Great Wall Pegasus (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.

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

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)N
m

(b) Connect the bugle wire;

(c

 Mount the bugle cap.

Steering System

 Steering Column

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

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)N
m(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

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

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.

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.

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.

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

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

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

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

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)

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.

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.