GROUP 3 DISASSEMBLY AND ASSEMBLY
1. STEERING UNIT
1) STRUCTURE
29-4
1 21
29-5
29-6
29-3
29-1
29-2 2
27-3 18
27-2 27-4 3
27-1 11
5 14
15 4
13
22
6
23
16
24
8
10 24
19
10
13
10
7 20
17
12
22B7SS08
1 Dust seal 13 Gerotor set 27 P-port check valve
2 Retaining seal 14 Bearing race 27-1 Plug
3 Cap seal 15 Bore screw 27-2 Poppet
4 Thrust bearing 16 Drive 27-3 Spring seat
5 Ball 17 End cap 27-4 Spring
6 Pin 18 Gland bushing 29 Relief valve
7 Spacer 19 Plate 29-1 Spool
8 Centering spring 20 Cap screw 29-2 Bushing
9 Washer 21 Housing 29-3 Spring
10 O-ring 22 Spool 29-4 Spring seat
11 O-ring 23 Sleeve 29-5 Plug
12 Rolled screw 24 Plate spring 29-6 O-ring
5-13
2) TOOLS
(1) Holding tool.
5-69(1)
(2) Assembly tool for O-ring and kin-ring.
5-69(2)
(3) Assembly tool for lip seal.
5-69(3)
(4) Assembly tool for cardan shaft.
5-69(4)
5-14
(5) Assembly tool for dust seal.
5-70(1)
(6) Torque wrench 0~7.1kgfÂm
(0~54.4lbfÂft)
13mm socket spanner
6, 8mm and 12mm hexagon sockets
12mm screwdriver
2mm screwdriver
13mm ring spanner
6, 8 and 12mm hexagon socket spanners
Plastic hammer
Tweezers 5-70(2)
3) TIGHTENING TORQUE
L : Left port
R : Right port
T : Tank
P : Pump
D353SE23
Port Size Torque [kgfÂm(lbfÂft)]
L 3/4 UNF - 16 6.1 Ü0.6 (44.1Ü4.3)
R 3/4 UNF - 16 6.1 Ü0.6 (44.1Ü4.3)
T 3/4 UNF - 16 6.1 Ü0.6 (44.1Ü4.3)
P 3/4 UNF - 16 6.1 Ü0.6 (44.1Ü4.3)
Mounting bolt M10Ý1.5 4.0 Ü0.5 (29Ü3.6)
5-15
4) DISASSEMBLY
(1) Disassemble steering column from
steering unit and place the steering unit in
the holding tool.
Screw out the screws in the end cover(6-
off plus one special screw).
5-72(1)
(2) Remove the end cover, sideways.
5-72(2)
(3) Lift the gearwheel set(With spacer if fitted)
off the unit.
Take out the two O-rings.
5-72(3)
(4) Remove cardan shaft.
5-72(4)
5-16
(5) Remove distributor plate.
5-73(1)
(6) Screw out the threaded bush over the
check valve.
5-73(2)
(7) Remove O-ring.
5-73(3)
(8) Shake out the check valve ball.
B20H7SS09
5-17
(9) Take care to keep the cross pin in the
sleeve and spool horizontal. The pin can
be seen through the open end of the
spool. Press the spool inwards and the
sleeve, ring, bearing races and thrust
bearing will be pushed out of the housing
together.
5-73(4)
(10) Take ring, bearing races and thrust
bearing from sleeve and spool. The outer
(Thin) bearing race can sometimes "stick"
in the housing, therefore check that it has
come out.
5-74(1)
(11) Press out the cross pin. Use the special
screw from the end cover.
5-74(2)
ö A small mark has been made with a
pumice stone on both spool and sleeve
close to one of the slots for the neutral
position springs(See drawing).
If the mark is not visible, remember to
leave a mark of your own on sleeve and
spool before the neutral position springs
are disassembled.
5-74(3)
5-18
(12) Carefully press the spool out of the sleeve.
5-74(4)
(13) Press the neutral position springs out of
their slots in the spool.
5-75(1)
(14) Remove dust seal and O-ring.
5-75(2)
Disassembling the pressure relief valve
(15) Screw out the plug using an 8mm hexagon
socket spanner.
