Tài liệu hệ thống lái

tài liệu hệ thống lái Hyundai aero space _Steering Syste

SYSTEM

GENERAL ST - 2 SPECIFICATION ST - 6 SERVICE STANDARDS ST - 7 TIGHTENING TORQUE ST - 8 TROUBLESHOOTING ST - 9 SERVICE PROCEDURE ST-14 INTEGRAL POWER STEERING GEAR ST-27 POWER STEERING OIL PUMP ST-37 POWER STEERING OIL TANK ST-43

The steering system allows the driver to freely change the traveling direction of the vehicle The steering force of thesteering wheel is transmitted through the steering shaft, power steering gear, pitman arm and drag link to the knuckle arm

to steer the vehicle

The system has an integral type power steering gear installed in the gear box to reduce the steering effort

The power steering system hydraulic pressure circuits are as shown below

Piping

Knuckle arm

Power steering oil pump

Pitman arm

Power steering oil reservoir tank

Slave lever Power steering gear

1st drag link

2nd drag link

ECYST02A

Steering Linkage

Drag Link Assembly

Leaf suspension type : The drag link transmits the force of power

steering gear pitman arm to slove lever and knucle arm

Steering Wheel and Shaft

The steering shaft is a tlelscopic and tilt type which can by adjusing

lock lever select the best driving position by adjusting lock lever

Lock lever

Free Lock Telescopic

Tilt

MA560040

Tie Rod Assembly

1 Leaf suspension type : It connects the laft and right tie-rod arm

2 The connecting point of tie arod and tie rod end is tightened by

a left hard bolt at left and a right hand bolt at right

Slave Lever (Leaf-suspension only)

The slave lever connects the 1st drag link and 2nd drag by

multi-plying the force from 1st drag link to 2nd drag link

Right Turn

When the steering wheel is turned clockwise, the load from the tires acts on the worm shaft to twist the torsion bar As aresult, the rotor turns clockwise with respect to the worm shaft, decreasing the axial direction groove clearance This limitsflow of the hydraulic oil to the oil tank and now the hydraulic oil from thr oil pump enters the cylinder chamber A to cause thepiston to move to the cylinder chamber B

The hydraulic oil in the cylinder chamber moves, the torsion bar that has been twisted returns to the neutral position Theforce that has caused twisted returns to the neutral position The force that has caused twisting of the torsion bar duringsteering is transmitted to the steering wheel as a steering reaction force which gives the driver a sence of steering response

A left turn is also made on the same operating principles as the right turn but in opposite direction

Integral Power Steering Gear

This device consisting of the power cylinder section (output section) that also serves as the steering gear and the controlvalve section (control section) reduces the power required to operate the steering wheel

Straight Ahead Driving

When there is no steering torque from the steering wheel, no relative displacement is caused between the stub shaft and

th worm shaft and hence the rotor (or spool) is at the neutral position on the worm shaft (or sleeve) Accordingly, thehydraulic oil supplied by the oil pump is allowed to flow through the worm shaft groove back to the oil tank

Namely, no pressure diffference develops between cylinder chambers A and B so that the piston (ball nut) remainsstationay at the neutral position

CYST001C / CYST001D

Cylinder chamber B Worm shaft

Stub shaft

Piston

Rotor Cylinder chamber A

Torison bar

To cylinder chamber B

To cylinder chamber A Worm shaft

To oil tank

To oil tank

To cylinder chamber B

To cylinder chamber A

To oil tank

From oil pump

From oil pump

To cylinder chamber B

From oil pump

To cylinder chamber A

To cylinder chamber B

From oil pump

To cylinder chamber A

To oil tank

To cylinder chamber A Worm shaft

To oil tank

To cylinder chamber B

To cylinder chamber A

To oil tank

From oil pump

From oil pump

From cylinder chamber B

Rotor

Rotor Cylinder chamber A Stub shaft

Piston

Worm shaft

Cylinder chamber B Torison bar

Rotor turning direction

Manual Steering

Even if the hydraulic pressure ceases to act on the power steering

booster due to a stalled engine, defective oil pump, oil leaks or

other causes, the mechanical power is directly transmitted from

the stub shaft to the worm shaft by the stopper mechanism

pro-vided between the stub shaft and worm, allowing manual steering

Power Steering Oil Pump

The vanes mounted to the rotor move in and out along the inside

surface of the cam ring to cause suction and discharge of the

hy-draulic oil

1 Flow Control Valve

This valve causes excess amount of oil to flowback to the oil

tank to keep a constant flow of oil to the power steering booster

JMS56-011

Cam ring VaneRotor

Chamber A

Pump scution port

Flow control springSpoolChamber B

To power steering booster

Pump scution port

Metering orifice

2 Relief Valve

This valve keeps a constant hydraulic pressure

As shown right, the flow control valve and the relief valve work

together to keep a constant operating pressure

GENERAL

ItemSteering wheel

Steering shaft type

Steering gear type

Power steering gear

Power steering oil pump

Power steering oil

reservoir

Steering angle

(Turning wheel angle)

