STEERING SYSTEM

Structure ...................................................................................................................................... 9- 1
Steering System .................................................................................................................... 9- 1
Steering Control Valve ........................................................................................................ 9- 2
Tilt Steering Assembly ........................................................................................................ 9- 3

Procedures and Key Points for Removal and Installation .......................................................... 9 - 4

Tilt Steering and Steering Control Valve Assembly ............................................................ 9 - 4

Steering Control Valve ................................................................................................................ 9- 6

Disassembly.......................................................................................................................... 9- 6
Inspection After Disassembly .............................................................................................. 9 - 10
Reassembly .......................................................................................................................... 9 - 10

Troubleshooting .......................................................................................................................... 9 - 16

Service Data ................................................................................................................................ 9 - 17

9
 STEERING SYSTEM

Structure
Steering System

• 3

4 • F

C G
D E

A
C
D E

A
•
•
•
6
B 2
1
Oil flow
→ Turning to the left E
A →B→C → F →G
→ Turning to the right D
207167A

1 Tank (hydraulic) 4 Steering control valve

2 Oil pump 5 Steering wheel
3 Inlet section 6 Steering cylinder
(with built-in flow divider valve)

The steering system uses a hydraulic mecha-
nism consisting of a steering control valve
(orbit roll) and a flow divider valve to reduce
the operator’s steering effort.
The force applied to the steering wheel is con-
verted to hydraulic pressure by the steering con-
trol valve. This hydraulic pressure is then con-
verted to the rear axle steering force by the
steering cylinder.
The flow divider valve controls the flow of
hydraulic oil discharged from the oil pump. The
flow divider valve supplies to the steering con-
trol valve the amount of oil required only for
steering operation, and sends the remaining oil
to the hydraulic circuits of other devices.

9-1
STEERING SYSTEM

Steering Control Valve

13

T L R P

• • • •

• • •
•

• • •
•

5 6 7 8 1 9 10 2 11 3 12 4

200786

1 Long housing 10 Control spool

2 Spacer plate 11 Spacer
3 Meter (Gerotor) 12 Spacer
4 End cap 13 Check valve
5 Needle thrust bearing P Pump port
6 Centering spring T Tank port
7 Pin L Cylinder port (left)
8 Drive R Cylinder port (right)
9 Control sleeve

9-2
 STEERING SYSTEM

Tilt Steering Assembly

6°
6°
1
•
9

• •
5

10
3
▲

▲
4

206670A

1 Column housing 6 Universal joint

2 Lower shaft 7 Upper shaft
3 Column bracket 8 Column bushing
4 Lock cylinder 9 Bushing housing
5 Knob 10 Horn cord
The tilt steering assembly is installed to the wheel forward and backward.
bracket under the dash board. The tilt steering assembly can tilt ± 6° around
Pull down the knob, and move the steering the universal joint.

9-3
STEERING SYSTEM

Procedures and Key Points for Removal and Installation

Tilt Steering and Steering Control Valve Assembly

1
10
2

5 3

11
A
4 ▲
6 12 14

7 8
16
▲ 16
A 16
9
15
16
13
13 13

207059

Removal sequence
1 Steering wheel cap, Nut, Washer 9 Lower cover (rear)
2 Steering wheel 10 Cover (front)
3 Transmission shift lever 11 Floor plate
4 Console box cover 12 Tilt steering assembly
5 Console box 13 Hoses
6 Upper cover (front) 14 Bolt, Washer, Cushion, Collar, Spring
7 Lower cover (front) washer
8 Upper cover (rear) 15 Steering control box assembly
16 Elbows, Connectors, Pipes

9-4
 STEERING SYSTEM

Key points for removal

Removing steering wheel
Use a special tool to remove the steering wheel. Steering wheel puller
Special tool needed
Steering wheel puller 91268-10600

CAUTION
Do not hit the end of steering shaft when the
steering wheel is removed.
205770

