Steering system

Section I General structure of HOWO steering system

I. Configuration of power steering and steering control device

Figure 1 Configuration sketch of hydraulic power steering and steering control device

1. Steering wheel 2. Return ring 3. Contact ring 4. Ignition lock assembly 5 10. Steering column cover 6.
Steering column 7 steering column cover mounting support 8. Steering column sleeve 9. Spring 10. Wiring
harness mounting bracket 12. Steering column mounting support 13. Steering column guide sleeve 14. cardan
joint 15. adjusting handle 16. stop screw 17. Steering telescopic shaft 18.Steering column casing 19.
Bushing 20. steering gear 21. High pressure pipe 22. Steering power-assisted vane pump 23. Oil inlet tube
24 steering oil tank 25. Steering oil tank mounting bracket 26. Steering rocker arm 27. Steering gear bracket

The steering system is consisted of steering wheel, steering column, cardan joint and steering
column.The steering wheel is φ450mm.

II. Several instruction drawings of HOWO model typical hydraulic power

steering system pipelines
Figure 2. Hydraulic power steering system instruction drawing of 4X2、6X4 single steering front axle model etc.

1. Power steering gear 2. High pressure pipe 3 Steering oil pump 4. Steering oil tank 5. Oil inlet tube 6. Oil return
pipe

Figure 3. Hydraulic power steering system instruction drawing of 6×2 model with supporting shaft that may rise

1. Power steering gear 2. 4. 7. 8. 9. high pressure pipe 3.steering oil pump 5. Steering oil tank 6.
Controlling valve for support shaft rising 10. Oil inlet tube 11. Oil return pipe

Figure 4. Hydraulic power steering system instruction drawing of 8×4 double steering front axle model etc.

1. Power steering gear 2. 4. 6. high pressure pipe 3.steering oil pump 5. Steering oil tank 7. Active cylinder
8. Oil inlet tube 9. Oil return pipe

Figure 2, Figure 3, Figure 4 are hydraulic power steering system instruction drawing of several
typical HOWO model. Figure 2. is Hydraulic power steering system instruction drawing of 4X2、
6X4 single steering front axle model etc, with simple structure. Figure 3. is hydraulic power
steering system instruction drawing of 6X2 model with supporting shaft that may rise, the steering
oil pump drives not only the steering but also the auxiliary cylinder for lifting shaft, the pipe 7, 8
in the figure are oil in and out openings connected to lifting shaft auxiliary cylinder. Figure 4. is
hydraulic power steering system instruction drawing of 8X4 double steering front axle model.

Section II Steering system primary assembly

I. Power steering gear
In the system the ZF8098 integral hydraulic power steering gear from ZF corporation of Germany
is employed, the control valve is rotary valve, with variable gear ration and self-regulating
hydraulic steering limit valve. With inside pressure safety valve. The setting pressure is 170bar,
gear ratio is 22.2～26.2
1. Steering gears technical parameters
Model ZF8098 ZF8095

Rated front axle load(Kg) 6500 8000 6000

Max. output torque(Nm) (4954～5829) 5717～6726 4356-5146

Max. pressure(Mpa) 18.3 18

oil pump flow rate(L/min) 16～20 16

Gear ratio 22.2～26.2 15.7～18.5

steering wheel turns 6.2 4.4

Rocker arm pivot angle 94° 94°

weight(Kg) 41 27
2. Steering gear operation principle
(1) ZF8098 steering gear property
ZF8098 steering gear is a kind of ball-nut type steering gear, in which always there are two stage
transmission, the first stage is screw and nut transmission, the second is rack and sector
transmission. Usually used for all kinds of light and medium truck, also for some light off-road
vehicle.
With screw transmission, the force is passed to steering nut via the ball, driving the nut travel
axially. Meanwhile, by the action of friction torque from screw, nut and balls, all the balls rolling
in the screw channel, making the “balls flow”.

