Bendi Landoll Forklift Bendi AC/DS DuraSteer™ Operator’s Manual F-648-R2

Bendi AC/DS DuraSteer™ Operator’s Manual

LANDOLL CORPORATION 1900 North Street Marysville, Kansas 66508 (785) 562-5381 800-428-5655 ~ WWW.LANDOLL.COM F-648-R2

Table of Contents

1

Forklift Safety and Familiarity Getting Started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Operator Training & Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Site Supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Terminology and Illustrations Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Understanding Safety Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Bendi AC/DS Forklift Safety Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Operator Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Seat Safety Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Emergency STOP Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Tipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Longitudinal Tipping Can Occur When: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Lateral Tipping Can Occur When: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Lateral or Longitudinal Tipping Can Occur When Driving: . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Traveling and Load Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Visibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Battery Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Service Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Side Shifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 Available Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 Fork Positioner, Non-Side Shifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 In case of a fire! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 Additional Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 Vehicle Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 Identification Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

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Forklift Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 Traction Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 Safety Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 Traction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 Mast Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 Side Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 Operator’s Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 Driver Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 Battery Cover Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16 Mast Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19 Available Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20 EE Series (Electrical Enclosure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20 Cold Storage (Freezer Package) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20 Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21 Fork Positioner, Non-Side Shifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21 Lights and Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22 Shipping, Receiving and Inspecting Forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Items Furnished with the Forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Items Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Tools and Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 To Prepare the Forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Using the Hydrometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Charging a Wet Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Preparing a Dry Cell Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Inspection Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Visual Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 To check the brake interlock: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 To check the brake interlock: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Replacing the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Rollout Battery Tray Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Storage, Towing or Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Forklift Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Battery Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Towing the Forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 To Ship the Forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Using Lifting Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

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Understanding the Bendi AC/DS Forklift F-648-R2

Overview and Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Operator Training and Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Understanding Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Basic Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Load Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Tilting Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Knowing the Rated Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Data Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Maximum Fork Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Determining the Weight of the Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Bendi Serial Number Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Understanding Workplace Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Dock boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Forklifts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Warning Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Working in Hazardous Environments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Atmospheric/Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Chemical Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

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Operating the Bendi AC/DS Forklift Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Operator’s Daily Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Accelerator Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Steering Wheel and Tilt Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Seat Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Dash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Parking (Hand) Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Direction Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Lift Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Tilt Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Side Shift Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Attachment Lever(s) - Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Operating Instructions - Basic Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Getting On and Off the Forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Driving Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Starting and Traveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Turning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Mast Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

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Operating Instructions – Handling a Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Setting the Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Retrieving a Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Transporting a Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Unloading The Forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 In Case of Forklift Overturning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Using Lifting Equipment to Move a Forklift to Another Location . . . . . . . . . . . . . . . . . . . . . . 4-15

5

Checklists and Specifications Inspections Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Daily Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Operator’s Daily Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Checking Chassis Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Safety Warnings and Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Data Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 ESD Straps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Service Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Mast Racking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Hydraulic Cylinders, Fittings, and Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Check Structural Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Rust or Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Overhead Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Operator Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Dash Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Accelerator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Lift/Lower Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Tilt Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Side-Shift Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Direction Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Speed Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Return to Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Lights and Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Specifications Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

iv

F-648-R2

Chapter 1

Forklift Safety and Familiarity Getting Started This chapter of the Bendi AC/DS Operator’s Manual discusses important safety information regarding the operation and maintenance of the Bendi AC/DS forklift.

The Bendi AC/DS forklifts have been designed for optimum safety of their operators. Please follow the safety guidelines listed in this section and adhere to all Important, Caution, Warning, and Danger notes found within this manual.

To develop the skills required:

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

Landoll forklifts meet or exceed ASME B56.1 - Part III, Safety for Powered Industrial Trucks and certain models are FMRC approved by meeting or exceeding requirements of FMRC Class 7820, ANSI/UL-583 standard for Battery Powered Industrial Trucks, Type E. The electrical system complies with UL-583 requirements for type E Electrical Battery-Powered, Industrial Truck construction.

1. Receive training, pursuant to OSHA 1910.178(1), in the proper operation of this forklift.

2. Understand the capabilities and limitations of the forklift.

3. Become familiar with the construction of the forklift and see that it is maintained in good condition.

NOTICE NO modifications or additions may be made to this forklift without prior written permission from Landoll Corporation.

4. Read and understand the warnings and operating procedures in this manual.

Landoll Corporation

IMPORTANT

1900 North Street

The Bendi AC/DS Model forklifts have been designed for optimum safety of their operators. Please follow the safety guidelines listed in this section and adhere to all Important, Caution, Warning, and Danger notes found within this manual.

Marysville, KS 66508 U.S.A.



WARNING

When the forklift is in operation, always keep loose clothing, jewelry, hair and fingers out of the restricted areas (especially pinch areas) as labeled on the forklift.

This chapter on Safety must be read, understood and adhered to strictly by all operators and service personnel using the Bendi AC/DS forklift.

Do not use this forklift until this manual has been thoroughly read. Failure to comply may cause risk of death or serious injury to personnel.

Material Handling Product Group

Telephone:

(785) 562-5381

Fax:

(785) 562-4853

Operator Training & Safety



DANGER

Every forklift operator must be trained in accordance to the rules provided by appropriate legislation. Employers must ensure that each powered industrial forklift operator is competent to operate a powered industrial forklift safely, as demonstrated by the successful completion of a relevant training course. Operating a powered industrial forklift without the proper training can cause serious injury or death.

1-1

FORKLIFT SAFETY AND FAMILIARITY



WARNING

Do not make modifications or additions to electrical devices. Do not tamper with, remove, disconnect safety features, or modify protective guards (such as overhead guards or load backrest extensions).

Any of the above could affect forklift capacity and/or safe forklift operation and is a serious safety violation that could cause personal injury and/or weakened overall forklift construction.

No Modifications or Additions may be made to this forklift without prior written permission from Landoll Corporation.

Site Supervision

This manual references many illustrations to follow the procedures and help to locate components on the Bendi AC/DS forklift.

Understanding Safety Statements Various types of safety information on the following pages and on the product decals attached to the vehicle can be found on the following pages. This section explains their meaning.

The Safety Alert Symbols mean personnel and property SAFETY IS INVOLVED!

NOTICE Special notices that include helpful hints. Read and understand thoroughly.

Supervision is an essential element in the safe operation of powered industrial forklifts.

The site supervisor must check that the Operator’s Manual is in the seat compartment on the forklift at all times. Operators must be trained on the use, maintenance, and safety aspects of the Bendi AC/DS forklifts under the supervision of a trained and experienced operator.

