Hydraulic Power Steering

Basic Principle
Content

> FUNCTIONING OF STEERING

> RACK & PINION TYPE STEERING
> POWER STEERING
- WORKING PRINCIPLE
- LINKAGES
- PINION VALVE ASSEMBLY

> ON LINE TESTING

> KEY POINTS FOR POWER STEERING
> WORKING OF PUMP
2
 OVERALL VIEW OF STEERING SYSTEM

Rack & Pinion Type

Steering system

3
HOW STEERING SYSTEM WORKS.

4
Turning the Car
> For a car to turn smoothly, each wheel must follow a different
circle. Since the inside wheel is following a circle with a smaller
radius, it is actually making a tighter turn than the outside wheel. If
you draw a line perpendicular to each wheel, the lines will intersect
at the center point of the turn. The geometry of the steering linkage
makes the inside wheel turn more than the outside wheel.
> .

5
DIFFERENT TYPES OF STEERING SYSTEMS

• Rack and Pinion Type

• Re-circulating Ball Screw Type

MANUAL STEERING POWER ASSISTED

Hydraulic Power Electrically Assisted

Pinion Type EPS

(PEPS)

Column Type EPS

(CEPS)
6
WHAT IS RACK &PINION STEERING SYSTEM & HOW IT
WORKS
The pinion gear is attached to the steering shaft. When you turn the
steering wheel, the gear spins, moving the rack. The tie rod at each end of
the rack connects to the steering arm on the spindle (see diagram below).

7
 RACK & PINION TYPE STEERING (RPS)

The rack-and-pinion gear set does two things:

•It converts the rotational motion of the steering wheel into
the linear motion needed to turn the wheels.
•It provides a gear reduction, making it easier to turn the
wheels.
On most cars, it takes three to four complete revolutions of the
steering wheel to make the wheels turn from lock to lock (from
far left to far right).

Some cars have variable-ratio steering, which uses a rack-and-

pinion gear-set that has a different tooth pitch (number of teeth per
inch) in the center than it has on the outside. This makes the car
respond quickly when starting a turn (the rack is near the center),
and also reduces effort near the wheel's turning limits.

8
 CONSTRUCTIONAL DETAIL OF POWER
STEERING

9
 Power Steering
There are a couple of key components in power steering in addition
to the rack-and-pinion or re-circulating-ball mechanism.

10
 Power Steering System (Rack & Pinion type)

In
Right Left Turn
Turn Oil Flow Out
Oil Flow Left Turn

Right
Turn

11
WORKING PRINCIPLE
•The engine driven hydraulic pump supplies oil at a pressure to a control valve
(Pinion Valve Assembly) situated in housing that supports the pinion shaft.
•The movement of steering wheel imparts movement to the control valve through
the steering column.
•The torsion bar moves the control valve, which in turn directs the oil to one side
of the piston inside the steering housing( Cylinder Tube), depending on the
direction of rotation of steering wheel.
•The control valve is a rotary spool type valve controlled by the torsion bar
impregnated in the steering case.

•The spool valve is a shaft with six flutes and a sleeve, which has six internal axial
grooves. Radial ports in the sleeve and shaft pass the oil from the supply to the
lines connected to the piston chamber/rack housing.

•The amount of twist of the torsion bar an the movement of the spool valve is
proportional to the effort applied by the driver on steering wheel in any direction.
•Initial power steering assist is obtained at about 0.5 degree deflection of the
torsion bar and the assist rises progressively as the bar deflection rises to about 4
degrees.
•The maximum deflection allowed in any direction is limited to 7 degree with the
help of a series of the splines between the shaft and the sleeve.

12
POWER STEERING WORKING PRINCIPLE
(Continue)

Part of the rack contains a cylinder with a piston in the

middle. The piston is connected to the rack. There are
two fluid ports, one on either side of the piston.
Supplying higher-pressure fluid to one side of the piston
forces the piston to move, which in turn moves the rack,
providing the power assist.
We'll check out the components that provide the high-
pressure fluid, as well as decide which side of the rack to
supply it to, later in the article. First, let's take a look at
another type of steering.

13
 Power Rack-and-pinion

14
 Power steering gear and linkage

15
 System construction

The power steering system consists of:

- Rack and pinion steering gear box
- Power steering oil pump
- Oil reservoir
- Tubes
The power steering system uses a hydraulic pressure which is generated
by the power steering pump to reduce the effort required to turn the
steering wheel. The power steering pump is mounted on the front of the
engine. The pump has a vane-type design, and is driven by the
crankshaft through a drive belt.
The power steering fluid is drawn into the pump from the reservoir when
the engine is running. The fluid is pressurized by a power steering switch
and a control valve located in the power steering pump.

