Bendi Landoll B3/30 Very Narrow Aisel Forklift Planned Maintenance Manual

VERY NARROW AISLE FORKLIFT PLANNED MAINTENANCE MANUAL Bendi B3/30

LANDOLL CORPORATION

MATERIAL HANDLING PRODUCTS

Material Handling Products Group 1900 North Street Marysville, Kansas 66508 Telephone (785)562-5381· FAX: (785)562-4853 www.Landoll.com Publication No. F-444-0808 August,2008

Table of Contents DESCRIPTION

PAGE NO.

Using This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Planned Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Tools or Equipment Required · · · · · · · · · · · · · · · · · · · · · 2-3 Special Tools Required . . . . . . . . . . . . . . . . . . . . 2-3 Safety Equipment Required . . . . . . . . . . . . . . . . . . 2-3 Inspection and Maintenance Program . . . . . . . . . . . . . . . . . . . . . 2-4 Inspection Program · · · · · · · · · · · · · · · · · · · · · · · · · · 2-4 Maintenance Program · · · · · · · · · · · · · · · · · · · · · · · · · 2-5 Inspection and Maintenance Responsibilities . . . . . . . . . . . . . . . . . 2-5 Operator’s Daily Checklist · · · · · · · · · · · · · · · · · · · · · · · 2-5 Shift Inspection · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-6 Hourly Inspection Checklist · · · · · · · · · · · · · · · · · · · · · · 2-6 Installation Inspection · · · · · · · · · · · · · · · · · · · · · · · · · 2-6 Routine Maintenance Schedule for Bendi 3 Wheel Forklifts· · · · · · 2-7 Inspection and Maintenance Practices . . . . . . . . . . . . . . . . . . . . . 2-7 Inspection and Maintenance for Bendi 3 Wheel Series Forklifts · · · · · · 2-8 Inspection and Maintenance for Bendi 3 Wheel Series, Facilities ONLY · · 2-9 Preparing for Inspection or Maintenance · · · · · · · · · · · · · · · 2-9 Performance Testing · · · · · · · · · · · · · · · · · · · · · · · · · 2-10 Completing Performance Testing· · · · · · · · · · · · · · · · · · · 2-11 Fork Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Measuring Fork Thickness and Distortion · · · · · · · · · · · · · · 2-13

B3 Ser II Forklift Planned Maintenance Manual i

Mast Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Inspection Check List · · · · · · · · · · · · · · · · · · · · · · · · · 2-16 Load Roller Maintenance · · · · · · · · · · · · · · · · · · · · · · · 2-16 Chain Maintenance · · · · · · · · · · · · · · · · · · · · · · · · · · 2-17 Chain Inspection . . . . . . . . . . . . . . . . . . . . . . . 2-17 Chain Lubrication . . . . . . . . . . . . . . . . . . . . . . 2-17 Chain Adjustment . . . . . . . . . . . . . . . . . . . . . . 2-18 Measuring Chain Stretch. . . . . . . . . . . . . . . . . . . 2-18 Check Lift Operation · · · · · · · · · · · · · · · · · · · · · · · · · 2-19 Check Primary Lift Chain · · · · · · · · · · · · · · · · · · · · · · · 2-20 Checking and Adjusting Degree of Tilt · · · · · · · · · · · · · · · · 2-21 Side Shift Circuit Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 2-23 Checking for Leaks. . . . . . . . . . . . . . . . . . . . . . 2-23 Identification Plate and Safety Warnings . . . . . . . . . . . . . . . . . . . 2-24 Lubricating the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 Tilt Cylinder Clevis · · · · · · · · · · · · · · · · · · · · · · · · · · 2-26 Main Rotation Bearings/Gears · · · · · · · · · · · · · · · · · · · · 2-27 Battery Rollout Tray· · · · · · · · · · · · · · · · · · · · · · · · · · 2-28 Fork Positioner Lubrication, Non-Side Shifting (Option) · · · · · · · 2-29 Inspect Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30 Chunking (Chipping) or Embedded Objects · · · · · · · · · · · · · 2-31 Undercutting and Uneven Wear · · · · · · · · · · · · · · · · · · · 2-31 Flat-spotting· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-32 To Extend Tire Life · · · · · · · · · · · · · · · · · · · · · · · · · · 2-32 Drive Wheel Lug Nuts · · · · · · · · · · · · · · · · · · · · · · · · 2-33 Check Planetary Gear Box . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33 Replacing Motor Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36 Exposing the Motors · · · · · · · · · · · · · · · · · · · · · · · · · 2-36 Traction Drive Motor Brushes · · · · · · · · · · · · · · · · · · · · 2-37 Lift Pump and Power Steering Motor Brushes · · · · · · · · · · · · 2-39 Check Service Drum Brakes . . . . . . . . . . . . . . . . . . . . . . . . . 2-41 To Check the Brakes · · · · · · · · · · · · · · · · · · · · · · · · · 2-41 Power Steering System Maintenance . . . . . . . . . . . . . . . . . . . . . 2-42 Check Power Steering · · · · · · · · · · · · · · · · · · · · · · · · 2-43 Filling and Air Bleeding the Power Steering System · · · · · · · · · 2-44 Lubricate Steer Wheel Knob . . . . . . . . . . . . . . . . . . . . . . . . . 2-44 Check Hydraulic Functions . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45 Check the Return-to-Neutral . . . . . . . . . . . . . . . . . . . . . . . . . 2-46 Check Driver’s Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47 Floor Plate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48 Check Master Cylinder Fluid Level . . . . . . . . . . . . . . . . . . . . . . 2-49 Hydraulic System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 2-50

B3 Ser II Forklift Planned Maintenance Manual ii

Check Hydraulic Oil Level · · · · · · · · · · · · · · · · · · · · · · 2-51 Change Hydraulic Oil Filter · · · · · · · · · · · · · · · · · · · · · · 2-53 Change Hydraulic Oil · · · · · · · · · · · · · · · · · · · · · · · · · 2-54 Battery Care and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 2-56 Electrical Static Discharge · · · · · · · · · · · · · · · · · · · · · · 2-57 Check Batteries · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-58 To Check the Battery · · · · · · · · · · · · · · · · · · · · · · · · · 2-59 Battery Charging · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-60 Inspecting the Bearings, Race and Inner Seal . . . . . . . . . . . . . . . . 2-61 Check Nuts, Bolts, and Screws . . . . . . . . . . . . . . . . . . . . . . . . 2-63 Inspect Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . 2-64 Curtis Controller · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-65 General Practice · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-66

B3 Ser II Forklift Planned Maintenance Manual iii

Using This Manual This Bendi 3 Wheel Planned Maintenance Manual is a guide to the daily operation and service of your Bendi 3 Wheel Fork Lift Truck. It is designed to be used as a reference tool in your everyday use of this truck.

Bendi is a trademark of the Landoll Corporation. All other brand and product names are the trademarks of their respective holders.

This section describes the routine inspections, adjustments and settings, and lubrication needed to keep your Bendi 3 Wheel lift truck in optimum performance and stability, with minimum “downtime.”

This manual is organized describing planned maintenance procedures from the front to the back of the forklift. Hourly check list requirements are included beginning on page 1-5 to aid the mechanic in systematically checking through the forklift. Make copies of these checklists to use in documenting the service performed on the truck.

Note: Some checklists are multiple pages. Please verify that you check all items required at the proper interval times.

B3 Ser II Forklift Planned Maintenance Manual 1- 1

Using this Manual

B3 Ser II Forklift Planned Maintenance Manual 1-2

Using this Manual

Bendi 3 Wheel Operator’s Daily Checklist Daily pre-shift inspection is an OSHA requirement. It is important that these inspections are documented.

Date _____________________ Truck No. _________________ Location __________________ Shift _____________________

Inspector __________________ Model No. _________________ Serial No. _________________ Drive Hour Meter Reading _________

Record Fluids Added: Battery Water________________ Hydraulic Oil ________________ Hoist Hour Meter Reading (option)_____________

Operator's Daily Checklist SAFETY & OPERATIONAL CHECKS Have a qualified mechanic correct all problems.

Forks, Top Clip Retaining Pin and Heel - Condition Load Backrest Extension - Attached Lift and Lowering Control - Functioning smoothly Tilt Control - Forward and Back - Functioning smoothly Sideshift Control - Functioning smoothly Hang-on Attachment- Functioning smoothly, securely attached, fittings attached Steering Operation - Functioning smoothly Accelerator and Brake Pedal - Functioning smoothly Controls (Turn Power On); Investigate unusual noises immediately Horn, Lights, Seat Switch - Functioning properly Parking Brake and Service Brake - Functioning smoothly Drive Control - Forward/Reverse - Functioning smoothly Battery - Check water/electrolyte level and charge Battery Discharge Indicator/Hour Meter - Functioning Battery Restraint System - Adjust and Fasten Hood and Seat Latch - Function properly Operator’s Compartment Capacity Plate Attached Info. matches Model, Serial No., and Attachments; Operator’s Manual in Case Seat Belt, Buckle, and Retractors - Functioning smoothly Overhead Guard - Properly mounted and attached Overall machine - Keep clean and tidy appearance

O.K. (X)

Need Maintenance

Ref. Page 2-12 ** 2-45 2-45 2-23 ** ** ** ** 2-47 2-40 ** 2-58 2-57 ** ** 2-24

** ** *

B3 Ser II Forklift Planned Maintenance Manual 1-3

Using this Manual Operator's Daily Checklist SAFETY & OPERATIONAL CHECKS Have a qualified mechanic correct all problems.

O.K. (X)

Need Maintenance

Hydraulic Oil, Battery, Brake Fluid - Check levels and for leaks Tires - Check for debris; Drive Tire Lug Nuts - Torque to 225 ft.lbs. (300 Nm) Finger Guards - Attached Major Structural Points (Front Rotation, Mast Braces, Overhead Guard) - Check for cracks Hydraulic Cylinders, Pump, Valve - Check for leaks, noise, proper function Safety Warnings - Attached (Refer to Operator’s Manual for Location) * Those items which do not have page referenced have no procedure available. ** Refer to the Bendi 3 Wheel Operator's Manual (F-492-___) .

B3 Ser II Forklift Planned Maintenance Manual 1-4

Ref. Page 2-51 2-58 2-49 2-33 ** ** 2-50 2-24

Using this Manual

BENDI 3 WHEEL 1st 50-100 Hour Inspection Checklist To be performed after 1st 50-100 hours of truck operation in addition to the required pre-shift daily inspection.

Date _____________________ Truck No. _________________ Location __________________ Shift _____________________

Inspector __________________ Model No. _________________ Serial No. _________________ Drive Hour Meter Reading _________

Record Fluids Added: Battery Water________________ Hydraulic Oil ________________ Hoist Hour Meter Reading (option)_____________

1st 50-100 Hour Inspection Checklist SAFETY & OPERATIONAL CHECKS Have a qualified mechanic correct all problems.

Mast chains - Inspect, Clean, and Lubricate Power Steering System - Fill and Air Bleed Drive Wheels - Retorque lug nuts Gear Box - Drain, flush, and refill

O.K. (X)

Need Maintenance

Ref. Page 2-17 2-42 2-33 2-33

B3 Ser II Forklift Planned Maintenance Manual 1-5

Using this Manual

BENDI 3 WHEEL 1st 200 Hour Inspection Checklist To be performed after 1st 200 hours of truck operation in addition to the required pre-shift daily inspection.

Date _____________________ Truck No. _________________ Location __________________ Shift _____________________

Inspector __________________ Model No. _________________ Serial No. _________________ Drive Hour Meter Reading _________

Record Fluids Added: Battery Water________________ Hydraulic Oil ________________ Hoist Hour Meter Reading (option)_____________

1st 200 Hour Inspection Checklist SAFETY & OPERATIONAL CHECKS Have a qualified mechanic correct all problems.

O.K. (X)

Need Maintenance

Mast - Inspect all friction surfaces and check lift chain tension Lift and Tilt Cylinder - Check operation Power Steering Pump - Check Operation Brake Pedal - Check for free play Parking and Service Brakes - Check for effectiveness Contactor Points and Microswitches - Check operation Control Panel - Clean surface Hydraulic Oil Pump - Check Operation Switches (interlock, direction, parking/seat, key, pressure/temperature - Check Operation Wires, Connections, Bolts, and Nuts - Check * Those items which do not have page referenced have no procedure available. ** Refer to the Bendi 3 Wheel Operator's Manual (F-492-___) .

B3 Ser II Forklift Planned Maintenance Manual 1-6

Ref. Page 2-17 2-21 2-43 * ** ** * ** ** 2-63

Using this Manual

BENDI 3 WHEEL 200 Hour Inspection Checklist To be performed after each 200 hours of truck operation in addition to the required pre-shift daily inspection.

