STEERING SYSTEM

Structure and Function ......................................................................... 9 – 1

General ..................................................................................................... 9 – 1
Steering Gear Assembly ........................................................................... 9 – 2
Steering Hydraulic System ........................................................................ 9 – 3
Removal and Installation ...................................................................... 9 – 4
Removal ................................................................................................... 9 – 4
Installation ................................................................................................ 9 – 6
Steering Gear .......................................................................................... 9 – 7
Disassembly ............................................................................................. 9 – 7
Inspection and Repair (after disassembly) ................................................ 9 – 10
Reassembly .............................................................................................. 9 – 11
Inspection and Repair (after reassembly) ................................................. 9 – 14
Power Cylinder ........................................................................................ 9 – 15
Disassembly .............................................................................................. 9 – 15
Inspection and Repair (after disassembly) ................................................ 9 – 16
Reassembly .............................................................................................. 9 – 16
Inspection ................................................................................................. 9 – 18

9
 STEERING SYSTEM

Structure and Function

General
1 2

14

4 5

3
11

10
7

8
13
15

9
12
207554

1 From hydraulic tank 9 Power cylinder

2 Hydraulic pump (gear pump) 10 Rear axle bellcrank
3 Flow priority valve 11 To hydraulic tank
4 Hydraulic control valve 12 Drag link
5 Main relief valve 13 End link
6 Steering relief valve 14 Steering wheel
7 Steering gear assembly 15 Pitman arm
8 Power steering control valve

The power steering system of this forklift truck is a oil under pressure to flow into power cylinder 9. This
hydraulic, semi-integral type that features a power causes the power cylinder to move end link forward or
steering cylinder connected midway in the mechanical backward. As the link 13 moves, bellcrank 10 linked
control linkage. to it turns, which moves the linkage of the rear axle
With this system, almost all steering motions are linked to the bellcrank such that the wheels are steered
created through extension and retraction of the rod of to the desired direction.
power cylinder. The flow of the hydraulic oil pressure When turning the steering wheel, the operator can feel
that controls extension and retraction of the power adequate steering resistance as pitman arm 15 and drag
cylinder rod is as follows: link 12 move following the power-cylinder-initiated
Hydraulic pump 2 ➞ Flow priority valve 3 built in the movement of end link 13 and the movement is
control valve’s inlet section ➞ Power steering control transmitted as reaction through the inside mechanism of
valve 8 located at the bottom of the steering gear steering gear assembly 7 to the steering wheel. Even in
assembly. the event of loss of hydraulic pressure, steering is still
possible as the steering wheel movement is transmitted
When the operator turns the steering wheel, the spool through the linkage consisting of pitman arm 15 and
valve in control valve 8 moves up or down, allowing drag link 12.

9-1
STEERING SYSTEM

Steering Gear Assembly

The steering gear assembly has single-piece steering shaft 1
which extends from the top to the bottom of the assembly.
There are three sections A, B and C on the steering shaft to
which the assembly’s major component blocks are attached
as shown in the drawing to the right.
To section A at the top, the steering wheel is attached. The
steering wheel is splined to the shaft so that its rotation is
transmitted directly to the steering shaft.
To section B at the middle portion is attached the steering
gear which causes pitman arm 9 to move through a
mechanical means. This section of the steering shaft has a
left-hand screw worm with which ball nut 2 is engaged.
Since there are recirculating steel balls between the worm
and nut, the nut can be moved up and down with minimum
friction. On one side of the ball nut, there are rack teeth and
the rack teeth are in mesh with sector gear 3. As the sector
gear is moved, the shaft of the sector gear turns and pitman
arm 9 connected to the shaft move back or forth.
For example, when the steering wheel is turned clockwise,
steering shaft 1 first moves up, while turning, by the
reaction force of the ball nut. The upward movement of the
shaft, however, is restricted by the component block at
section C. Then ball nut 2 (or the rack teeth on the nut’s
side) moves down.
Now, sector gear 3 is turned counterclockwise, causing
pitman arm 9 to turn also counterclockwise (as shown in the
drawing by arrow ).
The component block located in section C at the bottom of
the steering shaft is a sliding type directional control valve
(steering valve) which controls the flow of oil going to and
returning from the hydraulic power cylinder. The steering
valve consists of cylindrical spool valve 4 which is held in
position around the steering shaft through top and bottom
needle bearings 7 and connected indirectly to the shaft by
lock nut 8 and ring plate 10. The spool moves up together
with the steering shaft when the steering wheel is turned
clockwise (as the shaft has a left-hand screw worm). This is
also true when the steering wheel is turned
counterclockwise except that the shaft and spool now move 208685
downward. Through upward and downward movements of *1 Steering shaft 6 Reaction spring
the spool in stationary valve body 5, the flow of oil to and
*2 Ball nut 7 Needle bearing
from the power cylinder is controlled appropriately.
3 Sector gear 8 Lock nut
As described above, the steering shaft moves up or down 4 Spool valve 9 Pitman arm
whenever the steering wheel is turned. The shaft’s 5 Valve body 10 Ring plate
movement, either upward or downward, compresses
reaction springs 6 built into the valve. When turning of the * Parts 1 and 2 forms an integrated unit called “ball
steering wheel is stopped, the reaction springs push the screw assembly”.
steering shaft and bring it to the straight-ahead position.

