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Maintenance Manual
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Project N125
Transmission System Maintenance Manual
Version:1.0
Edited by:
Proofread by:
Reviewed by:
Standardized
by:
Countersigned
by:
Approved by:
Anhui Jianghuai Automobile Co., Ltd.
Year Month Day
No. N 125-NAM - PV - DP -
G9-18
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steering system
1.Overview ………………………………………………………………………
2.Main data and
specification ……………………………………………………………
3.decomposition, assembly, inspection,
reassembly …………………………………………………
4.Malfunction
diagnosing ……………………………………………………………………
4.Frequent Malfunction elimination
method …………………………………………………………
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1.Overview
Automobile power steering system is made up of steering device, power steering pipe line
device. steering device is the executive module of hydraulic power steering system; steering
device is made up of steering wheel assembly, steering column assembly, steering shaft&driving
universal joint, steering column under shield, commutator assembly, commutator transmission
shaft, steering device with tie rod assembly and so on.
steering device
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power steering pipe line device is made up of steering pump, power steering oil reservoir
assembly, oil pump inlet oil pipe assembly, oil pump outlet oil pipe assembly, powering steering
oil inlet pipe assembly and so on. steering oil pimp, with engine together, is to provide hydraulic
power source to system; steering oiler has fuctions of storage, cooling and filtering the oil.
power steering pipe line device
2.Main data and specification
steering wheel diameter (mm) 390
steering turns 3.19
cylinder diameter 50mm
working oil pressure ≥8.85Mpa
working conditions temperature -40℃ ~135℃
Pump rated flow 7.5L/min
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3.decomposition, inspection, assembly
decomposition
steering device
①horn button ②steering wheel nut and spring washer ③steering wheel ④steering column assembly
⑤steering shaft&driving universal joint ⑥strapping tape ⑦steering column under shield
⑧commutator assembly ⑨commutator transmission shaft ⑩steering device with tie rod assembly
11
2
3
4
5
6
7
8
9
10
1
2
3
5
4
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power steering pipe line device
①power steering pump ②power steering oil reservoir ③oil pump outlet oil pipe ④oil pump inlet
oil pipe ⑤powering steering oil inlet pipe
disassembly and reassembly
steering wheel
1.pull out the horn button
2.Remove steering wheel mounting nut with
sleeve and ratchet spanner, remove steering
wheel mounting spring washer
3.Remove steering wheel
combination switch involucrum
1.Remove combination switch under involucrum
2.Remove steering column under shield cover
assembly
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steering column assembly, steering
shaft&driving universal joint,
steering column under shield
1.Remove strapping tape with needle-nose
pliers
2.Remove under universal joint connecting bolt
3.Remove 4 upper universal joint connecting
bolts in turns.
4.Remove steering column
5.Remove middle, left, right bolts of steering
column under mounting shield in turns
5.Remove steering column under universal joint
mounting bolt
6.Remove steering column under mounting body
assembly
7.Remove steering column under mounting body
assembly.
steering column assembly
1.Remove steering shield strapping tape.
2.Remove 4 mounting bolts of steering column
with cocket wrench.
3.pull apart steering shield involucrum,
remove connecting bolt between steering column
and under shaft with sleeve
4.Remove steering column
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Steering column under shield +
steering shaft&driving universal
joint
1.Remove connecting bolt between steering
shaft&driving universal joint and commutator
assembly.
2.Remove 3 fixing bolts of steering column
under shield(on the floor)
3.Remove steering column under shield and
steering shaft&driving universal joint
together. Disassemble steering column under
shield+steering shaft&driving universal joint
4.Remove 3 connecting screw of steering column
under shield assembly, remove steering shield
body in turns
5.Mark with marker pen on steering
shaft&driving universal joint, disengage
assembly limit sleeve ， disassemble and
separate assembly upper&under semi-axis
6.Take out dustproof rubber sleeve , mounting
seat and gland of steering column under shield
assembly
Attention:
Disassembly steering shaft&driving universal
joint upper&under semi-axis and dustproof
sleeve, mark the position, aim at the position
when reassemble, in order to ensure stability
of device.
