CHAPTER 10 STEERING SYSTEM

Chapter 10 STEERING SYSTEM

1. Specifications

Item Specification
Steering type Full-hydraulic power steering
Displacement volume 369 cm3(22.5 in.3) /rev
Steering control valve Rated flow 45.4 L (11.995 US gal.)/min
Max pressure 17.2 MPa (175.4 kgf/cm²) [2494.7 psi]
Steering wheel outside diameter 320 mm (12.60 in.)

2. Structure
2.1 Steering System

8 6

4
9
1 2 3
506007

1. Hydraulic tank 6. Control valve for other operation devices

2. Return filter 7. Check valve
3. Suction strainer 8. Steering valve
4. Gear pump (Oil pump) 9. Power steering cylinder
5. Priority valve

10-1
CHAPTER 10 STEERING SYSTEM
This lift truck employs a full-hydraulic system that consists of When the steering system requires a small quantity of
the steering valve, priority valve, power steering cylinder, hydraulic oil, the rest of the hydraulic oil will be supplied to
and others. Also, with a load sensing mechanism the other operation devices. Except the time when the steering
operator is provided with steering operations which are is operated, most of the hydraulic oil can be used for load
comfortable and lightly affected by the road condition. The handling devices.
turning of the steering wheel is changed to a hydraulic
pressure in the steering valve, then transformed to the
steering force in the power steering cylinder on the rear
axle. Hydraulic oil discharged from the oil pump is supplied
to the steering valve. The flow rate required for the steering
operation is determined at the priority valve.

10-2
 CHAPTER 10 STEERING SYSTEM
2.2 Steering Valve

14 15
3 10 13 11 4 6

1) 6
5 2)

1)
2)

1) 2)
3)
8 9 2 1 7 12 5
500073
1. Spool 10. Port L
2. Sleeve 11. Port R
3. Outlet port (Port T) 12. Housing
4. Inlet port (Port P) 13. Check valve
5. Rotor 14. Rotary valve section
6. Rotor ring 15. Metering section
7. Drive shaft 1) Metering pump areas
8. Centering spring 2) Metering pump areas
9. Pin 3) Gerotor set

The steering valve consists of two sections: rotary valve
section and metering section.
The rotary valve section consists of spool, sleeve, and
housing.
Spool is splined to connect with the steering shaft.
When the spool is turned, the sleeve rotates, which causes
the following passages to open:
(1) Passage from inlet port to metering section
(2) Passage from metering section to port L or port R
(3) The passage that allows oil to flow from the steering
cylinder to outlet port.
The metering section is a small hydraulic pump consisting of
a rotor ring and a rotor called a gerotor set.
The spool and the rotor are commonly connected to the
drive shaft. Thus, when the steering wheel is turned, the
rotor rotates in the same direction and at the same speed as
the steering wheel does.
When the steering wheel is not turned, oil from the inlet
port flows to the outlet port and returns to the hydraulic
tank.
At this point, the oil passage to metering section is blocked
by spool and sleeve.
When the steering wheel is turned clockwise, the oil from
inlet port flows into metering pump areas 1). The rotor
rotates as the steering wheel turns, and the oil in metering
pump areas 2) is forced into the steering cylinder through
the port.
When the steering wheel is turned counterclockwise, oil
flows in the direction reverse to the above. So the oil is
forced into the steering cylinder through port L.
As pressure oil from the inlet port acts as a rotating force to
the rotor, the steering wheel can be turned with a little
effort.
Normally, the check valve blocks a bypass flow since it is
pushed to the left by an oil pressure from the inlet port.
When the oil supply from port of the hydraulic valve stops
for some reason, the bypass passage opens to allow the oil
from the hydraulic tank to flow into the metering section.
When the steering wheel is turned, the metering section
acts as a manually-operated pump to allow the oil to flow
into the steering cylinder.

10-3
CHAPTER 10 STEERING SYSTEM

5 2
1
1 2
L T

R P

3 5 4
3 4
500081
1. Port L 4. Inlet port (Port P)
2. Port R 5. Load sensing
3. Outlet port (Port T)

The steering valve is provided with a load sensing circuit.

