RANE TRW STEERING

SYSTEMS LIMITED

Customer Support

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
H
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BENEFITS OF
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POWER
STEERING
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
H BENEFITS OF POWER STEERING
O
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E 15 mkg

STEERING EFFORTS AT PARKING

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3 mkg
2 mkg
1 mkg

HCV CAR HCV CAR

MANUAL POWER
STEERING STEERING

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EFFORTLESS STEERING
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H BENEFITS OF POWER STEERING
O
M LOCK TO LOCK MANUAL STEERING
E TOTAL TURNS 6 TO 7

LOCK TO LOCK POWER STEERING

TOTAL TURNS 3 TO 4

40

OUTPUT ANGLE (DEG)

30

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20

10

7 6 5 4 3 2 1 0 1 2 3 4 5 6 7

INPUT TURNS
LH TURN RH TURN
SAP
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QUICK RESPONSE

H BENEFITS OF POWER STEERING
O
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Vehicle fitted with Vehicle fitted with

Manual Steering Power Steering
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ABSORBS ROAD SHOCKS


H BENEFITS OF POWER STEERING
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E

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GREATER SAFETY AND
PRECISE CONTROL
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H
SYSTEM LAYOUT OF
O POWER STEERING
M
E
Power Steering
Reservoir
Retur
n
Line
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Suction
Line su re
s
Pre ne
Li

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Power Steering
Pump Power Steering
FI Gear
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H
DESIGN OF HFB 64 GEAR
O
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E FULLY INTEGRAL GEAR CONSISTS OF :
A MANUAL STEERING MECHANISM
- Re-Circulating Ball & Nut type
- Smooth & Efficient

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HYDRAULIC POWER CYLINDER & PISTON
- With Proprietary Seal
- Leak Proof & Smooth Action
A HYDRAULIC CONTROL VALVE
- Rotary Type
- Compact & Direct Acting
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- ALL PUT TOGETHER IN A SINGLE
COMPACT PACKAGE
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H HFB 64 GEAR
O CROSS SECTION
M
E

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
H HFB 64 GEAR
O CROSS SECTION (1)
M
E

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
H HFB 64 GEAR
O CROSS SECTION (2)
M
E

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
H HFB 64 GEAR
O OPERATION
M
E When the driver turns the steering wheel, he activates the
steering gear input shaft. A torsion bar pinned at its one end to
the input shaft and the other end to the worm shaft, turns with the
input shaft and exerts a rotational force on the worm shaft. In
response to this rotational force the worm shaft acting through
the re-circulating ball mechanism, tries to move the rack piston
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axially through the gear housing cylinder bore.

The rack piston’s axial movement is resisted by its engagement

to the sector shaft, which is connected by linkage to the steered
wheels. Because of this resistance, the torsion bar is twisted by
the input shaft, thereby actuating the control valve. Pressurised
fluid directed by the control valve assists in moving the rack
piston axially through the cylinder bore. The rack piston then
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turns the sector shaft to steer the vehicle.

H HFB 64 GEAR – CROSS SECTION
O OIL FLOW - NEUTRAL
M
E

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
H HFB 64 GEAR – CROSS SECTION
O ROTARY CONTROL VALVE - NEUTRAL
M
E

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
H HFB 64 GEAR – CROSS SECTION
O OIL FLOW - RIGHT TURN
M
E

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
H HFB 64 GEAR – CROSS SECTION
O ROTARY CONTROL VALVE – RIGHT TURN
M
E

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
H HFB 64 GEAR – CROSS SECTION
O OIL FLOW – LEFT TURN
M
E

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
H HFB 64 GEAR – CROSS SECTION
O ROTARY CONTROL VALVE – LEFT TURN
M
E

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
H HFB 64 GEAR – SHOCK ABSORBTION
O ROTARY CONTROL VALVE
M
E

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
H HFB 64 GEAR
O FUNCTION OF POPPET
M Function of Poppets :
E
HFB 64 gears are equipped with
two unloading valves, one at each
end of the rack piston. One valve
or the other depending on the
direction of turn will trip as the
steered wheels approach the axle
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stops (which must be set
according to manufacturers
specification).
Advantages of Poppets :

Reduces pressure in the gear

Reduces heat generated by the pump

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Reduce forces on the steering linkages

H HFB 64 GEAR
O SPECIFICATION
M
E  Maximum recommended steered axle weight for lock : 5,454 KGS
to lock static parking

 Torque Output at 90% efficiency : 2130 Nm at 1000 Psi (69 Ba

4260 Nm at 2002 Psi (138 B

 No. of Steering Wheel turns for drop arm movement : 5.4 max.