Steering nut
Ball

bearing Sector
Rocker arm shaft
Single lip seal

Retaining ring
double lip seal
Steering screw stem
Retaining ring
Snap spring
Steering gear housing
Snap spring
Housing end cover

Figure 5. Beijing Cherokee steering gear Figure 6 Ball-nut type steering gear operation
principle
(2) ZF8098 steering gear structure
The ZF8098 steering gear is composed of controlling valve, power cylinder and complete manual
steering system.The pressure oil for steering gear is supplied with steering pump driven by engine,
the oil tank receives low pressure oil from the steering gear, and supply oil to steering pump.
The cylinder is composed of housing(A) and piston (B), the piston turn the rotating of steering
axle(C) into linear motion, and drive rocker arm sector shaft(F)turn.
The piston(B) and worm(D) move via the ball circuit, as the worm rotate, the ball enter the worm
surface in sequence, pass through the cycling tube, the balls may cycle on the worm.
The controlling valve is composed of rotary valve( C) and valve housing(D), there are 6 grooves
on their cylindrical surface.
The torsion rod(E) connected to rotary valve and valve housing via fix pin respectively, allows the
control valve in neutral position when the steering wheel kept still.
The safety valve(G) can limit unusual oil pressure in steering gear.
Oil charge valve(H) supplies oil to steering gear through oil return pipes as the steering gear
operating and the steering pump inactive,The variable gear ratio steering gear provides less gear
ratio than constant ratio steering gear, assuring steering lightness.For large steering angle, the
steering gives large gear ratio, thus provides the rocker arm sector shaft more powerful hydraulic
assist force.If the hydraulic power system failures, the steering force is smaller than that of
constant gear ratio.

(3) ZF8098 steering gear following assist operation principle

It is the control valve sectional view in the view, at two ends of the piston, the high pressure is
shown in red, and the low pressure is yellow.
J, K oil inlet gap L, M oil return gap N, O axial groove P oil return groove

As the torque passed from steering axle to valve housing, the torsion rod will generate elastic
torsion, which bring twisting force between turning valve and valve housing of control valve unit,
thus force the valve housing offset the original neutral position.
With steering wheel hold on
The torsion rod turn the control valve to neutral position. The oil enters into screw grooves of
valve housing through the oil channel on steering gear housing, passing through 3 even distributed
radial holes and reaching into the arch controlling channel of steering valve.
As the controlling groove on rotary valve aligned to that on valve housing, the oil enters the artic
axial groove(N and O) through the oil inlet gap(J and K), and then flows to one end or two ends of
the auxiliary piston through the axial oil channel.
As the control valve in neutral position, the oil reach both end of the piston, and pass through the 3
oil return grooves on rotary valve return to oil tank.
Turn right
As the steering wheel turned right, the force on piston left end is larger than other end, so the
piston move right and provides following power assistance.
As the control groove turns in clockwise direction, the oil inlet gap(K) open wide so that the oil
pass through, the other oil inlet gap(J) close, prevent the oil flowing into axial groove(O) on valve
housing. So the oil flows to the axial groove(N) on valve housing only from the oil inlet gap(K),
and through raceway to piston left end. The other oil inlet gap(J) is closed to prevent the oil
flowing return to oil tank and the pressure rising.
The oil at piston right end is discharged, passes the oil return gap(M) and oil return groove(P),
through the oil channel in rotary valve to oil tank.
Turn left
As the steering wheel turned left, the force on piston right end is larger than other end, so the
piston move left and provides following power assistance.
As the control groove turns in counter-clockwise direction, the oil passes through inlet gap(J) and
axial groove(O) to right end of piston. The oil at piston left end passes the raceway, oil return
gap(L) and oil return groove(P), through the oil channel in rotary valve to oil tank.
(4) Hydraulic steering limiter function