The load sensing circuit functions to balance the oil pressure 1
between the downstream of variable orifice in the steering
valve and the counterside of spool in the priority valve. This
offers a smooth steering operation that is not affected by 2 L R 3
the variation in load conditions. T P
LS OF
5
4 LS DS PP
EF
T

6
7
P 8

9
10 11

12
500083
1. Steering cylinder 7. Main relief
2. Input 8. Priority valve
3. Load sensing steering valve 9. Filter
4. Steering relief 10. Pump
5. High pressure 11. Engine
6. Filter 12. Tank

10-4
 CHAPTER 10 STEERING SYSTEM
2.3 Steering Column

6
7 9
13°

５°
10
７°

8
11
1

2
12
2
13
1) 3
2)
5 14
3)
4

506008
1. Steering column 10. Column position when tilted fully backward
2. Bracket (Secured to chassis) 11. Steering column mounting plate (A)
3. Tilt lock lever 12. Tilt angle setting plate (B)
4. Column lock lever 13. Bolt
5. Lock pin 14. Nut
6. Column position when tilted fully forward 1) Hold
7. Column position when lock is released 2) Loosen
8. Combination switch mounting 3) Lock release
9. Column position when NEUTRAL (non-tilt)
(tilted 30 degrees from the vertical line)

Note: When the tilt lock lever is turned counterclockwise, the steering column mounting plate (A) and tilt angle setting plate
(B) are fixed between the bolt and nut.

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 first, and
loosen the tilt lock lever by turning it clockwise. Then, tilt the
steering column to the optimal angle and turn the tilt lock
lever counterclockwise (pull upward) to lock.
The column lock lever is used to tilt the steering column
forward for the operator's easy access to the seat or for
service work. Tilt the steering column forward by pushing
down the lock lever in 3) direction to disengage the column
lock lever from the lock pin.

10-5
CHAPTER 10 STEERING SYSTEM
3. Removing and Installing Steering Valve Piping
3.1 Main Components

6
2
5
1
4

3
8
506009
1. Hose (From priority valve to steering valve P port) 5. Hose (From load sensing LS port to priority valve LS
2. Hose (From steering valve T port to main return pipe) port)
3. Hose (From steering valve L port to power steering 6. Steering valve
cylinder L port) 7. Priority valve
4. Hose (From steering valve R port to power steering 8. Check valve
cylinder R port)

3.2 Suggestions for Disassembly and Assembly

(1) Be sure to perform the hydraulic system maintenance

work in a clean area, and be careful not to allow any 1)
abrasive foreign objects to enter the system.
(2) Replace the O-ring with a new one when assembling.
(3) Hoses of the steering system (particularly in a high
pressure system) are safety critical parts. These parts
must be replaced with new ones disregarding with or
without damage after they have been used for the
specified period of time. For the replacement interval,
see “14. SERVICE DATA” .
(4) When removing or installing hoses, use a counterhold 2)
spanner to prevent excessive force from being applied 500092
on the mating fittings.
1) Nut

Ref. Tightening torque for nut

1) 49 ± 4.9 N·m (5.0 ± 0.5 kgf·m) [36.14 ± 3.61 lbf·ft]
2) 29 ± 3 N·m (2.96 ± 0.31 kgf·m) [21.39 ± 2.21 lbf·ft]

10-6
 CHAPTER 10 STEERING SYSTEM
4. Removing and Installing Steering Wheel, Steering Valve, and Tilt Lock Lever

2, 1) 1

7, 2)
4

5, 3)

609687A

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

Ref. Tightening torque

53 to 65 N·m (5.4 to 6.6 kgf·m)
1)
[39.09 to 47.94 lbf·ft]
26.8 to 40.2 N·m (2.73 to 4.10 kgf·m)
2)
[19.767 to 29.650 lbf·ft]
34 to 44 N·m (3.5 to 4.5 kgf·m)
3)
[25.08 to 32.45 lbf·ft]

10-7
CHAPTER 10 STEERING SYSTEM
4.1 Removing Steering Wheel

(1) Remove the horn button.

