Bendi Forklift 3 Wheel Trouble Shooting & Maintenance Manual_F-445-1208

ELECTRIC VERY NARROW AISLE FORKLIFT TROUBLESHOOTING AND CORRECTIVE MAINTENANCE MANUAL Bendi 3 Wheel SepExâ MODEL

LANDOLL CORPORATION Material Handling Products Group 1900 North Street Marysville, Kansas 66508 Telephone: (785)562-5381· FAX: (785)562-4853 www.Landoll.com · MHProd@Landoll.com

MATERIAL HANDLING PRODUCTS

Publication No. F-445-1208 December, 2008

Table of Contents Using This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Preliminary Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Curtis Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Drive Controller Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Hydraulic Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Brake Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Electrical Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Audible Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Visible Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Corrective Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Tools Needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Lifting the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Electrical Static Discharge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Forks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Removing Forks · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-5 Repairing Forks · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-5 Load Testing Forks · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-5

Troubleshooting & Corrective Maintenance i

Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Removing the Mast From the Truck · · · · · · · · · · · · · · · · · · · · · 3-6 Mast Maintenance · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-8 Sideshifter· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-8 Mast Carriage Assembly · · · · · · · · · · · · · · · · · · · · · · · · · · 3-10 Removing the Tilt Cylinders · · · · · · · · · · · · · · · · · · · · · · · · · 3-10 Drive Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Removing Drive Wheel · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-11 Traction Drive Motor and Gear Box · · · · · · · · · · · · · · · · · · · · · 3-12 To Begin… . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Replacing the Gear Box . . . . . . . . . . . . . . . . . . . . . . 3-13 Replacing the Traction Drive Motor . . . . . . . . . . . . . . . . 3-14 Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Brake Drum Assembly· · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-17 Disassembling and Inspecting Wheel Bearings . . . . . . . . . . 3-18 Assembling Wheel Bearings . . . . . . . . . . . . . . . . . . . . 3-19 Changing Brake Shoes . . . . . . . . . . . . . . . . . . . . . . . 3-20 Replacing the Brake Shoe Assembly · · · · · · · · · · · · · · · · · · · · 3-22 Repairing Brake Wheel Cylinders · · · · · · · · · · · · · · · · · · · · · · 3-24 Hydraulic Drum Brakes · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-25 Measure Diameter . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 Replacing Brake Drum Assemblies . . . . . . . . . . . . . . . . 3-26 Parking Brake Assembly · · · · · · · · · · · · · · · · · · · · · · · · · · 3-27 Parking Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . 3-27 Adjusting Parking Brake Lever . . . . . . . . . . . . . . . . . . . 3-28 Replacing Parking Brake Lever Assembly . . . . . . . . . . . . . 3-29 Parking Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . 3-30 Checking Parking Brake Switch . . . . . . . . . . . . . . . . . . 3-30 Replacing Parking Brake Switch . . . . . . . . . . . . . . . . . . 3-31 Replacing the Parking Brake Cable . . . . . . . . . . . . . . . . 3-32 Parking Brake Assembly . . . . . . . . . . . . . . . . . . . . . . 3-33 Adjusting Parking Brake . . . . . . . . . . . . . . . . . . . . . . 3-33 Changing Parking Brake Shoes or Replacing Parking Brake Assembly . . . . . . . . . . . . . . . . . . . . . . 3-34 Replacing Any Other Hydraulic Brake Component · · · · · · · · · · · · · 3-34

Troubleshooting & Corrective Maintenance ii

Brake Pedal Assembly · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-35 Drum Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 Brake Pedal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 Service Brake Linkage . . . . . . . . . . . . . . . . . . . . . . . 3-36 Brake Light/Accelerator Switch · · · · · · · · · · · · · · · · · · · · · · · 3-38 Brake Light/Accelerator Switch Adjustment . . . . . . . . . . . . 3-38 Brake Light/Accelerator Switch Replacement . . . . . . . . . . . 3-39 Master Cylinder · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-40 Replacing Master Cylinder . . . . . . . . . . . . . . . . . . . . . 3-40 Bench Bleed the Master Cylinder. . . . . . . . . . . . . . . . . . 3-43 Bleeding Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44 Service Brake Pedal Assembly · · · · · · · · · · · · · · · · · · · · · · · 3-46 Accelerator Pedal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46 Floor Plate Removal· · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-47 Adjusting Accelerator Pedal · · · · · · · · · · · · · · · · · · · · · · · · · 3-48 Replacing Accelerator Module · · · · · · · · · · · · · · · · · · · · · · · 3-48 Motor Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50 Lift/Steer Motor and Pump · · · · · · · · · · · · · · · · · · · · · · · · · 3-51 Hydraulic Return Filter· · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-52 Change Hydraulic Oil Filter . . . . . . . . . . . . . . . . . . . . . 3-52 Steer Pump Relief Valve · · · · · · · · · · · · · · · · · · · · · · · · · · 3-53 Checking and/or Adjusting Pressure . . . . . . . . . . . . . . . . 3-53 Hydraulic Control Valve Assembly · · · · · · · · · · · · · · · · · · · · · 3-56 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56 Hydraulic Control Valve and Switches . . . . . . . . . . . . . . . 3-59 Hydraulic Lift Pot . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62 To Adjust and/or Replace. . . . . . . . . . . . . . . . . . . . . . 3-62 Steering Column/Dash Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65 Remove Right Side Cover· · · · · · · · · · · · · · · · · · · · · · · · · · 3-66 Display · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-67 Brush Wear Indicator (BWI) LED's · · · · · · · · · · · · · · · · · · · · · 3-67 Key Switch· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-68 Option Rocker (On/Off) Switches · · · · · · · · · · · · · · · · · · · · · · 3-69 Steering Wheel · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-70 Steering Column (Console) · · · · · · · · · · · · · · · · · · · · · · · · · 3-70 Steering Orbital Control Unit · · · · · · · · · · · · · · · · · · · · · · · · 3-72 Direction Control Lever · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-73 Replacing Direction Control Switch. . . . . . . . . . . . . . . . . 3-73

Troubleshooting & Corrective Maintenance iii

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-74 Curtis Electrical Control Panel · · · · · · · · · · · · · · · · · · · · · · · 3-74 1309 Parameter Install Tool · · · · · · · · · · · · · · · · · · · · · · · · · 3-74 Parameter Install Requirements· · · · · · · · · · · · · · · · · · · · · · · 3-75 Model 1311 Handset · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-76 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-76 Directions for use . . . . . . . . . . . . . . . . . . . . . . . . . . 3-76 Calibration of 1244 Accelerator Controller · · · · · · · · · · · · · · · · · 3-77 Setting the Lift Pot · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-78 Replacement · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-79 Replacing Complete Control Panel . . . . . . . . . . . . . . . . . 3-79 Replacing Any Other Single Controller Component . . . . . . . . 3-79 Horn · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-84 Removing the Horn . . . . . . . . . . . . . . . . . . . . . . . . . 3-84 Replacing Hydraulic Tank · · · · · · · · · · · · · · · · · · · · · · · · · · 3-86 Seat Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87 Seat Switch · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-87 Replacing the Switch and Cable . . . . . . . . . . . . . . . . . . 3-87 Overhead Guard, Lighting, and Alarms . . . . . . . . . . . . . . . . . . . . . . . 3-89 Lights · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-89 Back Up Alarms · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-90 Rotational Seals, Bearings or Steering Gear . . . . . . . . . . . . . . . . . . . . 3-88 Removing Steering Gear Only · · · · · · · · · · · · · · · · · · · · · · · 3-92 Rotation Seals and Bearings · · · · · · · · · · · · · · · · · · · · · · · · 3-93 Hints for Reassembly · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-94 Hydraulic Fittings and Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-95 Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-96

Troubleshooting & Corrective Maintenance iv

Using This Manual This B3 Series Model* Troubleshooting and Corrective Maintenance Manual is a guide to aid you in troubleshooting and correcting any problems you may have with your B3 Series Fork Lift Truck. It is designed to be used as a reference tool in your everyday use of this truck.

The manual is divided into two sections. It is designed to work through the truck and any problem which may arise from the front to the back of the forklift.

Troubleshooting When a problem develops, see this section for troubleshooting procedures, in chart form. Troubleshooting procedures are defined as battery problems, hydraulic problems, traction drive problems, brake problems, electrical problems, audible problems, and visible problems.

Once the problem is isolated, see the next section, Corrective Maintenance, for the adjustment and/or repair instructions.

Corrective Maintenance The corrective maintenance section details the maintenance procedures for your truck. These procedures include major adjustments, settings, mechanical, and electrical repairs which may need to addressed. These procedures are described in the section from the front to the rear of the truck.

* Landoll and B3 Series are trademarks of the Landoll Corporation. All other brand and product names are the trademarks of their respective holders.

Troubleshooting & Corrective Maintenance 1- 1

Bendi IC Forklift Operator’s Manual 1-2

Troubleshooting This chapter contains troubleshooting procedures to help diagnose and solve problems. Once the problem is isolated you must refer to Chapter 3, Corrective Maintenance for the repair instructions.

Troubleshooting procedures are arranged as: · Curtis Drive Controller Problems · Hydraulic Problems · Brake Problems · Electrical Problems · Audible Problems · Visible Problems, including battery troubleshooting

Preliminary Procedures · Thoroughly review the problem with the operator so you have a complete description of what is wrong. · Check the operator’s driving practices and operating procedures to see if operator error could be the problem.

If you suspect operator error, review the operating procedures with the operator, or have the operator read the B3 Series Operator’s Manual (F-492-___) provided with each truck. · If you are sure it is operator error, return the truck to service and see that the operator is properly retrained before being allowed to drive the truck. · Check the planned maintenance log to make sure that the log is up-to-date and the problem is recorded. If it is not, or if there is no log, begin one and start by performing an planned maintenance inspection of the truck (See Appendix A of the B3 Series Operator’s Manual (F-492-___) and the B3 Series Planned Maintenance Manual (F-444-___). · After the problem has been corrected, operate the truck again to verify the repair and to ensure there are no additional problems. If no other problems exist, return the truck to operation. If other problems are found, troubleshoot and repair them before returning the truck to operation.

Troubleshooting & Corrective Maintenance 2-1

Troubleshooting

Curtis Troubleshooting Drive Controller Problems If misoperation on the truck occurs, you must hook up the 1311 handset to the system controller to find the fault(s). Or, troubleshooting of the motor controller can be done with a computer laptop using a Curtis computer interface. (Landoll p.n. 145405) With the status code number, follow the procedures outlined in the status codes instruction manual to determine the problem and corrective action (See Electrical System on page 3-74 for handset information and the Appendix in the B3 Series Service Manual (F-446) for further information on the 1244 Motor Controller, 1254 Hydraulic System Controller, and the 840 Display.

Troubleshooting & Corrective Maintenance 2-2

Troubleshooting

Hydraulic Problems

#

Problem

Chart - Hydraulic Problems Cause

Suggested Repair

Lift, Tilt, and Sideshift Problems 1.

Mast does not lift load.

Attempting to lift a load in excess of the truck’s capacity.

• NEVER attempt to lift a load heavier

than the specified rating of the truck.

• Also see “Traveling and Load

Handling,” in the B3 Series Operator's Manual (F-492-___) for additional information.

• See “Understanding Stability,” in

the B3 Series Operator's Manual (F-492-___) Low hydraulic oil.

• Low levels can cause the pump to

“cavitate” and not permit full lift of the mast. See “Check Lift Operation,” in the B3 Series Planned Maintenance Manual (F-444-___).

• Check reservoir oil level. Replenish

as needed. See “Check Hydraulic Oil Level,” in the B3 Series Planned Maintenance Manual (F-444-___).

Faulty hydraulic control valve.

• Bent or damaged spool, worn

internal seals - repair or replace as needed.

• Check appropriate “Appendix” index

tab, for vendor service information, where applicable.

Faulty pump.

• The hydraulic pump section may be

damaged - replace the pump.

Note: If the pump was faulty, • Check appropriate “Appendix” index other mast functions would tab for vendor service information, also be affected. where applicable.

Hydraulic cylinders leaking or binding.

• Determine which cylinder is leaking

or binding - rebuild or replace.

• Seal kits are available for most

cylinders - see Mast Parts List (F-386-___, F-387-___, or F-388-___).

Troubleshooting & Corrective Maintenance 2-3

Troubleshooting

# 1.

Problem

Chart - Hydraulic Problems Cause

Suggested Repair

Mechanical damage of the mast.

• Check mast for damage and signs of

Insufficient system pressure.

• Check hydraulic pressure of system

misadjustment. See “Check Lift Operation,” in the B3 Series Planned Maintenance Manual (F-444-___). relief valves. For an overview of the system, see “Hydraulic System,” in the B3 Series Operator's Manual (F-492-___) • Try re-adjusting the pressure relief

valves. Maximum system pressure must not exceed 3,000 psi.

• See “Checking and/or Adjusting

Pressure,” on page 3-56.

• Check valves for seal leaks, sticking

or misadjustment.

• Repair or replace and/or re-adjust

accordingly.

• If problem persists, replace the relief

valve cartridge.

• Check appropriate “Appendix” index

tab, for vendor service information, where applicable.

Lift linear accelerator out of adjustment or not working properly 2.

Mast lifts slowly - loss of Attempting to lift a load in lift speed. excess of the truck’s capacity.

• See "Setting the Lift Pot," on page

3-78.

• NEVER attempt to lift a load heavier

than the specified rating of the truck.

• Also see “Traveling and Load

Handling,” in the B3 Series Operator's Manual (F-492-___) for additional information.

• See “Understanding Stability,” in the

B3 Series Operator's Manual (F-492-___) Insufficient pump or relief valve pressure.

• See “Mast does not lift load,” on

Mechanical damage of the mast.

• See “Mast does not lift load,” on

Hydraulic cylinders leaking or binding.

• See “Mast does not lift load,” on

Lift linear accelerator out of adjustment or not working properly

• See "Setting the Lift Pot" page 3-78.

page 2-3. page 2-3. page 2-3.

Troubleshooting & Corrective Maintenance 2-4

Troubleshooting

# 3.

Problem Mast drifts downward.

Chart - Hydraulic Problems Cause

Suggested Repair

Excessive load - attempting to • See “Mast does not lift load,” on lift loads beyond the capacity of page 2-3. the truck.

Lift hydraulic cylinders leaking or binding.

• Determine which cylinder is leaking

or binding - rebuild or replace.

• See “Mast does not lift load,” on

page 2-3.

• Seal kits are available for most

cylinders - see B3 Parts List (F-493___).

Air in cylinder.

• Run mast to full extent three times

to remove all air.

Bad check valve.

• Check appropriate “Appendix” index

tab for vendor service information, where applicable.

Faulty lift control valve.

• Oil may be bypassing between the

spool and body - repair or replace directional control valve.

• The spool is not centering properly

or is broken - repair or replace directional control valve.

• Check appropriate “Appendix” index

tab for vendor service information, where applicable.

3.

Mast does not tilt.

Inoperative tilt directional control valve.

• Repair or replace.

• See "Removing the Tilt Cylinder,"

page 3-10.

• Check appropriate “Appendix” index

tabs for vendor service information, where applicable.

Insufficient pump or relief valve pressure.

• See section “Insufficient pump or

Hydraulic cylinder leaking or binding.

• Tilt cylinder is leaking or binding -

relief valve pressure,” beginning on page 2-4. rebuild or replace.

• Seal kits are available for tilt

cylinders - see B3 Parts List (F-493-___), for replacement items.

• See "Removing the Tilt Cylinder,"

page 3-10.

Hydraulic switch out of adjustment or is broken

• See "Hydraulic Control Valve and

Switches," on page 3-59.

Troubleshooting & Corrective Maintenance 2-5

Troubleshooting

#

Problem

5.

Steering drifts/wanders or is erratic.

Chart - Hydraulic Problems Cause Improperly sized tires.

Suggested Repair

• Check tire specs described in the

B3 Series Operator's Manual (F-492-___).

• See "Inspect Tires" in the B3 Series

Planned Maintenance Manual (F-444-___).

Low fluid or leaks in power steering system.

• Check hydraulic fluid level -

replenish as necessary.

• See “Check Hydraulic Oil Level,” in

the B3 Series Planned Maintenance Manual (F-444-___).

• Check all related components for

seal or fitting leaks - repair or replace.

Loose steering pump and motor • Check and tighten mounting brackets and mounting between assembly mounting. motor and pump.

• See “Lift/Steer Motor and Pump”

page 3-51.

Air in the hydraulic system.

• Check the inlet connections to

determine where air is being drawn into the system.

• Tighten loose connections.

• Bleed hydraulic system.

Worn or loose wheel bearings.

• Check wheel bearings - replace as

needed.

• See “Disassembling and Inspecting

Wheel Bearings,” on page 3-95.

Worn or out-of-adjustment steer • See “Steering Column (Console),” on page 3-70. assembly.

• Failed or weak orbitrol centering

spring will cause the steering to drift - replace accordingly.

• Check appropriate “Appendix” index

tab for vendor service information, where applicable.

Troubleshooting & Corrective Maintenance 2-6

Troubleshooting

#

Problem

Chart - Hydraulic Problems Cause Insufficient hydraulic pressure at the steering pump.

Suggested Repair

• Check hydraulic pressure of

steering relief valve (2,600 psi).

• See “Lift/Steer Motor and Pump”

page 3-51.

• Check steering motor for seal leaks,

sticking or misadjustment - repair or replace.

• Check appropriate Appendix index

tab for vendor service information, where applicable.

6.

Hard steering effort in one or both directions.

Improperly sized tires.

• Check tire specs described in the

B3 Series Operator's Manual (F-492-___).

• See "Inspect Tires" in the B3 Series

Planned Maintenance Manual (F-444-___).

Vehicle overloaded.

• NEVER exceed capacity of the

truck. Check capacity nameplate for tire specs.

• Also see “Understanding Stability,”

in the B3 Series Operator's Manual (F-492-___) Low hydraulic fluid.

• See “Check Hydraulic Oil Level,” in

the B3 Series Planned Maintenance Manual (F-444-___).

Low flow rate or fluid pressure.

• Restriction in fluid return line or line

is too small. Remove line, clean and/or replace line.

• Check pump. See “Lift/Steer Motor

and Pump” page 3-51.