T right spool U left spool V piston right room W piston left room
X adjusting screw(RH) Y adjusting screw(LH)
The hydraulic limiter can prevent the steering gear from being turned to limitation by maximum
operation pressure, which can protect the steering gear and pump, as well as inhibiting too high oil
temperature.
Double action hydraulic steering limiter consists of two spools with spring, mounted on the piston
and protrudes from the piston.
As the piston moving right to limitation, the right spool(T) is pushed into piston by right adjusting
screw(X), and the left spool(U) is pushed into piston by oil pressure, the oil in piston left room,
which pressure is depressed by limiter valve hole, flows to the piston right room, then return to oil
tank. On the other hand, if the piston moves left, it is also like this.
Special hints:
With the hydraulic limiter open, the steering gear still can turn out, but as the hydraulic power
assistant reduce greatly, the steering torque on steering wheel must be larger, until to the steering
limitation.
▲ At both ends of the piston, the high pressure is red ,the low pressure is yellow, the decreased
pressure is brownish red
Hints: The steering control valves that controlling the oil flow by the relative motion of valve and
valve housing, called as rotary valve type control valve, as well as rotary valve for short.

Play Stop

Rotary valve structure and operation principle

II. Steering pump
ZF steering pump is a kind of vane hydraulic oil pump, specially designed for power steering to
supply pressure, with little moving parts( the drive shaft, rotor and vane), high accuracy axial
sealed matching surface, high efficiency, the optimum volume ratio.The oil flow rate from pump is
almost constant during the whole engine speed range.The structure shown as below:

703 Drive shaft 706 Ball bearing 708 Oil seal 709 Needle bearing 710 Casing 715 Location pin 718
Front thrust plate 721 Rotor unit 723 Rear thrust plate 726 Cover 729 Spool 730 Spring

III. Steering oil tank

The oil tank used to store, filtrating and cooling steering system oil.
The oil tank is produced by Tianxong auto components Co. Ltd of Hubei province, with oil filling
filter, and the filter element is located on the oil return inlet.Compared to the oil tank of STEYR
model, this tank has advantages as below: With improved cover and sealing rings, the matching of
cover and tank body is more powerful, which prevents the oil leaking efficiently; the oil filler,
ventilation valve, oil stick are all located on the cover, allowing a compacted structure, saving
more space benefit for the overall vehicle layout, meanwhile, the checking of oil level and oil
filling may conducted simultaneously, provides more simple operation.
Maximum flow rate 40L/min;
1. Oil tank volume 2.9L;
2. The volume is 2.4L up to mark ”MAX”;
3. The zinc electroplating chromate conversion
coating on inner and outer surface is not more
than 8m, according to specification of
QZZ3004;
4. Operation temperature range is -40°C ～
+100°C;
MAX 5. The filter fineness is 20m;
MIN 6. The filter safety opening pressure is 0.1 ～
0.18MPa;
7. The other requirements should meet the
JB5089-91《Technical requirements of oil filter
paper element 》;
8. the filter is 80 mesh per square inch;
9. All the fittings should be plug up to prevent
others from entering the oil tank.

Power steering pump structure instruction drawing

1. oil tank assembly 2.filter element lower gasket 3. grating plate 4. filter assembly 5. bolt to filter element
6. “O” ring 7. spring mount 8. pressing spring 9. colatorium assembly 10. washer 11.oil tank cover seal
ring 12. oil tank cover 13. oil filler support 14. support seal ring 15. oil filler cover assembly with oil stick
16. oil filler cover seal ring
IV. Pressure oil pipe, oil return pipe and oil inlet pipe
These parts form the power steering hydraulic system, make the oil flow and cool it.
The oil pipes distribution of HOWO model shown as below:

4×2、6×4 etc. single steering axle model 6×2、8×4 etc. double steering axle model

V. Steering tie rod

Steering lateral rod, steering drag rod structure are as below:It is left and right turn screws
respectively at two ends of the rod, which gives facilities for assembling and adjusting.

Steering tie rod and ball joint structure

1. cover 2. pressing spring 3. upper ball support 4. lower ball support 5 steel wire lock ring 6. lag 7. plastic cone
sleeve 8. steel wire lock ring 9. ball pin 10. hex slotted nut 11.cottor pin 12. steering tie rod joint 13. lubricating
nipple 14. hex nut 15.clamp 16. Hexagon headed bolt 17. tie rod
Section Ⅲ Maintenance of Steering System

