Bendi Forklift B30 & B40 AC DS Maintenance Manual F-649-R0 - PDF DOWNLOAD

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Bendi B30 and B40 AC/DS DuraSteer™ Maintenance Manual

LANDOLL COMPANY, LLC 1900 North Street Marysville, Kansas 66508 (785) 562-5381 800-428-5655 ~ WWW.LANDOLL.COM F-649-R0

Table of Contents

1

Introduction, Safety, and Specifications Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Service Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Decal Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 General Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Safety Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Lock Out/Tag Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Battery Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Good Battery Care Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Lifting and Blocking the Forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Prior to TIlt Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Mast Service Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Mast Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Cleaning & Inspecting the Forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 Fluid Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 UNC SAE Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 UNF SAE Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 Metric Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 Parker® Brand Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 Aeroquip® Brand Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 Gates® Brand Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 Emergency STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15 Towing the Forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

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2

Inspections Inspection Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Daily Inspection Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Operator’s Daily Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 1st 50 Hours or 2 Weeks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 500 Hour or Monthly Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 2000 Hour or Yearly Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 4500 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Inspections and Scheduled Maintenance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Tools and Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Cleaning and Inspecting the Forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Inspection and/or Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Performance Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Daily Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Safety Warnings and Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Data Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 ESD Straps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Service Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Mast Racking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Hydraulic Cylinders, Hoses, and Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Battery Restraint System and Rollout Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Operator Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Dash Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Accelerator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Lift/Lower Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Tilt Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Side-Shift Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Direction Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Speed Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Return To Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 Lights and Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

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Scheduled Maintenance 1st 50 Hours or 2 Week Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Mast Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Load Backrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Hydraulic Oil Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Steering Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Front Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Gear Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

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500 Hour or Monthly Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Operator’s Seat and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Hydraulic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Checking and Adjusting Hydraulic Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Motors and Gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 General Mast Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Major Structural Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Controllers and Wire Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Forklift Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 2000 Hour or Yearly Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Brake Fluid Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Change Planetary Gear Box Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 4500 Hour Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Hydraulic Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

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Troubleshooting Preliminary Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Troubleshooting Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Visual Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Audible Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Hydraulic Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Brake Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Electrical Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

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Corrective Maintenance Corrective Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Mast and Front End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Removing the Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Repairing Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Load Testing Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Removing the Mast From the Forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Removing Front Plate Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Removing the Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Floor Plate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

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Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Check Service Disc Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Disc Brake Rotors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Replacing the Brake Caliper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Replacing Brake Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Changing Brake Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Parking Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 Replacing the Linear or Rotary Pot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 Brake Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 Replacing Any Other Hydraulic Brake Component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 Electrical Static Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 ESD Strap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 Inspecting the Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 Direction Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 Replacing a Complete Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23 Check Hydraulic Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23 Hydraulic System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 Hydraulic Fittings and Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29 Side Shift Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30 Steering Wheel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30 Steering Column (Console) Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31 Steering Orbital Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32 Front Rotation Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33 Steer (Front Rotation) Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34 Steering Column and Dash Display Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35 Powertrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36 Inspecting the Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36 Rear Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36 Check Planetary Gear Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37 Replacing the Gear Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39 Replacing the Traction Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39 Load Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40 Accelerator Pedal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42 Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43 Horn Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43 Replacing the Switch and Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43 Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43 Overhead Guard, Lighting and Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45

iv

F-649-R0

6

Calibration and Programming Controller Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Dash Display Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Forklift Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 1314 Controller Software Installation and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Software Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Software Update Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Communicating with Bendi AC/DS Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Menu Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Program Menu Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Landoll Traction Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 1 - Speed Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 Dual Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19 Device Parameter Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 Landoll Parameter Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 Inputs Parameter Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21 Outputs Parameter Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21 Battery Parameter Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21 Motor Parameter Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22 Controller Parameter Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22 Cutback Parameter Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23 Vehicle Parameter Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23 CAN Status Parameter Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23 Curtis Controller Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23 LED Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24 Controller Fault History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24 Controller Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25 Controller Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32 Controller Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32

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vi

F-649-R0

Chapter 1

Introduction, Safety, and Specifications Before You Begin Introduction This manual is intended for the service technician seeking information on product maintenance and service replacement parts. Refer to this manual for troubleshooting guides and information.

Operating Instructions Operating instructions for the Bendi AC/DS are located in the Operator’s Manual (P/N F-648) which is shipped with every forklift. If the operator’s manual is missing on your forklift, replace immediately by calling Landoll Company, LLC at 800-423-4320 or ordering online at companystore.landoll.com.

NOTICE Special Notices that include helpful maintenance hints. Read and thoroughly understand.



Proceed with caution. Failure to heed may cause injury to person or damage product.



WARNING

Proceed with caution. Failure to heed warning will cause injury to person or damage product.

Service Training Service Training is available for the forklift technician from Landoll Company, LLC. Topics covered include the operation, repair, and maintenance, hydraulic systems, and electrical systems. Contact Landoll Company, LLC at www.landoll.com for more information.

CAUTION



DANGER

Proceed with extreme caution. Failure to heed warning will cause injury or death to person and damage to product.

Required Tools Both SAE and metric tools needed should be found in well-equipped service centers. Assorted open-end, box-end, Allen and adjustable wrenches along with assorted sockets, screwdrivers, and non-marring mallets should be available to properly perform maintenance and repair.

B

UL Type:

Model: Truck S/N: Mast S/N: Battery Volts:

D

Rated Capacity (lb/kg):

A/H @ 6 Hr: Max. Min. Truck Wt. w/o Battery (lb/kg): Nominal Power (kw): Max. Drawbar Pull (lb/N): Max. Towpoint Rating (lb/N):

UL Type:

Battery Weight (lb/kg):

THIS TRUCK COMPLIES WITH THE REQUIREMENTS OF BS EN ISO 3691 PART 1 For more info tel: +44 7825 278871

Load Center (A) IN CM

Actual Capacity Weight (C) Height (D) LB KG IN CM

ATTACHMENT CAPACITY ON SEPARATE DATA PLATE

Figure 1-1: Serial and Capacity Plate

1-1

INTRODUCTION, SAFETY, AND SPECIFICATIONS

Decal Identification

Figure 1-2: Decal Identification

1-2

F-649-R0

INTRODUCTION, SAFETY, AND SPECIFICATIONS 1. Danger Rollover Decal 2. Overload Warning Decal 3. Before Operating Decal 4. Cover Open Warning Decal 5. Proper Vehicle Loading Decal 6. Made In USA Flag Decal 7. Battery Warning Decal 8. Side Shift Caution Decal 9. Overhead Guard Decal 10. Tire Replacement Decal 11. Operator Warning Decal 12. Overhead Guard Pinch Point Decal 13. Bendi Directional Decal 14. Rotation Indicator Decal 15. Hydraulic Oil Level Decal

16. Bendi Horn Decal 17. No Riders Decal 18. Do Not Remove Guard Decal 19. Apply Park Brake Decal 20. Drexel Yellow Bendi 8 Decal 21. Drexel Yellow Bow-Tie Decal 22. Battery Lead Warning Decal 23. Brevini Oil Specification Decal 24. Ser 4 Hyd Filter Decal 25. Landoll.com Gray Decal 26. Bendi 12 Decal 27. Black Outline 20” Landoll Decal 28. BXXAC Side Decal 29. Data Plate 30. Danger Pinching Decal

1-3

INTRODUCTION, SAFETY, AND SPECIFICATIONS

Replacement Parts The Model Number and Serial Number are required when ordering maintenance and repair parts for the Bendi AC/DS forklift. This information is located on the data plate. See Figure 1-1. Only Landoll approved parts are to be used for service. A Landoll Parts Manual (P/N F-647) may be obtained by calling 800-423-4320 or ordering online at companystore.landoll.com • The data plate is located on the right side below the lift controls.

General Maintenance Instructions



CAUTION

• Steel toe shoes and eye protection are required when maintaining or repairing a forklift.

• Ear protection may also be required per OSHA standards.

• Keep feet, hands, and all other body parts away from all mast areas and pinch points.

• Power industrial forklifts may become hazardous if scheduled maintenance is neglected. Therefore adequate maintenance facilities, as well as trained personnel and procedures, should be provided.

Maintenance and inspection shall be performed in conformance with the following practices: 1. A scheduled maintenance, lubrication, and inspection system shall be followed. OSHA Standards require daily inspections before each shift.

2. Only qualified and authorized personnel shall be permitted to inspect, maintain, or service the forklift.

3. Before leaving the forklift unattended: • Stop the forklift.

• Lower the mast completely.

• Place direction controls in neutral.

• Turn key switch off and remove the key.

• Block the wheels, especially if the forklift is on an incline.

4. Before servicing the forklift: • Perform a Lock Out/Tag Out operation on the forklift.

• Raise drive wheels off the floor.

• Use chocks or other positive positioning devices.

• Block load engaging means (forks), inner mast and/or chassis (outer mast) before working under them.

1-4

• Locate an area with adequate clearance when evaluating performance of the forklift or attachments.

5. Before operating the forklift: • Be in an operating position, i.e., faced forward, left hand on steering knob, right hand on control levers, and left foot firmly planted on the floor plate.

• Start the forklift.

• Place direction control in neutral.

• Check functions of lift systems, directional control, speed control, steering, warning devices, brakes, and any attachments that are equipped.

6. Keep fire protection equipment present.

7. DO NOT use an open flame to check fluid levels.

8. DO NOT use an open flame to check for leakage of electrolyte, fluids, or oil.

9. DO NOT use open pans of fuel or flammable cleaning fluids to clean parts.

10. Keep shop well ventilated, clean, and dry.

11. Brakes, steering mechanisms, control mechanisms, lift overload devices, guards, and safety devices shall be inspected regularly and maintained in safe operating conditions.

12. Capacity, operation plates, maintenance instruction plates or decals shall be maintained in legible condition.

13. All lift mechanisms and components shall be regularly inspected and properly maintained to ensure safe operating conditions.

14. All 2 systems and related components shall be regularly inspected and properly maintained to ensure safe operating conditions.

• Cylinders and other similar parts shall be checked to assure that “drift” has not developed to an extent that it would create a hazard.

15. Batteries, motors, controllers, limit switches, protective devices, electrical conductors, and connections shall be regularly inspected and properly maintained to ensure safe operating conditions.

• Special attention shall be paid to the condition of electrical insulation.

16. The forklift shall be kept in clean condition to minimize fire hazards and facilitate detection of loose or defective parts.

17. Modifications and/or additions, which affect capacity and safe forklift operation, shall not be performed by the customer or user without prior written approval of Landoll Company, LLC. In addition, capacity, operation, and maintenance instruction plates along with decals may not be removed or altered except by Landoll Company, LLC.

F-649-R0

INTRODUCTION, SAFETY, AND SPECIFICATIONS 18. It is not recommended that Landoll parts are to be used for any maintenance or repairs.

• A Landoll Parts Manual (Part Number F-647) may be obtained by calling 800-423-4320 or order online at companystore.landoll.com.

19. Optional equipment shall not restrict the operator’s field of vision.

20. Optional equipment shall not interfere with safe and efficient operation of the forklift or its controls.

Safety Guidelines Lock Out/Tag Out NOTICE In the interest of operator safety and operator compliance with OSHA regulations, guidelines have been developed to perform service and maintenance on the forklift.

Before Performing service and maintenance on the forklift, review the following sections in this manual for additional procedures to be followed.

Anytime you are doing maintenance or repair on the Landoll Bendi AC/DS forklift, unless it must be on for investigative testing, remove the key from the console. Disconnect the battery cable connector and install a commercially available Lock Out/Tag Out device at the battery connectors and remove the main power fuse, since it’s possible to have a duplicate key.

• Remove the key from the console.

• Disconnect the battery cable connectors.

• Install Lock Out/Tag Out device at the battery connectors.

• Remove the main power fuse.

• Place Lock Out/Tag Out warning reminder on the steering wheel.

Battery Safety Bendi AC/DS forklifts include a heavy gauge, pre-molded top compartment cover and a side door to secure the battery in the compartment.

Both covers include latches to lock the compartment. A cutout in the overhead guard is also provided for easy battery service.

The compartment top cover and the side door must be lowered/closed and securely locked in place whenever the battery is installed.



CAUTION

• Wear protective clothing, rubber apron, boots, gloves, and full-face shield when performing any maintenance on the battery.

• DO NOT allow electrolyte to come in contact with eyes, skin, clothing, or the floor. If electrolyte contacts eyes, flush immediately with clean water. OBTAIN MEDICAL ATTENTION IMMEDIATELY. • Should electrolyte be spilled on the skin, rinse promptly with clean water and soap. A baking soda solution (one pound to one gallon of water) will neutralize acid spilled on clothing, floor, or other surfaces. Apply solution until bubbling stops and rinse with clean water.

• Keep battery vent plugs firmly in place at all times, except when adding water or taking hydrometer readings.

• DO NOT bring any type of flame or spark near the battery.

• DO NOT place any electrically conductive tool on the battery that could cause a spark. Gas formed while the battery is charging is highly explosive. This gas remains in the cells long after charging is complete.

• Keep the battery clean. Foreign matter in the electrolyte will result in poor battery performance.

• Follow the battery manufacturer’s instructions concerning maintenance and repair.

1-5

INTRODUCTION, SAFETY, AND SPECIFICATIONS



CAUTION

• Only qualified and experienced personnel shall perform maintenance and repair on batteries.

• Make certain the charger being used matches the voltage and amperage of the forklift battery. This voltage is listed on the forklift data plate. See Figure 1-1.

• Before connecting or disconnecting batteries to the charger, make sure the charger is “OFF”. Attempts made to do this while the charger is “ON” could result in serious injury to the operator and damage could occur to the charger with sparks or electrical spikes.

• Keep sparks or open flame away from the battery or the charging area. BATTERY FUMES ARE EXPLOSIVE! • NEVER smoke or have an open flame near the battery. Gas formed during charging is explosive and can cause injury. Consult the charger manufacturer’s manual covering your charger for operation and maintenance.

• The battery must meet size, weight, and voltage requirements of the forklift.

Battery Removal and Installation



CAUTION

Battery Removal: • When removing the battery, move the forklift to an area intended for battery care, on a level floor.

• Turn the key switch to the “OFF” position and remove the key.

• Perform a Lock Out/Tag Out. “Lock Out/Tag Out” on page 1-5.

• Never remove the battery partially from the forklift without a roller stand in place.

• Lower load completely.

• DO NOT allow any electrically conductive object to come in contact with the top of the battery. This may cause a short circuit when removing or transporting the battery. Use an insulator (such as plywood) to cover the top of the battery during removal.



CAUTION

Battery Installation: • When installing the battery, move the forklift to an area intended for battery care.

• The load forks must be all the way down to the floor.

• Turn the key switch to the “OFF” position and put the key in a secure place.

Good Battery Care Recommendations • • • • • •

1-6

Add approved water only.

Keep electrolyte levels proper.

Keep battery top clean and dry.

Keep flame and metal away from the battery top.

Keep vent caps tightened.

Cool before charging/operating battery above 115 degrees F.

F-649-R0

INTRODUCTION, SAFETY, AND SPECIFICATIONS

Hydraulic System



T

IMPORTANT Before performing maintenance on the hydraulic system, relieve system pressure by:

WARNING

• High pressure fluids are dangerous and can puncture the skin and cause severe injury.

• Relieve all pressure from the hydraulic system before attempting to service it.

• Make sure all hydraulic lines are tight before starting the system. Leaks in the hydraulic system can pierce the skin and cause severe injury. Any fluid injected into the skin under high pressure should be considered a medical emergency despite a normal appearance of the skin. Medical attention should be administered immediately.

• Moving the forklift to a level area.

• Eliminating any load on the forks.

• Lowering the mast completely or place blocks under the mast if it is the part being serviced.

• Relieve any excess system pressure by moving the steering wheel in both directions.

Figure 1-3: Truck Blocking

1-7

INTRODUCTION, SAFETY, AND SPECIFICATIONS

Lifting and Blocking the Forklift • Move the forklift to a level area designated for repair.

• Keep forks empty and low to the ground.

• Turn the key switch to the OFF position and remove the key from the console.

• Disconnect the battery and Lock Out/Tag Out the forklift as described in “Lock Out/Tag Out” on page 1-5.

• Use a jack or hoist with a 32,000 lb. (16 ton) minimum lift capacity.

• Keep the height of the lifted forklift to a minimum.

• Set the forklift on designated hardwood blocks.

See Figure 1-3. Blocks are required on each of the four corners of the forklift to provide a safe and stable repair position.

Prior to TIlt Cylinder Repair



WARNING

DO NOT place feet or hands in any area through the mast or in the forklift pinch points. Servicing the tilt cylinders requires the use of an overhead hoist, hoist slings, and wheel blocks. The overhead hoist and slings must have a rating appropriately greater for the weight of the mast being serviced. DO NOT work under or around a forklift that is not properly secured.

• Forklift repair must be in a level, designated service area.

• Lower the mast completely to the floor.

• Disconnect the battery and lock out the forklift as described in “Lock Out/Tag Out” on page 1-5.

Chock wheels so that the forklift cannot move.

• Attach a sling and hoist to all of the top cross braces so the mast sections cannot move.

Mast Service Precautions



WARNING

• The mast is EXTREMELY heavy. Extra care should be taken to minimize possible injury.

Make sure the hoist is rated for weight of the mast.

• When servicing the mast or sections of the mast, hardwood blocks (4”X4”, 100 X 100mm or larger) shall be used to keep individual sections of the mast from falling. In addition to the hardwood blocks, chains shall be used to hold the mast sections from moving, in both the vertical and horizontal directions.

• Mast work is to be done in a flat designated area.

• NEVER walk under or stand on the forks.

• Remove forks before starting mast repairs.

• NEVER reach through the upright open areas of the mast.

• NEVER maintain or repair the mast without supports or while anyone is near the forklift (ASME B56.1-2000) • Raise the mast and position blocks under the second stage mast.

• Using an appropriate set of C-clamps, secure wooden blocks to the mast channel.

• For mast inspection, use only an approved safety platform or step ladder.

• NEVER repair mast chains; they are to be replaced.

• NEVER replace an individual mast chain. All chains are to be replaced in pairs.

Mast Removal For mast information, “Removing the Mast From the Forklift” on page 5-2.

1. Move the forklift to a level designated service area.

2. Turn the key switch to the OFF position and remove the key from the console.

3. Remove the forks.

4. Turn the steering wheel left and right several times to relieve any excess hydraulic pressure.

5. Slowly and carefully remove the lift, tilt and side shift hoses. Use a container to catch oil and an oil absorbent product to absorb any spills.

6. Remove the two tilt pins and hardware holding the mast to the front plate by tilt cylinders.

1-8

F-649-R0

INTRODUCTION, SAFETY, AND SPECIFICATIONS 7. Disconnect all wiring (if) used between the mast and the forklift body.

8. Support the mast using the sling and an overhead hoist.

9. Chain the individual sections of the mast together at the upper cross braces.

Cleaning & Inspecting the Forklift Landoll Company, LLC strongly discourages the use of power washes for cleaning forklifts. The high pressure water and soap can damage components such as electrical boards, circuitry and wiring. Water and other cleaning residue promotes the formation of rust and corrosion or may otherwise degrade some forklift components. The recommended method for dust removal is compressed air. For localized cleaning, the preferred method of cleaning is the use of a non-flammable solvent.

IMPORTANT Carefully review manufacturer provided WARNING labels and MSDS information when using solvents of other chemicals. Follow the recommended precautions regarding use of personal protective equipment and adequate ventilation to avoid breathing toxic fumes. Adhere to the manufacturer’s instructions regarding safe use and proper disposal methods.

• Clean metal parts with a de-greasing type solvent cleaner and wipe dry with a clean 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. to avoid corrosion.

• For non-metal parts, clean using a mild soap solution, shop vacuum for dust and loose dirt, or 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 supervisor or all defects and record it in the forklift log book.

• Inspect all screw and hardware for stress marks, breaks, cracks, thread defects, etc.

• Replace all damaged or questionable parts with Landoll approved replacement parts before operating the forklift.

• Take care to properly identify and tag each part, its order of removal, and location. Use a non-destructive marker, such as a felt-tipped pen. Take photographs and notes as necessary to be able to re-assemble the product correctly.

Please contact a Landoll technician with any questions 1-800-428-5655 x 4778.

1-9

INTRODUCTION, SAFETY, AND SPECIFICATIONS

Specifications Lubrication Specifications Name

Lubrication

Notes

Hydraulic System

Conoco Power flow HE (ISO Grade 46) Filtered to ISO 4406 cleanliness code 15/13/11 or equivalent Grade oil filtered to 15/13/11.

Drain, flush, and refill

Brake System

DOT 3 Silicone Brake Fluid

Fill

Steer Wheel Bearings

Alvania Grease No. 2

Clean and re-grease Lightly oil

Steering Knob

Light weight oil

Battery Rollers (optional)

SAE 30W oil

Clean and re-oil

Gear Case

Mobilube SHC-630 only

Drain, flush, and refill

Grease Fittings

Molybdenum EP Chassis Grease

Clean and re-grease

Mast Rails

Molybdenum EP Chassis Grease

Clean and re-grease

Mast Chains

SAE40W oil or Bowman Heavy Load Red Grease

Clean and re-oil

General Lubrication

SAE 20 Lubricating Oil

Clean and re-oil

*Failure to refill with oil that meets ISO 4406 cleanliness code 15/13/11 may void the warranty. Typical “NEW” oil DOES NOT meet this specification. Contact Landoll Company, LLC or your lubricant supplier for recommendation.

Torque Specifications Component

Torque

Drive Wheel

225 ft-lbs. (305 Nm.)

Fluid draining and filling plug

16 ft-lbs. (22 Nm.)

Drive motor with vehicle frame

130 ft-lbs. (176 Nm.)

Steering Actuator • Drive Coupling

30 ft-lbs. (41 Nm,)

Mast • Chain guard cap screws

48-52 ft-lbs. (65-71 Nm.)

• Main lift cyl. plunger retainer

95-125 ft-lbs. (129-169 Nm.)

• Free lift cyl. plunger retainer

275-300 ft-lbs. (373-407 Nm.)

• Chain and hose sheave screws

26-30 ft-lbs. (35-41 Nm.)

• Lift chain adjusting nuts

50-70 ft-lbs. (68-95 Nm.)

• Backrest screws

145 ft-lbs. (197 Nm.)

Overhead Guard Bolts

170 ft-lbs. (230 Nm.)

Fluid Capacities Item Hydraulic Tank

Capacity - Quarts (Liters) 11 gallons (42 liters)

Brake Fluid

2 pints (1 liter)

Gear Box

16 oz. (0.24liters) per side

1-10

F-649-R0

INTRODUCTION, SAFETY, AND SPECIFICATIONS General Torque Specifications (rev. 4/97) These tables provide tightening torques for general purpose applications when special torques are not specified on process or drawing. Assembly torques apply to plated nuts and cap screws assembled without supplemental lubrication (as received condition).

They DO NOT apply if special graphite moly-disulfide or other extreme pressure lubricants are used. When fasteners are dry (solvent cleaned) add 33% to as received condition torque. Bolt head identification marks indicate grade and may vary from manufacturer to manufacturer.

Thick nuts must be used on grade 8 cap screws. Use the value in [ ] if using prevailing torque nuts.

UNC SAE Torque Specifications Size

SAE Grade 2 Ft-lbs.

Nm.

SAE Grade 5 Ft-lbs.

Nm.

SAE Grade 8 Ft-lbs.

Nm.

1/4-20

4 [5]

5 [7]

6 [7]

8 [9]

9 [11]

12 [15]

5/16-18

8 [10]

11 [14]

13 [13]

18 [18]

18 [22]

24 [30]

3/8-16

15 [19]

20 [26]

23 [29]

31 [39]

35 [42]

47 [57]

7/16-14

24 [30]

33 [41]

35 [43]

47 [58]

55 [62]

75 [84]

1/2-13

35 [43]

47 [58]

55 [62]

75 [84]

80 [100]

108 [136]

9/16-12

55 [62]

75 [84]

80 [100]

108 [136]

110 [137]

149 [186]

5/8-11

75 [94]

102 [127]

110 [137]

149 [186]

170 [212]

230 [287]

3/4/10

130 [162]

176 [220]

200 [250]

271 [339]

280 [350]

380 [475]

7/8-9

125 [156]

169 [212]

320 [400]

434 [542]

460 [575]

624 [780]

1-8

190 [237]

258 [321]

408 [506]

553 [686]

680 [850]

922 [1152]

1-1/8-7

270 [337]

366 [457]

600 [750]

813 [1017]

960 [1200]

1302 [1627]

1-1/4-7

380 [475]

515 [644]

840 [1050]

1139 [1424]

1426 [1782]

1933 [2416]

1-3/8-6

490 [612]

664 [830]

1010 [1375]

1369 [1864]

1780 [2225]

2413 [3017]

1-1/2-6

650 [812]

881 [1101]

1460 [1825]

1979 [2474]

2360 [2950]

3200 [4000]

UNF SAE Torque Specifications Size

SAE Grade 2 Ft-lbs.

Nm.

SAE Grade 5 Ft-lbs.

Nm.

SAE Grade 8 Ft-lbs.

Nm.

1/4-28

4 [5]

5 [7]

7 [9]

9 [12]

10 [12]

14 [16]

5/16-24

9 [11]

12 [15]

14 [17]

19 [23]

20 [25]

27 [34]

3/8-24

17 [21]

23 [28]

25 [31]

34 [42]

35 [44]

48 [60]

7/16-20

27 [34]

37 [46]

40 [50]

54 [68]

60 [75]

81 [102]

1/2-20

40 [50]

54 [68]

65 [81]

88 [110]

90 [112]

122 [152]

9/16-28

60 [75]

81 [102]

90 [112]

122 [152]

130 [162]

176 [220]

5/8-18

85 [106]

115 [144]

130 [162]

176 [220]

180 [225]

244 [305]

3/4/16

150 [188]

203 [255]

220 [275]

298 [373]

320 [400]

434 [542]

7/8-14

140 [175]

190 [237]

360 [450]

488 [610]

500 [625]

678 [847]

1-14

210 [263]

285 [357]

540 [675]

732 [915]

760 [950]

1030 [1288]

1-1/8-12

300 [375]

407 [508]

660 [825]

895 [1119]

1080 [1350]

1464 [1830]

1-1/4-12

420 [525]

569 [712]

920 [1150]

1247 [1559]

1500 [1875]

2034 [2542]

1-3/8-12

560 [700]

759 [949]

1260 [1575]

1708 [2135]

2010 [2512]

2725 [3406]

1-1/2-12

730 [912]

990 [1237]

1640 [2050]

2223 [2779]

2660 [3325]

3606 [4508]

1-11

INTRODUCTION, SAFETY, AND SPECIFICATIONS Metric: Coarse thread metric class 10.9 fasteners and class 10.0 nuts and through hardened flat washers, phosphate coated, Rockwell “C” 38-45. Use value in [ ] if using prevailing torque nuts

Metric Torque Specifications Nominal thread diameter (mm)

Newton Meters

Foot Pounds

6

10 [14]

7 [10]

7

16 [22]

12 [16]

8

23 [32]

17 [24]

10

46 [60]

34 [47]

12

80 [125]

60 [75]

14

125 [155]

90 [115]

16

200 [240]

50 [180]

18

275 [330]

205 [245]

20

385 [450]

290 [335]

24

670 [775]

500 [625]

27

980 [1105]

730 [825]

30

1330 [1470]

990 [1090]

33

1790 [1950]

1340 [1450]

36

2325 [2515]

1730 [1870]

39

3010 [3210]

2240 [2380]

1-12

F-649-R0

INTRODUCTION, SAFETY, AND SPECIFICATIONS Hydraulic Fitting Torque Specifications (REV. 10/97) 37 degree JIC, ORS, and ORB This chart provides tightening torques for general purpose applications when special torques are not specified on process or drawing.

Assembly torques apply to plated nuts and cap screws assembled without supplemental lubrication (as received condition). They DO NOT apply if special graphite moly-disulfide or other extreme pressure lubricants are used. When fasteners are dry (solvent cleaned) add 33% to as received condition torque. Bolt head identification marks indicate grade and may vary from manufacturer to manufacturer. Thick nuts must be used on grade 8 cap screws. Use value in [ ] if using prevailing torque nuts

Parker® Brand Fittings Dash Size

37 Deg. JIC Ft-lbs.

Nm.

O-ring (ORS)

O-ring boss

Ft-lbs.

Ft-lbs.

Nm.

-4

11-13

15-17

-5

14-16

---------------

21-23

-6

20-22

34-36

25-29

Nm.

13-15

-8

43-47

58-62

40-44

-10

55-65

100-110

58-62

-12

80-90

134-146

75-85

-16

115-125

202-218

109-121

-20

160-180

248-272

213-237

-24

185-215

303-327

238-262

-32

250-290

--------------

310-340

O-ring (ORS)

O-ring boss

Aeroquip® Brand Fittings Dash Size -4

37 Deg. JIC Ft-lbs.

Nm.

Ft-lbs.

Nm.

Ft-lbs.

Nm.

11-12

15-16

10-12

14-16

14-16

20-22

-5

15-16

20-22

---------------

---------------

16-20

24-27

-6

18-20

24-28

18-20

24-27

24-26

33-35

-8

38-42

52-58

32-35

43-47

50-60

68-78

-10

57-62

77-85

46-50

62-68

75-80

98-110

-12

79-87

108-119

65-70

88-95

125-135

170-183

-14

--------------

--------------

--------------

---------------

160-180

215-245

-16

108-113

148-154

92-100

125-136

200-220

270-300

-20

127-133

173-182

125-140

170-190

210-280

285-380

-24

158-167

216-227

150-165

204-224

270-360

370-490

1-13

INTRODUCTION, SAFETY, AND SPECIFICATIONS

Gates® Brand Fittings Dash Size

37 Deg. JIC Ft-lbs.

-4

10-11

Nm.

O-ring (ORS)

O-ring boss

Ft-lbs.

Ft-lbs.

10-12

Nm.