• Check hydraulic pressure -

2,600psi.

Components in steering linkage • Find source of problem and repair, such as binding or making noise.

Steering column - See “Steering Column (Console),” on page 3-70.

Orbital steering unit - See “Steering Control Unit,” on page 3-72.

7.

Lost motion at the steering wheel.

Steering wheel loose on column or stripped.

• Check and re-torque the steering

wheel locking nut.

• See “Steering Wheel,” on page

3-70.

Troubleshooting & Corrective Maintenance 2-7

Troubleshooting

#

Problem

Chart - Hydraulic Problems Cause Air in the hydraulic system.

Suggested Repair

• Check the inlet connections to

determine where air is being drawn into the system.

• Tighten loose connections.

• Bleed hydraulic system.

8.

Truck turns too slowly.

See “Steering drifts/wanders or is erratic,” on page 2-6.

Pump Problems 9.

No hydraulic pressure.

Pump driven in the wrong direction of rotation after servicing.

• Change the drive direction

immediately to prevent seizure.

• Correct the pump cartridge ring

position for each direction of rotation.

• Check appropriate “Appendix” index

tab for vendor service information, where applicable.

Coupling or shaft sheared or disengaged.

• Disassemble the pump from motor

Oil intake line is restricted.

• Check all strainers and filters for dirt

and check the shaft and motor for damage. and sludge - clean or replace.

• See “Change Hydraulic Oil Filter,” in

the B3 Series Planned Maintenance Manual (F-444-___).

Fluid viscosity too heavy to pick • Completely drain the system. up prime.

• Add new filtered oil of the proper viscosity. See Appendix B of the B3 Series Operator's Manual (F-492-___) for recommended lubricants.

• See “Change Hydraulic Oil Filter,” in

the B3 Series Planned Maintenance Manual (F-444-___).

10.

Leaking fluid.

Cracked or cut hoses, where applicable.

• Replace. NEVER attempt to patch a

hose.

• See “Hydraulic Fittings and Hoses,”

on page 3-95.

Loose or faulty hose clamps, where applicable.

• Tighten and/or replace clamp.

Loose or faulty hydraulic fittings.

• Tighten and/or replace. Be careful

• Replace hose.

not to strip the threads, rendering the fitting defective.

• See “Hydraulic Fittings and Hoses,”

on page 3-95.

Troubleshooting & Corrective Maintenance 2-8

Troubleshooting

#

Problem

Chart - Hydraulic Problems Cause Oil seals deteriorated.

Suggested Repair

• Disassemble the unit and replace

the oil seals.

• Check appropriate “Appendix” index

tab for vendor service information, where applicable.

11.

Pump making noise.

Pump intake partially blocked.

• Service the hydraulic tank intake

strainer.

• Check the fluid condition and, if

necessary drain and flush the hydraulic system. Refill with clean oil.

• See “Change Hydraulic Oil,” in the

B3 Series Planned Maintenance Manual (F-444-___).

12.

Significant loss of speed under load.

Air leaks at the intake or shaft seal. (Oil in reservoir would possibly be foamy.)

• Check intake lines (hoses and

Damaged pump/motor mounting.

• Repair and/or replace.

Lack of sufficient oil supply.

• Check for faulty relief valve and

fittings) and seals for leaks. Repair all leaks.

adjust or replace as required.

• Check for and repair worn pump.

• See Appendix B of the B3 Series

Operator's Manual (F-492-___) for recommended lubricants.

Excessive heat.

• Locate excessive heat source

(usually a restriction) in the system and correct the condition.

High internal pump leakage.

• Replace pump • Check appropriate “Appendix” index

tab for vendor service information, where applicable.

Severely worn or damaged internal splines.

• Disassemble and replace motor or

pump.

• Check appropriate “Appendix” index

tab for vendor service information, where applicable.

Troubleshooting & Corrective Maintenance 2-9

Troubleshooting

Troubleshooting & Corrective Maintenance 2-10

Troubleshooting

Brake Problems # 1.

Problem Service brakes do not stop the truck.

Chart - Brake Problems Cause Low fluid level in master cylinder reservoir.

Suggested Repair

• See “Check Drum Brakes,” in the

B3 Series Planned Maintenance Manual (F-444-___).

• If low, check for leaking fittings or

lines - tighten and/or replace.

• Brake line fittings are made of soft

metal. Be careful not to strip the threads, rendering the fitting defective.

• Also check wheel cylinder for leaks -

rebuild or replace.

• See “Master Cylinder,” on page

3-40 and "Hydraulic Brake Drums," on page 3-25.

Worn brake shoes.

• Check brake shoes for wear or

defects -always replace both sides.

• See “Check Drum Brakes,” in the

B3 Series Planned Maintenance Manual (F-444-___).

• See “Changing Brake shoes,” on

page 3-20.

Brake pedal linkage adjustment.

• Check linkage for loose nuts,

broken or stressed linkage, misadjustment - repair and re-adjust.

• See “Service Brake Pedal

Assembly,” on page 3-46.

Brake pad contamination.

• If hydraulic oil, brake fluid or grease

come in contact with the shoes, they must be wiped clean and the pads must be sanded using a fine emery cloth.

• If the pads are saturated, they must

be replaced.

Troubleshooting & Corrective Maintenance 2-11

Troubleshooting

#

Problem

2.

Spongy or soft service brake pedal.

Chart - Brake Problems Cause Possible air in brake lines.

Suggested Repair

• Bleed air from brake lines - indicated

by bubbles in fluid during fluid bleed, or when checking the master fluid reservoir.

• See “Bleeding Brakes,” on page

3-44.

• Check brake system for loose fittings

and cross threaded fittings.

• Also check master cylinder reservoir

fluid level - low level can allow air into lines.

• See “Check Service Disc Brakes,”

in the B3 Series Planned Maintenance Manual (F-444-___).

Faulty seals in master cylinder or low fluid level.

• Examine the brake lines and master

cylinder for leaks - repair immediately, then bleed the brakes.

• Check brake calipers.

• Check master cylinder piston for

worn seals.

• Remove the master cylinder filler

cap and “slowly” press the brake pedal. A pulse of fluid should be seen in the cylinder reservoir. If not, replace the cylinder.

• See “Master Cylinder,” on page

3-40.

3.

Parking brake does not hold the truck.

Brake cable system malfunction • Check parking brake linkage for loose nuts, broken or stressed or out of adjustment. linkage, misadjustment - repair and re-adjust.

• See "Parking Brake Assembly,” on

page 3-27.

Service brakes not working properly.

• See “Service brakes do not stop the

truck,” on page 2-11.

Troubleshooting & Corrective Maintenance 2-12

Troubleshooting

Electrical Problems

# 1.

Problem Frayed or broken wires.

Chart - Electrical Problems Cause This may be caused by improperly secured wires or harnesses allowing pinching or excessive movement (vibration).

Suggested Repair

• Repair or replace wires and harnesses and secure properly.

• See “Inspect Electrical Connections,” in the B3 Series Planned Maintenance Manual (F-444-___).

• Make sure wires do not come in contact with any moving parts or are not pinched in access doors or cover panels.

2

Lights do not work.

Defective LEDs.

• Replace the light.

• See “Lights,” on page 3-89.

Blown Fuse.

• Check the "Lights" fuse.

Electrical problem - frayed or broken wires, faulty switch or electronics.

• Check related wire harnesses and connectors for contact problems, broken wires, etc.

• Continuity check on/off switches replace as needed.

• See “Intermittent Electrical Problems,” on page 2-13.

3.

Intermittent electrical problems.

Loose electrical connections.

• Check for excessive vibration or poor maintenance procedures.

• Tighten contacts as needed.

• Examine cable assemblies for tight connections.

• Wire terminal crimps should be secure and wire stranding must not be frayed or corroded.

Troubleshooting & Corrective Maintenance 2-13

Troubleshooting

Audible Problems #

Problem

1.

Back up alarm does not sound.

Chart - Audible Problems Cause Faulty alarm module.

Suggested Repair

• Continuity check alarm module -

replace as needed.

• See “Back Up Alarms,” on page

3-90.

Electrical problem - frayed or broken wires, faulty direction control lever or electronics.

• See “Inspect Electrical

Connections,” in the B3 Series Planned Maintenance Manual (F-444___).

• Check related wire harnesses and

connectors for contact problems, broken wires, etc.

• Examine cable assemblies for tight

connections.

• Wire terminal crimps should be

secure and wire stranding must not be frayed or corroded.

• Check wiring to relay.

• See “Intermittent electrical

problems,” on page 2-13.

2.

Unusual noise when truck is in motion.

Rubbing or binding brake pads in front wheels.

• Try to isolate the cause of the noise.

• Drive truck slowly having another

operator check for the unusual noise.

• Step on brakes lightly to see if

brakes are binding or rubbing excessively - repair or replace.

• See “Brake System,” on page 3-16.

Faulty drive motor assembly.

• If unit is suspected, it must be

removed from the truck and replaced.

• See “Traction Drive Motor and

Gearbox,” on page 3-12.

• Check appropriate Appendix section,

for vendor service information, where applicable.

3.

Singing noise.

Insufficient fluid level.

• Check fluid level. See “Check

Planetary Gear Box,” in the B3 Series Planned Maintenance Manual (F-444-___).

Faulty motor bearing.

• Repair or replace motor. See

“Traction Drive Motor and Gearbox,” on page 3-12.

Troubleshooting & Corrective Maintenance 2-14

Troubleshooting

# 4.

Problem Muffled grinding noise.

Chart - Audible Problems Cause Faulty wheel bearings - could be insufficient grease or high pre-stress or excessive play on bearings.

Suggested Repair

• Determine if noise is in the front or

rear.

• For rear - See “Disassembling and

Inspecting Wheel Bearings,” on page 3-18.

• For front - See “Traction Drive Motor

and Gear Box,” on page 3-12.

Damaged gearing - could be • Dismount gear box and examine for damage. insufficient fluid, excessive play in bearing • See “Traction Drive Motor and Gear Box,” on page 3-12.

5.

Clicking noise during a turn.

Loose or shifting component.

• Try to isolate the area of the noise,

then check for loose parts, misalignment, load shifting, etc.

• Check that components are in place

and properly torqued. See Appendix B in the B3 Series Operator's Manual (F-492-___).

6.

Horn does not work.

Faulty horn assembly or pushbutton.

• Disconnect horn wires and

pushbutton - continuity test horn with leads connected to battery power.

• Check related wire harnesses and

connectors for contact problems, broken wires, etc.

• Examine cable assemblies for tight

connections.

• Wire terminal crimps should be

secure and wire stranding must not be frayed or corroded.

• See “Intermittent electrical

problems,” on page 2-13.

Blown fuse

• Check for a blown fuse on fuse

panel.

• Check for electrical short - in horn or

electrical connections.

7.

Rubbing noise from the rear wheels.

Faulty wheel bearing or damaged wheel shaft.

• Dismount suspected wheel and

examine bearings and shaft.

• See “Disassembling and Inspecting

Wheel Bearings,” on page 3-18.

• Check for foreign material lodged

inside wheel hub - remove and repair and/or replace as needed.

Troubleshooting & Corrective Maintenance 2-15

Troubleshooting

# 8.

Problem

Chart - Audible Problems Cause

Scraping noise when the Out of alignment. mast is operated

Suggested Repair

• Realign and shim mast rails

accordingly.

• See “Mast,” on page 3-6.

Faulty hydraulic cylinder - lift, tilt • Determine which cylinder is bad rebuild or replace. and/or shift.

• Seal kits are available for most

cylinders - see Mast Parts List(s) (F-386-___, F-387-___, or F-388-___) for replacement items.

• See “Mast,” on page 3-6.

Faulty load roller

• Replace load roller

Needs lubrication

• Lubricate mast as described in

Appendix B of the B3 Series Planned Maintenance Manual (F-444-___) •

9.

Pump making noise.

See “Pump Problems,” beginning on page 2-8.

Troubleshooting & Corrective Maintenance 2-16

Troubleshooting

Visible Problems #

Problem

1.

Cracked or exceptionally worn forks.

Chart - Visible Problems Cause

Suggested Repair

Fatigue, age, excessive lifting of • When replacing forks - Forks must be replaced in pairs. overweight loads, straightness of blade and shank, fork angle • Check straightness of the upper or height differences between face of each blade and the front fork tips. face of each shank. If deviation exceeds 0.5% of the length of the blade and/or height of shank • If you find any defect in respectively, replace forks. the forks or mounting • Check angle between upper face of components, take the fork blade and load face of each forklift out of service shank. If deviation exceeds 3° from until the forks are reoriginal specification, replace forks. paired. Failure to do so can cause the load to • Check difference in height between fall resulting in serious each fork blade (measured at the tip injury or death. with the fork mounted on the carriage). If difference in tip heights exceeds 3% of the length on the blade, replace the forks.

WARNING

• See “Removing Forks,” on page

3-5.

Excessive wear or defective hooks.

• Check each fork, especially at the

heal area. If thickness is reduced to 90% of original thickness, replace the forks.

• Check support face of the top hook

and the retaining faces of both hooks for wear, crushing or other deformations. Excessive clearance between fork and carriage requires fork replacement.

WARNING • Forks requiring repair must be returned to the original manufac-

turer.

• Never try to repair surface cracks or wear by welding. If a fork is re-

set, make sure it is heat treated before it is returned to service.

• A fork that has undergone repairs must be load tested before it is

returned to service. The test facility must test forks according to paragraph 7.25.3 (ASME B56.1-2000), except that the test load must be 2.5 times the rated capacity marked on the fork.

2.

Leaking fluid.

Cracked, split, or cut hoses.

• Replace. NEVER attempt to patch a

hose.

• See “Hydraulic Fittings and Hoses,”

on page 3-95.

Troubleshooting & Corrective Maintenance 2-17

Troubleshooting

#

Problem

Chart - Visible Problems Cause

Suggested Repair

Loose or faulty hydraulic fittings. • Tighten and/or replace. Be careful not to strip the threads, rendering the fitting defective.

• See “Hydraulic Fittings and Hoses,”

on page 3-95.

Pump or motor oil seals, rings, gaskets, etc. deteriorated by excessive heat or corrosion.

• Replace seals in bad unit or replace

unit.

• Check appropriate “Appendix” index

tab for vendor service information, where applicable.

3.

Puddles/leakage in area of front drive wheels.

Loose or faulty hydraulic fittings. • Locate source of leak. Tighten and/or replace fittings.

• Be careful not to strip the threads,

rendering the fitting defective.

• See “Hydraulic Fittings and Hoses,”

on page 3-95.

Loose brake line fittings.

• Locate source of leak. Tighten

and/or replace fittings.

• Brake line fittings are made of soft

metal. Be careful not to strip the threads, rendering the fitting defective.

• See “Brake System,” on page 3-16.

Faulty seal/gasket in drive motor.

• Locate source of leak - gear box.

• Replace unit.

• See “Traction Drive and Gear Box”

on page 3-12.

• Check appropriate “Appendix” index

tab for vendor service information, where applicable.

Faulty seals/gaskets in main hydraulic pump.

• Check the hydraulic pump assembly

for excessive wear, oil leaks, loose or defective fittings.

• Replace seals or replace unit.

• See “Lift/Steer Motor and Pump”

page 3-51.

• Also see “Pump Problems,” on page

2-8.

• Check appropriate “Appendix” index

tab for vendor service information, where applicable.

Troubleshooting & Corrective Maintenance 2-18

Troubleshooting

#

Problem

Chart - Visible Problems Cause Leaking wheel cylinder.

Suggested Repair

• Replace wheel cylinder.

• See “Master Cylinder,” on page

3-40 and "Repairing Brake Wheel Cylinders," on page 3-24.

• See “Bleeding Brakes,” on page

3-44.

4.

Grease blotches around rear steer wheels

Faulty grease seal in steer wheel assembly.

• Check seal rings and wheel shaft for

damage in seal area.

• Replace the inner grease seal.

(especially on inside of wheel rim).

• See “Disassembling and Inspecting

Wheel Bearings,” on page 3-18.

5.

Puddles/leakage near mast.

Loose hose or hydraulic fitting.

• Locate source of leak, cylinder,

manifold hose, cylinder hoses, etc.

Tighten and/or replace fittings.

• Be careful not to strip the threads,

rendering the fitting defective.

• See “Hydraulic Fittings and Hoses,”

on page 3-95.

Leaking cylinder - lift, tilt and/or sideshift.

• Determine bad cylinder - rebuild

and/or replace.

• See “Mast,” on page 3-6.

• Seal kits are available for most

cylinders - see B3 Series Parts List (F-493-__) for replacement items.

6.

Frayed or broken wires.

This may be caused by improperly secured wires or harnesses allowing pinching or excessive movement (vibration).

• Repair or replace wires and

harnesses and secure properly.

• See “Inspect Electrical

Connections,” in the B3 Series Planned Maintenance Manual (F-444-___).

• Make sure wires do not come in

contact with any moving parts or are not pinched in access doors or cover panels.

7.

Scraping marks on the mast.

Rail misalignment.

• Realign rails. See “Mast,” on page

3-6.

Faulty roller

• Replace roller.

Troubleshooting & Corrective Maintenance 2-19

Troubleshooting

# 8.

Problem Excessive tire wear.

Chart - Visible Problems Cause Hard starting and stopping.

Suggested Repair

• Examine operator’s driving habits

and train operator accordingly.

• Excessive “hard” stops and starts

contribute to abnormal brake and tire wear.

• See “Check Drum Brakes,” in the

B3 Series Planned Maintenance Manual (F-444-___).

• See “Inspect Tires,” in the B3 Series

Planned Maintenance Manual (F-444-___).

Excessive overloading or improper weight distribution.

• NEVER lift loads in excess of what is

recorded on the capacity nameplate in the B3 Series Operator's Manual (F-444-___).

• Excessive overloading or improper

weight distribution placed on the drive train will eventually render the gear box defective and could cause wheel traction problems; in turn, premature tire wear.

• Also see “Understanding Stability,” in

the B3 Series Operator's Manual (F-444-___).

Faulty drive motor bearings causing alignment problems.

• Check appropriate “Appendix” index

Improper tire durometer.

• Repair only with Landoll

tab for vendor service information, where applicable. recommended spare parts.