Ⅰ. Check the hydraulic oil level in the oil tank

Firstly, clean the oil tank and its perimeters to avoid ingress of contamination. Please always not
the scale on the oil stick when checking the oil level.
▲ When the engine is not started, the oil level must reach the upper limit of dip stick.
▲ When engine is running, the oil level shall be in the middle of the upper and lower scale of dip
stick. When the engine stops, the oil level will rise 1 - 2cm. If the oil level rises by more than 2cm,
the air in the steering system must be exhausted.
Ⅱ. Replace hydraulic oil
▲ For new vehicles, the hydraulic oil must be replaced after running 2,500km. Meanwhile, the
filter element in the oil tank must be cleaned. In the subsequent operations, the hydraulic oil and
filter element must be replaced every 20,000km (or half a year). In addition, the discharged oil
shall not be reused.
▲ When changing the oil, always note the cleanness so as to prevent ingress of dirty or foreign
matters into the oil system.
Ⅲ. Oil discharging requirement
1. Jack up the front axle and then loosen the oil inlet pipe and oil return pipe on the steering gear.
2. Start the engine and keep it running for a short period of time (Max. 10 seconds), and aspirate
the oil from oil pump and oil tank.
3. Store the discharged oil in a vessel.
4. Connect oil inlet pipe and oil return pipe again.
5. Open the bolt of the oil return inlet located at the bottom of steering gear.
6. Turn the steering wheel repeatedly till no oil can be discharged.
▲ Note: there will be some residual oil in the steering gear. When it is required to completely
drain oil in the steering gear due to the oil product problem, the steering gear shall be removed
from the vehicle and shall be sent to the ZF service center for dismantlement and overhaul.
Ⅳ. Keep the hydraulic oil clean
Monthly check oil level, and regularly check the cleanness of hydraulic oil.
Ⅴ. Check the rotatable parts
During the first maintenance, always check the clearance of rotatable parts, for example, steering
transverse and straight pull rod joints. If the clearance is too large, please replace the relating
rotatable part. During the first maintenance, the relevant locations shall be applied with lubricating
grease.
★ 1: Tightening torque of steering system
Tightening torque of clamping bolt of steering gear bracket 280N.m
Tightening torque of clamping bolt of steering gear 520N.m
Tightening torque of clamping nut of steering wheel 70~80N.m
Tightening torque of cross universal joint of steering gear telescopic shaft
48＋5N.m
Tightening torque of clamping nut of steering rocker arm 570+57N.m(8098)/520
+52N.m(8095)
Tightening torque of steering crosswise/ straight pull rod ball pin nut
M20×1.5: 210-230N.m
M24×1.5: 250-280N.m
Tightening torque of steering crosswise/ straight pull rod split collets nut 70-90 N.m

★ 2: Temperature requirement for steering system oil

▲ If the vehicle remains stationery and engine runs at maximum speed, the oil temperature shoul d
be basically stable and less than 100℃.
▲ The vehicle runs in urban area, countryside and highway, oil temperature should be basically
stable and less than 80℃.
▲ Push the throttle forward and allow the engine run at maximum rotation speed. Under 4- 6km /
h traveling speed, the vehicle steering wheel reaches dead angle, after completion of eight shape
traveling, the oil temperature shall not be higher than 120℃.
▲ Measure the temperature at a location close to the bottom in the oil tank.
▲ Ambient temperature: 15 - 25℃

★ 3: hydraulic oil grade: ATFⅢ

★ 4: replacement method of hydraulic oil

(1) Raise the front axle up.
(2) Open the tank cap; remove the oil return pipe on the steering gear.
(3) Start the engine, keep it idling for 10 seconds, simultaneously, turn the steering wheel from the
right to the left to the limit position for several times, so as to discharge the oil in the oil tank,
booster pump and steering gear.
(4) Tighten the oil return pipe again (keep it clean to prevent dirt or foreign matter entering into
the oil system), clean the oil tank, fueling filter and filter elements. It is recommended to replace
the filter element when change oil every time.
(5) After topping up the oil tank by hydraulic oil, allow the engine idling, repeatedly turn the
steering wheel, meanwhile, constantly supplement oil till the oil level does not drop or no bubble
appears, by this time, the oil level shall be within the scale of oil stick.
Note: always use hydraulic oil that meets specific requirement for oil replacement