14-16

-5

13-15

---------------

---------------

-6

17-19

18-20

24-26

-8

34-38

32-40

37-44

-10

50-56

46-56

50-60

-12

70-78

65-80

75-83

-14

--------------

65-80

--------------

-16

94-104

92-105

111-125

-20

124-138

125-140

133-152

-24

156-173

150-180

156-184

-32

219-243

--------------

--------------

1-14

Nm.

F-649-R0

INTRODUCTION, SAFETY, AND SPECIFICATIONS

Emergency STOP B30 Stop Button: Press this button to shut down the drive and all mast movement. The forklift drifts to a “STOP”. Immediately set the parking brake.

To continue, pull out on the button to reset the switch.

See Figure 1-4.

B40 Emergency Disconnect: Pull the disconnect handle to remove power and shut down drive and mast movement. The forklift drifts to a “STOP”. Immediately set the parking brake.

To continue, plug the cable back into the Emergency Disconnect. See Figure 1-4.

Use this button: • In case of fire, smoke or overheating.

• If a person comes between the forklift and a fixed object.

• In case an accident occurs.

• In case of a short circuit or other electrical malfunction e.g., if the pump motor is on continuously.

Figure 1-4: Emergency Interrupts

Towing the Forklift If the forklift breaks down and cannot be repaired at that location, it may be towed by attaching a suitable hook and chain to the tow pin located in the cutout at the lower rear of the forklift. See Figure 1-5.

Carefully and slowly tow the forklift backwards to the service repair area. An operator must be on the towed forklift, wearing a seat belt.

1-15

INTRODUCTION, SAFETY, AND SPECIFICATIONS



WARNING

• Have the service brake applied when hooking up the tow chain.

• Tow the forklift at a speed of 2 mph or less.

• DO NOT make sharp turns when towing the forklift. The towed forklift will be difficult to steer. USE EXTREME CAUTION and keep the towed vehicle at a slow, manageable speed.

• Forks must be empty.

• Forks must not be more than 12” off the floor.

• With the park brake disabled, the forklift can roll easily - USE EXTREME CARE. • Failure to reset the park brake will result in an unsafe condition.

• Towing vehicle must have a pull and braking capacity greater than 8,000 lbs.

• Maximum towing speed should not exceed 2 mph.

• Always tow the forklift in the reverse direction.

Figure 1-5: Tow Pin

NOTICE Be careful, the forklift will roll easily and steering will be difficult.

Brake functions will not be equivalent to an operational forklift.

1. The key switch must be in the “OFF” position.

2. There should be no load on the forks and no higher than 12 inches off the ground.

3. Firmly attach the tow device from the towing vehicle to the forklift tow pin provided on the lower rear side of the forklift frame.

4. Keep the towing speed below 2 mph. The operators of the towing vehicle and the disabled forklift should maintain communication and visual contact while observing the towing operation.

1-16

F-649-R0

Chapter 2

Inspections Inspection Introduction Inspections and preventative maintenance are an essential part of maintaining all industrial equipment. A well planned inspection program is essential to operator safety and forklift longevity.

The inspection program recommended by Landoll Company, LLC periodically checks the integrity of Bendi forklift systems, e.g., checking operator’s functions, fluid levels, and overall conditions.

• Checking performance of operator functions, e.g., lift, tilt, side shift, attachment, and traction systems.

• Checking for leaks.

• Checking fluid levels.

• Making sure components are securely attached.

• Checking the tires.

Preventative maintenance is the responsibility of both the daily operator and the forklift technician.

To make sure these and other systems are checked periodically, Landoll Company, LLC has developed a system of checklists. A blank copy of each checklist can be found on pages 2-2 through 2-6.

These checklists include • Operator’s Daily Checklist • 1st 50 Hour Inspection Checklist • 500 Hour Inspection Checklist • 1000 Hour Inspection Checklist • 2000 Hour Inspection Checklist • 4500 Hour Inspection Checklist Except for the Operator’s Daily Checklist, these tasks are usually performed by a service and maintenance facility that is approved by Landoll Company, LLC. These inspection sheets should be copied, completed and maintained by the forklift technicians.

IMPORTANT Recommended service inspections are based on normal operating conditions. If the forklift is subjected to severe or above normal operating conditions, extreme temperatures, excessive dust or wet environments, or if the forklift is around corrosive materials, service must be performed at more frequent intervals.

IMPORTANT The performance of the Landoll Bendi AC/DS is dependent on the condition of the battery installed in the forklift. To ensure a long battery life and dependable forklift performance, perform the daily inspection of battery electrolyte and follow the service recommendations of the battery’s supplier.

Daily Inspection Checklist The following pages are OSHA (Occupational Safety and Health Administration) required check sheets. These sheets should be copied and the copies used for maintenance checks on your Bendi AC/DS forklift. It is the operator’s duty to inspect the lift before each shift and report all problems to the person in charge of forklift maintenance. Have a qualified mechanic correct all noted problems.

Daily pre-shift inspection is an OSHA requirement, regulation 1910.178(q)(7). Report any defect immediately to your supervisor.

The daily inspection includes: • Visual inspection of the entire forklift for any defect.

• Visual check for any hydraulic leaks.

• Check that all controls and gauges work properly.

2-1

INSPECTIONS To be performed before the start of every shift. Have a qualified service technician correct all problems before operating the forklift.

Date

Inspector

Shift

Location

Truck Number

Model Number

Serial Number

Hr. Meter

Battery Fluid Added

Hyd. Oil Added

Operator’s Daily Checklist Safety and Operational Checks

Description

Safety Warnings and Operator’s Manual

Attached and legible

Data Plate

Attached and legible

Tires

Check for debris

Static straps

Check presence and condition

Parking brake

Check operation

Service brakes

Check operation and fluid fill level

Forks, top clip retaining pin, and heel

Check condition

Mast racking

Check for proper lift operation

Hydraulic oil

Check fluid level

Hydraulic cylinders

Check for leaks

Battery

Check water/electrolyte level and charge

Battery restraint system

Adjust and fasten

Turn power on Dash display Steering

Status

Bendi AC/DS

Pass/Fail

Comments

Investigate unusual noises Check hour meter/BDI Check for fault codes Check operation Check accelerator operation Check lift/lower control operation Check tilt control operation Check side-shift control operation

Controls

Check directional switch operation Check speed select switch operation Check return-to-neutral operation Check seat switch operation Check Horn operation Optional attachment switch operation

Lights and backup alarm (if equipped)

Check switch operation

Seat adjustments

Lumbar and slide operation

Seat belt, buckle, and retractors

Check operation

Overhead guard

Check for damage and cracks

2-2

F-649-R0

INSPECTIONS To be performed after the 1st 50 hours or 2 weeks of forklift operation, whichever comes first, IN ADDITION to the required pre-shift daily inspection. Have a qualified technician correct all problems before operating the forklift.

Date

Inspector

Shift

Location

Truck Number

Model Number

Serial Number

Hr. Meter

Battery Fluid Added

Hyd. Oil Added

1st 50 Hours or 2 Weeks Safety and Operational Checks

Description

Mast chains

Inspect, clean, and check tension

Load backrest

Re-torque bolts to 150 ft-lbs. (203 Nm)

Load wheels and Drive wheels

Re-torque lug nuts to 225 ft-lbs. (305 Nm)

Hydraulic oil

Check level

Steering actuator hydraulic coupling

Re-torque to 30 ft-lbs. (41 Nm)

Steering actuator mount bolts

Re-torque to 460 ft-lbs. (624 Nm)

Front plate mount bolts

Re-torque to 760 ft-lbs. (1030 Nm)

Gear box

Drain, flush, and refill

Status

Bendi AC/DS

Pass/Fail

Comments

The gearbox drain/flush/fill occurring after the first 50 hours or 2 weeks of operation is CRITICAL to the life of your forklift.

2-3

INSPECTIONS To be performed EVERY 500 hours or month of forklift operation, whichever comes first, IN ADDITION to the required pre-shift daily inspection. Have a qualified technician correct all problems before operating the forklift.

Date

Inspector

Shift

Location

Truck Number

Model Number

Serial Number

Hr. Meter

Battery Fluid Added

Hyd. Oil Added

500 Hour or Monthly Checklist Safety and Operational Checks

Description

Turn power on

Investigate unusual noises

Dash display

Check hour meter, BDI, and fault codes

Status

Bendi AC/DS

Pass/Fail

Comments

Check accelerator operation Check lift/lower control operation Check tilt control operation Check side-shift control operation Check directional switch operation Controls

Check speed select switch operation Check return-to-neutral operation Check seat switch operation Check horn operation Check service brake operation Check steering operation Optional attachment operation

Seat adjustments

Check operation of slide and lumbar

Seat belt, buckle, and retractors

Functioning smoothly

Lights and backup alarm

Check operation

Switches, e.g., direction, park brake, key, etc.

Check and Tighten

Fans

Check operation

Hydraulic in-tank filter

Replace filter element

Exterior of hydraulic tank breather

Clean

Hydraulic hoses, tubes, and connections

Check for wear and leaks

Reeving hoses

Check condition Check fwd/rwd tilt angles

Tilt cylinder

Jam nut tight Grease pivots and forklift end of cylinder

Lift and sideshift cylinders

Check for leaks and wear Grease steer actuator Check steer pot

Steering

Lube steering knob Check pressure, i.e., 1900 PSI (13,100 kPa)

Rotation stops Actuator seals

2-4

Check for wear and cracks Re-torque Grease (2 total)

F-649-R0

INSPECTIONS

500 Hour or Monthly Checklist Safety and Operational Checks

Description

Status

Bendi AC/DS

Pass/Fail

Comments

Check for leaks and pad wear Service brake

Check electrical connector and pot Check brake fluid level

Parking brake

Check operation and pad wear Check tire condition; remove debris

Wheels

Re-torque drive axle wheel lug nuts to 225 ft-lbs. (305 Nm)

Load wheel bearings

Clean and fill with grease Clean and torque studs and bolts

Motors

Clean cooling vents Check hydraulic pump motor for leaks

Gearbox

Check for leaks Check, clean, and lube rails and chains Check, clean, and lube mast carriage

Mast

Check for wear Check, clean, and lubricate attachment (if equipped) Check for smooth operation

Forks, top clip retaining pin, and heel

Check condition

Load backrest

Re-torque to 150 ft-lbs. (203 Nm)

Major structural points, e.g, axle mount, overhead guard, rotation pin, etc.

Check for damage and cracks

Data plate

Intact and accurate

Battery cover

Lifts smoothly and easily

Battery

Check for leaks, clean, and neutralize

Battery rollout tray (if equipped)

Check safety restraints and safety switch

Battery restraints

Adjust and fasten

Wire connections

Check Check for faults

Controller

Clean surface

Over Head Guard

Retorque Attaching Hardware

Check operation of contactor points

2-5

INSPECTIONS To be performed EVERY 2000 hours or year of forklift operation, whichever comes first IN ADDITION to the required pre-shift daily inspection. Have a qualified technician correct all problems before operating the forklift.

Date

Inspector

Shift

Location

Truck Number

Model Number

Serial Number

Hr. Meter

Battery Fluid Added

Hyd. Oil Added

2000 Hour or Yearly Checklist Safety and Operational Checks

Description

Mast chains

Check tension

Hydraulic reservoir suction screen

Clean with solvent

Gear box

Drain, flush, and refill

Brake fluid

Change

Steering actuator coupling

Re-torque to 30 ft-lbs. (41 Nm)

Steering actuator mounts

Re-torque to 460 ft-lbs. (624 Nm)

Front plate mount bolts

Re-torque to 760 ft-lbs. (1030 Nm)

2-6

Status

Bendi AC/DS

Pass/Fail

Comments

F-649-R0

INSPECTIONS To be performed EVERY 4500 hours or year of forklift operation, whichever comes first IN ADDITION to the required pre-shift daily inspection. Have a qualified technician correct all problems before operating the forklift.

Date

Inspector

Shift

Location

Truck Number

Model Number

Serial Number

Hr. Meter

Battery Fluid Added

Hyd. Oil Added

4500 Hour Safety and Operational Checks Hydraulic oil

Description

Status

Bendi AC/DS

Pass/Fail

Comments

Change

*Failure to refill with oil that meets ISO 4406 cleanliness code 15/13/11 may void the warranty. Typical “NEW” oil DOES NOT meet this specification. Contact Landoll Company, LLC or your lubricant supplier for recommendation. See “Lubrication Specifications” on page 1-10.

2-7

INSPECTIONS

Inspections and Scheduled Maintenance Requirements This section describes the planned maintenance requirements, adjustments, and lubrication necessary to ensure safe and efficient operation of the Bendi AC/DS forklift. Planned maintenance procedures are designed to extend the service life of the forklift and prevent unnecessary repairs. Thoroughly review this section prior to inspecting or servicing the forklift.

Inspection schedules are provided at the end of this chapter and also in the Operator’s Manual provided with the forklift.

Recommended lubricants and torque values are found in “Torque Specifications” on page 1-10.



DANGER

Failure to follow these guidelines can cause serious injury or death: • NEVER perform maintenance or service procedures unless specifically indicated in this manual or at the specific request of supervisory personnel. All other service and maintenance on your Bendi AC/DS forklift must be provided by a facility authorized by Landoll Company, LLC to perform these services.

• Wipe up any spills immediately to prevent slipping, fire, explosion, or contact with hazardous materials.

• Failure to use lifting equipment of adequate capacity to lift and move your Bendi AC/DS forklift can cause lifting equipment failure.

• Removing the counterweights or uprights will change the center of gravity of the forklift.

This can cause the forklift to tip. The battery is considered part of the forklift’s counterweight.

To help avoid fire related injuries: • Have fire extinguishing equipment present in the work area.

• DO NOT allow sparks or open flames while checking fluid level, leaking oil, or electrolyte.

• DO NOT use fuel or flammable cleaning fluids to clean parts.

Tools and Equipment Required Read and comply with all applicable SAFETY precautions when servicing the forklift. See the section “Before You Begin” on page 1-1 at the beginning of this manual.

2-8

Common sense and standard precautions apply when servicing machinery and must always be used.

In addition to a good portable light source and various tools, as explained in “Required Tools” on page 1-1, the following tools and equipment may be required.

• Hydraulic jack, appropriate for the weight being raised.

• Safety stands, appropriate for the weight being supported.

• Overhead crane, appropriate for the weight being lifted and/or supported.

• Grease gun.

• Torque wrench - capable of measuring at least 500 Ft-lbs. (678nm).

• Drain pan, capable of holding at least 11 gallons (41.6 liters) of hydraulic fluid.

• Angle wrenches • Before using any solvent or cleaning solution, be sure that it will not damage the part you are cleaning.

For example, gasoline should never be used to clean parts. Gasoline is highly flammable and may damage some types of rubber and plastic. Hydraulic brake fluid (standard, not silicone type) is often used to clean rubber parts. It also removes paint quickly, so care should be exercised when it is used.

• Tag all parts for identification and location before removal and mark all mating parts for accurate re-assembly.

• Protect finished surfaces from damage caused by dropped wrenches, spilled solvent, etc.

• Use a penetrating oil to loosen difficult screws, nuts, or bolts. A hand-held impact driver is a handy tool when removing tight fasteners.

• Certain bolts, screws, or nuts are secured with a non-permanent thread-locking compound at the factory e.g., Loctite Primer and Blue Sealant #243 or equivalent (Landoll P/N 115627). When these parts are replaced, a non-permanent thread-locking compound must be reapplied.

• No parts, except those press-fit assembled, require unusual force to disassemble. If you encounter trouble, determine the reason for the difficulty, before proceeding.

• Cover all openings caused by removing parts or sub-assemblies to keep objects from falling in where additional damage could result.

• When assembling two parts, start all of the fasteners first, then tighten them evenly and in a staggered manner. Be sure both mating surfaces are aligned, not cocked or off-center.

F-649-R0

INSPECTIONS • Observe standard torque ratings for the size and type of fastener as listed starting in “Torque Specifications” on page 1-10.

• Be sure to use the proper nuts, bolts, and other fasteners as rated, e.g., SAE Grade 5, SAE Grade 8, ISO Prop Class 8.8, etc.

• All fasteners must be replaced with the identical type.

• Use only Landoll approved replacement parts.

Cleaning and Inspecting the Forklift Landoll Company, LLC strongly discourages the use of power washers for cleaning forklifts. The high pressure water and soap can damage components such as electrical boards, circuitry and wiring. Water and other cleaning residue promotes the formation of rust and corrosion or may otherwise degrade some forklift components. The recommended method for dust removal is compressed air. For localized cleaning, the preferred method of cleaning is the use of a non-flammable solvent.

Carefully review manufacturer provided WARNING labels and MSDS information when using solvents or other chemicals. Follow the recommended precautions regarding use of personal protective equipment and adequate ventilation to avoid breathing toxic fumes. Adhere to the manufacturer’s instructions regarding safe use and proper disposal methods.

• Clean metal parts with a de-greasing type solvent cleaner and wipe dry with a clean 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. to avoid corrosion.

• For non-metal parts, clean using a mild soap solution, shop vacuum for dust and loose dirt, or 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 supervisor of all defects and record it in the forklift log book.

• Inspect all screws and hardware for stress marks, breaks, cracks, thread defects, etc.

• Replace all damaged or questionable parts with Landoll approved replacement parts before operating the forklift.

• Take care to properly identify and tag each part, its location, and its order of removal. Use a non-destructive marker, such as a felt-tipped pen.

Take photographs and notes as necessary.

• If you have any questions about parts or reassembly contact Landoll Company, LLC at 800-423-4320.

Inspection and/or Maintenance • Inspect the forklift in an area that has sufficient clearance to check all operator functions.

• Lower forks to the ground and tilt mast forward.

• Use wheel chocks or other positive positioning devices if drive functions will not be checked.

• Raise the drive wheels so they are not in contact with the floor when checking operator functions while leaving the forklift in a stationary position.

• Block the mast to prevent it from engaging.

• Use adequately rated hoisted equipment if the forklift will be hoisted for service.

• NEVER remove counterweights or uprights. This will change the center of gravity and can cause an unstable condition.

Performance Testing



CAUTION

Before leaving the forklift make sure that: • The parked forklift will not cause an obstruction or safety hazard and is clean of the path of fire exits/equipment.

• The forklift will not be left unattended on an incline.

• Make sure all accessories are off before continuing.

If the forklift is inoperative and you must leave it parked on an incline, securely block all wheels and remove the key.

1. The operator should be properly seated in the operator’s seat before beginning testing procedures.

2. Turn the key switch to the “ON” position.

3. Set direction switch to the “FORWARD” position.

4. Check functions described in the Operator’s Daily Checklist or other Checklists.

Daily Inspections Safety Warnings and Manual Check for damage and missing decals. Check that the decals are legible. Clean and/or replace as needed. See Figure 1-1. Check that the Operator’s Manual is with the forklift and in good condition.

2-9

INSPECTIONS

Data Plate The data plate should be checked to verify capacity ratings and lift heights. Also check the serial number of the forklift and mast to make sure they match up with the corresponding numbers on the data plate.

Wheels and Tires The condition of the tires are to be checked along with the accessible lug nuts torqued at the beginning of each shift.

The forklift 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, tires must always be replaced with the type originally supplied, as listed on the specification sheet at the end of this manual. It is also recommended to replace worn tires in pairs. Drive tires with tread must be replaced when the tread depth is less than 1/16” (1.6mm) at the deepest point.



CAUTION

If tires have excessive wear and/or chunking or lug nuts are missing, repair and/or have service replace immediately. DO NOT use the forklift.

2. Inspect tires for undercutting and uneven wear.

Undercutting is caused by continuous overloads, rapid sharp turns, operating on slopes, loose spindles, transporting loads with a high center of gravity, or transporting off center loads. This causes the rubber to bulge out over the edge of the steel band, cutting the rubber just above the base band.

Uneven tire wear is usually the result of mechanical defects, such as badly adjusted brakes, misaligned wheels, or a faulty drive axle.

3. Check that the tires remain centered on the wheels to prevent splitting of the base band and tread separation. Correct defects as soon as possible.

4. Flat spotting can occur from excessive heat, a load left on the forks overnight, or locking the brakes with excessive skidding.

5. Avoid oil, grease, gasoline, and acid.

6. Torque drive wheel lug nuts to 225ft. lbs. (305Nm) and make sure no lug nuts are missing.

ESD Straps Two ESD Straps are installed just behind the front axle.

These straps will drain all static electricity build-up that may occur on the Bendi AC/DS forklift. ESD Straps should be in fair condition, bolted securely to the body and touching the ground.

1. Inspect the tire for chunking or embedded objects.

This is caused by running over objects on a littered floor, overloading, or bad driving habits - sharp, rapid turns at high speeds or rapid starts and stops.

• Remove any embedded foreign material and torn pieces of tread as soon as it is noticed.

• Replace chunked tires if they produce a rough bouncy ride.

Figure 2-2: ESD Strap

Parking Brake The parking (hand) brake is located to the left of the control levers.

Operation- Pull the parking (hand) brake towards the back of the forklift to set it. Push it away to release it. The forklift cannot be driven while the parking (hand) brake is engaged. The forklift will not repsond to the accelerator pedal unless the parking (hand) brake is pushed forward all the way.

Figure 2-1: Tire wear and Damage 2-10

F-649-R0

INSPECTIONS



CAUTION

This test will cause the drive wheel to lock. DO NOT test the parking brake at high speed. Check parking brake at creep speed only.

Service Brakes With the key switch set to ON, drive forward slowly and then steadily apply the brake pedal. The forklift should stop smoothly without noticeable side pull or vibration. If any problems are detected, remove the forklift from service immediately until it is repaired.

Check the Brake Fluid Level The Master Cylinder reservoir is located under the floor plates just above attached to the brake pedal assembly.

Remove the bolt on the lid and check the levels as indicated. The reservoir is full when the oil level is at the fill line.

Forks Check the forks for cracks, inspecting closely the heel portion of the forks. If any cracks are found replace the fork. Never attempt to repair, weld, or alter a fork.



Hydraulic Oil NOTICE If the forklift has been in operation, let the forklift sit for several minutes before checking the oil level to allow time for the oil to return to the tank.

Completely lower the mast. Lift floor mat and remove left floor plate and pull out the dipstick to ensure the oil level reads between the marks. Add recommended oil if the level is low. See page 1-10.

Hydraulic Cylinders, Hoses, and Fittings Check underneath the forklift for evidence of fluid leaks.

Look for hydraulic hose wear, damage, and leaks. Make sure clamps and fittings are tight. In the event that leaks are detected, immediate corrective action must be taken.

DO NOT operate the forklift until repairs are made and the hydraulic fluid level has been checked.

FILL LOCATION

DIPSTICK

CAUTION

• DO NOT service carriage forks while the key switch is on. If a control lever is accidentally moved, serious injury could occur.

• Use only Landoll approved replacement parts. Use only quality forks that are forged or have an up-set heel and the same capacity rating as the factory installed forks.

• NEVER use forks repaired by welding.

• Always replace both forks. Switching forks from one forklift to another can be dangerous if the capacity of the forks is not known.

HYDRAULIC OIL TANK Figure 2-3: Reservoir Location

Mast Racking With the key switch turned “ON”, tilt the unloaded mast rearward. The mast should stop when the tilt cylinders bottom with no evidence of mast twist (racking). If twisting occurs, adjust the tilt cylinder rods.

Battery Before performing any inspections or maintenance on the battery read “Battery Safety” on page 1-5.

It is important to properly maintain the battery to ensure long life, strong voltage potential, and safety of the battery.

2-11

INSPECTIONS Good Battery Care Recommendations: • • • • • • • • •

Add approved water only - never add acid.

Keep electrolyte levels proper.

Keep battery top clean and dry.

Keep flame and metal away from the battery top.

Keep vent caps tightened.

Avoid charging/operating battery above 115°F. Use only approved, correct voltage/current, chargers.

Keep battery cover open when charging.

If in doubt, call your local Landoll service technician.

Using a Hydrometer As the battery discharges, the specific gravity of the electrolyte reduces. A hydrometer allows you to check specific gravity of the cells, thus the charge state of the battery.

1. Remove a cap from one or two of the cells. Gently squeeze (compress) the bulb of the hydrometer.

2. Insert the tube of the hydrometer into the cell electrolyte. Slowly release the bulb to allow fluid to draw into the hydrometer. Enough fluid must enter the hydrometer to allow the float to move freely.

3. The specific gravity of the electrolyte is read off the scale of the float where it emerges from the fluid. It is a good practice to select many different and multiple cells.

4. When returning the electrolyte to the battery, ensure that the fluid is returned to the cell it was taken from and be very careful not to splash the electrolyte.

Figure 2-4: Using a Hydrometer

2-12

Specific Gravity Correction Temp °F

Correction

Temp °F

Correction

39-41

-0.012

101-103

+0.008

42-44

-0.011

104-106

+0.009

45-47

-0.010

107-109

+0.010

48-50

-0.009

110-112

+0.011

51-53

-0.008

113-115

+0.012

54-56

-0.007

116-118

+0.013

57-60

-0.006

119-121

+0.014

61-63

-0.005

122-124

+0.015

64-66

-0.004

125-127

+0.016

67-69

-0.003

128-130

+0.017

70-72

-0.002

131-133

+0.018

73-75

-0.001

134-136

+0.019

76-78

0

137-139

+0.020

79-81

+0.001

140-142

+0.021

82-84

+0.002

143-145

+0.022

85-87

+0.003

146-148

+0.023

88-91

+0.004

149-151

+0.024

92-94

+0.005

152-154

+0.025

95-97

+0.006

155-157

+0.026

98-100

+0.007

158-160

+0.027

Replacing the Battery Replacing the battery requires lift and support apparatus capable of supporting the weight and size of the battery.

Check the data plate for battery information. See Figure 1-1.

An external battery roller tray stand is also helpful, and available through a Landoll distributor, to allow the battery to be pushed into the compartment.

To Replace a Battery: 1. Return the forklift to service charging station area.

2. Set the key switch to “OFF” and remove key from easy access.

3. Place blocks in front of and behind all wheels.

4. Unlatch the compartment cover (below drivers seat) and raise the battery compartment top cover.

5. Secure the cover to the overhead guard latch and insert the locking pin. Jiggle cover to be sure latch is secured. See Figure 2-5.

6. Open the right side door by sliding the locking lever to the right, then swing the door fully opened.

7. Disconnect the battery/forklift cable disconnect and lay the battery cable across the battery top. See Figure 2-6.

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INSPECTIONS

OVERHEAD GUARD

LATCH AND PIN LATCH BRACKET

COMPARTMENT COVER

10. To prevent roll-out, measure the width of the new battery. Adjust the retainer brackets located on the underside of the compartment top cover to approximately 0.500” to 0.750” (12.7 mm to 19 mm) wider than the width of the battery. Tighten and torque the screws.

11. When installing the battery, it must be pushed up against the rear wall panel and centered within the battery compartment. See Figure 2-6.

12. Close and secure the compartment side door and connect the battery electrical connector (blue).

Situate the excess wiring between the battery and the side wall of the forklift, making sure the wires are not exposed causing a “pinch” condition when the top cover is closed.

13. Release the overhead guard latch and lower and secure the top cover. Make sure the cover latch is secured and that no wires are pinched.

Figure 2-5: Overhead Guard Battery Cover Latch

Figure 2-6: Removing the Battery 8. Lift the compartment side door spring latch up to release the latch pins in the battery tray and the rear counterweight.

9. Place and connect the appropriate lift and support apparatus (overhead crane, crossbar and chains) within the overhead guard cutout, then carefully lift and slide the battery from the forklift. See Figure 2-6.

2-13

INSPECTIONS

Figure 2-7: Battery Disconnects

Charging a Wet Cell Battery 1. Remove each vent cap and check electrolyte levels.

Ambient temperature should be +77° F (+25° C) to get a proper reading. In cold weather, batteries may look dry.

2. DO NOT add water until a proper temperature is obtained; cold weather can affect the level. If water must be added, use only distilled water.

3. Make sure the electrolyte level is at the level indicator.

4. Replace the vent caps. They must be secured in place during charging.

5. Charge the battery using a constant current charger set to 5% of the six-hour battery capacity. For example, 55 amps for an 1,100 AH (ampere-hour) battery.

• Ordinarily, the charge should take about 3 to 5 hours to complete.

• During the initial charge the volume of electrolyte decreases through electrolysis and evaporation.

Water approved for use in lead-acid storage batteries should be added if the electrolyte level falls below the level indicator.

• If the cell temperature rises higher than +110° F (+61.2° C) either reduce the charging current to half the original value or stop charging until the temperature falls below +110° F (+61.2° C). If the charging current is reduced, extend the charging time accordingly.

6. Refer to “Specific Gravity Correction” on page 2-12 for Specific Gravity correction factors dependent upon electrolyte temperature.

2-14

7. Continue charging until the cells gas freely and the specific gravity remains constant over a three-hour period. At the end of the charge period the cell voltages rise to about 2.55 volts and the specific gravity rises to about 1.280, corrected to 77° F. 8. When charging is complete, ensure the vented cell caps on the battery are secure.

9. Connect battery cables and install battery in forklift.

Charging a Dry Cell Battery 1. Remove and discard plastic film seals from each cell vent hole (if present).

2. Fill the cells to the level indicator using dilute battery grade sulfuric acid with a specific gravity between 1.260 and 1.270 corrected to +77° F (+25° C). The temperature of the electrolyte should be no higher than 90° F (32° C).

3. Allow the cells to soak for 2 to 3 hours after filling.

The electrolyte level may drop slightly because of absorption into the plates and separators. If it does, add more electrolyte to restore the level.

4. Charge the battery, using a constant current charger set to 5% of the six-hour battery capacity. For example, 55 amps for an 1100 AH (ampere-hour) battery. The time required for an initial charge is approximately 8 hours.

F-649-R0

INSPECTIONS 5. During the initial charge the volume of electrolyte decreases through electrolysis and evaporation.

Water approved for use in lead-acid storage batteries should be added if the electrolyte level falls below the level indicator.