Troubleshooting & Corrective Maintenance 2-20

Corrective Maintenance Introduction This section is divided by features from the front of the truck to the rear. For each feature, major adjustment and/or settings, mechanical repairs, and electrical control system repairs are addressed. A general list of features is listed below along with page references.

It is important to always locate the section which pertains to your needs, then read the entire procedure before attempting to adjust, repair and/or replace parts.

It is recommended to always use genuine Landoll replacement parts to maintain the overall high quality performance and guarantee maximum truck stability and to minimize downtime.

FEATURE/SYSTEM

PAGE NO.

FEATURE/SYSTEM

PAGE NO.

Forks

3-5

Steering Column/Dash Assembly

3-65

Mast

3-6

Electrical System

3-74

Mast Carriage Assembly

3-10

Hydraulic Tank

3-86

Drive Train

3-11

Seat Assembly

3-87

Brake System

3-16

Overhead Guard, Lighting, and Alarms 3-89

Accelerator Pedal Assembly

3-46

Front Assembly

3-91

Motor Compartment

3-50

Hydraulic Fittings/Hoses

3-95

Troubleshooting & Corrective Maintenance 3-1

Corrective Maintenance

Tools Needed The tools required to service the B3 Series lift truck are those found in a well-equipped service center, in both English and Metric sizes. For example, an assortment of open-end and box wrenches, socket and Allen wrenches with drivers, adjustable wrenches, flat blade and Phillips head screw drivers, and non-marring type mallets should be available.

Additionally, you should carry a flashlight and drop light, brake adjusting wrench, feeler gauges, a calibrated torque wrench and a standard ohm meter, analog or digital.

Before You Begin When it becomes necessary to do an electrical or mechanical service repair or maintenance procedure, it is important to review and practice the following safety suggestions.

Warning You could be injured and the truck could be damaged if you try to do service work without qualified experience.

If you use the wrong grade replacement parts, in time, they can break or loosen. Serious injury could occur. It is recommended to use Landoll replacement parts before you attempt any truck maintenance. · Be sure to use the proper nuts, bolts and other fasteners. Many are specifically rated; that is, SAE Grade 5, SAE Grade 8, ISO Prop Class 8.8, etc., and must be replaced with the identical type. · Whenever possible, return the truck to a service area having sufficient lighting, work space and an assortment of tools needed to complete the repair. · Set the key switch to OFF and place the key in your pocket. · Set the direction control lever to NEUTRAL and set the parking brake.

CAUTION To be certain the truck will not move, place wedges (or blocks of wood) at the front and back of the tires. If you are servicing the brakes or tires, place the block at the front and rear of the tire farthest away from the one being serviced, that is, the tire on the opposite side of the truck and at the opposite end. · Disconnect the battery. · Never place a tool or any metal object on top of the battery where it could possibly touch battery terminals causing a short or serious electrical shock.

Troubleshooting & Corrective Maintenance 3-2

Corrective Maintenance

Lifting the Truck 1. Always place an appropriate support stand or blocks of wood (8” square; 204 mm square minimum) under the truck if it is being lifted, then lower the truck to the support, having the lifting device and support both support the weight of the truck (See Figure 3-1).

DANGER GETTING UNDER A TRUCK WHEN IT IS LIFTED OR JACKED IS DANGEROUS AND MAY CAUSE SERIOUS INJURY. NEVER GO UNDER A LIFT TRUCK THAT IS SUPPORTED ONLY BY A JACK OR CRANE.

CRANE

SUPPORT BLOCKS OF WOOD WOOD BLOCKS TO PREVENT TIPBACK AND ROLL

lift truck pm

Figure 3-1 Jack and Support the Truck

1. Make sure all lifting devices and supports, such as a jack or support stand, blocks of wood, are capable of handling the weight of the load.

2. Open compartments or covers as necessary for easy access.

Troubleshooting & Corrective Maintenance 3-3

Corrective Maintenance

Electrical Static Discharge Normal precautions concerning the handling of metaloxide semi-conductors (MOS) components are applicable in order to minimize the risk of damage to these devices by ELECTRICAL STATIC DISCHARGE. This entails avoiding contact with the pins of the devices.

Any external clothing, overalls, etc. manufactured of nylon or a similar material must not be worn as they are capable of reaching extremely high voltage potentials caused by friction during normal wear.

Use a grounding wrist band to protect microprocessors from static electricity and always touch a metal surface (other than the truck) before touching a PCB.

Cleaning and Inspection · Always clean all metal parts with a de-greasing-type cleaner solvent and wipe dry with a clean shop rag. · Allow parts to air dry. · Do not allow cleaning solvent to come in contact with rubber parts or rubber insulation, such as electrical wiring, seals, etc.

IMPORTANT !

Cleaning solvents can be TOXIC and FLAMMABLE. Pay particular attention to all WARNING labels provided by the solvent manufacturer, such as, protection during use, personal health precautions and ventilation to avoid breathing vapors. · For non-metal parts, clean using a mild soap solution, shop vacuum for dust and loose dirt and a dust pan and brush. · Inspect all parts thoroughly for breaks, cracks, tears, burrs, scoring, warping or sharp edges, glazing, rust pitting, flat spots, etc. Notify your immediate supervisor of all defects and record it in the truck log book. · Inspect all screws and hardware for stress marks, breaks, cracks, thread defects, etc. · Replace all damaged or questionable parts. · Take care to properly identify and tag each part and its order of removal. If necessary, keep notes and put markings on parts using a non-destructive marker, such as a felt-tipped pen.

Troubleshooting & Corrective Maintenance 3-4

Corrective Maintenance

Forks Removing Forks 1. First, review “Before You Begin,” page 3-2.

2. Slide the fork so the hook on the fork lines up with the notch on the bottom of the carriage.

3. Pull the fork tine upward until the hook is free of the carriage (See Figure 3-2).

Note: As an alternate method, raise the forks a few inches from the floor and place a block of wood under the fork. Slowly lower the forks. The block of wood lifts the fork to unhook it from the carriage.

4. Lift the fork off the carriage. Various forks can be heavy - use adequate lifting apparatus or ask for a helper as needed.

5. To replace the forks, perform steps 1 through 3 in reverse order.

Repairing Forks The following information is provided for authorized service facilities ONLY. TO UNLOCK

If you suspect that a fork needs to be repaired, return it to the manufacturer or other expert of equal competence, for repair. Never try to repair surface cracks or wear by welding the fork. If you need to reset a fork, make sure it is heat treated before it is returned to service.

Load Testing Forks The following information is provided for authorized service facilities ONLY.

frkrls

A fork that has undergone repairs, other Figure 3-2 Changing Forks than repair or replacement of the positioning lock and/or marking, must be load tested before it is returned to service. The testing facility must test the forks according to paragraph 7.25.3 (ASME B56.1-2000) except that the test load must be 2.5 times the rated capacity marked on the fork.

Troubleshooting & Corrective Maintenance 3-5

Corrective Maintenance

Mast WARNING Only trained and experienced technicians or your Landoll service representative must be allowed to service the mast assembly.

Never place any part of one's body into the working area of the mast.

Never work on the mast while it is loaded; remove the load first.

Observe all safety precautions while operating the overhead crane and lifting apparatus.

Removing the Mast From the Truck To remove the mast, the work area must be clean and clear of obstacles, large enough to lay the mast horizontally, have a concrete floor and an overhead crane and frame rated to at least three (3) tons and three or four 6” x 6” x 48” (53 mm x 53 mm x 1,219 mm) solid planks of wood.

It is recommended to thoroughly steam clean the mast, removing all dirt and grease.

Record the roller clearances and chain adjustments before removing the carriage or rails (See "Mast Maintenance" in the B3 Series Planned Maintenance Manual (F-444-___)).

Make notes as you disassemble the mast while referring to the Appendix section of this manual (F-445). A separate manual is available for the triplex (3-stage) and quad masts.

1. First, review “Before You Begin,” page 3-2.

2. Remove the forks. Review “Removing Forks,” on page 3-5.

3. Remove the four bolts and hardware holding the backrest to the mast. Carefully remove the backrest. The backrest is heavy - use adequate lifting apparatus or ask for a helper.

STRAP

4. At the mast, disconnect the lift cylinder hose.

5. Oil will drain from the cylinder lines and the hoses.

Have shop rags handy to clean oil spills. Plug and/or cap the cylinder ports. and hoses to prevent further oil drainage. Tag each hose for identification.

6. Attach on overhead crane and strap, rated to 3 tons, and apply slight lift to the mast (See Figure 3-3).

pm mast lift

Figure 3-3 Supporting the Mast

Troubleshooting & Corrective Maintenance 3-6

Corrective Maintenance 7. Disconnect the two tilt cylinders from the mast-See "Removing Tilt Cylinders," beginning on page 3-10. (See Figure 3-3).

8. With the tilt cylinders disconnected from the mast, move the overhead crane forward slightly to provide a gap between the mast and the front mounting plate. (See Figure 3-6).

9. Remove the trunnion pin bolts (5/8"-11) and hardware. (See Figure 3-6).

WARNING The mast may swing from the lift truck, be alert and cautious!

10. Lay the mast horizontally, carriage side facing up, across three or four 6” x 6” x 48” (53 mm x 53 mm x 1,220 mm) planks of wood.

Note: Be careful if top of mast is lower than the bottom of mast when laying flat.

The carriage will slide to top causing damage to the mast or even injury. It is recommended to secure the carriage to the mast if possible.

11. Dismantle, clean and inspect the mast assemblies and subassemblies as instructed in the Mast Service Manuals.

12. Reassemble the mast in reverse order, using your notes as necessary and the enclosed Mast Service Manuals.

13. Before returning the mast to service, perform all adjustment procedures listed in enclosed Mast Service Manuals. Refer to the Appendix.

Troubleshooting & Corrective Maintenance 3-7

Corrective Maintenance Mast Maintenance See Mast vendor information located in the Appendix of the B3 Series Service Manual (F-446).

Sideshifter 1. First, review "Before you Begin," page 3-2.

SIDESHIFT ASSEMBLY

2. Park the truck on a clean, flat, level surface with enough room to work in the area safely.

3. Apply the hand parking brake and block all wheels.

LEFT SIDESHIFT

(RIGHT)

RIGHT SIDESHIFT

sideshift

(LEFT)

Figure 3-4 Sideshift Cylinder

4. Set the key switch to OFF and place the key in your pocket.

5. Relieve the hydraulic pressure in the system by turning the steering wheel two times to the left, then two times to the right and move the joystick in both directions.

6. Disconnect the battery.

7. Disconnect the two hydraulic hoses (Left and Right) at the sideshift cylinder (See Figure 3-4).

8. Cap and plug the hoses and cylinder ports. Also tag the hoses for identification. Have rags handy to soak up oil spills.

9. To remove the sideshift assembly from the truck and/or service sideshift components, see the Appendix.

TO FILTER TO LH TILT CYLINDER TEE TO LH SIDE SHIFT PORT TO PRESSURE GAUGE TO AUX. PUMP BOTTOM PORT TO MAST LIFT PORT TO RH TILT CYL TEE TO RH SIDE SHIFT PORT hyd control valve hoses

Figure 3-5 Hydraulic Control Valve Hoses

Troubleshooting & Corrective Maintenance 3-8

Corrective Maintenance

MAST ASSEMBLY MAST TRUNNION MOUNT MAST BUSHING TRUNNION PIN BOLTS HYDRAULIC HOSES

TILT CYLINDER

TILT CYLINDER MOUNT

removemast

Figure 3-6 B3 Mast Assembly

Troubleshooting & Corrective Maintenance 3-9

Corrective Maintenance

Mast Carriage Assembly Removing the Tilt Cylinders

1. First, review “Before You Begin,” page 3-2.

2. If the cylinder is being removed, disconnect the two hydraulic hoses from the tilt cylinder. Cap and plug the hoses and cylinder ports. Also tag the hoses for identification. Have rags handy to soak up oil spills (See Figure 3-7).

3. Mark the location of the cylinder jam nut for reassembly to the new cylinder.

Note: The jam nut is usually at the end of the threads which is closest to the barrel of the cylinder.

4. On the mast end of the cylinder, remove the bolt and hardware from the tilt cylinder pin weldment and remove the pin from the tilt cylinder clevis (See Figure 3-7).

Note: If mast has not been removed, the mast and masthead weldment will fall forward to main rotation pin placement. Hold the mast up with a crane.

HYDRAULIC PORTS TILT CYLINDER JAM NUT CLEVIS

tilt cyl adj

Figure 3-7 B3 Tilt Cylinder Location

5. Remove bolts (4) from tilt cylinder mounts and remove cylinder.

Note: To repair the tilt cylinder, replace seals, wiper, o-rings, etc., see B3 Series Parts List (F-493-___).

6. Reconnect cylinder to mast assembly in reverse order.

Troubleshooting & Corrective Maintenance 3-10

Corrective Maintenance

Drive Train Removing the Drive Wheel

WARNING The truck is equipped with tires of a size and hardness that provide the necessary traction and still maintain a proper shape to minimize tipping. To maintain stability and maximum reliability, you must always replace tires with the type originally supplied, as listed on the specification sheet at the beginning of this manual.

It is also recommended to replace worn tires in pairs. Treaded drive tires must be replaced when the groove is gone.

1. First, review “Before You Begin,” page 3-2.

2. Set the key switch to OFF and place the key in your pocket.

3. Apply the parking brake and disconnect the battery. Make sure the other wheels are securely blocked so that the truck cannot move.

4. Lift and support the truck so that the drive wheel is clear of the floor by no more than 1” (25.4 mm). Also see “Lifting the Truck,” on page 3-3.

5. Remove the six lug nuts (See Figure 3-8) 6. Using adequate support, remove the wheel.

Note: The wheel and tire weigh over 200 lbs. (90.7 kg.).

7. When installing the new wheel, tighten and torque the six lug nuts in a staggering fashion, following the numbering pattern (See Figure 3-9).

8. Tighten to 225 ft. lbs. (300 Nm) (See General Torque, Hydraulic Fitting Torque, and B3 Series Special Torque Tables in Appendix B of the B3 Series Operator's Manual (F-492-____)).

Troubleshooting & Corrective Maintenance 3-11

Corrective Maintenance Traction Drive Motor and Gear Box This section explains servicing the traction drive unit.

To Begin…

1. First, review “Before You Begin,” page 3-2.

2. Set the key switch to OFF and place the key in your pocket.

3. Apply the parking brake. Make sure all wheels are securely blocked so that the truck cannot move.

4. Raise the front of the truck 6” to 8” (15 - 20 cm) off the floor surface and support the truck in this position. Review previous section “Lifting the Truck,” on page 3-3.

5. Remove the drive wheel assembly to access the gearbox (See Figure 3-8).

The traction drive assembly is very heavy and awkward to handle. It must be supported as it is being removed from the truck. See Figure 3-10 for a complete breakdown of the load wheel and traction drive assembly.

INLINE GEAR BOX LUG NUTS (6)

TIRE AND WHEEL ASSEMBLY remove load wheel assy

Figure 3-8 Removing Load Wheel

Troubleshooting & Corrective Maintenance 3-12

Corrective Maintenance

Replacing the Gear Box 1. First, review “Before You Begin,” page 3-2.

2. Support the unit as the mounting screws are removed.

1

3. Remove the eight M16-2 x 30 hex socket screws and hardware holding the gear box to the truck frame (See Figure 3-10).

6

3

4

4. Evenly support the gear box and allow the shaft to slide free of the motor.

5 2

5. Place the gear box on a sturdy work bench. Use wood planks to balance and support the assembly while on the workbench.

6. To service the gear box, see the Appendix.

Figure 3-9 Tire Tightening Sequence

Also, see B3 Series Parts List (p/n F-493-____) for an overview and replacement parts.

7. Reassemble the gear box to the truck by following the preceding steps in reverse order.

8. Tighten and torque the M16-2 x 30 screws (See General Torque, Hydraulic Fitting Torque, and B3 Series Special Torque Tables in Appendix B of the B3 Series Operator's Manual (F-492____)).

WARNING When installing a new gear box unit, it is shipped from the factory without oil, therefore you must add oil before putting the unit into operation (See B3 Series Operator's Manual (F-492-____) for lubrication requirements).

For proper oil fill instructions, see “Check Planetary Gear Box,” in the B3 Series Planned Maintenance Manual (F-444-___).

Troubleshooting & Corrective Maintenance 3-13

Corrective Maintenance Replacing the Traction Drive Motor 1. Repeat preceding steps to remove the gear box (See “Replacing the Gear Box” , beginning on page 3-13) 2. Support the unit as the mounting bolts are removed.

DRIVE MOTOR GEARBOX DRIVE WHEEL

HEX HEAD SCREW, ½-13 X 2

drive line assy

Figure 3-10 Load Wheel and Traction Drive Assembly

Troubleshooting & Corrective Maintenance 3-14

Corrective Maintenance 3. Remove the twelve 1/2-20 x 2 hex socket screws and hardware holding the motor to the motor mount weldment (See Figure 3-10).

4. With the motor supported, rotate the motor to align the electrical connecting terminals to the slots machined in the motor mount weldment (See Figure 3-10).

5. Slide the motor out far enough to install a second strap around the motor. This strap is to support the motor from outside the truck frame.

6. Place the assembly on a sturdy work bench. Use wood planks to balance and support the assembly while on the workbench.

7. Assemble the new motor by following the preceding steps in reverse.

8. Tighten and torque the screws (See General Torque, Hydraulic Fitting Torque, and B3 Series Special Torque Tables in Appendix B of the B3 Series Operator's Manual (F-492-____)).

9. To service the traction drive motor, see B3 Series Parts List (F-493-____) for an overview and replacement parts.

Troubleshooting & Corrective Maintenance 3-15

Corrective Maintenance

Brake System WARNING Safety must always be paramount when working on brake system components.

Do not use parts that do not appear to be in perfect working condition. It is recommended to use only Landoll genuine replacement parts.

Whenever servicing a brake component, it is recommended to service both sides of the truck to prevent premature wear and uneven braking action.

If you are unsure about a procedure, seek professional help. Contact your Landoll service representative.

Wear eye protection. If brake fluid comes in contact with your eyes, immediately rinse them with water and seek medical attention.

Use only DOT #3 brake fluid.

Brake fluid will damage paint. Cover all body parts and be careful not to spill fluid during this procedure.