1
(2) Remove the steering wheel nut and remove the
steering wheel using the wheel puller. 2

4
500094
1. M12 bolt 3. Wheel puller
2. M8 bolt 4. Steering wheel

Special tool name Part number

Wheel puller 91268-10600

R CAUTION
When removing steering wheels, DO NOT tap the top end of the steering shaft.

4.2 Installing Steering Wheel

(1) Turn the protrusion on the steering wheel angle sensor

of combination switch by hand to orient the direction 1)
as shown in the illustration.
(2) Apply a thin coat of grease on the sliding portion of the 2)
horn contact under the steering wheel boss.
(3) Install the steering wheel by orienting it in the straight
forward traveling position. (The protrusions on the
combination switch must be engaged with the notches
on the steering wheel.)
5)
Rotate the steering wheel to both directions several
times to make sure the complete fit. 3)
(4) Before tightening the steering wheel nut, make sure
the automatic return of the combination switch works
properly. 2)
(5) If the automatic return does not work, repeat steps (3) 1
and (4) above.
(6) Tighten the steering wheel nut to the specified torque.
4)

506011

1. Combination switch 3) Protrusions form an isosceles

1) Horn switch contact triangle
2) Front 4) Front of lift truck
5) Protrusion

10-8
 CHAPTER 10 STEERING SYSTEM
4.3 Inspecting Steering Wheel After Installation

Checking steering effort

(1) Apply the parking brake.
(2) Run the engine until hydraulic oil temperature reaches
a range of between 40 and 60°C (104 and 140 °F).
(3) Attach a spring scale on the rim or spoke of the steering
wheel, and measure the steering effort required to turn
the steering wheel clockwise or counterclockwise from
the straight-ahead position. Steering effort must be less
than the specified value given below.

506012

Item Standard
Steering effort
10 N (1.2 kgf) [2.25 lbf]
(at steering wheel rim)

4.4 Removing Steering Valve

(1) Remove the cover around the steering column.

(2) Disconnect the five hoses from the steering valve.
(3) Remove the steering wheel mounting bolts, and
1)
remove the steering valve.

500097

1) Mounting bolts

Ref. Bolt tightening torque

34 to 44 N·m (3.5 to 4.5 kgf·m)
1)
[25.08 to 32.45 lbf·ft]

10-9
CHAPTER 10 STEERING SYSTEM
4.5 Installing Steering Wheel

(1) Apply grease on the serrated area on the lower part of

the steering shaft.
(2) Tighten the steering valve mounting bolts to the
specified torque.
(3) Tighten the hose nuts to the specified torque.
(4) Bleed air after assembly.

Bleeding steering system

(1) Lift the rear wheels off the ground and support the
body on stands.
(2) Turn ON the engine and operate the accelerator pedal
to vary the engine speed while turning the steering
wheel fully to the right and left. This bleed air from the
relief valve.

4.6 Disassembling Tilt Lock Lever

(1) Put alignment marks across the tilt lock lever 1 and nut
3 for the proper installation at assembly. 1)
(2) Remove lever mounting bolt 2, and remove the tilt lock
lever 1.

2)

1
2 500098

1. Tilt lock lever 1) Lever aspect

2. Lever mounting bolt
3. Nut

10-10
 CHAPTER 10 STEERING SYSTEM
4.7 Assembling Tilt Lock Lever

If the matchmarks which were made earlier, have

disappeared, or when the lever is replaced with a new one, 1)
install the lever as instructed below.
(The illustration on the right shows the relation of the parts
when the tilt position is in NEUTRAL and the column lock
lever is locked.)
2)
(1) Tighten nut 3 to the tightening torque of 11 to 15 N·m
(1.1 to 1.5 kgf·m) [8.11 to 11.06 lbf·ft]. (This is a lever
locked state).
(2) Select the optimal locked position for the tilt lock lever
1 and fit the tilt lock lever 1 into the serration of nut 3. 1
The optimal position is within the range which formed
by the intersection of the notched section 2) of the
bracket and the upper aspect of the lever.
2
(3) Tighten bolt 2.
(4) Loosen the tilt lock lever 1, and make sure that the
bracket slides in the entire tilting range without
interfering with other parts.
3

