Chapter 10 STEERING SYSTEM

1. Structure and Functions....................................................................... 10-1

1.1 Steering System .................................................................................................... 10-1
1.2 Steering Valve ....................................................................................................... 10-2
1.3 Steering Column.................................................................................................... 10-3
2. Disassembly and Reassembly............................................................. 10-4
2.1 Disassembly and Reassembly .............................................................................. 10-4
2.2 Steering Wheel and Steering Valve, Removal and Installation ............................. 10-5
2.3 Steering Wheel ...................................................................................................... 10-5
2.4 Steering Valve ....................................................................................................... 10-6
2.5 Tilt Lock Lever ....................................................................................................... 10-7
3. Steering Valve ....................................................................................... 10-8
3.1 Disassembly .......................................................................................................... 10-8
3.2 Reassembly......................................................................................................... 10-10
4. Troubleshooting.................................................................................. 10-14
5. Service Data......................................................................................... 10-15

10
 STEERING SYSTEM

Chapter 10 STEERING SYSTEM

1. Structure and Functions

1.1 Steering System
5 3 P

PF

4 T2 T1
L
R To lift cylinder
T
P

1 2
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Main Components
1 Hydraulic tank 4 Steering valve
2 Hydraulic pump (gear pump) 5 Steering wheel
3 Inlet section of hydraulic control valve 6 Steering cylinder
(Including flow priority valve)

The steering system of this lift truck is full hydraulic. the steering wheel is turned, the pump rotor rotates
The oil drawn by hydraulic pump 2 from hydraulic tank and delivers the pressure oil from either port L or port
1 enters the inlet section of the hydraulic control valve R of the steering valve 4 to the steering cylinder 6
3 through the P port. There is built-in flow priority valve
in the inlet section. The function of the flow priority
valve is to deliver pressure oil preferentially to steering Simultaneously, the return oil passage from the steer-
valve 4. From the PF port, the oil flows to the P port of ing cylinder in the steering valve 4 opens and the
the steering valve. return oil flows from the port T of the steering valve to
the port T2 of the inlet section of the hydraulic control
valve
When the steering wheel 5 is not turned, the oil from
the port T of the steering valve 4 returns to the hydrau-
lic tank 1 through the port T2 of the inlet section of the The steering cylinder piston's response to both outgo-
hydraulic control valve. ing and incoming pressure oil causes the cylinder rod
to extend either left or right. This action causes the tie
rod to turn the knuckle, which moves the rear wheels.
When the steering wheel is turned, the oil flows into a
small hydraulic pump located inside the steering valve
4. The core part of this pump is a trochoid pump rotor For the priority valve and the steering cylinder, refer to
called "Gerotor" (refer to the "1.2 Steering Valve"), "Chapter 11 HYDRAULIC SYSTEM" and "Chapter 8
which rotates coaxially with the steering wheel. When REAR AXLE," respectively.

10-1
STEERING SYSTEM

1.2 Steering Valve

A B a,b,c : Metering pump inlets

3 10 13 11 4 6
d,e,f : Metering pump outlets

c 6
5 d

b
e

a f

g
8 9 2 1 7 12 5
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1 Spool 8 Centering spring A: Control section

2 Sleeve 9 Pin B: Metering section
3 Outlet port (port T) 10 Port L
4 Inlet port (port P) 11 Port R
5 Rotor 12 Housing
6 Rotor ring 13 Check valve
7 Drive shaft

The steering valve consists of two sections: control At this moment, the oil passage to the metering sec-
section A and metering section B. Control section A, is tion B is blocked by the spool 1 and the sleeve 2.
a rotary type directional control valve section that con- When the operator turns the steering wheel clockwise,
sists of spool 1, sleeve 2, and housing 12. the passage in the steering valve opens, allowing
The spool 1 is splined to the steering shaft. pressure oil to flow through inlet port 4 into areas a, b,
When the spool 1 is turned, the sleeve 2 rotates, which and c. The rotor 5 rotates as the steering wheel turns,
causes the following passages to open. oil in areas d, e, and f is forced into the steering cylin-
der through the port 11.
(1) A passage that allows oil to flow from the inlet port
When the steering wheel is turned counterclockwise,
4 to the metering section B.
oil flows in the direction reverse to the above, entering
(2) A passage that allows oil to flow from the metering the steering cylinder through left turn port 10.
section B to either port L or R.
As the pressure oil from the inlet port 4 applies a rotat-
(3) A passage that allows the return oil from the ing force to the rotor 5, the steering wheel can be
steering cylinder to the outlet port T. turned with less effort.
Metering section B is a small hydraulic pump called a Normally, the check valve 13 blocks a bypass flow
"Gerotor" consisting of rotor ring 6 and rotor 5. Both since it is pushed to the left by the pressure oil from
Spool 1 and rotor 5 are coupled to the drive shaft 7. the inlet port.
When the steering wheel is turned, the rotor 5 rotates When the oil supply from the port PF of the hydraulic
in the same direction and at the same speed as the control valve stops for some reason, the bypass flow
steering wheel does. When the steering wheel is not opens to allow the oil from the hydraulic tank to flow
turned, the oil from the inlet port P flows to the outlet into the metering section B. When the steering wheel
port T and returns to the hydraulic tank. is turned, the metering section acts as a manually-
operated pump, which pumps the oil into the steering
cylinder.