Troubleshooting & Corrective Maintenance 3-16

Corrective Maintenance Brake Drum Assembly

WARNING Brake shoes must be replaced on both wheels at the same time.

NEVER replace the shoes on only one wheel.

Do not, under any circumstances, use petroleum-based solvents to clean brake parts. Use only brake cleaner or denatured alcohol.

Do not use compressed air to blow dust particles from the brake assembly.

Make sure you strictly adhere to all clearances and torque specifications.

When you are finished working on the brakes, test them carefully under controlled conditions before releasing the truck for operation.

If the contact surfaces of the drum show cracks, score marks, deep grooves, a raised lip on the outer edge, or signs of overheating or warping, the drum must be replaced.

If a problem is suspected, do not release or drive the truck until the problem is corrected. "

Troubleshooting & Corrective Maintenance 3-17

Corrective Maintenance

HUB CAP O-RING LOCK NUT LOCK WASHER OUTER CONE INNER CONE

SPINDLE SEAL

wheel bearings

Figure 3-11 Wheel Bearing Assembly

Disassembling and Inspecting Wheel Bearings 1. Lift axle and support so that wheel to be inspected is free to rotate.

2. Measure the tire diameter. If the diameter of the tire is less than 13”, Landoll recommends that the tire be replaced (See Figure 3-11).

3. Remove hub cap, 5/32 x 1-1/2 cotter pin, 1-14 hex slot nut, spindle washer, and outer bearing cone.

4. Slide hub/wheel assembly from spindle. Remove inner bearing cone and seal from hub.

5. Clean bearing cones and seal. Clean bearing cups inside hub.

6. Replace bearing if rollers are pitted, rusted, or cracked.

7. Replace bearing cones if cones are cracked or pitted.

Note: You should pre-pack the bearings with grease before replacing. Bearing cups and cones should be replaced as a set.

8. Replace seal if worn or damaged.

Troubleshooting & Corrective Maintenance 3-18

Corrective Maintenance Assembling Wheel Bearings 1. If bearing cups are replaced, clean hub and press new bearing cups into hub (See Figure 3-11).

2. Pack wheel bearings with grease.

3. Place outside face of wheel down on bench. Insert inner bearing and carefully drive seal in until flush with hub.

4. Carefully slide hub, bearing, and seal assembly onto spindle.

IMPORTANT Be careful! Avoid damaging grease seal. A damaged seal must be replaced.

5. Insert outer bearing cone and washer. Tighten hex slot nut against spindle washer.

6. Adjust bearing preload by slowly rotating hub while tightening hex slot nut until resistance is felt. (Approximately 75 ft/lbs) Back nut off 1/16 of a turn or until a notch aligns with the spindle cross-hole.

7. Readjust if the wheel does not rotate smoothly.

8. Ensure that the cavity between the two wheel bearings has an adequate amount of grease.

9. Apply a thin layer of grease to the hub cap o-ring and press hub cap into hub.

Troubleshooting & Corrective Maintenance 3-19

Corrective Maintenance Changing Brake Shoes 10. First, review “Before You Begin,” page 3-2.

11. Set the key switch to OFF and place the key in your pocket.

12. Disconnect the battery.

13. Make sure all the other wheels are securely blocked so that the truck cannot move.

14. Raise the side of the truck being serviced.

15. Remove the hub cap and o-ring. (See Figure 3-11).

16. Loosen the lock nut and remove.

17. Remove the brake drums.

Note: If the wheel will not come off, make sure the parking brake is completely released. In extreme cases of wear, the brake must be fully returned (detuned) before the wheel can be removed. Brake fluid will damage paint. Have a container and shop rags handy to soak up any spilled brake fluid. Cover all body parts and be careful not to spill fluid during this procedure. DO NOT USE FORCED AIR TO BLOW BRAKE DUST FROM THESE PARTS! 18. Check the inside contact surfaces of the drums for cracks, score marks, deep grooves, a raised lip on the outer edge, and signs of overheating. If the drums show blue spots, indicating overheated areas, the drum must be replaced. Also, look for surface glazing, grease or brake fluid on the shoe contact surfaces. Grease and brake fluid can be removed from metal surfaces, but if the shoes are contaminated, they must be replaced. Surface glazing, which is a glossy, highly polished finish, can be removed with medium grit emery cloth. (100-120 grit) 19. Before removing the internal brake components, wash (spray) them with brake cleaner and allow to dry. Position a container under the brake assembly to catch the excess residue. (See Figure 3-13).

20. Pull or press to release the star wheel adjuster latches and turn the star wheel to retract both the front and rear brake shoes.

21. Loosen one clamp hold-down screw and remove the other screw to allow the clamp to drop down making it easer to remove the front and rear return springs.

22. Unhook and remove both return springs.

23. Release and remove the bottom return spring, then release and remove the self-adjuster assembly.

24. Press in on the hold-down spring and pop it to one side (opposite of where hook is attached) to free the spring hook from the rear of the brake backing plate. This will require some force to compress the spring to pop it free.

25. Remove both hold down screws and the hold down clamp. Carefully separate the front and rear shoes from the wheel cylinder and parking brake lever assembly.

26. Clean the area and check the wheel cylinder for leaks. Pull back on the bottom portion of the rubber boot on both sides of the cylinder. If it is not dry, see "Wheel Cylinder," page 3-24).

Troubleshooting & Corrective Maintenance 3-20

Corrective Maintenance 27. Check the brake lines for cracking, splits, or any apparent weakness - replace as needed.

Hold-down Clamp

28. Check both wheel cylinder pistons for signs of fluid leakage, indicating a defective seal which must be repaired.

Note: It is recommended to resurface the drums when changing brakes to eliminate the possibility of out-of-round drums. Record the amount that is removed during resurfacing. If the drums have been turned-down to 0.060" (1.524 mm) they must be replaced.

Front and Rear Return Springs

Hold-down Springs Self-adjuster assembly

29. SPARINGLY lubricate the brake shoe contact areas of the Figure 3-12 Removing Wheel Assembly backing plate with high temperature grease. Install the new brake shoes and install the brake drum (two outer hex head screws and hardware). Do not allow any grease to come on contact with braking area of the shoe. Torque the screws (See General Torque, Hydraulic Fitting Torque, and B3 Series Special Torque Tables in Appendix B of the B3L Series Operator's Manual (F-492-____).

30. Install the new brake shoes by following the above instruction in reverse order. Be sure that all springs are properly hooked at both ends and that they hold-down clamp screws are tight and torqued (See General torque, Hydraulic Fitting Torque, and Bendi B3 Model Special Torque Tables in appendix B of the Bendi B3 Operator's Manual (F-492-_____). (See Figure 3-13).

31. Wiggle the brake assembly to ensure that the shoes are centered on the backing plate. (See Figure 3-12) 32. Reinstall components in reverse order.

33. Bleed the brakes. (See page 3-44).

34. Pump the brakes several times to seat the new brake shoes.

35. If the forklift does not perform as stated above, reinspect the brake shoes for wear (See "Check Service Brakes," in the B3 Series Planned Maintenance Manual (F-444-___)).

36. Make a few normal stops in forward and reverse to allow the brakes to further seat themselves. DO NOT lock the brakes which could cause flat spots.

Troubleshooting & Corrective Maintenance 3-21

Corrective Maintenance Replacing the Brake Shoe Assembly IMPORTANT! Whenever servicing or replacing a brake assembly, it is recommended to service both sides of the truck to prevent premature wear and uneven braking action.

IMPORTANT! It is recommended when replacing a wheel cylinder assembly to purge the entire brake system of old, possibly contaminated fluid.

37. Repeat Steps 1 through 8 of preceding section “Changing Brake Shoes," beginning on page 3-20.

38. Check the brake lines for cracks, splitting, or any apparent weaknesses. Replace as needed.

39. Install the new brake assembly in reverse order making sure the brake shoes are properly installed.

40. Bleed the brakes (See "Bleeding Brakes," on page 3-44).

It is recommended when replacing a brake shoe assembly to purge the entire brake system of old, possibly contaminated fluid.

41. Repeat Steps 19 through 21 of preceding section “Changing Brake Shoes”, beginning on page 3-21.

Troubleshooting & Corrective Maintenance 3-22

Corrective Maintenance

BRAKE SHOES WHEEL CYLINDER HOLD DOWN CLAMP

BRAKE ADJUSTER SPRINGS

drum brakes

Figure 3-13 Drum Brake Assembly Overview

Troubleshooting & Corrective Maintenance 3-23

Corrective Maintenance Repairing Brake Wheel Cylinders The wheel cylinder, if it freezes-up or shows signs of leakage, must be replaced before returning the truck to operation.

WARNING Whenever replacing a wheel cylinder assembly or internal parts, you must service both sides of the truck to prevent premature wear and uneven braking action.

1. Set the key switch of OFF and place the key in your pocket.

2. Raise the side of the truck being serviced.

3. Remove the wheel. (See "Replacing Brake Drum Assemblies", page 3-26) Wheel Cylinder

4. Remove the brake shoes (See "Changing Brake Shoes", on page 3-20)

Brake Line

5. Using a flare-nut wrench, disconnect the brake fluid inlet line from the wheel cylinder. Have rags handy to soak up any spilled fluid.

6. Do not pull the brake line away from the cylinder. Plug the end to reduce fluid loss and contamination.

7. Remove the two bolts holding the cylinder to the backing plate. wheelcyl

8. Install the new cylinder making sure the bolts are properly seating and tightened to Figure 3-14 Wheel Cylinder Repair the specified torque (See General Torque, Hydraulic Fitting Torque, and Bendi 3 Model Special Torque Tables in Appendix B of the Bendi 3 Operator's Manual. (F-492-____) 9. Connect the brake inlet line and install the brake shoe assembly and drum. To avoid stripping the brass threads, do not overtighten the brake line fittings (See "Changing Brake Shoes," on page 3-20).

10. Reinstall the components in reverse order.

11. Bleed the brakes (See "Bleeding Brakes" on page 3-44) Note: When replacing a brake assembly, a wheel cylinder or a master cylinder, it is advisable to purge the entire brake system of old, possibly contaminated fluid.

Troubleshooting & Corrective Maintenance 3-24

Corrective Maintenance Hydraulic Brake Drums

WARNING Whenever servicing and/or replacing a brake drum assembly, you must service both sides of the truck to prevent premature wear and uneven braking action.

Repeat steps 1 through 5 of preceding section “Changing Brake Shoes”, beginning on page 3-20.

Check the drums for scoring, cracks, deep grooves, a raised lip on the outer edge, signs of overheating, out of round or other damage.

Drum diameter measurements may be checked with the drum removed from the truck. Use a brake drum gauge to check run-out. Measure the diameter in several different areas of the drum to check diameter.

Measure Diameter Using a brake drum gauge, measure the diameter at four or more points on the drum and make sure all measurements are taken at the same distance in from the outer edge of the drum.

Thickness variations of more then 0.005” (0.13 mm) can cause pedal pulsation and/or vibration when applying the brakes. A drum that does not meet these specifications must be turned or replaced.

Troubleshooting & Corrective Maintenance 3-25

Corrective Maintenance Replacing Brake Drum Assemblies 1. Repeat Steps 1 through 8 of preceding section “Changing Brake Shoes”, beginning on page 3-20.

2. Check the brake lines for cracks, splits or any apparent weaknesses. Replace as needed.

IMPORTANT! To remove the drum, you might need to loosen up on the brake adjuster. If the brake shoes are tight against the drum, excessive force on the drum will damage the drum or backing plate making the brake assembly unserviceable.

SPINDLE 3. Loosen the locknut and hardware from the spindle (See Figure 3-15).

BRAKE ASSEMBLY

DO NOT remove the nut from the assembly at this time.

4. Rock the drum back and forth while gently pulling on the drum. (See Figure 3-15).

BRAKE ADJUSTER

5. If needed, Using the rubber mallet (dead-blow hammer), hit the drum on the opposite side, driving it towards the loosened nut.

BRAKE DRUM

6. Repeatedly hit the drum evenly in a circular motion until it pops free, then remove the nut.

LOCKNUT

Figure 3-15 Brake Assembly

Troubleshooting & Corrective Maintenance 3-26

Corrective Maintenance 7. Remove the drum and tire assembly. (See Figure 3-15)

IMPORTANT! The removal of the drum and tire is as a completed assembly. The tire is pressed on to the drum.

8. Inspect the condition of the brake assembly.

IMPORTANT! When handling the new drum, protect the finish surfaces from damage, such as nicks, deep scratches, dents from dropping, corrosion, etc. Damage to the braking surfaces renders the brake drum defective.

9. Install the new drum and tire assembly to the spindle. Install, tighten and torque the flanged hex nut (See General Torque, Hydraulic Fitting Torque, and B3 Series Special Torque Tables in Appendix B of the B3 Series Operator's Manual (F-492-____)).

Note: Make sure there is no grease on the shaft/nut area before installing and torquing the nut.

10. Reassemble in reverse order.

11. Bleed the brakes (See "Bleeding Brakes," on page 3-44).

12. Repeat Steps 19 through 21 of preceding section “Changing Brake Shoes,” beginning on page 3-20.

Parking Brake Assembly The parking brake assembly includes: · Parking Brake Lever · Parking Brake Switch · Parking Brake Cable · Parking Brake Caliper Assembly

Parking Brake Lever The amount of vertical travel of the parking brake lever should allow the lever to move from the horizontal position up to the vertical position, having the brake fully applied in the vertical position.

Troubleshooting & Corrective Maintenance 3-27

Corrective Maintenance

CAUTION Adjusting the parking brake lever too tight will overheat brake shoes and drums causing premature wear; or overheat the drive motors, causing premature failure.

Adjusting Parking Brake Lever 1. First, review “Before You Begin,” page 3-2.

2. Set the key switch to OFF, then place the key in your pocket and disconnect the battery.

3. Block all wheels.

4. Raise the right side of the truck until the right rear tire clears the floor by no more than 1” (25.4 mm) - see “Before You Begin,” page 3-2.

5. Pull up on the parking brake lever as far as possible using moderate force (See Figure 3-16). The amount of vertical travel should allow the lever to snap into the full vertical position. The right rear wheel should not turn when attempting to turn by hand.

WARNING Before reaching in to turn the wheel, make sure the truck has sat idle long enough to cool. Various parts can get extremely hot during operation. Also make sure you are wearing work gloves.

6. Release the parking brake by pushing downward as far as the lever will travel.

7. To adjust, loosen the Allen head adjustment setscrew. Turning the lever clockwise tightens the setting; counterclockwise loosens the setting. After adjustment, tighten Allen head adjustment setscrew.

Note: Do not overtighten. You will separate the cable from the clevis ends.

8. Apply and release the parking brake five or six times to stretch (seat) the cable, then double check your adjustment.

9. If this fails to properly adjust the park brake, see “Adjusting Parking Brake Assembly,” page 3-33.

Troubleshooting & Corrective Maintenance 3-28

Corrective Maintenance Replacing Parking Brake Lever Assembly 1. First, review “Before You Begin,” page 3-2.

2. Set the key switch to OFF, then place the key in your pocket and disconnect the battery.

3. Make sure all the other wheels are securely blocked so that the truck cannot move.

4. Remove floor plates (See "Floor Plate Removal," page 3-47).

5. Remove control valve cover (See Figure 3-17).

6. Remove e-brake switch.

Note: The parking brake lever assembly will be attached to the right side of the steering wheel.

APPLIED 90 o TRAVEL

7. Disconnect the clevis end brake cable.

ADJUSTMENT SETSCREW RELEASED

8. Replace with new parking brake lever assembly.

9. Reassemble in reverse order.

10. Adjust park brake (See "Adjusting Parking Brake Lever" on page 3-28).

handbrk

Figure 3-16 Parking Brake Vertical Travel

Troubleshooting & Corrective Maintenance 3-29

Corrective Maintenance Parking Brake Switch The parking brake switch electrically resets the controller to its neutral state.

Checking Parking Brake Switch 1. First, review “Before You Begin,” page 3-2.

2. Set the key switch to OFF and place the key in your pocket.

3. Disconnect the battery.

4. Make sure all the wheels are securely blocked so that the truck cannot move.

5. Remove floor plates (See "Floor Plate Removal," page 3-47).

6. Remove the control valve cover (See Figure 3-17).

7. Disconnect e-brake cutout switch connector.

8. Connect the ohm meter leads to the switch wires.

PARKING BRAKE LEVER ASSEMBLY

HYDRAULIC VALVE BRACKET

EMERGENCY BRAKE CUT-OUT SWITCH

Note: The meter should show less than 1 ohm.

9. Slowly pull up on the brake lever, the meter reading must be “OPEN”, indicating the switch is released before the lever reaches its full locking position.

PARKING BRAKE CABLE

BRAKE SHOE ASSEMBLY

BRAKE CABLE CLEVIS

IMPORTANT! If the meter does not read "OPEN", the switch needs to be replaced (See "Replacing Parking Brake Switch" on page 3-31.

park brake assy

Figure 3-17 Replacing Parking Brake Lever

10. Disconnect the ohm meter.

11. Reassemble in reverse order.

Troubleshooting & Corrective Maintenance 3-30

Corrective Maintenance Replacing Parking Brake Switch 12. First, review “Before You Begin,” page 3-2.

13. Set the key switch to OFF and place the key in your pocket.

14. Apply the parking brake and disconnect the battery.

15. Make sure all the other wheels are securely blocked so that the truck cannot move.

16. Remove floor plates (See "Floor Plate Removal," page 3-47) and control valve cover to expose the parking brake mechanics (See Figure 3-35).

17. Disconnect the switch at the wire connector and unscrew the switch from the dash.

18. Install the new switch in reverse order and tighten the jam nut (See Figure 3-17).

19. Connect the switch at the connector.

IMPORTANT! The plunger is preset and has no adjustment. It is always activated in the resting position.

20. Reassemble in reverse order.

21. To check the operation of this switch: · Start the truck and release the parking brake. · Set the control lever to FORWARD and very slowly increase motor speed. · As the truck is moving forward at slow speed, slowly pull up on the brake lever. · The truck must immediately slow to a STOP. · If the truck continues moving forward, recheck the setting and operation of the switch.

WARNING DO NOT release or operate the truck if you are in doubt about the effectiveness of the parking brake system. Contact your Landoll service representative for assistance.