1
2 500098

1. Tilt lock lever 1) Lever aspect

2. Lever mounting bolt
3. Nut

10-11
CHAPTER 10 STEERING SYSTEM
5. Disassembling Steering Valve
5.1 Disassembly Sequence

6
5

11

7
9

10

500099

1. End cap, Bolt, O-ring, Spacer 6. Thrust needle, Bearing races

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. Housing

10-12
 CHAPTER 10 STEERING SYSTEM
5.2 Suggestions for Disassembling Steering Valve

(1) Place the steering valve housing body in a vertical

position with the end cap facing upward. When using a
vise, lightly clamp the mounting flange of the housing.
Place copper plates between the housing and the jaws
of vise and pay attention not to hold too tight.

500100

(2) Remove end cap screw 3 and remove the end cap 2.
2
1
3

500101
1. O-ring 3. End cap screw
2. End cap

(3) Remove the O-ring from the end cap, and remove the
spacer 2 installed on the splines in the gerotor rotor. 1
(4) Remove the gerotor 3. Pay attention not to drop the
rotor 4 from the rotor ring.
(5) Remove the O-ring 1 from the gerotor.
4

2 3

609689
1. O-ring 3. Gerotor
2. Spacer 4. Rotor

10-13
CHAPTER 10 STEERING SYSTEM

(6) Remove the drive shaft 3.

(7) Remove the spacer plate 2. 2
(8) Remove the O-ring 1 from the housing. 1

3
500103
1. O-ring 3. Drive shaft
2. Spacer plate

(9) Remove the adapter screw 1 with a flat-tip screw driver.

(10) Remove the housing from vise, and turn the housing 1
upside down to remove the ball 2. (Pay attention not to
drop or lose the ball.) 2

609738
1. Adapter screw 2. Ball

(11) Place the housing on a clean cloth facing the flange

upward not to damage the finished surface.
Remove the retaining ring 1 from the housing with a
flat-tip screw driver. Be careful not to damage the
machine finished surface.

609739
1. Retaining ring

10-14
 CHAPTER 10 STEERING SYSTEM

(12) Place the pin in the horizontal position by turning the

spool and sleeve, and push the spool and sleeve with
your thumb to remove the seal gland bushing 1 from
the housing.
(13) Remove the seal gland bushing oil seal.
(14) Remove the dust seal from the seal gland bushing with 1
a flat-tip screw driver.

500106
1. Seal gland bushing

R CAUTION
Pay attention not to damage the seal gland bushing.

(15) Remove 2 bearing races and the thrust needle.

2 3
1

500109
1. Bearing race 3. Bearing race
2. Thrust needle

(16) Pull out the sleeve 2 and spool 3 as a set from housing 1
in the direction indicated by the arrow. Then, pull out
the pin 4.
1

3 4
609740
1. Housing 3. Spool
2. Sleeve 4. Pin

R CAUTION
Slowly remove by rotating slightly so that the sleeve does not jam within the housing.

10-15
CHAPTER 10 STEERING SYSTEM

R CAUTION
Put a matchmark on the spool and sleeve before disassembling.

(17) Push the spool 2 in sleeve 1 slightly forward and

remove the centering springs 3. 1 3
Remove the spool from the sleeve by pulling it toward
the rear end of the sleeve while turning slowly.
2

609690
1. Sleeve 3. Centering springs
2. Spool

5.3 Inspecting Steering Valve after Disassembly

Inspect sliding faces between sleeve and housing, and

between sleeve and spool.
(1) Inspect sliding movement in subassembled condition.
(2) If any unusual sliding movement is detected, inspect
sliding surfaces.
If any damage such as wear, scratches, burrs, or rust are
found, replace the whole steering valve with a new one.

10-16
 CHAPTER 10 STEERING SYSTEM
6. Assembling Steering Valve
6.1 Preparation

- Prepare new parts to replace damaged parts.

- Wash all metal parts. Dry and blow off any foreign objects using compressed air.
- Always use new parts provided in the seal kit.

R CAUTION
- Apply a thin coat of oil on each part during assembly.
- Apply grease on O-rings.
- Do not wear fabric gloves when assembling. Lint or fibers may enter the valve and cause failure.