TypeO.D (Outer Diameter)

TypeCylinder I.D

StrokePiston operating area (cm2)

Oil capacity (Type

Displacement (no load) cc/rev

Controlled flow ( / min)

Permissible ratating range rpmType

Capacity ( )High decklower deck

SpecificationsTwo-spoke type

500 mmUniversal joint (with telescopic tilt mechamism)Ball-nut type

Intergral type

100 mm85.6 mm78.512.3 (125)

Approx 1.5Vane type201712.2(125)

350 to 3700Separate from pump1.8-2.0

45374235

-2°

Normal miximum hydraulicpressure MPa (kgf/cm2)

Regulated pressure rpm(relief valve) MPa (kgf/cm2)

15 to 35 0.2 or less

15’ or less

30’ or less

[38] 0.015-0.111 [42] 0.045-0.175 38

0.2 to 0.5

39 to 78 (4 to 8)

[90] 0.11 - 0.10 to 0.5 [35.5] 0.01 to 0.03 57.97 47.97 -

-10.3 MPa (105 kgf/cm 2 )

-

-0.4 0.4 37.9

-0.16 0.04 - 0.03 or more 57.87 47.87 0.09

0.03

-Remedy and remarks Adjust

Correct or replace assembly

Replace assembly

Replace assembly

Replace Replace Replace

Adjust by adjusting screw pitman arm end runout Adjust by adjusting screw

Replace Replace Adjust.

Replace Replace

No deposition, wear of flaw that may catch bar to be tolerated Replace.

No deposition, wear or flaw that may catch bar to be tolerated Replace as flow control valve assembly or rear body assembly Replace as flow control valve assembly or rear body assembly

Play of joint in turning direction

(play of needle bearing and spider)

Play of yoke spline tube and steering

lowershaft (spline shaft) in turning direction

Sleeve lever shaft to bushing clearance

Connecting link plate to bushing clearance

Sector shaft outside

diameter

Steering gear backlash

(Straight ahead position)

Worm starting torque after completion of

assembly (straight ahead position) Ncm (kgf·cm)

Body (cylinder) to ball screw (piston) clearance

Ball screw assembly play in axial direction

Sttering gear backlash

Sleeve to rotor clearance

Sector shaft O.D.

Ridge wear of pressure plate and side plate

rotor and vane sliding portion

Flow control valve to rear body clearance

Pump relief set pressure (at 1,800 rpm)

Play in axial direction (vertical)

Pitman arm side Side cover side

Packing portion Bearing portion

SERVICE STANDARDS

Steering shaft yoke boltLock plate stopper boltWorm shaft and yoke attaching boltGrease nipple

Ball stud castle nutSteering shaft mountingLock lever bolt

Steering lever supportingPitman arm nut

Ball tube screwTaper plugRetainer

Adjusting screw lock nutSide cover bolt

Adjusting plugValve housing boltPlug (air breather)Lock ring

PlugCartridge assembly screwRear body bolt

Flow control valve plugHose connector boltOil pump gear mounting boltPlate screw

Thread size Dia

x Pitch mmM20 x 1.5M52 x 1.5

M10 x 1.25M5 x 0.8M20 x 1.25M6 x 0.75M20 x 1.5 M12 x 1.25M8 x 1.25M12 x 1.25M36 x 1.5M6 x 1.0

PT 1/8M32 x 1.5

M14 x 1.5M12 x 1.25M80 x 1.5M16 x 1.5M10 x 1.25M80 x 1.5M48 x 1.5 -M6 x 1.0

7839-69

48-633.9-6.449-543-5200-340369.819.6390-4404.4-5.48.8-1.3

115-12554-64225-245115-1256.9-13

295-3905.9-8.849-5949-5918-25883.9-4.9

84-7

4.9-6.40.4-0.655.0-5.50.3-0.520.7-34.53.71240-450.45-0.550.9-1.3

12-135.5-6.523-2512-130.7-1.3

30-400.6-0.95-65-61.8-2.590.4-0.5

Tighten fully, turn back by 180°, tightenagain to 39 (4), then turn back by 20°and stake