Troubleshooting & Corrective Maintenance 3-31

Corrective Maintenance Replacing the Parking Brake Cable

BRAKE CABLE LOCK NUT YOKE

1. First, review “Before You Begin,” page 3-2.

2. Set the key switch to OFF and place the key in your pocket.

3. Disconnect the battery.

4. Make sure all the other wheels are securely blocked so that the truck cannot move.

5. Remove floor plates (See "Floor Plate Removal," page 3-47) and control valve cover to expose the parking brake mechanism.

brake cable

Figure 3-18 Parking Brake Cable Brake End

6. Remove the cable from the truck noting how the cable is positioned (See Figure 3-18).

7. Feed the new cable from the parking brake lever to the wheel motor in the same manner as the one removed, then connect both ends.

8. Adjust the parking brake cable - see “Adjusting Parking Brake Lever,” page 3-28.

9. Reassemble in reverse order.

WARNING DO NOT release or operate the truck if you are in doubt about the effectiveness of the parking brake system. Contact your Landoll service representative for assistance.

Troubleshooting & Corrective Maintenance 3-32

Corrective Maintenance

Parking Brake Assembly The parking brake assembly is used for holding the forklift in place while the driver is not there after it is activated by pulling the park brake lever.

Adjusting the Parking Brake 1. First, review “Before You Begin,” page 3-2.

2. Set the key switch to OFF, then place the key in your pocket and disconnect the battery.

3. Make sure all the other wheels are securely blocked so that the truck cannot move.

4. Remove floor plates (See "Floor Plate Removal," page 3-47).

5. Loosen adjustment bolt jam nut (See Figure 3-18).

6. Adjust actuator adjustment bolt to desired position (See Figure 3-18).

IMPORTANT! The adjustment should be set that so when the park brake lever is screwed all the way out (completely counterclockwise) and the lever is pulled to its full vertical position, the parking brake holds the wheel as stated in the section “Adjusting Park Brake Lever,” on page 3-28.

7. Tighten adjustment bolt jam nut.

8. Reassemble in reverse order.

Troubleshooting & Corrective Maintenance 3-33

Corrective Maintenance Changing Parking Brake Shoes or Replacing Parking Brake Assembly 1. First, review “Before You Begin,” page 3-2.

2. Set the key switch to OFF, then place the key in your pocket and disconnect the battery.

3. Raise the side of the truck being worked on.

4. Make sure all the other wheels are securely blocked so that the truck cannot move.

5. Remove floor plates (See "Floor Plate Removal," page 3-47).

IMPORTANT! The parking brake cable assembly and bracket will be loose when hardware is removed. Remove the parking brake assembly carefully so that the actuator pins, yoke, and parking brake springs do not fall out.

6. Either remove brake assembly or replace brake shoes with new ones.

7. Reassemble in reverse order.

8. Adjust parking lever assembly (See "Adjusting Parking Brake," on page 3-33).

Replacing Any Other Hydraulic Brake Component 1. First, review “Before You Begin,” page 3-2.

2. Set the key switch to OFF and place the key in your pocket.

3. Apply the parking brake and disconnect the battery.

4. Make sure all the other wheels are securely blocked so that the truck cannot move.

5. Remove floor plates (See "Floor Plate Removal," page 3-47).

6. Replace the damaged component.

IMPORTANT! Use flare-nut wrenches to remove these lines. Do not overtighten the fittings to avoid stripping the brass threads.

7. Bleed the brakes (See "Bleeding Brakes," page 3-44).

8. Reassemble in reverse order.

Troubleshooting & Corrective Maintenance 3-34

Corrective Maintenance Brake Pedal Assembly Drum Brakes The drum brakes are self-adjusting. When properly working, adjustments after the initial setup are unnecessary. Refer to “Changing Brake Shoes,” page 3-20.

Brake Pedal The service brake pedal has about 1" maximum free-play before any pressure is applied to the brakes, (or before the pedal moves the master cylinder plunger).

The pedal also has a maximum range of travel of up to only 0.500” (12.7 mm) before it contacts the positive stop hex screw, and includes a brake light switch that energizes the brake STOP lights, where applicable, and has a switch for disengaging traction drive. The brake light/accelerator switch is factory set to trip just as the brake pedal begins its downward stroke.

Troubleshooting & Corrective Maintenance 3-35

Corrective Maintenance Service Brake Linkage 1. First, review “Before You Begin,” page 3-2.

2. Set the key switch to OFF, place the key in your pocket, and disconnect the battery.

3. Before doing any adjustment, check for: · low fluid level in the master cylinder reservoir (See "Check Master Cylinder Fluid Level," in the B3 Series Planned Maintenance Manual (F-444-___). · air or leaks in the system · worn brake shoes (See “Changing Brake Shoes," page 3-20).

Any of these conditions can affect pedal free-play. Proceed to the appropriate heading for repairs.

4. Remove the left floor plate to expose the brake pedal linkage and master cylinder (See "Floor Plate Removal," page 3-47).

5. Loosen 5/16” (7.94 mm) lock nut on the master cylinder push rod (See Figure 3-19).

BRAKE PEDAL

BRAKE SWITCH (NORMALLY CLOSED)

1.0

MASTER CYLINDER CRANK PLATE

BRAKE SWITCH AND MASTER CYL

Figure 3-19 Master Cylinder and Brake Switch Assembly

Troubleshooting & Corrective Maintenance 3-36

Corrective Maintenance 6. Turn the rod clockwise to increase dimension on the pedal; turn counterclockwise to decrease dimension. See Figure 3-20 for free play adjustment dimension and note.

Tighten the adjustment lock nut against the brake pedal yoke.

7. Install the left floor plate.

8. Connect the battery and check for proper brake operation as follows: · Accelerate the forklift to full speed. · Apply the brakes to quickly STOP the wheels. · Release the brake pedal after the wheels stop, then accelerate again to full speed. · Release the accelerator pedal to allow the truck to coast to a stop. · Both brakes should stop very closely together (around the same time). · Repeat this procedure two times in forward and in reverse directions.

9. If the forklift does not perform as stated above, reinspect the brake shoes for wear.

(See "Check Service Brakes," in the B3 Series Planned Maintenance Manual F-444___).

Troubleshooting & Corrective Maintenance 3-37

Corrective Maintenance Brake Light/ Accelerator Switch 3-3/16”

Brake Light/ Accelerator Switch Adjustment 1. First, review “Before You Begin,” page 3-2.

2. Set the key switch to OFF, place the key in your pocket, and disconnect the battery.

3. Slightly loosen both brake switch hex head screws (See Figure 3-19).

NOTE: HOLE IN CRANK PLATE MUST BE IN END OF YOKE SLOT FARTHEST AWAY FROM MASTER CYLINDER BEFORE MAKING ADJUSTMENT TO 3-3/16” AND TIGHTENING PUSH ROD LOCK NUT. free play brake adjust

Figure 3-20 Free Play Brake Adjustment

4. Connect the ohm meter leads to the wires knowing which switch you are on.

5. Slowly push down on the brake pedal. Before the pedal reaches its first locking position the meter must read one of the following: a. The meter must show a reading of open at the full upright pedal position for brake lights (2 black wires). b. The meter must show a reading of closed (or less than 1 ohm) at the full upright pedal position for accelerator switch (2 green wires).

6. Slide the brake switch forward or backward to locate the switch at this position - to just trip as the pedal begins its downward stroke (See Figure 3-19).

7. Carefully tighten and torque the screws (8 to 10 ft. lbs.; 11-14 Nm) to secure the switch without moving the setting, then release the brake pedal to verify the setting.

8. Disconnect the ohm meter.

9. Connect the battery and start the truck.

10. Apply the brakes while checking that the lights turn ON and/or the accelerator switch interrupts before pressure is applied to the master cylinder.

Note: Do not lock the brakes when stopping to avoid “flat-spotting.”

Troubleshooting & Corrective Maintenance 3-38

Corrective Maintenance Brake Light/Accelerator Switch Replacement 1. First, review “Before You Begin,” page 3-2.

2. Set the key switch to OFF and place the key in your pocket.

3. Disconnect the battery, block the wheels and release the parking brake.

4. Remove floor plates (See "Floor Plate Removal," page 3-47).

5. Unscrew and remove the switch assembly from the brake pedal frame and install the new switch (See Figure 3-21).

6. To set the switch (See "Brake Light/Accelerator Switch Adjustment," on page 3-38).

BRAKE LIGHT/ACCEL CUTOUT SWITCH ADJUSTMENT SLOTS

CRANK PLATE

Figure 3-21 Brake Light Switch

Troubleshooting & Corrective Maintenance 3-39

Corrective Maintenance Master Cylinder Replacing Master Cylinder 1. First, review “Before You Begin,” page 3-2.

2. Set the key switch to OFF and place the key in your pocket.

3. Apply the parking brake, disconnect the battery and block the wheels.

4. Remove floor plates (See "Floor Plate Removal," page 3-47.)

5. Remove the master cylinder fill cap and rubber diaphragm (two round head screws).

Note: Siphon out as much fluid as possible. Install and tighten the fill cap and diaphragm before removing the cylinder (See Figure 3-22).

6. Place rags under the brake line connections. Have a plastic cap or bag handy to cover the end of the line to limit fluid spillage. (See Figure 3-22)

IMPORTANT! Brake fluid will damage paint. Cover all body parts and be careful not to spill fluid during this procedure.

RUBBER RD DIAPHRAGM

FILL CAP MASTER RC CYLINDER

H ROD PUSH R

BRAKE LINE CONNECTION mstrcyl

Figure 3-22 Master Cylinder Assembly

Troubleshooting & Corrective Maintenance 3-40

Corrective Maintenance 7. Using a flare-nut wrench, disconnect the brake fluid line at the rear of the cylinder (See Figure 3-23).

Note: Flare-nut wrenches should be used as they wrap around the nut to prevent rounding off the flats.

8. Carefully pull the brake line away from the cylinder. Seal or plug the brake line and master cylinder port to prevent fluid loss and/or contamination.

9. Disassemble the yoke from the master cylinder crank plate (one 5/16-18 screw and hardware) (See Figure 3-23).

10. Remove the two master cylinder mounting bolts (3/8-16) and remove the cylinder from the truck.

BRAKE LINE MASTER CYLINDER

PIVOT BUSHING BRAKE RETURN SPRING SWITCH

Brake pedal assy

Figure 3-23 Master Cylinder Removal

Troubleshooting & Corrective Maintenance 3-41

Corrective Maintenance 11. Remove the reservoir cap and discard any fluid remaining in the reservoir.

12. Mark the push rod lock nut setting, then remove the yoke and lock nut from the old cylinder and install it to the new cylinder, maintaining the same lock nut setting.

Note: The push rod lock nut should be installed so that when the pedal is completely retracted, the yoke to the master cylinder crank plate hardware is loose, when it is completely assembled.

Note: Whenever the master cylinder is removed and/or replaced, the hydraulic brake system must be bled. The time required to bleed the system can be reduced and made easier if the master cylinder is filled with brake fluid and bench-bled before installing the cylinder into the truck (See "Bench Bleed the Master Cylinder," on page 3-43).

13. Replace the new master cylinder in reverse order.

IMPORTANT! Brake fluid will damage paint. Cover all body parts and be careful not to spill fluid during this procedure. Wipe up any spilled fluid immediately, then flush the area with clean water.

Troubleshooting & Corrective Maintenance 3-42

Corrective Maintenance Bench Bleed the Master Cylinder Since high pressure is not involved in the bench bleed procedure, your finger can be used to plug the cylinder hole and prevent air intake.

1. Support the cylinder (in a vise) to prevent fluid spillage while allowing you to push the internal piston with the push rod (See Figure 3-24).

2. Remove the filler cap and fill the cylinder with DOT 3 brake fluid.

3. Slowly push in on the rubber boot and cylinder plunger (push rod) assembly to force air from the cylinder, then hold the push rod in (See Figure 3-24).

4. Press your finger tightly over the master cylinder outlet port to prevent air from being drawn back into the cylinder when you release the push rod, or feed a separate line (flexible tubing) from the cylinder port(s) and immerse the other end in the container of new brake fluid.

Wait several seconds to allow fluid to be drawn from the reservoir to the cylinder bore, then repeat this step. When you push the push rod in again it will force your finger from the master cylinder outlet port to expel any trapped air (See Figure 3-24).

Place rags under the brake line fitting to soak up any fluid loss.

5. When only brake fluid is expelled from the master cylinder outlet port, hold the push rod in and seal the master cylinder outlet port with an appropriate threaded plug or plastic cap, then release pressure on the push rod.

6. Fill the master cylinder reservoir and install the filler cap and gasket.

PUSH IN MASTER CYLINDER

MASTER CYLINDER OUTLET PORT PUSH ROD PLUNGER AND RUBBER GROMMET

bleed-1

Figure 3-24 Support and Bench Bleed the Cylinder

Troubleshooting & Corrective Maintenance 3-43

Corrective Maintenance Bleeding Brakes Bleeding the brake system is necessary to remove any air that is trapped when replacing brake lines, wheel cylinders or the master cylinder. To avoid extensive damage to the system, use only DOT 3 brake fluid.

WARNING Wear eye protection. If brake fluid comes in contact with your eyes, immediately rinse them with water and seek medical attention.

Check the fluid level often during the bleeding operation and add fluid as needed to prevent the level from falling low enough to allow air bubbles into the master cylinder.

Use only fresh (new) DOT 3 brake fluid. NEVER use old or used brake fluid. It contains moisture which will deteriorate the brake system components.

It is necessary to bleed both wheels if air has entered the system due to low fluid level or if a brake line has been disconnected at the master cylinder or at the tee fitting.

If the brake pedal feels spongy when pressed and goes almost to the mechanical stop but regains height when pumped, air has entered the system. The system must be bled. If no fittings were recently opened for service, check for leaks that would have allowed air into the system and repair leaks before attempting to bleed the system.

Have an assistant handy, as well as a supply of brake fluid, an empty container, a length of 3/16” (4.763 mm) clear plastic or vinyl tubing to fit over the cylinder bleeder fitting and a six point wrench to open and close the fitting.

WARNING DO NOT allow fluid to run down the inside of the brake caliper and onto the brake pad. It will contaminate the brake lining material causing an unsafe brake condition and unnecessary repair.

1. First, review “Before You Begin,” page 3-2.

2. Set the key switch to OFF and place the key in your pocket.

3. Apply the parking brake and disconnect the battery.

4. Block the wheels so that the truck cannot move.

5. Start with the right wheel as viewed from inside the driver's compartment (the wheel farthest from the master cylinder).

6. Loosen the bleeder fitting slightly, then tighten it to a point where it is snug but can be loosened quickly and easily.

Troubleshooting & Corrective Maintenance 3-44

Corrective Maintenance 7. Fit a length of tubing over the bleed screw and immerse the other end in the container of new brake fluid. Check that the tubing fits tightly over the bleeder fitting (See Figure 3-25).

8. Check fluid level in the master cylinder. Fill as needed before you begin.

9. Have someone slowly press on the brake pedal several times to build pressure in the system, then hold the pedal down.

IMPORTANT !

Be careful when handling bleeder screws. Rust may cause the fitting to easily break off if forced. Installing a new bleeder screw may include overhaul. Spray the fitting with penetrating oil before attempting to loosen it to help prevent problems.

brake bleed

Figure 3-25 Bleeding Brakes

10. Loosen the cylinder bleed screw until fluid starts to flow. Watch for air bubbles at the immersed end of the tube.

11. When the brake pedal bottoms, tighten the bleed screw, then release the pedal. DO NOT release pressure on the pedal until the bleed screw is tightened.

12. Repeat Steps 8 through 11 as many times as needed until the fluid draining in the container is free of air bubbles.

13. Check the master cylinder fluid level and fill as needed before beginning the other side.

14. Check the operation of the brakes. The pedal should feel solid when depressed, with no sponginess. If necessary, repeat this procedure.

Troubleshooting & Corrective Maintenance 3-45

Corrective Maintenance

BRAKE LINE MASTER CYLINDER

PIVOT BUSHING BRAKE RETURN SPRING SWITCH

Brake pedal assy

Figure 3-26 Brake (Service) Pedal Assembly

Service Brake Pedal Assembly The service brake assembly (brake pedal) includes: · The mechanical brake pedal assembly, containing a pivot bushing The only normal repair items are the switch, the pivot bushing, or the brake return spring (See Figure 3-26).

Accelerator Pedal Assembly The accelerator assembly consists of the linear potentiometer, harness, and accelerator pedal (See Figure 3-27).

Troubleshooting & Corrective Maintenance 3-46

Corrective Maintenance Floor Plate Removal This panel provides access to the accelerator module assembly which is mounted to the underside of the floor plate. The master cylinder and service brake pedal and linkage are mounted within the frame well.

1. Thoroughly clean the floor area using brush and dustpan or vacuum.

2. Pull up the rubber floor mat. Be careful around the accelerator pedal to avoid tearing the mat (See Figure 3-27).

3. Remove the left floor plate from the truck frame (See Figure 3-27).

Note: All planned maintenance checks can be done by removing only the left floor plate.

4. If more extensive maintenance is necessary, remove the hardware holding the control valve cover plate and remove plate.

5. Remove the hardware holding the right floor plate to the truck frame. Carefully lift the right floor plate. Note that the accelerator pedal assembly and linear accelerator assembly are still attached to the right floor plate.

Note: The accelerator module electrical harness will restrict how far the plate can be lifted. To fully remove the plate you must disconnect the electrical harness.

6. Reassemble in reverse order.

Note: It is recommended to leave all hardware loose when reinstalling for proper fit. After the floor plate hardware is installed, torque to recommended values (See General Torque Table in Appendix B of the B3 Series Operator's Manual (F-492-___)).

Troubleshooting & Corrective Maintenance 3-47

Corrective Maintenance RH FLOOR PLATE

LH FLOOR PLATE

ACCELERATOR AND MOUNTING PLATE (MOUNTED TO UNDERSIDE OF FLOOR PLATE)

FLOORPLATE

Figure 3-27 Floor Plate Removal and Linear Accelerator Module Assembly

Adjusting Accelerator Pedal 1. First, review “Before You Begin,” page 3-2.