Remove seal washers.
D353SE10
5-19
(16) Unscrew the setting screw using an 8mm
hexagon socket spanner.
D353SE11
(17) Shake out spring and piston. The valve
seat is bonded into the housing and cannot
be removed.
D353SE12
(18) The pressure relief valve is now disassem-
bled.
D353SE13
5-20
5) ASSEMBLY
(1) Assemble spool and sleeve.
ö When assembling spool and sleeve only
one of two possible ways of positioning
the spring slots is correct. There are
three slots in the spool and three holes in
the sleeve in the end of the spool / sleeve
opposite to the end with spring slots.
Place the slots and holes opposite each 5-76(1)
other so that parts of the holes in the
sleeve are visible through the slots in the
spool.
(2) Place the two flat neutral position springs
in the slot.
Place the curved springs between the flat
ones and press them into place (see
assembly pattern).
5-76(2)
(3) Line up the spring set.
5-76(4)
(4) Guide the spool into the sleeve. Make
sure that spool and sleeve are placed
correctly in relation to each other.
5-77(1)
5-21
(5) Press the springs together and push the
neutral position springs into place in the
sleeve.
5-77(2)
(6) Line up the springs and center them.
5-77(3)
(7) Guide the ring down over the sleeve.
ö The ring should be able to rotate free of
the springs.
5-77(4)
(8) Fit the cross pin into the spool / sleeve.
5-78(1)
5-22
(9) Fit bearing races and needle bearing as
shown on below drawing.
5-78(2)
ö Assembly pattern for standard bearings
1
1 Outer bearing race 2
2 Thrust bearing 3
3 Inner bearing race
4 Spool
5 Sleeve 4
5
5-78(3)
Installation instruction for O-ring
(10) Turn the steering unit until the bore is
horizontal. Guide the outer part of the
assembly tool into the bore for the spool /
sleeve.
5-78(4)
5-23
(11) Grease O-ring with hydraulic oil and place
them on the tool.
5-79(1)
5-79(2)
(12) Hold the outer part of the assembly tool in
the bottom of the steering unit housing
and guide the inner part of the tool right to
the bottom.
5-79(3)
(13) Press and turn the O-ring into position in
the housing.
5-79(4)
5-24
(14) Draw the inner and outer parts of the
assembly tool out of the steering unit bore,
leaving the guide from the inner part in the
bore.
5-80(1)
Installation instructions for lip seal
(15) Lubricate the lip seal with hydraulic oil and
place it on the assembly tool.
5-80(2)
5-80(3)
(16) Guide the assembly tool right to the
bottom.
5-80(4)
5-25
(17) Press and turn the lip seal into place in the
housing.
5-81(1)
(18) With a light turning movement, guide the
spool and sleeve into the bore.
ö Fit the spool set holding the cross pin
horizontal.
5-81(2)
(19) The spool set will push out the assembly
tool guide.
The O-ring are now in position.
5-81(3)
(20) Turn the steering unit until the bore is
vertical again. Put the check valve ball
into the hole indicated by the arrow.
5-81(4)
5-26
(21) Screw the threaded bush lightly into the
check valve bore. The top of the bush
must lie just below the surface of the
housing.
5-82(1)
(22) Grease the O-ring with mineral oil approx.
viscosity 500 cSt at 20ä
C.
5-82(2)
(23) Place the distributor plate so that the
channel holes match the holes in the
housing.
5-82(3)
(24) Guide the cardan shaft down into the bore
so that the slot is parallel with the
connection flange.
5-82(4)
5-27
(25) Place the cardan shaft as shown - so that
it is held in position by the mounting fork.
5-83(1)
(26) Grease the two O-rings with mineral oil
approx. viscosity 500 cSt at 20ä C and
place them in the two grooves in the gear
rim. Fit the gearwheel and rim on the
cardan shaft.
5-83(2)
(27) Important
Fit the gearwheel(Rotor) and cardan shaft
so that a tooth base in the rotor is
positioned in relation to the shaft slot as
shown.
Turn the gear rim so that the seven
through holes match the holes in the
housing.
5-83(3)
(28) Fit the spacer, if any.
5-83(4)
5-28
(29) Place the end cover in position.