2
1
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commutator assembly, commutator
transmission shaft
1.Remove connecting bolt between steering
transmission shaft and steering device
2.Remove fixing nut between commutator and
frame, fixing bolt 1, fixing bolt 2, fixing
bolt 3.
3.Take out commutator and commutator
transmission shaft
commutator assembly
Remove 3 assembling bolts and nuts, take out
steering assembly.
3
1
2
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commutator transmission shaft
Remove 2 assembling bolts in turns, take out
commutator transmission shaft
steering device with tie rod assembly
1.Remove splitpin and hex slotted nut of
left&right steering joint, take out steering
tie rod ball and spigot
.
2.Disconnect steering pipe line
3.Remove 4 assembling bolts from sub-frame in
turns, take out mounting frame, rubber
mounting liner and steering device with tie rod
assembly parts.
power steering oil reservoir
1.Remove steering kettle front&rear
mounting bolt
2.Take out power steering oil reservoir
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power steering oiler tie-in
Remove hose clamps， remove oil pipe and oil
return line pipe（connect with power steering
oiler）
pipe clamp bolt
1.Remove the 2 bolts of pipe clamp beside power
steering oiler.
2.Remove the pipe clamp bolt of sub-frame with
ratchet spanner
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3.Remove the pipe clamp bolt beside power
steering
4.Remove the bolt connecting frame pipe clamp
of high-pressure oil tube
5.Remove the bolt of oil return line pipe clamp
as shown in the picture
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6.Remove the pipe clamp bolt of oil return line
pipe connecting frame
power steering oil pump tie-in
1.Remove high-pressure oil tube with
open spanner, remove high-pressure oil tube
tie-in (connect with power steering oil pump)
2.Remove hose clamps, remove inlet oil pipe
(connect with inlet oil pipe)
Steering device
1.bracket bushing assembly: remove
bracket and bushing in turns.
2.outer ball joint assembly: screw hex nut with
spanner, and then remove the outer ball joint.
3.gear shield and clamps: remove hex nut and
fixing gear shield clamps & monaural stepless,
withdraw from gear shield.
4.inner ball assembly: fix gear flat square,
screw inner ball joint assembly with spanner,
and remove inner ball joint assembly.
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5.adjusting mechanism: remove adjusting plug
screw, spring, gear fulcrum bearing, plug
cover and so on.
6.Valve assembly and accessories:screw bolt
and remove Valve assembly.
7.Limiting sleeve assembly: screw limting
sleeve assembly with auxiliary tool.
8.gear assembly: draw out gear plunger
assembly.
9.left&right pipe line assembly: remove
left&right pipe line assembly.
inspection and maintenance
If there is any wear and tear or error state after inspection, it shall need some necessary
proofread or parts replacement.
reassembly
reassembly sequence is on the contrary to disassembly sequence.
Project
Quanti
ty Tightening torque （N.m）
Steering wheel fixing nut 1 35～40
steering column mounting nut 2 18～22
steering column mounting bolt 2 18～25
connecting bolt between steering column and
under shaft 125～30
connecting bolt between under shaft and
power steering device 1 25～30
power steering device fixing bolt 4 90～110
connecting nut between steering tie rod end
and steering joint 2 50～60
oil pipe and bolt of fixing bracket 9 9～11
oiler bracket fixing bolt 3 18～22
oiler bracket fixing bolt 4 18～23
oiler bracket fixing bolt 5 18～24
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power steering pump bracket mounting bolt
Q14010100 1 50～60
power steering pump bracket mounting bolt
Q1461060 1 50～60
power steering pump bracket connecting bolt
3406742U2010 1 20～25
power steering pump bracket connecting bolt 1 22～30
power steering pump and high-pressure oil
tube connecting piercing bolt 1
57～63
4.