Only those individuals trained to operate and/or service this forklift may do so. Familiarization and driving practice with a new forklift must be arranged in a safe area, away from other forklifts, obstacles and people. The training program must be applied to all new operators, regardless of previous experience.

Operator performance must be evaluated to ensure he/she has the proper skills and knowledge to operate the forklift. Operators must be retrained when new equipment is introduced, existing equipment is modified, operating conditions change, or an operator’s performance is determined unsatisfactory.

The forklift must be inspected daily for problems or damage risking the safety of the driver and any people in the work area, or possible damage to the forklift and the load being moved. When forklifts are used on a round-the-clock basis, they must be inspected after each shift. Problems found must be reported and corrected.

The forklift must be taken out of operation until all repairs have been made and the forklift has been reinspected for safety.

Terminology and Illustrations Used Whenever front, rear, right and left are mentioned throughout this manual, it is assumed that the view point is from the operator’s position seated in the forklift looking toward the forks.

1-2



DANGER

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



WARNING

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



CAUTION

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

Bendi AC/DS Forklift Safety Statements The safety statements contained in this manual relate to the operation and maintenance of the Bendi AC/DS forklifts.

NOTICE Make sure the operator has read and understands the information contained in this manual and on the machine signs (decals) before attempting to operate or maintain this vehicle.

F-648-R2

FORKLIFT SAFETY AND FAMILIARITY The location of each machine sign on the Bendi AC/DS forklift is illustrated below.

24

Make sure each machine sign is checked before operating this Bendi AC/DS forklift and replace any that are no longer legible, missing or damaged.

15 3

21

30 6

10

23

4

INSIDE WHEEL WELL 9

13

14

18

16

5

2

19

25

1 17

7

20

11 12 26

22 8

28

29

27

Figure 1-1: Decal Placement 1-3

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

1-4

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

F-648-R2

FORKLIFT SAFETY AND FAMILIARITY

Operator Safety



WARNING

• Set all directional controls to NEUTRAL position before turning the key switch to ON. • To avoid personal injury when operating the forklift, be extremely cautious that NO body part (feet, arms, legs, fingers) or clothing are outside the operator’s compartment. They may be caught by aisle supports, other forklifts or any obstacle in the area.

• Know the location of all pinch points, as indicated by the WARNING and DANGER labels on the forklift.

• Be cautious when there are other people or fixed objects in the working area.

• Drive carefully and slowly onto dock boards and bridge plates. Do not exceed the rated capacity of the dock boards or bridge plates and ensure dock boards or bridge plates are properly secured, with anchors or with devices that will prevent slipping.

• Dock boards must have substantial contact with both the dock and the carrier, preventing them from rocking or sliding.

• Maintain a safe distance from the edge of ramps, platforms and other similar working surfaces.

When leaving the operator’s compartment the forks must be lowered to the floor, the mast must be placed in a vertical position, all controls must be in a NEUTRAL position, and the key switch must be set to the OFF position. Forklift wheels must be blocked if the forklift is parked on an incline.

• Be cautious when the load reduces visibility.

See page 1-8.

• Ensure that people stand clear of the rear swing area before making turns.

• The operator is responsible for observing all safety instructions and regulations in his/her daily work routine, related to the use of this forklift.

• Be careful at cross aisles, doorways and other intersecting locations where people may step into the path of the forklifts travel.

• Check the condition of the forklift at the start of each work shift. Check the operation of the steering and brakes, the direction control lever, tilt and lift/lower control, parking brake, horn, signaling devices and the overall condition of the battery.

• Make sure all access/service panels, doors and covers are installed, closed and latched tight. Do not operate the forklift with panels, doors and covers removed, opened or unlatched.

• Keep the forklift clean and in good working order.

Report any problems or damage risking the safety of the driver or any people in the work area. Problems found must be reported and corrected. The forklift must be taken out of operation until all repairs have been made and the forklift has been reinspected for safety.

• Always start, stop, change direction, travel and brake smoothly so as not to shift the load and/or overturn the forklift.

• Do not indulge in stunt driving or horseplay.

NOTICE The forklift is considered unattended when the operator is 25 feet (7.6 m) or more away from the forklift even when the forklift is still in his/her view or whenever the operator leaves the forklift and it is not in view.

Parking Brake The parking break includes a safety interlock that shuts down the drive and pump motors, disables the direction control lever and applies the brakes to prevent further forklift movement. To continue, the direction control lever must be set to neutral, the parking brake must be released, and then the direction control lever can be set to the desired location.

Seat Belt The drivers seat belt must always be worn when driving the forklift.

Sit up straight in the driver’s seat.

The belts should be pulled across the operator. Do not let the belt twist.



CAUTION

Make sure the release button on the buckle is positioned so it can be unbuckled quickly in case of an emergency.

1-5

FORKLIFT SAFETY AND FAMILIARITY



Seat Safety Switch

WARNING

A twisted belt has the potential to cause serious injury. In a crash or a tip-over, the full width of the belt would not be available to take up the impact forces.

If the operator leaves the driver’s seat, a limit switch is released. The drive and pump motors are disabled to prevent further forklift movement.

To continue, the operator must first sit in the seat, set the direction control lever in NEUTRAL, then select the direction of travel.

Push the latch plate into the buckle until it clicks. Pull up on the latch plate to make sure it is secure.

The lap part of the belt must be worn low and snug on the hips, just touching the thighs.

NOTICE A two to three second delay is programmed into the seat switch to avoid nuisance shutdown and interruption of normal operations.

Figure 1-2: Emergency Interrupts

Emergency STOP Button

Tipping Hazards

Press this button to shut down the drive and all mast movement. The forklift drifts to a STOP. Immediately set the parking brake.

If a tip-over occurs, the operator should follow these guidelines:

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

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

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

• in case an accident occurs.

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

1-6

• Do not jump.

• Brace feet firmly.

• Hold on tight.

• Lean away from the tip.

The most likely causes of tip-over are listed in this section. However, the operator must use good judgment based on proper training and experience to determine turning sharpness and speed for the load being handled and the operating surface or road conditions.

A forklift can tip longitudinally (tipping over the front or rear wheels) or laterally (tipping either to the left or right side).

F-648-R2

FORKLIFT SAFETY AND FAMILIARITY



DANGER

Forklift tip-over can cause serious injury or death to the operator or others in the area. Every operator must be thoroughly familiar with the tipping hazards listed in this section and must always avoid any operation of the forklift which is likely to result in tipping.

All forklifts that elevate and tilt loads are subject to the risk of tipping over, especially when accelerating or when applying the brakes abruptly. Transporting loads off-center also increases the risk of tip-over.