10-2
 STEERING SYSTEM

1.3 Steering Column

Column position when steering column

is tilted fully forward
Column position when lock is released 13° Column neutral tilt position
(inclination of 30 degrees to vertical line)
5° Column position when steering column is
7°
tilted fully backward

Combination switch Steering column

mounting plate mounting plate (A)
1

2
Tilt angle
setting plate (B)
2
Bolt
Fix 3

Loosen
5 Nut
Lock release
4
When the tilt lever 3 is turned counterclockwise,
the plates A and B are fixed between the bolt and nut.

217337

Main Components
1 Steering Column 4 Column lock lever
2 Bracket (secured to truck body) 5 Lock pin
3 Tilt lock lever

The steering column tilt angle is adjustable in the

range of 5 degrees forward and 7 degrees backward
as shown in the illustration.
To adjust the tilt angle, lock the column lock lever 4
first, and loosen the tilt lock lever 3 by turning it clock-
wise. Then, tilt the steering column 1 to the optimal
angle and turn the tilt lock lever counterclockwise (pull-
ing upward) to lock.
The column lock lever 4 is used to tilt the steering col-
umn forward for the convenience of the operator to get
on and off the lift truck and during maintenance. Tilt
the steering column forward by pushing down the tilt
lock lever 3 to disengage the column lock lever 4 from
the lock pin 5.

10-3
STEERING SYSTEM

2. Disassembly and Reassembly

2.1 Disassembly and Reassembly
1
7
A
6
5

4 7

2 6
View A
4

217326

Main parts or devices

1 Steering valve 5 Hose and pipe (steering valve T port → T2 port)
2 Hydraulic control valve 6 Hose (steering valve L port ←→ steering cylinder)
(The illustration shows MC valve.) 7 Hose (steering valve R port ←→ steering cylinder)
3 Steering cylinder
4 Hose
(PF port → steering valve P port)
Disassembly and Reassembly
(1) Be sure to perform the maintenance work of the (4) When removing or installing hoses, use a double
hydraulic system in a clean place and be careful spanner as needed to prevent excessive force
not to allow abrasive foreign substances to enter from being applied to the matching fittings.
the hydraulic system.
(5) Bleed air after reassembly.
(2) O-rings must be replaced, once disturbed. Air bleeding method is as follows.
(3) Steering system hoses (especially high-pressure (a) Raise the rear tires off the floor by placing jack
section) are critical safety parts. These hoses stands under the lift truck body.
must be replaced at their specified time interval,
even if damage is not found. For a replacement (b) While changing the speed of the engine by
time interval, follow the "Operation & Maintenance pressing the accelerator pedal, turn the steer-
Manual." ing wheel lock-to-lock to release air pressure.

10-4
 STEERING SYSTEM

2.2 Steering Wheel and Steering Valve, Removal and Installation

2 1
Tightening torque:
52.6 to 64.4 N·m
(5.36 to 6.57 kgf·m)
[38.8 to 47.5 lbf·ft]
3
4

7
Tightening torque: 4
26.7 to 39.9 N·m
(2.72 to 4.07 kgf·m)
[19.7 to 29.4 lbf·ft]
5 Tightening torque:
26.7 to 39.9 N·m
Apply grease. (2.72 to 4.07 kgf·m)
[19.7 to 29.4 lbf·ft]
6 213776

Disassembly sequence
1 Steering wheel 5 Steering valve mounting bolt
2 Nut 6 Steering valve
3 Spring washer 7 Steering column assembly mounting bolt
4 Cover 8 Steering column assembly

