A logistics warehouse reported that a Heli CPD25 electric forklift had excessive play in the steering wheel. The operator had to turn the steering wheel nearly half a turn before the rear wheels started to turn, making it dangerous for navigating narrow aisles.
The technician first checked the hydraulic steering cylinder (steer cylinder) for leaks, which was dry. The priority valve pressure was tested and found to be within spec (80 bar). The focus then shifted to the mechanical linkage. The steering column connects to the orbitrol (hydraulic steering control unit) via a coupling.
Upon removing the steering column cover, the technician found that the universal joint (U-joint) connecting the steering wheel shaft to the orbitrol was loose. The pinch bolt had sheared off, and the spline was worn. This caused a delay between the operator turning the wheel and the orbitrol actually activating. The U-joint was replaced.
However, there was still some play. The rear steer axle was jacked up off the ground. The technician grabbed the rear wheels and tried to wiggle them. There was noticeable "clunking" and play. The tie-rod ends were tight, but the steering knuckle pivot bearings (kingpin bearings) were found to be dry and worn. The ball bearings inside the bearings had flattened from years of impact, allowing the whole hub assembly to move laterally.
The repair involved replacing the steering column U-joint and pressing new taper roller bearings into the steering knuckles. After reassembly and greasing, the steering play was reduced to the manufacturer's specification of less than 5 degrees of wheel rotation, restoring precise control.
