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STEERING SYSTEM: DESCRIPTION

Steering System
Description
Steering System with MicroCommand II Controller

4
8

6 1

2
8609014

Oil Flow Sequence


1. From hydraulic tank 5. Steering cylinder
2. Hydraulic pump 6. Mast operating valve
3. Integral priority valve 7. To hydraulic tank
4. Steer gear 8. Pressure switch

General Information
This steering system is a closed-center, load- Load sense steering, with the ability to control
sense circuit with a dynamic signal. The integral flow and pressure, will react the same, regardless
priority valve on the pump provides steering flow of flow. This means smooth pressure-compensated
on demand, diverting the excess flow to the mast steering. Standby losses are low because of low
operating valve. The pressure switch increases pump pressures. The dynamic signal provides
the motor RPM for steering when the wheel is fast response.
turned.

6.1
STEERING SYSTEM: DESCRIPTION

Steering System with Optional EV100ZX Controller

6 4

1
8609044

Oil Flow Sequence


1. From hydraulic tank 4. Steering cylinder
2. Steering pump 5. Mast operating valve
3. Steer gear 6. To hydraulic tank

General Information
This steering system is an open-center type,
where the steering fluid is provided by a dedicated
steering pump. The oil is constantly available and
flows through the steer gear and back to the tank
via the mast operating valve.
In this type of steering system, only the small
dedicated steer pump is pressurized, providing an
efficient, energy-conservative system.

6.2
STEERING GEAR: REMOVAL & INSTALLATION

Steering Gear
Removal
Steering Wheel

8609016

Sequence
1. Nut, washer
2. Wheel

Removal Installation
Use a special tool. To install, follow the reverse of the removal
sequence.
Special Tool Part Number
Wheel puller 91268-10600

Wheel puller

203466A

6.3
STEERING GEAR: REMOVAL & INSTALLATION

Steering Gear with MicroCommand II Controller

5 1

1
8609015

Sequence
1. Hose connectors, O-rings
! WARNING
2. Mounting hardware
Hydraulic pressure can cause personal
3. Steer gear injury. Before any steering system hydraulic
4. Spacer lines or components are disconnected,
make sure all hydraulic pressure is released
5. Grommet in the steering system. Move the steer
wheels to the left and right, then straight.

NOTE
For servicing the steer cylinder, see REAR
AXLE section.
For servicing the pump and valve, see
HYDRAULIC SYSTEM section.

6.4
STEERING GEAR: REMOVAL & INSTALLATION

Steering Gear with Optional EV100ZX Controller

5
1

8609045

Sequence
1. Hose connectors, O-rings
! WARNING
2. Mounting hardware
Hydraulic pressure can cause personal
3. Steer gear injury. Before any steering system hydraulic
4. Spacer lines or components are disconnected,
make sure all hydraulic pressure is released
5. Grommet in the steering system. Move the steer
wheels to the left and right, then straight.

NOTE
For servicing the steer cylinder, see REAR
AXLE section.

6.5
STEERING GEAR: REMOVAL & INSTALLATION

Inspection after Removal


1. Inspect the grommets for cracks or tears in
the rubber or for signs of aging. Check the
O-rings for damage.

Installation
To install, follow the reverse order of the removal
sequence. Tighten bolts to the specified torque

3.4 kgf•m
Tightening torque for bolts (24.6 lbf•ft)
[33.4 N•m]

6.6
STEERING GEAR: DISASSEMBLY

Disassembly
Steering Gear with MicroCommand II Controller

5
4 8609017

Sequence
1. End cap, screws, seal 5. Needle thrust bearing
2. Meter, seal, spacer 6. Spool and sleeve assembly
3. Spacer plate, drive, seal 7. Check valve
4. Seal gland bushing assembly