Inspection after installation

Steering wheel play
Check the steering wheel play while idling the
engine.
Steering effort
(1) Pull the hand brake lever. Run the engine and
warm the hydraulic oil to a operation temper-
ature of 40 to 60 °C (104 to 140 °F).
(2) Attach a spring balance to the rim (or a spoke)
of the steering wheel, and measure the steering
torque required to turn the steering wheel
clockwise or counterclockwise.
Steering effort 205771A
1.96 (0.2) [1.44]
N·m (kgf·m) [lbf·ft]
Tangential force 12.7 (1.3) [2.87]
N (kgf) [lbf]

Air bleeding
Air in the hydraulic system such as the steering
cylinder, the flow divider valve and the piping may
cause shimmy and abnormal noise.
(1) Jack up the rear tires. For procedures, refer to
REAR AXLE section.
(2) Depress and release the accelerator pedal
repeatedly to change the engine revolution
speed, while turning the steering wheel to
lock-to-lock positions.

9-5
STEERING SYSTEM

Steering Control Valve

Disassembly

5
4

207179

Disassembly sequence
1 End cap, Screws, Seal
2 Meter, Seal, Spacer
3 Spacer plate, Drive, Seal
4 Seal gland bushing assembly
5 Needle thrust bearing
6 Spool and sleeve assembly
7 Check valve

9-6
 STEERING SYSTEM

Suggestions
Removing the end cap
Clamp the unit in a vise with the meter end up.
Clamp lightly on the edges of the mounting area,
using protective material on the vise jaws.
Housing distortion can result if the jaws are over-
tightened.

207180

Remove the cap screws and the end cap. Remove Seal washer
the seal from the end cap.

Cap screw

End cap
Seal 207181

Removing the meter

Remove the meter, taking care not to let the inner Seal
star drop. Remove the seal from the meter.
Remove the drive spacer(s).

Meter
Spacer(s)
207182

Removing the drive

Remove the drive and spacer plate. Remove the
seal from the housing.

Spacer plate
Seal Drive

207183

9-7
STEERING SYSTEM

Removing the seal gland bushing

Use a thin-bladed screwdriver to pry the retaining
ring from the housing.

200665

Rotate the spool and sleeve assembly until the pin

is horizontal. Push the spool and sleeve assembly
forward with you thumbs just far enough to free
the gland bushing assembly from the housing.

200666

Remove the quad ring seal from the seal gland

bushing. Use a thin-bladed screwdriver to pry the
dust seal from the bushing. Do not damage the Quad
ring
bushing.
▲
seal
▲

▲ Seal gland
bushing
Dust seal
207184

Removing the needle thrust bearing

Remove the two bearing races and the needle
thrust bearing from the spool and sleeve assembly.
Needle Bearing
thrust race
bearing

Bearing
race

207185

9-8
 STEERING SYSTEM

Removing spool and sleeve assembly

Remove the spool and sleeve assembly from the
end of the housing. Do not jam the spool and
sleeve assembly. Rotate it slowly when removing
it from the housing. Pull the pin from the spool and
sleeve assembly.

Pin
200667

Pull the spool partially from the control end of the Spring
sleeve and carefully remove the centering springs package
from the spool by fingers. Push the spool back
through and out of the sleeve. Rotate the spool
slowly when removing it from the sleeve.

200668

Removing the check valve

Remove the seal from the housing. Remove the set
screw. Screw a # 10-24 machine screw into the end Seal
of the check ball seat. Then, by pulling on the
screw with pliers, lift the seat out of the housing.
Remove the two seals from the seat. Tip the hous-
ing to remove the check ball and check ball retain-
er.
5/8” seal Check ball
retainer

Check
Set ball
screw 7/16”
Check ball
seat seal
207188

9-9
STEERING SYSTEM

Inspection After Disassembly

1. Check all mating surfaces. Replace any parts
that have scratches or burrs that could cause
leaks.
2. Clean all metal parts in clean solvent. Blow
dry with air. Do not wipe dry with cloth or
paper towels because lint or other materials in
the hydraulic system cause damage. Do not
use a coarse grit or try to file or grind these
parts.