Section Ⅳ Common Malfunctions and Troubleshooting Methods for

Steering System

The power steering system basically suffers from two common malfunctions: heavy steering
and misalignment.
If steering is heavy, firstly check whether the connection of steering mechanism (including
transverse and straight pull rod, steering knuckle, etc.) is too tight, or the tire pressure is too low,
or steering drive is too tight, especially check whether steering knuckle king pin and bushing are
worn, scratched, burnt, short for lubrication. And check whether the thrust bearing of king pin is
short for lubrication or damaged. And then check whether steering booster system is short of oil or
has air inside per the above described procedure, and finally check steering booster pump and
steering gear. The approach can quickly and precisely identify the malfunction for heavy steering.
If the steering booster system is short of oil and has air inside, except for heavy steering
problem, the steering is also accompanied with "peep" noise.
If the heavy steering is caused by malfunction of steering booster pump, firstly check the
safety valve and flow control valve of the booster pump. Poor sealing or weakened spring force of
these two valves will result in low overflow pressure, and consequently, the oil pressure in booster
system can not meet specific requirement. If these two valves are normal, it is required to perform
overhaul inspection. If found pump blade or rotor internal cavity is scratched, the steering oil
pump shall be replaced accordingly. And this problem is mainly caused by dirty oil.
If internal leakage occurs to the steering gear and the oil pressure in booster pump can not be
established, always perform overhaul inspection to the steering gear and replace the sealing
elements of rack piston. If the piston or cylinder surface of the piston inside the cylinder block is
severely scuffed, always replace the steering gear assembly. Scuffing of cylinder bore is mainly
caused by dirty oil. Therefore, special attention shall be given to the cleanliness and sealing of the
booster system.
Ⅰ. Heavy steering operation
Cause Troubleshooting method

1. Oil shortage in the tank, or air presence Fill to standard height and exhaust air
in the oil tank

2. Oil leak in power steering system Find out oil leak position, tighten connector or replace
damaged mechanical elements

3. Distribution valve damaged Replace damaged mechanical elements

4. Distribution valve torsion bar failure Replace

5. Oil deficient of steering oil pump, or Check and adjust oil pump, replace damaged
without oil supply mechanical elements

6. Steering oil pump drive parts damaged Replace damaged mechanical elements

7. Steering gear damaged Check and replace damaged steering gear

8. Steering gear mechanical elements fit Check various mechanical elements of steering gear
clearance too small, lubricant starvation item by item, if they are too tight, please adjust and fill
in various movement joints lubrication oil

9. Front wheel alignment incorrect or Check front wheel alignment, readjust or repair
parts distorted distorted mechanical elements

10. Steering knuckle bushing or thrust Replace bushing or thrust block

block damaged

11. Tire pressure too low Inflate to standard value

12. Insufficient lubrication or burning of Lubricate steering column pin or perform overhaul
steering knuckle inspection

Ⅱ. Steering swing or misalignment

Cause Troubleshooting method

1. Distribution valve torsion bar elasticity weakened Replace

or damage, or inappropriate adjustment during
installation

2. Inappropriate adjustment of steering gear Check and adjust steering gear auxiliary
auxiliary transmission or excessive worn clearance transmission, replace mechanical elements
suffered from excessive wear

3. The wheel hub bearing and steering gear ball joint Readjust and replace mechanical element
are loosened suffered from excessive wear

4. Front wheel alignment incorrect Check front wheel alignment, adjust it if

necessary
5. Steering gear bracket and steering gear Tighten anchor bolt to standard value
hold-down nut loosened

6. Right and left tire pressure uneven Inflate to standard value

7. Tire or wheel hub unbalanced Rebalance, replace if necessary

Ⅲ. Uneven left and right steering:

Cause Troubleshooting method

1. Torsion bar of distribution valve deviates from the Recheck and adjust
middle position

2. Uneven scratch or wear of rotary disk valve plate or Replace

valve body internal surface

3. Inappropriate adjustment of steering limiting valve Readjust steering limiting valve

at one side