6.7
STEERING GEAR: DISASSEMBLY

Disassembly
Steering Gear with Optional EV100ZX Controller

5
4
8609048

Sequence
1. End cap, screws, seal 4. Seal gland bushing assembly
2. Meter, seal, spacer 5. Needle thrust bearing
3. Spacer plate, drive, seal 6. Spool and sleeve assembly

6.8
STEERING GEAR: DISASSEMBLY

Working Rules and Tips Suggestions


The steering gear, complete with the control Removing the End Cap
valve, is a precision-machined component. As Clamp the unit in a vise with the meter end up.
such, it must be handled with extreme care. Clamp lightly on the edges of the mounting area,
Cleanliness is imperative: work in a clean place using protective material on the vise jaws. Housing
and use clean tools. distortion can result if the jaws are overtightened.
1. Clean the disassembled parts with a volatile
solvent such as trichlene or chlorobenzene,
and dry them with compressed air. This does
not apply to rubber parts.
2. Oil seals, O-rings, and the like are rubber
parts. Never clean them with solvent. Blow dirt
off rubber parts with compressed air and keep
them immersed in a pool of hydraulic oil until
they are ready for reassembly. A rubber part
showing even slight wear and tear must be
replaced. Rubber parts are expendable com-
ponents that should be replaced once a year. 8609018

3. Parts to be installed by pressing or forcing


need special treatment. Remove the cap screws and the end cap. Remove
a. Oil Seals the seal from the end cap.
Oil seals, once removed, must not be Seal washer
reused. After disassembly, examine the oil
seals in place (in the gear box and side
cover). If they are in good condition, leave
them in place. When installing a replace-
ment oil seal, be careful not to score or
scratch the lip area. Cap
screw

End cap

Seal 8609019

6.9
STEERING GEAR: DISASSEMBLY

Removing the Meter Removing the Seal Gland Bushing


Remove the meter, being careful not to drop the Use a thin-bladed screwdriver to pry the retaining
star. Remove the seal from the meter. Remove ring from the housing.
the drive spacer(s).

Seal

Meter 8609022
Spacer(s)
8609020

Rotate the spool and sleeve assembly until the pin


is horizontal. Push the spool and sleeve assembly
Removing the Drive forward with your thumbs just far enough to free
Remove the drive and spacer plate. Remove the the gland bushing from the housing.
seal from the housing.

Seal
gland
bushing

Spacer
Drive plate
Seal 8609023
8609021

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
bushing.

Quad
ring
seal

Seal
gland
bushing
Dust seal
8609024

6.10
STEERING GEAR: DISASSEMBLY

Removing the Needle Thrust Bearing Push the spool partially from the control end of
Remove the two bearing races and the needle the sleeve and carefully remove the centering
thrust bearing from the spool and sleeve assembly. springs from the spool by hand. Push the spool
back through and out of the sleeve. Rotate the
spool slowly when removing it from the sleeve.

Needle Bearing Spring


thrust race package
bearing

Bearing
race

8609025

8609027

Removing Spool And Sleeve Assembly


Remove the spool and sleeve assembly from the Removing the Check Valve
end of the housing. Do not bind the spool and (Trucks with MicroCommand II Controller)
sleeve assembly. Rotate it slowly when removing
it from the housing. Push the pin from the spool Remove the seal from the housing. Remove the
and sleeve assembly. set screw. Screw a #10-24 machine screw into
the end of the check ball seat. Then, by pulling
on the screw with the pliers, lift the seat out of
the housing.
Remove the two seals from the seat. Tip the
housing to remove the check ball and check ball
retainer.

Seal

Pin

8609026

5/8” Check
seal ball
retainer
Set Check
screw ball
Check 7/16”
ball seat seal
8609028

6.11
STEERING GEAR: DISASSEMBLY

Removing the Housing Seal (Trucks with Inspection after Disassembly


Optional EV1000ZX Controller Only) 1. Check all mating surfaces. Replace any parts
Remove the seal from the housing. 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
Seal paper towels because lint or other matter can
get into the hydraulic system and cause dam-
age. Do not use a coarse grit or try to file or
grind these parts.