2.3 Steering Wheel

2.3.1 Removal
(1) Remove the horn button.
M12 bolt
(2) Remove the steering wheel nut 2 and then,
remove the steering wheel 1 using a wheel puller. M8 bolt

Special tool needed 91268-10600

Wheel puller
Wheel puller 91268-10600

Steering wheel

When removing the steering wheel, do not tap the top

213777
end of the steering shaft.
Wheel puller setting

10-5
STEERING SYSTEM

2.3.2 Installation
Install in the following sequence.
Front Horn switch contact
(1) Turn the projection (a) on the steering wheel
angle sensor of the combination switch by hand to
Cancel cam
orient the same direction as shown in the illustra-
tion.
(2) Apply a thin coat of grease to the sliding area of (a)
the horn contact underneath the steering wheel Projections
boss. form an
isosceles
(3) Orient the steering wheel to the forward driving triangle.
Front
position. Install the steering wheel so that its con- Forward
cave point fits the projection of the combination
switch. Rotate the steering wheel to both direc-
tions several times to make sure the complete fit.
(4) Before tightening the steering wheel nut, make Combination switch
sure that the automatic return of the combination
switch functions properly.
213778
(5) If automatic return does not function, repeat the
step (3) and (4).
(6) Tighten the steering wheel nut to the specified
torque.

Inspection after Installation

Steering effort
(1) Pull the hand brake lever.
(2) Run the engine to warm the hydraulic oil tempera-
ture up to between 40 and 60 °C (104 and 140
°F).
(3) Attach a spring scale to the rim (or a spoke) of the
steering wheel, and measure the steering effort
required to turn the steering wheel clockwise or
counterclockwise from the straight-ahead posi- 213779
tion. Steering effort should be the value specified
below or lower.
Unit: N (kgf) [lbf]
13
Steering effort
(1.3)
(at steering wheel rim)
[2.92]

2.4 Steering Valve

2.4.1 Removal
(1) Remove the cover 4 around the steering column.
(2) Disconnect four hoses from the steering valve.
(3) Remove the bolt 5 and then, remove the steering
valve 6.

10-6
 STEERING SYSTEM

2.4.2 Installation
For installation of the steering valve, follow the
removal sequence in reverse, while following the
instructions below.
Face the elbow right
(1) Apply grease to the serrated area on the lower downward to install.
part of the steering shaft. Tightening torque of nut:
(2) Tighten the mounting bolt to the specified torque. 34 to 39 N·m
(3.47 to 3.98 kgf·m)
(3) Be careful about the orientation when installing [25.1 to 28.8 lbf·ft]
the elbow on the steering valve. Tighten it to the
specified torque.

213780

2.5 Tilt Lock Lever

2.5.1 Disassembly
(1) Put alignment marks on the tilt lock lever and the
nut (B) for proper installation at reassembly. Top face of lever
(2) Remove the bolt (A) and then, remove the tilt lock
lever.

Tilt lock lever

Lever mounting bolt

Nut (B)

Bolt (A)

Tilt lock lever

213781
2.5.2 Reassembly
If the alignment marks have disappeared, or the lever
is being replaced with a new lever, install the lever by
referring to the following steps. (The illustration on the
right shows the relation of the parts when the tilt posi-
tion is in the neutral and the column lock lever is
locked.)
(1) Tighten the nut B to the tightening torque of 11 to
15 N·m (1.1 to 1.5 kgf·m) [8.1 to 11.1 lbf·ft]. (This
represents a lever-locked condition.)
(2) Select the optimal position for the tilt lock lever in
a locked condition, and fit the tilt lock lever into the
serrated section of nut B. The optimal position is
where the star-marked notch section of the
bracket intersects with the top face of the lever.
(3) Tighten the bolt A.
(4) Loosen the tilt lock lever and check that the
bracket slides in the entire tilting area without
interfering with other parts.

10-7
STEERING SYSTEM

3. Steering Valve
3.1 Disassembly

11

10

213782

Disassembly sequence
1 End cap, Bolts, O-ring, Spacers 6 Thrust needle, Race bearing
2 Gerotor set, O-ring 7 Control sleeve
3 Drive shaft, Spacer plate, O-ring 8 Control spool
4 Retaining ring 9 Pin
5 Seal gland bushing, O-ring, 10 Centering spring
Oil seal, Dust seal 11 Long housing

Suggestions for Disassembly

(1) Retaining ring removal
Remove the ring from the housing by gently pry-
ing its end out of the groove. Do not damage the
machined surface.