2. Set the key switch to OFF and place the key in your pocket.

3. Block wheels.

4. Remove the floor plates (See Figure 3-27).

Note: It is recommended to hold the right hand floor plate in a vice while doing this procedure.

5. Loosen the allen head fastener on the pedal arm so that it can rotate freely. Rotate the pedal until the pedal touches the rear of the slot. Tighten the fastener.

6. Install floor plate assembly back on the forklift.

7. Install left hand floor plate.

8. Refer to Landoll Setup Procedure, located in "Calibration of 1244 Accelerator Controller" on page 3-77 to recalibrate the controller.

Replacing Accelerator Module 1. First, review “Before You Begin,” page 3-2.

2. Set the key switch to OFF and place the key in your pocket.

3. Apply the parking brake, disconnect the battery and block all wheels.

4. Remove the floor plates (See "Floor Plate Removal," on page 3-47).

Troubleshooting & Corrective Maintenance 3-48

Corrective Maintenance

RIGHT SIDE FLOOR PLATE 5/16-18 X 1 SCREW

ACCELERATOR PEDAL ACCELERATOR 5/16-18 LOCK NUT

accelpedal2

Figure 3-28 Floor Plate Removal and Accelerator Module Assembly 5. Remove the two round head screws (5/16-18 x 1) and hardware securing the accelerator to the floor panel (See Figure 3-29).

6. Disassemble the accelerator from the floor plate and install the replacement accelerator in its place (See Figure 3-28).

7. Loosen the allen headed fastener on the pedal arm and orient the pedal 90 degrees up. Insert the flat part of the arm through the slot, rotate and mate the accelerator mounting surface to the underside of the floor plate. Align with the 5/16" bolts and tighten to secure the accelerator.

8. Adjust the pedal (See Adjusting Accelerator Pedal, page 3-48).

Troubleshooting & Corrective Maintenance 3-49

Corrective Maintenance

Motor Compartment This section explains the following: · Lift/Steer Motor And Pump · Hydraulic Return Filter

FLOOR PLATE

5/16 -18 X 1 SCREW

· Hydraulic Control Valve

ACCELERATOR

5/16 LOCK NUT WIRING HARNESS accelpedal

Figure 3-29 Accelerator Module Assembly

Troubleshooting & Corrective Maintenance 3-50

Corrective Maintenance

LIFT STEER

pumps

Figure 3-30 Motor Compartment

Lift/Steer Motor and Pump 1. First, review “Before You Begin,” page 3-2.

2. Set the key switch to OFF and place the key in your pocket.

3. Apply the parking brake and disconnect the battery.

4. Make sure all the wheels are securely blocked so that the truck cannot move.

5. Remove the floor plates (See "Floor Plate Removal," on page 3-47).

6. Unhook the accelerator pedal wiring harness. (See Figure 3-29).

7. Remove the lower dash cover weldment (See Figure 3-27).

8. Remove seat pedestal cover weldment (See Figure 3-27).

9. Replace desired component (See Figure 3-30).

Note: Be sure to cap and plug all hydraulic ports and mark any cables that are removed in this process.

10. Reassemble component in reverse order.

Troubleshooting & Corrective Maintenance 3-51

Corrective Maintenance Hydraulic Return Filter Change Hydraulic Oil Filter 1. Position the truck on a flat surface, set the parking brake and block the wheels to prevent movement.

2. Set the key switch to OFF and place the key in your pocket.

3. Disconnect the battery.

4. Remove the floor plates (See “Floor Plate Removal,” page 3-47). Then, remove control valve cover plate.

5. Using a clean, lint-free cloth, clean the area around filter and replacement element.

6. Unscrew and remove old filter element.

7. Coat the top O-ring seal on the new filter element with a thin film of hydraulic oil, then screw the new element onto the housing screw (See Figure 3-31).

8. Operate the hydraulic system by running the mast functions and observe the filter for oil leaks.

9. Reinstall the control valve cover plate and floor plates.

Troubleshooting & Corrective Maintenance 3-52

Corrective Maintenance

HYDRAULIC FILTER CAP HYDRAULIC FILTER ASSEMBLY PRESSURE PORT RELIEF VALVE

hyd filter

Figure 3-31 Hydraulic Return Filter

Steer Pump Relief Valve The steering hydraulic pump is a single cavity vane pump. Pressure is controlled by a pressure relief valve, located in the manifold by the hydraulic filter.

Power steering pressure is set at 2,600 psi ±100 psi (179 bar, ± 7 bar) (See Figure 3-32).

A pressure gauge port is provided, with a “quick-coupler,” (pressure service kit, Landoll p/n: 0018152) for reading the steer pump pressure.

Note: Before you service this valve for possible pressure problems, make sure there are no leaks in the hydraulic system and that there is sufficient oil in the tank. Both conditions can contribute to low pressure problems.

(Also see "Power Steering System," in the B3 Series Operator's Manual (F-492-___) for additional circuit information.)

Checking and/or Adjusting Pressure 1. First, review “Before You Begin,” page 3-2.

2. Set the key switch to OFF, place the key in your pocket 3. Remove the floor plates (See “Floor Plate Removal,” page 3-47). Then, remove control valve cover plate.

Troubleshooting & Corrective Maintenance 3-53

Corrective Maintenance 4. For ease in checking pressure Landoll Service offers a Pressure Check Kit (p/n: 0018152) which includes a 3,000 psi (207 bar) pressure gauge, hose and quick-coupler).

If you are using your own system, have shop rags and a small container handy to collect any oil spills.

5. Turn the steering wheel briefly from one side to the other to relieve system pressure allow oil to drain.

6. Connect the pressure check kit quick-coupler (female end) to the coupler (male end) on the filter manifold block (See Figure 3-32). · If you are not using the pressure check kit, remove the quick-coupler and install an appropriate fitting to accept your pressure gauge arrangement. · Have rags handy to collect the oil leakage. · Install your 3,000 psi (207 bar) pressure gauge arrangement to the fitting.

7. Start the truck. `

PRESSURE GAUGE, 3000 PSI MAXIMUM RELIEF VALVE CARTRIDGE CHECK VALVES (2 TOP, 2 BOTTOM)

STEER CONTROL VALVE CARTRIDGES steervlv

Figure 3-32 Steering Hydraulic Valve Assembly

Troubleshooting & Corrective Maintenance 3-54

GAUGE PORT W/ QUICK COUPLER

Corrective Maintenance

CAUTION To adjust pressure, the truck (pump) must be running to create hydraulic pressure. Always pay attention to what you are doing when servicing the truck while it is running.

8. Turn the steering wheel fully to the right and hold the wheel to allow pressure buildup.

The pressure reading must be 2,600 psi, ±100 psi (179 bar, ± 7 bar) maximum.

9. Release the steering wheel.

IMPORTANT! Do not turn and hold the steering wheel against the rotation limit for long periods of time. Excessive pressure is applied to the circuit which can, over long periods of time, generate heat and damage internal components.

10. Loosen the locknut and adjust the internal relief valve head (5/32” Allen wrench) by turning clockwise to increase pressure or counterclockwise to decrease pressure.

Tighten locknut after adjustment (See Figure 3-32).

If the pressure is low and cannot be adjusted to the proper value, check the pump and make sure there are no leaks in the hydraulic system.

If the pressure is too high and cannot be adjusted to the proper value, replace the relief valve.

11. Turn the steering wheel from one side to check the hydraulic connections for leaks.

12. With pressure set at 2,600 psi ±100 psi (179 bar, ± 7 bar) maximum, set the key switch to OFF. 13. Turn steering wheel to release pressure.

14. Remove pressure gauge.

15. Reassemble in reverse order.

Troubleshooting & Corrective Maintenance 3-55

Corrective Maintenance Hydraulic Control Valve Assembly General Individual directional control, pressure valve assemblies and gauge ports (for psi readings) are located on the hydraulic control valve or the steering control valve manifolds. The hydraulic control valve manifold is located behind the control valve cover plate.

The following procedure explains how to replace a specific valve should a sluggish or sticking valve spool be suspect.

IMPORTANT !

If you remove the valve from the truck for servicing (hex head screws and hardware), when reinstalling the valve be certain to tighten the mounting screws in a staggering fashion while applying equal pressure to all screws. If the screws are not tightened and torqued evenly, you could create a stress crack, thus internal oil leaks, rendering the valve defective.

The main hydraulic pump for lift, tilt, pivot, and shift (mast functions) is a single cavity pump (5 gpm). System pressure varies from 2,650 psi, ±65 psi (183 bar, ± 4 bar) minimum, up to 3,000 psi, ±65 psi (206 bar, ±4 bar) maximum. Actual pressure is determined by mast size, load requirements and lift speed.

Check with your Landoll service representative for actual setting.

The main pump pressure relief valve is located on the hydraulic control valve.

A pressure gauge port is provided, with a “quick-coupler,” (pressure service kit, Landoll p/n: 0018152) for reading the main pump pressure (See Figure 3-33).

Note: Before you service this valve for possible pressure problems, make sure there are no leaks in the hydraulic system and that there is sufficient oil in the tank. Both conditions can contribute to low pressure problems.

(Also see "Mast Systems," in the B3 Series Operator's Manual (F-492-___) for additional circuit information.)

To Check and/or Adjust Pressure 1. First, review "Before you Being," page 3-2.

2. Set the key switch to OFF, place the key in your pocket, and disconnect the battery.

3. For ease in checking pressure, Landoll Service offers a Pressure Check kit (p/n: 0018152) which includes a 3,000 psi (21 MPa) pressure gauge, hose and quick-coupler).

4. If you are using your own system, have shop rags and a small container handy to collect any oil spills.

5. Remove the control valve cover, located to the right of the drivers seat. (See Figure 3-35).

6. Operate the function joysticks briefly to relieve system pressure.

Troubleshooting & Corrective Maintenance 3-56

Corrective Maintenance

PRESSURE GAUGE 3,000 PSI (21 Mpa) MAXIMUM

LIFT SPOOL POT TILT SWITCH (SW15)

TILT LEVER

SHIFT SWITCH (SW16)

LIFT LEVER SHIFT LEVER

PRESSURE RELIEF VALVE GAUGE PORT, W/ QUICK COUPLER cntrlvlv

Figure 3-33 Connecting Pressure Gauge

7. Connect the pressure check kit quick-coupler (female end) to the coupler (male end) on the control valve. · If you are not using the pressure check kit, remove the quick-coupler and install ain appropriate fitting to accept your pressure gauge arrangement. · Have rags handy to collect the oil leakage. · Install your 3,000 psi (21 MPa) pressure gauge arrangement to the T fitting. (See Figure 3-33)

CAUTION All parts connected to the gauge port must be capable of handling up to 3,000 psi (21 MPa). To adjust pressure, the truck (pump) must be running to create hydraulic pressure. Always pay attention to what you are doing when servicing the truck while it is running.

8. Connect the battery and set the key switch on ON. 9. To check and/or set pressure, yo must hold the TILT joystick in the lower position to build pressure, then set the relief valve.

Troubleshooting & Corrective Maintenance 3-57

Corrective Maintenance 10. Loosen the relief valve jam nut (See Figure 3-34).

11. Adjust the relief valve by turning clockwise to increase pressure, counterclockwise to decrease pressure (See Figure 3-34).

12. Release the joystick immediately once the pressure is set (2,700 psi, 18 MPa).

IMPORTANT! Do not hold the joystick (bottomed out) for long periods of time. Excessive pressure applied to the circuit generates heat which can, over periods of time, damage internal components. If the pressure is low and cannot be adjusted to the proper value, check the pump and make sure there are no leaks in the hydraulic system. If the pressure is too high and cannot be adjusted to the proper value, replace the relief valve.

13. Tighten the jam nut.

14. Set the key switch to OFF, place the key in your pocket, and disconnect the battery.

15. Operate the function joysticks briefly to relieve system pressure.

LOOSEN LOCK NUT

CLOCKWISE TO INCREASE

16. Remove the pressure gauge quick-coupler. (Or your own pressure gauge system and then reinstall the quick-coupler)

COUNTER CLOCKWISE TO DECREASE

17. Connect the battery and set the keys witch to ON. adjstprs

18. Lift and lower the mast from a few feet a few times to check the hydraulic system for leaks.

Figure 3-34 Relief Valve Setting

19. Set the key switch to OFF and disconnect the battery 20. Reassemble all items previously removed.

`

Troubleshooting & Corrective Maintenance 3-58

Corrective Maintenance Hydraulic Control Valve and Switches

CONTROL VALVE LEVER KNOBS

1. First, review “Before You Begin,” page 3-2.

LIFT, TILT, AND SHIFT LEVERS

2. Set the key switch to OFF, place the key in your pocket, and disconnect the battery.

3. Apply the hand brake, disconnect the battery and block the wheels.

4. Relieve pressure in the system by turning the steering wheel two times to the left, then two times to the right and move the joysticks in both directions.

5. Remove control valve lever knobs. (See Figure 3-35).

CONTROL VALVE COVER 5/16-18 X 3/4 BUTTON HEAD CAP SCREW AND HARDWARE HYDRAULIC CONTROL VALVE SERVICE (PARKING) BRAKE LEVER removing hyd valve cover

Figure 3-35 Control Valve Cover

SWITCH WIRING HARNESS

6. Loosen jam nuts at bottom of the lever, rotate levers so that the outside levers contact the inside lever. This will allow the removal of the valve cover.

7. Remove the control valve cover to expose the hydraulic control valve.

8. Inspect the spool actuator end (upper) or the switch actuator end (lower) for leakage).

9. If leakage is found, the spool seals can be replaced. If there is leakage within the spools, as determined by drift in the hydraulic actuator, the valve will need to be replaced.

PLUGGED PORTS switch wiring harness

Figure 3-36 Plugged Ports and Wiring Harness

10. Remove the valve from truck by first identifying/marking all tubes, disconnecting and plugging all hydraulic tubes.

Have rags handy to soak up oil spills.

11. Disconnect the swing wiring harness from the truck wiring harness at the Deutsch connector. (See Figure 3-36).

Troubleshooting & Corrective Maintenance 3-59

Corrective Maintenance 12. Place valve on a bench or in a vice.

SWITCH/LIFT POT BRACKET

13. Seals can only be removed by removing the spools.

14. The spool actuator and the switch/pot mount housing must be removed to remove the spool. (See Figure 3-38).

15. Remove the switch/lift pot mount housing. a. Remove the two fasteners that hold the switch/lift pot bracket in place. Set aside, do not disconnect. b. Remove the remaining two fasteners from the housing.

SPOOL ACTUATOR SWITCH/POT MOUNT HOUSING hyd control valve 1

Figure 3-37 Switch/Pot Housing Removal

16. Remove the spool actuator. a. Remove the four fasteners that hold the actuator in place. b. Pull the lever rearward to release the lever from the spool c. Slide the actuator from the spool and set aside.

17. Slide the housing from the spool. (See Figure 3-38).

LIFT LEVER SPOOL ACTUATOR SPOOL

SIDESHIFT LEVER TILT LEVER hyd control valve 2

Figure 3-38 Spool Actuator Removal

Troubleshooting & Corrective Maintenance 3-60

Corrective Maintenance 18. Remove the spool by sliding it through the bottom of the valve.

SWITCH/LIFT POT END SEAL SEAL RETAINER

19. When removing the spool, the switch/lift pot end seal and seal retainer may be removed.

(See Figure 3-39) 20. Remove the spool and set it aside.

21. Spool actuator end seal is captivated in the valve casting; remove using a pick tool. (See Figure 3-40).

SPOOL

22. Insert new seal into groove.

23. Place new switch/lift pot end seal and retainer over spool prior to reinsertion of spool.

hyd control valve 3

Figure 3-39 Removing the Spool

24. Lubricate the seal with grease (NLGI #2, Texaco #880); slide switch/lift pot mount housing over spool.

25. Insert the two fasteners that do not hold the switch/pot bracket and tighten to hold housing.

26. Assemble the switch/pot bracket to the remaining holes.

SPOOL ACTUATOR END SEAL hyd control valve 4

Figure 3-40 Spool Actuator End Seal Removal

Troubleshooting & Corrective Maintenance 3-61

Corrective Maintenance 27. Ensure that the hole is facing up prior to reassembly of spool actuator. (See Figure 3-41).

28. Apply grease (NLGI #2, Texaco #880) to actuator end prior to assembly of the spool actuator.

29. Pull back on the spool actuator shaft while sliding over the spool, actuator must insert into spool hole to ensure proper operation. This is a blind assembly operation.

The spool is vertical if properly assembled and the housing is tight against the valve casting.

SPOOL ACTUATOR

30. Insert fasteners and tighten.

31. Reassemble valve to truck.

32. Attach and tighten all tubes.

33. Operate valve functions and check for leaks prior to mounting cover and realignment of levers.

SPOOL HOLE hyd control valve 5

Figure 3-41 Spool Switch/Pot Housing Removal

Hydraulic Lift Pot General The hydraulic lift pot is replaced as a complete unit with the wiring harness.

To Adjust and/or Replace 1. First, review “Before You Begin,” page 3-2.

2. Set the key switch to OFF and place the key in your pocket.

3. Apply the parking brake, disconnect the battery and block the wheels.

4. Relieve pressure in the system by turning the steering wheel two times to the left, then two times to the right and move the joysticks in both directions.

5. Remove control valve lever knobs. (See Figure 3-35).

6. Loosen jam nuts at bottom of lever, rotate levers so that the outside levers contact the inside lever. This will allow removal of valve cover.

7. Remove the control valve cover to expose the hydraulic control valve.

Troubleshooting & Corrective Maintenance 3-62

Corrective Maintenance 8. Replacing the lift pot is more easily accomplished if the valve is removed from the truck.

CLAMP SCREW POT RETURN SPRING

9. Mark/identify each tube connected to the valve.

Disconnect the tubes from the valve and remove valve from the mounting bracket.

10. Place valve on bench or in a vise.

11. The lift pot is part of the valve harness assembly and must be replaced as a unit.

POT DRIVE ARM Lift pot spring removal

12. Remove the lift pot bracket from end of valve; this will provide better access to the pot return spring, pot drive arm, clamp screw, and mounting nut.

13. Loosen clamp screw and remove arm from pot. Slide return spring off of pot shaft.

Note the orientation of the spring for reassembly. (See Figure 3-43).