Longitudinal Tipping Can Occur When: • the forklift is overloaded.

• the mast is tilted forward excessively, with or without a load.

• the load is raised and brakes are applied while the forklift is traveling forward or backward.

• the load is raised and the forklift is accelerated while it is traveling forward or backward.

• the forklift is driven forward down a steep incline with a load.

Lateral Tipping Can Occur When: • the forklift is turned sharply while traveling rapidly in either direction, with or without a load. An unloaded forklift can tip easier than a loaded forklift (with the load lowered).

• the load is raised and the forklift is being turned while traveling in either direction.

• the load is raised and the forklift is being turned and accelerated or braked while traveling forward or backward.

• the forklift is turned while traveling on a ramp or other inclined surface.

• a load heavier than the rated capacity is lifted.

Tipping over in these conditions is made more likely by overloading, excessive mast tilt or off-center positioning of the load.

Soft tires can also reduce stability. The forklift is equipped with tires of a size and hardness that will provide the necessary traction and maintain a proper shape to minimize tipping. Always replace tires with the type originally supplied by the manufacturer.

Lateral or Longitudinal Tipping Can Occur When Driving: • over objects on the floor or ground.

• off the edge of a paved surface.

• into a pothole in a paved surface.

• off the edge of a loading dock, or off the edge of a loading ramp. (It is important to avoid driving too close to the edge of a dock or ramp).

When loading or unloading a highway truck or trailer, make sure the highway truck can not move away from a dock while loading is in process. Make sure the highway truck or trailer has its brakes applied, key switch turned off, and if on a an incline, has the wheels blocked.

Tipping can also occur if the forklift collides with another forklift or other vehicle, or if the mast runs into an overhead obstruction.

Traveling and Load Handling • Observe all traffic regulations. Keep to the right and maintain a safe distance from the forklift ahead based on speed of travel. Keep the forklift under control at all times.

• Yield the right of way to other people in the area.

• Slow down and sound the horn at cross aisles and other locations where visibility is obstructed.

• Keep a clear view of the path of travel and be alert for other traffic, people and safe clearances.

• Under all travel conditions, operate the forklift at a speed that permits the forklift to a complete stop in a safe manner.

• Do not handle unstable loads. Use care when tilting forward or backward, stacking, depositing, or retrieving a load. Never travel with the mast tilted forward.

• Never exceed the forklift’s maximum lifting capacity.

Refer to “Standard Bendi Forklift Specifications”, beginning on page 5-2 and identification plate located in the operator’s compartment. See Figure 1-7.

• The data plate lists the load weights allowable for various fork heights, battery information, and also lists the forklift model number, serial number and other basic forklift data.

• Pay particular attention when picking up a new load, to ensure the load weight and height requirements are within the forklift’s capacity.

• Forklift stability and handling may be adversely affected.

• Do not transport loads or other items within the operator’s compartment or other areas of the forklift.

• Properly position the load on the forks before lifting.

1-7

FORKLIFT SAFETY AND FAMILIARITY • Spread forks as far apart as the load permits and push completely under the load. Check that forks and loads are centered. Use care when handling off-center loads.

• Travel with forks straight ahead and the mast tilted backward.

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

• Travel with forks or load in recommended traveling position.

Both covers include latches to lock the compartment. A cutout in the overhead guard is also provided for easy battery service. See Figure 1-3.

• Elevate mast or load only to pick up or deposit a load.

Watch out for obstructions, especially overhead.

Watch all clearances.

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

• Tilt a loaded mast slowly.

• Do not release the lift/tilt joystick control lever suddenly when lowering loads. This may cause bouncing of the carriage, which could dump the load.

• Do not allow anyone, under any circumstances, to walk or stand under the forks or any part of the load.

• No part of the body should ever be placed between the mast structures or any moving part of the forklift.

• Do not turn when traveling on ramps. When descending ramps, travel forward (forks facing downhill) when empty, travel backward (forks facing uphill) when carrying a load.

• Use care even when traveling without a load. Avoid high speeds, sharp turns and abrupt stops.

Speed Travel speed must be chosen according to the situation, such as, the load being handled, road surface conditions, visibility, people working in the area, moving and fixed objects in the area, cross aisles and so on.

Always operate the forklift at a speed that will permit it to be brought to a stop in a safe manner.



WARNING

Careless driving, such as fast starts or abrupt braking, excessive speed at turns or through cross aisles, sudden stops, or hard turns at high speeds can all lead to serious personal injury and damage to the forklift and load. Always drive with safety as the number one goal.

Visibility

Care The forklift battery contains concentrated sulfuric acid, which can cause severe chemical burns. When the battery is charging, it releases hydrogen. Hydrogen is a colorless, odorless and highly explosive gas which can be ignited by a spark. Eliminate all sparks/flames from the charging area.

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

The battery is very heavy, and if restrains are not replaced after maintenance, the battery could slide out of the forklift (causing electrical shorts, spilling acid or causing the forklift to tip over).

The battery is also used as a counterweight. A different size or weight battery could cause the forklift to become unstable and tip. Use a battery that meets the weight and size specifications shown on the identification plate in the operator’s compartment.

OVERHEAD GUARD CUTOUT

BATTERY COMPARTMENT TOP COVER AND SEAT BATTERY COMPARTMENT TOP COVER LOCKING LATCH BATTERY ADJUSTMENT BRACKET (BOTH SIDES)

BATTERY COMPARTMENT SIDE DOOR

Where visibility is restricted, travel at very slow speed and use the horn frequently.

Always ask for a helper to guide the operator safely through the area when visibility is restricted.

Always rotate in the driver’s seat to face in the direction of travel.

1-8

Figure 1-3: Battery Compartment and OHG Cutout

F-648-R2

FORKLIFT SAFETY AND FAMILIARITY



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.

Consult the label on the battery for information on cell-type, ampere-hour capacity, charge rate and normal full-charge voltage. Do not charge the battery at a current greater than 1.5 amp per 100 amp-hours capacity at the end of charge.

Packaged with every battery are specific instructions for battery safety, care and use, and a Materia Safety Data Sheet (MSDS). Read these documents thoroughly before performing any service to the battery.

Never place a tool or any metal object on top of the battery where it could possibly touch battery terminals causing a short or serious electrical shock.



WARNING

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

Always disconnect the battery before performing any forklift maintenance and be sure to wear protective clothing and safety glasses working with battery acid or the battery in general.

Use caution when changing battery connections to ensure that the polarity is not reversed.