Reassembly

6
4

3
207189

Reassembly sequence
1 Check valve 5 Spacer plate and Seal
2 Spool and Sleeve assembly 6 Drive
3 Needle thrust bearing 7 Meter and Seal
4 Seal gland bushing assembly 8 End cap, Screw, Seal

9-10
 STEERING SYSTEM

NOTE
Replace seals once disturbed. Lubricate all
seals with clean petroleum jelly such as
Vaseline.

Suggestions
Reassembling the check valve
Use needlenose pliers to place the check ball
retainer into the housing. Make sure that the check Set screw
vale is square in the housing. Install the ball into
the housing. Seal Check ball seat
Lubricate the seals and install them on the check Seal
ball seat. Lubricate the seat and lower it into the Check ball
housing. Do not twist or damage the seals. Push
the seat to the shoulder of the housing. Check ball
retainer
Install the set screw. Use a 1/4” Allen wrench to
tighten the set screw. Make sure that the top of the 207190
set screw is slightly below the housing mounting
surface.

11.3 N·m
Tightening torque for
(1.2 kgf·m)
set screw
[8.3 lbf·ft]

Reassembly the spool and sleeve

Assemble the spool and sleeve so that the spring Control Spring
slots line up. Rotate the spool while sliding into sleeve slot
the parts together.
Spring
Some sets have identification marks. Align these slot
marks. Test for free rotation.
Control
Align spring slots of both parts in line. Position spool
one end of the centering springs in Spring Identification
Installation Tool and compress the other end. Push marks
the spring set into the spool sleeve assembly while 207191
withdrawing the installation tool at the same time.
Special tool needed
Spring installation tool 97157-00100

9-11
STEERING SYSTEM

Center the spring set in parts so that they push

down evenly and flush with the upper surfaces of
the spool and sleeve.

200671

Install the pin through the spool and sleeve to the

point where pin ends are flush with the sleeve.
Insert the spool and sleeve assembly, placing the
splined end to enter the housing first.

Pin
207192
NOTE
Be extremely careful that the parts do not jam.
Push the parts into place with a slight rotating
action. Keep the pin nearly horizontal and
check for free rotation without allowing the
pin to drop into the discharge groove in the
housing.

Reassembling the needle bearing

Install the seal in the housing. Install the two races
and the needle thrust bearing as shown. Needle
▲

thrust Bearing
bearing race (2)
▲

Seal

207193

9-12
 STEERING SYSTEM

Reassembling the seal gland bushing

1. Install the dust seal in the bushing with the flat Retaining
ring

▲
side facing towards the bushing.
2. Install the quad ring seal in the bushing by
Seal
smoothing it into place with your finger. Do gland

▲
not use any seal that falls freely into the bushing
pocket of the bushing. (with seals)
3. Install the bushing assembly over the spool
end with a twisting motion. Tap it into place
with a rubber head hammer. Make sure the 200673
bushing is flush against with the bearing race.
4. Install the retaining ring in the housing and tap
Screwdriver
on the ring end or pry it with a screwdriver Dust seal
around the entire circumference to ensure a
Retaining ring
good setting.
Seal gland
bushing
Quad ring seal
Seal

207195

Reassembling the spacer plate

1. Clamp the housing in a vise, equipped with
soft jaws or softened with rag, clamping
lightly over the edges of the mounting area.
Do not overtighten the vise jaws.

NOTE
Check that the spool and sleeve are flush with
or slightly below the surface of the housing.
207196

9-13
STEERING SYSTEM

2. Install the seal in the housing. Place the

spacer plate on the housing and align the bolt
holes with the tapped holes in the housing.

207197

Reassembling the driver

1. Make a mark across the splined end of the
drive to indicate the direction of the slot at the Port surface
opposite end of the drive. •
2. Rotate the spool and sleeve assembly until the Drive
pin is parallel with the port surface. Install the
drive and make sure that it engages the pin.
Pin parallel with
This mark should be parallel to the port sur- port surface
face.