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 Recommended working travel : 45 deg of drop arm movem
side.

 Hydraulic Steering limiter : Adjustable to suit vehicle in

 Flow required for 1.5 steering wheel turns / second : 11.53 litres / minute

 Maximum operating pressure : 130 bar

 Steering gear ratio : 20.4 : 1

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 Approximate weight of steering gear (less droparm) : 35 Kgs.
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H
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RANE ADVANCED
VANE TYPE
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PUMP
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 RANE AVP PUMP SALIENT FEATURES
H
AVP PUMP : Advanced Vane Pump
O
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E Vane type pump
-Less Vibration and Noise
-Good Volumetric Efficiency

Wide Operating Speeds

-500 to 6000 RPM
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Wide Operating Temperature

- (-) 25 deg. Celsius to 100 deg. Celsius
Ball Bearing
- for Better Shaft Support
Powder Metal Internals
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- for Better Pump Performance

H AVP PUMP – FUNCTION
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 AVP PUMP
H
O OPERATION
M
The pump is driven by transmitting Power from the engine
E to the pump drive shaft by either a belt or gears thus
turning the rotor mounted on the spline of the drive shaft.

When the rotor turns, the ten vanes mounted in the rotor
slots are opened and pressed against the inner surface
of the cam ring by centrifugal force create the pumping
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action. The cartridge consists of cam, rotor and vanes.

The Pressure plates and the Side plates mounted on either

side of the cartridge drawn in and discharge the hydraulic
fluid. The pairs of intake and discharge ports are located
symmetrically to the bearings by the discharge pressure
are thus balanced. This type is called balanced vane
NEXT type pump.
 AVP PUMP
H FLOW CONTROL VALVE - OPERATION
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Flow Control Valve - Operation

The flow control valve controls the rate of flow with in the Power Steering Circuit. This is because,
since the discharge rate per oil pump revolution (characteristic discharge rate) is constant, the
discharge rate per unit time increases and decreases in proportion to the engine speed. To
NEXT maintain uniform performance, the Power Steering requires a flow rate that remains with in a
certain fixed range.
 AVP PUMP
H
O RELIEF VALVE - OPERATION
M
E

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Pressure Relief Valve

Operation:
The pressure relief valve controls the maximum pressure inside Power Steering Circuit. When the
Steering wheel resistance is high, the hydraulic pressure required for Power Steering is also high
and vice versa. Whenever the road wheels contact an obstacle or wheel stopper, which requires
NEXT additional force to Steer the wheel, the pressure will increase infinitely. Therefore a mechanism is
required to prevent excessive force being applied and to protect the Steering mechanism
 Pump Photo AVP 30 - 03
H
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AVP 30 PUMP ASSY.
 AVP 30 PUMP
H
O SPECIFICATION
M
E
 Type : Vane Type Pump

 Cartridge Size : 15 cc / revolution

 Controlled Fow : 12 Litres / Minute at & Above 1000 RPM

 Relief Valve Pressure Setting : 145 Bar

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 Direction of Rotation : Right Hand (CW)

 Pump Speed : 500 RPM (Minimum)

3000 RPM (Maximum)

 Drive : Belt / Gear / Direct

 Hydraulic Fluid : A T F or Equivalent

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
H
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MAINTENANCE

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 &

TROUBLE SHOOTING

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
H RECOMMENDED POWER STEERING OIL
O
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AUTOMATIC TRANSMISSION FLUID
E
TYPE “A” OR “F” or
DEXRON II - ATF

CASTROL TQ
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SERVO TRANS FLUID TYPE A

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BHARAT AUTOMATIC TRANSMISSION FLUID
 POWER STEERING OIL & FILTER
H
CHANGE SCHEDULE – ON HIGHWAY VEHICLE
O
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E

Change Oil & Filter at

PREV Every 80,000 Kilometers or
1 year whichever is earlier

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 POWER STEERING OIL & FILTER
H
CHANGE SCHEDULE – OFF HIGHWAY VEHICLE
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Change Oil & Filter at
Every 1200 hours of Operation

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 Power Steering Oil & Filter
H
O Change Procedure
M
Clean off thoroughly around the reservoir top cover surface, body, bottom
E surface and pipe connections.