Keep vent plugs in place and clean at all times.

When replacing this battery, use the same type battery as specified on the forklift rating. Failure to comply could result in an unbalanced condition, resulting in tipping the forklift and possible personal injury or loss of life.

Be sure to replace, close and/or retighten any battery restraints which have been installed on the forklift.

Service Repair When it becomes necessary to do any service repair or maintenance to the forklift, it is important to first review the following safety guidelines.



WARNING

Personnel and property could be injured and the forklift could be damaged if there’s an attempt to do service work without proper training or equipment.

1. Sufficient knowledge, experience and the proper tools and replacement parts are necessary before attempting any forklift maintenance.

2. 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.



WARNING

If the wrong nuts, bolts or other fasteners are used, parts can later break or loosen. Serious injury could occur.

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

4. Set the key switch to OFF, set the direction control lever to NEUTRAL and set (engage) the parking brake.

5. Disconnect the battery.

6. Never place a tool or any metal object on top of the battery where it could possibly touch battery terminals causing a short or serious electrical shock.

7. Make sure all lifting devices and supports, such as, a jack or support stand, are capable of handling the weight of the load being applied.



WARNING

To be certain the forklift will not move, place wedges (or blocks of wood) at the front and back of the tires.

When servicing the brakes or tires, place the blocks at the front and rear of the tire farthest away from the one being serviced (the tire on the opposite side of the forklift and at the opposite end).

8. Always place an appropriate support stand under the forklift, if it is being lifted.Then, lower the forklift to the stand, having both the lifting device and stand supporting the weight of the forklift.

1-9

FORKLIFT SAFETY AND FAMILIARITY



DANGER

Getting under a forklift when it is lifted or jacked is dangerous and could cause serious injury or death. Never go under a forklift that is supported only by a jack.

9. Fully open the required forklift covers and be sure they are braced to prevent accidental closing.

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

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

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

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

Figure 1-4: Fork Check Points

Available Options Fork Positioner, Non-Side Shifting Forklifts using automatic non-side shifting fork positioners require additional SAFETY attention.

D



WARNING

Fire Extinguisher If the forklift includes a fire extinguisher, it should be inspected monthly or more frequently, if circumstances dictate. The extinguisher should be checked to see that: • it is not damaged.

• the discharge outlet is not blocked.

Pay strict attention to all safety labels affixed to the fork positioner and backrest.

• it is fully charged.

No riding or standing under any part of the load or on the forks.

• the instruction pamphlet is clearly visible.

NEVER reach through the backrest or between the fork positioner mechanism.

The top of the load must not extend above the top of the backrest.

The load must never exceed the capacity of the fork positioner as stated on the data plate affixed within the operator’s compartment.

Daily, check the upper hook engagement, the fasteners, the lower hook engagement and inspect for hydraulic oil leaks. See Figure 1-4.

• the seal is not broken.

Also see page 1-20 for additional operating information.

NOTICE Dry-powder extinguishers are shipped fully charged. Do not experiment with the extinguisher since even a small amount of discharge could cause it to slowly lose the rest of its pressure, rendering the extinguisher useless.

Report any problems to the supervisor and remove the forklift from service until the problem is corrected.

1-10

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FORKLIFT SAFETY AND FAMILIARITY

In case of a fire!

• Have everyone evacuate the area immediately.

• Call the fire department, no matter what the size of the fire. Emergency telephone numbers should be posted at each telephone.

• Always use the extinguisher correctly, according to the directions on the label and in this manual.

Professionals should handle large fires.

• Be ready to leave the area in the event the fire cannot be controlled immediately.

Additional Publications Additional information that describes the safe operation and use of forklifts is available from the following sources: • Employment safety and health standards or regulations e.g., Occupational Safety and Health Administration (USA), Canada Material Handling Regulations • Safety codes and standards e.g., American National Standard, ANSI B56.1 Safety Standard for Lift Trucks

• High efficiency - field oriented motor controller the enables smooth low speed control including zero speed position hold. Controller includes thermal protection based on motor and controller temperature.

• Control lever operation for load functions- utilizing a three-function hydraulic control valve. A fourth (4th) function hydraulic valve is available for an approved Class II attachment.

• 48 volt DC battery with emergency disconnect button or connector, latching battery cover with drive interlock, plus side access compartment with slide strips or optional rollers.

• Duplex, triplex or quadplex high visibility mast configurations.

• Lift capacity from a maximum of 3,000 lbs./1,361 kgs. up to 4,000 lbs./1,814 Kg. at 24”/600 mm load center.

• Ergonomically designed operator compartmentincludes sit-down operator position, adjustable driver’s seat, tilt/telescoping steering wheel, hand lever direction control, arm rest and operator supply tray.

• Publications from government safety agencies, government insurers private insurers and private organizations e.g., Accident Prevention Manual for Industrial Operations, from the National Safety Council

• Safety interlocks- key switch activation and operator seat safety switch, plus an electrical lockout requiring the control lever to be in the neutral, or center position before power can be restored.

• Operator Safety Training Course- describes forklift safety, good maintenance practices, and training programs. Training is available from a Landoll dealer for Bendi Forklifts. The Landoll part number is 107218.

Landoll forklifts meet or exceed ASME B56.1 - Part III, Safety for Powered Industrial Trucks and are FMRC approved by meeting or exceeding requirements of FRMC Class 7820, ANSI/UL-583 standard for Battery Powered Industrial Trucks, Types E, ES, and EE.

Vehicle Description

The electrical system complies with UL-583 requirements for type E, EL (optional), and EE (optional) Electrical Battery-Powered, Industrial Truck construction.

The Bendi AC/DS is a narrow aisle type forklift. The principle is the weight of the load, which is carried on the forks in front of the load wheels and is offset by the combined weight of the heavy forklift chassis and its battery unit. To maintain a safe counterbalance limit, a ballast weight is mounted to the rear of the forklift chassis.

Machine Model, serial and option numbers (where applicable) are stamped on the identification plate affixed within the operator’s compartment. See Figure 1-7.

Bendi forklifts are available in capacities from 3,000 to 4,000 lbs. The front end can be pivoted 180 degrees.

This permits the vehicle to act as a conventional as well as a narrow aisle forklift.

The Bendi AC/DS forklift also offers: • Four-wheel configuration: dual rear wheel drive front wheel actuated steering.

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FORKLIFT SAFETY AND FAMILIARITY

NOTICE Bendi AC/DS forklift operators and service personnel must familiarize themselves with this manual and the Bendi AC/DS forklift to provide safe and efficient operation. Practice runs in a controlled and safe area, away from obstacles and other personnel, are recommended.