5-84(1)
(30) Fit the special screw with washer and
place it in the hole shown.
5-84(2)
(31) Fit the six screws with washers and insert
them. Cross-tighten all the screws and
the rolled pin.
ÂTightening torque : 4.0Ü0.5kgfÂm
(28.9Ü3.6lbfÂft)
5-84(3)
(32) Place the dust seal ring in the housing.
5-84(4)
5-29
(33) Fit the dust seal ring in the housing.
5-85(1)
(34) Press the plastic plugs into the connection
ports.
ö Do not use a hammer!
5-85(2)
5-30
2. STEERING CYLINDER
1) STRUCTURE
8
12 7
6
5
4
10
9
2 11
12
1
9
10
4
5
6
7
8
B207SE21
1 Tube assembly 5 Rod seal 9 O-ring
2 Rod assembly 6 Back up ring 10 O-ring
3 Gland 7 Dust wiper 11 Piston seal
4 Bushing 8 Snap ring 12 Bushing
5-31
2) DISASSEMBLY
ö Before disassembling steering cylinder, release oil in the cylinder first.
(1) Put wooden blocks against the cylinder tube, then hold in a vice.
(2) Remove the gland by hook a wrench in the notch of cylinder head and turn counter-clockwise.
(3) Remove the cylinder rod and piston from the tube.
(4) Check wear condition of the sealing parts. If there are some damage, replace with new parts.
3) CHECK AND INSPECTION mm(in)
Criteria
Check item Remedy
Standard size Repair limit
Clearance between 0.064~0.137 0.180 Replace
piston & cylinder tube (0.0025~0.0054) (0.0070) piston seal
Clearance between 0.024~0.112 0.120 Replace
cylinder rod & bushing (0.0009~0.0044) (0.0049) bushing
Seals, O-ring Damage Replace
Cylinder rod Dents Replace
Cylinder tube Biting Replace
4) ASSEMBLY
(1) Install a new piston seal the groove on the piston.
ö Be careful not to scratch the seal too much
during installation or it will not seat properly.
D353SE27
(2) Install the rod seal to the position in the gland
applying a slight coat with grease prior to install.
D353SE28
5-32
(3) Install the dust wiper to the gland using a special
installing tool. Coat the dust wiper with grease
slightly before installing.
(4) Set a special tool the cylinder, gland assembly
into the cylinder tube.
D353SE29
(5) Using a hook spanner, install the gland
assembly, and tighten it with torque 40Ü4kgfÂm
(289Ü29lbfÂft).
D353SE30
(6) After the gland assembly was installed to the
cylinder tube, calk at the tube end into the groove
on the gland to prevent screw loosening.
ö If it need calking again, never using previous
calking position.
D353SE31
(7) Move the piston rod back and forth several times for the full distance of its stroke. This helps to
seat the ring and seals before applying full hydraulic pressure to the cylinder.
(8) Install cylinder into trail axle.
(9) While idling the engine with the rear wheels off the ground, operate the steering wheel left and
right alternately.
ö Then, repeat the above operation at gradually increasing engine rpm. This releases air
from the system and completes preparation for operation.
(10) Stop the engine, lower the floating rear wheels, and check pump joints for oil leaks and looseness
and retighten, them as required.
5-33
3. STEERING AXLE
1) STRUCTURE
ö Do not remove the stopper bolt unless necessary.