If the cell temperature rises higher than +110° F (+43° C) either reduce the charging current to half the original value or stop charging until the temperature falls below +110° F (+43° C). If the charging current is reduced, extend the charging time accordingly.

6. Continue charging until the cells gas freely and the specific gravity remains constant over a three-hour period. At the end of the charge period the cell voltages rise to about 2.55 volts and the specific gravity rises to about 1.280 (corrected to 77° F).

7. If the specific gravity exceeds 1.290 after charging, dilute with distilled water and continue to charge for two more hours.

8. If the specific gravity is below 1.280 after charging, add electrolyte with a specific gravity of 1.400 until the battery has a specific gravity between 1.280 and 1.290. Then resume charging for another two hours.

Battery Restraint System and Rollout Option The battery restraint should be in place at all times when a battery is installed in the forklift. A switch that detects the battery restraint will disable the forklift if the restraint is not in place.

Rollout Battery Removal 1. Remove the safety retainer bar, deactivating the safety switch.

2. Position battery roll out stand next to the forklift and align the stand with the path of the battery.

3. Roll the battery onto the stand.

Rollout Battery Installation 1. Change and charge batteries in accordance with ANSI/NFPA 505.

2. Check to be sure the key is off.

3. Open the right hand door.

4. If using a rollout stand, position the battery stand next to the forklift. Align stand with battery compartment. Battery roller stand should be at the same height as the forklift.

5. Push battery into the forklift’s battery compartment or lower if using a hoist.

6. Install the rollout battery arm bar, or the forklift will not operate. See Figure 2-8.

7. Connect the battery.

Figure 2-8 Rollout Battery Arm Bar

Operator Controls In order to test many of the operator controls the forklift must be running. When powering on the forklift be sure to investigate any unusual noises and record them on the Operator’s Daily Checklist.

Dash Display Ensure that the Battery Discharge Indicator, Speed and Direction Indicators, Hour Meter and other readouts are functioning properly.

Steering Before operating the forklift, check the steering system to make sure it operates correctly. To check the steering system: 1. Get in the operator’s compartment and turn the key switch to the “ON” position.

2. While applying the service brake, release the parking brake and set the direction control lever to “FORWARD” or “REVERSE”. The hydraulic pump motor should start running.

3. If the motor does not start, first check that the parking brake is released.

4. While moving forward or backward slowly (to avoid flat-spotting), verify that the forklift turns left and right with a relatively smooth, easy motion.

5. While moving forward or backward slowly, turn the steering wheel completely to the right (a full right-hand turn).

6. While moving slowly in either direction, turn the steering wheel completely to the left (counterclockwise) while counting the number of full revolutions. The steering wheel must complete approximately 7-9 revolutions, lock-to-lock.

7. Next, turn the steering wheel completely to the right (clockwise) while counting the number of revolutions.

The steering wheel must complete approximately 7-9 revolutions, ±1/2 revolution, lock-to-lock.

2-15

INSPECTIONS 8. Sit in the forklift without touching the steering, set the direction switch to neutral, and check that the pump turns off.



Accelerator With the key switch set to “ON”, gradually push on the accelerator. The further pressed, the faster the forklift will operate. Let up on the accelerator and the forklift should come to a controlled stop. Check to make sure the control does not stick or catch. If any problems are detected, remove the forklift from service immediately until it is repaired.

Lift/Lower Control With the key switch turned “ON”, raise the mast. The hydraulic motor should start running as soon as the control is moved out of the neutral position and stop as soon as the control returns to the neutral position, except when lowering. The motor shouldn't run at all when lowering the mast, unless steering is active.

Check that the primary mast cylinder extends fully and that the lift carriage rises to the top of the inner rails before the secondary cylinders begin to move.



WARNING

NEVER place head, hands, arms, or feet in the mast area! Make sure there is sufficient room above the forklift to raise the mast safely.

When the lift carriage reaches the top of the inner rails, the secondary cylinders and middle rails begin lifting.

Check to make sure the rails travel smoothly and that there is no chatter or visible binding.

• With the mast fully extended, begin lowering the mast. The secondary cylinders and middle rails fully lower first, followed by the primary cylinder and the lift carriage. Check for smooth travel with no chattering or visible binding.

• If there is noticeable chatter or binding, immediately notify the supervisor or service personnel.

• DO NOT attempt to operate the forklift until the problem is repaired.

Tilt Control Move the tilt lever forward and aft, tilting the mast to both extents, watching for racking.

Racking occurs when the tilt cylinder strokes are uneven.

(One cylinder bottoms before the other).

2-16

The mast rails then twist, eventually causing them to crack and separate. Proper tilt degree adjust is 5° forward and 8° backward maximum.

CAUTION

If this problem is left uncorrected, serious damage to the mast assembly or the tilt cylinders can occur, causing the need for extensive repair and downtime.

1. To check for racking, find a reasonably level floor area to park the forklift on and center the mast on the forklift.

2. Raise the mast about 36” (914mm) from the floor and tilt the mast full forward and rearward several times watching for twisting at the ends of the stroke.

3. If there is any twisting or racking, both tilt cylinder rods must be readjusted. Remove the forklift from service immediately and repair.

Side-Shift Control At least once every working shift, the side shifting mechanism must be inspected for visible damage and defects. Any changes occurring with the mechanism or its workings must be reported immediately to the supervisor.

Moving parts of the side shifting mechanism entail the danger of pinching, crushing, or snagging. Safe distance must be maintained at all times to prevent clothing or body parts from being caught by the moving parts.

When side shifting, closely watch the load and forks throughout the entire operation to prevent over shift or snagging the load on other objects.

Operate the side shift only when the load is lifted off the ground.

Direction Control Check the direction control switch in both positions.

• When the direction control switch is pushed forward and the accelerator pressed the forklift should move forward.

• When the direction control switch is pushed backwards and the accelerator is pressed the forklift should move backwards.

Speed Switch Test to ensure that the fast and slow speed settings change the maximum speed of the forklift.

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INSPECTIONS

Return To Neutral When you move the direction control the forklift will shift to neutral. When this switch happens the forklift should slow to a stop.

Horn Press the horn button located beside the directional control on the right arm rest. Make certain the horn sounds when button is actuated.

Lights and Alarm Check lights for proper on/off operation. Check that alarms sound when intended. Repair and/or replace as needed.

Seat

SEAT SWITCH AND CABLE Figure 2-9: Seat Switch

Seat Switch

Seat Adjustment

The driver’s seat limit switch system includes an interlock that shuts down the drive and pump motors and disables the direction control (resets to NEUTRAL) bringing the forklift to a smooth “STOP”. The mast functions remain operable.

To check the seat switch: 1. Sit in the driver’s seat, set the key switch to “ON” and release the parking brake.

2. Set the control lever to “FORWARD” and slowly increase motor speed until the forklift begins to move.

3. Have operator lift from the seat far enough to release the seat switch. The forklift must immediately slow to a “STOP”, and steering is disabled.

4. If the forklift continued moving forward, it must be removed from operation and the seat switch must be replaced.

A lever under the front of the seat releases the catch for forward or backward seat adjustment. Weight or suspension adjustment is controlled by the hand wheel.

A gauge showing the adjusted level is located to the right of the adjustment hand wheel.

Rake Adjustment The rake adjustment has three adjustment positions.

Operation - Lift seat at the front corners. Adjust seat forward or backward until in position. Push front corners of seat down to lock in place.

Seat Belt Push the latch plate into the buckle until it clicks. Pull up on the latch plate to make sure it is secure. The lap part of the belt must be worn low and snug on the hips, just touching the thighs. Push the release button to release the seat belt.

2-17

INSPECTIONS

2-18

F-649-R0

Chapter 3

Scheduled Maintenance 1st 50 Hours or 2 Week Checklist Mast Chains The chain must be adjusted so each strand is under equal tension for proper load distribution and mast operation. To determine whether the chains are properly adjusted: 1. Remove load from forks.

2. Raise the mast to put the chains under tension.

3. Press the center of a strand of chain with your thumb, then press at the same place on the other chain of the pair.

4. Each chain in a pair should have equal “give”. If tension is not equal, adjust them as described in the manufacturer’s mast service manual.

4. Measure the distance from the floor to the bottom heel of each fork tine. Measurement must be 1/8” (3.175 mm) minimum to 1/4” (6.35 mm) maximum. If it is not within 1/8” to 1/4” (3.175 mm to 6.35 mm), adjust the primary lift chain accordingly.

Measuring Chain Stretch If the chains stretch beyond the recommended amount, they should be replaced in pairs. Chain stretch can be measured with a chain wear scale. See Figure 3-1. The scale indicates whether the distance between two chain links is within tolerance. The shaded area in the illustration compares a stretched chain to a new chain.

Measure the chains according to the instructions printed on the chain wear scale, without load on the carriage.

• To check the free lift chains, raise the carriage 1ft. (30 cm) off the ground to put tension on the chains.

• To check the main lift chains, raise the mast until the inner upright starts to extend putting tension on the chains.

Check Primary Lift Chain 1. Park the forklift on a flat, level surface.

2. Set the mast in the center of the forklift, facing straight ahead, level to the floor and empty (unloaded).

3. Set the key switch to “OFF”, remove the key and place the key in a secure area.

Figure 3-1: Measuring Chain Stretch

Check Lift Operation 1. Check the lift cylinders to ensure proper sequencing.

If adjustment is needed. “Check Primary Lift Chain” or See “Supplier Provided Documentation” on page 7-1.

2. Check to see that an unloaded mast will completely lift to full lift height (the relief opens). If it will not, check the hydraulic oil level in the reservoir and add oil if necessary.

3. Load the mast and raise it approximately to 5’ (1.524m), then quickly lower the mast until it is about 6” (152.4mm) above the floor and stop the mast abruptly.

4. Make sure the elevating channel rollers maintain proper contact with the mast channel.

3-1

SCHEDULED MAINTENANCE 5. Look for signs of galling where the rollers contact the rail. See Figure 3-4. Galling is indicated by track marks in the rails that are 1/4” to 1/2” (6.35mm to 12.7mm) wide running up the rail. Normal track marks are no more than 1/4” (6.35mm) wide.

6. If galling is detected, adjust the rollers for the proper clearance over the full length of the mast rails. See Chapter 5 for reference.

Load Backrest Fasteners for the load backrest may loosen due to vibration or weather conditions. Torque the backrest fasteners to 150 ft-lbs. (203 Nm).

Wheels and Tires Load Wheels should be inspected and re-torqued. See “Wheels and Tires” on page 2-10.

Hydraulic Oil Check Hydraulic oil should be checked and filled if necessary.

See “Hydraulic Oil” on page 2-11.

Steering Actuator The hydraulic coupling and mount bolts for the steering actuator should be re-torqued. See “Torque Specifications” on page 1-10.

Front Plate The front plate mounting bolts should be re-torqued. See “Torque Specifications” on page 1-10.

Gear Box The planetary drive gearbox assemblies (right and left side) are filled with oil at the factory. An oil change is necessary after the first 50 hours maximum of operation in order to remove particles worn down during the running-in phase.

Changing Gear Box Oil



CAUTION

If the forklift has been in operation recently for any period of time the oil could be very hot. Use special gloves and/or allow the forklift to cool completely before changing the oil. It is best to drain fluid while the unit is warm, but not HOT. NEVER drain oil into sewer lines.

3-2

1.

2.

3.

4.

5.

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

Park the forklift on a level surface.

Lower the forks all the way to the ground.

Apply the parking brake.

Set the key switch to the “OFF” position and remove the key from the console.

6. Disconnect the battery.

7. Begin a Lock Out/Tag Out procedure.

8. Make sure all the other wheels are securely blocked so that the forklift cannot move.

9. Raise the vehicle. Use jack stands or other suitable supporting device rated for the correct weight capacity.

10. Raise the drive wheels to allow the tires to rotate.

11. Remove the wheel from the gearbox being serviced.

12. Thoroughly clean the area around the fill and drain/level plugs.

13. To drain, turn the gear box so that one of the drain plugs is at the lowest point. If rotating the gear box proves difficult, brake a 2” X 4” (5cm X 10cm) block between the wheel studs and rotate. See Figure 3-2.

14. Place a drain pan capable of storing up to 32 ounces (1.0 liter) of fluid under the drain plug.

15. Using a 4 mm Allen key, unscrew the drain/level (position A) and fill (position B) plugs.

16. Drain the fluid completely into the drain pan.

17. Once the fluid has been drained, replace the drain/level plug in position A.

NOTICE In order to complete the following step you will need to undo the Lock Out/Tag Out and run the gearbox. After the gearbox has been run you will need to immediately redo the Lock Out/Tag Out. 18. Wash the interior of the gearbox with cleaning liquid as recommended by the lubricant manufacturer.

• Put liquid into the gearbox through the fill plug and replace the fill plug.

• Run the gearbox for a few minutes at high speed.

• Drain the cleaning fluid from the gearbox in the same way as described for draining the oil.

• Clean any contaminants from the magnetic trap and O-ring seal on the plugs.

19. To fill the gear box, turn until the drain/level hole in position A is about 15° below the horizontal center line of the gear box.

F-649-R0

SCHEDULED MAINTENANCE 20. Fill the gear box with synthetic gear lube through position B until fluid flows out from position A. Fluid capacity is approximately 1 pint (16 oz). DO NOT OVERFILL. 21. Install both plugs. Tighten to 25ft-lbs. (34Nm).

22. Wipe off any oil on the outside of the gear box.

23. Turn the gearbox a few times to eliminate any air pockets and recheck fluid level. The oil level should be checked again after a short driving period. Add more oil if necessary.

5mm HEX SOCKET BOLT

4mm HEX SOCKET FILL PLUG B 5mm HEX SOCKET BOLT

5mm HEX SOCKET BOLT

B 4mm HEX SOCKET FILL PLUG

4mm HEX SOCKET DRAIN/LEVEL PLUG

A

5mm HEX SOCKET BOLT

DRAINING THE PLANETARY GEARBOX

15° A

4mm HEX SOCKET DRAIN/LEVEL PLUG

FILLING THE PLANETARY BOX

Figure 3-2: Draining Gearbox

500 Hour or Monthly Inspections Operator’s Seat and Controls The first part of the 500 hour inspection is identical to the daily inspection of controls beginning with “Daily Inspections” on page 2-9 and continuing to the end of the inspection.

Hydraulic Maintenance Change the Hydraulic Oil Filter



CAUTION

After prolonged forklift use, hydraulic oil will become hot and can burn the skin. Allow hydraulic oil to cool to a tolerable temperature before performing this procedure.

1.

2.

3.

4.

5. Set the key switch to the OFF position and remove the key from the console.

6. Disconnect the battery.

7. Begin a Lock Out/Tag Out procedure.

8. Make sure all the other wheels are securely blocked so that the forklift cannot move.

9. Remove the floor mat and left floor plate. See Figure 5-4.

10. Using a clean, lint-free cloth, clean the area around the filter element housing and remove the filter housing cover.

11. Unscrew the hydraulic oil filter cap and remove the old filter, and replace. SEE FIGURE NN 12. Operate the hydraulic system by running the mast functions and observe the filter for oil leaks.

13. Check the hydraulic fluid level and reinstall the driver’s floorplate.

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

Park the forklift on a level surface.

Lower the forks all the way to the ground.

Apply the parking brake.

3-3

SCHEDULED MAINTENANCE

Brakes Service Brakes

Figure 3-3: Hydraulic Filter

Checking and Adjusting Hydraulic Pressure



WARNING

HIGH PRESSURE FLUIDS CAN BE DANGEROUS! Before continuing with this section, read about the warnings of pressurized hydraulic oil under “Hydraulic System” Warning page 1-7.

The service brakes are hydraulically-actuated, disc brakes, similar to an automotive disc brake system. They are installed to the gear box / motor assembly, on the rear wheels only.

The brakes should be checked every 500 hours of operation. Normal brake pad life is approximately 3,000 hours of operation, as determined by driving conditions. If the forklift is near or beyond this time frame, the brakes must be inspected.

New brake pads are approximately 0.265” (6.7mm) thick; replace them when the pad thickness is 0.0625” (1.588 mm) or less at the thinnest point.

A few indications of possible brake pad replacement are: • Excess travel of the service brake pedal • The forklift pulling to one side when the brakes are applied • Squealing when you apply the brakes Drive the forklift at creep speed and apply brakes lightly to determine if brakes pads are contacting the disc (rotor). You should feel a slight pulsating effect as the pads contact the disc.

Parking Brake The parking brake operation should be checked. See “Parking Brake” on page 2-10. The parking brake pad wear is also to be checked every 500 hours.

Wheels and Tires Hydraulic Hoses Check underneath the forklift for evidence of fluid leaks.

Look for hydraulic hose wear, damage, and leaks. Make sure clamps and fittings are tight. In the event that leaks are detected, immediate corrective action must be taken.

DO NOT operate the forklift until repairs are made and the hydraulic fluid level has been checked.

Tilt, Lift, and Side Shift Cylinders All of the cylinders should be checked for leaks and wear of the cylinder, if any leaks or unusual wear is discovered the forklift must be repaired before operating the forklift.

The tilt cylinder should also be greased and angles checked to be a maximum of 5° forward and 8° backward. The tilt cylinder jam nuts should also be tightened.

Steering

The wheels and tires should be checked for debris and the lug nuts re-torqued. See “Wheels and Tires” on page 2-10. The wheel bearings should also be repacked at this time. The disassembly and inspection procedure is detailed in “Disassembling and Inspecting Wheel Bearings” on page 5-40.

Motors and Gearboxes Drive and pump motor studs and bolts should be re-torqued. Cooling vents on the motors should be cleaned out. The hydraulic pump and gearboxes should be inspected for leaks.

General Mast Inspection Perform the following general mast inspections: 1. Check the lift cylinder for proper sequencing. See “Lift/Lower Control” on page 2-16.

The steering actuator and knob should be greased. See Figure 3-6. Inspect the rotation stops for wear and cracks and replace if necessary. Re-torque the stops.

3-4

F-649-R0

SCHEDULED MAINTENANCE 2. Check if the unloaded mast elevates to full lift (relief should open). If mast will not go to full lift, check the hydraulic fluid level in the reservoir and add fluid if required.

3. With load on forks in front carry position, elevate to approximately 5 feet (1.524 meters). Lower fast to within 6 inches (152.4mm) of floor and stop abruptly.

The mast should stop with a solid effect, if the forks rebound, bleed the hydraulic cylinder.

4. Check the carriage rollers and elevating channel rollers for proper contact with mating surface.

5. Look for signs of galling where the rollers contact the rail. See Figure 3-4.

• Galling is indicated by track marks in the rails that are 1/4” to 1/2” (6.35mm to 12.7mm) wide running up the rail. Normal track marks are no more than 1/4” (6.35mm) wide.

6. If galling is detected, adjust the rollers for the proper clearance over the full length of the mast rails.

7. Check for proper lift chain adjustments.

8. Check for chain contact with retaining lip on sheaves.

Figure 3-5: Fork Heel to Floor

Forks Forks should be inspected for wear and cracks. If you suspect that the 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.

Major Structural Points



CAUTION

Immediately pull forklift from service and repair if frame cracks are found.

Rust Or Corrosion

Figure 3-4: Channel Galling 9. Measure the distance from the floor to the bottom heel of each fork tine. See Figure 3-5. This measurement must be 1/8” (3.175mm) minimum to 1/4” (6.35mm) maximum.

10. If it is not within 1/8” to 1/4” (3.175mm to 6.35mm), adjust the primary lift chain accordingly.

11. Visually inspect the chains for cracks, stretched or stressed links and broken pins.

12. When raising the mast, listen for usual chain noise and watch the action of the chain for anything unusual.

13. Watch for unusual pulley movement or pulley wobble that would indicate a worn mast bearing.

Check the forklift frame, side panels, floor panels as well as mast assemblies for rust and corrosion. Clean rusty or corroded areas and repaint, if applicable. Apply a thin coat of oil to any bare metal surface.

Overhead Guard Check the overhead guard, making sure that it is firmly attached to the forklift and that all fasteners are secured.

The overhead guard is adjustable to accommodate various drivers and operating restrictions (low ceilings,

Battery The battery and restraints should be inspected as detailed in “Battery” on page 2-11.

3-5

SCHEDULED MAINTENANCE

Controllers and Wire Connections.

All of the wire connectors should be checked to ensure proper connection and that the connector does not show abnormal wear. Remove any dirt or debris from the controller surface. Check that all fuses are properly seated and that the contactor points are operating properly.

TILT CYLINDER

HYDRAULIC RESERVOIR

MAST CHAIN

RESERVOIR CAP STEERING KNOB

MAST RAIL

MASTER CYLINDER

STEERING ACTUATOR Figure 3-6: Lubrication Locations

Forklift Lubrication In the following procedures, the location of grease fittings or surfaces to be greased are by either a grease-gun or brush. See Figure 3-6. Before brush applying grease to bearing pad surfaces, wipe out the channel to remove any foreign matter that may have accumulated since your last lubrication.

3-6

GEAR CASE



DANGER

DO NOT service the forklift and/or mast area while the key switch is ON. If a joystick, steering wheel or accelerator pedal is accidentally moved, serious injury could occur.

F-649-R0

SCHEDULED MAINTENANCE 1. Before lubricating the forklift, lower the forks, set the key switch to the “OFF” position.

2. Certain grease fittings may include protective plastic caps. Remove them before applying grease.

Remember to replace the caps when finished.

3. Make sure all grease fittings are wiped clean before lubricating. If any of the fittings are corroded or blocked, replace them.

4. After a forklift cleaning, lubricate all unprotected grease fittings and metal-to-metal surfaces, located outside the forklift.

5. Interval frequency can be recorded from the running hours read on the hour meter in the driver’s compartment.

6. See “Lubrication Specifications” on page 1-10 for recommended lubricants.

Tilt Cylinder Fixed End Bearing 1. Start the forklift and pivot the mast straight forward to the normal carry position.

2. Set the key switch to “OFF”, remove the key from the key switch and place in a secure area.

3. Perform a Lock Out/Tag Out procedure.

4. Grease fitting on end of tilt cylinder until fresh grease is squeezed from the bearing. Wipe off excess grease. The rod end of the cylinder is a “lube free” bearing.

2000 Hour or Yearly Inspections Brake Fluid Change Brake fluid should be changed every 2000 hours. The process for this is listed in “Brake Hydraulics” on page 5-17.

Change Planetary Gear Box Oil The planetary drive gear box (right and left side) assemblies (2) are filled with oil at the factory. An oil change is necessary after the first 50 hours maximum of operation in order to remove particles worn down during the running-in phase. Thereafter, an oil change is only required once every 2000 hours or yearly, whichever comes first. Also, if the forklift has been in storage for one year or more, the oil should be changed before placing the forklift into operation. See Figure 3-2.

4500 Hour Inspection Hydraulic Oil Change Hydraulic oil should be changed every 4500 hours. The process for this is listed in “Changing Hydraulic Oil” on page 5-23.

Main Rotation Seals 1. Start the forklift and pivot the mast straight forward to the normal carry position.

2. Set the key switch to “OFF”, remove the key from the key switch and place in a secure area.

3. Perform a Lock Out/Tag Out procedure.

4. Grease the upper and lower front rotation seal fittings until fresh grease is squeezed from each seal bearing.

5. Wipe off excess grease.

Fork Positioner Lubrication (Option) 1. Start the forklift and position the mast straight ahead.

2. Set the key switch to “OFF”, remove the key from the key switch and place in a secure area.

3. Before lubricating the positioner rails, wipe off excess lubricant and dirt buildup from within the rail channels and dirt from the top and bottom of the rail grooves.

4. Using a brush, lubricate the top areas on the fork rails, including a thin film on the front face of both rails. Using a grease gun apply grease to the lower fork rails.

5. Wipe off excess grease.

3-7

SCHEDULED MAINTENANCE Table provided for general use.

NOTES:

3-8

F-649-R0

Chapter 4

Troubleshooting Preliminary Procedures

Troubleshooting Charts

Before performing any maintenance or repair to any part of the forklift read “Before You Begin” on page 1-1.

• Thoroughly review the problem with the operator to obtain a complete description of what is wrong.

• Observe 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, and/or have the operator read the Operator’s Manual (P/N F-648) provided with each forklift.

• If the problem is determined to be operator error, return the forklift to service and see that the operator is properly retrained before being allowed to drive the forklift.

• 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 a planned maintenance inspection of the forklift. See the Operator’s Manual or see the “Daily Inspection Checklist” on page 2-1.

• After the problem has been corrected, operate the forklift again to verify the repair and to ensure there are no additional problems. If no other problems exist, return the forklift to operation. If other problems are found, troubleshoot and repair them before returning the forklift to operation.

This chapter contains troubleshooting procedures to help diagnose and resolve problems. Once the problem is identified, refer to the referenced section for repair instructions.

Troubleshooting Chart procedures are arranged as: 1. Visual Problems 2. Audible Problems 3. Hydraulic Problems 4. Brake Problems 5. Electrical Problems

4-1

TROUBLESHOOTING

Visual Problems Problem Worn or damaged forks

Common Causes

Suggested Repairs/Corrections

Fatigue, age, or excessive lifting of overweight loads

• Replace both forks. See “Repairing Forks” on page 5-2.

• Replace faulty components and/or re-adjust. See “General Mast Inspection” on page 3-4.

• Re-lubricate. See “Forklift Lubrication” on page 3-6.

Out-of-adjustment mast Scrape marks on the mast Improper lubrication Frayed or broken wires

Improperly secured wires or harnesses

Hard starting and stopping

Excessive tire wear

Excessive overloading or improper weight distribution

Faulty load wheel bearings

Faulty drive motor Faulty gearbox Loose wheel lug nuts

Grease blotches around wheels

4-2

Faulty grease seal

• See dealer for service options • Replace the tire and review the proper operation of the forklift • For replacement. See “Wheels and Tires” on page 3-4.

• For proper operation review, see “Operating Instructions - Basic Procedures” in the Operator’s Manual (Landoll P/N F-648).

• NEVER attempt to lift a load heavier than the specified rating of the forklift.

• See “Traveling and Load Handling” in the Operator’s Manual (Landoll P/N F-648) for additional information.

• Replace. See “Disassembling and Inspecting Wheel Bearings” on page 5-40.

• Repair or replace. See “Replacing the Traction Drive Motor” on page 5-39.

• Replace. See “Replacing the Gear Box” on page 5-39.

• Tighten. See “Wheels and Tires” on page 3-4.

• Replace.

• For load wheels. See “Disassembling and Inspecting Wheel Bearings” on page 5-40.

• For drive wheels. See “Replacing the Gear Box” on page 5-39.

F-649-R0

TROUBLESHOOTING

Visual Problems Problem

Common Causes Cracked, split, or cut hoses/tubes

Loose or faulty hydraulic fittings

Leaking fluid Faulty hydraulic o-rings, seals, and/or gaskets

Faulty hydraulic pump

Suggested Repairs/Corrections • Replace. See “Hydraulic Fittings and Hoses” on page 5-29.

• Tighten or replace. See “Hydraulic Fittings and Hoses” on page 5-29.

• Replace faulty hydraulic o-rings, seals, and/or gaskets • For the hydraulic control valve assembly See “Hydraulic Control Valve Assembly” on page 5-26.

• For the steering orbital assembly See “Steering Orbital Control Unit” on page 5-32.

• For the hydraulic actuator assembly. See “Front Rotation Assembly” on page 5-33.

• For the in-tank filter assembly See “Change the Hydraulic Oil Filter” on page 5-24.

• For the tilt cylinders See “Removing the Tilt Cylinder” on page 5-3.

• For the lift cylinders See “Lift Technologies Mast Service Manual” on page 7-1.

• For the side shift cylinders See “Side Shift” on page 7-1.

• Replace. See “Replacing the Hydraulic Pump and Motor” on page 5-26.

4-3

TROUBLESHOOTING

Visual Problems Problem

Common Causes

Faulty hydraulic o-rings, seals, and/or gaskets

Puddles/leakage in area of the drive wheels

Loose or faulty hydraulic fittings

Faulty hydraulic pump

Faulty gearbox assembly

Loose or faulty brake line fittings

Faulty brake caliper

Loose hydraulic fittings

Faulty hoses/tubes

Puddles/leakage near mast Faulty hydraulic o-rings, seals, and/or gaskets

4-4

Suggested Repairs/Corrections • Replace faulty hydraulic o-rings, seals, and/or gaskets • For the hydraulic control valve assembly See “Hydraulic Control Valve Assembly” on page 5-26.

• For the steering orbital assembly See “Steering Orbital Control Unit” on page 5-32.For the in-tank filter assembly See “Change the Hydraulic Oil Filter” on page 5-24.

• Tighten and/or replace. See “Hydraulic Fittings and Hoses” on page 5-29.

• Replace. See “Replacing the Hydraulic Pump and Motor” on page 5-26.

• Repair or replace. See “Replacing the Gear Box” on page 5-39.

• Tighten and/or replace. See “Replacing Brake Lines” on page 5-10.

• Rebuild or replace. See “Replacing the Brake Caliper Assembly” on page 5-9.

• Tighten and/or replace. See “Hydraulic Fittings and Hoses” on page 5-29.

• Replace. See “Hydraulic Fittings and Hoses” on page 5-29.

• Replace faulty hydraulic o-rings, seals, and/or gaskets • For the hydraulic actuator assembly. See “Front Rotation Assembly” on page 5-33.

• For the tilt cylinders See “Removing the Tilt Cylinder” on page 5-3.

• For the lift cylinders See “Lift Technologies Mast Service Manual” on page 7-1.

• For the side shift cylinders See “Side Shift” on page 7-1.

F-649-R0

TROUBLESHOOTING NOTE If any unusual sounds are detected, attempt to pinpoint the location of the noise as well as what the forklift is doing.

Always check for loose parts or any extra debris that could cause the sound.

