GROUP 3 DISASSEMBLY AND ASSEMBLY

1. POWER STEERING PUMP

1) STRUCTURE
13
11

2 12

10

6
2

15

14

10

9
8

7 BP157SS06

1 Flange 6 Segment 11 Bolt

2 Housing 7 Parallel pin 12 Bolt
3 Cover 8 Oil seal 13 Nylon ball
4 Pinion shaft 9 Bushing 14 Name plate
5 Internal gear 10 O-ring 15 Rivet

5-13
2) DISASSEMBLY
11
(1) Screw out the screws(11,12) from the 12
cover.

11

BP157SS07)

(2) Remove the cover(3), sideways.

BP157SS08

(3) Lift the internal gear(4) with bushing(9)

and segment(6) off the unit.
4
9

BP157SS09

(4) Remove O-ring(10) and internal gear(5).

10

BP157SS10

5-14
(5) Remove housing(2) from the flange(1).

BP157SS11

(6) Remove O-ring(10) and bushing(9) from

flange(1).

10
9

BP157SS12

(7) Remove oil seal(8) and parallel pin(7)

from flange(1).

7
1

8
BP157SS13

5-15
3) ASSEMBLY
 Clean all parts carefully with low aromatic
kerosine.
 Check all parts carefully and replace if
necessary.
 Before assembly, lubricate all parts with
hydraulic oil and grease rubber parts with
vaseline.
 Perform the assembly in the reverse order
of disassembling but be carefule of
following points.

(1) Mounting bolt tightening torque.

11
12
ÂBolt(11,12) : 3.7 kgfÂm (26.8 lbfÂft)

11

BP157SS07

5-16
2. STEERING UNIT
1) STRUCTURE
28-2
28-1
1 21

25
26 2
18
27-2 3
27-4 11
5 14
27-3 15 4
13
27-1 22

6
23

24
8
16
24
10

19
10

13

10
7
20
17
9

12
B207SS10

1 Dust seal 13 Gerotor set 24 Plate spring

2 Retaining ring 14 Bearing race 25 Plug
3 Cap seal 15 Bore screw 26 O-ring
4 Thrust bearing 16 Drive shaft 27 Check valve
5 Ball 17 End cap 27-1 Guide
6 Pin 18 Bushing 27-2 Shim
7 Spacer 19 Plate 27-3 Spring
8 Center spring 20 Cap screw 27-4 Washer
9 Washer 21 Housing 28 Suction valve
10 O-ring 22 Spool 28-1 Roll pin
11 O-ring seal 23 Sleeve 28-2 Ball
12 Rolled screw

5-17
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)

5-18
(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)

5-19
3) 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)

5-20
(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 and suction

valve pins and balls.

D353SE09

5-21
(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)

5-22
(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

(14) Screw out the plug using an 8mm hexagon
socket spanner.
Remove seal washers.

D353SE10

5-23
(15) Unscrew the setting screw using an 8mm
hexagon socket spanner.

D353SE11

(16) Shake out spring and piston. The valve

seat is bonded into the housing and cannot
be removed.

D353SE12

(17) The pressure relief valve is now disassem-

bled.

D353SE13

5-24
4) 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 5-76(1)
holes opposite each 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)

5-25
(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)

5-26
(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)

5-27
(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)

5-28
(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)

5-29
(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)

5-30
(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)

5-31
(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)

5-32
(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)

5-33
(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)

5-34
3. STEERING HYDRAULIC MOTOR
1) DISASSEMBLY
(1) Seal plugs
Put the motor in a holding tool, with the
output shaft downward.
For end port version, use 10mm(0.4in)
hexagon socket spanner.
Seal plug

B15T5SM01

(2) Drain plug & washer

Drain plug
A/flat, other version : 19mm(0.75in)
Washer
Not SAE washer.

B15T5SM02

(3) Screws, washers(7 off)

Use a 13mm(0.5in) spanner socket. 7 screws

7 washers

B15T5SM03

(4) End cover, gear wheel set, O-ring(2 off)

Remove end cover sideways.
End cover
Keep fingers under the gear wheel set to
prevent the parts from falling out. O-ring
Caution!
Parts can fall Gear wheel set

O-ring

B15T5SM04

5-35
(5) Cardan shaft, plate, O-ring.
Remove orderly. Distributor plate

O-ring

Cardan shaft

B15T5SM05

(6) Output shaft

Shaft and bearings should normally not be
removed from housing. However, if
necessary for inspecfion and cleaning,
remove the shaft from the housing front Output shaft
end. The rear bearing can thus remain in
the housing. After this, turn the motor.