Disconnect the suction hose from reservoir and drain oil.

Loosen the cover-fixing bolt and remove cover.

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Remove filter cartridge and cover seal. Discard them.

Disconnect the drag link from Drop Arm / Pitman arm. (Refer Vehicle
Service Manual)

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 Power Steering Oil & Filter
H
O Change Procedure
M
Clean off thoroughly steering gear body and bottom poppet adjuster
E screw and the near by surfaces.

Measure the poppet adjuster screw (Size 3/8” UNF) height from the
housing surface. Loosen the seal nut (A/F 17 mm) remove nut and screw.
Drain oil by turning the steering lock to lock few times.

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Inspect the poppet adjuster screw threads and clean. Install the adjuster
screw in the same position as before. Screw the seal nut (Replace the
seal nut if the original one is damaged in the seal area) and tighten it to
12-18 LB ft. torque.

Wipe dry reservoir inner surface with clean cloth (without loose threads)
and install new cartridge and cover seal.
 
Connect the suction hose and tighten the hose Clip.
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 Power Steering Oil Filling, Starting
H
O & Bleeding Procedure
M
Fill the reservoir nearly full. Crank the engine for 10 seconds without, if
E possible, allowing to start. If the Engine does start, shut it off
immediately. Check and refill the reservoir. Repeat atleast three times,
each time checking and refilling the reservoir.
 
Caution :
 
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Do not allow the fluid to drop significantly or run out of the reservoir.
This may induce air into the system.
 
Start the engine and check for oil leak/s, if noticed shut the engine
immediately and take corrective action, to arrest the leakage.
 
Start the engine and let it idle for 2 minutes. With the engine at steady
speed, check for bubble / foaming in the oil. If present, it indicates that
air is getting sucked into the system. Check the suction line / fittings /
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the pump shaft seal area and correct, if necessary.
 Power Steering Oil Filling, Starting
H
O & Bleeding Procedure
M
Start the engine again and steer the wheels from full right to full left turn
E several times. Add fluid, as necessary.
 
The above procedures should remove all air from the steering system.
 
Once the system is bled properly and free from foaming, there won’t be
appreciable change in oil level in the reservoir, when the engine is started
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/ stopped repeatedly.
 
Position the cover on the Reservoir and tighten the cover fixing bolt.
Check oil level with engine running and top up to “H” mark.
 
Connect drag link to drop arm. (Refer Vehicle Service Manual)
 
Check steering performance.

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 Power Steering Oil
H
O Flushing Procedure
M Always use fresh Power Steering oil, for flushing. In case of non
E availability of sufficient quantity of fresh Power Steering oil, the drained
oil may be used after filtering (use filter paper – Size : 10 microns).
 
Minimum quantity of oil required is 4 litres (If the filtered oil quantity is
less add fresh oil)
 
Drain the oil from the system (Refer draining procedure)
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Fit new filter assy. and fill the system with fresh / filtered oil (Refer Filling
and Starting procedure)
 
Start the engine and allow it to run for few minutes. With the engine
idling, steer the wheels from RH lock to LH lock & back atleast 10 times.
Ensure oil level does not drop below the suction fitting in the reservoir.
 
Stop the engine and drain the oil from the system. Remove the flushing
NEXT filter cartridge. Store it separately (can be used again for flushing).

H
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MAINTENANCE
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TIPS

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
H MAINTENANCE TIPS
O
M Regularly check the fluid and the fluid level in the Power Steering Reservoir
E Always use puller to remove pitman arm

Investigate and correct any external leak, no matter how minor

Replace Power Steering Filters and Power Steering Oil in compliance with
specification
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Always maintain grease pack applied behind the input and output shaft dirt
and water seal protector as a general maintenance procedure.

Avoid fouling of hoses and pipe lines with the chassis / gear. Ensure proper
clamping of hoses and pipe lines,
Ensure adequate gap to remove Reservoir top cover / filter assy. during
maintenance at the time of body building.