213783

10-8
 STEERING SYSTEM

(2) Seal gland bushing removal

Position the control spool and control sleeve
assembly so that the pin is even with the center of
the assembly. Remove the gland bushing.

213784

(3) Control spool and sleeve removal

Remove the control spool and sleeve assembly
from the housing by pulling it toward the end of
the housing opposite to the flange. Remove the
pin from the assembly.

To prevent damage to the housing, slowly pull out the

assembly while twisting.

213785

(4) Control spool and sleeve disassembly

Before disassembly, put alignment marks across the

spool and the sleeve for proper installation at reas-
sembly.

Pull the control spool from the sleeve enough to permit

removal of the centering springs. Remove the center-
ing springs.
Remove the spool from the sleeve by pulling it toward
213786
the rear end of the sleeve while turning slowly.

Inspections after Disassembly

(1) Check sliding areas between the sleeve and the
housing and between the sleeve and the spool.
(a) Check for sliding movement in the sub-assem-
bly condition.
(b) Check the sliding surfaces for any unusual slid-
ing movement. If any defect such as wear,
scratches, burrs, or rust is found, replace the
assembly with a new one.

10-9
STEERING SYSTEM

3.2 Reassembly

8 6

11

3 4 2 5 1
10

213787

Reassembly
1 Long housing 7 Seal gland bushing, Oil seal, Dust seal, O-ring
2 Control sleeve 8 Retaining ring
3 Control spool 9 Drive shaft, Spacer plate, O-ring
4 Centering spring 10 Gerotor set, O-ring
5 Pin 11 End cap, O-ring, Spacer, Bolts
6 Thrust needle, Race bearing

Be sure to make the following preparations before

reassembly.
(1) For damaged parts, prepare new parts for
replacement.
(2) Clean surfaces of all metal parts, blow off foreign
substances with compressed air and dry them.
(3) Prepare new O-ring seals and lip seals for seal
kits.

Observe the following instructions during reassembly.

(1) Apply a thin coat of oil to each part before installa-
tion.
(2) Apply grease to O-rings
(3) Do not use cloth gloves when reassembling
because lint or fibers may enter inside the valve.

10-10
 STEERING SYSTEM

Suggestions for Reassembly

(1) Reassembly of control spool and sleeve
Check the direction in which the spring groove of
the sleeve is aligned with that of the spool and Spring groove
then, slide the spool into the sleeve while twisting
the spool. Spring groove
Ensure that the match marks align (matching
mark made during disassembly or a maker pro-
vided matching mark).

Matching marks
Check that the control spool rotates smoothly in the
213788
control sleeve.

(2) Installation of centering springs

Align the spring grooves of the spool-and-sleeve
and stand the spool-and-sleeve on a flat bench.
Use the spring inserting tool to install springs.
Place each set of the three springs back to back
and pinch six springs in the tool with notches on
both sides facing downward.
As shown in the illustration, push one end of the
springs with fingers and push the springs into the
spool-and-sleeve groove. In case there is no
inserting tool, assemble the springs by alternately
inserting them one by one, right and left. 213789

Spring inserting tool 97157-00100

(3) Insertion of the control spool-and-sleeve assem-

bly into the housing
Insert the pin into the hole of the control spool-
and-sleeve assembly and align both ends of the
pin with the outside diameter of the sleeve. Insert
the spool-and-sleeve assembly into the housing
from the rear (in the direction as shown in the
illustration).
Insert the spool-and-sleeve assembly while slowly
twisting it with the pin kept at a horizontal position.
Insert the spool-and-sleeve assembly until its rear
edge face becomes flush with the edge face of the 213790
housing. Do not insert any further.

(4) Install O-ring and thrust bearing.

(5) Installing seal
(a) Install dust seal to seal gland bushing. See the
illustration for orientation. Then install the X-
ring seal.
(b) After installing the O-ring, fit the seal gland
bushing into the spool while turning the seal
gland bushing. Drive the bushing into the spec-
ified position by a plastic hammer. Check that
the bushing contacts the top face of the thrust
213791
bearing race evenly.
Securely fit the retaining ring into the housing
groove.