Audible Problems Problem

Common Causes Faulty backup alarm

Loose or disconnected connector Backup alarm does not sound Faulty connector Faulty harness wire Faulty directional control switch Loose or disconnected connector

Faulty connector Faulty harness wire Horn does not work

Faulty horn switch Blown fuse Faulty horn contactor Faulty horn Faulty service brake or parking brake assembly Faulty drive motor assembly

Unusual noise when forklift is in motion

Loose nuts and/or bolts Faulty gearbox Faulty wheel bearings

Suggested Repairs/Corrections • Check and/or replace. See “Back Up Alarms” on page 5-44.

• Fix connection. See “Controllers and Wire Connections.” on page 3-6.

• Replace. See “Controllers and Wire Connections.” on page 3-6.

• See dealer for service options • Replace See “Direction Control Lever” on page 5-21.

• Fix connection. See “Controllers and Wire Connections.” on page 3-6.

• Replace. See “Controllers and Wire Connections.” on page 3-6.

• See dealer for service options • Replace. See “Horn Service” on page 5-43.

• Replace. See “Fuses” on page 5-45.

• Replace. See “Inspecting the Contactors” on page 5-21.

• Replace. See “Horn Service” on page 5-43.

• Repair and/or replace. See “Brakes” on page 5-5.

• Repair or replace. See “Replacing the Traction Drive Motor” on page 5-39.

• Tighten • Replace. See “Replacing the Gear Box” on page 5-39.

• Replace. See “Disassembling and Inspecting Wheel Bearings” on page 5-40.

4-5

TROUBLESHOOTING

Audible Problems Problem

Common Causes Faulty wheel bearings Loose drive wheel lug nuts Faulty steering orbital assembly

Unusual noise when forklift is turning

Faulty steering actuator assembly

Faulty hydraulic pump

Faulty hydraulic pump motor assembly Loose nuts and/or bolts Mast components are out of alignment Damaged mast components

Unusual noise when lifting or lowering a load

Faulty hydraulic pump

Faulty hydraulic pump motor assembly Faulty hydraulic control valve assembly

4-6

Suggested Repairs/Corrections • Replace. See “Disassembling and Inspecting Wheel Bearings” on page 5-40.

• Tighten • Repair and/or replace. See “Steering Orbital Control Unit” on page 5-32.

• Repair and/or replace. See “Removing the Steering Actuator” on page 5-33.

• Replace. See “Replacing the Hydraulic Pump and Motor” on page 5-26.

• Repair and/or replace. See “Replacing the Hydraulic Pump and Motor” on page 5-26.

• Tighten • Re-align. See “General Mast Inspection” on page 3-4.

• Replace. See “Removing the Mast From the Forklift” on page 5-2.

• Replace. See “Replacing the Hydraulic Pump and Motor” on page 5-26.

• Repair and/or replace. See “Replacing the Hydraulic Pump and Motor” on page 5-26.

• Repair and/or replace. See “Hydraulic Control Valve Assembly” on page 5-26.

F-649-R0

TROUBLESHOOTING

Audible Problems Problem

Common Causes Low hydraulic oil

Faulty hydraulic pump motor

Faulty hydraulic pump

Unusual noise when using the hydraulics

Faulty hydraulic cylinders

Faulty steering orbital assembly

Faulty steering actuator assembly Faulty hydraulic control valve assembly

Suggested Repairs/Corrections • Refill. See “Hydraulic Oil” on page 2-11.

• Repair and/or replace. See “Replacing the Hydraulic Pump and Motor” on page 5-26.

• Replace. See “Replacing the Hydraulic Pump and Motor” on page 5-26.

• Repair and/or replace.

• For the tilt cylinders See “Removing the Tilt Cylinder” on page 5-3.

• For the lift cylinders See “Lift Technologies Mast Service Manual” on page 7-1.

• For the side shift cylinders See “Side Shift” on page 7-1.

• Repair or replace. See “Steering Orbital Control Unit” on page 5-32.

• Repair or replace. See “Removing the Steering Actuator” on page 5-33.

• Repair or replace. See “Hydraulic Control Valve Assembly” on page 5-26.

4-7

TROUBLESHOOTING NOTE Low hydraulic pressure can cause most hydraulic systems to act in an unexpected manner. Check the Low Hydraulic Pressure section before checking other specific sections.

Hydraulic Problems Problem

Common Causes

Suggested Repairs/Corrections

Fluid viscosity too heavy to pick up prime

• Change out the hydraulic oil See “Hydraulic Oil” on page 5-23.

• Check reservoir oil level: Replenish as needed. See “Hydraulic Oil” on page 2-11.

• Check the strainer and filter, Clean and/or replace See “Change the Hydraulic Oil Filter” on page 5-24.

• Check, re-adjust, and/or replace the hydraulic relief valve. See “Hydraulic Control Valve Assembly” on page 5-26.

• Check hydraulic system for leaks: Repair or replace as needed.

• Replace the pump motor. See “Replacing the Hydraulic Pump and Motor” on page 5-26.

• NEVER attempt to lift a load heavier than the specified rating of the forklift.

• See “Traveling and Load Handling” in the Operator’s Manual (Landoll P/N F-648) for additional information.

• Replace damaged parts. See “Removing the Mast From the Forklift” on page 5-2.

• Check for misadjustment of mast See “Removing the Mast From the Forklift” on page 5-2.

• Repair or replace affected cylinder. See “General Mast Inspection” on page 3-4.

• Repair or replace damaged or worn parts. See “Hydraulic Control Valve Assembly” on page 5-26.

Low hydraulic oil

Dirty or clogged filters Low Hydraulic Pressure Misadjusted or faulty hydraulic relief valve Leaks in the hydraulic system

Faulty hydraulic pump

Excessive load, i.e., attempting to lift loads beyond the capacity of the forklift

Mast does not lift load

Mechanical damage of the mast

Lift cylinders leaking or binding

Faulty hydraulic control valve assembly

4-8

F-649-R0

TROUBLESHOOTING

Hydraulic Problems Problem

Common Causes

Excessive load, i.e., attempting to lift loads beyond the capacity of the forklift

Mast lifts slowly, i.e., loss of lift speed

Mechanical damage of the mast

Lift cylinders leaking or binding

Hydraulic pump motor assembly encoder faulty or not plugged in

Excessive load, i.e., attempting to lift loads beyond the capacity of the forklift

Mast drifts downward

Lift hydraulic cylinders leaking or binding Air in cylinder

Bad check valve

Faulty tilt directional control valve Mast does not tilt Tilt cylinders leaking or binding

Suggested Repairs/Corrections • NEVER attempt to lift a load heavier than the specified rating of the forklift.

• See “Traveling and Load Handling” in the Operator’s Manual (Landoll P/N F-648) for additional information.

• Replace damaged parts. See “Removing the Mast From the Forklift” on page 5-2.

• Check for misadjustment of mast See “Removing the Mast From the Forklift” on page 5-2.

• Repair or replace affected cylinder. See “General Mast Inspection” on page 3-4.

• Make sure the pump motor encoder is plugged into the forklift harness.

• Replace the pump motor encoder.

• NEVER attempt to lift a load heavier than the specified rating of the forklift.

• See “Traveling and Load Handling” in the Operator’s Manual (Landoll P/N F-648) for additional information.

• Repair or replace affected cylinder. See “General Mast Inspection” on page 3-4.

• Bleed the hydraulic system. See “Lift Technologies Mast Service Manual” on page 7-1.

• Replace check valve See “Hydraulic Control Valve Assembly” on page 5-26.

• Replace faulty parts See “Hydraulic Control Valve Assembly” on page 5-26.

• Repair or replace affected cylinder. See “Removing the Tilt Cylinder” on page 5-3.

4-9

TROUBLESHOOTING

Hydraulic Problems Problem

Common Causes Improperly sized tires

Damaged tires

Steering drifts/wanders, is erratic, or forklift turns to slowly

Worn or loose wheel bearing cones

Faulty steering orbital assembly

Air in the hydraulic system

Improperly sized tires

Damaged tires

Worn or loose wheel bearing cones

Inside drive wheel not dropping out Hard steering effort in one or both directions Components in steering linkage binding or making noise

Restriction in fluid return tube Faulty steering orbital assembly

Faulty load sense valve

4-10

Suggested Repairs/Corrections • Check tire part numbers found in the Bendi AC/DS Parts Manual (Landoll P/N F-647) • Check, repair, and/or replace tire See “Wheels and Tires” on page 3-2.

• Check, repack, and/or replace faulty wheel bearing cones. See “Disassembling and Inspecting Wheel Bearings” on page 5-40.

• Replace See “Steering Orbital Control Unit” on page 5-32.

• Tighten loose inlet connections.

• Bleed the hydraulic system. See “Steering Orbital Control Unit” on page 5-32.

• Check tire part numbers found in the Bendi AC/DS Parts Manual (Landoll P/N F-647) • Check, repair, and/or replace tire See “Wheels and Tires” on page 2-10.

• Check, repack, and/or replace faulty wheel bearing cones. See “Disassembling and Inspecting Wheel Bearings” on page 5-40.

• Check steer sensor settings and adjust as needed • Check steer sensor and replace as needed • Repair or replace affected parts • For the steering column assembly See “Steering Column and Dash Display Assembly” on page 5-35.

• For the steering orbital assembly See “Steering Orbital Control Unit” on page 5-32.

• Remove line, clean, and/or replace. See “Hydraulic Fittings and Hoses” on page 5-29.

• Replace See “Steering Orbital Control Unit” on page 5-32.

• Clean inspect, and/or replace load sense cartridge. See “Steering Orbital Control Unit” on page 5-32.

F-649-R0

TROUBLESHOOTING

Hydraulic Problems Problem

Common Causes

Suggested Repairs/Corrections

Steering wheel loose on column or stripped

• Check, re-torque, and/or replace the steering wheel locking nut.

• Tighten loose inlet connections.

• Bleed the hydraulic system. See “Steering Orbital Control Unit” on page 5-32.

• Change the drive direction immediately to prevent seizure.

• Check and replace parts as needed. See “Replacing the Hydraulic Pump and Motor” on page 5-26.

Air in the hydraulic system Lost motion at the steering wheel

Pump driven in the wrong direction of rotation after servicing Coupling or shaft sheared or disengaged between hydraulic pump and pump motor

4-11

TROUBLESHOOTING

Hydraulic Problems Problem

Common Causes Cracked or cut hoses or tubes

Loose or faulty hydraulic fittings

Leaking hydraulic oil Faulty hydraulic o-rings, seals, and/or gaskets

Air leaks at the intake or shaft seal

Hydraulic pump making noise

Damaged hydraulic pump or hydraulic pump motor assembly mounting Faulty hydraulic pump

4-12

Suggested Repairs/Corrections • Replace See “Hydraulic Fittings and Hoses” on page 5-29.

• Tighten and/or replace. See “Hydraulic Fittings and Hoses” on page 5-29.

• Replace faulty hydraulic o-rings, seals, and/or gaskets • For the hydraulic control valve assembly See “Hydraulic Control Valve Assembly” on page 5-26.

• For the steering orbital assembly See “Steering Orbital Control Unit” on page 5-32.

• For the hydraulic actuator assembly See “Front Rotation Assembly” on page 5-33.

• For the in-tank filter assembly See “Change the Hydraulic Oil Filter” on page 5-24.

• For the tilt cylinders See “Removing the Tilt Cylinder” on page 5-3.

• For the lift cylinders See “Lift Technologies Mast Service Manual” on page 7-1.

• For the side shift cylinders See “Side Shift” on page 7-1.

• Check and replace the faulty intake line and/or hydraulic pump. See “Hydraulic System Components” on page 5-25.

• Repair or replace. See “Replacing the Hydraulic Pump and Motor” on page 5-26.

• Replace. See “Replacing the Hydraulic Pump and Motor” on page 5-26.

F-649-R0

TROUBLESHOOTING

Brake Problems Problem

Common Causes Low fluid level in master cylinder reservoir Air in the brake lines

Service brakes DO NOT stop the forklift

Faulty brake pedal Worn brake pads Brake pad contamination

Brake pedal is soft or spongy

Air in the brake line

Parking brake does not keep the forklift still

Faulty or out-of-adjustment parking brake cable system

Suggested Repairs/Corrections • Refill See “Service Brakes” on page 2-11.

• Bleed the brake lines See “Bleeding Brakes” on page 5-19.

• Repair or replace faulty parts.

See “Service Brake Pedal Assembly” on page 5-20.

• Replace. See “Changing Brake Pads” on page 5-10.

• Clean and/or replace. See “Changing Brake Pads” on page 5-10.

• Bleed the brake lines See “Bleeding Brakes” on page 5-19.

• Re-adjust and/or replace. See “Parking Brake Assembly” on page 5-11.

4-13

TROUBLESHOOTING

Electrical Problems Problem

Frayed or broken wires

Cause

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

Lights DO NOT work

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

Intermittent electrical problems

Loose electrical connections

4-14

Suggested Repair • See dealer for service options.

• See “Forklift Calibration” on page 6-2.

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

• Check fuse labeled “Lights.”

• See dealer for service options • Continuity check on/off switches replace as needed See “Forklift Calibration” on page 6-2.

• Check for excessive vibration or poor maintenance procedures.

• Tighten contacts as needed.

• Examine cable assemblies for tight connections. See “Forklift Calibration” on page 6-2.

• See dealer for service options.

F-649-R0

Chapter 5

Corrective Maintenance Corrective Maintenance This section is divided by features. For each feature, major adjustment and/or settings, mechanical repairs, and electrical control system repairs are addressed.

NOTICE As a Safety Reminder, Duplicate Safety Information and Precautions from Chapter 1 will be shown.

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.



WARNING

• Damage to personnel and the forklift will result if service work is attempted without proper qualified experience.

• It is recommended to always use Landoll replacement parts when performing any forklift maintenance.

• Failure to use correct replacement parts may result in a failure which may cause serious injury or death.





CAUTION

To be certain the forklift will not move, place wedges, e.g., or blocks of wood at the front and back of the tires. When servicing the brakes or tires, place the block at the front and rear of the tire farthest away from the one being serviced, i.e., the tire on the opposite side of the forklift and at the opposite end.

• Be sure to use the proper nuts, bolts, and other fasteners. Many are specifically rated: SAE Grade 5, SAE Grade 8, ISO Prop Class 8.8, etc. must be replaced with the identical type.

• Whenever possible, return the forklift to a service area having sufficient lighting, work space and an assortment of tools needed to complete the repair.

• Set the key switch to the OFF position and remove the key from the console.

• Set the direction control lever to NEUTRAL and set the parking brake.

• Read and follow the safety and standards information in chapter 1.

WARNING

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.

5-1

CORRECTIVE MAINTENANCE

Mast and Front End Removing the Forks 1.

2.

3.

4.

5.

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

Park the forklift on a level surface.

Lower the forks all the way to the ground.

Apply the parking brake.

Set the key switch to the “OFF” position and remove the key from the console.

Disconnect the battery.

Begin a Lock Out/Tag Out procedure.

Slide the fork so the hook on the fork lines up with the notch on the bottom of the front plate.

Pull the fork tine upward until the hook is free of the carriage. See Figure 5-1.

6.

7.

8.

9.

Repairing Forks The following information is provided for authorized service facilities ONLY. If you suspect that the 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. A fork that has undergone repairs, other 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.

Removing the Mast From the Forklift 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 3 tons and 3 or 4 6” x 6” x 48” (152 mm x 152mm x 1,219 mm) solid planks of wood.

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

Record the roller clearances and chain adjustments before removing the front plate or rails.

Make notes as you disassemble the mast while referring to “Supplier Provided Documentation” on page 7-1.

 Figure 5-1: Changing Forks

NOTICE 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 if from the front plate.

10. Lift the fork off of the front plate. Various forks can be heavy - use adequate lifting apparatus or ask for a helper as needed.

11. To replace forks, perform steps 9 through 11 in reverse order.

5-2

WARNING

• The mast may swing from the lift forklift, be alert and cautious!

• 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.

• Be careful! If the top of the mast is lower than the bottom of the mast when laying flat, the carriage will slide to the top, causing damage to the mast or even injury. It is recommended to secure the carriage to the mast if possible.

F-649-R0

CORRECTIVE MAINTENANCE 1.

2.

3.

4.

5.

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

Park the forklift on a level surface.

Lower the forks all the way to the ground.

Apply the parking brake.

Set the key switch to the “OFF” position and remove the key from the console.

6. Disconnect the battery.

7. Begin a Lock Out/Tag Out procedure.

8. Remove the forks.

9. Remove the two bolts and hardware holding the backrest to the mast. Carefully remove the backrest; it can be heavy - use adequate lifting apparatus or ask for a helper.

10. Attach an overhead crane and strap, rated to 3 tons, and apply slight lift to the mast. See Figure 5-2.

11. Visually inspect the chains for cracks, stretched or stressed links and broken pins. When raising the mast, listen for usual chain noise and watch the action of the chain for anything unusual. Watch for unusual pulley movement or pulley wobble that would indicate a worn mast bearing.

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

STRAP

16. Lay the mast horizontally, carriage side facing up, across three or four 6” x 6” x 48” (152 mm x 152 mm x 1,219 mm) planks of wood.

17. Dismantle, clean and inspect the mast assemblies and subassemblies as instructed in “Supplier Provided Documentation” on page 7-1.

18. Reassemble the mast in reverse order, using your notes as necessary.

19. Before returning the mast to service, perform all adjustment procedures listed in enclosed “Supplier Provided Documentation” on page 7-1.

Removing Front Plate Assembly 1.

2.

3.

4.

5.

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

Park the forklift on a level surface.

Lower the forks all the way to the ground.

Apply the parking brake.

Set the key switch to the “OFF” position and remove the key from the console.

6. Disconnect the battery.

7. Begin a Lock Out/Tag Out procedure.

8. Complete steps 2-10 of “Removing the Mast From the Forklift” on page 5-2.

9. Hook up a hoist to the front plate assembly and put slight tension on the strap.

10. Remove and mark the hoses to the tilt cylinder. Cap and plug the hoses and cylinder to keep dirt out.

11. Remove the 7/8-9 X 2-1/4” bolts securing the Front Plate Assembly to the frame.

Removing the Tilt Cylinder NOTES Only apply these steps if the mast has been removed.

40D, 45D & 50D SERIES Figure 5-2: Supporting the Mast 13. 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.

14. Remove the four hex head cap screws (5/8-11 x 2-1/2”), the lower mast pins and hardware. See Figure 5-3.

15. Raise the mast enough to release the mast hooks from their supports.

1.

2.

3.

4.

5.

6.

7.

8.

9.

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

Park the forklift on a level surface.

Lower the forks all the way to the ground.

Apply the parking brake.

Set the key switch to the “OFF” position and remove the key from the console.

Disconnect the battery.

Begin a Lock Out/Tag Out procedure.

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.

5-3

CORRECTIVE MAINTENANCE 10. Mark the location of the cylinder jam nut for reassembly to the new cylinder.

NOTICE The jam nut is usually at the end of the threads closest to the barrel of the cylinder.

11. 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 5-3.

NOTICE If mast has not been removed, the mast and masthead weldment will fall forward to main rotation pin placement.

12. On the front rotation plate side, remove the bolt and hardware holding the tilt cylinder in on the front rotation plate.

NOTICE To repair the tilt cylinder, replace seals, wiper, O-rings, etc., see Parts Manual (Landoll P/N F-647).

13. Reconnect cylinder to mast assembly in reverse order.

HEX SHOULDERED SCREW TILT CYLINDER TILT CYLINDER PIN

2-1/2” HEX SCREW

LOWER MAST PIN

HELICAL LOCKING WASHER

Figure 5-3: Mast Assemblies

5-4

F-649-R0

CORRECTIVE MAINTENANCE

Floor Plate Removal

Brakes

The right floor panel provides access to the accelerator assembly which is mounted to the underside of the right floor plate. The master cylinder and service brake pedal and linkage are mounted within the frame well, under the left floor panel.

1. Thoroughly clean the floor area using a vacuum.

2. Without tearing, pull up the rubber floor mat.

3. Remove the left floor plate from the forklift frame.

See Figure 5-4.

4. Carefully lift the right floor plate. The accelerator pedal assembly will still be attached to the right floor plate.

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

5. Reassemble in reverse order.

FLOOR MAT

RIGHT FLOOR PLATE

LEFT FLOOR PLATE

ACCELERATOR MODULE Figure 5-4: Floor Plate 6. To remove the floor mat, remove two fasteners that hold floor mat in place. The fastener passes through the floor mat and floor plate to hold mat on forklift.

Remove floor plate to expose right side floor plate fasteners.

General Information Braking of the Bendi AC/DS forklift is accomplished by using the drive motor for restraining forklift, or by putting pressure on the brake pedal. When the accelerator is released, the moving motion of the forklift is restrained by the drive motors and occurs in both the forward and reverse direction. Stopping the forklift can also be done by the normal pressing of the brake pedal.

• If a problem is suspected, DO NOT release or drive the forklift until the problem is corrected.

• Safety must always be paramount when working on brake system components.

• Parts that are not in perfect working condition should not be used. It is recommended to only use genuine Landoll parts.

• If you are unsure about a procedure, contact a trained Landoll service technician.

• Wear eye protection. If brake fluid comes in contact with eyes, immediately rinse 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 brake fluid during brake maintenance.

• Brake pads must be replaced on both wheels at the same time. NEVER replace the pads on only one wheel to ensure that both sides have equal braking and to prevent premature wear and uneven braking action.

• DO NOT use petroleum based solvents to clean brake parts. Use only brake cleaner or denatured alcohol.

• DO NOT use compressed air to blow particles from the brake assembly.

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

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

• The disc brakes are inherently self-adjusting. NO adjustments are necessary or provided.

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

5-5

CORRECTIVE MAINTENANCE

Check Service Disc Brakes

Required Tools

• The service brakes are hydraulically-actuated disc brakes, similar to an automotive disc brake system.

The brake calipers are installed onto the gearbox/motor assembly at the rear of the forklift.

• The brakes should be checked every 100 hours of operation. Normal brake pad life should reach approximately 3,000 hours of operation, but that figure can vary widely as determined by the operator and driving conditions. If you are near or beyond this time frame, you must inspect the brakes.

• New brake pads are approximately 0.265” (6.7 mm) thick. Replace them when the pad thickness is 0.0625” (1.588 mm) or less.

• The service brake pedal must also have about 1/2” (12.7 mm) of the travel remaining when the brakes are fully applied. If less than 1/2” (12.7 mm) is available, check the pads for wear and replace as needed.

• Drive the forklift at creep speed and apply brakes lightly to determine if brake pads are contacting the disc (rotor). You should feel a slight pulsating effect as the pads contact the disc.

Both SAE and metric open-end, box-end, Allen and adjustable wrenches along with assorted sockets and screwdrivers should be available to properly perform maintenance and repair.

• Rotors require a dial gauge to check run-out, and a micrometer, calibrated in ten-thousandths of an inch, to check thickness.

• To remove the rotor you will need a rubber mallet (dead-blow hammer) and a gear puller. DO NOT use an unprotected hammer.

• An ohm meter is required to test the parking brake switch.

• Brake rotor is fitted with threaded holes to ease disk removal. Use automatic steering wheel puller to prevent drive motor damage.

A few indications of possible brake pad replacement are: • Excess travel of the service brake pedal.

• The forklift pulling to one side when the brakes are applied.

• Squealing is heard when you apply the brakes.



CAUTION

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



CAUTION

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

5-6

F-649-R0

CORRECTIVE MAINTENANCE

BRAKE CALIPER SHIMS

BRAKE CALIPER ASSEMBLY

ROTOR

3/8-24 X 1-1/2 HEX HEAD SCREW

BLEEDER SCREWS

DRIVE MOTOR

5/16-18 X 1-1/4 HEX HEAD SCREW BRAKE CALIPER MOUNT

DRIVE END

Figure 5-5: Brake Assembly

Disc Brake Rotors

•

General Information • Whenever servicing and/or replacing a rotor assembly, you must service both sides of the forklift to prevent premature wear and uneven braking action.

• Check the rotors for scoring, cracks, deep grooves, raised lip on the outer edge, signs of overheating, rotor run-out or other damage. Rotor run-out should be measured while the rotor is being installed.

• Rotor thickness measurements may be checked with the rotor installed or removed from the forklift. Use a dial gauge to check run-out. Use a calibrated micrometer, calibrated in ten-thousandths of an inch, to check thickness. See Figure 5-6.

• Measure thickness, using a micrometer, at four or more points on the rotor and make sure all measurements are taken at the same distance inwards from the outer edge of the rotor.

• Thickness variations of more than 0.0005” (0.013 mm) can cause pedal pulsation and/or vibration when applying the brakes. A rotor that does not meet these specification must be replaced.

Figure 5-6: Dial Gauge

Check Lateral Run-Out (Warping) 1. First, review “Before You Begin” on page 1-1.

5-7

CORRECTIVE MAINTENANCE 2.

3.

4.

5.

Park the forklift on a level surface.

Lower the forks all the way to the ground.

Apply the parking brake.

Set the key switch to the “OFF” position and remove the key from the console.

6. Disconnect the battery.

7. Begin a Lock Out/Tag Out procedure.

8. Raise, jack up, and block both sides of the forklift to allow the drive wheel to rotate freely. See Figure 1-3.

9. Secure the dial indicator to the drive wheel electric motor casing so that the indicator button contacts the rotor at about 0.50” (13 mm) from the outer edge of the rotor. Set the dial indicator to zero.

10. SLOWLY turn the rotor (wheel/tire) by hand by one or two revolutions and observe the total indicated run-out.

11. If the run-out exceeds 0.0031” (0.08mm), replace the rotor. DO NOT resurface the rotor.

Replacing the Brake Rotor Assemblies



CAUTION

• To remove the roto disk, you will need a puller and a rubber mallet (dead-blow hammer). DO NOT pry on rotor as this may bend motor shaft. DO NOT USE an unprotected hammer as damage to the rotor will render it unserviceable.

• When handling the new rotor protect the finish surfaces from damage, such as nicks, deep scratches, dents from dropping, corrosion, oil or grease contamination, etc.

Damage to the braking surfaces renders the rotor and pads defective.

8. Make sure all the other wheels are securely blocked so that the forklift cannot move.

9. Remove the battery.

10. Remove the battery tray.

11. Remove the 3/8”-24 X 1-1/2” hex head cap screws securing the brake caliper assembly to the mounting plate. Capture the spacers (if used) and keep any shims separate for each side.

12. Remove brake caliper assembly.

13. Loosen the flanged hex nut (3/4-16, Grade 8) and hardware from the motor shaft. DO NOT remove the nut from the assembly at this time.

14. The brake rotor is fitted with 2-3/8-16 threaded holes to allow the use of a steering wheeel puller.

15. Loosen the bolts mounting holding the motor to the frame enough to move the motor out to allow a gear puller to be put on the brake rotor.

16. Depending on the model and the amount of clearance available, you may have to remove one of the drive motor to remove the rotor from the armature.

NOTICE The removal of the drive motor can be done as a completed assembly. It needs to be slid out just enough for the rotor to clear.

17. Slide the rotor assembly from the keyed drive shaft and discard. DO NOT lose the woodruff key.

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

19. Install the new rotor to the keyed drive shaft. Install, tighten and torque the flange hex nut at 150ft.lbs.

(203Nm).

20. Reassemble in reverse order.

NOTICE If the rotor must be replaced on a Bendi B30, you must loosen the drive motor and move it out slightly to allow room to remove the rotor. On a B40 moving the motor laterally is not required.

1.

2.

3.

4.

5.

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

Park the forklift on a level surface.

Lower the forks all the way to the ground.

Apply the parking brake.

Set the key switch to the “OFF” position and remove the key from the console.

6. Disconnect the battery.

7. Begin a Lock Out/Tag Out procedure.

5-8

F-649-R0

CORRECTIVE MAINTENANCE

Replacing the Brake Caliper Assembly

Repairing Brake Caliper Pistons

NOTICE

NOTICE

If the brake caliper piston freezes up or shows signs of leakage, it must be repaired or replaced.

Whenever servicing or replacing a caliper assembly or internal parts, you must service both sides of the forklift to prevent premature wear and uneven braking action.

Whenever servicing or replacing a caliper assembly, you must service both sides of the forklift to prevent premature wear and uneven braking action. Whenever a brake caliper is disconnected, the entire brake system must be purged of old brake fluid.



CAUTION

DO NOT apply too much air pressure to the bore, or the piston will eject and cause damage to the piston and/or technician. Stand back from the piston while air is being applied.

1.

2.

3.

4.

5.

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

Park the forklift on a level surface.

Lower the forks all the way to the ground.

Apply the parking brake.

Set the key switch to the “OFF” position and remove the key from the console.

6. Disconnect the battery.

7. Begin a Lock Out/Tag Out procedure.

8. Make sure all the other wheels are securely blocked so that the forklift cannot move.

9. Remove the battery.

10. Remove the battery tray.

11. Remove the 3/8”-24 X 1-1/2” hex head cap screws securing the brake caliper assembly to the mounting plate. Capture the spacers (if used) and keep any shims separate for each side.

12. Disconnect the brake lines, using a flare-nut wrench.

Plug or cap the ends to avoid fluid loss and contamination.

13. Remove brake caliper assembly 14. Install the new caliper assembly in reverse order making sure the brake pads are properly installed.

15. Bleed the brakes. “Bleeding Brakes” on page 5-19.

1.

2.

3.

4.

5.

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

Park the forklift on a level surface.

Lower the forks all the way to the ground.

Apply the parking brake.

Set the key switch to the “OFF” position and remove the key from the console.

6. Disconnect the battery.

7. Begin a Lock Out/Tag Out procedure.

8. Make sure all the other wheels are securely blocked so that the forklift cannot move.

9. Remove the battery.

10. Remove the battery tray.

11. Remove the 3/8”-24 X 1-1/2” hex head cap screws securing the brake caliper assembly to the mounting plate. Capture the spacers (if used) and keep any shims separate for each side.

