ZF 8098 Scania 1
ZF 8098 Scania 1
ZF 8098 Scania 1
Issue 2 en
Contents
General .................................................................................. 3
General
The power steering gear is designed for a system
pressure of 150 bar and a maximum torque of
6726 Nm from the sector shaft. The steering gear
ratio is variable at 17-20:1.
The power steering gear has an integrated
pressure limiting valve and a hydraulic wheel end
lock.
The wheel end lock is self-adjusting.
Function Description
Operation without power
steering
If a fault occurs and there is no power steering,
the power steering gear will operate as a mechan-
ical steering gear. The vehicle can be steered but
the steering will be much heavier.
When the steering wheel is turned, the torque is
transferred to the power steering gear input shaft.
A torsion bar is fixed onto the input shaft and
onto the worm screw. When the torsion bar has
been turned approximately 7°, a pin engages and
transfers the torque mechanically to the worm
screw.
The set of balls between the worm screw and
piston transfers and reinforces the torque to the
piston which is then displaced into the steering
gear housing cylinder.
Part of the underside of the piston is shaped like a
rack which engages with the sector shaft teeth.
The varying contact radius between the piston 1 Internal hexagon bolt - automatic wheel end lock
rack and the sector shaft teeth along with the ball
2 Valve - wheel end lock
screw pitch determines the power steering gear
ratio and the number of turns of the steering 3 Worm screw
wheel. 4 Torsion bar
The sector shaft transfers torque to the steered 5 Control valve
wheels via the droparm, draglink, guide arm and 6 Input shaft
track rod. 7 Steering gear housing
8 Sector shaft
9 Set of balls
10 Servo piston
Neutral position
If no torque affects the torsion bar, the control
valve is in neutral position. The inlet and return
channels of the power steering gear are then
connected with each other.
If the engine is running, oil circulates from the
hydraulic pump through the control valve and
back to the oil reservoir via the return line.
Left-hand turn
A high oil pressure provides
steering force - a high oil flow
provides a rapid steering
response
The quantity of oil which passes into the
cylinder chamber is determined by the speed of
the steering wheel movements.
The oil pressure which is built up is determined
by the resistance from the steered wheels
depending on the axle weight and friction
between the tyres and road surface.
The control valve controls the difference
between the turning of the input shaft and
worm screw so that the pressure and flow are
optimally adjusted in every steering situation.
Variable steering resistance in the steering
wheel gives the driver information about and
control of the steering process.
If the steered wheels are suddenly exposed to a
shock load, this force will be transferred to the
worm screw and will cause it to turn rapidly.
When the worm screw is turned, the control
valve is also turned in relation to the input
shaft. The control valve then controls the full
oil flow to the low pressure side of the piston
where the oil pressure is rapidly increased. The
oil pressure forms a counter force which
dampens the shock loads before they are
transferred to the steering wheel.
1 2 3 4 5 4 3 2
101 787
1
Full wheel lock angle is required during the adjustment, which results in the sleeve on the internal
hexagon bolt being displaced.
101 788
When the piston approaches the end lock position, the piston pin is pressed into the valve sleeve and
opens the valve on the low pressure side.
The function of wheel end lock is to reduce the If the nominal wheel lock angles are
fluid pressure in the power steering gear, and subsequently increased, wheel end lock is
thereby also its torque when the wheels are automatically set.
close to their end positions.
If the nominal wheel lock angles are reduced,
Without this function a considerable increase in both set screws must be renewed.
pressure and temperature would be produced in
the system if the wheels were forced against It is also necessary to renew the set screws if:
their end lock positions with great force. This
would also place a great load on the steering • The length of the draglink, i.e. the straight
components. ahead position, has been altered.
The wheel end lock consists of two valves • The input shaft on a detached power
integrated into a longitudinal channel in the steering gear (or on a power steering gear
piston. The valves are held closed by a which has been detached from the steering
compression spring placed between the valves linkage) is rotated more than
and opened by two piston pins. The ends of the 1.6 revolutions from its centre position.
piston pins protrude through valve sleeves into
the ends of the piston.
When the oil pressure on the high pressure side
of the piston is higher than the oil pressure
between the valves, oil is allowed in through
the pressure side valve.
When the piston approaches the end lock
position, the relevant piston pin is pressed into
the valve sleeve and opens the valve on the low
pressure side. The oil pressure on the pressure
side is reduced because the oil flows through
the valves and piston over to the low pressure
side and on to the oil reservoir via the return
channel.
The closer the piston is to the end position, the
more the oil pressure is reduced, resulting in
ever reducing servo effect. The driver therefore
cannot apply full load to the power steering
gear in the end lock position.
101 783
Work Description
Cleanliness
The need to keep everything clean when
working on power steering gears cannot be
emphasised enough.
Damage on power steering gear components
and seals are mainly due to contaminants in the
hydraulic system.
Pay particular attention to the following:
• Clean the power steering gear at the hose
connections before these are disconnected.
Remove any flaking paint from the power
steering gear.
• Immediately plug the connection holes in
the power steering gear.
• Always change the oil and oil filter after
renewing any seals or renewing the power
steering gear.
• Remove the oil reservoir when changing
filter.
• Clean the outside and inside of the oil
reservoir before fitting a new filter.
• Always use a clean container when filling
oil.
The oil is not filtered until it returns from
the power steering gear.
• Never top up with used fluid.
Changing seals
Special tools
110 276
87 017 Insert for clamp sleeve AM2
87 018 Clamp sleeve for input shaft 87 018
AM2
110 278
87 292 Drift 87 292
R1
00 1849
87 582 Drift 87 582
R2
110 330
98 148 Fixture A
98 450 Drift R2
00 1633
98 450
98 743 Drift C1
Other tools
! WARNING!
102 154
102 153
100297
11 Check that there are no depressions or other
surface damage to the piston teeth by running
your fingernail over them.
Turn the worm screw and check that there is
no surface damage in the ball race or on the
worm screw end surface.
Check that any valve pins are straight, spring-
loaded and move easily.
! WARNING!
5
4
100215
100246
be renewed. Use assembly sleeve 99 238
with spacing ring and sleeve 99 237.
100245
2 Press a marking scraper into the seals and
carefully bend them out of the grooves. Take
care not to damage the edges of the grooves.
! WARNING!
102 154
22 Fit a new seal and new input shaft dust cover.
Fit the dust cover marking opposite the
steering gear housing marking.
Remove the assembly sleeve from the input
shaft.
Set the power steering gear centre position by
turning the input shaft so that the markings
on the input shaft and the sector shaft
correspond as illustrated.
Specifications
General data
Left-hand turn Straight Right-hand turn
ahead
position
Steering wheel lock 2.4 turns 0 2.4 turns
Angle reading on sector 47° 1) 0 47° 1)
shaft
Gear ratio 20.0:1 17.0:1 20.0:1
Torque from sector shaft 6726 Nm 5717 Nm 6726 Nm
at 150 bar
Weight (exc. drop arm) 39 kg
Oil volume 3.8 l
Tightening torque
Pressure limiting valve 30 Nm
Adjusting bolt (wheel end lock) 15 Nm
Bolts, cover 190 Nm
Nut, guide arm - power steering gear 800 Nm