8609059

6.12
STEERING GEAR: REASSEMBLY

Reassembly
Trucks with MicroCommand II Controller

6
4

3
8609029

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, screws, seal

6.13
STEERING GEAR: REASSEMBLY

Reassembly
Trucks with Optional EV100ZX Controller

5
3

2
8609060

Sequence
1. Spool and sleeve assembly 5. Drive
2. Needle thrust bearing 6. Meter and seal
3. Seal gland bushing assembly 7. End cap, screws, seal
4. Spacer plate and seal

6.14
STEERING GEAR: REASSEMBLY

Suggestions
Reassembling the Check Valve (Trucks with Reassembling the Spool and Sleeve
MicroCommand II Controller Only) Assemble the spool and sleeve so that the spring
Use the needlenose pliers to lower the check ball slots line up. Rotate the spool while sliding the
retainer into the housing. Make sure that it is parts together.
straight. Install the ball into the housing. Some sets have identification marks. Align these
Lubricate the seals and install them on the check marks. Test for free rotation.
ball seat. Lubricate the seat and lower it into the
housing. Do not twist or damage the seals. Push
the seat to the shoulder of the housing.
Install the set screw. Use a 1/4” allen wrench to Control Spring
sleeve slot
tighten the set screw. Make sure that the top of
the set screw is slightly below the housing Spring
slot
mounting surface. Control
spool
1.2 kgf•m Identification
Tightening torque for marks
(8.3 lbf•ft)
set screw
[11.3 N•m]
8609031

Set screw Bring spring slots of both parts in line. Position


one end of the centering springs in Spring
Seal
Installation Tool and compress the other end.
Check ball seat Push the spring set into the spool sleeve assem-
Seal bly while withdrawing the installation tool at the
Check ball same time.

Special Tool Part Number


Check ball
retainer Spring installation tool 97157-00100
8609030

NOTE
Replace all old seals with new seals. Lubricate
all seals with clean petroleum jelly such as
Vaseline.

6.15
STEERING GEAR: REASSEMBLY

Center the spring set in parts so that they push Reassembling the Needle Bearing
down evenly and flush with the upper surfaces of Install the seal in the housing. Install the two
the spool and sleeve. races and the needle thrust bearing as shown.

Needle
thrust Bearing
bearing race (2)

Seal

8609032 8609034

Install the pin through the spool and sleeve until


it is flush at both sides of the sleeve.
Position the spool and sleeve assembly so that the
splined end of the spool enters the housing first.

Pin
8609033

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

6.16
STEERING GEAR: REASSEMBLY

Reassembling the Seal Gland Bushing Reassembling the Spacer Plate


1. Install the dust seal in the bushing with the 1. Clamp the housing in a vise, clamping lightly
flat or smooth side facing towards the bushing. over the edges of the mounting area. Do not
2. Install the quad ring seal in the bushing by overtighten the vise jaws.
smoothing it into place with your finger. Do
not use any seal that falls freely into the NOTE
pocket of the bushing.
Check to ensure that the spool and sleeve are
3. Install the bushing assembly over the spool flush or slightly below the surface of the housing.
end with a twisting motion. Tap it into place
with a rubber hammer. Make sure the bushing
is flush against a bearing race.

Retaining
ring
Seal
gland
bushing
(with
seals)

8609037

8609035

NOTE
4. Install the retaining ring in the housing and
tap on the ring end or pry it with a screwdriver Clean the mounting surface of the housing by
around the entire circumference to properly wiping with the palm of a clean hand. Clean
seat it in the groove. each of the flat surfaces of the spacer and
meter in a similar way prior to reassembly.
Screwdriver Do not use a cloth or paper towel to clean
Dust seal
these surfaces.
Retaining ring
Seal gland bushing
Quad ring seal 2. Install the seal in the housing. Place the
Seal spacer plate on the housing and align the bolt
holes with the tapped holes in the housing.