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Always use genuine spares


H MAINTENANCE TIPS
O
M Do not cold straighten, hot straighten or bend any Steering
E system component

Keep tyres inflated to correct pressure

Prevent internal bottoming of the Steering Gear

PREV Do not Mix different Grade of Power Steering Oil

Encourage all drivers to report any malfunctions or accidents that could

have damaged steering components

Do not allow dirt and foreign matter to enter into the

Steering System

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Always use genuine spares
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H
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MINOR
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ADJUSTMENTS

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 MINOR ADJUSTMENTS
H Worm Pre load Adjustment
O Preliminary Jobs
Check with Engine off and the front wheels in SAP
M
Finger tip force is required to check any free play at Steering Wheel as a resultant of up and
E down movement of Input Shaft

There be should be no play. Adjust if play is detected as detailed below

Procedure :
Back off the worm shaft adjusting screw sealing nut three turns and the worm shaft pre load
adjusting screw one turn

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Inspect the threads between the sealing nut and housing end for foreign matter. Check the
threads and replace sealing nut, if necessary

While some one lightly rotates the Steering Wheel back and forth one inch total, torque the
worm shaft pre load adjusting screw to 4.13 to 4.83 NM

Caution : while torquing the adjusting screw, make sure that the worm shaft
adjusting screw sealing nut does not tighten against the housing

Torque the worm shaft adjusting screw sealing nut to 95 to 108 NM making sure that the worm
shaft pre load adjusting screw does not move
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Frequency of Checking :
It is recommended to check the play at every 30,000 KMs
 MINOR ADJUSTMENTS
H Sector Shaft Back Lash Adjustment
O Preliminary Jobs
Check for the sector shaft center position (timing mark at the end of sector shaft perpendicular
M to worm shaft / input shaft )

E Grasp the Drop arm and gently try to move it back and forth in the direction of travel of drop
arm

There be should be no play. Adjust if play is detected as detailed below

Procedure :
Loosen the jam nut and turn the adjusting screw clockwise untill the sector shaft and rack
piston are in contact. Then turn the adjusting screw counter clockwise one turn
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At this point there should be lash at the drop arm

To adjust, Slowly turn the adjusting screw clock wise untill no lash is felt at the drop arm

Hold the adjusting screw in place and tighten the jam nut to 54 to 60 NM

Recheck the drop arm for lash. Turn the Steering wheel ¼ turn each side from center. No lash
should be felt.

If lash felt repeat the above adjustments

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Reconnect the drag link to drop arm

Frequency of Checking :
 MINOR ADJUSTMENTS
H Poppet Valve adjustment
O Preliminary Jobs – Conditions for adjustments of poppet

M Poppet Should be adjusted, in case any of the following conditions have occurred :
E Changing to a larger tyre

Reduction in the vehicle(s) wheel cut

Pitman arm was mistimed, and has been corrected

Steering gear is being installed on a different vehicle

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Steer axle stop bolt(s) were bent or broken

Steer axle U-bolt(s) were bent or broken

Incorrect alignment procedures are used

Procedure for adjustment :

Before you adjust the poppets, set the axle stops according to the manufacturers specifications

Install a diagnostic gauge (DG) into the supply line from Pump to the Steering Gear (Pressure
Line). Make sure that the flow meter can be pressurised. Bring the fluid temperature
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between125 deg. F and 135 Deg. F (51.7 deg. C and 57.2 deg. C), using the method to warm the
sysem.
 MINOR ADJUSTMENTS
H Poppet Valve adjustment
O
M With the engine at idle, have someone turn the steering wheel to full lock. If the sector shaft
rotates clockwise, adjust the poppet adjusting screw. If the sector shaft rotates on the other
E side, adjust the other poppet adjusting screw

Caution : If relief pressure is reached while the steering wheel is at full lock (axle
against axle stop), release the steering wheel from the position. At no time should relief
pressure maintained for longer than 5 seconds as damage to the pump may result.

Note : You must maintain enough force on the steering wheel to ensure that the steering
control valve is completely closed when reading presure gauge.
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Once you have determined which poppet to adjust, loosen the poppet adjusting screw sealing
nut and the poppet adjusting screw until the pressure gauge reads maximum system (pump)
pressure with steering wheel at full lock.

Caution : Do not unscrew the adjusting screw more than required, as otherwise it
would come out of the gear.

Screw in adjusting screw untill the supply pressure drops to 50% of relief pre-setting. Tighten
adjusting screw lock nut to 12-18 ft-lbs (16-24 Nm)

NEXT To adjust the other poppet, repeat the above instructions for full lock in the other direction.