12. Disconnect the brake lines, using a flare-nut wrench.

Plug or cap the ends to avoid fluid loss and contamination.

13. Remove the brake caliper assembly from the forklift.

14. Restrain the piston in the caliper to stop the piston, then lightly apply compressed air to the inlet port.

15. Once the piston releases, remove the O-ring seals and discard. Be careful not to scratch metal surfaces.

DO NOT use metal tools when removing the seal.

16. Remove both bleeder screws.

17. Inspect the piston and the caliper housing bore for corrosion, worn plating, scoring, nicks, etc. Crocus cloth may be used to polish out light corrosion only. If extensive corrosion exists, the entire brake caliper assembly must be replaced.

18. Thoroughly wipe out the bore area and clean all parts, lubricate the pistons, caliper, and O-ring seals with fresh DOT #3 brake fluid.

19. Install the O-ring seal to the pistons and slide the pistons into the housing bore. Make sure the O-ring seals DO NOT twist as the piston is inserted.

20. Bottom out the piston into the bore and install the new brake pads.

21. Reinstall caliper assembly onto caliper bracket.

5-9

CORRECTIVE MAINTENANCE 22. Bleed the brakes. “Bleeding Brakes” on page 5-19.

Replacing Brake Lines 1.

2.

3.

4.

5.

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

Park the forklift on a level surface.

Lower the forks all the way to the ground.

Apply the parking brake.

Set the key switch to the “OFF” position and remove the key from the console.

6. Disconnect the battery.

7. Begin a Lock Out/Tag Out procedure.

8. Make sure all the other wheels are securely blocked so that the forklift cannot move.

9. Remove the battery.

10. Remove the battery tray.

11. Disconnect the brake lines, using a flare-nut wrench.

Plug or cap the ends to avoid fluid loss and contamination.

12. Remove the 1/4-20 hex nuts that hold the brake lines in place.

13. Install the new brake line into the retaining clamps and re-install the brake line into the forklift.

14. Refill the brake fluid and bleed the brakes.

“Bleeding Brakes” on page 5-19.

Changing Brake Pads 1.

2.

3.

4.

5.

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

Park the forklift on a level surface.

Lower the forks all the way to the ground.

Apply the parking brake.

Set the key switch to the “OFF” position and remove the key from the console.

6. Disconnect the battery.

7. Begin a Lock Out/Tag Out procedure.

8. Make sure all the other wheels are securely blocked so that the forklift cannot move.

9. Remove the battery.

10. Remove the battery tray.

11. Remove the 3/8”-24 X 1-1/2” hex head cap screws securing the brake caliper assembly to the mounting plate. Capture the spacers (if used) and keep any shims separate for each side.

12. If preferred, although not necessary, disconnect the brake lines, using a flare-nut wrench. Plug or cap the ends to avoid fluid loss and contamination.

13. Be prepared to clean any brake fluid spills. DO NOT spill brake fluid on caliper housing.

5-10

14. Remove the two outer hex head screws and hardware to allow pads to be removed from caliper assembly.

15. Remove both old disc brake pads.

16. Push the piston into the caliper bore to provide clearance between the new brake pads and the rotor during reassembly.

17. Check the contact surfaces of the brake rotor for cracks, score marks, deep grooves, a raised lip on the outer edge, signs of overheating, or rotor run-out.

If any of these are present, the rotor must be replaced. “Disc Brake Rotors” on page 5-7.

NOTICE If the rotor must be replaced on a Bendi B30, you must loosen the drive motor and move it out slightly to allow room to remove the rotor. On a B40 moving the motor laterally is not required.

18. Look for the presence of surface glazing, grease or brake fluid on the brake pad contact surfaces.

Grease and brake fluid can be removed using denatured alcohol or brake cleaner. However, if the pads become contaminated, they must be replaced.

19. Check the brake lines for cracking, splits or any apparent weakness. If any problem is detected replace the brake line.

20. Check all brake caliper pistons for signs of fluid leakage, indicating a seal which must be replaced.

21. Tighten the new brake pads and reassemble the caliper (two outer hex head screws and hardware).

22. Install the brake caliper assembly to its brake caliper mount. Ensure correct number of shims are installed between the caliper and the mount. Pads should have the same clearance from the disk prior to actuation of the brakes.

23. Bleed the brakes. “Bleeding Brakes” on page 5-19.

24. Reassemble and check the forklift and brake operation. Connect the battery and check for proper brake operation as follows: • Accelerate the forklift slowly.

• Apply the brakes to quickly “STOP” the wheels. Be careful not to lock the wheels while braking.

• Release the brake pedal after the wheels stop, then accelerate again.

• Release the accelerator pedal to allow the forklift to coast to a stop.

• Both wheels should have equal amounts of resistance.

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CORRECTIVE MAINTENANCE

• Repeat this procedure two times in the forward and reverse directions. If the forklift does not perform as stated above, reinspect the brake calipers for wear.

• 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 tire flat spots.

Figure 5-7: Bleeder Screws and Brake Mechanism

Parking Brake System



Parking Brake Assembly

• Adjusting the parking brake lever too tight will overheat brake rotors, causing premature wear or overheat the drive motors, causing failure.

• Wear work gloves before reaching in to turn wheel and allow the forklift to cool. Various parts can get extremely hot during operation.

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

Parking Brake Lever The amount of travel of the parking brake lever should allow the lever to move from the released position to the brake position, having the brake fully applied before handle travel is at its maximum.

CAUTION

Checking Parking Brake Adjustment 1.

2.

3.

4.

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

Park the forklift on a level surface.

Lower the forks all the way to the ground.

Apply the parking brake.

5-11

CORRECTIVE MAINTENANCE 5. Set the key switch to the “OFF” position and remove the key from the console.

6. Disconnect the battery.

7. Begin a Lock Out/Tag Out procedure.

8. Make sure all the other wheels are securely blocked so that the forklift cannot move.

9. Raise the right side of the forklift until the rear drive tire clears the floor by no more than 1” (25mm).

10. Pull up on the parking brake handle as far as possible using moderate force. The amount of vertical travel should allow the handle to snap into the full vertical position. The left rear wheel should not turn when attempting to turn by hand.



Replacing Parking Brake Lever Assembly

Parking Brake Lever

WARNING

Before reaching in to turn the wheel, make sure the forklift has sat idle long enough to cool.

Various parts can get extremely hot during operation. Also make sure you are wearing work gloves.

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

12. To adjust, loosen the Allen head adjustment setscrew. Turning the level clockwise tightens the setting: counterclockwise loosens the setting. After adjustment, tighten Allen head adjustment screw.

NOTICE DO NOT OVERTIGHTEN. You will separate the cable from the clevis ends.

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

14. If this fails to properly adjust the park brake, see “Adjusting Parking Brake Caliper” on page 5-13.

5-12

Parking Brake Switch

Figure 5-8: Parking Brake Lever 1.

2.

3.

4.

5.

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

Park the forklift on a level surface.

Lower the forks all the way to the ground.

Apply the parking brake.

Set the key switch to the “OFF” position and remove the key from the console.

6. Disconnect the battery.

7. Begin a Lock Out/Tag Out procedure.

8. Make sure all the other wheels are securely blocked so that the forklift cannot move.

9. Remove the lower dash cover weldment.

10. Disconnect the clevis end brake cable.

11. Replace the new parking brake lever assembly.

12. Remove brake linkage and brake switch cam from the old lever assembly and install it on the new lever.

13. Reassemble in reverse order.

14. Adjust the park brake. “Adjusting Parking Brake Caliper” on page 5-13.

F-649-R0

CORRECTIVE MAINTENANCE Checking the Parking Brake Switch The parking brake switch electrically disables the forklift when applied and is connected to the park brake handle.

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

2. Park the forklift on a level surface.

3. Lower the forks all the way to the ground.

4. Apply the parking brake.

5. Set the key switch to the “OFF” position and remove the key from the console.

6. Disconnect the battery.

7. Begin a Lock Out/Tag Out procedure.

8. Make sure all the other wheels are securely blocked so that the forklift cannot move.

9. Remove the hydraulic control valve cover.

10. Disconnect the e-brake cutout switch connector.

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

• The meter should show <1 ohm while the parking brake is disengaged.

12. Slowly pull back on the brake lever.

• The meter reading must be “OPEN,” indicating the switch is released before the lever reaches its full locking position.

• If the meter does not read “OPEN,” the switch needs to be replaced.

13. Disconnect the ohm meter.

14. Reassemble in reverse order.

Replacing Parking Brake Switch 1.

2.

3.

4.

5.

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

Park the forklift on a level surface.

Lower the forks all the way to the ground.

Apply the parking brake.

Set the key switch to the “OFF” position and remove the key from the console.

6. Disconnect the battery.

7. Begin a Lock Out/Tag Out procedure.

8. Make sure all the other wheels are securely blocked so that the forklift cannot move.

9. Disconnect the switch at the Deutsch connector and release the jam nut on the park brake handle.

10. Remove the jumper harness, if used, from the switch.

11. Install the new switch in reverse order.

12. Connect the switch at the connector.

To check the operation of the switch: • Start the forklift and release the parking brake.

• Set the control lever to “FORWARD” and very slowly increase motor speed.

• As the forklift is moving forward at slow speed, slowly pull up on the brake lever.

• The forklift must immediately slow to a “STOP”.

• If the forklift continues moving forward, recheck the setting and operation of the switch.

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

Replacing the Parking Brake Cable 1.

2.

3.

4.

5.

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

Park the forklift on a level surface.

Lower the forks all the way to the ground.

Apply the parking brake.

Set the key switch to the “OFF” position and remove the key from the console.

6. Disconnect the battery.

7. Begin a Lock Out/Tag Out procedure.

8. Make sure all the other wheels are securely blocked so that the forklift cannot move.

9. Remove the hydraulic valve cover to expose the parking brake mechanism.

10. Remove the cable from the forklift noting how the cable is positioned.

11. At the parking lever, pull the pin that connects the cable to the parking brake linkage.

12. At the caliper, remove the bolt that holds to yoke to the caliper. Remove the yoke, tension spring and the two flat washers, noting placement on the old cable.

Replace parts on the new cable, positioning the yoke in the same location.

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

14. Adjust the parking brake cable.

15. Reassemble in reverse order.

Parking Brake Caliper Assembly The parking brake caliper assembly is used for holding the forklift in place while unattended, and is activated by pulling the park brake lever.

Adjusting Parking Brake Caliper 1. First, review “Before You Begin” on page 1-1.

2. Park the forklift on a level surface.

3. Lower the forks all the way to the ground.

5-13

CORRECTIVE MAINTENANCE 4. Apply the parking brake.

5. Set the key switch to the “OFF” position and remove the key from the console.

6. Disconnect the battery.

7. Begin a Lock Out/Tag Out procedure.

8. Make sure all the other wheels are securely blocked so that the forklift cannot move.

9. Loosen adjustment bolt to desired position.

10. The adjustment should be set so that when the park brake lever is screwed all the way out (completely counterclockwise) and the lever is pulled to its full vertical position, so the caliper holds the rotor.

11. Tighten adjustment bolt jam nut.

12. Reassemble in reverse order.

3/4-16 FLANGE HEAD NUT 3/8-16 FLANGE HEAD LOCK WASHER

BRAKE ROTOR

BRAKE MOUNT

PARKING BRAKE CALIPER

5/16-18 FLANGE NUT ROUND HEAD SQUARE NECK 3/8-16 X 1-1/4 SCREW Figure 5-9: Parking Brake

Changing Parking Brake Pads or Replacing Parking Brake Caliper 1.

2.

3.

4.

5.

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

Park the forklift on a level surface.

Lower the forks all the way to the ground.

Apply the parking brake.

Set the key switch to the “OFF” position and remove the key from the console.

6. Disconnect the battery.

5-14

7. Begin a Lock Out/Tag Out procedure.

8. Make sure all the other wheels are securely blocked so that the forklift cannot move.

9. Make sure all the other wheels are securely blocked so that the forklift cannot move.

10. Remove the 3/8”-16 x 1-1/4” round head square neck screws and nuts from the park brake bracket. See Figure 5-9.

F-649-R0

CORRECTIVE MAINTENANCE

NOTICE The parking brake caliper and bracket will be loose when hardware is removed. Remove the parking brake caliper carefully so that the caliper pads, backing plate and actuator pin DO NOT fall.

11. Either remove the caliper for replacement or replace brake pads with new ones.

12. Reassemble in reverse order.

13. If needed, adjust the brake caliper.

Brake Pedal The service brake pedal has about 1” (25mm) 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 0.50” (12.7mm) before in 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 factor set to trip just as the brake pedal begins its downward stroke.

13. Tighten the adjustment lock nut against the brake pedal yoke.

14. Install the left floor plate.

15. Connect the battery and check for proper brake operation as follows: • Raise and block the forklift off of the ground.

• 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 forklift to coast to a stop.

• Both wheels should stop at the same time.

• Repeat this procedure two times in forward and in reverse directions.

16. If the forklift does not perform as stated above, reinspect the brake calipers for wear.

(3-3/16)

Service Brake Linkage 1.

2.

3.

4.

5.

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

Park the forklift on a level surface.

Lower the forks all the way to the ground.

Apply the parking brake.

Set the key switch to the “OFF” position and remove the key from the console.

6. Disconnect the battery.

7. Begin a Lock Out/Tag Out procedure.

8. Make sure all the other wheels are securely blocked so that the forklift cannot move.

9. Before doing any adjustment, check for: • Low fluid level in the master cylinder reservoir.

• Air or leaks in the system.

• Worn brake pads. “Brake Assembly” on page 5-7.

• Any of these conditions can affect pedal free-play.

• Proceed to the appropriate heading for repairs.

10. Remove the left floor plate to expose the brake pedal linkage and master cylinder. See Figure 5-4.

11. Loosen the 5/16” free play adjustment nut on the master cylinder push rod. See Figure 5-10.

12. Turn the rod clockwise to increase the dimension on the pedal; turn it counterclockwise to decrease the dimension.

Figure 5-10: Brake Linkage

Brake Light/Accelerator Switch Adjustment 1.

2.

3.

4.

5.

6.

7.

8.

9.

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

Park the forklift on a level surface.

Lower the forks all the way to the ground.

Apply the parking brake.

Set the key switch to the “OFF” position and remove the key from the console.

Disconnect the battery.

Begin a Lock Out/Tag Out procedure.

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

Slightly loosen both brake switch hex head screws.

See Figure 5-11.

5-15

CORRECTIVE MAINTENANCE 10. Connect the ohm meter leads to the appropriate switch being tested.

11. Slowly push down on the brake pedal. Before you feel pedal resistance, the meter must read one of the following: • The meter must show a reading of open at the full upright pedal position for brake lights (2 black wires).

• 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).

12. Slide the brake switch forward or backward to locate the switch at this position - to engage as the pedal begins its downward stroke. See Figure 5-10.

13. 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.

14. Disconnect the ohm meter.

15. Start the forklift.

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

NOTICE To avoid “flat-spotting” the tires, DO NOT lock the brakes when stopping.

Replacing the Linear or Rotary Pot To replace the linear pot or rotary pot, disconnect the connector to the assembly and remove the 2 bolts holding the assembly into position and replace the assembly. Calibration is required through the dashboard calibration procedure. “Forklift Calibration” on page 6-2.

Brake Light Switch Replacement 1.

2.

3.

4.

5.

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

Park the forklift on a level surface.

Lower the forks all the way to the ground.

Apply the parking brake.

Set the key switch to the “OFF” position and remove the key from the console.

6. Disconnect the battery.

7. Begin a Lock Out/Tag Out procedure.

8. Make sure all the other wheels are securely blocked so that the forklift cannot move.

9. Remove the left floor plate. See Figure 5-4.

10. Unscrew and remove the switch assembly from the brake pedal frame and install the new switch. See Figure 5-12.

11. Set the switch. “Brake Light/Accelerator Switch Adjustment” on page 5-15.

LINEAR POT

BRAKE SWITCH FILL CAP

MASTER CYLINDER Figure 5-11: Brake Switch Assembly (Prior to 1/28/14) 5-16

F-649-R0

CORRECTIVE MAINTENANCE

ROTARY BRAKE SENSOR

BRAKE SWITCH

FILL CAP

MASTER CYLINDER Figure 5-12: Brake Switch Assembly (After 1/28/2014)

Brake Hydraulics Replacing Master Cylinder



CAUTION

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

1.

2.

3.

4.

5.

6.

7.

8.

9.

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

Park the forklift on a level surface.

Lower the forks all the way to the ground.

Apply the parking brake.

Set the key switch to the “OFF” position and remove the key from the console.

Disconnect the battery.

Begin a Lock Out/Tag Out procedure.

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

Remove the left floor plate. See Figure 5-4.

5-17

CORRECTIVE MAINTENANCE 10. Remove the master cylinder fill cap and rubber diaphragm (two round head screws). See Figure 5-11.

11. Siphon out as much fluid as possible. Install and tighten the fill cap and diaphragm before removing the cylinder.

12. Place rags under the brake line connections. Have a plastic cup or bag handy to cover the end of the line to limit fluid spillage.

13. Using a flare-nut wrench, disconnect the brake fluid line at the rear of the cylinder.

14. 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.

15. Disassemble the yoke from the master cylinder crank plate (one 5/16-18 screw and hardware).

16. Remove the two master cylinder mounting bolts and remove the cylinder from the forklift.

17. Remove the reservoir cap and discard any fluid remaining in the reservoir.

18. 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.

19. Replace the new master cylinder in reverse order.

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

• Whenever the master cylinder is removed or replaced, the hydraulic brake system must be bled. The time required to bleed the system can be reduced if the master cylinder is filled with brake fluid and bench-bled before installing the cylinder into the forklift.

Bench Bleed the Master Cylinder 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 5-13.

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.

5-18

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

5. When only brake fluid is expelled from the master cylinder outlet port, hold the push rod in and seat 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

PUSH ROD PLUNGER AND RUBBER GROMMET CYLINDER OUTLET PORT

Figure 5-13: Bench Bleeding

Check Master Cylinder Fluid Level The master cylinder is located below the driver’s left compartment floor plate.

1. Remove the left floor plate. See Figure 5-4.

2. First, clean the reservoir cap to avoid fluid contamination, then remove the fill cap an rubber gasket.

3. Additional fluid is needed when the fluid level is below the FULL line stamped in the master cylinder housing body.

4. Add fluid as needed. DO NOT OVER FILL. Use only #3 DOT brake fluid from a clean, sealed source.

5. Reinstall the reservoir fill cap and rubber gasket.

Tighten only enough to provide a leak-proof seal.

F-649-R0

CORRECTIVE MAINTENANCE

NOTICE

NOTICE

DO NOT overtighten. This could crimp, split or damage the seal.

Have an assistant available, as well as a supply of brake fluid, an empty clean 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.

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

 •

•

CAUTION

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

DO NOT allow fluids to go inside the brake caliper and onto the brake pad. It will contaminate the brake lining and cause failures.

NOTICE 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 into the master cylinder. Use only new #3 DOT brake fluid from a sealed container. NEVER use old or used brake fluid. It contains moisture which will deteriorate the brake system components.

NOTICE It is necessary to bleed both wheels if air has entered the system. Air in the brake system can be caused by low fluid level or if a brake line has been leaking or disconnected. If the brake pedal feels spongy when pressed and travels 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 repair leaks before attempting to bleed the system.

1.

2.

3.

4.

5.

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

Park the forklift on a level surface.

Lower the forks all the way to the ground.

Apply the parking brake.

Set the key switch to the “OFF” position and remove the key from the console.

6. Disconnect the battery.

7. Begin a Lock Out/Tag Out procedure.

8. Make sure all the other wheels are securely blocked so that the forklift cannot move.

9. Start with the right wheel (the wheel furthest from the master cylinder).

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

11. 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 5-14.

12. Check fluid level in the master cylinder. Fill before you begin.

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

NOTICE Be careful when handling bleeder screws. Rust may cause the fitting to break. Spray the fitting with penetrating oil before attempting to loosen.

Use a 6 sided wrench instead of a 12-sided wrench.

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

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

16. Repeat steps 8 through 11 as many times as needed until the fluid draining into the container is free of air bubbles.

5-19

CORRECTIVE MAINTENANCE 17. Fill the master cylinder fluid level and add as needed before bleeding the other side.

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

BLEED SCREWS (USE FLARE NUT WRENCH)

Electrical



CAUTION

Before any maintenance or work is performed on the electrical system of the forklift, perform a Lock Out/Tag Out procedure, disconnect the battery, raise the forklift and put blocks on the underside of the forklift.

Electrical Static Discharge

Figure 5-14: Bleeding with Container

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.

Replacing Any Other Hydraulic Brake Component 1.

2.

3.

4.

5.

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

Park the forklift on a level surface.

Lower the forks all the way to the ground.

Apply the parking brake.

Set the key switch to the “OFF” position and remove the key from the console.

6. Disconnect the battery.

7. Begin a Lock Out/Tag Out procedure.

8. Make sure all the other wheels are securely blocked so that the forklift cannot move.

9. Remove covers as needed.

10. Replace the damaged component and reassemble.

Make all adjustments needed to insure brakes are operating correctly.

11. Test the operation of the forklift brakes.

• Normal precautions concerning the handling of electronic components are applicable in order to minimize the risk of damage to these devices by Electrical Static Discharge. Avoid contact with the pins of these devices and insure that when they are removed from a printed circuit board (PCB), the pins are strapped together with conductive tape.

Immediately place the PCB in static-free bubble wrap or an ESD bag.

• Smocks over normal clothing must be worn to discharge high voltage potentials caused by friction during normal wear.

• Use a grounding wrist band to protect microprocessors and all electronic components from static electricity and always touch a metal surface (other than the forklift) before touching a PCB. These precautions are especially necessary with respect to microprocessor devices, found on the hydraulic control PCB’s of this forklift.

ESD Strap The ESD (Electrical Static Discharge) Strap which will be installed just behind the front steering assembly. This device will drain all static electricity build up that may occur on the Bendi AC forklift. See Figure 5-15.

Figure 5-15: ESD Strap Location

5-20

F-649-R0

CORRECTIVE MAINTENANCE

Inspecting the Contactors Contactors are set at the factory and should not require any adjustment. During the life of the contactor, they may become discolored, blacked, or corroded. Cleaning or maintenance is not necessary. Replacement is recommended instead of maintenance. If one contactor is due for replacement, it is recommended that they are all replaced as a set.

Direction Control Lever The directional control lever (forward-neutral-reverse) is located on the battery cover. Each assembly is available as a complete unit.

Replacing Direction Control Lever 1.

2.

3.

4.

5.

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

Park the forklift on a level surface.

Lower the forks all the way to the ground.

Apply the parking brake.

Set the key switch to the “OFF” position and remove the key from the console.

6. Disconnect the battery.

7. Begin a Lock Out/Tag Out procedure.

8. Make sure all the other wheels are securely blocked so that the forklift cannot move. Raise the battery cover.

9. Remove the directional control lever wires from the contact blocks on the main harness.

10. Replace in reverse order.

11. Test for proper operation.

Check the Return-to-Neutral 1. Sit in the driver’s seat, and turn the key switch “ON”.

2. Set the direction control lever to “FORWARD”.

3. Slowly move the forklift forward, then slowly lift yourself off the seat, the forklift should come to a stop.

4. Turn the key switch “OFF”, then back on again.

5. Press on the accelerator pedal.

6. The forklift must not move.

7. If the forklift does not move, take your foot off the accelerator pedal. Place the directional control lever in “NEUTRAL” then back to “FORWARD” again.

8. Slowly push on the accelerator pedal. The forklift should move forward. If it does not move. “Curtis Controller Troubleshooting” on page 6-23.

9. Repeat preceding Steps 1 through 6, but instead of turning the key switch “OFF” in Step 4, lift yourself from the driver’s seat for 5 seconds to allow the switch interlock to release. The forklift must react as stated in Steps 4 through 8.

0$,1 +$51(66

Figure 5-16: Control Panel Wiring 5-21

CORRECTIVE MAINTENANCE

Replacing a Complete Control Panel 1.

2.

3.

4.

5.

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

Park the forklift on a level surface.

Lower the forks all the way to the ground.

Apply the parking brake.

Set the key switch to the “OFF” position and remove the key from the console.

6. Disconnect the battery.

7. Begin a Lock Out/Tag Out procedure.

8. Make sure all the other wheels are securely blocked so that the forklift cannot move.

9. Remove the rear control compartment cover.

10. Mark and remove all cables connected to high current terminals of the panel and disconnect the main harness. See Figure 5-18.

11. Remove mounting hardware that secures the assembly to the forklift and remove the panel or single component from the forklift.

12. Reassemble in reverse order. All cables installed on the motor controllers must use Landoll approved fasteners. Refer to the Parts Manual (Landoll P/N F-647).

High Current Connections Definition B+ = Positive Battery to Controller.

B- = Negative Battery to Controller.

13. Tighten cables connected to the high current terminals, identified on the controller housing as B+, B-, U, V and W to 90 in-lbs (10.2Nm).

14. After replacing the controller it must be reprogrammed. See “1314 Controller Software Installation and Operation” on page 6-3.

M8 BOLT HIGH LOAD SAFETY WASHER LUG M8 TERMINAL

EXPLODED VIEW Figure 5-17: Cable Installation U = Motor phase U. V = Motor phase V. W = Motor phase W.

Figure 5-18: Controller Panel

5-22

F-649-R0

CORRECTIVE MAINTENANCE

Hydraulics Check Hydraulic Functions 1. Position the forklift on a level, flat surface. Clear area around the forklift.

2. Turn the key switch to the “ON” position.

3. Make sure your right foot is on the floor of the operator’s compartment and prepared to brake.

4. Pull either control lever to see if the hydraulics are working. The pump must turn “OFF” immediately as you release the control lever.

5. If the pump keeps running. “Curtis Controller Troubleshooting” on page 6-23.

6. Visually check cylinders, valve and hoses for leaks or other signs of wear.

Check hydraulic fluid level.

Hydraulic Oil Check Hydraulic Oil Level 1. Lower the mast to within a few inches of the ground, then tilt it back completely.

2. Side shift the mast to the far right and return it to the straight forward position (normal carry position).

3. With the key switch in the “OFF” position turn the steering wheel left and right until it become very difficult to turn.

4. The fill/dipstick cap is located under the floor plate.

Remove the left floor plate. See Figure 5-4.

5. Clean the area around the dipstick.

6. Pull the dipstick out and wipe it clean. Reinsert and then check the dipstick to determine oil level.

NOTICE • It is important that the proper level of oil be maintained at all times. Failure to check the oil level as recommended could cause serious mast function operating problems.

• The oil level indicated on the dipstick is most accurate when the oil is at operating temperature of 130°F to 176°F (54°C to 80°C).

• DO NOT overfill. Having the level above the FULL line does not allow enough area for expansion when the oil heats during normal operation.

7. Remove the dipstick again, holding the dipstick tip level and check the oil level.

• The oil level should be between the ADD and FULL lines • The oil level must NOT be above the FULL line, drain oil as needed see “Lubrication Specifications” on page 1-10 for recommended oil • The oil level must NOT be below the ADD line, add oil as needed • Repeat steps 6 and 7 until the proper oil level is achieved.

8. If the fluid appear very dirty or dark in color, check the forklift’s maintenance log for the last fluid and filter change and service it accordingly.

9. Install dipstick, making sure it is seated. Close controller compartment and reconnect battery.

Changing Hydraulic Oil 1.

2.

3.

4.

5.

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

Park the forklift on a level surface.

Lower the forks all the way to the ground.

Apply the parking brake.

Set the key switch to the “OFF” position and remove the key from the console.

6. Disconnect the battery.

7. Begin a Lock Out/Tag Out procedure.

8. Make sure all the other wheels are securely blocked so that the forklift cannot move.

9. Remove the left floor plate. See Figure 5-4.

10. Open the fill/dipstick cap mounted under the floor plate.

11. The hydraulic reservoir drain plug is located in the bottom of the forklift, underneath the reservoir. See Figure 5-19.

12. Slide a flat collection pan (minimum 10 gallons/38 liters) under the drain plug, then remove the plug.

13. Change the hydraulic filter. “Change the Hydraulic Oil Filter” on page 5-24.

14. When the tank is empty clean the magnetic trap on the drain plug of any contaminates.

15. Reinstall the drain plug, tightening the plug to 16 ft-lbs. (22 Nm). “General Torque Specifications (rev. 4/97)” on page 1-11.

16. Add hydraulic oil. “Lubrication Specifications” on page 1-10. DO NOT overfill.

17. Replace the fill/dipstick cap, turn clockwise and make sure it is tightened securely.

18. Remove the Lock Out/Tag Out notices and locks.

19. Run lift to check for leaks.

20. With the lift “OFF” and the forks down, check the oil level on the dipstick and add oil accordingly.

5-23

CORRECTIVE MAINTENANCE 13. Operate the hydraulic system by running the mast functions and observe the filter for oil leaks.

14. Check the hydraulic fluid level and reinstall the driver’s floor plate.

+,*+ 35(6685( 2,/ ),/7(5 FILTER ELEMENT

+<'5$8/,& 2,/ '5$,1 3/8* Figure 5-19: Hydraulic Oil Drain Plug

Change the Hydraulic Oil Filter



CAUTION

After prolonged forklift use, hydraulic oil will become hot and can burn the skin. Allow hydraulic oil to cool to a tolerable temperature before performing this procedure.



DANGER

Hydraulic oil can be under very high pressure. A pinhole leak is not easily seen and if it pierces the skin, it can cause injury and possible death.

1.

2.

3.

4.

5.

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

Park the forklift on a level surface.

Lower the forks all the way to the ground.

Apply the parking brake.

Set the key switch to the “OFF” position and remove the key from the console.