9-2
 STEERING SYSTEM

Steering Hydraulic System

208686

1 Hydraulic tank 6 Steering cylinder

2 Hydraulic pump 7 Steering system relief valve
3 Hydraulic control valve 8 Main relief valve
4 Flow priority valve 9 Return line
5 Steering valve

The oil drawn by hydraulic pump 2 from hydraulic tank When the steering wheel is turned left, the oil flows
1 enters the inlet section of the hydraulic control valve through the same passage as when the steering wheel is
3 through the P port. There is built-in flow priority turned right but in the reverse direction.
valve 4 in the inlet section. The function of the flow The hydraulic pressure of the steering system is
priority valve is to deliver oil pressure preferentially to maintained at a level lower than the maximum pressure
steering valve 5 in the steering gear assembly through by steering system relief valve 7 which opens when the
the PF port. (For the structure of the priority valve, pressure is sensed at the PF port of the inlet section
refer to the “GROUP 10 HYDRAULIC SYSTEM”.) exceeds the limit. The relief valve is located below the
From the PF port, the oil flows to the P port of the inlet section and its opening pressure is set at 8.3+0.4/-
steering valve. 0 MPa (85 + 05 kgf/cm2) [1215 + 070 psi].
When the steering wheel is not turned (in the straight-
ahead position), the oil flows through the steering
valve’s T port to the T2 port in the hydraulic control
valve’s inlet section and then returns to hydraulic tank
1 through return line 9.
When the steering wheel is turned right, the spool
moves upward. The oil entering the P port of steering
valve 5 flows out of the valve through the R port and
goes to the head end of steering cylinder 6, pushing the
rod out. The oil in the rod end of the cylinder goes to
the T2 port after passing through the L port and then
the T port of steering valve 5.
9-3
STEERING SYSTEM

Removal and Installation

Removal

1 4

3
8

9
7

6
5

207555

Sequence
1 Steering wheel, Nut 7 Steering gear assembly
2 Turn signal switch 8 End link assembly, Tie rod end assembly, Nut
3 Console box assembly, Clamp, Rubber 9 Power cylinder assembly,
4 Floor plate, Cover Tie rod end assembly, Nut
5 Hose, Pipe, Hose clamp, Connector
6 Drag link assembly, Tie rod end assembly, Nut

Start by:
(a) Disconnect the horn wiring from the terminals.
(b) Disconnect the turn signal switch wiring connector.
(c) If necessary, disconnect the console box harness
connector.
(d) Separate the lower ball joint of neutral switch.

9-4
 STEERING SYSTEM

Suggestion for Removal

1. Steering wheel removal

Remove the steering wheel with soft head hammer.

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

208748

2. Removing power cylinder

Jack up the rear end of the truck, and support it by placing
wood blocks under the side frame members, right and left.
Work under the truck to disconnect the power cylinder and
take it down.

202790

Inspection and Repair (after removal)

Drag link
Check for distortion, cracks, twisting or damaged threads.
Check tie rod end for play. Also check the dust seal for
damage.

9-5
STEERING SYSTEM

Installation

Assembly Dimensions and Tightening Torques

9 10
4
16 1

2 5

7 12
6
11

13 14 15 8
207556

NOTE
Assembly dimensions 1 thru 5, refer to the effective thread length measured from the end face of the nut.