16
 Steering gear box assembly

17
 Steering gear box assembly

1. Tie rod end 14. Snap ring

2. Lock nut 15. Seal
3. Boot clip 16. Bearing
4. Boot 17. Pinion shaft assembly
5. Boot wire 18. Bolt
6. Inner ball joint 19. Valve housing
7. Rack bushing 20. O-ring
8. O-ring 21. Steering gear housing
9. Seal 22. Mounting rubber
10. Lock nut 23. Mounting bracket
11. Yoke plug 24. Oil pipe
12. Spring 25. Rack
13. Support yoke 26. Inner guide
18
 Construction of the power steering gear box

19
 Operation of the pinion and valve assembly (at the center
position)

20
 Operation of the pinion and valve assembly (at the
center position)

21
 Operation of the pinion and valve assembly (turning left)

22
 Operation of the pinion and valve assembly (turning left)

23
 Operation of the pinion and valve assembly (turning right)

24
 Operation of the pinion and valve assembly (turning right)

25
 Rotary Valve

A power steering system should assist the driver only when he is

exerting force on the steering wheel (such as when starting a
turn). When the driver is not exerting force (such as when driving
in a straight line), the system shouldn't provide any assist. The
device that senses the force on the steering wheel is called the
rotary valve.
The key to the rotary valve is a torsion bar. The torsion bar is a
thin rod of metal that twists when torque is applied to it. The top
of the bar is connected to the steering wheel, and the bottom of
the bar is connected to the pinion or worm gear (which turns the
wheels), so the amount of torque in the torsion bar is equal to the
amount of torque the driver is using to turn the wheels. The more
torque the driver uses to turn the wheels, the more the bar twists.

26
 The input from the steering shaft forms the inner part of a spool-valve assembly. It also
connects to the top end of the torsion bar. The bottom of the torsion bar connects to the
outer part of the spool valve. The torsion bar also turns the output of the steering gear,
connecting to either the pinion gear or the worm gear depending on which type of steering
the car has.

27
CONTINUE

As the bar twists, it rotates the inside of the spool valve

relative to the outside. Since the inner part of the spool
valve is also connected to the steering shaft (and therefore
to the steering wheel), the amount of rotation between the
inner and outer parts of the spool valve depends on how
much torque the driver applies to the steering wheel.
When the steering wheel is not being turned, both
hydraulic lines provide the same amount of pressure to
the steering gear. But if the spool valve is turned one way
or the other, ports open up to provide high-pressure fluid
to the appropriate line.

28
 PART II

IMPORTANT ON LINE TESTS

29
IMPORTANT ON LINE TESTS
1. AIR LEAK TEST
• Low Pressure Test ( 1 bar)
• High Pressure Test ( 7 bar)
Purpose :
• To check external leakage from
- Tube fittings
- Feed tubes
- Oil seals

30
IMPORTANT ON LINE TESTS
2. High Pressure Endurance Test
• Test Pressure 120 bar (Hydraulic)
• Cyclic test
Purpose :
• To check internal leakage from
- Piston ring
- PV Assembly seals
Note : In case of external leakage ,oil leakage can be
checked visually from outside portion of cylinder tube
and Pinion Housing
31
IMPORTANT ON LINE TESTS
3. Rotational Torque
• Test done in Power On condition
• Hydraulic oil flow 6 LPM
Purpose :
• To check that the assembly meet the specified
rotational torque criteria
Typically
- Maximum torque
- Torque variation
Note : Rotational torque value is adjusted by adjusting
rack twist (yoke clearance amount)
32
IMPORTANT ON LINE TESTS
4. Reverse sliding force
• Test done in Power On condition
• Hydraulic oil flow 6 LPM
Purpose :
• To check that the assembly meet the specified sliding force
criterion
Typically
- Maximum sliding force
- Sliding force variation
Note : This is important to get good returnability of
steering
33
IMPORTANT ON LINE TESTS
5. Performance Characteristics
• Test done in Power On condition
• Hydraulic oil flow 6 LPM
Purpose :
• This is the test of valve characteristics in term of
Hydraulic pressure vs torque characteristics
• Evaluation is done at low pressure and high pressure

Note : This characteristics determines the operation of

power steering function
34
IMPORTANT ON LINE TESTS
5. Hydraulic Nose Test
• Test done in Power On condition
• Test is performed along with Performance Characteristic
test
Purpose :
To detect noise due to oil flow in the hydraulic power steering
system

35
 PART-III
KEY TO QUALITY OF
POWER STEERING
IMPORTANT FACTORS
• CLEANINESS
-THE ASSEMBLY ROOM
- WASHING LIQUID
- PARTS
- Rack Bar
- PV Assembly
- Pinion Housing
- Valve Housing
- Oil seals
- Bearing
- Feed tube

