How to assembly steering gear in vehicle

Until the pressure and return conduits aren't connected, the plugs need to stay in the housing. In this way the dust will stay outside steering box. The most comfortable way to install steering gear's arm is to do it before assembly, unless the assembly refers to PR-110 bus, where the steering gear's arm need to be installed directly in the vehicle, before assembly. Then the whole action is being realized right after the steering box was screwed to the bearer. When you put steering gear's arm onto the segment shaft you need to remember to place them precisely. In the end you need to screw the nut tight with the right moment and secure it.

Steering gear's nut moment:

• M35x1,5 - 400 Nm
• M42x1,5 - 500 Nm

To assembly steering box in a vehicle you need to do as follows:

1. Install bearer to vehicle's chassis.
2. Install a steering box on the bearer and screw it tight. You need to use M18x1,5 screws with 10.9 durability and hardened washers. Screw moment 350 Nm.
3. Steering box:
   1. with stiff steer column:
      
      Install steering-wheel, skrew the nut tight with the right moment. Skrew in the 92 sliding contact and skrew tight with 5 Nm moment.
      
      Steering gear's nut moment:
      • steering-wheel's shaft with 1:20 bell:
        • M22x1,5 mm - 75-85 Nm
        • M24x1,5 mm - 80-90 Nm
        • M28x1,5 mm - 80-90 Nm
      • steer shaft with cylindrical multinotch and 1:16 bell:
        • M22x1,5 mm - 40-50 Nm
        • M26x1,5 mm - 60-70 Nm
   2. with articulated steer shaft:
      
      Install cross coupling or elastic coupling between steer shaft and steering box and connect it together with a use of fit screws and screw it tight with the right moment:
      • M8 - 34 Nm
      • M10x1,5 - 49 Nm
4. Set the steering gear in position to driver straight ahead (half of total turns of steering-wheel).
5. Set the front wheels in the direction to drive forward.
6. Fasten the oil pump in the bearer and set the required tightness of fan belts, making a test with a thumb.
7. Connect the pump and oil tank with suction, press and return conduits. If you need to bend the hoses do it when it's cold to avoid scale.
8. Fasten the steer rod.
9. Fill up the system with oil destined for hydraulic systems (we recommend the use of Boxol 26).
   
   Filling up the system with oil:
   
   Attention! While filling the hydraulic system with oil you need to be careful not to empty the tank fully, because the air might get sucked in.
   

   Unless the pump has low rotations while filling with oil, it will intake too much air and the air bubbles will cause that the whole deaeration process will last longer. Steering box might have several different positions and in some cases total deaeration of the system might not be possible. Air remaining inside the steering box will flow away after some time. In that case it is suggested to detach the longituindal rod from steering gear's arm and use the whole piston's stroke. During the ride the rest of air is absorbed by oil and then emitted in the tank. To Fill the system with oil you need to use the inlet opening. When you do it for the first time you need to take off tank's cover and fully fill up the tank. Then you need to turn on the starter several times to distribute the oil in the system. During this process the oil level is dropping fast and you need constantly pour some more oil in order not to let in the air.

10. Deaerate the system.
    
    Deaeration of the system:
    

    When the hydraulic system is filled with with oil in the way that with motor running the level doesn't drop below the lower oil level, so you can then enjoy the ride. Next you need turn the steering-wheel fully right and left to push the air out of cylinder. Simultaneously you need to observe the oil level fill it up in case it drops. You need to repeat the whole process till the level of oil will be balanced,.and air bubbles will stop swimming out. Next you need to take off the seal cover and put on a transparent hose. Screw off the deareting screw for about 0,1 - 1 turn, and wait for the air to flow away. In the moment when the oil will be swimming out of the screw, you need to turn it tight, put on the cover and fill up the tank with oil. After correct deaeration with engine running, the oil level shouldn't get higher than 1 - 2 cm.

    Oil level check-up:
    

    Oil level should be checked-up after 5000 - 6000 km mileage or after 100 - 120 working hours. In case of oil drop you need to fill it up so the level crosses the line over 1 - 2 cm. With engine running oil level drops a litlle bit, but not more than 1 - 2 cm. After shutting it off it should even to its' initial level. If the level gets higher than assumed it most probably because of the air in the system.