Unauthorized driving by untrained or unskilled personnel must be strictly prohibited.

All safety notices in this manual, those found in heading SAFETY of this manual, and the safety regulations or standards valid in the local area must be strictly enforced.

7

3

6

2

5 D

1

4

Figure 1-6: Component Locations

Identification Plate The identification plate, which lists the rated capacity, serial number and other vehicle characteristics is located to the left of the seat.

Figure 1-5: Data Plate Location

Component Identification The following illustration will help locate components on the Bendi AC/DS forklift. See Figure 1-6.

Figure 1-7: Identification Plate

1. Forks 2. Load Backrest 3. Mast 4. Load Wheels 5. Drive Wheels 6. Overhead Guard 7. Steering Column

1-12

Forklift Overview Frame The frame consists of 3/8” to 1” thick (9.525 mm to 25.4 mm) steel panels welded together to form the backbone of the forklift. A number of thick rectangular steel shaped (counterweights) are welded within the frame to counterbalance the forklift against the weight of its load.

The rear wall of the forklift also includes a thick steel plate to add additional counterbalance.

F-648-R2

FORKLIFT SAFETY AND FAMILIARITY NOTE The size and weight of the battery is also used as a counterbalance.

Traction Drive Bendi AC/DS forklifts are dual-drive, four-wheeled forklifts, having two steerable, load support wheels in the front and two independently controlled drive wheels in the rear. The rear drive wheels consists of a gear box and a separate AC electric motor, controlled by the transistorized controller. “See Electrical System,” on this page for additional information.

Brake System The rear drive wheels are equipped with hydraulically-actuated dry disc brakes. The brake activates a master cylinder to apply hydraulic pressure to wheel calipers, forcing the disc pads to grip the rotor.

The system is a dedicated system using standard DOT #3 brake fluid and non-asbestos disc pads.

Parking Brake A parking brake system is fitted to the left-side drive unit disk brake caliper and is equipped with a cable-actuated dry disc brake (puck). The system is hand-lever actuated, and is electrically interlocked to create a NEUTRAL condition when the brake lever is actuated.

As the lever is raised to apply the brake, the drive and pump motors shut down and the directional control electrically resets to NEUTRAL, preventing further movement of the forklift.

To continue, the operator must first set the direction control lever to NEUTRAL, release the parking brake, then set the control lever to the desired direction of travel.

Safety Interlock Both a key lock switch (key switch) and operator’s seat switch must be activated before the forklift can move. The seat switch is activated when the operator is seated in the driver’s seat (also see “Seat Safety” on page 1-6 for additional information.

Electrical System The electrical system includes the battery, four transistorized controllers, solenoid contactors, safety interlocks, meters, power cables, and electrical harnesses. The electrical system complies with UL-583 requirements for type E, ES, and EE Electrical Battery-Powered, Industrial Truck construction.

Traction Dual traction controllers are used, each having a maximum rating of 350 amps. Controllers provide full time dual rear wheel drive with steer position sensing to independently control the speed of each rear drive wheel during varying degrees of turn. Inside wheel reversing occurs at full turn, which also reduces the outside turning radius. Motor draws and operating temperatures are greatly reduced, while speed control, longer motor life, lower operating temperatures, increased motor torque and longer running times are greatly improved.

The full speed range from 0 to 100% is controlled through the controller with maximum efficiency. Starting on a ramp is also accomplished without rollback with positive and smooth acceleration control.

Battery A 48 volt lead-acid battery provides drive power, as well as power for the hydraulic system, and power for lights and other auxiliary equipment.

For maintenance and/or emergencies, a red emergency stop button, B30/quick disconnect handle, B40, is provided. The red emergency stop button (B30) is located on the right-hand side of the driver’s compartment. The quick disconnect handle (B40) is located to the lefts side of the seat. See Figure 1-2.

For maintenance, the driver's seat compartments cover, a hinged side cover, overhead guard cutout and slide strips allow easy battery removal from the right side. As an option, rollers can be provided for additional battery maneuverability.

Hydraulic System The system uses a single pump to generate pressure and flow to meet the needs of both the steering system and the mast system. Only the amount of oil needed by the steering system is provided to the steering system.

The amount of oil diverted to the steering system is based on operator input, allowing the excess oil to return to tank at a lower pressure, reducing the demands on the battery.

The hydraulic pump motor is speed controlled to provide adequate steering response and is enabled through the selection of the forklift direction. Additional pump flow is provided linearly with the actuation of the lift function.

Actuation of both the tilt and side shift functions provide step increases in pump flow to meet the demands of the function while ensuring adequate flow to the steering system.

System cooling uses convection and conduction of heat from the reservoir, hydraulic tubing and cylinders to maintain a safe operating temperature below 175°F (97.22°C).

1-13

FORKLIFT SAFETY AND FAMILIARITY A steel mesh suction filter, within the hydraulic reservoir, plus an easily accessible return line filter (10 micron rating) with a contamination level of ISO 2943 or better, is used for oil filtration.

Steering The steering system shares oil with the main hydraulic system. A single pump that is controlled through the AC pump motor controller generates steering flow and pressure. Oil is diverted from the main control valve to the steering control unit based on demand from the operator. As the steering wheel is turned, the on-demand oil is sent to the steering motor at the front of the forklift causing the forklift to turn.



WARNING

Driving speed of the forklift must be governed by the work environment, such as slippery floors, cross aisles, slanted driving surfaces, load size, visibility or other people working in the area.

Never travel at speeds with or without a load that could be dangerous to personnel and property.

Also see the safety section in the beginning of this manual.

Mast Controls Mast positioning is achieved by operating the hydraulic control valve via the three hydraulic control levers.

Hydraulic pressure is provided by a vane pump driven by a single AC electric motor. The pump operates continuously, ensuring enough oil for the steer circuit operation of lift, tilt, and side shift cause an increase in pump speed of operation is somewhat slower.

A 4th function hydraulic valve is available for an approved Class II optional attachment.

Side Shift The side shift circuit provides the means for moving the mast laterally (left-to-right). Side shift movements are accomplished using a double-acting, double-ended hydraulic cylinder (equipped with end-of-stroke cushioning) to produce a smooth, non-jerky motion.

Operator’s Compartment Driver Controls Driving controls for the Bendi AC/DS forklift include a steering wheel, horn button, a forward and reverse lever, foot brake pedal, accelerator pedal for speed control, hand-actuated parking brake lever and an emergency disconnect handle or switch. See Figure 1-8.

