dismantle the steering drive shaft from the worm shaft.
3.
Tear down and connect the swing arm:
(a)
Tear down the swing arm fixing bolts;
(b) Tear down the swing arm from the steering gear with SST.
4.
Tear down the fixing bolts of steering gear;
Tear down the fixing bolts from the steering gear and then the
steering gear can be disassembled.
Steering System
Power Steering (Power Steering Gear)
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SR-20
Steering system - Steering Linkage
Steering Linkage
Dismantle and mount of steering linkage
N
m
specified torque
Parts that cannot be reused after being used
side drag rod assembly
joint clip
intermediate lateral drag rod assembly
auxiliary steering arm
80
10(Dr)
83
10(SL SK SY)
142
10(SF)
78
10(SJ)
91
10(Dr)
59
5(SF)
91
10(Dr SF)
90
10(SL SK SY)
78
10(SJ)
Remark
(a)
Where the bolts of recirculating ball are connected with
the arm or lever, the lubricant on its surface should be
cleaned.
(b)
Screw up the bolts and nuts of re-circulating ball to the
specified torque, and then screw the nut forward to the
degree that the split pin can be encased in.
(c)
Check the Alignment of Front Wheel and side slip after
any part of steering linkage is mounted.
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SR-21
Steering System - Steering Linkage
SST
SST
SST
A
A
B
B
B=B
A=A
Points on Dismantle and Mount
1.
Tear down and connect the swing arm on segmental
gear shaft:
(a)
Loosen the swing arm nuts;
(b)
Tear down the swing arm from the segmental gear shaft
with SST;
(c)
Mount the swing arm on the segmental gear shaft and
mount the spring washer and nut when connecting.
2.
Tear down the swing arm from the intermediate lateral
drag rod;
Tear down the swing arm from the intermediate lateral drag
rod with SST.
3.
Tear down the side drag rod assembly from the
intermediate lateral drag rod;
Use the SST to tear down the side drag rod assembly from the
intermediate lateral drag rod;
4.
Connect the side drag rod assembly:
(a)
Screw the two ends in the side drag rod.
Remark: the thread length at the two ends that cannot screw in
the side drag rod should be equal.
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