Date _____________________ Truck No. _________________ Location __________________ Shift _____________________

Inspector __________________ Model No. _________________ Serial No. _________________ Drive Hour Meter Reading _________

Record Fluids Added: Battery Water________________ Hydraulic Oil ________________ Hoist Hour Meter Reading (option)_____________

200 Hour Inspection Checklist SAFETY & OPERATIONAL CHECKS Have a qualified mechanic correct all problems.

Mast, Carriage, or Attachment Friction Surfaces Clean, inspect for wear or damage, and lubricate Lift Chains - Clean and lubricate Extend Mast - Check for Excessive Wear Attachment Control - Operational Accelerator - Functioning Smoothly Controls (Turn Power On); Investigate Unusual Noises Immediately Instrument Monitors - Functioning Parking and Service Brakes - Functioning Smoothly, Check Pads for Excessive Wear Hydraulic Fluid Level - Check and Fill Exterior of Hydraulic Tank and Oil Tank Breather Clean Lift and Power Steering Pumps - Clean dust from motors Lift and Power Steering Pumps - Check brushes for pressure or wear Lift and Power Steering Pumps - Check commutator surface for roughness Battery - Thoroughly Clean Battery Box and Connectors - Neutralize and clean Battery - Check water/electrolyte level Battery - Check structure and electrical conditions Traction Motors - Clean dust Seat Belt, Buckle, and Retractors - Functioning Smoothly

O.K. (X)

Need Maintenance

Ref. Page 2-17 2-17 2-15 ** ** ** ** 2-41 2-51 * * 2-39 2-39 * * 2-58 * * **

B3 Ser II Forklift Planned Maintenance Manual 1-7

Using this Manual 200 Hour Inspection Checklist SAFETY & OPERATIONAL CHECKS Have a qualified mechanic correct all problems.

O.K. (X)

Need Maintenance

Tires - Check for Debris; Drive Tire Lug Nuts - Torque to 225 ft. lbs. (300 Nm) Wheel Bearings - Clean and fill with grease Leaks - Gearbox Oil, Brake Fluid, Hydraulic Oil, Battery

Hydraulic Hoses and Connections - Check for Wear Switches (interlock, direction, parking/seat, key, pressure, and temperature) - Check Wire connections and sending units - Check Grease Fittings - Service * Those items which do not have page referenced have no procedure available. ** Refer to the Bendi 3 Wheel Operator's Manual (F-492-___) .

B3 Ser II Forklift Planned Maintenance Manual 1-8

Ref. Page 2-33

2-33 2-49 2-51 2-58 2-50 ** * 2-25

Using this Manual

BENDI 3 WHEEL 600 Hour Inspection Checklist To be performed after each 600 hours of truck operation in addition to the required pre-shift daily inspection.

Date _____________________ Truck No. _________________ Location __________________ Shift _____________________

Inspector __________________ Model No. _________________ Serial No. _________________ Drive Hour Meter Reading _________

Record Fluids Added: Battery Water________________ Hydraulic Oil ________________ Hoist Hour Meter Reading (option)_____________

600 Hour Inspection Checklist SAFETY & OPERATIONAL CHECKS Have a qualified mechanic correct all problems.

200 Hour Checklist Mast, Carriage, or Attachment Friction Surfaces Clean, inspect for wear or damage, and lubricate Lift Chains - Clean and lubricate Extend Mast - Check for Excessive Wear Attachment Control - Operational Accelerator - Functioning Smoothly Controls (Turn Power On); Investigate Unusual Noises Immediately Instrument Monitors - Functioning Parking and Service Brakes - Functioning Smoothly, Check Pads for Excessive Wear Hydraulic Fluid Level - Check and Fill Exterior of Hydraulic Tank and Oil Tank Breather Clean Lift and Power Steering Pumps - Clean dust from motors Lift and Power Steering Pumps - Check brushes for pressure or wear Lift and Power Steering Pumps - Check commutator surface for roughness Battery - Thoroughly Clean Battery Box and Connectors - Neutralize and clean Battery - Check water/electrolyte level Battery - Check structure and electrical conditions Traction Motors - Clean dust Seat Belt, Buckle, and Retractors - Functioning Smoothly

O.K. (X)

Need Maintenance

Ref. Page

2-17 2-17 2-15 * * * * 2-41 2-51 * * 2-39 2-39 * * 2-58 * * *

B3 Ser II Forklift Planned Maintenance Manual 1-9

Using this Manual 600 Hour Inspection Checklist SAFETY & OPERATIONAL CHECKS Have a qualified mechanic correct all problems.

O.K. (X)

Need Maintenance

Tires - Check for Debris; Drive Tire Lug Nuts - Torque to 225 ft. lbs. (300 Nm) Wheel Bearings - Clean and fill with grease Leaks - Gearbox Oil, Brake Fluid, Hydraulic Oil, Battery

Hydraulic Hoses and Connections - Check for Wear Switches (interlock, direction, parking/seat, key, pressure, and temperature) - Check Wire connections and sending units - Check Grease Fittings - Service 600 Hour Checklist Forks, Top Clip Retaining Pin and Heel - Condition Load Rollers - No Greater than 1/16” Mast Chains - Lube with SAE 40W oil or Bowman Heavy Load Red Grease - Check for Wear and Stretch Steering Operation - Functioning Smoothly; Lubricate Steering Knob Brake Fluid - Check Level Hydraulic Oil Filter - Change element and check for Proper Level - Check Pressures Traction Motor Brushes - Check pressure and wear, and surface on commutator for roughness Battery - Check resistance between truck body and negative/positive terminal Battery Rollers - Remove, clean, and repack Contactor Points and Microswitches - Check operation Control Panel - Clean surface Traction Motor - Clean commutator Operator’s Compartment Capacity Plate Attached Information Matches Model, Serial No., and Attachments Check All Connections for Proper Torque * Those items which do not have page referenced have no procedure available. ** Refer to the Bendi 3 Wheel Operator's Manual (F-492-___) .

B3 Ser II Forklift Planned Maintenance Manual 1-10

Ref. Page 2-33

2-33 2-49 2-51 2-58 * * * 2-25 2-12 * 2-15 2-44 2-49 2-53 2-37 * * * * 2-37 2-24

2-63

Using this Manual

BENDI 3 WHEEL 1000 Hour Inspection Checklist To be performed after each 1000 hours of truck operation in addition to the required pre-shift daily inspection.

Date _____________________ Truck No. _________________ Location __________________ Shift _____________________

Inspector __________________ Model No. _________________ Serial No. _________________ Drive Hour Meter Reading _________

Record Fluids Added: Battery Water________________ Hydraulic Oil ________________ Hoist Hour Meter Reading (option)_____________

1000 Hour Inspection Checklist SAFETY & OPERATIONAL CHECKS Have a qualified mechanic correct all problems.

200 Hour Checklist Mast, Carriage, or Attachment Friction Surfaces Clean, inspect for wear or damage, and lubricate Lift Chains - Clean and lubricate Extend Mast - Check for Excessive Wear Attachment Control - Operational Accelerator - Functioning Smoothly Controls (Turn Power On); Investigate Unusual Noises Immediately Instrument Monitors - Functioning Parking and Service Brakes - Functioning Smoothly, Check Pads for Excessive Wear Hydraulic Fluid Level - Check and Fill Exterior of Hydraulic Tank and Oil Tank Breather Clean Lift and Power Steering Pumps - Clean dust from motors Lift and Power Steering Pumps - Check brushes for pressure or wear Lift and Power Steering Pumps - Check commutator surface for roughness Battery - Thoroughly Clean Battery Box and Connectors - Neutralize and clean Battery - Check water/electrolyte level Battery - Check structure and electrical conditions Traction Motors - Clean dust Seat Belt, Buckle, and Retractors - Functioning Smoothly

O.K. (X)

Need Maintenance

Ref. Page

2-17 2-17 2-15 * * * * 2-41 2-51 * * 2-39 2-39 * * 2-58 * * *

B3 Ser II Forklift Planned Maintenance Manual 1-11

Using this Manual 1000 Hour Inspection Checklist SAFETY & OPERATIONAL CHECKS Have a qualified mechanic correct all problems.

O.K. (X)

Need Maintenance

Tires - Check for Debris; Drive Tire Lug Nuts - Torque to 225 ft. lbs. (300 Nm) Wheel Bearings - Clean and fill with grease Leaks - Gearbox Oil, Brake Fluid, Hydraulic Oil, Battery

Hydraulic Hoses and Connections - Check for Wear Switches (interlock, direction, parking/seat, key, pressure, and temperature) - Check Wire connections and sending units - Check Grease Fittings - Service 600 Hour Checklist Forks, Top Clip Retaining Pin and Heel - Condition Load Rollers - No Greater than 1/16” Mast Chains - Lube with SAE 40W oil or Bowman Heavy Load Red Grease - Check for Wear and Stretch Steering Operation - Functioning Smoothly; Lubricate Steering Knob Brake Fluid - Check Level Hydraulic Oil Filter - Change element and check for Proper Level - Check Pressures Traction Motor Brushes - Check pressure and wear, and surface on commutator for roughness Battery - Check resistance between truck body and negative/positive terminal Battery Rollers - Remove, clean, and repack Contactor Points and Microswitches - Check operation Control Panel - Clean surface Traction Motor - Clean commutator Operator’s Compartment Capacity Plate Attached Information Matches Model, Serial No., and Attachments Check All Connections for Proper Torque 1000 Hour Checklist Power Steering System - Fill and Air Bleed Motor - Check that terminal studs and mounting bolts are clean and tight Motor - Clean cooling holes of debris or restrictions * Those items which do not have page referenced have no procedure available. ** Refer to the Bendi 3 Wheel Operator's Manual (F-492-___) .

B3 Ser II Forklift Planned Maintenance Manual 1-12

Ref. Page 2-33

2-33 2-49 2-51 2-58 * * * 2-25 2-12 * 2-15 2-44 2-49 2-53 2-37 * * * * 2-37 2-24

2-63 2-44 * 2-37

Using this Manual

BENDI 3 WHEEL 2000 Hour Inspection Checklist To be performed after each 2000 hours of truck operation in addition to the required pre-shift daily inspection.

Date _____________________ Truck No. _________________ Location __________________ Shift _____________________

Inspector __________________ Model No. _________________ Serial No. _________________ Drive Hour Meter Reading _________

Record Fluids Added: Battery Water________________ Hydraulic Oil ________________ Hoist Hour Meter Reading (option)_____________

2000 Hour Inspection Checklist SAFETY & OPERATIONAL CHECKS O.K. Need Maintenance Have a qualified mechanic correct all (X) problems.

200 Hour Checklist Mast, Carriage, or Attachment Friction Surfaces Clean, inspect for wear or damage, and lubricate Lift Chains - Clean and lubricate Extend Mast - Check for Excessive Wear Attachment Control - Operational Accelerator - Functioning Smoothly Controls (Turn Power On); Investigate Unusual Noises Immediately Instrument Monitors - Functioning Parking and Service Brakes - Functioning Smoothly, Check Pads for Excessive Wear Hydraulic Fluid Level - Check and Fill Exterior of Hydraulic Tank and Oil Tank Breather Clean Lift and Power Steering Pumps - Clean dust from motors Lift and Power Steering Pumps - Check brushes for pressure or wear Lift and Power Steering Pumps - Check commutator surface for roughness Battery - Thoroughly Clean Battery Box and Connectors - Neutralize and clean Battery - Check water/electrolyte level Battery - Check structure and electrical conditions Traction Motors - Clean dust Seat Belt, Buckle, and Retractors - Functioning Smoothly Tires - Check for Debris; Drive Tire Lug Nuts - Torque to 225 ft. lbs. (300 Nm) Wheel Bearings - Clean and fill with grease

Ref. Page

2-17 2-17 2-15 ** ** ** ** 2-41 2-51 * * 2-39 2-39 * * 2-58 * * ** 2-33

B3 Ser II Forklift Planned Maintenance Manual 1-13

Using this Manual 2000 Hour Inspection Checklist O.K. Need Maintenance SAFETY & OPERATIONAL CHECKS (X) Have a qualified mechanic correct all problems.