8609036

8609038

6.17
STEERING GEAR: REASSEMBLY

Reassembling the Driver Reassembling the Meter


1. Place a mark across the splined end of the 1. Install seal in the meter.
drive to indicate the direction of the slot at the
opposite end of the drive.
2. Rotate the spool and sleeve assembly until
Meter
the pin is parallel with the port face. Install the (Gerotor)
drive and make sure that it engages the pin.
This mark should be parallel to the port face.

Seal

Port face
Drive
8609040

Pin parallel
with port face 2. With the seal side of the meter towards the
spacer plate, align the star valleys (A) on the
Pin
drive (B). Note the parallel relationship of ref-
erence lines A, B, C, and D. Align the bolt
8609039 holes without disengaging the meter from the
drive.

Meter (Gerotor)
star valley
A

Drive
(marked)
C

Port
face
Pin 8609041

6.18
STEERING GEAR: REASSEMBLY

Reassembling the End Cap (Trucks with Inspection after Reassembly


MicroCommand II Controller Only) Check the steer gear for smooth, free rotation in
1. Install the drive spacer(s) in the meter. Install both directions.
the seal in the end cap. Install the end cap on
the meter and align the holes.

End Cap
Seal screw
Drive cap
spacer(s)
Seal
washer

8609042

2. Install dry cap screw(s) with new seal washers.


Pretighten all of the screws, then torque them
in the sequence shown below.

8609043

1.7 kgf•m
Pretightening torque for bolts (12.5 lbf•ft)
[17 N•m]
3.2 kgf•m
Final tightening torque (23 lbf•ft)
[31.2 N•m]

6.19
STEER PUMP: DESCRIPTION

Steer Pump
Removal
Trucks with Optional EV100ZX Controller ONLY

2
8609046

Sequence
1. Motor mounting hardware
2. Pump mounting hardware

Start By:
1. Remove the battery.
2. Remove the acid tray.
3. Disconnect the cables and wires from the
steer pump motor. Mark the wire leads and
cables so they can be correctly reconnected.
4. Disconnect the hydraulic lines from the pump.

6.20
STEER PUMP: DESCRIPTION

Suggestions Installation
Removing the Motor and Pump Assembly 1. To install, reverse removal sequence.
After disconnecting the steer pump hoses, motor 2. Replace rubber grommets.
cables, and harness leads, remove the pump
and motor assembly by removing the motor
bracket mounting hardware where the bracket is
bolted to the frame.

Removing the Pump


Remove the pump from the motor.

6.21
STEER PUMP: DISASSEMBLY

Disassembly
7

5
4

1
8609074

Sequence
1. Cover 5. Ring
2. Spring 6. Retaining ring
3. Pressure plate 7. Shaft and bearing
4. Rotor and vanes 8. Body and seal

6.22
STEER PUMP: DISASSEMBLY

Working Rules and Tips Suggestions


The steer pump is a precision-machined compo- Removing the Motor and Pump Assembly
nent and must be handled with extreme care.
Disconnect the steer pump hoses, motor cables,
Cleanliness is imperative: use clean tools and
and harness leads. Remove the pump and motor
work in a clean place.
assembly by removing the motor bracket mounting
1. Clean the disassembled parts with a volatile hardware where the bracket is bolted to the frame.
solvent such as trichlene or chlorobenzene
and dry them with compressed air. This does Removing the Pump
not apply to rubber parts. Remove the pump from the motor.
2. Oil seal, O-rings, and the like are rubber
Removing The Pump Cover
parts. Never wash them with solvent. Blow
dirt off rubber parts with compressed air and Remove the four bolts holding the rear cover on
keep immersed in a pool of hydraulic oil until the pump. Remove the cover. Remove the O-ring
they are ready for reassembly. A rubber part located in the groove of the cover.
showing even slight wear and tear must be
replaced. Rubber parts are expendable com-
ponents and should be replaced yearly.
3. Parts to be installed by pressing or forcing
need special treatment.
Oil Seals
An oil seal, once removed, must not be
reused. After disassembly, examine the oil
seal in place (in the housing) and, if in sound
condition, leave it in place. When installing a
replacement oil seal, be careful not to score 8609075
or scratch its lip portion.