6.2 Assembly Sequence

86

11

3 4 2 5 1
10
500110
1. Housing 7. Seal gland bushing, Oil seal, Dust seal, O-ring
2. Sleeve 8. Retaining ring
3. Spool 9. Drive shaft, Spacer plate, O-ring
4. Centering spring 10. Gerotor set, O-ring
5. Pin 11. End cap, O-ring, Spacer, End cap screw
6. Thrust needle, Bearing races

10-17
CHAPTER 10 STEERING SYSTEM
6.3 Suggestions for Assembly

Assembling spool and sleeve

Align the spring grooves in the spool and sleeve, then slide
the spool into the sleeve while rotating the spool. 2)
Ensure that the marks are aligned with each other (the 1)
matchmarks made during disassembly or the matchmarks
provided by the maker).

3)
500112
1) Spring groove 3) Matchmark
2) Spring groove

R CAUTION
Be sure that the spool rotates smoothly in the sleeve without any restrictions.

Installing centering spring

(1) Align the spring grooves in the spool and sleeve
assembly, and stand the spool and sleeve assembly on
a flat workbench.
1
(2) Use a spring insertion tool to install springs. Place three
pieces of centering spring back to the back of the other
three pieces. Pinch the six pieces of spring with the
insertion tool placing the notches on the both ends
facing downward. See the illustration on the right.
(3) Hold one end of the springs with fingers and push the
springs into the notches of the spool and sleeve
assembly. If the spring insertion tool is not available, 609741
insert the springs one by one alternately from the right
and left. 1. Special tool

Special tool name Part number

Spring insertion tool 97157-00100

Inserting spool and sleeve assembly into housing

(1) Insert the pin into the spool and sleeve hole. Align the
pin ends to the sleeve outside diameter.
(2) Insert the spool and sleeve assembly from the back of
housing (as shown in the illustration).
Insert the spool-and-sleeve assembly while slowly
rotating it with the pin being kept at a horizontal
position.
Insert the spool and sleeve assembly until its rear end
becomes flush with the housing end face. Do not insert
farther.
500114

10-18
 CHAPTER 10 STEERING SYSTEM

Installing O-ring and thrust bearing

2
(1) Install bearing race 3 and thrust needle 2
to the spool.
1 3
(2) Install O-ring 1 on the housing.

500115
1. O-ring 3. Bearing race
2. Thrust needle

Installing seal
(1) Install dust seal 1 to the seal gland bushing 2. The 5
installing direction is as shown in the figure. Install oil
seal 3.
(2) Install O-ring 4 and install the seal gland bushing 2 into
the spool by rotating the bushing. Tap the bushing into
its correct position with a plastic hammer.
(3) Check that the bushing horizontally contacts the race
upper face of thrust bearing.
(4) Install the retaining ring 5 firmly in the housing groove.
699742

1 2
3
5
4

609743
1. Dust seal 4. O-ring
2. Gland bushing 5. Retaining ring
3. Oil seal

10-19
CHAPTER 10 STEERING SYSTEM

Installing spacer plate

(1) Use soft pads to hold the housing in a vise or wrap the
housing with soft cloth before holding the housing
with a vise.
Hold the flat section of flange in a vise.
Do not hold it in a vise too tight.
Note: Ensure that the spool and sleeve are flush with the
housing surface or they are in a slightly lower position
than the surface.

500118

(2) Install the ball 1 in the hole of seven thread holes on the
housing end face as shown in the illustration.
(3) Install the adapter screw 2 to the hole having the ball 1. 2
1

609744
1. Ball 2. Adapter screw

(4) Install the O-ring on the housing. Place the spacer plate
on the housing and align the bolt hole to the tap hole in
housing.

500120

R CAUTION
The bolt holes and oil holes are different in pitch diameters.

10-20
 CHAPTER 10 STEERING SYSTEM

Installing drive shaft

(1) Rotate the spool and sleeve assembly to make the port 1)
surface of the housing parallel with the pin.
(2) Insert drive shaft 1, and engage the pin 2 with the yoke 1
of drive shaft.
(3) Draw an alignment mark like the line B in the next
illustration on the end face of drive shaft spline with a
felt-tip pen to ensure the proper positioning during the 2)
following process.