Leaks - Gearbox Oil, Brake Fluid, Hydraulic Oil, Battery

Hydraulic Hoses and Connections - Check for Wear Switches (interlock, direction, parking/seat, key, pressure, and temperature) - Check Wire connections and sending units - Check Grease Fittings - Service 600 Hour Checklist Forks, Top Clip Retaining Pin and Heel - Condition Load Rollers - No Greater than 1/16” Mast Chains - Lube with SAE 40W oil or Bowman Heavy Load Red Grease - Check for Wear and Stretch Steering Operation - Functioning Smoothly; Lubricate Steering Knob Brake Fluid - Check Level Hydraulic Oil Filter - Change element and check for Proper Level - Check Pressures Traction Motor Brushes - Check pressure and wear, and surface on commutator for roughness Battery - Check resistance between truck body and negative/positive terminal Battery Rollers - Remove, clean, and repack Contactor Points and Microswitches - Check operation Control Panel - Clean surface Traction Motor - Clean commutator Operator’s Compartment Capacity Plate Attached Information Matches Model, Serial No., and Attachments Check All Connections for Proper Torque 1000 Hour Checklist Power Steering System - Fill and Air Bleed Motor - Check that terminal studs and mounting bolts are clean and tight Motor - Clean cooling holes of debris or restrictions 2000 Hour Checklist Hydraulic Oil - Change Hydraulic Reservoir Suction Screens - Clean with Solvent Gear Box - Drain, flush, and refill Contactor Coils - Check resistance * Those items which do not have page referenced have no procedure available. **Refer to the Bendi 3 Wheel Operator's Manual (F-492-___) .

B3 Ser II Forklift Planned Maintenance Manual 1-14

Ref. Page 2-33 2-49 2-51 2-58 * ** * 2-25 2-12 * 2-15 2-44 2-49 2-53 2-37 * * * * 2-37 2-24 2-63 2-44 * 2-37 2-54 * 2-33 *

Planned Maintenance This section describes the routine inspection and maintenance requirements, adjustments and lubrication necessary to keep your Bendi 3 Wheel Model forklift truck operating safely and efficiently with minimum downtime. This section must be thoroughly understood before you inspect or perform maintenance on the forklift.

A maintenance schedule is provided in Appendix A of the Bendi 3 Wheel Operator's Manual (F-492-___). The following checklists are included in this manual beginning on page 1-3. · Operator's Daily Checklist · 1st 50-100 Hour Inspection Checklist · 1st 200 Hour Inspection Checklist · 200 Hour Inspection Checklist · 600 Hour Inspection Checklist · 1000 Hour Inspection Checklist · 2000 Hour Inspection Checklist Note: Some checklists are multiple pages. Please verify that you check all items required at the proper interval times.

Copy these checklists to use when performing planned maintenance procedures for the forklift so that you may keep proper records for your truck.

Recommended lubricants, lubrication points, and torque values are found in Appendix B of the Bendi 3 Wheel Operator's Manual (F-492-___).

B3 Ser II Forklift Planned Maintenance Manual 2-1

Planned Maintenance

Overview Planned maintenance procedures are designed to extend the service life of the truck and prevent minor problems from becoming major repairs that are expensive both in terms of downtime and money.

IMPORTANT !

Read and comply with all applicable SAFETY precautions when servicing this truck. See the Safety chapter at the beginning of this manual.

Recommended service intervals, as stated in the Routine Maintenance Schedule located in Appendix A of the Bendi 3 Wheel Operator's Manual (F-492-___), are based on normal operating conditions. If the truck is subjected to severe or above normal operating conditions, extreme temperatures, excessive dust or wet environments, or if the truck is around corrosive materials, service must be performed at shorter intervals.

Common sense and standard precautions apply when servicing machinery and must always be used. · 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 reassembly. · 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, for example, 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 assembled with a press-fit, require unusual force to disassemble. If you encounter trouble, determine the reason for the difficulty, then proceed. · Cover all openings caused by removing parts or sub-assemblies with clean rags to keep objects from falling in where additional serious 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. · Observe standard torque ratings for the size and type of fastener (See Appendix B of the Bendi 3 Wheel Operator's Manual (F-492-___) for General Torque, Hydraulic Fitting Torque, and Bendi 3 Wheel Special Torque Tables). · Be sure to use the proper nuts, bolts and other fasteners. Many are specifically rated; that is, SAE Grade 5, SAE Grade 8, ISO Prop Class 8.8, etc., and must be replaced with the identical type. It is recommended to use only Landoll authorized replacement parts.

B3 Ser II Forklift Planned Maintenance Manual 2-2

Planned Maintenance Tools or Equipment Required In addition to a good portable light source and various tightening tools, 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. (678 Nm). · Drain pan, capable of holding at least 13 gallons (50 liters) of hydraulic fluid. · Hydrometer with thermometer (for measuring specific gravity and temperature of battery electrolyte).

Special Tools Required The following special tools may be required: · Commutator undercutting tool. · Brush seater/commutator cleaner abrasive stone.

Safety Equipment Required The following safety equipment may be required: · Bicarbonate of soda (to neutralize any acid spills). · Safety goggles or full-face shield (to guard against acid splash). · Rubber gloves and apron (to guard against acid splash). · Dust mask (for protection against abrasive dust when servicing commutators, brake linings, etc.)

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Planned Maintenance

Inspection and Maintenance Program Inspection Program The inspection program designed by Landoll Corporation periodically checks the integrity of Bendi 3 Wheel forklift systems such as: · Checking performance of operator functions such as lift, tilt, side shift, attachment, and traction systems · Checking for leaks · Checking fluid levels · Making sure components are securely attached · Checking the tires To make sure these and other systems are checked periodically, Landoll Corporation has developed a system of checklists. A blank copy of each checklist can be found beginning on page 1-3. These checklists include: · Operator’s Daily Checklist · 1st 50 - 100 Hour Inspection Checklist · 1st 200 Hour Inspection Checklist · 200 Hour Inspection Checklist · 600 Hour Inspection Checklist · 1000 Hour Inspection Checklist · 2000 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 Corporation.

B3 Ser II Forklift Planned Maintenance Manual 2-4

Planned Maintenance Maintenance Program In addition to the inspection program, Landoll Corporation has set up a planned maintenance program. Planned maintenance procedures include: · Drain, flush, and refill transmission fluid · Clean hydraulic reservoir suction screens · Lubricate mechanical systems · Remove, clean, and inspect battery rollers (optional)

Warning Never perform any maintenance or service procedures unless specifically indicated in this manual or requested by your supervisor. All other service and maintenance on your Bendi 3 Wheel forklift must be provided by a facility authorized by Landoll Corporation to perform these services. Failure to follow these guidelines can cause serious injury or death.

Planned maintenance tasks are usually performed by a service and maintenance facility that is approved by Landoll Corporation. Operators may be asked to assist in some routine maintenance procedures. Never perform any of these maintenance procedures unless directed by your supervisor.

Inspection and Maintenance Responsibilities Operator’s Daily Checklist Note: Daily inspection is an OSHA requirement. Report any defect immediately to your supervisor!

The operator is required to daily inspect the forklift. This includes: · visual inspection of the entire machine for any defect. · visual check for any leaks · check hydraulic oil, battery, and brake fluid levels · check that all controls and gauges work properly Photocopy the Operator’s Daily Checklist on page 1-3 or use the form supplied by your supervisor. The form also contains reference page numbers for specific inspection and planned maintenance procedures included in this manual. · Inspect the truck and fill out the form · Report defects to your supervisor · Return the form to your supervisor · If your Bendi 3 Wheel forklift fails to perform in a safe manner during your shift, stop and park the vehicle, remove the key, and report the problem to your supervisor immediately.

B3 Ser II Forklift Planned Maintenance Manual 2-5

Planned Maintenance Shift Inspection The following checks should be carried out on a machine before you start a new shift or if you take the machine over from another operator. These checks are included in the daily inspection checklist that is required at the start of everyday.

Upon starting the shift with a new machine or when taking responsibility for a truck from another person, ensure that:

ü ü ü ü ü

All of the controls function correctly.

The wheels are free from damage.

All warning devices are operating correctly.

The seatbelt functions.

The mast functions correctly and doesn’t get snagged or jammed.

Warning ALL DEFECTS MUST BE REPORTED TO THE PERSON IN CHARGE IMMEDIATELY. FAILURE TO DO SO COULD RESULT IN THE TRUCK BECOMING DANGEROUS IN OPERATION AND COULD CAUSE SERIOUS INJURY

Hourly Inspection Checklist During these inspections technicians from an authorized service and maintenance facility will inspect all mechanical and electrical systems and perform planned maintenance operations designated by Landoll Corporation. Photocopy the 1st 50-100, 1st 200, 200, 600, 1000, and 2000 Hour Inspection Checklists beginning on page 1-5.

Installation Inspection When your Bendi 3 Wheel forklift is installed, the authorized service facility is required to complete an Installation Checklist and a Customer Truck Installation Report. The installation report initiates the warranty for the vehicle. Photocopy both of these pages which are located in Appendix A of the Bendi 3 Wheel Operator's Manual (F-492-__), fill out, and return to the Landoll Corporation.

B3 Ser II Forklift Planned Maintenance Manual 2-6

Planned Maintenance Routine Maintenance Schedule for Bendi 3 Wheel Forklifts The Routine Maintenance Schedule for Bendi 3 Wheel Forklifts is located in Appendix A of the Bendi 3 Wheel Operator's Manual (F-492-__). The checklists which begin on page 1-3 reflect the information contained in the Maintenance Schedule and should be photo copied and used to document any inspection and maintenance procedures performed on the truck. Note that each task should be performed at the time interval or number of operation hours indicated, whichever comes first.

Warning Never perform any maintenance or service procedures unless specifically indicated in this manual or requested by your supervisor. All other service and maintenance on your Bendi 3 Wheel forklift must be provided by a facility authorized by Landoll Corporation to perform these services. Failure to follow these guidelines can cause serious injury or death.

Typically an authorized service and maintenance facility performs planned maintenance procedures. At times operators may be requested to assist in performing routine maintenance, such as doing routine lubrication. If requested to do so, make sure you read and understand the guidelines discussed in the “Inspection and Maintenance Practices for Bendi 3 Wheel Forklift Operators,” beginning on page 2-8.

Inspection and Maintenance Practices This section explains the general cautions and warnings you should observe during inspection and maintenance procedures. In addition, the duties of the operator and service and maintenance technician are explained. Finally, these specific procedures are explained: · Preparing for Inspection or Maintenance · Performing Testing · Completing Performance Testing

Warning Wipe up any spills immediately to prevent serious injury or death from slipping, fire, explosion, or contact with hazardous materials.

Failure to use lifting equipment of adequate capacity to lift and move your Bendi 3 Wheel forklift can cause lifting equipment failure, which can lead to serious injury or death.

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Planned Maintenance

Warning Removing the counterweights or uprights will change the center of gravity of the truck and can cause the truck to tip. The battery is considered part of the truck’s counterweight. Failure to follow these guidelines can cause the truck to tip over and result in serious injury or death.

To help avoid fire hazards: Have fire protection equipment present in the work area.

Do not use an open flame to check fluid level, leaking oil, or electrolyte.

Do not use fuel or flammable cleaning fluids to clean parts.

FAILURE TO FOLLOW THESE GUIDELINES CAN CAUSE SERIOUS INJURY OR DEATH.

Inspection and Maintenance Practices for Bendi 3 Wheel Forklift Operators These guidelines will help prevent downtime for your Bendi 3 wheel forklift and maintain it in a safe operating condition: · Perform the tasks listed on the Operator’s Daily Checklist beginning on page 1-3 even if you are taking responsibility of the truck from another operator. You are responsible for the condition of the forklift on your shift. Work together as a team with your co-workers, supervisor, and authorized service facility to keep the truck in peak operating condition. Accidents happen when you assume another operator has checked out the forklift. · Keep your truck clean to minimize fire hazards and facilitate detection of loose or defective parts. · Follow the procedures outlined in “Preparing for Inspection or Maintenance,” “Performance Testing,” and “Completing Performance Testing.”

If you are asked or required to perform basic lift truck maintenance, make special note of the following: · Before you perform service or maintenance on a Bendi 3 Wheel forklift, read and understand the Bendi 3 Wheel Forklift Operator’s Manual (F-492-__), Bendi 3 Wheel Planned Maintenance Manual (F-444-__), Bendi 3 Wheel Troubleshooting and Corrective Maintenance Manual (F-445-__), and machine safety signs.

Observe the procedures and practices contained in the “The following information is provided for authorized service facilities ONLY” sections in this manual.

B3 Ser II Forklift Planned Maintenance Manual 2-8

Planned Maintenance Inspection and Maintenance Practices for Authorized Facilities ONLY · Follow the procedures outlined in “Preparing for Inspection or Maintenance”, page 2-9; “Performance Testing”, page 2-10; and “Completing Performance Testing” page 2-11. · Inspect and maintain motors, controllers, limit switches, protective devices, electrical conductors, connections, and electrical insulation as described in the applicable section of ASME B56.1-2000. · Only use replacement parts, including tires, that are equal to, or exceed, the quality of the parts supplied by the original equipment manufacturer. Install parts, including tires, according to procedures established by Landoll Corporation. · When you remove tires, follow industry safety practices as described in the applicable section of ASME B56.1-2000.