1-14

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FORKLIFT SAFETY AND FAMILIARITY

Figure 1-8: Operator’s Compartment • Accelerator Pedal - is pressed by the driver’s right foot to control the speed of the forklift. See Figure 1-9.

Travel varies according to the weight of the load. A Bendi AC/DS has a maximum speed of 6.5 mph (miles per hour)/10/5 kph (kilometers per hour) with no load (empty), 6.0 mph/9.7 kph with a load.

• Brake Pedal - when pressed with driver’s right foot, applies the service brakes bringing the forklift to a safe STOP. See Figure 1-9.

• Key Switch - switches electrical power to the forklift ON and OFF. See Figure 1-10.

NOTE The Bendi AC/DS is designed for “plugging,” therefore, the service brake pedal should only be used in an emergency situation.

1-15

FORKLIFT SAFETY AND FAMILIARITY

Battery Cover Latch The driver’s seat and side panel are part of the pre-molded battery compartment top cover.

The cover includes a mechanical retention latch and pin to secure the battery access cover to the overhead guard when opened. See Figure 1-11. Another hold down latch is provided to secure the cover closed.

• Direction Control Lever - located on the driver’s side panel and selects the direction of travel of the forklift (forward or reverse). See Figure 1-8.

• Horn Push Button - located on the driver’s side panel. Press directly on the mushroom push button to sound the horn. See Figure 1-8.

• Driver’s Seat - is adjustable to accommodate the driver’s weight (seat cushion spring tensions), backrest tilt and distance from the pedals. The seat also includes a circuit interrupt safety switch.

See“Safety Interlock” on page 1-13.

Figure 1-9: Pedals

KEY SWITCH Figure 1-10: Steering Column

1-16

F-648-R2

FORKLIFT SAFETY AND FAMILIARITY

COVER HOLD DOWN LATCH

OHG LATCH AND PIN BATTERY COVER PIN Figure 1-11: Battery Cover Latch Emergency STOP push button/disconnect - Activate the emergency stop button (B30)/disconnect handle (B40) to shut down the drive and pump motors and all mast movement. The forklift drifts to a STOP, immediately set the parking brake. To continue, reset the disconnect.

Use this button/handle: • in case of fire, smoke or overheating.

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

• in case an accident occurs.

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

• Lift, Tilt, and Shift - Lift, tilt, and shift movements of the mast and lift carriage are accomplished using the three levers (joysticks) located on the driver’s side panel. Each lever provides independent movement and each is marked with a graphic icon to represent the function it controls. See Figure 1-8.

To continue, the operator must first set the direction control lever to NEUTRAL, release the parking brake, then set the lever to the desired direction.

• Rear View Mirror - attached to the front top of the overhead guard. The mirror is adjustable up and down, and side to side.

• Telescoping Steering Column - pressed upwards to release the column so it may be adjusted up or down for the driver’s comfort. See Figure 1-12.

• Operator Switch Panel - includes three on/off rocker switches to activate optional packages installed on the forklift. See Figure 1-13.

LEFT switch - for headlights.

CENTER switch - for factory or user supplied accessories.

RIGHT switch - for speed mode - toggles between fast and slow. Slow mode used for training and in confined spaces. Speeds can be adjusted by authorized technician.

• Parking Brake Lever - engages the parking brake when the handle is pulled upwards. The drive and pump motors shut down and the direction control resets to NEUTRAL. See Figure 1-8.

1-17

FORKLIFT SAFETY AND FAMILIARITY

NOTICE Once the battery capacity reaches 15% the lift pump motor will shut down, thus disabling the lift function.

• Hour Meter- displays number of hours that the forklift has been used. Hours accumulate when the forklift is on and operator is in the seat.

• Speed Indicator - displays the speed mode that the forklift is in.

• Status/Fault Display Window - displays fault messages from drives and status of drives if problems occur.

• Direction Indicator - displays the status of forward/reverse switch.

Figure 1-12: Steering Column • Display Panel - The Dash Display is located on the column behind the steering wheel. It is comprised of the following gauges, displays, and switches.

• Scroll and Enter Buttons - used to enter information into system through display. These are used by an authorized technician.

• Maintenance Hours - If enabled, the forklift hours that preventative maintenance is required is shown in this field. This must be enabled and set by an authorized technician.

• BDI (battery discharge indicator) - shows battery capacity. See Figure 1-13. “Battery Low Lift Lockout” will display in message window when the battery condition is too low to support mast function.

STATUS/ FAULT DISPLAY SPEED INDICATOR

DIRECTION INDICATOR

-

+ %

0

316.9

HOUR METER ENTER BUTTON BATTERY DISCHARGE INDICATOR

50

hrs

ACCESSORY SWITCH

100

316 SVC

SPEED MODE SWITCH SCROLL BUTTONS MAINTENANCE HOURS, IF ENABLED

HEADLIGHT/TAILLIGHT TOGGLE SWITCH (WHERE FITTED)

Figure 1-13: Operator Switch Panel 1-18

F-648-R2

FORKLIFT SAFETY AND FAMILIARITY

Mast Assemblies Various Mast assembly configurations (duplex, triplex, and/or quadplex) can be installed on the Bendi AC/DS forklifts to provide both collapsed and extended heights suitable for most customer requirements. The lifting capacity of the mast also varies depending on the forklift and its application. Load capacities are determined at 24” (609.6mm) centers, centered on the mast and include all attachments on the carriage.

• Rail extension - in which both the middle and inner rails move, carrying the carriage upward. See Figure 1-16.

The Bendi AC/DS Specifications lists the dimensions of standard masts available for these forklifts. Also check the identification plate in the operator’s compartment for the maximum lifting capabilities based on the particular forklift and mast combination. See Figure 1-7.

The forklifts are counterweighted to compensate for all positions of the maximum allowed load.

Masts are engineered to distribute thrust loads evenly between the rollers and rails. Masts move as a unit, providing maximum strength and endurance for the rated load and consists of up to three pairs of channels or rails (steel beams) rolling one within the other on steel rollers.

Figure 1-14: Mast in Collapsed Position

The outer rails provide guidance and support for the middle rails, which in turn guide and support the inner rails. The forklift forks are mounted on a carriage assembly that runs on rollers within the inner rails. See Figure 1-14.

A primary cylinder is supported by the inner rails and hydraulically controlled. As the primary cylinder rod extends, a sheave and chain assembly lift the fork/carriage upward at twice the distance covered by the cylinder rod.