10-11
STEERING SYSTEM

Retaining ring

214082

(6) Installing spacer plate

(a) Before holding the housing in a vise, use a soft
pad or wrap a soft cloth around the housing.
Hold the flat section of flange in a vise.
Do not hold it in a vise too tight.
Note: Make sure that the spool and sleeve are flush
with or slightly lower than the surface of hous-
ing.

214871

(b) Install O-ring to the housing. Place the spacer

plate on the housing, and align the bolt hole
with the tap hole of housing.

214872

(7) Installation of drive shaft

Turn the control spool-and-sleeve assembly so
the port surface of the housing is parallel with the Port surface
pin.
Drive shaft
Insert the drive shaft to engage the pin in the yoke
of the drive shaft. To insure positioning in the fol-
lowing work process, draw a line such as line B in Pin parallel with
the illustration right below on the end face of the port surface
drive shaft spline with a felt-tip pen.
Pin
213793

10-12
 STEERING SYSTEM

(8) Installation of gerotor set

Face the O-ring side of the rotor set toward the Root of “Gerotor” A
spacer plate side and fit the rotor set into the drive set star
shaft by aligning the root (line A) of the rotor set B
with line B of the drive shaft. Spacer plate
C
Check that lines A, B, C, and D are in parallel with D
each other. Drive shaft
(with marked line)
Align bolt holes of the "Gerotor" set with the drive
shaft and star kept engaged.
This procedure is important in determining the
valve timing of this unit.
213794

(9) Installation of end cap

Install the end cap in the gerotor set and align the
End cap
holes. Apply oil to bolt threads and tighten bolts
evenly in the sequence as shown in the illustration
on the right. The tightening torque is shown in the Cap screw
table below.
Install the steering shaft in the spool and check
that the spool turns smoothly.
Unit: N·m (kgf·m) [lbf·ft] O-ring

Tightening torque of end Drive spacer

28.4 (2.9) [21]
cap mounting bolt
214873

213795

10-13
STEERING SYSTEM

4. Troubleshooting

No steering flow
(1) Foreign materials clogged in spool pit Disassemble and clean.
(2) Spring in spool settles Replace spring.
Malfunction of relief valve
(1) Low relief pressure Adjust relief pressure.
Flow priority valve fail-
ure (2) Damaged valve seating surface Replace valve assembly.
(3) Settling of spring Replace spring, and adjust the relief
pressure.
Oil leak from relief valve
Steering (1) Damaged O-rings on the valve body Replace O-rings.
wheel circumference
is too stiff.
Clogging in "Gerotor" Disassemble and clean.
Malfunction by spool seizure due to for- Replace.
Steering valve failure eign material
Damaged bearing Replace.
Excessive tightening of end cap bolt Reassemble.
Piston rod distorted Replace.
Steering cylinder failure
Faulty piston seal Replace.
Steering valve and tilt column assembly Adjust.
Misalignment
malfunction
Other failures Flattened hose or pipe Replace.
Seizure of spool or sleeve Replace.
Steering Steering valve failure
wheel Breakage of centering spring Replace.
movement
Trapped air Bleed.
is
unstable. Other failures Flattened hose or pipe Replace.
Faulty piston seal of steering cylinder Replace.

10-14
 STEERING SYSTEM

5. Service Data
Unit: N·m (kgf·m) [lbf·ft]
Truck type
Item
1 ton class 2 ton class 3 ton class
Steering effort (at steering wheel rim) N (kgf) [lbf] A 13 (1.3) [2.9] or less
Tightening torque of steering wheel nuts A 52.6 to 63.5 (5.36 to 6.47) [38.8 to 46.8]
Tightening torque of steering bracket bolts A 27 to 35 (2.75 to 3.56) [19.9 to 25.8]
Steering valve mounting bolt tightening torque A 26.7 to 39.9 (2.72 to 4.07) [19.7 to 29.4]
cc (cu in.) /
Displacement A 69 (4.21) 96 (5.86) 120 (7.32)
rev
Steering valve
Rotating torque in normal operation A 1.5 (0.15) [1.11]
Tightening torque of cap bolt 1 A 28.4 (2.9) [21]
MPa +0.5 +5.1 +0.5 +5.1 +0.5 +5.1
8.8 0 (90 0 ) 10.3 0 (105 0 ) 10.3 0 (105 0 )
Steering system relief valve set pressure (kgf/cm2) A +72.5 +72.5 +72.5
[psi] [1276 0 ] [1494 0 ] [1494 0 ]

213796

A: Standard value

10-15