Preparing for Inspection or Maintenance · Inspect the truck in an area that has sufficient clearance to check all operator functions. · Lower forks to the ground and tilt mast forward. · If you will not operate the truck to check operator functions, block the wheels with chocks or other positive truck-positioning devices. · If you will operate the truck to perform operator function, raise the drive wheels so they clear the floor. · Block the mast to prevent it from engaging. · If you need to hoist the truck make sure the hoisting equipment has adequate size and capacity to move the equipment. · Never remove counterweights or uprights. This will change the center of gravity and can cause an unstable condition.

B3 Ser II Forklift Planned Maintenance Manual 2-9

Planned Maintenance Performance Testing Note: Make sure all accessories (lights, etc.) are off before continuing.

KEY SWITCH

1. Make sure you are in the operator’s seat.

DIRECTION LEVER

2. Make sure your right foot is on the floor of the operator’s compartment.

3. Set the direction control lever (See Figure 2-1), in the neutral position.

4. Turn the key switch to the ON RUN position (See Figure 2-1).

5. Set the direction control lever in the forward position. performance testing

6. Check functions described in the Operator’s Daily Checklist or Hourly Checklists beginning on page 1-3.

Figure 2-1 Direction Control Lever Location

B3 Ser II Forklift Planned Maintenance Manual 2-10

Planned Maintenance Completing Performance Testing After all performance tests are completed as described in the Operator's Daily Checklist: 1. Apply the parking brake (See Figure 2-2).

2. Tilt the mast forward.

3. Lower the forks to the ground.

TILT LEVER ATTACHMENT BUTTON (OPTION)

HORN PUSH BUTTON DIRECTION CONTROL LEVER

SIDE SHIFT LEVER

Note: Make sure all accessories are off (lights, etc.) before you turn the key switch to the Off position.

LIFT LEVER

4. Turn the key switch to the OFF position

PARKING (HAND) BRAKE

5. Remove the key.

Figure 2-2 Parking Brake Location Before you leave the truck make sure that: · The parked truck will not cause an obstruction or safety hazard. · The forklift is clear of fire exits, fire equipment, and stairways. · The truck is not left unattended on an incline. · If the truck is inoperative and you must leave it parked on an incline, securely block the wheels and remove the key.

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Planned Maintenance

Fork Inspection Warning Never operate your Bendi 3 Wheel forklift if you suspect the forks are damaged. Report fork damage to your supervisor immediately. Failure to follow this recommendation can cause serious injury or death.

It is recommended to use only Landoll Corporation replacement parts.

NEVER use forks repaired by welding.

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

Check the top clip retaining pin and fork heel for signs of cracks and wear. Report any signs of cracks and wear to your supervisor immediately.

The following information is provided for authorized service facilities ONLY. Check the forks, and associated components, as required by the various checklists beginning on page 1-3. The following discussion provides detailed procedures necessary to provide a complete fork inspection.

Warning If you find any defect in the forks or mounting components, take the forklift out of service until the fork is repaired or replaced. Failure to follow this guideline can cause the load to fall resulting in serious injury or death.

Rated Capacity and Load Center - The rated capacity of each fork must be at least half of the rated capacity stated on the identification plate. The load center of each fork must match the load center stated on the identification plate. If the values do not match, replace the fork with one that has the correct characteristics.

Cracks - Visually examine the forks for cracks and, if considered necessary, perform a non-destructive crack detection test. Pay special attention to: · Fork heel · Welds that attach mounting components to the fork blank · Top clip retaining pin Straightness of Blade and Shank - Check the straightness of the upper face of each blade and the front face of each shank. If the deviation from straightness exceeds 0.5% of the length of the blade and/or the height of the shank, respectively, repair or replace the fork set.

Fork Angle - Check the angle between the upper face of each fork blade and the load face of each shank. If the deviation exceeds 3o from the original specification, repair or replace the fork.

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Planned Maintenance Difference in Height Between Fork Tips - Check the difference in height between each fork blade (measured at the tip with the fork mounted on the fork carrier. If the difference in tip heights exceeds 3% of the length of the blade, repair or replace the fork.

Positioning Lock - Check the positioning lock on each fork to make sure it functions properly. If any problems are noted, repair or replace the fork.

Wear - Two different areas of the fork and fork attachment should be checked for wear. · Fork Blade and Shank - Check each fork blade and shank for wear, pay special attention to the area surrounding the heel of the fork. If the thickness is reduced to 90% of the original thickness, repair or replace the fork. · Fork Hooks - Check the support face of the top hook and the retaining faces of both hooks for wear, crushing, and other local deformations. If any of these deficiencies cause excessive clearance between the fork and the fork carrier, repair or replace the fork.

Figure 2-3 Measuring Fork Thickness

Fork Marking - If the fork marking is not clearly legible, it should be remarked by the fork manufacturer, or their representative, in accordance with paragraph 7.25.2 (ASME B56.1-2000).

Measuring Fork Thickness and Distortion 1. Position the truck on a flat surface, set the parking brake and block the wheels to prevent movement.

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

3. Measure fork thickness (See Figure 2-3).

4. Compare your fork measurement to the original thickness.

5. 0.0625” (1.59 mm) is the maximum acceptable wear for a standard fork size of 1-1/2” x 4” (38.1 mm x 101.6 mm). If the fork is worn by more than 0.0625” (1.59 mm), the acceptable limit, replace both forks.

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Planned Maintenance SHANK

2” x 4” x 24” FLAT STEEL BAR

24” CARPENTER’S SQUARE

Y VALUE 18.00”

BLADE

frkdstrn

Figure 2-4 Fork Distortion Distance

6. Measure the distortion distance (Y) of your forks (See Figure 2-4).

7. For this measurement, use a flat bar 4” x 24” (101.6 mm by 609.6 mm), that is 2” (50.8 mm) thick. Also use a 24” (609.6 mm) carpenter’s square (See Figure 2-4).

8. Table 4-6 shows the acceptable Y distances. If the forks exceed the distance in the chart, replace them (See Table 2-1).

Blade

Length

Maximum

“Y” Value

32”

812.8 mm

3/4”

19 mm

36”

914.4 mm

31/32”

25 mm

40”

1,016 mm

1-7/32”

31 mm

48”

1,219 mm

1-1/2”

38 mm

Table 2-1 Maximum “Y” Values 9. Next, measure the elevation of each fork tip. If the difference is more than 3/4” (19.1 mm), replace the forks (See Figure 2-4).

10. Check the forks for cracks, paying close attention to the heel portion of the forks. If any cracks are found, replace the fork.

11. Every 2,400 hours, inspect the forks with magnetic particle or a dye penetrant inspection. If no test equipment is available in-house, send the forks to a qualified materials testing laboratory.

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Planned Maintenance

Mast Maintenance The following information is provided for authorized service facilities ONLY. To inspect and adjust the mast assembly, also see the Appendix of the Bendi 3 Wheel Troubleshooting and Corrective Maintenance Manual (F-445-___). For mast parts list manuals, see: · 40D Triple Mast Parts List

F-386

· 45D Quad Mast Parts List

F-387

· 50D Triple Mast Parts List

F-388

Perform maintenance on the mast as required by the Hourly Checklists beginning on page 1-3 and Routine Maintenance Schedule for Bendi 3 Wheel Forklifts located in Appendix A of the Bendi 3 Wheel Operator's Manual (F-492-___). Guidelines are provided in the following paragraphs.

Note: Any warranty repair must be pre-approved by the mast manufacturer.

Warning Never work on the mast with a load on the forks or attachment in the raised position without supports or while anyone is near the lift truck control handles per ASME B56.1-2000.

Mast adjustment procedures can produce unexpected movement of the upright rails and other parts. Be careful and alert.

The forks must be empty. NEVER perform adjustments or inspections with a loaded mast.

NEVER walk or stand under raised forks. NEVER stand on top of or climb on any part of the mast rails.

NEVER reach through upright open areas.

Wood blocks used for clamping must be square on the ends and not tapered or rounded. Use only hardwood blocks which are free from cracks and other visual damage. Tuck blocks into the channel under the roller where specified.

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

NEVER attempt to repair a chain. If any problem is found in a chain, it must be replaced and chains must be replace in sets. NEVER replace only one chain.

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Planned Maintenance

Warning All mast rail rollers, carriage rollers, chain sheaves and cylinder head guide rollers (where applicable) are self-lubricating and sealed.

Roller bearing life depends on the application and conditions of operation.

Inspection Check List · Chain stretch · Chain and roller adjustment, triplex mast · Primary lift chain adjustment · Secondary lift chain adjustment · Rail channel roller inspection · Carriage channel roller inspection

Load Roller Maintenance 1. Check for proper load roller shimming as required by the Routine Maintenance Schedule for SL Series Forklifts.

2. The maximum side-to-side clearance, between load rollers, and the outer, or inner intermediate upright assemblies, is 1/16 in. (1.5 mm) (See Figure 2-5).

3. To check the clearance, insert a pry bar between the upright and roller, and measure the clearance at the “XXX” (See Figure 2-5).

4. If additional shims are required, refer to the appropriate manufacturer’s mast service manual.

Figure 2-5 Load Roller Maintenance

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Planned Maintenance Chain Maintenance Regular inspection and lubrication of the chains will increase their service life and reduce downtime. When you perform chain maintenance, make sure you follow the guidelines in “Chain Inspection”, “Chain Lubrication”, “Chain Adjustment”, and “Measuring Chain Stretch”.

Chain Inspection Inspect the chains as required by the Hourly Checklists beginning on page 1-3 and Routine Maintenance Schedule for Bendi 3 Wheel Forklifts in the Bendi 3 Wheel Operator's Manual (F-492-__). Check for the following: · Chain wear. If one chain appears to be worn replace both chains of the pair. · Rust and corrosion. If chain joints become tight from rust and corrosion, loosen them with SAE 40W oil or penetrating oil. If they cannot be loosened, or if the tight joints are caused by bent pins, plates, or peened plate edges, replace both chains. · Cracked side plates. Replace both chains. · Protruding or turned pins. Replace both chains. · Side wear. If pins and outside plates show signs of wear, check for misalignment of sheaves, anchors or other components. Correct the misalignment. If wear is excessive, replace both chains. · Worn, broken or misaligned chain anchors. Replace or adjust as required.

Chain Lubrication

Caution The chains must be coated with a film of lubricant at all times. · Lubricate the chains as required by the Hourly Checklists beginning on page 1-3 and Routine Maintenance Schedule for Bendi 3 Wheel Forklifts located in Appendix A of the Bendi 3 Wheel Operator's Manual (F-492-__). Use lubricant listed on the Lubrication Chart located in Appendix B of the Bendi 3 Wheel Operator's Manual (F-492-__). · Each pair of chains has been factory-lubricated using heat and pressure to force the lubricant thoroughly into the chain links. Avoid removal or contamination of this factory applied lubricant. Do not wash, sand blast, etch, steam clean, or paint the chains.

B3 Ser II Forklift Planned Maintenance Manual 2-17

Planned Maintenance Chain Adjustment 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. Extend 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.

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 2-6). 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 1 ft (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.

Figure 2-6 Measuring Chain Stretch

B3 Ser II Forklift Planned Maintenance Manual 2-18

Planned Maintenance Check Lift Operation 1. Check the lift cylinders to ensure proper sequencing. If adjustment is needed, see the Appendix in the Bendi 3 Wheel Troubleshooting and Corrective Maintenance Manual (F-445-__).

CHANNEL ROLLERS

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

3. Load the mast and raise it approximately 5’ (1.524 m).

Quickly lower the mast until it is about 6” (152.4 mm) above the floor and stop the mast abruptly.

chnlrlr

Figure 2-7 Channel Roller Contact 4. Make sure the elevating channel rollers maintain proper contact with the mast channel (See Figure 2-7).

5. Look for signs of galling where the rollers contact the rail (See Figure 2-8).

GALLING

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

6. If galling is detected, adjust the rollers for the proper clearance over the full length of the mast rails (See “Inspection Check List,” page 2-16).

chnlgoge

Figure 2-8 Channel Galling

B3 Ser II Forklift Planned Maintenance Manual 2-19

Planned Maintenance Check Primary Lift Chain This adjustment procedure is for both Triplex and Quad mast assemblies.

FORKS EMPTY, LEVEL, AND FACING FORWARD

1. Park the truck on a flat, level surface, with the parking brake engaged.

2. Set the mast in the center of the truck, facing straight ahead, level to the floor and empty (unloaded). (See Figure 2-9).

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

4. Measure the distance from the floor to the bottom heel of each fork tine (See Figure 2-10).

fork level

Figure 2-9 Fork Level Gauge

This measure must be 1/8” (3.175 mm) minimum to 1/4” (6.35 mm) maximum.

5. If it is not within 1/8” to 1/4” (3.175 mm to 6.35 mm), adjust the primary lift chain accordingly. (See "Inspection Check List"’ on page 2-16.)