1 Drag link end (front) assembly dimension mm (in.) 12 (0.47)

2 Drag link end (rear) assembly dimension mm (in.) 14 (0.55)
3 Power cylinder tie rod end assembly dimension mm (in.) 9 (0.35)
4 End link (front) assembly dimension mm (in.) 10 (0.39)
5 End link (rear) assembly dimension mm (in.) 3 (0.12)
6 Center to center of ball studs mm (in.) 470 (18.50)
7 Tightening torque for power cylinder end nut N·m (kgf·m) [lbf·ft] 157 (16) [116]
8 Tightening torque for end link nut N·m (kgf·m) [lbf·ft] 157 (16) [116]
9 Tightening torque for drag link end nut N·m (kgf·m) [lbf·ft] 49 (5) [36]
10 Tightening torque for drag link end nut N·m (kgf·m) [lbf·ft] 49 (5) [36]
11 Tightening torque for drag link lock nut N·m (kgf·m) [lbf·ft] 49 (5) [36]
12 Tightening torque for drag link lock nut N·m (kgf·m) [lbf·ft] 49 (5) [36]
13 Tightening torque for power cylinder lock nut N·m (kgf·m) [lbf·ft] 172 (17.5) [127]
14 Tightening torque for end link lock nut N·m (kgf·m) [lbf·ft] 172 (17.5) [127]
15 Tightening torque for end link lock nut N·m (kgf·m) [lbf·ft] 172 (17.5) [127]
16 Tightening torque for steering gear bolts N·m (kgf·m) [lbf·ft] 59 (6) [43]

9-6
 STEERING SYSTEM

Steering Gear

Disassembly

11

12 9
8

7
10

6
5

204570A

Sequence
1 Pitman arm, Nut, Spring washer 8 Ring plate, Needle roller bearing
2 Cap, Nut, Gasket, Nut 9 Column assembly, O-ring,
3 Side cover, O-ring, Shims, Adjusting screw Needle roller bearing, Oil seal, Bushing
4 Sector shaft 10 Ball-and-screw assembly
5 End cover, O-ring 11 Gear box, Snap ring, Oil seal
6 Lock nut, Ring plate, Needle roller bearing 12 Needle roller bearing, O-ring
7 Valve assembly, Ring plate, Valve spool,
Reaction piston spring, Pipe seat,
Valve housing

Start by:
Measure the starting torque of the worm with a torque
wrench or a spring balancer.

9-7
STEERING SYSTEM

General Precautions
The steering gear, complete with the control valve, is a
precision-machined component and, must be handled with
greater care. Cleanliness is of utmost importance; use clean
tools and work in a clean place.
(1) Clean the disassembled parts with high flash-point
solvent. Blow them dry with compressed air; however,
this does not apply to rubber parts.
(2) Oil seals, O-rings and the like are rubber parts. Never
wash them with the solvent. Blow dirt off rubber parts
with compressed air, and keep them immersed in
hydraulic oil until they are used in reassembly.
A rubber part showing even slight tear or wear must be
replaced. Rubber parts are expendable items, and
should be renewed at intervals of one year.
(3) Parts to be installed by pressing or forcing
(a) Oil seals
An oil seal, once disturbed must not be re-used in
reassembly. After disassembling, examine the oil
seals in place (in the gear box and rear cover) and,
if they are in sound condition, leave them there.
When installing a replacement oil seal, be careful
not to score or scratch its lip portion.
(b) Needle roller bearings
These bearings are in the gear box and side cover,
all press-fitted in such a way that they are not
replaceable. If any of the needle roller bearings is
found in worn-down or otherwise defective
condition, replace the whole gear box and side
cover assembly.
(4) Put mating marks as appropriate on parts for their
correct alignment during reassembly.

Suggestions for Disassembly

1. Removing pitman arm

Make a mark across the pitman arm and sector shaft. Using
the special tool A, remove the pitman arm from the sector A
shaft.
Special tool needed

Pitman arm puller A 91268 - 01800

A conventional puller may be used for removal of pitman

arm. 200294

9-8
 STEERING SYSTEM

2. Removing side cover

Turn the adjusting screw clockwise to remove the side
cover.

3. Removing sector shaft

Rotate the worm to bring the sector shaft to the position
shown, and lightly tap the serrated end of the shaft to force
it out of the box.
200295

4. Removing lock nut

Using a screwdriver, loosen the staked portion of the nut.

200296

5. Disassembling control valve

Separate the control valve from the gear box, and pull the
spool straight out, taking a firm grip on its head. Set the
valve body on the work bench as shown, and pull out the
inner parts by lifting them straight up.