Tighten to 115 (12) and stake at 2 point

Power

steering

oil tank

Probable cause Hard steering

Steering linkage defective

Front axle defective

Other troubles Power steering gear mechanism defective

Steering linkage defective

Front axle defective Other troubles

Thrust bearing damage

Ball of ball screw worn

Low fluid level in oil tank Air in oil circuit not completely bled Improper fluid viscosity

Trouble in power steering gear system Incorrect pipe connections

Defective oil pump (or malfunction) Flow control valve in faulty operation Universal joint abnormally worn, damaged or poorly lubricated

Deformed link King pin poorly lubricated Poor front wheel alignments(toe-in, camber, caster) Front wheel tires underinflated

Thrust bearing damaged Cargo and passengers are unevenly loaded in the front.

Worn rack and gear in ball screw unit

Worn bearing in sector shaft Worn ball in ball screw

Loose power steering gear mounting bolts Air trapped and air not completely bled

Looseness in universal joint

Looseness in drag link ball stud

Looseness in tie rod end ball stud Worn wheel hub bearing

Worn king pin or bushing Uneven brake application

Repair or replace Correct

Replace steering shaft assembly or apply grease Replace link

Apply grease Correct front wheel alignments

In flate as specified value Replace

Disperse the load evenly Replace screw and housing sector shaft

Replace bearing Replace screw and housing sector shaft

Tighten to the specified torque Add fluid, retighten all parts, and bleed air

Pack with grease If the problem still persists, replace steering shaft assembly Replace knuckle arm, pitman arm or drag link

Replace tie rod end Replace

Replace Readjust or replace lining

TROUBLESHOOTING

Steering wheel is off-center Power steering gear defective Broken leaf spring

Uneven brake application Right and left tires unevenly inflated Right and left tires greatly different in the degree of wear

Right and left tires different in axial distance Bent rear axle housing

Excessive clearance between king pin and bushing Worn or deteriorated wheel hub bearing

Improper wheel alignment (particularly camber and caster) Looseness in knuckle arm or tie rod ball stud

Excessively uneven tire pressure Knuckle arm, tie rod arm, backing plate and nuckle, etc Improperly tightened

U-bolt, nut, etc of front spring loose Lateral and radial runouts of front tires, and ncorrect static and dynamic balance Improper play in ball screw unit and sector shaft Worn thrust bearing

Defective power steering booster Looseness in ball stud of drag link

Worn sector shaft and bearing Worn ball and groove in ball screw

Excessive runout of propeller shaft Reduction pinion and gear damaged and in poor tooth contact

Excessive tire runout

Correct Replace Replace Replace king pin or bushing Correct

Correct or replace Replace

Repair Inflate properly Replace tires

Correct axial distance Replace axle housing Replace king pin or bushing Replace

Correct wheel alignment

Replace knuckle arm or tie rod end

Adjust tire pressure Tighten to specified torque

Tighten to specified torque Correct wheel balance

Adjust Replace Correct or replace Replace knuckle arm, pitman arm or drag link Replace sector shaft and bearing Replace screw and housing assembly

Correct or replace Replace pinion and gear

or correct tooth contact Repair or replace

Front axle steering system defective

Other troubles

Front axle assembly defective

Power steering system defective

Other troubles

Probable cause

Adjust stub shaft rotating torque

Check and correct hydraulic circuit or replace screw and housing assembly

Bleed air and then add fluid

Check and correct valve or replace screw and housing assembly

Correct or replace oil pump Correct or replace piping Pack joints with grease Adjust to the specified air pressure Measure wheel alignments.

If incorrect, adjust to the specified value

Correct or replace Apply grease to king pin Replace screw and housing assembly

Replace with the specified hydraulic fluid

Low pressure due to fluid leaks

Valve malfunctioning

Piston damaged or foreign substance trapped

Power steering gear system defective

Power steering gear

defective

Probable cause

TROUBLESHOOTING

Rack mesh torque out of adjustment

Clogged hydraulic circuit

Air trapped due to low fluid level

Valve malfunctioning

Defective oil pump Clogged hydraulic piping Insufficient grease in steering linkage joints Insufficient front tire inflation pressure Incorrect front wheel alignments

King pin thrust bearing damage King pin short of grease

Valve and roll edge damaged or control seal ring or O-ring damaged

Improper fluid in power steering system

ront wheels out of balance

Worn drag link or tie rod end ball joint

Worn king pin and king pin bushing

Rack torque out of adjustment Clogged hydraulic circuit

Clogged hydraulic piping Front wheel alignment off

Adjust to specified pressure Measure wheel alignment.