This first stage of carriage lift is called free lift. It is the distance of lift available without increasing the overall height of the mast assembly. See Figure 1-15.

Figure 1-15: Mast in Free LIft Position

A secondary cylinder, attached to the outer rails, lifts the middle and inner rails progressively via chains, rollers and sheaves. The inner rails are raised at twice the rate of extension of the secondary cylinder piston.

This upward lift continues until the secondary cylinders are fully extended. See Figure 1-16.

The hydraulic fluid used to lift the primary cylinder is applied sequentially to the secondary cylinder. When the primary cylinder reaches full extension, the secondary cylinder begins to extend.

The differences in weights being supported by the cylinders, along with the differences in cylinder diameters, ensure that the primary cylinder will be fully extended before the secondary cylinder can begin to move. Consequently, when the mast is raised, it moves through two phases: • Free lift - in which only the carriage assembly moves, up to the maximum height allowed by the inner rails.

See Figure 1-15.

Figure 1-16: Mast Fully Extended

1-19

FORKLIFT SAFETY AND FAMILIARITY Downward movement of the mast is accomplished by releasing the hydraulic fluid from the cylinders back into the reservoir. The weight of the rails and carriage provides enough pressure to force the fluid from the cylinders. When the secondary cylinder piston is fully contracted, the primary cylinder begins to collapse, forcing its fluid back to the reservoir.

Cold Storage (Freezer Package)

The mast is supported by trunnions, which allow it to tilt fore and aft. The amount of tilt is controlled by two short hydraulic cylinders mounted between the bottom of the mast and the pivot arm. A mast indicator gauge (pointer) is located on both sides of the mast to indicate when the carriage/forks are perfectly level with the floor.

A dry-powder based fire extinguisher is mounted, using a quick-release bracket, to the outer cage surrounding the forklift operator. Dry-powder extinguishers help fight Class B and C type fires (oil, gas, grease, electrical, etc).

As an option, forklifts may be equipped with quadplex masts which utilize four sets of rails, referred to as Outer, Outer Intermediate, Middle, and Inner rails, respectively See Figure 1-16.

The primary cylinder and carriage operate the same as a triplex (three-rail) mast. When the secondary cylinders extend, they lift the middle rails. Through an intricate system of chains and sheaves, the rising middle rails pull up the outer intermediate rails at half the middle rail speed, and push up the inner rails at twice the middle rail speed.

The cold storage package includes treatment of electrical connections to inhibit corrosion. Harness connections are also sealed against moisture.

Fire Extinguisher

Fire extinguishers must be inspected monthly and the results recorded on the inspection tag attached to each extinguisher see below.

If the forklift is equipped with an extinguisher, see “Fire Extinguisher” on page 1-10. Also see “Fire Extinguisher Option” on page 1-20 for additional information.



WARNING

Dry-powder extinguishers are shipped fully charged. Do not experiment with the extinguisher, since even a small amount of discharge could cause it to slowly lose the rest of its pressure, rendering the extinguisher useless.

Figure 1-17: Quadplex Mast in Collapsed Position

Available Options EE Series (Electrical Enclosure) EE series or Electrical Enclosure forklifts are used in hazardous environments requiring protection from sparks, commonly produced by various electrical motors, contactors, switching devices, relays, etc. EE forklifts spark enclose all electrical components using specially designed covers and/or insulated metallic-seal enclosures to insulate sparks from the operating environment.

Figure 1-18: Fire Extinguisher

1-20

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FORKLIFT SAFETY AND FAMILIARITY

Load Backrest

Fork Positioner

Figure 1-19: Fork Positioner Overview/Setting

Fork Positioner, Non-Side Shifting Fork positioner options are hydraulically driven units that allow the forks to move equal distance from each other to accommodate the size for the load being moved.

The forks start at the center of the carriage and move equal distance to the outside and back again.

A push button is added to the pivot and shift joystick control.

Figure 1-20: Joystick Push Button 1-21

FORKLIFT SAFETY AND FAMILIARITY .

Lights and Alarms Various light and alarm option packages are available as follows: • Audible backup alarm - Sounds (beeps or talking) when the forklift is placed in reverse to alert all personnel in the area.

BACK UP ALARM

STROBE LIGHT

HEADLIGHT

TAIL LIGHT

• Rear LED strobe light - Includes 180° blackout for operator protection and is available with red, amber or blue lens.

• Headlights - Two LED lights with guards can be mounted on the mast or the overhead guard on the front, rear, or both.

• Stop/tail lights - Two LED light sets can be mounted to the back of the forklift or the overhead guard.

• Strobe light - Flashing backup strobe.

Figure 1-21: Examples of Lights and Alarms

1-22

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Chapter 2

Shipping, Receiving and Inspecting Forklift Before shipping from the Landoll Corporation, each Bendi AC/DS forklift is inspected to make sure the forklift received is in impeccable condition and equipped per order. However, we recommend that: • The forklift be inspected for any signs of physical damage during shipment. Note any apparent damage on the bill of lading and request the delivery agent to sign it. Report the damage to the distributor and the shipping company.

• Verify that the forklift configuration and options match the purchase order. Report any discrepancies to the Landoll distributor.

Items Furnished with the Forklift Standard Bendi AC/DS forklifts are shipped from the factory with one copy each of the Operator’s Manual and Inspection Check Sheets, a battery disconnect handle, and a set of ignition keys attached to the steering column.

Items Required When the forklift is received, a battery must be installed and must be replenished from a battery charger at certain intervals. No additional items are required to operate the forklift.

Tools and Test Equipment In general, no special tools or test equipment beyond those found in a well-equipped service center are required for general maintenance. However, custom bearing and seal installation tools and a calibrated torque wrench are helpful when performing more involved service.

To Prepare the Forklift 1. Check the hydraulic oil level - Completely lower the mast. Unscrew and remove the access door to the right of the operator seat. Pull out the dipstick to ensure the oil level reads between the marks.

2. Check the fluid level in the brake master cylinder reservoir - The Master Cylinder reservoir is located under the floor plates just above the brake pedal assembly. Remove the bolt on the lid and check the levels as indicated. The reservoir is full when the oil level is at the fill line.

3. Check the condition of the battery - The forklift battery contains concentrated sulfuric acid, which can cause severe chemical burns. When the battery is charging, it releases hydrogen. Hydrogen is a highly explosive gas, which can be ignited by a spark.

Shorting battery terminals can release enormous amounts of energy, causing sparks, flames, or heating nearby components to dangerous temperatures. The battery is also very heavy. If restraints are not replaced after maintenance, the battery could slide out of the forklift causing electrical shorts, acid to spill, or cause the forklift to tip.