6. Disconnect the battery.

7. Begin a Lock Out/Tag Out procedure.

8. Make sure all the other wheels are securely blocked so that the forklift cannot move.

9. Remove the floor mat and left floor plate. See Figure 5-4.

10. Using a clean, lint-free cloth, clean the area around the filter element housing and remove the filter housing cover.

11. Unscrew the hydraulic oil filter cap and remove the old filter, clean and replace. See Figure 5-20.

12. Remove endcap and replace high pressure filter element every 500 hours.

5-24

Figure 5-20: Hydraulic Oil Filter

Checking and Adjusting Hydraulic Pressure For ease of checking hydraulic pressure, Landoll offers a Pressure Check Kit (P/N 0018152) which includes a 5,000psi (345 bar) gauge, hose, and quick-coupler assembly. If you are using your own system, have shop rags, oil absorbent and a small container ready to collect any oil spills.



CAUTION

DO NOT hold a hydraulic control bottomed out for excessive periods of time. Extreme pressure is applied to the system which can, over periods of time, generate excessive heat, damage oil and 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 pressure, replace the relief valve.



DANGER

Hydraulic oil can be under very high pressure. A pinhole leak is not easily seen and if it pierces the skin, it can cause injury and possible death.

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

F-649-R0

CORRECTIVE MAINTENANCE 2.

3.

4.

5.

Park the forklift on a level surface.

Lower the forks all the way to the ground.

Apply the parking brake.

Set the key switch to the “OFF” position and remove the key from the console.

6. Disconnect the battery.

7. Begin a Lock Out/Tag Out procedure.

8. Make sure all the other wheels are securely blocked so that the forklift cannot move.

9. Remove the left floor plate. See Figure 5-4.

10. For this test, make sure that the hydraulic tank is properly filled.

11. Remove the control valve cover, located to the right of the driver’s seat.

12. Operate the function levers briefly to relieve any system pressure.

13. Connect the pressure check kit quick-coupler (female end) to the test port coupler (male end) on the control valve. See Figure 5-21.

• 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 any oil leakage.

• Install your 5,000 psi (345 bar) gauge arrangement to the tee fitting.

• All parts connected to the gauge port must be capable of handling up to 5,000 psi (345 bar).

• To adjust pressure, the forklift (pump) must be running to create hydraulic pressure. Always pay careful attention when servicing while the forklift is running. To check or set the pressure, you must pull the lift lever to dead-head the cylinder to build pressure, then set the relief valve.

14. Loosen the relief valve jam nut.

15. Reverse the Lock Out/Tag Out. 16. Connect the battery.

17. Turn the forklift “ON”.

18. Adjust the valve stem by turning clockwise to increase pressure or counterclockwise to decrease pressure.

19. Release the lift lever immediately once the pressure is set at 2,600 psi (179 bar).

20. Tighten the relief valve lock nut.

21. Set the key switch to the “OFF” position and remove the key from the console.

22. Disconnect the battery.

23. Perform a Lock Out/Tag Out procedure.

24. Operate the function controls momentarily to relieve system pressure.

25. Remove the pressure gauge quick-coupler or remove your gauge arrangement.

26. Reverse the Lock Out/Tag Out. 27. Connect the battery.

28. Turn the forklift “ON”.

29. Lift and lower the mast a few times to check forklift operation and check the hydraulic system for leaks.

30. Disconnect the battery.

31. Perform a Lock Out/Tag Out procedure.

32. Reassemble all covers and panels that were previously removed.

PRESSURE TEST PORT

Figure 5-21: Hydraulic Pressure Test

Hydraulic System Components This section explains service for the following: • Hydraulic Pump • Hydraulic Control Valve

5-25

CORRECTIVE MAINTENANCE Replacing the Hydraulic Pump and Motor

NOTICE Motor assembly is very heavy. Remember to connect the heavy cables in the correct order to ensure proper pump drive direction.

1.

2.

3.

4.

5.

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

Park the forklift on a level surface.

Lower the forks all the way to the ground.

Apply the parking brake.

Set the key switch to the “OFF” position and remove the key from the console.

6. Disconnect the battery.

7. Begin a Lock Out/Tag Out procedure.

8. Make sure all the other wheels are securely blocked so that the forklift cannot move.

9. Remove the battery and battery tray.

10. Move the hydraulic levers back and forth to relieve pressure from the lines.

11. Disconnect the suction and pressure hoses from the hydraulic pump. See Figure 5-22 (1). Place shop rags underneath the connections to catch hydraulic oil.

12. Mark and disconnect the two snap electrical connectors (2).

13. Mark and disconnect the three heavy gauge electrical cables (3).

14. Insert wooden blocks underneath the counterweight closest to the hydraulic motor on the right side. (B30 ONLY) 15. Hold and steady the counterweight with a floor jack.

(B30 ONLY) 16. Remove the three 3/8” fasteners to allow the pump and motor assembly to be elevated out of the frame.

17. Using an overhead hoist, remove the pump and motor assembly from the forklift and place it in the repair area.

18. Re-assemble in reverse order.

5-26

Figure 5-22: Pump Removal

Hydraulic Control Valve Assembly The following procedure explains how to replace a valve should a sluggish or sticking valve spool be suspect.

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.

The main hydraulic pump for lift, tilt and shift (mast functions) is a fixed displacement gear pump. System pressure must not exceed 3,000 psi, ±65 psi (20 bar, ±4.5 bar) maximum. Actual pressure is determined by mast size, load requirements and lift speed. See reference chart below: Bendi AC/DS Pump Speed in RPM’s

Mast Model

Lift Speed

35D Triple 35D Quad 40D Triple 45D Quad 50D Triple 55D Triple

1800 1750 1900 2400 2650 2850

F-649-R0

CORRECTIVE MAINTENANCE Hydraulic Control Valve and Switches Removal 1.

2.

3.

4.

5.

Figure 5-23: Operator Controls

NOTICE If you remove the valve from the forklift for servicing, when reinstalling the valve be certain to tighten the mounting screws in a staggered 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 pump pressure relief valve is part of the hydraulic control valve.

• A pressure gauge port is provided, with a “quick-coupler” (pressure service kit P/N 0018152) for reading the pump pressure on the hydraulic control valve. The pressure check port on the forklift is attached to the inlet port on the hydraulic control valve. See Figure 5-24.

PRESSURE TEST PORT

RELIEF VALVE

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

Park the forklift on a level surface.

Lower the forks all the way to the ground.

Apply the parking brake.

Set the key switch to the “OFF” position and remove the key from the console.

6. Disconnect the battery.

7. Begin a Lock Out/Tag Out procedure.

8. Make sure all the other wheels are securely blocked so that the forklift cannot move.

9. Relieve pressure in the system by moving the hydraulic levers back and forth a few times.

10. Remove the floor plates. See Figure 5-4.

11. Remove the valve cover.

12. Inspect the spool actuator end (upper) and switch actuator end (lower) for leakage. Also, inspect the valve for leakage between the valve sections.

13. 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 may need to be replaced. If leakage is found between sections, replace the O-ring between the sections.

14. Remove the valve from the forklift by first identifying and marking all hoses, disconnecting and plugging all hydraulic tubes. Be prepared to manage spills.

15. Disconnect the lift pot from the forklift wiring harness and switches from the forklift wiring harness at the Deutsch connector.

16. Remove the push/pull linkage from the spools by removing the cotter pins and pulling the pins from the spools.

17. Remove the bolts holding the valve to the valve mounting bracket.

18. Place valve on a bench or in a vice.

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

20. Remove the lift/pot switch mounts by removing the mounting screws.

21. Remove the fasteners on the spool actuation end and remove the cover plate.

Figure 5-24: Hydraulic Steer Ports 5-27

CORRECTIVE MAINTENANCE 32. Attach and tighten all hoses.

33. Operate valve functions and check for leaks.

Spool Section Rebuild

Figure 5-25: Spool Parts

NOTICE During this time, close inspection should be given, looking for leaks between sections. If there have been sectional leaks, simply unbolt the three bolts that hold the sections together, replace the leaking o-ring and tighten up the bolts holding the sections together. See “the parts manual (Landoll P/N F-647).

22. Remove the spool and end mechanism from the bore.

23. Remove the seal, wiper and seal plate from the tang/clevis end of the spool. A dental pick can be used to remove the wiper and o-ring. Use caution to avoid nicking the bore.

24. Remove the end mechanism form the cap end of the spool.

25. Remove all foreign material from the spool and seal the counter bores.

26. Lubricate the seal groove bores on the cap and tang/clevis ends of the housing.

27. Re-assemble the cap end of the spool with the new seals per the applicable end mechanism repair instruction and carefully reinsert the spool.

28. Install the new seal and wiper on the tang/clevis end of the spool using the seal plate to push them in prior to completing the seal plate cap screw installation and torque.

29. Assemble the switch pot brackets to the other end of the valve.

30. Apply grease (NLSI #2 Texaco #880) to actuator end prior to assembly of the spool actuator.

31. Reassemble valve to forklift.

5-28

The inlet assembly will include an o-ring, and the spool sections will include an o-ring, load check poppet and load check spring.

1. For proper reassembly alignment, lay valve components on a clean, hard, flat surface.

2. Thread tie rod nuts onto the short threaded end of each of the individual tie rods with the nuts threaded up the entire length of the threads.

3. Insert tie rods through tie rod holes of inlet housing, lay inlet on end with tie rods pointing up and install o-ring into groove. Special care must be taken to ensure o-ring has been completely installed in groove.

4. Place first spool section over inlet section with o-ring groove facing upward and install o-ring into groove.

5. Install load check poppet into load check cavity, nose first.

6. Once load check poppet has been properly installed, place load check spring in hollow cavity inside check poppet.

Hydraulic Lift Spool Sensor The hydraulic lift spool sensor is replaced as a complete unit. When replacing the lift spool sensor, re-calibration of the Bendi AC/DS is required.

Replacing the Lift Sensor 1.

2.

3.

4.

5.

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

Park the forklift on a level surface.

Lower the forks all the way to the ground.

Apply the parking brake.

Set the key switch to the “OFF” position and remove the key from the console.

6. Disconnect the battery.

7. Begin a Lock Out/Tag Out procedure.

8. Make sure all the other wheels are securely blocked so that the forklift cannot move.

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

10. Remove the floor plate to allow removal of the valve cover.

11. Disconnect the lift sensor from the valve harness at the Deutsch connector. Remove the red, black, and green wires from valve harness connector.

F-649-R0

CORRECTIVE MAINTENANCE 12. The lift spool sensor can be removed from valve without removing the valve from forklift. If valve is removed, label lines and prepare to manage leaks prior to removal.

13. Remove lift spool sensor housing from valve by removing 4-5 mm screws.

14. Replace magnet assembly on end of lift spool.

15. Install new sensor housing on valve.

16. Reassemble pot to valve.

17. Reinstall valve on forklift, if removed.

18. Connect lift spool sensor to valve harness. Red wire goes into position1, black wire into position 2, and green wire into position 3.

19. Start forklift, operate hydraulic system and check for leaks.

20. Calibrate lift pot input to controller. This adjustment is actually completed through the controller electronically.

21. Reinstall floor plates and valve cover.

1.

2.

3.

4.

5.

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

Park the forklift on a level surface.

Lower the forks all the way to the ground.

Apply the parking brake.

Set the key switch to the “OFF” position and remove the key from the console.

6. Disconnect the battery.

7. Begin a Lock Out/Tag Out procedure.

8. Make sure all the other wheels are securely blocked so that the forklift cannot move.

9. Before disconnecting any hydraulic fittings or hose assemblies, relieve the system pressure. This is accomplished by turning the steering wheel a few times in both directions and moving the control levers in both directions.

10. 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.

Be prepared to clean up any oil spillage. See Figure 5-27.

11. Always tag the hoses and fittings for identification. If necessary, keep notes and put markings on parts using a non-destructive marker.

12. 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.

HALL EFFECT SENSOR

Figure 5-26: Hall Sensor Location

Hydraulic Fittings and Hoses



DANGER

• 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 spills can cause falls. To avoid injury, make sure all spills are cleaned well with oil dry/wipes.

5-29

CORRECTIVE MAINTENANCE



NOTICE HSAE fittings DO NOT need a thread sealant.

They are straight thread and include an O-ring seal.

CAUTION

• Before you remove any hoses or tubes, relieve hydraulic system pressure. With the forklift off, operate the forklift controls several times in both directions.

• Check for hydraulic fluid leaks using a piece of cardboard or wood. DO NOT sue your bare hands.

• Remember to wear safety glasses.



DANGER

Hydraulic oil can be under very high pressure. A pinhole leak is not easily seen and if it pierces the skin, it can cause injury and possible death.

Check the hydraulic system pressure at the control valve fitting. System pressure must not exceed 3,000 psi (206 bar).

Steering Figure 5-27: Hydraulic Connections

Side Shift Circuit The following information is provided for authorized service facilities ONLY. Perform maintenance on the side shift circuit as required by the recommended checklists.

Check Side Shift Circuit Maintenance Side shift completely to the left and hold the control lever in this position for 5 seconds. Check for external leaks at the cylinder, fittings and hoses. Side shift completely to the right and repeat the procedure.

Steering Wheel Removal 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 the cover may crack. See Figure 5-28.

2. Loosen the steering wheel nut.

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.

NOTICE If the wheel is difficult to remove, use an automotive-type steering wheel puller. Avoid using hammers or pry bars.

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.

5-30

F-649-R0

CORRECTIVE MAINTENANCE 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.

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

STEERING KNOB REMOVE TO EXPOSE NUT

6. Remove the four bolts and hardware securing the orbital control unit to the steering column.

7. Remove the four bolts and hardware securing the steering column console to the bellows retainer plate.

See Figure 5-29.

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

9. When installing the new steering 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 the torque all mounting screws.

“Torque Specifications” on page 1-10.

Figure 5-28: Steering Wheel Assembly

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

1. Remove the floor plates. See Figure 5-4.

2. Remove the lower dash cover weldment. See Figure 5-29.

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

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

5-31

CORRECTIVE MAINTENANCE

Steering Orbital Control Unit 1. Remove the floor plates. See Figure 5-4.

2. Remove the lower dash cover weldment.

3. Review the section “Hydraulic Fittings and Hoses” on page 5-29.

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

5. Tag the port locations of each hydraulic line and fitting, then disconnect the four lines from the unit.

6. Immediately plug and cap all hose ends and tag each for identification. Be prepared to clean up any oil spills.

7. If the unit is being replaced, or the fittings are defective, notice the placement angle of the hose fittings then remove them. See Figure 5-30.

8. Install the new steering orbital control unit to the steering column by following the preceding steps in reverse order.

9. Check oil level in the hydraulic tank and fill as needed.

Figure 5-29: Steering Column Assembly

STEERING CONTROL UNIT

STEERING CONTROL VALVE

OPERATOR CONTROLS

Figure 5-30: Orbital Steering Control Unit Assembly

5-32

F-649-R0

CORRECTIVE MAINTENANCE

Front Rotation Assembly This section explains servicing the: • Steering Actuator.

• Stop blocks.

• Steer potentiometer You will need a 2 to 3 ton (1,814-2,722kg.) overhead crane to support the mast and/or the front end weldment, when you separate it from the forklift front rotation arm.

You will also need hydraulic jacks or large block of wood and a portable hydraulic press. This service is best performed at your service center as opposed to the customer facility.

Removing the Steering Actuator Before any assembly or disassembly of components, clean actuator shaft ends and coupling pockets in mount plates using brake parts cleaner. DO NOT use anything containing molybdenum disulphide.

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

2. Park the forklift on a level surface.

3. Lower the forks all the way to the ground.

4. Apply the parking brake.

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

6. Set the key switch to the “OFF” position and remove the key from the console.

7. Disconnect the battery.

8. Begin a Lock Out/Tag Out procedure.

9. Make sure all the other wheels are securely blocked so that the forklift cannot move.

10. Remove the mast. Disconnect and cap lift and side shift and fork positioner hoses. Support mast using overhead crane with strap over the top crossmember.

Remove lower pin mounting bolts and mast tilt cylinder pins. Lift mast and move out of work area.

11. Remove rotation cover over the top of rotation sensor. Remove rotation sensor, bracket and drive pin from end of actuator.

12. Lift up the front end of the frame behind the front axle. Remove front axle and remove from area.

13. While the front is still supported, place wood blocks in the middle of the frame behind the rear wheels.

This will keep the forklift from rocking backwards as you remove the front rotation assembly.

NOTE Without the front rotation assembly in place the forklift becomes very rear heavy and will tend to rotate back.

Blocks in the rear will prevent this from happening.

14. Disconnect the two lines that provide hydraulic fluid to the actuator. Label and disconnect the tilt hoses from the tilt bulkhead. Label and disconnect the tilt cylinder hoses at the tilt bulkhead. Remove tilt cylinders from front end assembly.

15. Loosen the 8-7/8-9 socket head bolts that fasten the actuator to the frame. Loosen the 4-1”-12 hex head bolts used to fasten the upper actuator mount to the front plate. Use cylinder mount pins and a strap to support the front end assembly while removing the 8 bolts. Once the actuator assembly is free from front end, and place, actuator side up, on a work surface to begin removing actuator from assembly.

16. Remove 4-1”-12 hex bolts from upper actuator mount. Loosen all rotation coupling fasteners on both ends of the actuator. Remove the fasteners from coupling and insert into jacking holes that are next to the clamping holes.

17. Evenly apply torque to each fastener until the coupling separates.

18. Using a pry bar or other lifting means, raise actuator to remove couplings from each end. Remove the upper actuator mount. The actuator can then be removed from the assembly.

ACTUATOR MOUNTING HOLES SHOULD BE PERPENDICULAR TO THE FRONT PLATE

Figure 5-31: Rotation Assembly

Hints for Reassembly 1. Refer to Landoll Drawing #146369 for front plate assembly directions.

2. Install rotation assembly onto forklift frame.

5-33

CORRECTIVE MAINTENANCE 3. Assemble front axle, connect all hoses, and reattach steering rotation sensor.

4. Assemble mast, connect hoses, and assemble front rotation sensor.

HORN

Stop Block The rotation stops act as a cushion when the front end is turned the full 180° in either direction. The rotation stop is replaced by simply removing the hex socket screw (3/8”-16). See Figure 5-32.

STEER SENSOR Figure 5-33: Front Rotation Sensor

To Adjust and/or Replace the Steer Sensor 1.

2.

3.

4.

5.

Figure 5-32: Stop Block

Steer (Front Rotation) Sensor The steer (front rotation) sensor is a hall effect device and replaced as a complete unit.

5-34

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

Park the forklift on a level surface.

Lower the forks all the way to the ground.

Apply the parking brake.

Set the key switch to the “OFF” position and remove the key from the console.

6. Disconnect the battery.

7. Begin a Lock Out/Tag Out procedure.

8. Make sure all the other wheels are securely blocked so that the forklift cannot move.

9. Position the forks (mast) straight ahead.

10. Remove the front rotation cover to expose the steer sensor. See Figure 5-33.

11. Remove the two 8-32x1-5/8 screws that hold the sensor to the mounting bracket. Lift sensor from bracket and from drive rod in actuator shaft. If sensor is being is replaced, remove nylon ty-wrap and disconnect from the harness.

12. Drive rod has a flat end that drives the steer sensor.

This end needs to be oriented at a 45 degree angle relative to forklift center line when the forks are straight forward. Loosen jam nut to adjust rod angle.

Tighten jam nut to secure drive rod.

13. The drive end of the sensor has a reference mark.

This mark shows the “home” position, which is when the forks are in the straight forward position.

F-649-R0

CORRECTIVE MAINTENANCE

Steering Column and Dash Display Assembly The following procedures describe access to and replacement of the steering console electrical components, as well as all other electrical components on the Bendi AC/DS forklift.

The console assembly includes the following and are accessible by removing the right side steering assembly cover (black) screws and hardware: • Auxiliary power rocker switch (fan, scanner, etc.)

• Headlights (rocker switch, where fitted) • Standard/Ramp Mode (allows current to increase in the ramp mode) • Tilt steering lever • Key switch

DASH DISPLAY

A

Remove the Display Panel 1.

2.

3.

4.

5.

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

Park the forklift on a level surface.

Lower the forks all the way to the ground.

Apply the parking brake.

Set the key switch to the “OFF” position and remove the key from the console.

6. Disconnect the battery.

7. Begin a Lock Out/Tag Out procedure.

8. Make sure all the other wheels are securely blocked so that the forklift cannot move.

9. Remove the steering wheel by removing center cap, removing nut, and using a puller to remove the steering wheel.

10. Remove the small screws that hold the top of the dash to column, these screws are labeled “B” in Figure 5-34. Lift top from steering column.

11. After removing the top from the steering column, you can disconnect the appropriate wiring harness from the back of the display and remove the dash display from its mounting plate. Replace any of the components found in the column.

ROCKER SWITCHES

B

Figure 5-34: Steering Console and Display

5-35

CORRECTIVE MAINTENANCE

Powertrain

Key switch 1. Unscrew the knurled switch collar ring to separate the switch from the base plate.

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

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

Rocker (On/Off) Switches Rocker switches are also used to control various light packages and accessories.

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

2. The accessory “ON/OFF” rocker switches are held by plastic tabs. Compress the tabs on one side at a time to release the switch body, then push up and lift out of the slot. See Figure 5-35.

Inspecting the Drive System The Landoll AC/DS forklift has an individual motor that drives each wheel.

Before attempting to replace any part of the drive unit, visually inspect the following components: • Check for leaks.

• Check all fluid levels.

• Check for loose, worn or frayed electrical cables.

• Check tires for gouges, cupping, flat spots and excessive wear.

Check for any loose bolts or fittings.

Rear Wheel Assembly Removing Drive Wheels



NOTICE

The forklift is equipped with tires of a size and hardness that provide the necessary traction while still maintaining a proper shape to minimize tipping. Replace worn tires in pairs. Treaded drive tires must be replaced when the groove is gone.

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

3. Insert the replacement switch in the slot and compress the tabs as needed to allow it to be inserted.

4. Connect the switch to the wire harness and close the steering column by reversing the steps outlined in the above section.

WARNING

1.

2.

3.

4.

5.

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

Park the forklift on a level surface.

Lower the forks all the way to the ground.

Apply the parking brake.

Set the key switch to the “OFF” position and remove the key from the console.

6. Disconnect the battery.

7. Begin a Lock Out/Tag Out procedure.

8. Make sure all the other wheels are securely blocked so that the forklift cannot move.

9. Lift and support the forklift so that the drive wheel being serviced is clear of the floor by no more than 1” (25.4mm). “Lifting and Blocking the Forklift” on page 1-8.

10. Remove the six lug nuts. See Figure 5-36.

11. Using adequate support, remove the wheel.

Figure 5-35: Rocker Switch Tabs

5-36

F-649-R0

CORRECTIVE MAINTENANCE

Check Planetary Gear Box

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

TIRE AND WHEEL ASSEMBLY

LUG NUTS (6)

GEARBOX AND MOTOR

The planetary drive gearbox assemblies (right and left side) are filled with oil at the factory. An oil change is necessary after the first 50 hours maximum of operation in order to remove particles worn down during the running-in phase. Thereafter, an oil change is only required once every 2000 hours or yearly, whichever comes first. Also, if the forklift has been in storage for one year or more, the change the oil before placing the forklift into operation.

 • • • • • •

Figure 5-36: Removing Load Wheel 12. When installing the new wheel, tighten and torque the six lug nuts in a staggering fashion, following the numbering pattern. See Figure 5-37.

13. Tighten to 225ft-lbs. (305 Nm). “Torque Specifications” on page 1-10.

•

•

•

Perform service only in a well-ventilated area.

DO NOT breathe the vapors.

Wear protective goggles, aprons, and gloves.

Avoid contact with skin, eyes, and clothes.

Failure to observe these precautions may result in death or injury.

If you become dizzy, get fresh air and medical help immediately.

If a solvent contacts your eyes, immediately treat in accordance with the manufacturer’s recommendations on the container.

DO NOT mix different types of lubricants.

Always read the label affixed to the lubricant’s container for all safety information before use.

Getting under a forklift when it is lifted or jacked is dangerous and could cause serious injury or death. NEVER go under a forklift that is supported only be a jack.



Figure 5-37: Tire Tightening Sequence

DANGER

CAUTION

• Always place an appropriate support stand under the forklift if it is being lifted. Lower the forklift to the stand, having both the lifting device and stand supporting the weight of the forklift.

• If the forklift has been in operation recently for any period of time the oil could be very hot. Use special gloves and/or allow the forklift to cool completely before changing the oil. It is best to drain fluid while the unit is warm, but not HOT. NEVER drain oil into sewer lines.

5-37

CORRECTIVE MAINTENANCE 1.

2.

3.

4.

5.

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

Park the forklift on a level surface.

Lower the forks all the way to the ground.

Apply the parking brake.

Set the key switch to the “OFF” position and remove the key from the console.

6. Disconnect the battery.

7. Begin a Lock Out/Tag Out procedure.

8. Make sure all the other wheels are securely blocked so that the forklift cannot move.

9. Raise the vehicle. Use jack stands or other suitable supporting device rated for the correct weight capacity.

10. Raise the drive wheels to allow the tires to rotate.

11. Remove the wheel from the gearbox being serviced.

12. Thoroughly clean the area around the fill and drain/level plugs.

13. To drain, turn the gear box so that one of the drain plugs is at the lowest point. If rotating the gear box proves difficult, brake a 2” X 4” (5cm X 10cm) block between the wheel studs and rotate. See Figure 5-38.

14. Place a drain pan capable of storing up to 32 ounces (1.0 liter) of fluid under the drain plug.

15. Using a 4mm Allen key, unscrew the drain/level (position A) and fill (position B) plugs.

16. Drain the fluid completely into the drain pan.

17. Once the fluid has been drained, replace the drain/level plug in position A.

20. Fill the gear box with synthetic gear lube through position B until fluid flows out from position A. Fluid capacity is approximately 1 pint (16 oz). DO NOT OVERFILL. 21. Install both plugs. Tighten to 25ft-lbs. (34 Nm).

22. Wipe off any oil spillage on the outside of the gear box.

23. Turn the gearbox a few times to eliminate any air pockets and recheck fluid level. The oil level should be checked again after a short driving period. If necessary, refill the oil.

NOTICE In order to complete the following step you will need to undo the Lock Out/Tag Out and run the gearbox. After the gearbox has been run you will need to immediately redo the Lock Out/Tag Out. 18. Wash the interior of the gearbox with cleaning liquid as recommended by the lubricant manufacturer.

• Put liquid into the gearbox through the fill plug and replace the fill plug.

• Run the gearbox for a few minutes at high speed.

• Drain the cleaning fluid from the gearbox in the same way as described for draining the oil.

• Clean any contaminants from the magnetic trap and O-ring seal on the plugs.

19. To fill the gear box, turn until the drain/level hole in position A is about 15° below the horizontal center line of the gear box.

5-38

F-649-R0

CORRECTIVE MAINTENANCE

5mm HEX SOCKET BOLT

4mm HEX SOCKET FILL PLUG B 5mm HEX SOCKET BOLT

5mm HEX SOCKET BOLT

4mm HEX SOCKET DRAIN/LEVEL PLUG

A

DRAINING THE PLANETARY GEARBOX

B 4mm HEX SOCKET FILL PLUG 5mm HEX SOCKET BOLT

15° A

4mm HEX SOCKET DRAIN/LEVEL PLUG

FILLING THE PLANETARY BOX

Figure 5-38: Draining Gearbox

Replacing the Gear Box



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 “Lubrication Specifications” on page 1-10.

For proper oil fill instructions. “Check Planetary Gear Box” on page 5-37..

1.

2.

3.

4.

5.

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

Park the forklift on a level surface.

Lower the forks all the way to the ground.

Apply the parking brake.

Set the key switch to the “OFF” position and remove the key from the console.

6. Disconnect the battery.

7. Begin a Lock Out/Tag Out procedure.

8. Make sure all the other wheels are securely blocked so that the forklift cannot move.

9. Lift and support the forklift so that the drive wheel being serviced is clear of the floor by no more than 1” (25.4mm). “Lifting and Blocking the Forklift” on page 1-8..

10. Remove the six lug nuts. See Figure 5-36.

11. Using adequate support, remove the wheel.

12. Support the gear box as the mounting screws are removed.

13. Remove the eight M16-2 x 30 hex socket screws and hardware holding the gear box to the forklift frame See Figure 5-38.

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

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

16. For gearbox service parts see the Parts Manual (Landoll P/N F-647).

17. Re-assemble the gear box to the forklift by following the preceding steps in reverse order.

18. Tighten and torque the M16-2 x 30 screws. “Torque Specifications” on page 1-10.

Replacing the Traction Drive Motor The Bendi AC/DS forklift is equipped with a left and right drive motor and also a motor that powers the hydraulic pump. The drive motors have sensors to monitor speed and position. The motors used on the Bendi AC/DS forklifts are AC motors and have no brushes. Motor maintenance consists of keeping the motors clean with the use of compressed air.

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

2. Park the forklift on a level surface.

3. Lower the forks all the way to the ground.

4. Apply the parking brake.

5-39

CORRECTIVE MAINTENANCE 5. Set the key switch to the “OFF” position and remove the key from the console.

6. Disconnect the battery.

7. Begin a Lock Out/Tag Out procedure.

8. Make sure all the other wheels are securely blocked so that the forklift cannot move.

9. Lift and support the forklift so that the drive wheel being serviced is clear of the floor by no more than 1” (25.4 mm). “Lifting and Blocking the Forklift” on page 1-8.

10. Remove the six lug nuts. See Figure 5-36.

11. Using adequate support, remove the wheel.

12. Support the gear box as the mounting screws are removed.

13. Remove the eight M16-2 x 30 hex socket screws and hardware holding the gear box to the forklift frame See Figure 5-38.

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

15. Remove the 3/8”-24 X 1-1/2” hex head cap screws securing the brake caliper assembly to the mounting plate. Capture the spacers (if used) and keep any shims separate for each side.