- ASSEMBLY FIXTURES & TOOLS

37
IMPORTANT FACTORS
• CLEANINESS
-THE ASSEMBLY ROOM
- WASHING LIQUID
- PARTS
- Rack Bar
- PV Assembly
- Pinion Housing
- Valve Housing
- Oil seals
- Bearing
- Feed tube
- ASSEMBLY FIXTURES & TOOLS
- PART HANDLING BINS
38
IMPORTANT FACTORS
• NO DENTS & SCRATCHE
-Rack Bar
- Cylinder Tube
- Oil seals
- PV Assembly
- Valve housing

39
DAILY CHECK ITEMS
- Cleanliness
- Contamination
- Machine check sheet
- Pokayoke check sheet
- Torque wrench calibration
- Rocket condition
- Fixtures and locators condition
- Leak master check
- Torque and performance heck master
- Daily analysis of rework / rejection

40
 PART-IV
POWER STEERING
PUMP
 PUMP
The hydraulic power for the steering is provided by a rotary-vane pump
(see diagram below). This pump is driven by the car's engine via a belt and
pulley. It contains a set of retractable vanes that spin inside an oval
chamber.

42
 Oil pump construction

1. Pulley
2. Shaft
3. Pressure switch
4. P/S pump body
5. Flow control
valve ass’y (built
in relief valve)
6. Cam ring
7. Rotor
8. Vane
9. Cover

43
 Oil pump construction

44
 Operation of the oil pump

Discharge
Intake side
Suction

Vane

Rotatin
g Suction
directio
n Discharge
Cam ring

Rotor
45
 Flow control valve

As the discharge rate of the power steering pump increases

in proportioning to the pump revolution speed, a flow
control valve is added to control it so that the optimum
amount of fluid for steering operation is supplied
according to the engine speed (driving condition).

Described below is its operation at different engine speeds.

46
 Flow control valve (when idling)

1. To gear case
2. From pump
3. To pump
4. Rod
5. Orifice A1

The fluid discharged from the pump is supplied through the

clearance around the rod in orifice A1 to the gear box.
47
 Flow control valve (when running at Low
Speed)

1. Flow control valve

2. Flow control spring

As the engine speed rises, the pump discharge rate increases and causes
a pressure difference to occur between both ends of the orifice (P1 – P2).
Thus the pressure exceeding the flow control spring force pushes the flow
valve to the right in figure, making the opening in the orifice narrower
through which only a necessary amount of fluid is fed to the gear box and
48 the excess fluid is returned to the pump.
 Relief Valve

1. Orifice A2
2. Relief valve
spring
3. Steel ball
4. Chamber A
5. Chamber B

The relief valve located in the flow control valve controls the maximum
hydraulic pressure.
The steel ball in the relief valve is under the hydraulic pressure in the
circuit coming through orifice A2. When the steering wheel is turned
and the hydraulic pressure increases higher than 75-82kg/cm2 (1060-
1160 psi), it compresses the relief spring to push the steel ball which
49 then allows the fluid to flow to the power steering pump.
 Flow control valve (when running at High
Speed)

As the engine speed rises higher, opening in the orifice is made

narrower and fluid flow to the gear box reduces. As a result, hydraulic
pressure application is slow at the start of the steering wheel turn. This
provides straight-ahead stability to suit the driving condition with the
steering wheel operated near its neutral position.
50
 Relief Valve

Such relief valve operation causes a pressure

difference to occur between chamber A and B.
Then the flow valve moves to the right to make
opening in orifice A1, maintaining the hydraulic
pressure constant.

51
CONTINUE

As the vanes spin, they pull hydraulic fluid from the return line at
low pressure and force it into the outlet at high pressure. The
amount of flow provided by the pump depends on the car's engine
speed. The pump must be designed to provide adequate flow when
the engine is idling. As a result, the pump moves much more fluid
than necessary when the engine is running at faster speeds.
The pump contains a pressure-relief valve to make sure that the
pressure does not get too high, especially at high engine speeds
when so much fluid is being pumped.

52
 BLEEDING
Bleeding is required when we are doing fluid
replacement
1. Jack up the Front Wheels and Support them by using a
rigid rack.
2. Fill the Oil reservoir with the specified fluid(Mitsubishi
ATF-11).up to the lower Position of the filter.
3. Manually turn the Oil pump pulley a few minute.
4. Turn the Steering wheel all the way to the left &to the
right five or six times.
5. Disconnect the High tension Cable .
6. While operating the starting motor intermittently,turn the
steering wheel all the way to the left &right five or six
times.(15to20seconds).
53
 7. Connect the high -tension cable.
8.Turn the steering wheel to the left and right until there are no
air bubbles in the Oil reservoir.
9.Confirm that the fluid is not milky,and then level is up to the
specified position on the level gauge.
10. Confirm that there is very little change in the fluid level
when the steering wheel is turned left&right.