Figure 3-42 Lift Pot Spring Removal

LIFT POT POT MOUNT NUT POT RETURN SPRING

14. Loosen pot mounting nut and remove lift pot from mounting bracket.

15. Remove wires connected to each switch.

loosen pot mount nut

Figure 3-43 Loosening Lift Pot Mounting Nut

Troubleshooting & Corrective Maintenance 3-63

Corrective Maintenance 16. Install new pot through mounting hole. The index peg on the pot housing must align with the hole in the bracket.

(See Figure 3-44).

POT RETURN SPRING GROOVE

17. Tighten mounting nut on to pot.

18. Slide pot return spring on to pot shaft past the input shaft and onto the threaded shaft.

Insert end of spring into hole in bracket. (See Figure 3-45).

19. Assemble pot drive arm onto pot while making sure that the remaining end of the return spring fits into groove at the end of the arm clamp. Tighten the clamp to the pot shaft enough to hold the arm in place.

20. Reassemble pot mount bracket to valve. Make sure that the arm is below the spool as the mounting screws are tightened.

21. After the mount bracket is in place, attach the remaining wires in the harness to the proper valve switches. Wires 4 and 5 are attached to the tilt switch and wires 6 and 7 are attached to the sideshift switch. (See Figure 3-46).

INDEX PEG index peg location

Figure 3-44 Location of Index Peg

POT RETURN SPRING LIFT POT MOUNTING NUT POT RETURN SPRING GROOVE

22. Adjust the new lft pot by: a. Connect a multimeter across pins 1 and 3 in the end connector on the valve harness. Set the multimeter to measure resistance. b. Using a flat screwdriver, adjust the pot until the multimeter reads 3.5K-3.6K ohms. c. Tighten the clamp screw on the drive arm.

23. Reinstall valve on truck.

SPRING RETENTION HOLE spring installation

Figure 3-45 Spring Installation

Troubleshooting & Corrective Maintenance 3-64

Corrective Maintenance 24. Attach and tighten hydraulic tubes.

25. Power truck, operate hydraulic system, and check for leaks.

26. Calibrate lift pot input to controller. See Appendix section of the Bendi B3 Series Service Manual.

27. Install covers and valve levers.

WIRES 4 AND 5 (TO TILT SWITCH) WIRES 6 AND 7 (TO SIDESHIFT SWITCH) wire reattachment

Figure 3-46 Location of Index Peg

Steering Column/Dash Assembly This procedure replaces the steering wheel, steering column, and components.

The console assembly includes the following: ·

Battery/Charge Indicator (Voltage Meter) and Brush Wear Indicator (BWI) LED's

· Auxiliary power rocker switch (fan, scanner, etc.) · Headlights (rocker switch, where fitted) · Standard/Creep mode (Allows speed to decrease in the creep mode) · Tilt steering lever · Key switch The above parts are accessed by removing the right side steering assembly cover (black) - ten (10) screws and hardware.

Troubleshooting & Corrective Maintenance 3-65

Corrective Maintenance

STEERING KNOB

(B) COVER SCREWS 3 EACH HALF

STEERING WHEEL WHEEL NUT

(A) COVER SCREWS 4 (2 EACH SIDE)

STEERING CONSOLE KEY SWITCH LOCATION

TILT STEERING LEVER LEFT SIDE COVER

RIGHT SIDE COVER RUBBER BOOT ORBITAL MOUNT PLATE

sterclm3

Figure 3-47 Remove Right Side Cover

Remove Right Side Cover 1. First, review “Before You Begin,” page 3-2.

2. Set the key switch to OFF and place the key in your pocket.

3. Apply the parking brake and disconnect the battery. Make sure the wheels are securely blocked so that the truck cannot move.

4. Remove the four large screws and hardware marked (A) (See Figure 3-47).

5. Remove the cover screws and hardware marked (B) (See Figure 3-47).

6. Pry the bellows (rubber boot) free of the steering column cover.

7. Remove the right side cover to expose the internal components of the steering column.

Troubleshooting & Corrective Maintenance 3-66

Corrective Maintenance Display 1. Repeat preceding section “Remove Right Side Cover” , beginning on page 3-66.

2. Reach inside the steering column and disconnect the appropriate display wire connectors from the main wire harness.

3. Remove the two knurled nuts and hardware holding the display to the panel.

4. Install the new display by reversing the above steps.

5. Connect the wire connector to the display and close the steering column by reversing the steps outlined in section “Remove Right Side Cover” , on page 3-66.

Brush Wear Indicator (BWI) LED's 1. Repeat preceding section “Remove Right Side Cover", beginning on page 3-66.

2. Reach inside the steering column and disconnect the brush wear indicator LED from the main wire harness (See Figure 3-47).

Note: Before disconnecting, note wire locations on LED and light polarity.

3. Remove jam nut and lock washer holding LED to the panel.

4. Install the new brush wear indicator LED by reversing the above steps.

5. Connect the wire connector to the brush wear indicator LED and close the steering column by reversing the steps outlined in section “Remove Right Side Cover”, on page 3-66.

Troubleshooting & Corrective Maintenance 3-67

Corrective Maintenance Key Switch 6. Repeat preceding section “Remove Right Side Cover,” beginning on page 3-66.

7. Reach inside the steering column and disconnect the appropriate switch connector from the main wire harness.

HEAVY DUTY KEY SWITCH PLATE

8. Unscrew the knurled switch collar ring to separate the switch from the base plate (See Figure 3-48).

9. Disconnect the wires from the switch terminals noting how they are connected to ensure proper orientation when connecting the new switch.

KEY SWITCH COLLAR RING

kyassmby2

Figure 3-48 Key Switch

10. Install the key switch by reversing the preceding steps.

11. Close the steering column by reversing the steps outlined in section “Remove Right Side Cover,” beginning on page 3-66.

Troubleshooting & Corrective Maintenance 3-68

Corrective Maintenance Option Rocker (On/Off) Switches Optional rocker switches are also used to control various light packages, or other accessories.

When an option is installed, the switch is activated.

1. Repeat preceding section “Remove Right Side Cover,” beginning on page 3-66.

2. Reach inside the steering column and disconnect the appropriate accessory switch connector from the main wire harness.

3. The accessory on/off rocker switches are held by plastic wings Figure 3-49 Option Rocker Switches (or tabs). Compress the wings (or tabs) on one side at a time to release the switch body, then push it up and out of the slot (See Figure 3-49).

Note: Be careful when compressing and pushing the switch in or out. The wings (tabs) could break off if the procedure is not done evenly on all sides.

4. Detach the wires from the defective switch, noting the connection arrangement for when installing the new rocker switch.

5. Insert the replacement switch in the slot and compress the wings (or tabs) as necessary to allow it to pop into place.

6. Connect the cable connector to the wire harness and close the steering column by reversing the steps outlined in section “Remove Right Side Cover,” beginning on page 3-66.

Troubleshooting & Corrective Maintenance 3-69

Corrective Maintenance Steering Wheel 1. Pry the plastic cover from the steering wheel using your finger tips. If you cannot grab the cover, you can start it by carefully using a medium sized flat blade screw driver and gently prying upwards. DO NOT force it or you may crack the cover.

2. Loosen the wheel nut (See Figure 3-47).

3. Pry the steering wheel upwards by wiggling and pulling straight up. It is important to pull up evenly on both sides of the wheel.

Note: If the wheel is difficult to remove, tap the wheel nut using a dead-blow hammer a few times. The wheel should remove easily.

4. Install the steering wheel by placing it over the shaft, aligning the wheel and shaft splines and pushing downward evenly until the nut can be installed.

5. Tighten the nut, keeping in mind the tighter the nut, the more difficult it will be to remove the steering wheel later on.

6. Replace cover.

Steering Column (Console) This is a two man operation, due to weight of steering column (approximately 30 pounds/14 kgs.). If an overhead crane is available, the crane could be strapped to the steering wheel for support.

1. Remove floor plates (See "Floor Plate Removal," page 3-47).

2. Remove the lower dash cover weldment (See Figure 3-50).

3. Disconnect the plugs that connect the dash harness to the main harness and any optional lighting harnesses.

4. Relieve hydraulic pressure in the system by turning the steering wheel a few times to the left and right.

5. Also pry (up) the bellows (rubber boot) free of the bellows retainer plate. This exposes the mounting plate for the steering column and the orbital control unit (See Figure 3-50).

IMPORTANT! Four screws secure the assembly to the orbital steering mount bracket for stability. Once removed the unit is supported by the hydraulic hoses only.

6. Remove the four bolts and hardware securing the orbital control unit to the steering column (See Figure 3-50).

Troubleshooting & Corrective Maintenance 3-70

Corrective Maintenance

steering assy.cdr

Figure 3-50 Console Dash Display Panel

7. Remove the four bolts and hardware securing the steering column (console) to the bellows retainer plate (See Figure 3-50).

8. With help, lift the steering column upwards to disengage the shaft from the orbital unit, then remove the steer column from the truck.

9. When installing the new steer column, you must turn the steering shaft until it aligns with the orbital unit and drops into place.

10. Continue by reversing the preceding steps making sure to tighten and torque all mounting screws (See General Torque, Hydraulic Fitting Torque, and B3 Series Special Torque Tables in Appendix B of the B3 Series Operator's Manual (F-492-___)).

Troubleshooting & Corrective Maintenance 3-71

Corrective Maintenance STEERING ORBITAL CONTROL UNIT

TO HYDRAULIC OIL FILTER MANIFOLD orbital steer unit

TO POWER STEERING PUMP TO HYDRAULIC STEERING CYLINDER

Figure 3-51 Steering Orbital Control Unit

Steering Orbital Control Unit 1. Remove floor plates (See "Floor Plate Removal," page 3-47).

2. Remove the lower dash cover weldment (See Figure 3-50).

3. Relieve hydraulic pressure in the system by turning the steering wheel a few times to the left and right.

4. Tag the port locations of each hydraulic line and fitting, then disconnect the four lines from the unit (See Figure 3-51).

Review section “Hydraulic Fittings and Hoses,” on page 3-95. Have shop rags handy to soak up any fluid spills.

Note: Immediately plug and cap all hose ends and tag each for identification.

Have shop rage handy to soak up any oil spills.

5. If the unit is being replaced, or the fittings are defective, notice the placement (angle) of the hose fittings then remove them.

6. Install the new steering orbital control unit to the steering column by following the preceding steps in reverse order (See Figure 3-51).

7. Check oil level in the hydraulic tank and fill as needed (See "Hydraulic System Maintenance," in the B3 Series Planned Maintenance Manual (F-444-___)).

Troubleshooting & Corrective Maintenance 3-72

Corrective Maintenance Direction Control Lever The directional control lever (forward-neutral-reverse) is a serviceable unit located on the right side of the seat base. (See Figure 3-52).

Replacing Direction Control Switch Note: Make sure to mark each wire on which location it goes in .

1. First, review “Before You Begin,” page 3-2.

2. Set the key switch to OFF and place the key in your pocket.

3. Apply the parking brake and disconnect the battery.

4. Make sure all the wheels are securely blocked so that the truck cannot move.

5. Raise the seatbase and latch it to the overhead guard weldment.

6. Mark the electrical connectors for correct assembly.

7. Remove the electrical connectors from the forward/reverse switch.

8. Loosen the locking nut from the forward/reverse switch and remove switch. (See Figure 3-52) 9. Install wiring in correct locations.

10. Replace in reverse order.

11. Close seat base.

12. Connect the battery and test for proper operation.

FORWARD/REVERSE SWITCH HORN BUTTON

SEAT BASE

SEATBASE

Figure 3-52 Seatbase

Troubleshooting & Corrective Maintenance 3-73

Corrective Maintenance

Electrical System Curtis Electrical Control Panel This section explains the electrical of the B3 Series and defines calibration, updates, adjustments, and replacements of the panel including drive controller, and the pump controller. The 1309 Serial Dongle Interface, the 1311, and the 1314 can be used to perform parameter adjustments (See Figure 3-54).

The 1254 is the hydraulic controller used in the system. The 1244 is a single traction controller.

1309 Parameter Install Tool The ParamDownloader Tool (Landoll PN 149411) is used to install a new parameter and data block in the Curtis motor controllers.

The controller model shown should be the same as that specified in the update folder.

Although adjustments can be done with the 1311 handset, Landoll recommends using the Curtis 1314 software package. This allows technicians to flash new parameters and install the latest updated codes into the Curtis controllers.

Troubleshooting & Corrective Maintenance 3-74

Corrective Maintenance Parameter Install Requirements

curtis dongle

Figure 3-53 Curtis 1309 ParamDownloader Tool · 1309 Serial Dongle (See Figure 3-53) ·

Operating System (Only Windows XP has been tested) ·

Windows 2000 Professional with SP4

·

Windows XP

·

Windows Vista

· Processor: 400 MHz Pentium processor or equivalent. (Minimum 1 GHz Pentium processor or equivalent recommended) · RAM: 96 MB minimum. (256 MB recommended) · Hard Disk: Up to 280 MB of available space may be required · Display: 800 X 600, 256 colors minimum. (1024 X 768 high color recommended) · Microsoft .net Framework 2.0 or greater · The programmer kit is Landoll P.N. 145405. This includes the Curtis 1314 Software program and the 1309 dongle interface. · 149411 SE Update Software.

Troubleshooting & Corrective Maintenance 3-75

Corrective Maintenance Model 1311 Handset Description LCD SCREEN

Program Monitor Faults Functions Controller Information Programmer Setup

+

^

^

^ -

^

CHANGE THE SELECTED ITEMS WITH THIS SWITCH

CHANGE THE SELECTED ITEMS’S VALUE (UP OR DOWN) WITH THIS SWITCH BOOKMARK MEMORY SWITCHES ALLOW YOU TO INSTANTLY RECALL PRESET DATA

m1311 controller

Figure 3-54 Model 1311 Handset

The 1311 handset (See Figure 3-54) is used to program and troubleshoot the 1244 motor controller and the 1254 hydraulic system controller. The 1311 gets it's power from the controller that it is plugged into and boots up after being plugged into the J3 port located on the monitored controller. The lift truck technician is aided by the liquid crystal display (LCD), the four-way selector switch, the +/- rocker switch, and the bookmark memory switches found on the 1311 handset. Data between the 1311 handset and the host controller is asynchronous. The 1311 handset supercedes the previous 1307 model.

Directions for use 1. Make sure the J3 connector of the controller is clean and is unobstructed from other wires or objects that could pinch the cord of 1311 handset programmer.

2. With the forklift key "on", plug the cord of the 1311 handset into the J3 plug of the controller. (See Figure 3-55) 3. Wait a few seconds for the 1311 handset to go through the initial boot-up. Upon completion, the curser will highlight the "Program" mode.

4. The technician is now ready to troubleshoot or adjust the parameter settings of the Landoll lift truck. Refer to pages 3-78 through 3-83 for controller parameters.

Troubleshooting & Corrective Maintenance 3-76

Corrective Maintenance Calibration of the 1244 Acceleration Controller 1. Connect the 1311 Programmer or the 1309 dongle into the 1244 lift controller at the J3 connector. (See Figure 3-55) 2. Turn the forklift on.

3. Monitor the throttle in the MONITOR>THROTTLE menu. When properly adjusted, the settings will be:

1244 CONTROLLER

a. 0% with the accelerator pedal at rest, and b. 100 % with the pedal fully depressed.

4. Adjustments can be made in the PROGRAM>THRTL DEADBAND menu to achieve 0% throttle with the accelerator pedal at rest.

5. 100% throttle can be achieved by adjusting the PROGRAM>THROTTLE MAX menu.

6. Verify operation from 0%-100%.

7. Setup is now complete. Unhook the 1311 from the J3 connector.

J3 CONNECTOR J3 CONNECTOR

Figure 3-55 J3 Connector Location

Troubleshooting & Corrective Maintenance 3-77

Corrective Maintenance Setting the Lift Pot Note: THROTTLE 2 is the input used for the lift accelerator. This input can be monitored using the 1311 programmer (Landoll PN 143837) or using the 1314 Software Package (Landoll PN 145405) with the 1309 dongle included in the kit.

Proper calibration of this potentiometer allows this input to be varied from 0 to 100% by retracting the lift lever from a centered position. The following procedure is used adjusting the range of the potentiometer.

1. Connect the 1311 programmer or 1309 dongle into the 1254 lift controller at J3. (See Figure 3-56)

1254 CONTROLLER

2. Turn the forklift on.

Note: The lift pump may be running slowly at initial key on. It will be adjusted in the next steps.

3. Monitor 'THROTTLE 2" in the MONITOR>THROTTLE 2 menu.

4. When properly adjusted, the THROTTLE 2 value will be at 0% with the lift lever centered and at 100% with the lift lever fully retracted. .

5. Adjustment can be made in the PROGRAM>DEADBAND menu to achieve 0% throttle with the lift lever centered.

6. 100% throttle can be achieved by adjusting the PROGRAM>THROTTLE MAX menu.

7. Verify operation from 0-100 %.

J3 CONNECTOR 1254 controller

Figure 3-56 1254 J3 Connector Location

8. Setup is now complete.

Troubleshooting & Corrective Maintenance 3-78

Corrective Maintenance Replacement Replacing Complete Control Panel 1. First, review “Before You Begin,” page 3-2.

2. Move the mast carriage completely to the lowest position.

3. Set the key switch to OFF and place the key in your pocket.

4. Apply the parking brake and disconnect the battery.

5. Make sure all the other wheels are securely blocked so that the truck cannot move.

6. Remove the door.

7. Remove all cables and disconnect the main harness.

Note: Make sure to mark all cables where they go.

8. Remove mounting hardware.

9. Using a proper lifting apparatus remove the panel from the forklift.

10. Reassemble in reverse order.

11. Calibrate the control panel .

Replacing Any Other Single Controller Component 1. First, review “Before You Begin,” page 3-2.

2. Set the key switch to OFF and place the key in your pocket.

3. Apply the parking brake and disconnect the battery.

4. Make sure all the other wheels are securely blocked so that the truck cannot move.

5. Replace component as needed (See Figure 3-57).

6. Reassemble in reverse order.

Note: If a controller is replaced, it must be reprogrammed using a personal computer and the 149411 update software.