Do not disassemle unless necessary !

B15T5SM06

(7) Screws, spigot flange

Use torques-spanner type T30, 9mm
Housing
(0.35in)screw driver or hexagon socket
spanner 4 or 5mm(0.16 or 0.20in).

Spigot flange

Screw
B15T5SM07

(8) O-ring, bearing race, shaft seal

Use a 2mm(0.08in) screw driver.
Housing

Bearing race

O-ring
Shaft seal
B15T5SM08

5-36
(9) Dust seal, needle bearing
Use a 4mm(0.16in) screw driver.
Housing

Needle bearing

Dust seal
B15T5SM09

5-37
2) ASSEMBLY
 Clean all parts carefully with low aromatic
kerosine
 Check all parts carefully and replace if
necessary
 Before assembly, lubricate all parts with
hydraulic oil and grease rubber parts with
vaseline.

(1) Needle bearing

Place needle bearing onto the output shaft
side.
Housing

Needle bearing

B15T5SM11

(2) Shaft seal

Knock the seal into position in the spigot
flange. Check that the seal lies against Housing
the cover recess.

Shaft seal
B15T5SM12

(3) Dust seal ring

Place the dust seal ring in the spigot
flange and knock it into position with a Housing
plastic hammer and appropriate mandrel.

Dust seal
B15T5SM13

5-38
(4) Bearing race, O-ring
Grease the O-ring with vaseline and fit the
bearing race and O-ring into the spigot Housing
flange.

Bearing race

O-ring
B15T5SM14

(5) Spigot flange

Turn so that the holes line up.
Housing

Spigot flange

B15T5SM15

(6) Screws(6 off)

ÂTightening torque
Η Slotted screw M6
Housing
0.5~0.8kgfÂm(3.6~5.8lbfÂft)
Θ Hexagon socket screws M5
0.5~1.0kgfÂm(3.6~7.2lbfÂft)
Ι Hexagon socket screws M6
1.2~1.5kgfÂm(8.7~10.8lbfÂft) Screw
Κ Torx screws M6
B15T5SM16
0.5~0.8kgfÂm(3.6~5.8lbfÂft)
ö Omit spring washer, if the screw head
is protruding from spigot flange when
screw has been tightened (old OMR
metric version only). After this, turn
the motor

5-39
(7) Output shaft(1 1/4inch splined shaft)
The rear shaft end of 1 1/4inch splined
shafts must be marked before fitted. Output shaft
The mark must be positioned vertically
above a communication slot leading up to
the front annular channel.
Grease the journals with hydraulic oil.

B15T5SM17

(8) O-ring, distributor plate

Grease the O-ring and put it in the O-ring Distributor plate
groove of the housing.
Turn the distributor plate so that the holes
O-ring
line up.

B15T5SM18

(9) Cardan shaft

Guide the cardan shaft down into the
motor housing. Cardan shaft

B15T5SM19

(10) Gear wheel set, O-rings

Place the O-rings(greased) in the O-ring O-ring
grooves of the gearwheel.
In gearwheels with non through splines Caution!
Parts can fall Gear wheel set
place the gearwheel with the recess in the
spline hole facing down towards the
housing. O-ring

B15T5SM20

5-40
(11) Gear wheel set
Place the gearwheel set on the cardan Caution!
Parts can fall Gear wheel set
shaft so that the top of a tooth in the
external teeth of the gearwheel are
vertically above the key slot in the output
shaft(cylindrical or tapered) or the top of a
tooth on a 1 inch splined shaft. In motors
with 1 1/4 inch splined shaft the tooth top
must be positioned vertically above the
B15T5SM21
mark, see point 13.
Turn the gearwheel set counter clockwise
until the cardan shaft and the gearwheel
start to mesh(15Á).
Turn the gearwheel rim so that the holes
made for the screws line up.

(12) End cover

Turn the end cover so that the holes line End cover
up.

Housing

B15T5SM22

(13) Washer, screws(7 off)

Use a 13mm spanner socket. 7 screws

ÂTightening torque : 7 washers

3.0~3.5kgfÂm(21.7~25.3lbfÂft)

B15T5SM23

5-41
(14) Washer, drain plug
Drain plug
Use a 19mm spanner socket.
ÂTightening torque : Washer

3~6kgfÂm(21.7~43.4lbfÂft)

B15T5SM24

(15) Seal plugs(threaded plugs)

Side port version.
Screw plastic plugs.

Seal plug

B15T5SM25

5-42