Fluid level change 11. Check whether or not the

change in the fluid level is
within 5mm within 5mm when the engine is
stopped &when it is running.if
the change of the fluid level is
5mm or more,the air has not
been completely bleed from the
system,and thus must be bleed
completely.

While engine While engine

54 running stopped
 The following points should be taken care:-

1. During Air bleeding,replenish the fluid supply so that

the level never fails below the lower position of the filter.
2. If Air bleeding is done while engine is running,the air
will be broken up and absorbed into the fluid;be sure to do
the bleeding only while cranking.
3.If the fluid level rises suddenly after the engine is
stopped the air has not been completely bled.
4. If the bleeding is not complete, there will be abnormal
noises from the pump and the flow control valve, and this
condition could cause a lessening of the life of the pump.

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 Specifications
•Steering Gear Type Rack &Pinion, End take off,
Integral Power Assisted.
•Rack Travel (Steering Gear) LH-75mm & RH-75mm,Maximum
•Overall Steering Ratio 20:1
•Total Turns Available on 3.75
Input shaft of the steering gear
•No. of steering Wheel rotation 3.6
(lock to lock)
•Torque required on input shaft 1.5 Nm
to move the rack (preload)
•Normal operating Pressure 85 bar
•Steering wheel diameter 395mm/365mm
•Power steering pump Sliding vane type-Positive
56 displacement.
 •Pump make Koyo
•Direction of pump rotation Clockwise when viewed from shaft
end
•Pump flow 8.5LPM @ 1000rpm
•Pump-Pressure Relief 75 kg/cm² or 75 bar
•Pump Drive Gear driven
•Wide Operating speed-pump 600 rpm-6500 rpm
•Wide Operating Temp.Pump -40° C to +120° C
Gear.
•Flow control cum pressure relief In built system
Valve in pump 7.5 +0.5/-0Mpa
8.5 ± 0.7 lit/min @ 1500 rpm
•Oil Capacity of reservoir 0.8 approx
•Oil capacity of system 0.8 approx

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 OIL PUMP PRESSURE TEST
1.Disconnect the pressure hose
from the Oil pump,and then
connect the special tools.
2. Bleed the air,and then turn the
steering Wheel several times while
the vehicle is not moving so that
the Temp. of the fluid rises to
Approx. 50-60ºC.
3.Start the engine and idle at
1,000±100r/min.
4.Fully close the shut off valve of
the pressure gauge and measure
the oil pump relief pressure to
confirm that it is within the
standard value range.(Standard
58 value-8.8mpa).
 5. If it is not within the standard value,replace the Oil pump.
6. Check whether or not the hydraulic pressure is the standard value
when no- load condition are created by fully opening the shut-off valve
of the pressure gauge.(Standard value- 0.2-0.5Mpa)
7.If it is not within the standard value,the probable cause is a
malfunction of the Oil line or steering gear box,so check these parts
and repair as necessary.
8. Fully open the shut off valve of the pressure gauge.
9. Turn the steering wheel all the way to the left or right;then check
whether or not the retention hydraulic pressure is the standard
value.(Standard value- 8.8Mpa).
10.When not within the standard value,replace the Power steering
gear box .
11.Remove the special tool,and then tighten the pressure
hose.(Tightening torque:17 Nm). And bleed the system.
59
 POWER STEERING OIL PRESSURE SWICTH
CHECK

1.Disconnect the pressure

hose from the Oil pump,and
then connect the special tool.
2. Bleed the air,and then turn
the steering wheel the several
times while the vehicle is not
moving so that the temp. of
the fluid rises to Approx. 50-
60ºC.
3. The engine should be idling.
4. Disconnect the connection
of the connector for the Oil
pressure switch,and place an
ohmmeter in position.

60
 5. Gradually close the shut-off valve of the pressure gauge and
increase the hydraulic pressure ,then check whether or not the
hydraulic pressure that activates the switch is the Standard
value(Standard value-1.5-2.0Mpa).
6. Gradually open the shut-off valve and reduce the hydraulic
pressure;then check whether or not the hydraulic pressure
that deactivates the switch is the standard value(Standard
value:0.7-2.0Mpa)
7.Remove the special tool,and then tighten the pressure hose
to the specified torque.(Tightening torque:17 Nm).
8. Bleed the system.

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