2
500121
1. Drive shaft 1) Port face
2. Pin 2) Pin is parallel to port face.

Installing gerotor set

1) A
(1) Install the O-ring on the gerotor. Place the gerotor O-
ring side to the spacer plate 1 side. Align the roots of B
gerotor rotor set 1) (Line A) to the line B of drive shaft 2
and assemble them.
1
C
(2) Check that lines A, B, C, and D are in parallel with each D
other.
2
(3) Keep the engagement of the drive shaft 2 and rotor,
and align the bolt holes of the gerotor set.
Note: This procedure is important as it determines the valve
timing of this unit.
500122
1. Spacer plate 1) Gerotor set, star valley
2. Drive shaft
(with marked line)

10-21
CHAPTER 10 STEERING SYSTEM

Installing end cap

1
Install the drive spacer 3 in the spline of rotor. Install the O-
ring 4 on the end cap 1. Place the end cap on the gerotor set
and align the bolt holes. 2

3
4
500123
1. End cap 3. Drive spacer
2. End cap screw 4. O-ring

Apply oil on the threads of end cap screw 2, and tighten the
bolts evenly in the sequence shown in the illustration. The
tightening torque is given in the table below.
Install the steering shaft in the spool and check that the
spool turns smoothly.

500124

Item Tightening torque

End cap screw 28 N·m (2.9 kgf·m) [20.65 lbf·ft]

10-22
 CHAPTER 10 STEERING SYSTEM
7. Troubleshooting

Condition Possible cause Action

Foreign objects clogged in
No steering Disassemble and clean
orifices of spool
flow
Spring in spool fatigued Replace spring
Low relief pressure Adjust relief pressure
Priority valve Damaged valve seating
malfunction Relief valve Replace valve assembly
surface
malfunction
Replace spring, and then adjust relief
Spring settling
pressure
Spring Damaged O-ring on the
Replace O-ring
Excessive settling valve body
steering Clogging in gerotor Disassemble and clean
effort
Sleeve and spool seizure due to foreign
Steering valve Replace
material
malfunction
Damaged bearing Replace
Overtightening of end cap bolts Retighten

Steering cylinder Piston rod deflection Replace

malfunction Damaged piston seal Replace
Steering valve and tilt column assembly
Misalignment Adjust
fault
Other malfunctions Flattened hose or pipe Replace

Steering valve Spool or sleeve seizure Replace

Unstable malfunction Damaged center spring Replace
steering
Air trap Bleed air
wheel
operation Other malfunctions Flattened hose or pipe Replace
Damaged piston seal of steering cylinder Replace

10-23
CHAPTER 10 STEERING SYSTEM
8. Service Data

Item Specification
Steering effort
(at steering wheel periphery) (at engine low-idling, Standard 28.0 N·m (2.86 kgf·m) [20.652 lbf·ft]
steering wheel 1 turn/sec of stationary steering)
Steering wheel play Standard 70 mm (2.76 in.)
Inside Standard 78° 27’
Steering angle
Outside Standard 51° 14’
Tightening 53 to 65 N·m (5.4 to 6.6 kgf·m)
Steering wheel nuts
torque [39.09 to 47.94 lbf·ft]
Tightening 26.8 to 40.2 N·m (2.73 to 4.10 kgf·m)
Steering bracket mounting bolts
torque [19.767 to 29.650 lbf·ft]
Displacement volume Standard 369 cm3(22.5 in.3)/rev
Rated flow Standard 45.4 L (11.995 US gal.)/min
Max pressure Standard 17.2 MPa (175.4 kgf/cm²) [2494.7 psi]
Tightening 34 to 44 N·m (3.5 to 4.5 kgf·m)
Steering valve Mounting bolt
torque [25.08 to 32.45 lbf·ft]
Rotary torque in normal
Standard 1.5 N·m (0.15 kgf·m) [1.106 lbf·ft]
steering
Tightening
End cap screw 1 28 N·m (2.9 kgf·m) [20.65 lbf·ft]
torque
Steering system relief valve set pressure Standard 17.2 MPa (175.4 kgf/cm²) [2494.7 psi]

500111

10-24