Pin 200675

Reassembling the meter

1. Install the seal in the meter.
Meter
(Gerotor)

Seal

207198

9-14
 STEERING SYSTEM

2. With the seal side of the meter towards the Meter (Gerotor)
spacer plate, align spline of the star (wheel) star valley
A
(A) on the drive (B). Noting the parallelism of
reference lines A, B, C, and D, align the bolt B
holes without disengaging the meter from the
drive. Drive
(marked)
C
•
D

Port
face
Pin 207199

Reassembling the end cap

End Cap
1. Install the drive spacer(s) in the meter. Install Seal screw
cap
the seal in the end cap. Install the end cap in Drive
the meter and align the holes. spacer
Seal
washer

207200

2. Install dry cap screw with new seal washers.

Pretighten all of the screws, then tighten them
progressively in the sequence as shown.

14.7 N·m
Initial torque for screws (1.5 kgf·m)
[10.8 lbf·ft]
23.5 N·m
Finishing torque for screws (2.4 kgf·m)
[17.3 lbf·ft] 200677

After installing the end cap, install the steering

wheel to the spool and make sure the spool rotates
smoothly.

9-15
STEERING SYSTEM

Troubleshooting
No steering flow
(1) Foreign materials clogged in — Disassemble and clean.
spool pit
(2) Fatigued or damaged spring — Replace spring.
in the spool
Defect in flow Malfunction of relief valve
divider valve (1) Decline in relief pressure — Adjust relief pressure.
7355 +490
0 kPa
+5
(75 0 kgf/cm2)
[1066 +71
0 psi]
(2) Damage on valve seating surface — Replace valve assembly.
(3) Fatigued or damaged spring — Replace springs and
adjust relief pressure.
Oil leak from relief valve
Stiff steering wheel operation

(1) Damaged O-rings on the — Replace O-rings.

valve body circumference

Defect in control Clogging in metering section — Disassemble and clean.

valve Malfunction of spool — Disassemble and clean.
Faulty bearing — Disassemble and
replace.

Defect in steering Bent piston rod — Repair or replace.

cylinder Faulty piston seal — Replace.

Faulty installation of steering

Misalignment — Repair.
valve or tilt column

Flattened pipe or mixing of — Clean or replace oil

Others
foreign materials line.

Sticking of spool or sleeve — Repair or replace.

Defect in control
Breakage of centering spring — Disassemble and
valve
replace.
Unstable steering operation

Flattened pipe or mixing — Clean or replace oil

Others of foreign materials line.
Faulty piston seal of steering cylinder — Replace.

Air trapped in hydraulic fluid — Bleed air.

Abnormal noise Loose installation of — Repair or replace.
power cylinder and socket end
9-16
 STEERING SYSTEM

Service Data
A = Standard value
Unit: mm (in.)
Truck Models
GP/DP15K, 18K GP/DP20K thru 35K
Items
Steering torque (at steering wheel rim)
N·m (kgf·m) [lbf·ft]
A 1.96 (0.2) [1.44]
While engine is running at low idle, rotate wheel at a
rate of one full turn per second, keeping standstill.
Inward (deg) A 82 83
Turning angle
Outward (deg) A 55 56
Tightening torque of steering wheel nuts
A 53.9 to 58.8 (5.5 to 6.0) [39.7 to 43.3]
N·m (kgf·m) [lbf·ft]
Tightening torque of steering bracket bolts
A 29.4 (3) [21.7]
N·m (kgf·m) [lbf·ft]
Displacement cc (cu.in.)/rev. A 73.8 (4.50) 96 (5.86)
Flow rate l (U.S. gal)/min 11 (3.00) 15 (4.00)
Maximum operating pressure
A 7355+490 +5 +71
0 (75 0 ) [1066 0 ]
Steering kPa (kgf/cm2) [psi]
control valve
Tightening torque of end cap bolt 1
A 31.2 (3.2) [23]
N·m (kgf·m) [lbf·ft]
Tightening torque of check valve set
A 11.3 (1.2) [8.3]
screw 2 N·m (kgf·m) [lbf·ft]

2 1

200786

9-17