1/8" - 1/4"

Figure 2-10 Fork Heel to Floor Adjust

B3 Ser II Forklift Planned Maintenance Manual 2-20

Planned Maintenance Checking and Adjusting Degree of Tilt 1. To check degree of tilt, be certain the truck is on a smooth, level surface.

2. Tilt the mast back its full stroke. Place a tilt gauge against the rear outer mast rail on the right side of the truck (See Figure 2-11).

TILT GAUGE

3. The gauge must read between 3.0° and 3.1° maximum. Continue to next step if adjustment is needed.

4. To adjust the degree of tilt, tilt the mast fully backward. tltdgre

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

Figure 2-11 Tilt Degree Adjust

Warning Do not service the tilt cylinder while the key switch is ON. If a joystick, steering wheel or accelerator pedal is accidentally moved, you could be caught between the mast and the truck, causing serious injury.

B3 Ser II Forklift Planned Maintenance Manual 2-21

Planned Maintenance TILT CYLINDER TILT CYLINDER JAM NUT

Figure 2-12 Tilt Cylinder Lock Nut Bracket 6. Loosen the tilt cylinder jam nut (See Figure 2-12).

7. Continue to rotate the tilt cylinder jam nut until it is tight against the cylinder rod shoulder.

8. Place the tilt gauge against the rear outer mast rail on the right side of the truck, about 6” (152 mm) above the pivot arm. The gauge must read between 3.0° and 3.1° maximum (See Figure 2-11).

Warning NEVER exceed 3.0° to 3.1° rear tilt. Rear tilt in excess of 3.1° can cause the truck to become unstable under certain conditions.

9. Relieve the hydraulic pressure on the tilt cylinder. Rotate the tilt cylinder rod, using a 1-3/4 open end wrench on the tilt cylinder jam nut. Looking at the rod end of the cylinder turn clockwise to shorten the rear tilt or counterclockwise to increase the rear tilt. It is best to turn the rod only a 1/2 turn at a time.

10. You may have to tilt the mast a number of times (repeating steps 8. and 9.) until the adjustment is correct.

11. When the adjustment is complete, reinsert the key and turn to the ON position. Using the tilt cylinder lever, tilt the mast back to its full stroke.

12. Tighten and torque the tilt cylinder jam nut against the cylinder clevis (See General Torque, Hydraulic Fitting Torque, and Bendi 3 Wheel Special Torque Tables in Appendix B of the Bendi 3 Wheel Operator's Manual (F-492-__)).

B3 Ser II Forklift Planned Maintenance Manual 2-22

Planned Maintenance

Side Shift Circuit Maintenance The following information is provided for authorized service facilities ONLY. Perform maintenance on the side shift circuit as required by the Hourly Checklists beginning on page 1-3 and Routine Maintenance Schedule for Bendi 3 Wheel Forklifts located in Appendix A. Guidelines are provided in the following paragraphs.

Warning Before you remove any hoses or tubes, relieve hydraulic system pressure. With the truck off, open the truck auxiliary control valve(s) several times in both directions.

Check for hydraulic fluid leaks using a piece of cardboard or wood.

Do not use your bare hands. Remember to wear safety glasses.

Hydraulic oil can be under very high pressure. A pinhole leak is not easily seen and if it pierces your skin, can cause gangrene, and possibly death, if not treated immediately by a physician familiar with this type of injury. · Check the hydraulic system pressure at the carriage hose fitting. Refer to the truck service manual for details on measuring hydraulic system pressure. The minimum recommended pressure is 2000 psi (140 bar). System pressure must not exceed 3500 psi (245 bar). · Check the hydraulic system flow volume at the carriage hose fitting. The recommended flow volume is 2 GPM (7.5 L/min).

Checking for Leaks To check side shift circuit performance.

1. Side shift completely to the left and hold the control handle in this position for 5 seconds. Check for external leaks at the motor, fittings, and hoses.

2. Side shift completely to the right and hold the control handle in this position for 5 seconds. Check for external leaks at the motor, fittings, and hoses.

B3 Ser II Forklift Planned Maintenance Manual 2-23

Planned Maintenance

Identification Plate and Safety Warnings Warning Make sure that the identification plate and safety warnings (decals) located on the truck are legible and the information provided match the characteristics of the truck (See Figure 2-13). Failure to follow this guideline can result in serious injury or death.

Contact Landoll Corporation if any accessories that modify the capacity and truck operation are planned. After the factory reviews your request, new identification tags will be issued to update the rated capacity and other operation characteristics.

See the Bendij 3 Wheel Operator's Manual (F-492-___) for a complete listing and location of all safety warnings.

IDENTIFICATION (CAPACITY) PLATE b3 id plate

Figure 2-13 Identification Plate and Safety Warnings

B3 Ser II Forklift Planned Maintenance Manual 2-24

Planned Maintenance

Lubricating the Truck 1. Before lubricating the truck, lower the forks, set the key switch to the OFF position, and set the parking brake.

2. Certain grease fittings may include protective plastic caps.

Remove them before applying grease. Remember to replace the caps when you are finished (See Figure 2-14).

Figure 2-15 Grease Gun and Brush Icon

3. In the following illustrations, the location of grease fittings or surfaces to be greased are marked by either a grease-gun or brush icon (See Figure 2-15).

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

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.

5. After high-pressure washing, lubricate all unprotected grease fittings and metal-to-metal surfaces, located outside the truck.

MAST RAILS CHAINS SIDESHIFT RAILS

MAST MOUNTING PINS ROTATION BEARINGS

STEERING GEARS STEERING WHEEL KNOB HYDRAULIC TANK

GEAR BOX

lube overview

BATTERY ROLLERS (OPTION)

Figure 2-14B3 Series Model Lubrication Overview

B3 Ser II Forklift Planned Maintenance Manual 2-25

Planned Maintenance 6. Interval frequency can be recorded from the running hours read on the hour meter in the driver’s compartment.

7. See Table in Appendix B of the Bendi 3 Wheel Operator's Manual (F-492-___) for recommended lubricants (See Figure 2-14).

Tilt Cylinder Clevis

Warning Do not service the truck 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.

1. Start the truck and pivot the mast straight forward to the normal carry position.

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

3. Grease clevis fitting on end of tilt cylinder until fresh grease is squeezed from the clevis. (See Figure 2-16).

4. Wipe off excess grease.

GREASE FITTING

grease tilt cyl

Figure 2-16 Mast Mounting Pins

B3 Ser II Forklift Planned Maintenance Manual 2-26

Planned Maintenance Main Rotation Bearings/Gears

Warning Do not service the truck 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.

1. Start the truck and pivot the mast straight forward. to the normal carry position.

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

3. Grease the upper and lower front rotation bearing fittings until fresh grease is squeezed from the lower bearing (See Figure 2-17).

4. Wipe off excess grease at the lower bearing.

grease gears

Figure 2-17 Main Rotation and Idler Gear Lubrication

B3 Ser II Forklift Planned Maintenance Manual 2-27

Planned Maintenance Battery Rollout tray (Option) 1. Set the parking brake and block the rear wheels (2).

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

3. Disconnect and remove the battery. See the Bendi B3 Series Operator's Manual (F-492-___) for instructions on replacing the battery.

ROLLOUT RESTRAINT/ RELEASE ARM W/ REQUIRED SPACERS ROLLOUT BATTERY TRAY

4. Using a brush and vacuum, clean the roller tray and restraint release arm area of any dirt or battery acid residue.

5. Remove the rollout restraint and brush apply a thin film of grease to the mating surfaces of the restraint arm and inside of bracket (See Figure 2-18).

6. Inspect each roller. Ensure that each roller spins freely. Replace rollers that do not spin.

roll-lub_1

Figure 2-18 Rollout Battery Tray Lubrication

7. Apply a drop or two of light machine oil to the release handle.

DO NOT over oil.

B3 Ser II Forklift Planned Maintenance Manual 2-28

Planned Maintenance Fork Positioner Lubrication, Non-Side Shifting (Option) 1. Start the truck and position the mast straight ahead.

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

WARNING Do not service the fork positioner while the key switch is ON. If the pivot or tilt joystick is accidentally moved, serious injury could occur.

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 shaded areas on the fork rails, including a thin film on the front face of both rails (See Figure 2-).

5. Wipe off excess grease.

Figure 2-

Fork Positioner, Non-Side Shifting

B3 Ser II Forklift Planned Maintenance Manual 2-29

Planned Maintenance

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

It is also recommended to replace worn tires in pairs. Treaded drive tires must be replaced when the tread depth is less than 0.0625” (1.6mm) at the deepest point.

Check all wheel nuts after 2 to 5 hours of operation: when new lift trucks begin operation and on all lift trucks when the drive wheels have been removed and installed. Tighten the nuts in a cross pattern to the correct torque value shown in the Routine Maintenance Schedule located in Appendix A of the Bendi 3 Wheel Operator's Manual (F-447-___). When the nuts stay tight for eight hours, the interval for checking the torque can be extended to 200 hours.

1. Inspect the tires for chunking (or chipping), embedded foreign material (wire, rocks, glass, metal, etc.), cuts, gouges, undercutting or uneven wear. Remove any object that will cause damage (See Figure 2-19).

2. Check for loose or missing hardware.

3. Remove any wire strapping or other material that is wrapped around the inside of wheel.

4. Make sure drive wheel nuts are tight.

Tighten the wheel nuts in a cross pattern to a correct torque value (225 ft. lbs., 300 Nm).

5. Careful driving habits can add additional miles to tire life.

Figure 2-19 Tire Tread Inspection

B3 Ser II Forklift Planned Maintenance Manual 2-30

Planned Maintenance Chunking (Chipping) or Embedded Objects Chunking, or chipping is caused by repeatedly running over objects on a littered floor which can chip away or produce deep cuts to the rubber surface of the tire.

Embedded objects, such as glass, metal chips, or nails left in a tire, and truck overloading cause the same effect.

Sharp, rapid turns at quick speeds, jack-rabbit starts and stops and other such bad driving habits can cause the same kind of damage (See Figure 2-19).

1. Remove any embedded foreign material from the tire as soon as it is noticed. Also remove torn pieces of tread.

2. To avoid overloading, always center the payload on the truck to equalize the load on all tires. Do not dangle the load on the ends of the forks. Also avoid fast cornering, which can cause an overload affect.

3. If the tires are chunked bad enough to produce a bouncy ride, replace them (See Figure 2-19).

Undercutting and Uneven Wear Undercutting is caused by continuous overloads, rapid, sharp turns, operating on slopes, a faulty steer axle, transporting loads with a high center of gravity, or transporting off-center loads (See Figure 2-19).

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

1. Undercutting causes the rubber to bulge out over the edge of the steel band, cutting the rubber just above the base band.

2. Check that the tires remain centered on the wheels to prevent splitting of the base band and tread separation.

3. Correct such defects as soon as possible.

B3 Ser II Forklift Planned Maintenance Manual 2-31

Planned Maintenance Flat-spotting Flat-spotting occurs when: · the truck has been sitting idle for some time after heavy use and is usually caused by the tires overheating. · the truck has standing loads (loads left on the forks overnight). · locking the brakes while traveling in either direction on grades (slopes), with or without a load, causing excessive skidding.

Polyurethane tires are extremely susceptible to this type of abuse.

1. Avoid excessive heat. Where possible, avoid contact with hot metal or operation for long periods in hot oven rooms. Excessive heating will break-down the tire structure.

Shields which prevent heat from striking tires directly will often prolong life.

2. Avoid standing loads. Solid tires will flat-spot when loads are left standing on the truck overnight. In extreme cases, a flat spot develops and the tire bounces with every revolution.

3. If the tires are flat-spotted bad enough to produce a bouncy ride, replace them.

4. Do not indulge in stunt driving or horseplay where excessive hard braking is needed, especially on grades (slopes).

To Extend Tire Life A few simple measures can help increase tire life and reduce maintenance (downtime) and cost of operation.

1. Inspect tires regularly and remove embedded objects immediately.

2. Check that the tires remain centered on the wheels.

3. Lubricate the truck according to the schedule provided at the beginning of this chapter; however, avoid over lubrication.

4. Keep runways clean and maintain floors in good repair, free from breaks, ruts, cracks and debris.

5. Avoid excessive heat, overloading and standing loads.

6. Regularly check axle alignment and steering.

7. Avoid sharp turns and quick starts and stops.

8. Avoid oil, grease, gasoline and acid. Wipe these compounds off as soon as possible.

Do not allow hydraulic oil to drip onto the tires.

B3 Ser II Forklift Planned Maintenance Manual 2-32

Planned Maintenance Drive Wheel Lug Nuts Retorque the drive wheel lug nuts once or twice during the first 50 to 100 hours of operation, then once every 250 hours thereafter. Also see “Check Nuts, Bolts, and Screws,” on page 2-63.