Malfunction diagnosing
：
frequent malfunction diagnosing sheet
malfuncti
on
malfunction
phenomenon
malfunction reason malfunction
elimination
oil leak
power steering
pump oil leak
power steering pump oil seal
damage
exchange power
steering pump oil
seal
oil leak of
pipe line and
oiler
oil pipe high temperature
ageing, faulty union and so
on
exchange oiler and
oil pipe
damage
power steering
pump damage
power steering pump oil seal
damage
exchange power
steering pump oil
seal
power steering pump shell
damage
exchange power
steering pump
hairpin
The system
pressure is low
spool valves obstruction
open-close
remove spool valves,
grinding and
cleaning to make it
slide freely
power steering
pump flow
inadequately
spool valves obstruction
open-close, spring lose
efficacy
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internal
pressure
relief
steering
device has no
pressure
spool valves obstruction
open-close and parts of
steering pump wear and tear
severely.
Check the safty
valve/pressure
relief valve,
exchange oil and
steering pump.
power steering
device
power steering device
internal pressure relief
Check the safty
valve/pressure
relief valve,
exchange oil and
power steering
device.
oil seal inside of the power
steering device lose
efficacy
exchange oil seal or
power steering
device
open the steering limitator
too early
adjust steering
limitator
noise
power steering
pump abnormal
sound
suction air
steering system
exhaust
driving medium inside of the
power steering pump damages
exchange power
steering pump
noise inside of
oil pipe/power
steering oiler
The oil pipe expand the noise
of steering pump and liquid
which is not absorbed in oil
pipe, thus lead to too much
noise in system.
This problem can only
be solved from
optimizing power
steering matching
aspect. Exchanging
any part alone
couldn't find the
solution, only if
adding resonant tube
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inside of oil pipe.
the
direction
of
sedimenta
tion
Left and right
direction are
both
a little heavy
oil level of power steering
oiler is too low
add oli
suction air eliminate air
steering column or steering
linkage obstruction
open-close
adjust linkage
Filter pf power steering
oiler block up
clean and exchange
power steering oiler
and steering oil
power steering pump damage
Check the output
operating pressure
of hydraulic
pressure pump with
piezometer, check
out whether the pump
is damaged; Further
inspections of
hydraulic pressure
oil filter and pipe
should be made if the
pressure or flow of
power steering is not
enough.
power steering device is not
good
Check out if the
power steering
device is damaged
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Check out if the triangle
belt skids or is too lose;
Check anastomosis of gear
transmission if the gear
transmits.
inspection and
adjustment of parts
quick steering
with idling
speed is quite
heavy
There is air in system
check and repair of
leak/exhaust air
inner pressure of power
system is a little low, fuel
delivery of power steering
pump is not enough; driving
belt is lax and skids.
overflow valve
misalignment; pressure
tubing will be deformed too
much under the influence of
high pressure oil, which
will lead to pressure
hysteresis and air entering
hydraulic system.
Check, adjust and
repair the entire
steering system
internal of power steering
pump wear and tear
exchange power
steering pump and
clean the entire
steering device
power
steering
liquid is
abnormal
power steering
liquid
produces
emulsion foam
There is air in the steering
system.
Exhaust air, check
out if there is leak
of oil and then solve
the problem.
There is liquid leakage in Check power steering
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steering system. oiler and pour oil
into oiler
deflecti
on driving
automobile
deflection
driving
steering round ball joint
loosen or front wheel
improper positioning
adjust front wheel
positioning,
steering round ball
steering gear connection
twist and deform or wear and
tear too much
pour steering liquid
and exhaust air
tightness of gear inside of
power steering device lose
balance
adjust or repair
tightness of power
steering device gear
returnability of steering
wheel is not good, steering
wheel shakes or hacking
check and adjust the
connecting parts of
steering system
according to
regulations