H
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STEERING

PREV COMPLAINTS

AND CAUSES

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 TROUBLE SHOOTING GUIDE
H
O  Normal Noise
M
E  Abnormal Noise
 Road Wander
 No Recovery
 Shimmy
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 Over Steering / Darting
 High Steering Effort in one direction
 High Steering Effort in both direction
 Lash at Steering Wheel
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 External Leakage
 Excessive Heat
 POWER STEERING -
H TROUBLE SHOOTING GUIDE
O NORMAL NOISE
M
You or the driver may hear a hissing noise from the control valve when it is actuated
E during a steering maneuver.

You or the driver may hear a noise as fluid by passes through the poppets at full
turn.

You or the driver may hear a noise from the system relief valve when it is required
to actuate.
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You or the driver may hear pump growl from some types of Power Steering pumps.

ABNORMAL NOISE

If the Power Steering pump is belt driven, a squealing noise may indicate that the
belts should be tightened or replaced.

A clicking noise heard during a turn, or when changing directions, may indicate that
some component is loose and shifting under load.
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A change in the normal noise of the pump may indicate that air has been induced
into the system or that fluid level is low.
 POWER STEERING -
H TROUBLE SHOOTING GUIDE
O ROAD WANDER
M
Tyre pressure incorrect or unequal left to right
E Components in steering linkage loose or worn (Steering wheel to road wheel)
Wheel bearings improperly adjusted or worn.
Front end alignment our of specification
Dry fifth wheel or poor finish on fifth wheel or trailer plate
Steering gear mounting bolts loose on frame
Steering gear improperly adjusted
Looseness in rear axle assemblies or trailer bogies
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NO RECOVERY

Tyre pressure low

Front end components binding
Front end alignment incorrect
Tight front axle king pins
Dry fifth wheel or poor finish on fifth wheel or trailer plate
Steering column binding
Pump flow insufficient
NEXT Steering gear improperly adjusted
Steering gear control valve sleeve sticky
 POWER STEERING -
H TROUBLE SHOOTING GUIDE
O
M SHIMMY
E Badly worn or unevenly worn tyres
Improperly mounted tyre or wheel
Wheel bearings improperly adjusted or worn
Components in steering linkage loose or worn
Wheels or brake drums out of balance
Front end alignment incorrect
Air in the hydraulic system
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OVERSTEERING OR DARTING

Dry fifth wheel or poor finish on fifth wheel or trailer plate

Front end components binding or loose
Steering column binding
Steering gear improperly adjusted
Steering gear control valve sleeve sticky
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Rear axle mounts (rear steer)
 POWER STEERING -
H TROUBLE SHOOTING GUIDE
O
M
E HIGH STEERING EFFORT IN ONE DIRECTION

Unequal tyre pressure

Vehicle overloaded
Inadequate hydraulic system pressure
Excessive internal leakage in one direction of turn only

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HIGH STEERING EFFORT IN BOTH DIRECTIONS

Low tyre pressure

Vehicle overloaded
Low hydraulic fluid level
Low pressure or flow from pump
Components of steering system binding
Restriction in return line, or line too small in diameter
Excessive internal leakage
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Oversize tyres
 POWER STEERING -
H TROUBLE SHOOTING GUIDE
O
M
E LAST MOTION (LASH) AT THE STEERING WHEEL

Steering wheel loose on the shaft

Loose connection between the steering gear, intermediate column and steering
column.
Steering gear loose on frame
Pitman arm loose on output shaft
Components in steering linkage loose or worn
PREV Steering gear improperly adjusted

EXTERNAL OIL LEAKAGE

Finding the location of leak may be difficult, since oil may run away from leak
source, the fittings, hoses, pump or gear to a low point on the gear or chassis

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A leak from the vent plug at the side cover indicates failure of the sector shaft oil
seal inside the side cover
 POWER STEERING -
H TROUBLE SHOOTING GUIDE
O
M
E EXCESSIVE HEAT

Heat should not exceed 250 deg F or 120 deg. Celsius on continuous run
Excessive pump flow
Vehicle over loaded
Undersized replacement hose or line
Restricted hose or line that is kinked or severely bent or internally blocked
Restricted recentering of gear valve caused by column bind or side load on the
PREV input shaft
Poppet not adjusted properly (Only for gear equipped with poppet)
Prolonged stationary vehicle operation

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