Troubleshooting & Corrective Maintenance 3-79

Corrective Maintenance

LANDOLL P.N. 143545 CONTROLLER SUB PANEL

HORN

1244 CONTROLLER

LANDOLL P.N. 146682 DRIVE CONTROLLER ASSY

1254 CONTROLLER

LANDOLL P.N.146688 REAR CONTROL PANEL

controllers

Figure 3-57 Electrical Control Panel

Troubleshooting & Corrective Maintenance 3-80

Corrective Maintenance 1244 MOTOR CONTROLLER WORKSHEET FOR LANDOLL B3 FORKLIFTS CONTROLLER PARAMETERS

RANGE

VALUE

UNITS

THROTTLE M1 BRAKING PERCENT

DESCRIPTION

0% - 100%

46

%

Maximum Mode 1 Neutral Braking current limit as a percentage of the specified M1 Braking current limit

THROTTLE M2 BRAKING PERCENT

0% - 100%

46

%

Maximum Mode 2 Neutral Braking current limit as a percentage of the specified M2 Braking current limit

THROTTLE M3 BRAKING PERCENT

0% - 100%

66

%

Maximum Mode 3 Neutral Braking current limit as a percentage of the specified M3 Braking current limit

THROTTLE M4 BRAKING PERCENT

0% - 100%

66

%

Maximum Mode 4 Neutral Braking current limit as a percentage of the specified M4 Braking current limit

END REGEN BRAKING TAPER RATE

1 - 64

20

1/32 Sec.

Sets the rate of regen current roll off as the vehicle approaches its stopping point. Varying this parameter will control the smoothness of the transition from braking to drive mode and will be specific to each application.

M1 MAX. SPEED LIMIT

Creep Speed to 100 100%

%

Maximum Mode 1 speed

M2 MAX. SPEED LIMIT

Creep Speed to 100 100%

%

Maximum Mode 2 speed

M3 MAX. SPEED LIMIT

Creep Speed to 100 100%

%

Maximum Mode 3 speed

M4 MAX. SPEED LIMIT

Creep Speed to 100 100%

%

Maximum Mode 4 speed

REGEN SPEED

0% - 100%

10

%

Sets the speed threshold at which plug braking ceases and regen braking will begin. This parameter will affect the feel of the vehicle while jockeying in tight areas.

THROTTLE DEADBAND

0% - 30%

4

%

Percentage of throttle movement which represents the neutral deadband

THROTTLE MAX. OUTPUT POINT

60% - 100%

100

%

Percentage of throttle movement at which full controller output duty cycle is attained

RESTRAINT

1 to 10

3

SEQUENCING DELAY

0-3

2.2

WELD CHECK

On/Off

ON

Defines whether the controller will register a fault if a welded main contactor is detected

MAIN CHECK

On/Off

ON

Defines whether the controller will register a fault if an open wire is detected at the main contactor coil driver output.

Adjusts the braking strength applied to the motor when throttle request is decreased or if the vehicle is moving when zero throttle is requested Sec.

Delay time before HPD and SRO faults are registered after the brake input is disengaged

Troubleshooting & Corrective Maintenance 3-81

Corrective Maintenance 1254 HYDRAULIC SYSTEM CONTROLLER WORKSHEET FOR LANDOLL B3 FORKLIFTS CONTROLLER PARAMETERS

RANGE

VALUE

UNITS

DESCRIPTION

SS 1 SPEED

0% - 100%

40

%

Programmed maximum Armature PWM for Speed Select 1

SS 2 SPEED

0% - 100%

40

%

Programmed maximum Armature PWM for Speed Select 2

SS 3 SPEED

0% - 100%

40

%

Programmed maximum Armature PWM for Speed Select 3

SS 4 SPEED

0% - 100%

40

%

Programmed maximum Armature PWM for Speed Select 4

SS 5 SPEED

0% - 100%

40

%

Programmed maximum Armature PWM for Speed Select 5

SS 6 SPEED

0% - 100%

40

%

Programmed maximum Armature PWM for Speed Select 6

LIFT MAX SPEED

0% - 100%

100

%

Programmed maximum Armature PWM for Lift

LOWER MAX SPEED

0% - 100%

100

%

Programmed maximum proportional valve current as a % of PV MAX CURRENT for Lower

THROTTLE 2 MAX SPEED

0% - 100%

100

%

Programmed maximum Armature PWM for Throttle 2

THROTTLE 3 MAX SPEED

0% - 100%

100

%

Programmed maximum Armature PWM for Throttle 3

MINIMUM SPEED

0% - 50%

0

%

Programmed minimum Armature PWM

SS ACCEL RATE

0.1 - 3

1

Sec.

Accel rate for Speed Select switches 1 - 6

SS DECEL RATE

0.1 - 3

1

Sec.

Decel rate Speed Select switches 1 - 6

THROTTLE ACCEL

0.1 - 3

1

Sec.

Accel rate for Throttles 1 - 3

THROTTLE DECEL

0.1 - 3

1

Sec.

Decel rate for Throttles 1 - 3

THROTTLE MAP

20% - 80%

80

%

Adjusts desired PWM output at 50% of movement of Throttles 1 - 3

DEADBAND

0% - 40%

15

%

Percentage of throttles movement which represents the neutral deadband

THROTTLE MAX

60% - 100%

75

%

Percentage of throttles movement at which full controller armature PWM is attained

CURRENT RATIO

1-4

3

Defines how much of the programmed current is available to the pump motor at reduced speed requests

LIFT LOCKOUT

On/Off

0

When "ON", if interlock goes low during a lift operation, the lift in progress will be completed but further lift requests will be ignored as long as the interlock input stays low.

Troubleshooting & Corrective Maintenance 3-82

Corrective Maintenance 1254 HYDRAULIC SYSTEM CONTROLLER WORKSHEET FOR LANDOLL B3 FORKLIFTS CONTROLLER PARAMETERS

RANGE

VALUE

UNITS

DESCRIPTION

START LOCKOUT

None (0), KSI (1), KSI+Interlock (2)

1

Prevents the pump motor from running if any of the throttle inputs is requesting above 25% output or if any of the speed select inputs is high when the controller is turned ON

CONTACT CONTROL

None (0), KSI (1), KSI (2), Interlock (3)

3

Control over closing pump contactor

SEQUENCING DELAY

0-3

0.3

Sec.

Allows the interlock switch to cycle within a set time without causing Start Lockout or Lift Lockout.

Troubleshooting & Corrective Maintenance 3-83

Corrective Maintenance Horn The horn button is located beneath the battery cover.

Removing the Horn 1. Make sure the key switch is OFF, placed in your pocket and that the battery is disconnected.

2. Remove control valve cover plate (See Figure 3-58).

3. Disconnect the electrical wires.

4. Remove the hex screws and hardware to separate the horn from the frame.

5. Install the new horn by reversing the preceding steps.

6. Connect the battery and test the horn.

HORN

B3 HORN

Figure 3-58 Horn Location

Troubleshooting & Corrective Maintenance 3-84

Corrective Maintenance

FILTER ASSEMBLY DIPSTICK STEERING CONTROL VALVE

SUCTION LINES

HOLD DOWN SCREW DRAIN PLUG HYDRAULIC RETURN LINE

hydraulic tank remove

Figure 3-59 Replacing Hydraulic Tank

Troubleshooting & Corrective Maintenance 3-85

Corrective Maintenance Replacing Hydraulic Tank 1. First, review “Before You Begin,” page 3-2.

2. Move the mast to the lowest level.

3. Set the key switch to OFF and place the key in your pocket.

4. Apply the parking brake and disconnect the battery.

5. Make sure all the wheels are securely blocked so that the truck cannot move.

6. Release all pressure from the hydraulic lines by moving the hydraulic control valve lift, tilt and sideshift levers in the forward and rearward positions several times.

7. Remove the battery and the battery tray.

8. Remove floor plates (See "Floor Plate Removal," page 3-47).

9. Remove the suction lines.

10. Remove the return tube.

11. Drain the hydraulic tank (See Figure 3-59).

Note: Make sure you have a sufficient container to hold the oil which is approximately 10 gallons.

12. Disconnect the hydraulic suction and return lines going to the hydraulic tank.

13. Remove dipstick neck assembly.

14. Remove breather cap assembly.

15. Remove steering control lines and valve.

16. Unbolt hydraulic tank from frame.

17. Remove hydraulic tank using proper lifting apparatus.

18. Replace in reverse order.

Troubleshooting & Corrective Maintenance 3-86

Corrective Maintenance DRIVER’S SEAT (VINYL OR CLOTH) HIP RESTRAINT SEAT CUSHION WEIGHT ADJUST KNOB

SLIDE RAILS

LIMIT SWITCH AND CABLE

seatswch2

Figure 3-60 Seat Switch

Seat Assembly Seat Switch The driver's seat micro switch and cable assembly are mounted to the bottom of the seat cushion.

Replacing the Switch and Cable 1. First, review “Before You Begin,” page 3-2.

2. Set the key switch to OFF and place the key in your pocket.

3. Apply the parking brake, disconnect the battery and block all wheels.

4. Release the seat latch and raise the seat to expose the underside. Make sure the seat is secured in the fully raised position.

5. Remove the hardware securing the front portion of the seat slide rails to the cover.

Then loosen the back two sets of hardware (See Figure 3-60).

6. Lower the seat, then raise the front of the seat up to expose the switch and cable mounting.

Have a helper disconnect the switch cable from the main harness, then unscrew the switch assembly.

7. Install the new switch and cable by performing the preceding steps in reverse order.

8. Before placing the truck back into operation, test it to be sure the switch functions properly (See "Check Driver's Seat Switch," in the B3 Series Planned Maintenance Manual (F-444-___).

Troubleshooting & Corrective Maintenance 3-87

Corrective Maintenance

HEADLIGHT OPTION

VOICE OR BEEPER BACKUP ALARM OPTION

STROBE AND REVERSE STROBE LIGHT OPTION

12V TAIL LIGHT OPTION light alarm assy

Figure 3-61 Overhead Guard Alarms and Lighting Options

Troubleshooting & Corrective Maintenance 3-88

Corrective Maintenance

Overhead Guard, Lighting, and Alarms Trucks equipped with optional flood / headlights, tail and stop lights, flashing or spot lights (strobe lights), etc. contain replaceable bulbs. Bulb replacement varies according to manufacturer (See Figure 3-61). Also, refer to B3 Series Parts List (F-493-____) for replacement parts.

Additional options can include backup alarms, etc (See Figure 3-61).

Lights

WARNING Make sure electrical power to the item being serviced is turned OFF and that the battery is disconnected. Wear eye protection.

1. First, review “Before You Begin,” page 3-2.

2. Set the key switch to OFF and place the key in your pocket.

3. Apply the parking brake and disconnect the battery.

4. To replace a serviceable light bulb, in most cases a plastic lens must be removed to expose the bulb (two or three screws and hardware).

5. Remove the bulb by pushing in while turning to the left (counterclockwise). Push the new bulb into the socket, and turn it to the right (clockwise).

For certain assemblies, wiggle and pull-up on the light tube to remove it from the base. Be careful to avoid breaking the glass tube in your hand.

Align the base of the new light tube over the base connector and press down to install the tube. Handle the new bulb carefully to avoid breaking the glass tube.

6. To replace the light assembly, simply disconnect the wire connector and remove the mounting hardware holding the light to its mounting bracket.

7. Where shielding (guard cover) is involved, make certain to replace the guard and reassemble the light.

Troubleshooting & Corrective Maintenance 3-89

Corrective Maintenance Back Up Alarms Two types of back up alarm are offered - beeping and voice (See Figure 3-61).

WARNING Make sure electrical power to the alarm is turned OFF and that the battery is disconnected. Wear eye protection.

1. First, review “Before You Begin,” page 3-2.

2. Set the key switch to OFF and place the key in your pocket.

3. Apply the parking brake and disconnect the battery.

4. To replace the alarm assembly, simple disconnect the wire connector and remove the mounting hardware holding the alarm to its mounting bracket (See Figure 3-61).

5. Reassemble in reverse order.

Troubleshooting & Corrective Maintenance 3-90

Corrective Maintenance

Idler Gear Bolt 7/8 Washer King Pin Thrust Bushing Steering Idler Bearing Spacer Steering Idler Gear Mount Tube Idler Tube Shim Steering Idler Gear Needle Roller Gear Bearing

Hydraulic Gear Nut Set Screw 1/4-28 X 1/4 Steering Pinion Motor Support Bearing

Idler Gear Spacer Slotted Hex Nut 2-12 UNF Upper Bearing Spacer Cotter Pin Roller Bearing Shaft Load Wheel Seal Load Wheel Bearing Bearing Cone Hex Screw 1/2-20 X 3 Steering Gear

Front End Weldment

Steering Motor

front assy

Figure 3-62 Front Assembly

Troubleshooting & Corrective Maintenance 3-91

Corrective Maintenance

Rotation Seals, Bearings or Steering Gear 1. First, review "Before you Begin," page 3-2.

2. Remove the mast. Review "Removing the Mast" on page 3-6.

DANGER GETTING UNDER A TRUCK WHEN IT IS LIFTED OR JACKED IS DANGEROUS AND COULD CAUSE SERIOUS INJURY. NEVER GO UNDER A LIFT TRUCK THAT IS SUPPORTED ONLY BY A JACK OR CRANE. 3. Always place an appropriate support stand or blocks of wood (8" square; 204 mm square minimum) under the truck if it is being lifted, then lower the truck to the support, having the lifting device and support both hold the weight of the truck.

4. Make sure all lifting devices and supports, such as a jack or support stand, or blocks of wood, are capable of handling the weight of the load.

5. Set the key switch to OFF and place the key in your pocket.

6. Apply the parking brake and disconnect the battery. Make sure all the wheels are securely blocked so that they cannot move.

7. Lift and support the truck so that the wheel being serviced is clear of the floor by no more than 1" (25.4 mm).

8. Remove the: · Cotter pin - 1/4 x 2-1/2 · Slotted hex nut - 2-12 UNF · Upper Bearing Spacer · Roller Bearing Pivot Shaft

To Remove Steering Gear Only Note: For other than gear service, the steering gear does not have to be separated from the front mounting plate.

9. Remove the six steering gear screws (1/2-20) that secure the gear to the mount.

10. Replace or repair the gear and reassemble in reverse order.

Troubleshooting & Corrective Maintenance 3-92

Corrective Maintenance Rotation Seals and Bearings 11. Slide a medium sized, long handled Phillips head screw driver through the cotter pin hole into the threaded portion of the rotation shaft. This prevents the shaft from dropping out the bottom and provides a handle for lifting.

12. From the bottom, remove the roller pin shaft retainer and hardware. This single pin secures the shaft to the bottom of the front plate weldment yoke.

13. To remove the rotation shaft from the rotation arm assembly, you must align all the parts to allow the shaft to be pulled up and out. The overhead crane on the mast may have to be raised or lowered a fraction of an inch to free the shaft.

14. With the shaft removed, roll the front plate weldment, mast assembly far enough away from the rotation arm assembly to allow for safe working conditions while servicing the bearings and the seals.

CAUTION Make sure the front plate weldment and mast assembly is stable I its location and secured to the overhead crane.

15. As you separate the front plate from the rotation arm, the lower bearing spacer may fall out. Immediately put in a safe place to avoid damage.

16. Remove the upper and lower seals and bearings 17. Use solvent to remove all traces of old grease from the bearings, rotation arm inner race and the rotation shaft. Allow the parts to air dry.

18. Carefully inspect the bearings for cracks, heat discoloration, worn rollers, etc. Check the upper and lower bearing races for wear and/or damage. If there is any doubt about the condition of these parts, replace them.

IMPORTANT! If a race is damaged, it must be replaced and it is good practice to replace both the upper and the lower at the same time. A portable hydraulic press (come-along) is preferred. The new race installation must be done carefully to maintain a level, parallel alignment between the upper and lower race.

Troubleshooting & Corrective Maintenance 3-93

Corrective Maintenance Hints for Reassembly · Pack the bearings with high-temperature bearing grease making sure the grease penetrates the rollers, cone and cage from the back side. Apply a thick coat of grease to the seal outer surfaces. · If the races are replaced, make sure they are properly seated against their machined stop within the rotation arm frame. · To install the rotation shaft, you must align all the parts. The overhead crane may have to be adjusted a fraction of an inch to allow the shaft to slide in place. · Remember to install the bottom spacer before you roll the front mounting plate/mast assembly back into place. · Starting at the top of the assembly, carefully install the rotation shaft. Align the shaft bottom through hole to the hole in the front plate weldment yoke. · Install the hex screw and hardware. Tighten and torque accordingly. · Install the top portion of the assembly. Tighten and torque accordingly. · Apply additional grease at the two grease fittings.

Troubleshooting & Corrective Maintenance 3-94

Corrective Maintenance Hydraulic Fittings and Hoses 1. Set the key switch to OFF and place the key in your pocket.

2. Disconnect the battery and block the wheels.

Warning Before disconnecting any hydraulic fittings or hose assemblies, relieve the system pressure, down to zero (0) psi. This is accomplished by turning the steering wheel a few times in both directions, and moving the control levers in both directions after the key switch is turned OFF. HIGH PRESSURE HYDRAULIC OIL LEAKS CAN PIERCE THE BODY AND CAUSE SEVERE INJURY TO PERSONNEL. ALWAYS REDUCE PRESSURE BEFORE OPENING ANY HYDRAULIC PRESSURE LINE. Oil is slippery and can cause falls. To avoid injury, wipe up spilled oil with shop rags, or apply an oil-dry and clean up after it has soaked up the spill.

3. Remove the hose coupling from the defective fitting. Use two wrenches; one wrench to loosen the hose coupling, and one to prevent the fitting from turning (See Figure 3-63).

Have rags handy to soak up any oil spillage.

4. Always tag the hoses and fittings for identification. If necessary, keep notes and put markings on parts using a non-destructive marker, such as a felt-tipped pen.

5. Remove the defective fitting and replace with a new fitting. Use two wrenches; one wrench to tighten the hose coupling, and one to prevent the fitting from turning (See Figure 3-63).

Note: SAE fittings do not need a thread sealant. They are straight thread and include an O-ring seal.

Figure 3-63 Removing Hoses/ Fittings

Troubleshooting & Corrective Maintenance 3-95

Corrective Maintenance

Notes _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________

Troubleshooting & Corrective Maintenance 3-96