1-4
1-12
1-3 1-31
1-12
1-26 1-29 1-12
1-25 1-30
1-23
1-32 1-3
1-17 1-29
1-24
1-30
1-16
1-21
1-15
1-20 1-35
1-14
2 1-34
1-13
1-18
4
1-22 1-36
3
1-2 1-4 1-1 1-17
1-16
1-6
1-5 1-27 1-15
1-28
1-33 1-18
1-15
1-16
1-4
1-17
2 1-11 1-8
1-34
1-35 1-7
1-9 1-33
1-15
1-36 4
1-16
3 1-17
20BC7SS08
1-1 Steering axle 1-15 Needle bearing 1-28 Shim (0.5 t)
1-2 Knuckle 1-16 Plug plate 1-29 Special washer
1-3 Link 1-17 Retaining ring 1-30 Split pin
1-4 Grease nipple 1-18 King pin 1-31 Steering cylinder
1-5 Set screw 1-19 Hub bolt 1-32 Shim (0.2 t)
1-6 Hexagon nut 1-20 Taper roller bearing 1-33 Oil seal
1-7 Bolt 1-21 Taper roller bearing 1-34 Block
1-8 Hexagon nut 1-22 Oil seal 1-35 Bushing
1-9 Hexagon bolt 1-23 Washer 1-36 Grease nipple
1-11 Hardened washer 1-24 Nut 2 Shim (0.5 t)
1-12 Link pin 1-25 Split pin 3 Hexagon bolt
1-13 Inner race bushing 1-26 Hub cap 4 Spring washer
1-14 Thrust bearing 1-27 Shim (0.2 t)
5-34
2) CHECK AND INSPECTION
C B A
20BC7SS13
mm(in)
Criteria
No. Check item Remedy
Standard size Repair limit
A Diameter of king pin 35(1.38) 34.8(1.370) Replace
B Vertical play of knuckle - 0.2(0.008) Adjust with shims
C Diameter of center pin 50(2.0) 49.5(1.9) Replace
- Rear axle, hub, knuckle, bearing ÂDamage, wear Replace
ÂSeizure, abnormal noise, defective rotation
5-35
3) DISASSEMBLY
ö Servicing work on the knuckle part can be carried
out without removing the axle assy from chassis. Tire
The work can be done by jacking up the balance
Taper roller bearing
weight part of the truck.
Castle nut
(1) Remove hub cap. Split pin
(2) Pull out split pin and remove castle nut and plain Plain washer
washer. Hub cap
(3) Take off the steering wheel tire. 20BC7SS14
(4) Using the puller, take off the wheel hub together
with the bearing.
Bearing
Be very careful because just before the hub
Wheel hub
comes off, tapered roller bearing will fall out.
(5) After wheel hub is removed take off the inner Oil seal
race of bearing. Knuckle
(6) Pull out oil seal.
ö Don't use same oil seal twice.
(7) Repeat the same procedure for the other side. Bearing
Moreover, when disassembling is completed,
part the slotted nut in the knuckle to protect the
threaded portion. 20BC7SS15
5-36
(8) Loosen set screw(1-5) and nut(1-6).
1-17
(9) Remove retaining ring(1-17), oil seal(1-33).
1-15
(10) Push out the king pin(1-18) without damaging 1-12
the knuckle arm (1-2).
1-18
(11) Pull out the needle bearing (1-15).
If any defect is observed in needle bearing(1-15), 1-2
pull it out by using extractor. 1-6
1-5 1-29
(12) Remove spilt pin (1-30), special washer(1-29)
1-30
and then pull out link pin(1-12).
(13) Remove knuckle arm(1-2). 1-33
1-17
20BC7SS16
4) ASSEMBLY
ö In reassembling, have all parts washed, grease
applied to lubricating parts, and all expendable
items such as oil seal and spring washers
replaced by new ones. 1-26
1-25
1-24
Perform the disassembly in reverse order. 1-21
(1) Tighten the set screw(1-5) of king pin.
ö There is a notch in the middle of the king pin(1-
18), make sure that this notch is on the special
bolt side.
1-20
(2) Do not hammer to drive in thrust bearing(1-14) 1-22
because it will be broken. Wheel hub
Always use drive-in tool. In assembling the thrust
bearing(1-14), be sure that the fixed ring of the
bearing is placed in position facing the knuckle(1-
2). 1-14
1-18
(3) Wheel hub
Η Mount oil seal(1-22) and inner race of tapered 1-2
roller bearing(1-20) on the knuckle(1-2). The 1-6
bearing should be well greased before 1-5
assembling.
Θ Install the outer race of the bearing(1-21) in the
wheel center and assemble to the knuckle.
Ι Tighten with castle nut(1-24) and locked with
split pin(1-25). In locking with split pin, locate the
hole for the split pin by turning the nut back 1/6
of a turn. Adjust the preload of bearing.
Κ Mount the wheel cap(1-26).
20BC7SS17
Bearing should be well greased before
assembling.
5-37