Removing the Spring


Lift the spring off the pressure plate.

8609076

6.23
STEER PUMP: DISASSEMBLY

Removing the Pressure Plate Removing the Retaining Ring


Lift the pressure plate off of the ring and remove The shaft and bearing assembly is held in place
the two locating pins from the ring. by an internal retaining ring on the driven end of
the pump. Remove the retaining ring using a
standard retaining ring tool.

8609077

Retaining
Removing the Rotor and Vanes
Ring
Remove the rotor and the vanes. Take care not
to lose any of the vanes.
8609080

8609078

Removing the Ring


Lift the ring off of the pump body.

8609079

6.24
STEER PUMP: DISASSEMBLY

Removing the Shaft and Bearing Removing the Seal and O-ring
1. Tap the end of the shaft very lightly to 1. Examine the shaft seal in place in the housing.
remove it from the pump body. Take extreme If it is in sound condition, do not attempt to
care not to damage the end of the shaft. remove it. Instead, use it as part of the rebuilt
2. Remove the external retaining ring from the unit. If there is any damage to the seal, re-
shaft to allow removal of the bearing. Tap the move it and do not reuse it.
end of the shaft very lightly to separate the 2. Remove the O-ring from the slot in the body.
bearing from the shaft. Take extreme care
not to damage the end of the shaft.

8609082

8609081

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 matter
can get into the hydraulic system and cause
damage. Do not use a coarse grit or try to file
or grind these parts.

6.25
STEER PUMP: REASSEMBLY

Reassembly
Trucks with Optional EV100ZX Controller Only

5
7
8

8609083

Sequence
1. Body and seal 5. Rotor and vanes
2. Shaft and bearing 6. Pressure plate
3. Retaining ring 7. Spring
4. Ring 8. Cover

6.26
STEER PUMP: REASSEMBLY

Suggestions Reassembling the Shaft and Bearing


Press the bearing onto the shaft and secure it
with the external retaining ring.
NOTE
Replace all old seals with new seals.
Lubricate all seals with clean petroleum jelly
such as Vaseline.

Reassembling the Shaft Seal


1. Install the seal in the housing, orienting the
seal lip as shown. Take care not to damage
the seal during installation.
8609085
2. The seal must be bottomed against the
shoulder when installed.
Reassembling the Shaft and Body
Install the shaft and bearing assembly into the
body, taking care not to damage the shaft seal
during installation. Secure the shaft by installing
the retainer ring.

8609084

Retaining
ring

8609086

6.27
STEER PUMP: REASSEMBLY

Reassembling the Ring Reassembling the Pressure Plate


Press the O-ring into the groove in the body. Install the pressure plate by slipping it over the
Place the ring on the body, aligning the bolt holes two pins
and the pin holes. Install the two pins through the
ring and into the body.

8609089

8609087

Reassembling the Spring


Slip the spring over the spring seat of the pres-
Reassembling the Rotor and Vanes
sure plate.
Slip the rotor over the splined portion of the shaft.
Insert a vane in each of the slots in the rotor.

8609090

8609088

6.28
STEER PUMP: REASSEMBLY

Reassembling the Cover Inspection after Reassembly


1. Press the O-ring into the groove in the cover. Check the pump for smooth, free rotation. Check
Place the cover on the ring and align the four for leaks after reinstallation in the truck.
bolt holes. Take care to properly orient the
discharge port to its original position prior to
assembly.
2. Install and tighten the cover bolts.

8609091

4.8 to 6.2 kgf•m


Tightening torque for cover bolts (35 to 45 lbf•ft)
[47 to 61 N•m]

6.29
Notes