Check Planetary Gear Box The planetary drive gear box assembly is filled with oil at the factory. An oil change is necessary after the first 100 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 truck has been in storage for one year or more, the oil should be changed before placing the truck into operation.

Also see Appendix of the Bendi 3 Wheel Service Manual (F-446-___) for Drive System installation, service, and maintenance information.

Warning Perform service only in a well-ventilated area. Do not breathe vapors.

Wear protective goggles, aprons, and gloves. Avoid contact with skin, eyes and clothes. Keep away from heat and flame. Do not smoke when using solvents or in the area where solvents are stored.

Failure to observe these precautions may result in death or injury.

If you become dizzy, get fresh air and medical help immediately. If solvent contacts your eyes, immediately treat in accordance with the manufacturer’s recommendations on the container.

Always read the label affixed to the fluid container for all safety information before use.

Do not mix different types of lubricant.

B3 Ser II Forklift Planned Maintenance Manual 2-33

Planned Maintenance 1. Position the truck on a flat surface, set the parking brake and block the wheels to prevent movement.

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

3. Disconnect the battery.

4. Raise the vehicle. Use jackstands, or other suitable supporting device, to support vehicle.

5. Raise the drive wheel to allow the tire to rotate.

6. Remove wheel from unit being serviced.

7. Thoroughly clean the area around the fill and drain/level plugs (See Figure 2-20).

Note: Always place an appropriate support stand under the truck if it is being lifted. Lower the truck to the stand, having both the lifting device and stand supporting the weight of the truck.

DANGER GETTING UNDER A TRUCK WHEN IT IS LIFTED OR JACKED IS DANGEROUS AND COULD CAUSE SERIOUS INJURY OR DEATH. NEVER GO UNDER A TRUCK THAT IS SUPPORTED ONLY BY A JACK. 8. To drain, turn the gear box so that one of the drain plugs is at the lowest point (See Figure 2-20).

If rotating the gear box proves difficult, brace a 2” x 4” (5cm x 10cm) between the wheel studs and rotate.

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

5mm HEX SOCKET BOLT

9. Place a drain pan capable of storing up to 32 ounces (1.0 liter) of fluid under the drain plug (See Figure 2-20).

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

4mm HEX SOCKET DRAIN/LEVEL PLUG

A

drain gear box

Figure 2-20 Draining Gear Box Oil

B3 Ser II Forklift Planned Maintenance Manual 2-34

Planned Maintenance 11. Drain the fluid completely into the drain pan.

CAUTION If truck has just been in operation for a period of time the oil could be very hot. Use special gloves or allow the truck to cool before changing the oil. It is best to drain fluid while the unit is warm, but not HOT! Never drain oil into sewer lines.

12. Once the fluid has been drained, replace the drain/level plug in position A (See Figure 2-20).

13. Wash the interior of the gear box with a suitable cleaning liquid as recommended by the lubricant manufacturer. a. Put liquid into the gear box through the fill plug. Replace the fill plug. b. Run the gear box for a few minutes at a high speed. c. Drain the cleaning liquid from the gear box in the same way as described for draining the oil in steps 8. through 11. d. Clean any contaminants from the magnetic trap and O-ring seal on the plugs.

14. To fill the gear box, turn until the drain/level hole in position A is about 15o below the horizontal center line of the gear box (See Figure 2-21).

15. Fill the gear box with synthetic gear lube through position B until fluid flows out from position A. See Appendix B of the Bendi 3 Wheel 5mm HEX Operator's Manual for SOCKET BOLT recommended lubricants. Fluid capacity B is approximately 1 pint.

For easy oil fill, use a hose and funnel arrangement, having an outside diameter of 0.50” (12.7 mm) (See Figure 2-21).

4mm HEX SOCKET FILL PLUG 5mm HEX SOCKET BOLT

DO NOT OVERFILL. 16. Install both plugs. Tighten to 25 ft. lbs. (34 Nm). fill gear box

17. Wipe off any oil spillage on the outside of the gear box.

15

o

A

4mm HEX SOCKET DRAIN/LEVEL PLUG

Figure 2-21 Filling Gear Box

18. Turn the gear box 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, top off the oil.

B3 Ser II Forklift Planned Maintenance Manual 2-35

Planned Maintenance

Replacing Motor Brushes To check the running hours of the various motors, turn the key switch off and on and record the hours shown on the display for the specific motor in question. Also see “Controls and Indicators,” in the Bendi 3 Wheel Operator's Manual (F-492-__).

Warning Disconnect the battery cables before working on electrical components. An electrical short may result in arcing which could cause serious burns.

Always wear a dust mask and eye protection when seating brushes, cleaning commutators, and/or blowing dirt out of motors using forced air.

Exposing the Motors When accessing the pump motor or power steering motor brushes, do the following: 1. Set the parking brake and all wheels not being serviced.

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

3. Disconnect the battery.

4. Remove the electrical enclosure cover.(See Figure 2-22)

(ELECTRICAL ENCLOSURE COVER REMOVED)

STEER MOTOR

LIFT MOTOR

STEER PUMP

LIFT PUMP

Figure 2-22 Frame Well Area and Motor Locations

B3 Ser II Forklift Planned Maintenance Manual 2-36

Planned Maintenance Traction Drive Motor Brushes Traction drive motor brushes have an approximate life expectancy of 2,500 to 3,000 hours.

1. Remove the drive tire.

2. Remove all screws securing the motor mounting bracket to the truck frame.

This will allow the unit to rotate within the truck, exposing all brush locations (See Figure 2-22).

Brush

3. Remove the retaining screw from the brush and screen motor cover halves.

Brush Spring

Slide the screen off the mounting pins to expose the brush assembly.

4. Remove the screw holding the brush pigtail wire connector to the assembly.

Figure 2-23 Pump Motor Layout and Brushes

5. Lift the retaining spring away from the brush, and remove the brush from its holder (See Figure 2-23).

6. If the brush is worn to within 3/8” (9.5 mm) of the wires, replace the brush.

7. Inspect the commutator for excessive wear, cracks or burn spots. If burn spots are found, the commutator must be cleaned (polished).

Cracks or excessive wear may require turning-down the commutator on a lathe or possibly replacing the assembly.

8. Next, inspect the mica bar-to-bar insulation. When excessive commutator wear results in flush or protruding mica insulation between the commutator bars, the mica must be undercut to approximately 0.025” (0.635 mm).

Also see “Traction Drive Motor and Gearbox,” in the Bendi 3 Wheel Troubleshooting and Corrective Maintenance Manual (F-445-__). The motor needs to be removed from the truck to repair the commutator or mica insulation.

B3 Ser II Forklift Planned Maintenance Manual 2-37

Planned Maintenance 9. After replacing all brushes, connect the battery and start the truck.

10. While the motor is running, check the brushes for proper contact with the commutator. If arcing is suspected, it is best to seat the brushes and clean the commutator using a brush seater/commutator cleaning stone.

11. Seating brushes - Select a stone wider than the brush. With the motor running, press down hard on the brush with an insulated tool and apply the stone at the leading edge of the brush for several seconds.

This allows stone material to pass under the brush. Repeat until brush is fully seated.

12. Cleaning the commutator - select a stone as large as practical. With the motor running, hold the stone lightly against the commutator, moving the stone slowly back and forth across the commutator face unit the excess film or burn spots are removed.

13. Reinstall motors and torque motor mounting screws.

14. Turn the truck OFF. Wearing a dust mask to protect from inhaling dust particles, use forced air and a vacuum to blow out and vacuum the dust created by seating the brushes and the commutator.

15. Disconnect the battery, then replace the brush and screen motor covers.

B3 Ser II Forklift Planned Maintenance Manual 2-38

Planned Maintenance Lift Pump and Power Steering Motor Brushes 1. Read the WARNING note on page 2-36.

2. Remove the motor cover. (See "Exposing the Motors," page 2-36).

3. Remove the retaining screw from the brush and screen motor cover halves. Slide the screen off the mounting pins to expose the brush assembly.

4. Remove the screw holding the brush pigtail wire connector to the assembly (See Figure 2-24).

Springs

Brush Wire Screw

5. Lift the retaining spring away from the brush, and remove the brush from its holder.

6. If the brush is worn down to within 3/8” (9.5 mm) of the wires, replace the brush.

Brushes

7. Inspect the commutator for excessive wear, cracks or burn spots. If burn spots are found, the commutator must be cleaned (polished) to remove them.

Cracks or excessive wear may require turning-down the commutator on a lathe or possibly replacing the assembly.

Figure 2-24 Pump and/or Power Steering Motor Brushes

8. Next, inspect the mica bar-to-bar insulation. When excessive commutator wear results in flush or protruding mica insulation between the commutator bars, the mica must be undercut to approximately 0.025” (0.635 mm).

9. After replacing all brushes, connect the battery and start the truck.

10. While the pump/steer motor is running, check the brushes for proper contact with the commutator. If arcing is suspected, it is best to seat the brushes and clean the commutator using a “brush seater/commutator cleaning stone.”

B3 Ser II Forklift Planned Maintenance Manual 2-39

Planned Maintenance 11. Seating brushes - Select a stone wider than the brush. With the motor running, press down hard on the brush with an insulated tool and apply the stone at the leading edge of the brush for several seconds.

This allows stone material to pass under the brush. Repeat until brush is fully seated.

12. Cleaning the commutator - Select a stone as large as practical. With the motor running, hold the stone lightly against the commutator, moving the stone slowly back and forth across the commutator face until the excess film or burn spots are removed.

13. Turn the truck OFF. Wearing a dust mask to protect from inhaling dust particles, use forced air and a vacuum to blow out and vacuum the dust created by seating the brushes and cleaning the commutator.

14. Disconnect the battery, then replace the brush, screen motor covers, and electrical enclosure cover.

Check Service Drum Brakes The service brakes are hydraulically-actuated, drum brakes, similar to an automotive drum brake system. They are installed on the rear wheels only.

The brakes should be checked every 100 hours of operation. Normal brake pad life is approximately 3,000 hours of operation, as determined by driving conditions. If you are near or beyond this time frame, you must inspect the brakes.

New brake shoes are approximately 0.250” (6.350 mm) thick; replace them when the shoe thickness is 0.0940” (2.380 mm) or less at the thinnest point.

A few indications of possible brake pad replacement are: · excess travel of the service brake pedal · the truck pulling to one side when the brakes are applied · squealing or grinding is heard when you apply the brakes Drive the truck at creep speed and apply brakes lightly, to determine if brakes shoes are contacting the drum. You should feel a slight pulsating effect as the shoes contact the drums.

If any of the above occurs during brake inspection, see “Brake System-Repair,” in the Bend 3 Wheel Troubleshooting and Corrective Maintenance (F-445-___).

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.

B3 Ser II Forklift Planned Maintenance Manual 2-40

Planned Maintenance To Check the Brakes The brakes are located in the two rear wheel drums.

1. Position the mast at it's lowest level.

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

3. Disconnect the battery .

4. Jack up the truck and rest the frame of the forklift on stands. Remove wheel studs.

5. Remove the drum and check it for scoring caused by excessively worn brake shoes (See Figure 2-25).

6. Brake linings must be replaced as a set when thickness measures less than 0.0938 " (2.381 mm or less) at the thinnest point. Check the linings for scoring, glazing, or an oil soaked condition. Check the return springs for discoloration or fatigue. It is recommended that return springs be replaced as a set.

7. If replacement is needed, always replace shoes on both sides of the truck. Also see “Brake System-Repair,” in the Bendi 3 Wheel Troubleshooting and Corrective Maintenance Manual (F-445-___).

8. Bleed brake system. Refer to "bleeding Brakes", in the Bendi 3 wheel Troubleshooting and Corrective Maintenance Manual (F-445-___) 9. Check brake lines for leaks, Repair leaks immediately - see “Rigid Brake Line,” in the Bendi 3 Wheel Troubleshooting and Corrective Maintenance Manual (F-445-___).

.0940 INCH MINIMUM

CHECK SPRINGS FOR DISCOLORATION AND FATIGUE

CHECK FOR LEAKS CHECK FOR GLAZING, SCORING AND OIL SOAKING

M18062

Figure 2-25 Checking Drum Brakes

B3 Ser II Forklift Planned Maintenance Manual 2-41

Planned Maintenance

Power Steering System Maintenance Perform maintenance on the power steering system as required. Guidelines are provided in the following paragraphs. · Fluid for the hydraulic power steering system comes from the central hydraulic reservoir. · Always use a puller to remove the steering wheel. Do not use a hammer, torch, or crow bar. · Investigate and immediately correct any play, rattle, shimmy, misalignment, or other unusual occurrence in the steering system. · Report any malfunction or accident that may have damaged a steering system part. · Do not attempt to weld any broken steering component. Replace the component with original equipment only. Do not cold straighten, hot straighten, or bend any steering part. · Investigate and correct any external leak in the steering system, no matter how minor the leak.