16. Remove brake caliper assembly.

17. Loosen the flanged hex nut (3/4-16, Grade 8) and hardware from the motor shaft. DO NOT remove the nut from the assembly at this time.

18. The brake rotor is fitted with 2-3/8-16 threaded holes to allow the use of an automotive steering wheel puller.

19. Loosen the bolts mounting holding the motor to the frame enough to move the motor out to allow a gear puller to be put on the brake rotor.

20. Depending on the model and the amount of clearance available, you may have to remove one of the drive motor to remove the rotor from the armature.

NOTICE The removal of the drive motor can be done as a completed assembly. It needs to be slid out just enough for the rotor to clear.

21. Slide the rotor assembly from the keyed drive shaft.

DO NOT lose the woodruff key.

22. Support the Drive Motor as the mounting bolts are removed.

23. Remove the twelve 1/2-20 x 2 hex socket screws and hardware holding the motor to the forklift frame See Figure 5-38.

5-40

24. With the motor supported, rotate the motor to align the electrical connecting terminals to the slots machined in the forklift frame side plate.

25. Slide the motor out the side of the forklift far enough to install a second strap around the motor. This strap is to support the motor from outside the forklift frame.

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

27. For drive motor service parts see the Parts Manual (Landoll P/N F-647).

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

29. Tighten and torque the screws. “Torque Specifications” on page 1-10.

Load Axle Checking Load Axle Wheels 1.

2.

3.

4.

5.

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

Park the forklift on a level surface.

Lower the forks all the way to the ground.

Apply the parking brake.

Set the key switch to the “OFF” position and remove the key from the console.

6. Disconnect the battery.

7. Begin a Lock Out/Tag Out procedure.

8. Make sure all the other wheels are securely blocked so that the forklift cannot move.

9. With the forklift raised and supported, spin each wheel and check for noise, rolling resistance and free play.

10. Rock the wheel in and out on the spindle. If there is any noticeable movement, the bearings should be checked and then repacked with grease and/or replaced.

Disassembling and Inspecting Wheel Bearings 1.

2.

3.

4.

5.

6.

7.

8.

9.

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

Park the forklift on a level surface.

Lower the forks all the way to the ground.

Apply the parking brake.

Set the key switch to the “OFF” position and remove the key from the console.

Disconnect the battery.

Begin a Lock Out/Tag Out procedure.

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

Lift axle and support so that wheels are free to rotate.

F-649-R0

CORRECTIVE MAINTENANCE 10. Measure the tire diameter. If the diameter of the tire is less than 13”, the tire must be replaced.

11. Remove hub cap, 5/32 x 1-1/2 cotter pin, 1-14 hex slot nut, spindle washer, and outer bearing cone. See Figure 5-39 for reference.

12. Slide hub/wheel assembly from spindle.

13. Remove inner bearing cone and seal from hub.

14. Clean bearing cones and seal.

15. Clean bearing cups inside hub.

16. Inspect the bearing cones and cups.

• Check for rust, cracks, and pitting.

• If anything is found replace both the cone and cup as a set.

• Pack the bearings with grease before installation.

17. Replace seal if worn or damaged.

Assembling Wheel Bearings 1. If bearing cups are replaced, clean hub and press new bearing cups into hub. See Figure 5-39.

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.

NOTICE Be careful! Avoid damaging the 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 75ft-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 is filled with grease by injecting grease into the grease fitting at the top of the steering yoke until grease flows through outer bearing.

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

BEARING CONE

SPINDLE WASHER O-RING

SEAL

HUB CAP BEARING CONE CASTLE NUT Figure 5-39: Wheel Bearing Assembly

5-41

CORRECTIVE MAINTENANCE FRONT AXLE BLOCK

1-8 X 5 HEX HEAD SCREW

AXLE AXLE PIVOT PIVOT BUSHING BUSHING

TILT BLOCK COVER STATIC STRAP

TRUNION O-RING 1/4-20 X 7/8 HEX HEAD SCREW

1/4-20 X ½ HEX SOCKET SCREW Figure 5-40: Load Axle Assembly

Axle Installation 1. To install, reverse the order of removal. See Figure 5-40.

2. After lowering the front, assemble front axle onto mounting blocks, tighten the 1-8 x 5-1/2 hex head cap screws to 400ft-lbs.

Accelerator Pedal Assembly The accelerator assembly consists of the linear potentiometer, harness, and accelerator pedal. When replacing the acceleration potentiometer maintenance has been performed, re-calibration of the Bendi AC/DS is required.

Adjusting Accelerator Pedal 1.

2.

3.

4.

5.

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

Park the forklift on a level surface.

Lower the forks all the way to the ground.

Apply the parking brake.

Set the key switch to the “OFF” position and remove the key from the console.

6. Disconnect the battery.

7. Begin a Lock Out/Tag Out procedure.

8. Make sure all the other wheels are securely blocked so that the forklift cannot move.

5-42

9. Remove the floor plates. See Figure 5-4.

10. It may help to hold the right hand floor plate in a vice while proceeding.

11. 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.

12. Install the floor plate assembly back on the forklift.

13. Install the left hand floor plate.

14. Refer to Landoll Setup Procedure, located in “Forklift Calibration” on page 6-2 to re-calibrate the throttle pot module.

Replacing Accelerator Module 1.

2.

3.

4.

5.

6.

7.

8.

9.

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

Park the forklift on a level surface.

Lower the forks all the way to the ground.

Apply the parking brake.

Set the key switch to the “OFF” position and remove the key from the console.

Disconnect the battery.

Begin a Lock Out/Tag Out procedure.

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

Remove the floor plates. See Figure 5-4.

F-649-R0

CORRECTIVE MAINTENANCE 10. Remove the two round head screws (5/16-18 x 1) and hardware securing the accelerator to the floor panel.

11. Disassemble the accelerator from the floor plate and install the replacement accelerator in its place.

12. Loosen the allen headed fastener on the pedal arm and orient the pedal 90° 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 in. bolts and tighten to secure the accelerator in place.

13. Adjust the pedal as shown in “Adjusting Accelerator Pedal” on page 5-42.

14. Re-calibrate the software as shown in “Forklift Calibration” on page 6-2.

8. Make sure all the other wheels are securely blocked so that the forklift cannot move.

9. Remove the hardware securing the front portion of the seat slide rails to the cover. Then loosen the back two sets of hardware.

10. Raise the front of the seat up to expose the switch and cable mounting.

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

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

13. Before placing the forklift back into operation, test it to be sure the switch functions properly.

Safety Features

This procedure checks the physical mechanics (actuation) of the driver’s seat switch only. The switch is part of the seat.

1. Start the forklift and release the parking brake.

2. The seat switch and actuator are internal to the seat cushion, located on the under side of the seat cushion between the cushion and the bottom plate.

3. Set the direction control lever in either FORWARD or REVERSE and slowly apply acceleration. As the forklift begins to slowly move in either direction, lift yourself from the driver’s seat just enough to release the switch in the seat cushion.

4. The forklift will not come to an immediate stop. You should lose forward direction (or reverse). The forklift will coast unless you use you brakes.

5. If the forklift continues, see “Seat Switch,” previously on this page or refer to Troubleshooting the Controller - Chapter 5.

Horn Service The horn button is located to the right of the direction control lever.

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

2. Park the forklift on a level surface.

3. Lower the forks all the way to the ground.

4. Apply the parking brake.

5. Set the key switch to the “OFF” position and remove the key from the console.

6. Disconnect the battery.

7. Begin a Lock Out/Tag Out procedure.

8. Make sure all the other wheels are securely blocked so that the forklift cannot move.

9. Remove front rotation cover plate.

10. Disconnect the electrical wires.

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

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

13. Connect the battery and test the horn.

Seat Switch

Replacing the Switch and Cable 1.

2.

3.

4.

5.

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

Park the forklift on a level surface.

Lower the forks all the way to the ground.

Apply the parking brake.

Set the key switch to the “OFF” position and remove the key from the console.

6. Disconnect the battery.

7. Begin a Lock Out/Tag Out procedure.

SEAT SWITCH AND CABLE

Figure 5-41: Seat Switch Assembly

5-43

CORRECTIVE MAINTENANCE

Overhead Guard, Lighting and Alarms Forklifts equipped with optional LED flood / headlights, tail and stop lights, flashing or spot lights (strobe lights), etc. do not contain replaceable bulbs. Bulb replacement must be done as a complete assembly.

Forklift Lighting Forklifts equipped with optional lighting, flashing or spot lights may contain replaceable bulbs or the housing may be replaced as a whole. Lighting replacement varies according to the manufacturer.

Headlights These lights have non-replaceable elements and are replaced as an entire unit.

Brake and Tail Lights 1.

2.

3.

4.

5.

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

Park the forklift on a level surface.

Lower the forks all the way to the ground.

Apply the parking brake.

Set the key switch to the “OFF” position and remove the key from the console.

6. Disconnect the battery.

7. Begin a Lock Out/Tag Out procedure.

8. Make sure all the other wheels are securely blocked so that the forklift cannot move.

9. The complete LED light assembly must be replaced to repair a faulty light assembly.

10. Pull off the complete LED light assembly. Exercise care to avoid breaking the LED assembly.

11. Disconnect the wire connector and remove the bracket that is attached to the overhead guard.

12. If shielding or guard covers are involved, make certain that the guard is replaced after the repair.

Reassemble in reverse order.

Back Up Alarms 1.

2.

3.

4.

5.

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

Park the forklift on a level surface.

Lower the forks all the way to the ground.

Apply the parking brake.

Set the key switch to the “OFF” position and remove the key from the console.

6. Disconnect the battery.

7. Begin a Lock Out/Tag Out procedure.

8. Make sure all the other wheels are securely blocked so that the forklift cannot move.

9. To access the alarm assembly, raise the seat base as it is located under the arm rest.

10. To replace the alarm assembly, disconnect the wire connector and remove the mounting hardware holding the alarm to the mounting bracket.

Figure 5-42: Overhead Guard Electrical

5-44

F-649-R0

CORRECTIVE MAINTENANCE

Fuses Shown below are the location of the Bendi AC System and Controller fuses. Exact size and amperage rating must but be retained when replacing. See Figure 5-43.

Figure 5-43: Controller Fuses

5-45

CORRECTIVE MAINTENANCE

5-46

F-649-R0

Chapter 6

Calibration and Programming Controller Theory of Operation The Bendi AC/DS forklift uses Curtis controllers that convert DC, i.e., battery power, to 3-phase AC. This allows for high bandwidth, efficiency, and low ripple torque generation. The Bendi AC/DS forklift uses 3 controllers, (master, pump, and slave) and a single dash display to control the various actions of the electrical systems. The master and slave controllers use the 2 drive motor assemblies along with an analog steer-angle sensor to: • Independently control the inner and outer wheel speed, forklift speed, and acceleration.

• Maintain a balanced wheel speed when moving straight.

• Implement a Limited Operation Strategy (LOS) in the case of a single drive motor failure, a sensor failure, or a partial controller failure for limp-home operation.

The master controller controls: • The parking brake switch.

• The service brake pedal sensor.

• The left drive motor assembly and sensor.

• The seat switch.

• The directional control switch.

• The battery rollout switch. (optional) • The speed mode selection switch.

• The accelerator pedal.

The slave controller controls: • The right drive motor assembly and sensor.

• The steer-angle sensor.

The pump controller controls: • The pump motor assembly and sensor.

• The hydraulic control valve switches and sensors, i.e., tilt-switch, side shift switch, and the lift sensor.

Dash Display Key Legend 1. “Enter Key” - Used to Enter the Calibration Mode and to make selections after they are located.

2. “Up Key” - Used to move “Up” through the selections.

3. “Down Key” - Used to move “Down” through the selections.

You must hold the enter button down until the change has been accepted.

Figure 6-1: Dash Display Keys

6-1

CALIBRATION AND PROGRAMMING

Dash Display Parameters The following parameters can be adjusted through the dash display: • Maintenance Monitor - Used to set the hour meter value at which the operator will be alerted that service is required, NXT SVC DUE. When the forklift meets or exceeds the value entered in this section, “SERVICE DUE” will be shown on the display.

• Steer Potentiometer (POT) Setup - Used to calibrate the steering position potentiometer.

• Accelerator Potentiometer (POT) Setup - Used to calibrate the accelerator potentiometer.

• Lift Potentiometer (POT) Setup - Used to calibrate the lift potentiometer.

• Brake Potentiometer (POT) Setup - Used to calibrate the brake potentiometer.

• Lift Lockout Setup - This parameter allows for adjustment of the battery capacity percentage when lift lockout is initiated.

Forklift Calibration While in the display’s calibration menus, the forklift will not move forward, backward, or perform any mast functions other than lowering the forks.

Forklift calibration is performed by activating the key switch and performing the following procedure: 1. At the Main Screen, press and hold the ENTER button for approximately 5 seconds. This will open the calibration menu. An asterisk (*) will show your selection. You can use the UP/DOWN arrows to toggle the selection. Hold down ENTER to select.

2. To adjust the screen’s contrast level, select LCD CONTRAST and hold the ENTER key. Press the UP and DOWN buttons to adjust the brightness to your preference.

3. To begin the forklift calibration, go back to the main screen, move the asterisk to TRUCK SETUP and hold the ENTER button. See Figure 6-1.

4. The next screen will give you the option to enter a password or to exit. To enter the password, select ENTER PW and hold enter, then use the UP/DOWN arrows to manipulate the value to the desired digit.

Pressing the ENTER button accepts that digit and moves onto the next one. Repeat this process for each digit. After entering the correct password, the truck setup menu will be displayed.

6-2

NOTICE The default password is: 4231 5. If you would like a reminder for maintenance, navigate to MAINT MONITOR selection and adjust the Service Due Hour Meter value as you require.

The digits show the number of hours in 100’s until the warning is shown. To disable this option, just enter 99900 hours into the field.

6. Next to calibrate the steer potentiometer, press the DOWN arrow button until the asterisk is to the right of STEEP POT SETUP, and press ENTER. 7. The next screen will show what operations you will need to perform to complete the calibration. Hold down the ENTER to begin.

• The asterisk moves to the right indicating the current step in the calibration you are currently in.

• Steer the forklift fully left and press ENTER. Steer the forklift to approximate straight and press ENTER. Steer the forklift to the right position and press ENTER. • When the asterisk is beside the EXIT, the steer pot calibration is complete 8. Accelerator Potentiometer Calibration: Navigate to ACCEL POT SETUP on the main menu and press ENTER. Press ENTER again to begin calibration.

• ACCEL ZERO calibration - Ensure the foot pedal is in the up position and press ENTER. • ACCEL FULL - Press the pedal to the floor and press ENTER. Monitor the accelerator pot voltage on the screen; ensure this value is changing with movement of the pedal between 0.1VDC and 5.2VDC. • When the asterisk is beside the EXIT, the accelerator pot calibration is complete.

9. Lift Potentiometer Calibration: Navigate to LIFT POT SETUP from the truck setup menu and press ENTER. Press ENTER again to begin the calibration.

• LIFT LEVER ZERO - Ensure the lift lever is in the neutral position and press ENTER. • LIFT LEVER FULL - Pull the lift lever back completely and press ENTER. Monitor the lift pot voltage on the screen; ensure this value is changing with the movement of the lever, with values ranging from 2.5VDC and 3.7VDC. • When the asterisk is beside the EXIT, the lift lever pot calibration is complete.

10. Brake Potentiometer Calibration: Select BRAKE POT SETUP from the truck setup menu and press ENTER. Press ENTER again to begin calibration.

F-649-R0

CALIBRATION AND PROGRAMMING • BRAKE PEDAL ZERO - Ensure the brake pedal is in the up position and press ENTER. • BRAKE PEDAL FULL - Press the brake pedal to the floor and press ENTER. Monitor the brake pot voltage on the screen; ensure this value is changing with the movement of the pedal between 0.1VDC and 5.1VDC. • When the asterisk is beside the EXIT, the brake pot calibration is complete.

11. Lift Lockout Setup: Select LIFT LOCKOUT from the truck setup menu and press enter. Press ENTER again to begin editing.

• Use the UP/DOWN arrows to manipulate the value to the desired percentage of battery charge before the “Limp Home” mode is activated and press ENTER to store the new value. This completes the Lift Lockout Setup.

1314 Controller Software Installation and Operation The 1314 controller software is used to manipulate, monitor and diagnose the Bendi AC/DS forklift performance and functions.

The following sections will guide you through the installation of the 1314 Controller Programming Station and explain the software program functionality.

*TRUCK SETUP LCD CONTRAST EXIT *PASSWORD **** EXIT “Password Ok”

Figure 6-3: 1309 Interface Cable (Part# 171549)

*LCD CONTRAST ADJUST CONTRAST EXIT *MAINT. MONITOR STEER POT SETUP ACCEL POT SETUP BRAKE POT SETUP LIFT LOCKOUT % EXIT *VEHICLE HRS NXT SVC DUE EXIT

Maint. Montor Sub-Menu

*STEER FULL LEFT STEER CENTER STEER FULL RIGHT STEER POT = VDC EXIT

Steer Pot Setup Sub-Menu

*ACCELERATOR ZERO ACCELERATOR FULL Accel Pot Setup ACCEL POT = VDC Sub-Menu EXIT *BRAKE PEDAL ZERO BRAKE PEDAL FULL BRAKE POT = VDC EXIT

Brake Pot Setup Sub-Menu

Figure 6-4: Controller to USB Cable Shown in Figure 6-3 is the serial to USB adaptor cable connected to the Curtis 1309 interface cable that is to be connected between the forklift controller and your laptop computer. Refer to “Cable Connections” on page 6-4 for forklift cable connector(s) locations.

*LIFT LOCKOUT % EXIT

Figure 6-2: Forklift Calibration Flow Chart 6-3

CALIBRATION AND PROGRAMMING =

Figure 6-5: Cable Connections

6-4

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CALIBRATION AND PROGRAMMING

Software Installation Procedure Follow the installation instructions below: 1. Insert Curtis 1314 PC Programming Station CD into your CD ROM drive.

2. If the screen in Figure 6-6 does not automatically appear, go to your computer directory, double click your CD drive (usually D:\) and double click “SETUP.EXE” as shown in Figure 6-7. If Autorun Fails Figure 6-7, click “NEXT.

Figure 6-6: Installation - Steps 1 and 2

Figure 6-7: Installation - Step 2, If Autorun Fails

6-5

CALIBRATION AND PROGRAMMING 3. Be sure to thoroughly read and understand the contents of the Software License Agreement.

4. If you agree click the radio button beside “I accept the agreement” then click “NEXT.”

Figure 6-8: Installation Steps 3 and 4 5. The next screen gives you the option to install the program in a specific location. In situations where multiple drives are used it may be helpful to use this option. For most users, the default location should be adequate. Click “NEXT.”

Figure 6-9: Installation - Step 5 6-6

F-649-R0

CALIBRATION AND PROGRAMMING 6. Click “INSTALL” to begin the process.

Figure 6-10: Installation - Step 6 7. If you see the screen in Figure 6-11, you have successfully installed the 1314 Curtis Program.

Click “FINISH” to launch the program. If you are not prepared to begin diagnostics uncheck the option beside “Run 1314 PC Programming Station.”

Figure 6-11: Installation - Step 7

6-7

CALIBRATION AND PROGRAMMING

Software Update Procedure This procedure must be completed before using the software, on every installation of the software. See Figure 6-12.

1. Open the 1314 Software program and select “Help.”

2. Select the “CHECK FOR UPDATES” menu.

This will use the internet to ensure that you have the latest revision level.

Figure 6-12: Check for Updates

6-8

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CALIBRATION AND PROGRAMMING

Communicating with Bendi AC/DS Controllers

Figure 6-13: Communicating with the Controllers • To initiate communications with the Bendi controllers, with the Curtis program open go to “OPTIONS”, then click “CHANGE PROTOCOL/PORT”, as shown in “Communicating with the Controllers” on page 6-9.

• The computer should be connected to the forklift’s harness labeled “Master,” and the forklift turned on.

• Select “ENHANCED SERIAL” protocol and then press the “CONNECT” button. See Figure 6-14.

Though, the communication port number may differ from computer to computer.

• Highlight the connected controller and select the icon for Device Parameters. See Figure 6-15. Once you’ve selected a parameter from the program tree you can adjust them in the active window.

• The device may be monitored by clicking on the “MONITOR” button. The monitor function is useful to see actual controller values during operation of the forklift.

Figure 6-14: Selecting Protocol and Port

6-9

CALIBRATION AND PROGRAMMING

Figure 6-15: Accessing Parameters

Figure 6-16: Accessing the Monitor

6-10

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CALIBRATION AND PROGRAMMING

Menu Overview See “Programmer Menu Legend” on page 6-11 for the following: Number 1 shows the Disconnect Icon.

Number 2 shows, from left to right, Device Info, Device Parameters, Device Monitor, Device Functions, and Fault Check.

Number 3 shows the controller currently connected. The Master Controller, The Slave Controller, and The Pump Controller.

Figure 6-17: Programmer Menu Legend

Program Menu Legend There are five menus, which in turn lead to nested sub-menus.

• Device Information — This displays data about the host controller, model and serial numbers, date of manufacture. See Figure 6-18.

• Parameters — This provides access to the programmable parameters.

• Monitor — This presents real-time values during vehicle operation; these include all inputs and outputs, as well as the mapped throttle values and conditioned throttle requests.

• Functions — This provides access to the controller-cloning commands and to the “reset” command.

• Faults — This presents diagnostic information and also a means to clear the fault history file.

After successfully connecting to the controller, proceed through the instructed menus and sub-menus to review all parameters.

Where available, descriptions for the following parameters are taken directly from Curtis Instruments, Inc.’s Integrated Traction & Hydraulic System Motor Controller Manual.

For All Parameters: To change actual value to a desired value, click in the white text field or use the slider just underneath. When complete, click OK to change value. All parameters are programmable from the Master Controller connection.

After successfully re-flashing a controller, make sure to clear the fault history of all comments.

Contact Landoll for Current Software Revision. See Figure 6-18.

Figure 6-18: Device Information

6-11

CALIBRATION AND PROGRAMMING

Figure 6-19: Landoll Traction, HPD Sequencing Delay (1 of 2)

Figure 6-20: Landoll Traction, HPD Sequencing Delay (2 of 2)

6-12

F-649-R0

CALIBRATION AND PROGRAMMING NOTE Parameters are programmed from the master controller connection.

Landoll Traction Menu Programmable Parameter HPD Sequencing Delay Steer Cont PWM Steering Off Delay Lift Lockout Level Multimode Functions, Rabbit Fwd Max Speed Multimode Functions, Turtle Fwd Max Speed Multimode Functions, Rabbit Rev Max Speed Multimode Functions, Turtle Rev Max Speed HourMeter, Set Total HM

HourMeter, 10’s of Hours

HourMeter, Remaining HRs in Mins

Maintenance Due, Next Service Due

Definition

Range

Actual value shows current duration the seat switch can be false until SRO (return to neutral) occurs.

Sets the voltage applied to the contactor coil.

Sets the amount of time that the pump will continue to run after the seat switch parameter is false.

Sets the percentage of battery discharge before lift lockout occurs. See NOTE A Sets the forward vehicle max speed in Rabbit Mode. See NOTE B

0.0 - 5.0 seconds 0 - 100% 0.0 - 30.0 seconds 0 - 99% 0 - 100%

Sets the forward vehicle max speed in Turtle See NOTE B Sets the reverse vehicle max speed in Rabbit Mode. See NOTE B

0 - 100%

Sets the reverse vehicle max speed in Turtle Mode. See NOTE B

0 - 100%

When set to “On,” values entered in “10’ths of Hours” and “Remaining HRs in Mins” parameters are sent to the controller.

Sets the value, i.e., the number of hours / 10, for number of hours. This value must be in multiples of 10.

Ex. For 1507.3 hours, 150 would be entered here (1507 hours / 10 = 150 Remainder of 7.3).

See NOTE C Sets the value for number of hours less than 10, entered in minutes.

Ex. For 7.3 hours, 438 would be entered here (7.3 x 60 = 438). See NOTE C When hour meter is equal to the value entered here, “SRVC DUE” will be displayed on the dash display. This is an optional parameter, and effective off is set to 99900 (factory default).

Off - On

0 - 100%

0 - 20,000

0 - 600

0 - 99900 hours

NOTES NOTE A: Lift lockout protects the operator from taking the battery below safe levels.

NOTE B: The ‘Rabbit’ and ‘Turtle’ functions determine the max speed traveled by 2 different modes of the speed mode selection switch.

NOTE C: “Hour Meter, 10’s of Hours” and “Hour Meter, Remaining Hours in Minutes” work in conjunction with each other to cover the total hours.

6-13

CALIBRATION AND PROGRAMMING NOTE Parameters are programmed from the master controller connection.

1 - Speed Mode Programmable Parameter Response, Full Accel Rate HS Response, Full Accel Rate LS Response, Low Accel Rate Response, Neutral Decel Rate HS Response, Neutral Decel Rate LS Response, Full Brake Rate HS

Response Full Brake Rate LS

Response, Low Brake Rate

6-14

Definition

Range

Sets the rate (in seconds) at which the speed command increases when full throttle is applied at high vehicle speeds. Larger values represent slower response.

Sets the rate (in seconds) at which the speed command increases when full throttle is applied at low vehicle speeds.

Sets the rate (in seconds) at which the speed command increases when a small amount of throttle is applied. This rate is typically adjusted to affect low speed maneuverability.

Sets the rate (in seconds) that is used to slow down the vehicle when the throttle is released to neutral at high vehicle speeds.

Sets the rate (in seconds) that is used to slow down the vehicle when the throttle is released to neutral at slow vehicle speeds.

Sets the rate (in seconds) at which the vehicle slows down from high speeds when full brake is applied or when full throttle is applied in the opposite direction.

Sets the rate (in seconds) at which the vehicle slows down from slow speeds when full brake is applied or when full throttle is applied in the opposite direction.

Sets the rate (in seconds) at which the vehicle slows down at all speeds when a small amount of brake is applied or when a small amount of throttle is applied in the opposite direction.

0.1 - 30.0 seconds

0.1 - 30.0 seconds 0.1 - 30.0 seconds

0.1 - 30.0 seconds 0.1 - 30.0 seconds 0.1 - 30.0 seconds

0.1 - 30.0 seconds

0.1 - 30.0 seconds

F-649-R0

CALIBRATION AND PROGRAMMING

1 - Speed Mode Programmable Parameter Response, Fine Tuning, Partial Decel Rate Response, Fine Tuning, HS (High Speed) Response, Fine Tuning, LS (Low Speed) Response, Fine Tuning, Reversal Soften

Response, Fine Tuning, Max Speed Accel

Response, Fine Tuning, Max Speed Decel

Definition

Range

Sets the rate (in seconds) that is used to slow down the vehicle when the throttle is reduced without being released to neutral. Larger values represent slower response.

Sets the percentage of the Typical Max Speed above which the HS parameters will be used.

0.1 - 30.0 seconds

Sets the percentage of the Typical Max Speed below which the LS parameters will be used.

0 - 100%

Larger values create a softer reversal from regen braking to drive when near zero speed.

This helps soften the transition when the regen and drive current limits are set to different values.

Controls the rate at which the maximum speed set point is allowed to change when the value of Max Speed is raised. The rate set by this parameter is the time to ramp from 0 rpm to Typical Max Speed rpm.

Ex. suppose Max Speed is raised from 1000 rpm to 4000 rpm. If Typical Max Speed is 5000 rpm, and the rate is 10.0 seconds, it will take 10.0 * (4000 - 1000) / 5000 = 6.0 seconds to ramp from 1000 rpm to 4000 rpm.

Controls the rate at which the maximum speed set point is allowed to change when the value of Max Speed is lowered.

Ex. suppose you change Max Speed from 4500 rpm to 2500 rpm. If Typical Max Speed is 5000 rpm, and the rate is 5.0 seconds, it will take 5.0 * (4500 - 2500) / 5000 = 2.0 seconds to ramp from 4500 rpm to 2500 rpm.

0 - 100%

0 - 100%

0.1 - 30.0 seconds

0.1 - 30.0 seconds

6-15

CALIBRATION AND PROGRAMMING NOTE Parameters are viewed from the master controller connection. Do not manually set any of the following settings through the software.

Throttle Programmable Parameters

Forward Deadband

Forward Max

Reverse Deadband

Reverse Max

6-16

Definition

Range

Defines the accelerator potentiometer voltage at the deadband threshold when the direction switch is set to FWD. This value is set automatically when calibrating through the dash display.

DO NOT set this through the software.

Defines the accelerator potentiometer voltage required to produce 100% controller output when the direction switch is set to FWD. This value is set automatically when calibrating through the dash display.

DO NOT set this through the software.

Defines the accelerator potentiometer voltage at the deadband threshold when the direction switch is set to REV. This value is set automatically when calibrating through the dash display.

DO NOT set this through the software.

Defines the accelerator potentiometer voltage required to produce 100% controller output when the direction switch is set to REV. This value is set automatically when calibrating through the dash display.

DO NOT set this through the software.

0.00 - 5.00 V

0.00 - 5.00 V

0.00 - 5.00 V

0.00 - 5.00 V

F-649-R0

CALIBRATION AND PROGRAMMING NOTE Parameters are viewed from the master controller connection. DO NOT manually set any of the following settings through the software.

Brake Programmable Parameter

Brake Deadband

Brake Max

Definition

Range

Defines the brake potentiometer voltage at the deadband threshold. This value is set automatically when calibrating through the dash display.

DO NOT set this through the software.

Defines the brake potentiometer voltage required to produce 100% controller output.

This value is set automatically when calibrating through the dash display.

DO NOT set this through the software.

0.00 - 5.00 V

0.00 - 5.00 V

6-17

CALIBRATION AND PROGRAMMING NOTE Parameters are programmed from the master controller connection.