200297

6. Removing ball bearing

Using the special tool (consisting of A and B), remove the
B A
ball bearing from the column.
Special tool needed

Steering puller A, B 91268 - 03200

Hook tool A to the bearing, and pull it out with tool B.

Ball bearing

202833

9-9
STEERING SYSTEM

7. Removing ball-and-screw assembly

Hold the gear box in a vise as shown, and pull out the
assembly in level position. If any part of this assembly is
worn or defective to require replacement, replace the whole
assembly.

200299

Inspection and Repair (after disassembly)

1. Control valve
Check the valve sleeve and spool for wear, rusting and
surface flaws such as scuffing, grooving, scratching, etc.
and, if necessary, replace as a set.

“P” mark

200300

2. Sector shaft
(1) Increase or decrease the shim thickness to reduce the Shims
clearance between the adjusting screw and sector shaft
to 0.1 mm (0.004 in.) or less. If the head of the screw is
worn, replace the screw.
(2) Replace the sector shaft if it is badly worn, damaged or
cracked. Adjusting screw

Clearance: Sector shaft

0.1 mm (0.004 in.),
maximum
200301

3. Ball-and-screw assembly
(1) If the recirculating ball nut rotates sluggishly on the
screw, wash the assembly in cleaning solvent, and test it
again for smoothness of rotation.
(2) Check the steering shaft for deflection with a dial gauge
as shown. If the deflection exceeds the service limit,
replace the shaft complete with recirculating balls.
200302

A: Standard value B: Repair or service limit

Unit: mm (in.)
A 0
Deflection of steering
shaft
B 1 (0.04), maximum

9-10
 STEERING SYSTEM

Reassembly

200303

208688

Sequence
11 ➞ 10❋ ➞ 9❋ ➞ 8 ➞ 7❋ ➞ 6 ➞ 5❋ ➞ 3 ➞ 1 ➞ 2
➞

12 4

Suggestions for Reassembly

4.9 mm
1. Reassembling gear box (0.19 in.)

Insert the oil seal (for sector shaft) as shown, and secure the
seal in place by snugly fitting the snap ring.
Snap ring

Oil seal

200304

9-11
STEERING SYSTEM

2. Installing balls and screw

Fit the largest-diameter part of the worm shaft into the
needle roller bearing in place.

200299

3. Reassembling column
Press the oil seal and ball bearing into position as shown.

NOTE
Press in the oil seal carefully to prevent oil leaks.

208689

4. Reassembling control valve

(1) Put the spool in the sleeve by aligning the “P” mark on
the sleeve with the small inside chamfer portion of the
spool, and position the reaction piston and centering
spring in place.

“P” mark

200300

(2) Install the needle roller bearing and plate, and install
the valve with “P” mark of the sleeve on the front cover
side.

200307

9-12
 STEERING SYSTEM

(3) After installing the plate and needle roller bearing,

attach the special tool A to the control valve. Tighten
the lock nut to a torque not exceeding 49 N·m (5 kgf·m)
[36 lbf·ft], and stake it at two places with a punch. At
this time, the steering torque of the shaft should be less
than 1.0 N·m (10 kgf·cm) [0.7 lbf·ft]. After stalking,
make sure that there is no rattle.
Special tool needed
A

Set plate A 91268 - 03300

200308

5. Installing end cover

20 to 29 N·m
Tightening torque for end
(2 to 3 kgf·m)
cover bolts
[14.5 to 21.7 lbf·ft]

6. Installing sector shaft

Center the ball nut as shown in the opening, and insert the
sector shaft, positioning them as in straight ahead position.
Secure the side cover by tightening its bolts to the specified
torque.

20 to 29 N·m
Tightening torque for side
(2 to 3 kgf·m)
cover bolts
[14.5 to 21.7 lbf·ft] 200309

7. Installing pitman arm

Install the pitman arm to the sector shaft by matching the
marks, and tighten the nut to the specified torque.

140 to 180 N·m

Tightening torque for
(14 to 18 kgf·m)
pitman arm nut
[101 to 130 lbf·ft]

200310

9-13
STEERING SYSTEM

Inspection and Repair (after reassembly)

1. Sector shaft backlash

Hold the steering wheel in a straight ahead position, and
measure the movement (backlash) of the free end of pitman
arm at a point 150 mm (5.9 in.) from the axis of sector shaft
with a dial gauge. Adjust the backlash with the adjusting
screw.