Caution Prevent dirt or other foreign matter from entering the hydraulic system; clean filler caps before checking oil level.

B3 Ser II Forklift Planned Maintenance Manual 2-42

Planned Maintenance Check Power Steering 1. Sit in the driver’s seat and set the key switch to ON. 2. While applying the service brake, release the parking brake and set the direction control lever to FORWARD or REVERSE. The power steering 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 truck 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 seven to nine revolutions, ±1/2 revolution, 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 seven to nine revolutions, ±1/2 revolution, lock-to-lock.

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

9. For disassembly and repair, see “Steering Assembly,” in the Bendi 3 Wheel Troubleshooting and Corrective Maintenance Manual (F-445-__).

B3 Ser II Forklift Planned Maintenance Manual 2-43

Planned Maintenance Filling and Air Bleeding the Power Steering System Fill and air bleed the power steering system per the schedule shown on the Routine Maintenance Schedule of the Bendi 3 Wheel Operator's Manual (F-492-__) 1. Lower the mast within a few inches of the floor and tilt the mast all the way back.

2. Fill the reservoir until it is between the F and E mark on the dipstick. DO NOT OVERFILL. 3. Run the steering through three complete cycles by turning the steering wheel all the way in one direction, then all the way the other direction.

4. Check and refill the reservoir after each cycle.

5. Add fluid until it is between the F and E marks on the dipstick.

Lubricate Steer Wheel Knob 1. While the truck is stationary and with the key switch OFF, apply a drop or two of light machine oil where the knob meets the steering wheel (See Figure 2-26).

2. Spin the knob a few times and wipe off excess oil.

sterknob2

Figure 2-26 Steering Wheel Knob

B3 Ser II Forklift Planned Maintenance Manual 2-44

Planned Maintenance

Check Hydraulic Functions 1. Position the truck on a level, flat surface. Clear area around the truck.

2. Turn the key switch to the ON RUN position.

3. Make sure your right foot is on the floor of the operator's compartment and prepared to brake.

4. Pull either joystick to see if hydraulics are working (See Figure 2-27).

The pump must turn OFF immediately as you release the joystick.

Figure 2-27 Checking Hydraulic Functions 5. If the pump keeps running, see "Hydraulic Control Valve and Switches," in the Bendi 3 Wheel Troubleshooting and Corrective Maintenance Manual (F-445-__).

6. Visually check cylinders, valves, and hoses for leaks or other signs of wear.

7. Check hydraulic fluid level.

B3 Ser II Forklift Planned Maintenance Manual 2-45

Planned Maintenance

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 truck forward, then stop by using the service brake.

4. Turn the key switch OFF, then back on again.

5. Press on the accelerator pedal.

The truck must not move. If it begins to move, see “Direction Control Lever,” in the Bendi 3 Wheel Troubleshooting and Corrective Maintenance Manual (F-445-__) to check the electrical function of the lever.

6. If the truck does not move, take your foot off the accelerator pedal. Place the directional control lever in NEUTRAL then back to FORWARD again.

7. Slowly push on the accelerator pedal. The truck should move forward. If it does not move, see “Direction Control Lever,” in the Bendi 3 Wheel Troubleshooting and Corrective Maintenance Manual (F-445-__) to check the electrical function of the lever.

8. Repeat preceding Steps 3. through 7., but instead of turning the key switch OFF in Step 5., lift yourself from the driver’s seat to allow the switch interlock to release. The truck must react as stated in Steps 5. through 7.

B3 Ser II Forklift Planned Maintenance Manual 2-46

Planned Maintenance

Check Driver’s Seat Switch This procedure checks the physical mechanics (actuation) of the driver’s seat switch only.

The switch is part of the seat (See Figure 2-28).

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

SLIDE RAILS

LIMIT SWITCH AND CABLE

seatswch2

Figure 2-28 Driver's Seat Switch

1. Start the truck 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 (See Figure 2-28).

3. Set the direction control lever in either FORWARD or REVERSE and slowly apply acceleration. As the truck 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. You should lose forward (or reverse) direction, but the truck will not come to an immediate stop. The truck will coast unless you use you brakes.

5. If the truck continues to apply torque to the wheel, see “Seat Switch,” in the Bendi 3 Wheel Troubleshooting and Corrective Maintenance Manual (F-445-___).

B3 Ser II Forklift Planned Maintenance Manual 2-47

Planned Maintenance

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

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

2. Pull up the rubber floor mat. Be careful around the accelerator pedal to avoid tearing the mat (See Figure 2-29).

3. Remove the left floor plate from the truck frame (See Figure 2-29). All planned maintenance checks can be done by removing only the left floor plate.

4. If more extensive maintenance is necessary, remove the hardware holding the accelerator pedal to the right floor plate. Carefully lift the right floor plate.

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

5. Install all screws when the panel(s) are reinstalled and make certain the accelerator harness is secured to the linear accelerator. Install rubber floor mat.

FLOOR MAT

RH FLOOR PLATE LH FLOOR PLATE

ACCELERATOR PEDAL FLOOR PLATES floorplate

Figure 2-29 Floor Plate Removal

B3 Ser II Forklift Planned Maintenance Manual 2-48

Planned Maintenance

Check Master Cylinder Fluid Level The master cylinder is located below the driver’s compartment floor plate.

1. Remove the left floor plate (See page 2-48).

2. First clean the reservoir cap to avoid fluid contamination, then remove the fill cap and rubber gasket (See Figure 2-30).

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. See Appendix B of the Bendi 3 Wheel Operator's Manual (F-492-___) for recommended lubricants.

MASTER CYLINDER

master cyl

Figure 2-30 Master Cylinder

5. Reinstall the reservoir fill cap and rubber gasket. Tighten only enough to provide a leak-proof seal.

Note: Do not overtighten. This could crimp, split, or damage the seal.

B3 Ser II Forklift Planned Maintenance Manual 2-49

Planned Maintenance

Hydraulic System Maintenance Maintain the hydraulic system, and associated components, as required by the various checklists beginning on page 1-3 and the Routine Maintenance Schedule for B3 Series Forklifts located in Appendix A of the Bendi 3 Wheel Operator's Manual (F-492-__). Guidelines for hydraulic system maintenance is provided in the following paragraphs.

Caution Do not allow hydraulic fluid level to drop significantly or allow the reservoir to run dry. This will induce air into the system and cause damage to hydraulic system components.

Caution Prevent dirt or other foreign matter from entering the hydraulic system; clean filler caps before checking oil level.

Cylinders and Valves - Check these components for drift and leakage. Refer to Landoll Corporation and other vendor service information for specifications.

Hoses and Tubelines - Check for cracks, hardening, or other signs of wear. Reroute any usable hoses that are kinked, severely bent, or rest against hot parts. Look for leaks, especially at couplings and fittings. Replace any hoses or tubelines that do not meet system flow and pressure ratings.

Hydraulic Fluid - Check fluid level and look for air bubbles. Check the filter.

See Appendix B of the Bendi 3 Wheel Operator’s Manual (F-492-__) for recommended lubricants.

Other Hydraulic System Components - Visually check other components to see if they are loosely mounted, show signs of leaks, or other damage or wear.

B3 Ser II Forklift Planned Maintenance Manual 2-50

Planned Maintenance 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 OFF, turn the steering wheel left and right until it becomes difficult to turn.

4. The fill cap is located below the floor mat and floor plates.

Disconnect battery and lift rear panel of joystick cover (See Figure 2-31).

5. First clean the area around the fill cap, then open the cap by turning counterclockwise. (See Figure 2-31).

IMPORTANT !

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.

OIL FILTER AND FILL CAP HYDRAULIC OIL DIPSTICK check hyd oil

Figure 2-31 Hydraulic Tank Below Control Panel Cover

B3 Ser II Forklift Planned Maintenance Manual 2-51

Planned Maintenance 6. Remove the dipstick again, holding the dipstick tip level and check the oil level (See Figure 2-32).

If the oil level is at the FULL line or between the FULL and ADD lines, the level is correct and no oil is needed.

If the oil is at or below the ADD line, you will need to add oil to bring it up to the FULL line (maximum).

ADD MARK

FULL MARK

IMPORTANT The oil level indicated on the dipstick is most accurate when the oil is at operating temperature (130oF to 200oF (53oC to 93oC)).

7. Add hydraulic oil as needed. See Appendix B of the Bendi 3 Wheel Operator's Manual (F-492-__) for recommended lubricants.

Figure 2-32 Oil Level on Dipstick

Do not overfill. Having the level above the FULL line does not allow enough area for expansion when the oil heats during normal operation.

8. If the fluid appears very dirty or dark in color, check the truck’s maintenance log for the last fluid and filter change and change accordingly.

9. Install the fill cap and turn clockwise, making sure it is tight. Install the cover and reconnect battery.

B3 Ser II Forklift Planned Maintenance Manual 2-52

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

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

3. Disconnect the battery.

4. Remove the driver’s cab floor plate exposing the oil dipstick, fill cap and oil filter combination. Remove the side access cover. See “Floor Plate Removal,” page 2-48.

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

6. Unscrew (counterclockwise) and remove the container cap and spring.

7. Reach in and remove the filter element by pulling upwards while turning the element slightly to release the bottom o-ring seal (See Figure 2-33).

8. Using a clean, lint-free cloth, clean the inside of the cartridge bowl.

9. Coat both o-ring seals on the new filter element with a film of hydraulic oil, then insert the new element into the bowl and press down to seat the bottom o-ring.

10. Align the container cap spring to the by-pass assembly pin, press down and hand tighten the container cap. Tighten the cap on additional 1/4 turn to seal the assembly.

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

12. Reinstall the driver's cab floor plate.

FILTER

hydraulic filter

Figure 2-33 Oil Filter Access

B3 Ser II Forklift Planned Maintenance Manual 2-53

Planned Maintenance Change Hydraulic Oil 13. The mast must be set to the normal carry position.

14. Set the parking brake and block the rear wheels (2).

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

16. Disconnect the battery.

17. Remove the driver's cab floor panel (See 'Floor Plate Removal,' page 2-53) to expose the oil reservoir fill cap, as well as the oil filter.

18. Open the fill cap (See Figure 2-31 on page 2-51).

19. The hydraulic reservoir (oil tank) drain plug is located in the bottom of the truck, on the right side (facing forward) near the steering column. (See Figure 2-34).

20. Slide a flat collection pan, having a capacity of 10 gallons (38 liters) minimum under the drain plug, then remove the plug (See Figure 2-34).

HYDRAULIC OIL FILTER

HYDRAULIC OIL DIPSTICK

HYDRAULIC ADAPTER DRAIN PLUG

hydraulic drain

Figure 2-34 Draining Oil Reservoir

B3 Ser II Forklift Planned Maintenance Manual 2-54

Planned Maintenance 21. Change hydraulic oil filter (See page 2-53).

22. Clean the magnetic trap on the drain plug of any contaminants. When the tank is empty, clean and reinstall the drain plug.

23. Add hydraulic oil. See Appendix B of the Bendi 3 Wheel Operator’s Manual (F-492-__) for recommended lubricants. Also see “Check Hydraulic Oil Level,” page 2-51.

Note: Do not overfill. Having the level above the FULL marker on the dipstick does not allow enough area for expansion when the oil heats during normal operation.

24. Replace the fill cap, turn clockwise, and make sure it is tightened securely.

25. Make sure the drain plug is tight enough to prevent oil leaks, but do not over tighten.

B3 Ser II Forklift Planned Maintenance Manual 2-55

Planned Maintenance

Battery Care and Maintenance The information below is only intended as a guide for battery care. For further information on the safe operation of batteries, refer to the applicable battery manufacturer’s guide.

Maintain the battery, and associated components, as required by the various checklists beginning on page 1-3 and the Routine Maintenance Schedule for Bendi 3 Wheel Forklifts located in Appendix A of the Bendi 3 Wheel Operator's Manual (F-492-__).

Detailed battery maintenance procedures are provided in the following paragraphs.

Warning Batteries contain acid which burns eyes and skin on contact. Wear goggles, protective clothing, and rubber gloves to keep acid off body.

In case of acid contact, wash immediately with water. In case of eye contact, get prompt medical attention and wash eye with clean, cool water for at least 15 minutes.

If electrolyte is taken internally, drink large quantities of water or milk! DO NOT induce vomiting. Get prompt medical attention.

Batteries produce explosive gases during operation and charging.

Keep your SL Series forklift in a designated area while you are charging or changing the batteries. Keep all sparks, arcs, and lighted tobacco away from the batteries. Failure to this can cause serious injury or death.

Make sure the batteries in your SL Series forklift weigh no more than the Maximum Service Weight of Battery and no less than the Minimum Service Weight of Battery stated on the identification plate.