If incorrect, adjust to specified value

Rebalance with wheel balancer

or replace tires or wheels Replace drag link assembly or tie rod end

Disassembly and replace if defective

Adjust stub shaft torque Check and correct circuit or replace screw and housing assembly

Correct or replace piping Measure wheel alignment If in- correct, adjust to specified value Adjust steering wheel play with adjusting screw of replace sector shaft

Replace screw and housing assembly

Check fluid level and hose clip, bleed air, or replace oil pump

Replace oil pump Retighten to specified torque Replace oil pump

Disassemble, check, and correct,

or replace defective parts Correct or replace hose or pipe

Problems not in power steering

Power steering Wheel defective

Probable cause

Worn sector shaft gear

Damaged or worn stub shaft serrations

Air in oil pump

Seizure of parts in oil pump Seizure of parts in oil pump Loose pump bracket mounting bolts and nuts Defective pump

Maximum generated hydraulic pressure insufficient due to defective oil pump

Hydraulic pressure generated during idling is excessively high due to clogged hydraulic line

The oil pump produces some howling sound which is not an indication

of any functional problem(particularly when turning the steering wheel while the vehicle in standstill)

• Worn front wheel bearings

• Mounted or jointed parts loose

• Incorrect pitman arm mounting angle

• Knuckle stopper bolt out of adjustment

• Fluid leaks from steering gear

• Fluid leaks from power steering gear

• Defective oil pump housing

• Defective gasket, oil seal

• Loose bolts

• Fluid leaks from oil tank due to overfilling

• Fluid leaks from oil tank due to trapped air

• Improperly welded pipes

• Loose hydraulic piping and connections

Replace Retighten to specified torque and replace detective parts Mount at correct position Using turning radius gauge, adjust clockwise and counter- clockwise steering angles with knuckle stopper bolts

Retighten leaky parts to fied torque or replace

speci-O-ring, seals, etc.

Retighten leaky parts to fied torque or replace

speci-O-ring, seals, etc.

Disassemble, check and replace

if defective Disassemble, check and replace

if defective Retighten to specified torque Adjust to specified level

Bleed air and adjust to specified level

Knuckle arm 200-340 Nm

(20.7~34.5 kgf·m)

78 - 107.8 Nm (8~11 kgf·m)

12.7 - 22 Nm (1.3~1.5 kgf·m)

78 - 107.8 Nm (8.0~11.0kgf·m)

78 Nm (8 kgf·m)

ECYST06A

1 Disconnect the battery (-) terminal.

2 Detach the column cover

3 Remove the all starter switch connector and cable band

4 Remove the combination switch connector

5 Insert key and turn to “ON” position

Remove the engine stop cable from starter switch

Multi-function switch Connector Column cover Starter switch Connector

6 Remove the starter switch with upper and low shaft assembly

as following

1) Before removal, fix the steering wheel not to turn and mark

an mating mark on spline shaft and spline tube

2) Remove the dust cover from the end of column and

re-move the support attaching bolt

3) Remove the lever and clutch set attaching bolt

4) Pull the upper and lower shaft assembly up and remove

7 Support the column end with vice

8 Remove the starter switch by inserting a twist off bolt

1) Drill a hole of 5.5~6.0mm diameter and 10~15mm depth

on bolt head for twist off

2) Insert a screw extractor and turn counter clockwise

direc-tion to extract the bolt

3) Remove the starter switch from steering column

Upper and lower shaft assembly Lever and clutch set attaching bolt Column and attaching bolt Dust cover

Spline shaft Spline tube

Lower cover

Installation

1 Tighten a new twist off bolt to 12.7~14.7 Nm (1.3~1.5kgf·m)

and extract the twist off bolt head

2 Inspect the function of steering lock operation after installation

3 Installation is the reverse procedure of removal

Steering wheel puller

2 Remove the wheel using a steering wheel puller

Mark an mating mark for reassembly

MA560210

Disassembly, Inspection and Adjustment

Disassembly

1 Steering upper shaft assembly

2 Spline shaft assemmbly

8 Spline tube assembly

Joint play in rotating direction

NV less than 15'

Axial play of steering shaft to column

NV 0.2mm or less

Joint play in rotating direction

NV less than 15' in angle

Spline shaft joint play in rotating direction

NV than 15' in angle

* Be sure make an mating mark at each joint before disassembly.