Backlash of ball nut with 0.3 mm (0.012 in.),

sector shaft maximum
200311
20 to 29 N·m
Tightening torque for
(2.0 to 3.0 kgf·m)
adjusting screw lock nut
[14 to 22 lbf·ft]

2. Swing angle of pitman arm

Rotate the steering wheel lock-to-lock, and measure the
swing angle of the pitman arm.

+ 6°
Swing angle of pitman arm 84° 0

200312

3. Starting torque (steering wheel side)

Hold the steering gear in a vise with the pitman arm in
vertical position, and make sure the steering shaft rotates
smoothly in both directions. Measure the starting torque of
the shaft in both directions of rotation.

1.0 N·m
Starting torque of steering
(10 kgf·cm)
shaft rotation
[0.7 lbf·ft]
202831A

9-14
 STEERING SYSTEM

Power Cylinder

Disassembly

1
❋
❋

❋
2

203814

Sequence
1 Guide assembly, Dust seal, Packing, 2 Piston rod, Nut, Seal, Piston
Guide bushing, O-ring 3 Cylinder tube, Tie rod end, Nut, Pin

NOTE

❋ (asterisk) denotes parts contained in Repair Kit.

Suggestion for Disassembly

Removing guide
(1) Loosen the staked portion of the cylinder tube with a
screwdriver, with the tube held in a vise at its port
(elbow) section.

200316

9-15
STEERING SYSTEM

(2) Put a socket and handle, engaging it to the notches

provided in the guide, and turn the guide
counterclockwise to loosen it.
Socket

200317

Inspection and Repair (after disassembly)

1. Cylinder tube
Check for wear, scuffing, scratching or rusting on its bore
surface.

2. Piston rod
Check for dents, scoring or wear. Also check for deflection.

1 mm (0.04 in.),
Deflection of piston rod
maximum
200319

3. Seals
Replace the dust seals, packing, O-ring and piston seal once
disturbed, or every year.

Reassembly
To reassemble, follow the reverse of disassembling
sequence, and observe the following precautions:

1. Installing piston to piston rod

Place the piston on the piston rod and secure it by
tightening the self-lock nut to the specified torque.

196 N·m
Tightening torque for
(20 kgf·m)
self-lock nut
[145 lbf·ft]

9-16
 STEERING SYSTEM

2. Inserting piston into cylinder

Using the guide A, gently insert the piston rod into the
cylinder tube squarely. A

NOTE
Apply hydraulic oil sufficiently to the piston and the
inside surface of cylinder tube.

Special tool needed 200320

Guide A 91868 - 00700,
MCF-1002

3. Installing dust seal

Using the installer, fit the dust seal to the guide.

4. Installing guide bushing

Using the rod cap B, place the guide bushing on the piston
rod. B
Special tool needed
Rod cap B 91868 - 01100,
MCF-1007

200322

5. Tightening guide bushing

Tighten the guide bushing to the specified torque.

265 N·m
Tightening torque for
(27 kgf·m)
guide bushing
[195 lbf·ft]

6. Staking cylinder tube (staking cylinder tube on

guide bushing)
Connect the steering oil hoses to the power cylinder
assembly, then apply oil pressure to the power cylinder. If
there is no oil leaking out, stake the cylinder tube on the
guide bushing at one point.

9-17
STEERING SYSTEM

Inspection

Steering wheel free play

15 to 30 mm
With the engine running at idling speed, measure the free (0.6 to 1.2 in.)
play at the wheel rim.

NOTE
Do not confuse the movement of control valve spool of
170 to 175 mm (6.7 to 6.9 in.) measured on the wheel
rim with the free play.

200325A
If the free play is out of this range, correct it by remedying the
causes stated in the “GROUP 12 TROUBLESHOOTING”.

Steering effort
(1) Set the parking brake, and run the engine, until the
water temperature gauge pointer moves into the white
zone, to warm up the hydraulic oil.
(2) Hook a spring balancer to the rim or spoke of the
steering wheel, and turn the wheel. Read the balancer
indication when the wheel begins to turn in both
directions.

20 N 202831A
Steering effort (at steering
(2 kgf)
wheel rim)
[4.4 lbf]

Adjustment of relief valve opening pressure

Refer to the “GROUP 10 HYDRAULIC SYSTEM” for the
method to be followed when adjusting the relief valve
opening pressure.

9-18