Failure to follow these guidelines can lead to truck instability causing serious injury or death.

Caution Make sure you don’t pinch any body parts when you latch the battery cover.

To avoid injury to personnel or damage to the equipment, consult Landoll Corporation’s procedures for replacing contacts for any battery connection.

Change and charge batteries in accordance with ANSI/NFPA 505.

When you plug in the charger, make sure you connect it to the cable that goes to the batteries NOT to the truck.

B3 Ser II Forklift Planned Maintenance Manual 2-56

Planned Maintenance · Only add distilled water to the battery cells. Overfilling battery cells is dangerous and any spillage must be wiped up immediately. · Use only a clean glass or other non-metallic container for storing distilled water used to top off the battery fluid. · Keep the battery container clean and dry. Any corrosion to metal components, caused by battery acid, must be neutralized with a solution of sodium bicarbonate or diluted ammonia. Smearing the terminals with petroleum jelly and applying acid proof paint to the battery container can prevent further corrosion. · Keep all sparks, arcs, and lighted tobacco away from the batteries. · Make sure the filler plugs are tight and the vents are clear. · If you take a truck out of service for any length of time, disconnect and remove the battery. · Disconnect the battery when you transport the truck. · Keep the battery fully charged while it is in storage. · Store spare batteries in a cool, dry place. Maintain the cells by topping off with distilled water and give it an equalizing charge each month. · Spare and replacement batteries must be the same type and weight as the original unit unless authorized by Landoll Corporation. · Make sure that lifting chains, slings, hooks, tools, and other metallic objects do not come into contact with the battery terminals. · Never operate a truck with the battery cover (seat base) removed. · Never remove the charging connector by pulling the lead. This could result in damage to the insulation inside the connector. · Never use or charge a battery that has a damaged connector and/or defective insulation. Repair or replace the connector.

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

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

Use a grounding wrist band to protect microprocessors from static electricity and always touch a metal surface (other than the truck) before touching a PCB. These precautions are especially necessary in respect of microprocessor devices, found on the hydraulic control PCB, of this truck.

B3 Ser II Forklift Planned Maintenance Manual 2-57

Planned Maintenance Check Batteries

Warning Always assume the battery is emitting hydrogen and employ proper safety precautions.

Do not smoke, use an open flame, or create arcs or sparks near the battery.

Packaged with every battery are specific instructions for battery safety, care and use, plus a Material Safety Data Sheet (MSDS). Read these documents thoroughly before servicing the battery.

Always disconnect the battery before performing any service.

Do not lay objects on the battery as they may cause a short circuit.

Shorting battery terminals can release enormous amounts of energy, causing electrical shock, sparks or flame, or heating nearby components to dangerous temperatures.

Truck batteries contain concentrated sulfuric acid which can cause severe chemical burns. When adding water to the battery, wear rubber gloves, protective clothing and safety glasses or full-face shield.

Use a plastic container or an automatic cell filler to prevent container breakage.

Neutralize acid spills immediately with Bicarbonate of Soda! If acid contacts the skin or eyes, wash with water immediately and seek medical help at once.

Use caution when changing battery connectors to ensure that correct polarity is maintained.

Keep vent plugs in place, fully tightened and clean at all times.

Be sure to replace and retighten any battery restraints which have been installed on the truck.

B3 Ser II Forklift Planned Maintenance Manual 2-58

Planned Maintenance To Check 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.

3. Slowly release the bulb to allow fluid to draw into the hydrometer.

4. Enough fluid must enter the hydrometer to allow the float to move freely.

5. The specific gravity of the electrolyte is Figure 2-35 Battery Charge State Using read off the scale of the float where it a Hydrometer emerges from the fluid (See Figure 2-35). It is a good practice to select a different cell each time a measurement is taken and to test more than one cell.

6. If the electrolyte temperature is above 77° F (25° C). Add a factor of 0.003 to the specific gravity reading for every 10° F (-12.2° C) above 77° F (25° C).

7. If the specific gravity of the battery is less than the manufacturer’s specification at 80% discharge, you must charge the battery (See page 2-60 for charging information).

8. When returning the electrolyte to the battery, return it to the same cell it was taken from and be very careful not to splash the electrolyte as it is squeezed from the hydrometer.

9. Check the level in all battery cells. If a level is below the top of the battery plates, add distilled water to bring the level above the plates (See Figure 2-36).

Figure 2-36 Battery Electrolyte Level High level marker indicates proper level immediately after charging. Low level marker indicates immediate need for additional water (See Figure 2-36).

CAUTION Avoid over filling as it will cause overflow (flooding) of the electrolyte, resulting in loss of electrolyte, battery tray corrosion, ground paths and loss of capacity or working ability 10. Replace all the vent caps and make sure they are tight.

B3 Ser II Forklift Planned Maintenance Manual 2-59

Planned Maintenance Battery Charging Charging Procedure 1. Park the truck in the charging bay and remove the key.

2. Unlatch and raise the seat base from the right side of the Bendi 3 Wheel.

Note: Do not fill battery cells until after full charge.

3. Make sure top of batteries are clean and dry.

4. Pull the connector attached to the battery leads from the connector attached to the forklift truck (See Figure 2-37).

5. Check the charger cable and plug for frayed insulation and broken connectors.

Caution Connecting the charger cable to the truck cable can cause damage to the forklift (See Figure 2-37).

6. Connect the charger cable to the battery cable (See Figure 2-37).

7. Follow charger manufacturer’s instructions to charge batteries.

8. Disconnect the charger cable and reconnect the connector attached to the battery leads to the connector attached to the forklift truck (See Figure 2-37).

9. Check the electrolyte levels and top off with distilled water as necessary. Add sufficient amount of distilled water to keep the acid level visible. Many types of cells have an indicator rib or similar projection above the separator guard. Do not fill above this marker. Refer to manufacturer’s instructions.

10. Lower the seat base from the right side of the Bendi 3 Wheel: a. Be sure the arm rest is raised and clear of the seat base. b. While supporting the seat base, release the restraint latch and lower the seat base.

CAUTION: Grip the seat base from the side only to avoid front pinch points. (Note warning decals). c. Lower and latch the arm rest.

Figure 2-37 Battery Connection

B3 Ser II Forklift Planned Maintenance Manual 2-60

Planned Maintenance

Inspecting the Bearings, Race and Inner Seal If inspection of the bearing cones, cups (race), and inner seal is deemed necessary, proceed as follows: 1. Bend back the tangs of the cotter pin and remove the pin from the wheel spindle (See Figure 2-38).

SEAL INNER BEARING OUTER BEARING CONE LOCK WASHER LOCKNUT HUB CAP WHEEL O-RING

bearing assy

Figure 2-38 Wheel Bearing Assembly

2. Remove the spindle nut and bearing washer, then carefully pull out on the wheel to loosen the bearing.

3. As the wheel is removed, remove the outer wheel bearing cone, which pops free as the wheel is pulled away.

Be careful not to damage the inner seal as the wheel is removed (See Figure 2-38).

4. If the inner seal is damaged, use a screwdriver to pry the seal from the wheel. Note how the seal is installed.

5. Remove the inner bearing cone.

Note: If the bearings must be replaced, use a standard puller to remove the inner and outer bearing cup (race) from the wheel rim.

6. Wash the bearing in a solvent. Examine it for damage. Allow the parts to air dry.

B3 Ser II Forklift Planned Maintenance Manual 2-61

Planned Maintenance 7. Spin the bearings and check for unusual sounds indicating rough surfaces or non-rotating rollers. Replace bearings if they are noisy or appear rough.

Also see “Steer Wheel Assembly,” in Bendi 3 Wheel Troubleshooting and Corrective Maintenance Manual (F-445-__).

8. Pack the bearings with high-temperature bearing grease making sure the grease penetrates the rollers, cone and cage from the back side. See Appendix B of the B3 Series Operator's Manual for recommended lubricants.

9. Clean the spindle and examine it for wear or scoring damage.

10. Install new bearing cup (race) by pressing into wheel rim. Apply an even force to prevent cracking the cup (race) during installation. Be sure that each bearing cup (race) is fully seated (bottomed out) against the shoulder in the rim bore.

11. Install the inner bearing cone into wheel rim. Install new inner seal.

12. Carefully set the wheel over the spindle and install the outer bearing cone, steel washer, then the spindle nut (See Figure 2-38).

13. While turning the wheel or rim counterclockwise, apply 240 to 260 in. lbs. of torque to the spindle nut.

14. Spin the wheel to make sure it turns free, then back off the wheel nut 1/2 turn. While turning the wheel, apply 20 to 25 in. lbs. (2.26 to 2.82 Nm) of torque to the nut.

Again, check to make sure the wheel turns freely.

15. Back-off the nut slightly as necessary to align it with the nearest hole. Insert and bend back the tangs of the new cotter pin.

16. Install the hub cap.

B3 Ser II Forklift Planned Maintenance Manual 2-62

Planned Maintenance

Check Nuts, Bolts, and Screws All major mechanical and major electrical connections (nuts, bolts, screws, etc.) must be checked and tightened periodically. Under severe operating conditions, checking and tightening inspection must be performed more frequently.

(See General Torque, Hydraulic Fitting Torque, and Bendi 3 Wheel Special Torque Tables in Appendix B of the Bendi 3 Wheel Operator's Manual (F-492-__)).

Check and tighten the following: · Drive wheel lug nuts. · Drive unit gear boxes and motor mounting bolts (front wheel).

To inspect the drive gear motor mounting bolts you must remove the front tire.

Jack (lift) the truck and place it on safety stands.

Warning When working under the truck, always use safety stands together with the lifting apparatus. Do not rely only on the lifting apparatus.

The lift could leak fluid or be accidentally released, allowing the truck to drop. · Steer wheel / axle assembly mounting bolts · Mast tilt cylinder pin locking bolts. · Mast mounting pin locking bolts. · Master cylinder clevis and mounting bolts. · All hydraulic pump and motor mounting bolts. · Hydraulic cylinder clevises. · Overhead guard mounting bolts.

B3 Ser II Forklift Planned Maintenance Manual 2-63

Planned Maintenance

Inspect Electrical Connections 1. Set the key switch to OFF and place the key in your pocket.

2. Disconnect the battery.

3. Open control panel cover (See Figure 2-39).

4. Thoroughly check all electrical connections, check for loose wires within a connector, loose connectors, frayed or broken wires, etc. (See Figure 2-39).

5. Check torque on all cable connections.

6. Repair as required. Pay special attention to the cable and contactor connections.

control panel cover

CONTROLLER COVER LOCATIONS (COVERS REMOVED)

Figure 2-39 Control Panel Covers Location

B3 Ser II Forklift Planned Maintenance Manual 2-64

Planned Maintenance Curtis Controller The Curtis Sepex control units, like all electrical apparatus, exhibits some thermal losses.

The semi-conductor junctions have finite temperature limits above which these devices may be damaged (See Figure 2-40) For these reasons, normal maintenance should guard against any action that could expose the components to excessive heat, such as steam cleaning; and/or that which could reduce heat dissipating ability of the control, such as restricting air flow.

Note: For additional information on the Curtis Controller, see the Appendix in the Bendi 3 Wheel Service Manual (F-446-___).

curtiscontrollers

Figure 2-40 Control Panels

B3 Ser II Forklift Planned Maintenance Manual 2-65

Planned Maintenance General Practice · Before performing any maintenance to the Curtis controller you must disconnect the battery. · Any controls that are be used in ambient temperatures of 100° F (38° C) or above must be brought to the immediate attention of the Landoll Corporation. · Never steam clean a controller or controller assembly.

In dusty areas, use low-pressure forced air to blow off the control. In oily or greasy areas, a mild solution of detergent or denatured alcohol may be used to wash off the control. Then, using low-pressure forced air, blow the unit completely dry. The control may also be cleaned using an electrical contact-type degreaser. · The use of a heat-transfer grease, such as Dow Corning #340, is recommended when reinstalling the Curtis panel. The grease helps dissipate heat. · Thermal boards and other exposed Curtis control parts should be kept free of dirt and paint that might change the effective resistance between points. · Use a lead-acid battery with a voltage and ampere hour rating specific for the vehicle. Follow normal battery maintenance procedures recharging the battery before 80% discharge and with equalizing charges capability.

B3 Ser II Forklift Planned Maintenance Manual 2-66

Equipment from Landoll Corporation is built to exacting standards ensured by ISO 9001 registration at all Landoll manufacturing facilities.

Model B3/30 Planned Maintenance Manual Re-Order Part Number F-444-0808 LANDOLL CORPORATION 1900 North Street Marysville, Kansas 66508 (785) 562-5381 800-428-5655 ~ WWW.LANDOLL.COM

Copyright 2008. Landoll Corporation “All rights reserved, including the right to reproduce this material or portions thereof in any form.”

F-444-0808