Power steering booster

Steering Shaft

Removal

1 Detach the dust cover from column end and remove the

steer-ing cover attachsteer-ing bolt

2 Make an align mark on steering shaft joint, power steering

booster, and stub shaft Then tightly tighten the steering lock

lever

3 Remove the link and steering shaft attaching bolt of bracket

4 Remove the steering shaft joint attaching bolt

5 Remove the steering shaft assembly from stub shaft with

in-stalled starter switch

Steering upper shaft attaching bolt

Locker lever

Link and steering shaft attaching bolt of bracket

Cyline shaft assembly

Steering cover mounting bolt

Dust cover Mating

5 6 7 8 SERVICE PROCEDURE

Mating mark

Integral power steering gear

Reassembly

Apply grease

Section A-A

48-62.7 Nm (4.9-6.4 kgf·m)

78-4Nm (8 kgf·m)

3.9-6.4 Nm (0.4-0.65 kgf·m)

Reassembly sequence

7 →6→5→ 2 →1→4→3

Steering shaft assemmbly

Spline tube assembly

MA560250

Matching mark

When connecting the steering shaft assembly to spline tube

assem-bly, align the mating mark and let the yoke surface to be the same

direction

Fix the 4 points of circle

When assembling, the yoke surface should

be the same direction

6

A

2.9-4.9 Nm (0.3-0.5 kgf·m)

6 7

8

9 10 11

11 12

12 13

14

15 16

17

18

19 20

21 22

11 12 4 3 2 1

Apply grease on sliding surface

8.8-13.7 Nm (0.9-1.4 kgf·m)

MA560280

1 Tighten the lock lever nut to 24 to 26 Nm (2.4 to 2.7 kgf·m)

Then, install the lock lever within the range "L" (72 to 94 mm)

so that the lock lever operating angle falls within 60° and 70°

Next, secure the lock lever with the plain washer and lock bolt

NOTE:

• Before tightening the lock lever nut, apply grease to

bolt threads, lock lever nut serrations, and the sliding

surfaces marked with *.

• Make sure that the clutch sliding surface is free from

grease.

2 With the lock lever pulled up to FREE position, check if the lock

lever nut is loosened and the lever and clutch set can move

smoothly up and down or forward and backward

3 Check to ensure that when the lock lever is in SET position, the

lock lever nut is tightened and lever and clutch set and clutch

are securely fixed

Washer and support set Spring

Lever and clutch set

Free position Set position

Reassembly

33.3-49 Nm 93.4-5.0 kgf·m)

13 14

Steering Linkage

Drag Link

1 Removal

Straighten the end of split pin of the drag link, pinch the split pin

head with pliers and remove the split pin, remove the nut, then

remove the drag link

CAUTION:

• Do not reuse the split pin once removed.

2 Disassembly

NOTE :

• Do not disassemble the drag link as it is nonmaintainable.

3 Inspection of ball stud

1) Move the ball stud section up and down and right and left

to check for any excessive play

2) Coat the shaded area in the ball stud section with grease

4 Installation of dust cover

Fit the dust cover over the end and pinch them between the

special tools, dust cover installer and end holder Using a vise,

press-fit the dust cover until the reinforcement ring is held

tight-up against the end Check the dust cover if evenly fitted

5 Fit the dust cover in drag link flute and fill dust cover with grease

Dust cover

Drag link

JJR56-023

Shaded area Drag link

Ball stud section

Ball section

JJR56-024

Dust cover installer Coat lips with grease Apply grease (molybdenum desulfide base grease)

Reinforcement ring End holder

Reinforcement

ring Dust cover

End

SERVICE PROCEDURE

ECYST03A

<Pitman arm side>

<Slave lever side>

<Knuckle side>

1st drag link Pitman arm

Nut Split pin

2nd drag link

Slave lever

Nut 1st drag link

Split pin

Nut Knuckle arm 2nd drag link

6 Installation

Torque the nut to specification and fit a new split pin into position

7 After installation, check and adjust toe-in

ECYST03A

<Pitman arm side>

<Slave lever side>

<Knuckle side>

1st drag link Pitman arm

Nut Split pin

2nd drag link

Slave lever

Nut 1st drag link

Split pin

Nut Knuckle arm 2nd drag link