Battery Programmable Parameter

Reset Volts Per Cell

Full Volts Per Cell

Empty Volts Per Cell

Discharge Time

Battery Discharge Indicator Reset Percent

6-18

Definition

Range

The reset voltage level is checked only once, when KSI is first turned on. Note that the BDI Reset Percent parameter also influences the algorithm that determines whether BDI percentage is reset to 100%. Reset Volts Per Cell should always be set higher than Full Volts Per Cell. Reset Voltage Level = Reset Volts Per Cell × number of cells in the battery pack.

DO NOT modify this from the Landoll default setting.

The full voltage level sets the key switch voltage that is considered to be 100% state-of-charge; when a loaded battery drops below this voltage, it begins to lose charge. Key switch voltage is viewable in the 1314 menu Monitor » Battery. Full Voltage Level = Full Volts Per Cell × number of cells in the battery pack.

DO NOT modify this from the Landoll default setting.

The empty voltage level sets the key switch voltage that is considered to be 0% state-of-charge. Empty Voltage Level = Empty Volts Per Cell × number of cells in the battery pack.

DO NOT modify this from the Landoll default setting.

Sets the minimum time for the BDI algorithm to count down the BDI percentage from 100% to 0%. State of Charge Level = ((Full Voltage Level - Empty Voltage Level) × BDI Percentage / 100) + Empty Voltage Level.

When a battery has a high BDI percentage, its float voltage at KSI On can sometimes cause false resets. The BDI Reset Percent parameter addresses this problem by allowing the user to define a BDI percentage value above which the BDI Percentage variable will not reset. When KSI is first powered on, the BDI percentage variable will reset to 100% only if (Key Switch Voltage > Reset Voltage Level) and (BDI Percentage < BDI Reset Percent).

0.900 - 3.000 V

0.900 - 3.000 V

0.900 - 3.000 V

0 - 600 minutes

0 - 100%

F-649-R0

CALIBRATION AND PROGRAMMING NOTES Parameters are programmed from the master controller connection.

Dual Drive Programmable Parameter Master, Steer Pot Min

Master, Steer Pot Zero

Master, Steer Pot Max

Definition

Range

Defines the steer potentiometer voltage when steering as far counterclockwise as possible.

This value is set automatically when calibrating through the dash display.

DO NOT set this through the software.

Defines the steer potentiometer voltage when the steering straight ahead. This value is set automatically when calibrating through the dash display.

DO NOT set this through the software.

Defines the steer potentiometer voltage when steering as far clockwise as possible. This value is set automatically when calibrating through the dash display.

DO NOT set this through the software.

0.00 - 5.00 V

0.00 - 5.00 V

0.00 - 5.00 V

6-19

CALIBRATION AND PROGRAMMING

Device Parameter Monitor Make sure that you have the controller selected (1) and click the Monitor Icon (2).

Figure 6-21: Monitor Menu

Landoll Parameter Details Monitor Value Name Lift Cutout Flag Steer Pump Speed Flag Parking Brake Switch Seat Switch Battery Roll Out Switch Mode Switch Throttle Switch Forward Switch Reverse Switch Main Cont Driver PWM Motor Temp Sensor Analog

6-20

Definition

Range

On when in Lift Lock-Out. On when in forward or reverse AND driver is on the seat.

On when the Parking Brake is engaged.

On when operator is in seat.

On when battery is correctly installed.

(Optional) On when in Rabbit Mode, Off when in Turtle Mode.

On when accelerator is depressed.

On when direction switch is engaged in the forward direction.

On when direction switch is engaged in the reverse direction.

100% setting to pull in contactor and 80% to hold contactor.

Linear thermocouple reading.

On - Off On - Off On - Off On - Off On - Off On - Off On - Off On - Off On - Off 0 - 100%

F-649-R0

CALIBRATION AND PROGRAMMING

Inputs Parameter Details Monitor Value Name Throttle Command Mapped Throttle Throttle Pot Brake Command Mapped Brake Brake Pot Steer Pot Steer Angle (deg) Interlock

Definition

Range

Shows, in percentage, the amount of command being requested of the controller.

Shows, in percentage, the throttle being requested of the motors, factoring in speed setting, angle of steer pot, etc.

Shows, in volts, the value of the throttle’s potentiometer wiper.

Shows, in percentage, the amount of command being requested of the controller.

Shows, in percentage, the deceleration of the motors, factoring in speed setting, direction of travel, etc.

Shows, in volts, the value of the second potentiometer’s wiper.

Shows, in volts, the value of the steering’s potentiometer wiper.

Shows, in degrees, the steer angle calculated by the controller.

Shows if the interlock is on or off.

-100 - 100%

Definition

Range

Shows, in volts, the value of the +5V supply for the left motor encoder.

Shows, in milliamps, the current of the +5V supply for the left motor encoder.

0.00 - 6.25 V

Definition

Range

-100 - 100%

0.0 - 5.5 V 0 - 100% 0 - 100%

0.0 - 5.5 V 0.0 - 5.5 V -90 - 90° On - Off

Outputs Parameter Details Monitor Value Name 5 Volts Ext Supply Current

5 - 200 mA

Battery Parameter Details Monitor Value Name BDI Capacitor Voltage Key Switch Voltage

Shows, in percentage, the battery’s state of charge.

Shows, in volts, the value of the controller’s internal capacitor bank at the B+ terminal.

Shows, in volts, the value of the KSI.

0 - 100% 0 - 105 V 0 - 105 V

6-21

CALIBRATION AND PROGRAMMING

Motor Parameter Details Monitor Value Name Motor RPM Temperature MotorSpeed A

MotorSpeed B

Definition

Range

Shows, in revolutions per minute, the speed of the motor.

Shows, in degrees Celsius, temperature at the sensor.

Shows, in revolutions per minute, the speed of the motor encoder phase A. Should equal MotorSpeed B. Shows, in revolutions per minute, the speed of the motor encoder phase B. Should equal MotorSpeed A.

-12000 - 12000 RPM -100 - 300 °C

Definition

Range

Shows, in amps, the RMS current of the controller, all 3 phases taken into account.

Shows, in degrees Celsius, the controller’s internal temperature.

Shows the state that the main contactor is in.

0 means open 1 means precharge 2 means weldcheck 3 means closing delay 4 means missing check 5 means closed (when Main Enable is on) 6 means delay 7 means arccheck 8 means opendelay 9 means fault 10 means closed (when Main Enable is off) Shows if the regen braking is taking place.

Shows the value of the VCL Runtime Error.

Shows the value of the cause of the VCL Runtime Error.

0 - 1000 A

0 - 12000 RPM

0 - 12000 RPM

Controller Parameter Details Monitor Value Name Current (RMS) Temperature

Main State

Regen VCL Error Module VCL Error

6-22

-100 - 300 °C 0 - 10

On - Off 0 - 65536 0 - 65536

F-649-R0

CALIBRATION AND PROGRAMMING

Cutback Parameter Details Monitor Value Name Motor Temp Cutback

Controller Temp Cutback

Undervoltage Cutback

Overvoltage Cutback

Definition

Range

Shows, in percent, the current available as a result of the motor temperature cutback function. A value of 100% indicates no cutback in current.

Shows, in percent, the current available as a result the controller temperature cutback function. A value of 100% indicates no cutback in current.

Shows, in percent, the current available as a result the undervoltage cutback function. A value of 100% indicates no cutback in current.

Shows, in percent, the current available as a result the overvoltage cutback function. A value of 100% indicates no cutback in current.

0 - 100%

Definition

Range

0 - 100%

0 - 100%

0 - 100%

Vehicle Parameter Details Monitor Value Name

Base Speed Captured

Displays the value of the motor base speed captured in the most recent acceleration. This value is used to set the Base Speed parameter (Program » Motor Control Tuning » Field Weakening Control menu), using the Base Speed.

0 - 8000

CAN Status Parameter Details Monitor Value Name

CAN NMT State

Definition

Range

Shows the current controller CAN NMT State.

0 means initialization 4 means stopped 5 means operational 127 means pre-operational.

Curtis Controller Troubleshooting The following troubleshooting chart provides information on the Curtis controller faults: • Fault code • Fault name and effect displayed on the dash display • Possible causes of the fault • Fault ‘set’ and ‘clear’ conditions

0 - 127

NOTICE Whenever a fault is encountered and no wiring or vehicle fault can be found, shut off the key switch and turn it back on to see if the fault clears. If it does not, shut off the key switch and remove the 35-pin connector. Check the connector for corrosion, damage, or unseated terminals. If necessary, clean the pins and re-insert them.

6-23

CALIBRATION AND PROGRAMMING

Controller Fault History

LED Legend LED Status Neither LED illuminated Yellow LED flashing Yellow and red LED’s both on solid Red LED on solid

What it Means Controller is not powered on; vehicle has dead battery; severe damage.

Controller is operating normally.

Controller is in Flash Program Mode.

Watchdog failure or no software loaded. Cycle key switch, and if necessary load software.

Red LED and Controller has detected a fault. yellow LED A 2-digit code flashed by the flashing yellow LED identifies the alternately specific fault.

One or two flashes by red LED indicate whether first or second code digit will follow.

Wait for the red LED to blink once. Count the number of times the yellow LED blinks for the 1st digit. Wait for the red LED to blink twice. Count the number of times the yellow LED blinks for the 2nd digit.

See Figure 6-22. For illustration, see photo or refer to Controller panel Figure 6-5, or the left, pump and right controllers, the interconnect cables and the LED lights.

The 1314 programmer can be used to access the controller’s fault history. Click on the icon as shown in “Fault Monitor” on page 6-24 and select the appropriate option. If you select Fault History, the programmer will read our all of the faults the controller has experienced since the last time the fault history was cleared. See Figure 6-24. After a problem has been diagnosed and corrected, clear the Fault History. This can be achieved by highlighting the individual fault, right clicking it, and clicking Clear. This allows the controller to accumulate a new list of faults which can help determine if a problem was indeed fixed.

NOTICE After successfully re-flashing a controller, make sure to clear the fault history of all comments.

Figure 6-23: Fault Monitor

Figure 6-22: LED Status

Figure 6-24: Fault History

6-24

F-649-R0

CALIBRATION AND PROGRAMMING (

Controller Troubleshooting Chart C o d e

Fault on the Programmer LCD Display (Bold) and What it Triggers

12

Controller Overcurrent ShutdownMotor; ShutdownMainContactor; ShutdownEMBrake; ShutdownThrottle; FullBrake; ShutdownPump Current Sensor Fault ShutdownMotor; ShutdownMainContactor; ShutdownEMBrake; ShutdownThrottle; FullBrake; ShutdownPump Precharge Failed ShutdownMotor; ShutdownMainContactor; ShutdownEMBrake; ShutdownThrottle; Full Brake; ShutdownPump Controller Severe Undertemp ShutdownMotor; ShutdownMainContactor; ShutdownEMBrake; ShutdownThrottle; FullBrake; ShutdownPump Controller Severe Overtemp ShutdownMotor; ShutdownMainContactor; ShutdownEMBrake; ShutdownThrottle; FullBrake; ShutdownPump Severe Undervoltage Reduced drive torque

13

14

15

16

17

T P

Possible Causes

Set/Clear Conditions

X X 1. External short of phase U, V, or W motor connections.

2. Motor parameters are mis-tuned.

3. Controller defective.

Set: Phase current exceeded the current measurement limit.

Clear: Cycle KSI.

X X 1. Leakage to vehicle frame from phase U, V, or W (short in motor stator).

2. Controller defective.

Set: Controller current sensors have invalid offset reading.

Clear: Cycle KSI.

X X 1. See Monitor menu » Battery: Capacitor Voltage.

2. External load on capacitor bank (B+ connection terminal) that prevents the capacitor bank from charging.

Set: Precharge failed to charge the capacitor bank to the KSI voltage.

Clear: Cycle Interlock input or use VCL function Precharge().

X X 1. See Monitor menu » Controller: Temperature.

2. Controller is operating in an extreme environment.

Set: Heatsink temperature below -40°C. Clear: Bring heatsink temperature above -40°C, and cycle interlock or KSI.

X X 1. See Monitor menu » Controller: Temperature.

2. Controller is operating in an extreme environment.

3. Excessive load on vehicle.

4. Improper mounting of controller.

Set: Heatsink temperature above +95°C. Clear: Bring heatsink temperature below +95°C, and cycle interlock or KSI.

X X 1. Battery Menu parameters are misadjusted. 2. Non-controller system drain on battery.

3. Battery resistance too high.

4. Battery disconnected while driving.

5. See Monitor menu » Battery: Capacitor Voltage.

6. Blown B+ fuse or main contactor did not close.

Set: Capacitor bank voltage dropped below the Severe Undervoltage limit (see page 55) with FET bridge enabled.

Clear: Bring capacitor voltage above Severe Undervoltage limit.

6-25

CALIBRATION AND PROGRAMMING

Controller Troubleshooting Chart C o d e

Fault on the Programmer LCD Display (Bold) and What it Triggers

18

Severe Overvoltage ShutdownMotor; ShutdownMainContactor; ShutdownEMBrake; ShutdownThrottle; FullBrake; ShutdownPump

22

Controller Overtemp Cutback Reduced drive and brake torque

23

Undervoltage Cutback Reduced drive torque

24

Overvoltage Cutback Reduced brake torque

25

+5V Supply Failure None, unless a fault action is programmed in VCL

6-26

T P

Possible Causes

X X 1. See Monitor menu » Battery: Capacitor Voltage.

2. Battery menu parameters are misadjusted.

3. Battery resistance too high for given regen current.

4. Battery disconnected while regen braking.

X X 1. See Monitor menu » Controller: Temperature.

2. Controller is performance-limited at this temperature.

3. Controller is operating in an extreme setting.

4. Excessive load on vehicle.

5. Improper mounting of controller X X 1. Normal operation. Fault shows that the batteries need recharging.

Controller is performance limited at this voltage.

2. Battery parameters are misadjusted.

3. Non-controller system drain on battery.

4. Battery resistance too high.

5. Battery disconnected while driving.

6. See Monitor menu » Battery: Capacitor Voltage.

7. Blown B+ fuse or main contactor did not close.

X X 1. Normal operation. Fault shows that regen braking currents elevated the battery voltage during regen braking.

Controller is performance limited at this voltage.

2. Battery parameters are misadjusted.

3. Battery resistance too high for given regen current.

4. Battery disconnected while regen braking.

5. See Monitor menu » Battery: Capacitor Voltage.

X X 1. External load impedance on the +5V supply (pin 26) is too low.

2. See Monitor menu » outputs: 5 Volts and Ext Supply Current.

Set/Clear Conditions Set: Capacitor bank voltage exceeded the Severe Overvoltage limit (see page 55) with FET bridge enabled.

Clear: Bring capacitor voltage below Severe Overvoltage limit, and then cycle KSI. Set: Heat sink temperature exceeded 85°C. Clear: Bring heat sink temperature below 85°C.

Set: Capacitor bank voltage dropped below the Undervoltage limit (see page 55) with the FET bridge enabled.

Clear: Bring capacitor voltage above the undervoltage limit.

Set: Capacitor bank voltage exceeded the Overvoltage limit (see page 55) with the FET bridge enabled.

Clear: Bring capacitor voltage below the Overvoltage limit.

Set: +5V supply (pin 26) outside the +5V±10% range.

Clear: Bring voltage within range.

F-649-R0

CALIBRATION AND PROGRAMMING

Controller Troubleshooting Chart C o d e

Fault on the Programmer LCD Display (Bold) and What it Triggers

28

Motor Temp Hot Cutback Reduced drive torque

29

Motor Temp Sensor Fault MaxSpeed reduced (LOS, Limited Operating Strategy), and motor temperature cutback disabled

31

Coil1 Driver Open/Short ShutdownDriver1

36

Encoder Fault ShutdownEMBrake

37

Motor Open ShutdownMotor; ShutdownMainContactor; ShutdownEMBrake; ShutdownThrottle; FullBrake; ShutdownPump Main Contactor Welded ShutdownMotor; ShutdownMainContactor; ShutdownEMBrake; ShutdownThrottle; FullBrake; ShutdownPump

38

T P

Possible Causes

X X 1. Motor temperature is at or above the programmed Temperature Hot setting, and the requested current is being cut back.

2. Motor Temp Control Menu parameters are mis-tuned.

3. See Monitor menu » Motor: Temperature and » Inputs: Analog2.

4. If the application doesn’t use a motor thermistor, Temp Compensation and Temp Cutback should be programmed Off. X X 1. Motor thermistor is not connected properly.

2. If the application doesn’t use a motor and motor thermistor, Motor Temp Sensor Enable should be programmed Off. 3. See Monitor menu » Motor: Temperature and » Inputs: Analog2.

X X 1. Open or short on driver load.

2. Dirty connector pins.

3. Bad crimps or faulty wiring.

X X 1. MotorCoil3 Driver Open/Short ShutdownDriver3 encoder failure.

2. Bad crimps or faulty wiring.

3. See Monitor menu » Motor: Motor RPM. X X 1. Motor phase is open.

2. Bad crimps or faulty wiring.

X X 1. Main contactor tips are welded closed.

2. Motor phase U or V is disconnected or open.

3. An alternate voltage path (such as an external precharge resistor) is providing a current to the capacitor bank (B+ connection terminal).

Set/Clear Conditions Set: Motor temperature is at or above the Temperature Hot parameter setting.

Clear: Bring the motor temperature within range.

Set: Motor thermistor input (pin 8) is at the voltage rail (0 or 10V).

Clear: Bring the motor thermistor input voltage within range.

Set: Main contactor driver (pin 6) is either open or shorted. This fault can be set only when Main Enable = Off. Clear: Correct open or short, and cycle driver.

Set: Motor encoder phase failure detected.

Clear: Cycle KSI.

Set: Motor phase U, V, or W detected open.

Clear: Cycle KSI.

Set: Just prior to the main contactor closing, the capacitor bank voltage (B+ connection terminal) was loaded for a short time and the voltage did not discharge.

Clear: Cycle KSI

6-27

CALIBRATION AND PROGRAMMING

Controller Troubleshooting Chart C o d e

Fault on the Programmer LCD Display (Bold) and What it Triggers

39

Main Contactor Didn’t close ShutdownMotor; ShutdownMainContactor; Shutdown EMBrake; ShutdownThrottle; Fullbrake; ShutdownPump Throttle Wiper High ShutdownThrottle

X X 1. Main contactor did not close.

2. Main contactor tips are oxidized, burned, or not making good contact.

3. External load on capacitor bank (B+ connection terminal) that prevents capacitor bank from charging.

4. Blown B+ fuse.

Set: With the main contactor commanded closed, the capacitor bank voltage (B+ connection terminal) did not charge to B+.

Clear: Cycle KSI.

X X 1. See Monitor menu » Inputs: Throttle Pot. 2. Throttle pot wiper voltage too high.

42

Throttle Wiper Low ShutdownThrottle

X X 1. See Monitor menu » Inputs: ThrottlePot. 2. Throttle pot wiper voltage too high.

43

Pot2 Wiper High FullBrake Pot2 Wiper Low FullBrake Pot Low Overcurrent ShutdownThrottle FullBrake ShutdownSteer EEPROM Failure ShutdownMotor; ShutdownMainContactor; Shutdown EMBrake; ShutdownThrottle; ShutdownInterlock; ShutdownDriver1 ShutdownDriver2; Shutdowndriver3; ShutdownDriver4; ShutdownPD; Fullbrake; ShutdownPump; TrimDisable;SevereDual; ShutdownSteer; LOSDual

X

Refer to Curtis

Set: Throttle pot wiper (pin 16) voltage is higher than the high fault threshold (can be changed with the VCL function SETUP POT FAULTS) Clear: Bring throttle pot wiper voltage above the fault threshold.

Set: Throttle pot wiper (pin 16) voltage is higher than the high fault threshold (can be changed with the VCL function Setup_Pot_Faults).

Clear: Bring throttle pot wiper voltage below the fault threshold.

Return Controller to Landoll Company, LLC for evaluation.

X

Refer to Curtis

41

44 45

46

6-28

T P

Possible Causes

Set/Clear Conditions

Return Controller to Landoll Company, LLC for evaluation.

X X 1. See Monitor menu » Outputs: Pot Low. 2. Combined pot resistance connected to pot low is too low.

Set: Pot low (pin 18) current exceeds 10mA. Clear: Clear pot low overcurent condition and cycle KSI.

X X 1. Failure to write to EEPROM memory. This can be caused by EEPROM memory writes initiated by VCL, by the CAN bus, by adjusting parameters with the programmer, or by loading new software into the controller.

Set: Controller operating system tried to write to EEPROM memory and failed.

Clear: Download the correct software (OS) and matching parameter default settings into the controller and cycle KSI.

F-649-R0

CALIBRATION AND PROGRAMMING

Controller Troubleshooting Chart C o d e

Fault on the Programmer LCD Display (Bold) and What it Triggers

47

HPD/Sequecing Fault.

Shutdown Throttle

49

Parameter Change Fault ShutdownMotor; ShutdownEMBrake; Shutdown Throttle; Fullbrake; ShutdownPump Battery Rollout Switch Fault in Left traction controller.

VCL Run Time Error ShutdownMotor; ShutdownMainContactor; ShutdownEMBrake; ShutdownThrottle; ShutdownInterlock; ShutdownDriver1; ShutdownDriver2; ShutdownDriver3: ShutdownDriver4; ShutdownPD; FullBrake; ShutdownPump; TrimDisable; SevereDual; ShutdownSteer; LOSDual External Supply Out of Range None, unless a fault action is programmed in VCL;

52

68

69

T P

Possible Causes 1. KSI, interlock, direction, and throttle inputs applied in incorrect sequence.

2. Bad crimp, faulty wiring or KSI switch.

See Monitor menu » Inputs.

X X 1. This is a safety fault caused by a change in certain parameter settings so that the vehicle will not operate until KSI is cycled. For example, if a user changes the Throttle Type, this fault will appear and require cycling KSI before the vehicle can operate.

Set/Clear Conditions Set: HPD (High Pedal Disable) or sequencing fault caused by incorrect sequence if KSI, interlock, direction and throttle inputs.

Clear: Reapply correct input sequence.

Set: Adjustment of a parameter setting that requires cycling of KSI. Clear: Cycle KSI.

Return Controller to Landoll Company, LLC for evaluation.

X X 1. VCL code encountered a runtime VCL error.

2. See Monitor menu » Controller:VCL Error Module and VCL Error. This error can then be compared to the runtime VCL module ID and error code definitions found in the specific OS system information file.

Set: Runtime VCL code error condition.

Clear: Edit VCL application software to fix this error condition; flash the new compiled software and matching parameter defaults; cycle KSI.

X X 1. External load on the 5V and 12V supplies draws either too much or too little current.

2. Fault Checking Menu parameters Ext Supply Max and Ext Supply Min are mistuned.

3. See Monitor menu » Outputs: Ext Supply Current.

Set: The external supply current (combined current used by the 5V supply [pin 26} and 12V supply {pin 25}) is either greater than the upper current threshold or lower than the low current threshold. The two thresholds are defined by the External Supply Max and External Supply Min parameter settings.

Clear: Bring the external supply current within range.

6-29

CALIBRATION AND PROGRAMMING

Controller Troubleshooting Chart C o d e

Fault on the Programmer LCD Display (Bold) and What it Triggers

71

OS General ShutdownMotor; ShutdownMainContactor; ShutdownEMBrake; ShutdownThrottle; ShutdownInterlock; ShutdownDriver1; ShutdownDriver2; ShutdownDriver3; ShutdownDriver4; ShutdownPD; FullBrake; Shutdown Pump; TrimDisable; SevereDual; Shutdown Steer; LOSDual PDO TImeout Shutdown Interlock; CAN NMT State set to Pre-operational

72

73

Stall Detected ShutdownMotor; SevereDual; ShutdownEMBrake; Control Mode changed to LOS

74

Fault On Other Traction Controller For information on this fault, plug the programmer into the other controller.

Dual Severe Fault ShutdownMotor; ShutdownMainContactor ShutdownEMBrake; Shutdown Throttle; FullBrake; Shutdown; Pump other controller; Same effects as this controller.

75

6-30

T P

Possible Causes

Set/Clear Conditions

X X 1. Internal Controller fault.

Set: Internal controller fault detected.

Clear: Cycle KSI.

X X Time between CAN OPDO messages received exceeded the PDO Timeout Period.

Set: Time between CAN PDO messages received exceeded the PDO Timeout Period.

Clear: Cycle KSI or receive CAN NMT message Set: No motor encoder movement detected.

Clear: Either cycle KSI, or detect valid motor encoder signals while operating in LOS mode and return Throttle Command=) and Motor RPM=0.

X X 1. Stalled motor.

2. Motor encoder failure.

3. Bad crimps or faulty wiring.

4. Problems with power supply for the motor encoder.

5. See Monitor menu » Motor: Motor RPM. X X 1. A fault is active on the other traction controller.

X X 1. Both taction controllers have active severe faults and therefore both will be disabled.

Set: In a Dual Drive traction system, any fault in the other traction controller will cause this fault to be set.

Clear: Clear all the active faults in the other traction controller.

Set: A severe fault in each traction controller will cause this fault to be set.

Clear: Correct the severe fault(s) in either controller to clear the Dual Severe Fault; of course, you will want to clear all faults on both controllers.

F-649-R0

CALIBRATION AND PROGRAMMING

Controller Troubleshooting Chart C o d e

Fault on the Programmer LCD Display (Bold) and What it Triggers

91

VCL/OS Mismatch ShutdownMotor; ShutdownMainContactor; ShutdownEMBrake; ShutdownThrottle; ShutdownInterlock; ShutdownDriver1; ShutdownDriver2; ShutdownDriver3; ShutdownDriver4; ShutdownPD; FullBrake; ShutdownPump VCL/OS Mismatch ShutdownMotor; ShutdownMainContactor; ShutdownEMBrake; ShutdownThrottle; ShutdownInterlock; ShutdownDriver1; ShutdownDriver2; ShutdownDriver3; ShutdownDriver4; ShutdownPD; FullBrake; ShutdownPump Encoder LOS (LimitedOperatingStrateg y).

Enter LOS control mode

91

93

98

Illegal Model Number ShutdownMotor; ShutdownMainContactor; ShutdownEMBrake; ShutdownThrottle; FullBrake; ShutdownPump

T P

Possible Causes

Set/Clear Conditions

1. The VCL software in the controller does not match the OS software in the controller.

Set: VCL and OS software DO NOT mach when KSI cycles, a check is made to verify that they match and a fault is issued when they don’t.

Clear: Download the correct VCL and OS software into the computer.

1. The VCL software in the controller does not match the OS software in the controller.

Set: VCL and OS software DO NOT mach when KSI cycles, a check is made to verify that they match and a fault is issued when they don’t.

Clear: Download the correct VCL and OS software into the computer.

1. Limited Operating Strategy (LOS) control mode has been activated, as a result of either an Encoder Fault (Code 36) or a Stall Detect Fault (Code 73).

2. Motor encoder failure.

3. Bad crimps or faulty wiring.

4. Vehicle is stalled.

Set: Encoder Fault (Code 36) or Stall Detect Fault (Code 73) was activated, and Brake or Interlock has been applied to activate LOS control mode, allowing limited motor control.

Clear: Cycle KSI or, if LOS mode was activated by the Stall Fault, clear by ensuring encoder senses proper operation, Motor RPM=0, and Throttle Command=0.

Set: Illegal Model_Number variable; when KSI cycles, a check is made to confirm a legal Model_Number, and a fault is issued if one is not found.

Clear: Download appropriate software for your controller model.

X X 1. Model_Number variable contains illegal value (not 1234, 1236, 1238, or 1298).

2. Software and hardware DO NOT match.

3. Controller defective.

6-31

CALIBRATION AND PROGRAMMING

Controller Troubleshooting Chart C o d e

Fault on the Programmer LCD Display (Bold) and What it Triggers

99

Dualmotor Parameter Mismatch ShutdownMotor; ShutdownMainContactor; ShutdownEMBrake; ShutdownThrottle; FullBrake; ShutdownPump

T P X

Possible Causes

Set/Clear Conditions

1. Dual Motor Enable parameter set On and Control Mode Select parameter not set to 1 (Speed Mode Express) or 2 (Speed Mode).

Set: When the Dual Drive software is enabled, the controller must be set to either Speed Mode Express or Speed Mode; otherwise this fault is set.

Clear: Adjust parameters to appropriate values for your application and cycle KSI.

Controller Maintenance There are no user serviceable parts in the Curtis 1234/36/38 controllers. No attempt should be made to open, repair, or modify the controller. Modifying the controller will void the warranty. It is recommended that the controllers and connections be kept clean and dry and that the controller’s fault history file be checked and cleared during service.

Controller Cleaning Periodically cleaning the controller exterior will help protect it against corrosion and possible electrical problems created by debris that is part of the operating environment. When working around any battery powered system, proper safety precautions should be taken.

NOTICE NEVER use a pressure washer to clean the controller.

Use the following cleaning procedure for routine maintenance: 1. Remove power by disconnecting the battery.

2. Discharge the capacitors in the controller by connecting a load across the controller’s B+ and B terminals.

3. Remove any dirt or corrosion from the power and signal connector areas. The controller should be wiped clean with a moist rag. Dry it before reconnecting the battery.

4. Make sure the connections are tight.

6-32

F-649-R0

Document Control Revision Log: Date

Revision

Improvement(s) Description and Comments

06/16/16

F-649-R0

Initial Release- Lani

Equipment from Landoll Company, LLC is built to exacting standards ensured by ISO 9001 registration at all Landoll manufacturing facilities.

Bendi B30 & B40 AC/DS Maintenance Manual Re-Order Part Number F-649-R0

LANDOLL COMPANY, LLC 1900 North Street Marysville, Kansas 66508 (785) 562-5381 800-428-5655 ~ WWW.LANDOLL.COM

Copyright 2015. Landoll Company, LLC “All rights reserved, including the right to reproduce this material or portions thereof in any form.”

F-649-R0