TL;DR
Hard steering points to the power steering pump or orbitrol valve. Loose steering with clunking is tie-rod or king pin wear. Check steering fluid level before anything else.
What you might see
- steering wheel requires excessive force to turn
- excessive play or wandering at the steering wheel
- forklift drifts in straight travel without steering input
- clunking when turning at low speed
Likely causes
Power steering fluid low or contaminated, reducing orbitrol pressure
Worn tie-rod ends introducing play between the steering cylinder and the wheel knuckle
Steering orbitrol (Danfoss-type) valve worn internally, unable to maintain steering pressure
King pin or steer axle bushing wear allowing the whole knuckle assembly to have lateral play
Required tools
- Hydraulic pressure gauge with fitting
- Toyota-specified power steering fluid
- Dial indicator (king pin play check)
- LOTO kit
- Wheel chocks
- Tie-rod end removal tool
Safety first
- Lock out and chock the forklift before working under it or near the rear axle.
- Never test steering system pressure alone. A second person is required to turn the wheel while you read the gauge.
Procedure
- 1
Check the power steering fluid reservoir level and condition. Top up with Toyota-specified fluid if low. Milky or burnt fluid requires a full flush.[1]
- 2
Lock out the forklift and chock all wheels.
- 3
Grab each rear (steer) wheel at 9 and 3 o'clock and try to rock it side to side. Play greater than 5 mm at the tire indicates king pin or bushing wear.[1]
- 4
Grasp each tie-rod end and pull and push axially. Any detectable movement at the joint indicates a worn tie-rod end. Replace in axle pairs.
- 5
Check the steering cylinder rod seals for leakage. A leaking steering cylinder reduces effective steering pressure.
- 6
If fluid level is correct, tie-rods are good, and steering is still hard, test orbitrol output pressure with a hydraulic gauge at the steering cylinder port during full lock turn.
Warning: Have a second person turn the wheel slowly while you watch the gauge. Keep hands clear of all moving linkage. - 7
Orbitrol pressure significantly below Toyota specification indicates a worn valve. Replace the orbitrol unit.
Sources
Toyota 8-Series Forklift Operator and Maintenance Manual, Toyota Material Handling
Toyota 8FGU Series Forklift Service Manual, steering system pressure specifications and tie-rod inspection procedures (general)
View source
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Stop fixing the same fault twice.
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