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. Consult the label on the battery for information on cell-type, ampere-hour capacity, charge rate and normal full-charge voltage. Do not charge the battery at a current greater that 1.5 amp per 100 amp-hours capacity at the end of the charge. Packaged with every battery are specific instructions for battery safety, care, and use, and a Material Safety Data Sheet (MSDS).

Read these documents thoroughly before performing any service to the battery. Always disconnect the battery before performing any forklift maintenance and be sure to wear protective clothing and safety glasses when working with battery acid or the battery in general.

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.

2-1



DANGER

Keep vent plugs in place and clean at all times.

Never place a tool or any metal object on top of the battery where it could possibly touch battery terminals causing a short or serious electrical shock. Use caution when changing battery connectors to ensure that the polarity is not reversed. When replacing this battery, the forklift must be equipped with a battery as specified on the rating. Failure to comply could result in an unbalanced condition, resulting in tipping the forklift and possible personal injury or loss of life.

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

If the forklift had been shipped with batteries installed, first remove the batteries from the forklift. If the batteries have been shipped with electrolyte installed, check the specific gravity of the electrolyte using a hydrometer to determine if a charge is needed.



WARNING

Always disconnect the battery before performing any forklift maintenance and be sure to wear protective clothing and safety glasses when working with battery acid or the battery in general.

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 in the cell electrolyte. Slowly release the bulb to allow fluid to draw into the hydrometer. Enough fluid must enter the hydrometer to allow the float to move freely.

3. The specific gravity of the electrolyte is read off the scale of the float where it emerges from the fluid. See Figure 2-1. It is good practice to select a different cell each time a measurement is taken and to test more than one cell.

4. If the reading is between 1.280 and 1.290, the battery is fully charged. If the reading is down near 1.150, the battery must be charged as described in “Charging a Wet Battery”.

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

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

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

2. If water must be added, use only distilled water.

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

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

Figure 2-1: Using a Hydrometer

Using the Hydrometer As the battery discharges, the specific gravity of the electrolyte reduces. A hydrometer checks the specific gravity of the cells, thus the charge state of the battery.

2-2

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

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

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

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

F-648-R2



CAUTION

Do not charge the battery at a finish current which exceeds the rating on the battery’s nameplate. Consult the label on the battery for information on cell-type, ampere-hour capacity, charge rate and normal full charge voltage. Do not charge the battery at a current greater than1.5 amp per 100 amp-hours capacity at the end of charge.

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

6. Refer to “Specific Gravity Correction” on page 5-5 for Specific Gravity correction factors dependent upon electrolyte temperature.

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

9. Connect battery cables and install battery in forklift.

Preparing a Dry Cell Battery



CAUTION

The forklift battery contains concentrated sulfuric acid which can cause severe chemical burns.

When the battery is charging, it releases hydrogen, a highly explosive gas which can be ignited by a spark. Shorting battery terminals can release enormous amounts of enormous amounts of energy, causing sparks or flame, or heating nearby components to dangerous temperatures. The battery is also very heavy. If restraints are not replaced after maintenance, the battery could slide out of the forklift, causing electrical shorts, acid to spill, or cause the forklift to tip.



DANGER

Keep vent plugs in place and clean at all times.

When replacing the battery, the forklift must be equipped with a battery as specified on the rating nameplate. Failure to comply could result in an unbalanced condition, resulting in tipping the forklift and possible personal injury or loss of life.

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



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. Consult the label on the battery for information on cell-type, ampere-hour capacity, charge rate and normal full-charge voltage. Do not charge the battery at a current greater that 1.5 amp per 100 amp-hours capacity at the end of charge. Packaged with every battery are specific instructions for battery safety, care and use, and a Material Safety Data Sheet (MSDS). Read these documents thoroughly before performing any service to the battery.

Always disconnect the battery before performing any forklift maintenance and be sure to wear protective clothing and safety glasses when working with battery acid or the battery in general. 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. Never place a tool or any metal object on top of the battery where it could possibly touch battery terminals causing a short or serious electrical shock. Use caution when changing battery connectors to ensure that the polarity is not reversed.



WARNING

If dizziness occurs while using cleaning solvents, get fresh air and medical help immediately. If solvent comes in contact with eyes, immediately treat in accordance with the manufacture’s recommendations supplied with the solvent container for all safety information before use.

2-3

1. Remove and discard plastic film seals from each cell vent hole (if present).

Inspection Check List

2. Fill the cells to the level indicator using dilute battery grade sulfuric acid with a specific gravity between 1.260 and 1.270 corrected to +77° F (+25° C). The temperature of the electrolyte should be no higher than 90° F (50° C).

1. Before releasing the forklift for use, prepare a log book or log sheet for each forklift at the site. List all service, repairs and adjustments performed, as well as equipment or operation problems and when they are noted and repaired (hour meter reading and date the service was performed).

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

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

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

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

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

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

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

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

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

9. When charging is complete, REPLACE the vented cell caps on battery.

10. Connect battery cables and install battery in forklift.

2-4

Permanent logs serve as a checklist to show maintenance and repair history and to record whether faults have been corrected. Perform inspections with the forklift key switch set to OFF, the control lever in the NEUTRAL position and all brakes set.

2. Always pay strict attention to all CAUTION, WARNING, and DANGER decals affixed to the forklift and thoroughly read the SAFETY chapter of this manual.

3. If a problem is noted or suspected, immediately report it to the supervisor, record it in the forklift log book, and have it checked and/or repaired before releasing the forklift for use.

Visual Checks Many problems can be spotted by a simple visual inspection of the forklift, such as oil leaks, damaged tire, cracks in welds or forks, damaged covers, etc. However, dirt, grease, oil and debris can mask some problems. If possible, the forklift should be washed on a regular basis.

To remove stubborn grease accumulations, a greasedissolving solvent may be needed. Make sure the solvent is not harmful to painted surfaces. After washing, lubricate all unprotected grease fittings and metal-to-metal surfaces, located outside the forklift. Refer to the Bendi AC/DS Maintenance Manual (F-649) for lubrication instruction.



DANGER

Grease solvents are often toxic and may be flammable. Use only in accordance with the solvent manufacturer’s recommendations supplied with the solvent. E.g., use only in a well-ventilated area and 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.

F-648-R2

• Brakes, Service - With the key switch set to ON, drive forward slowly, while steadily applying the brake pedal.

The forklift should stop smoothly without noticeable side pull or vibration. Any problems with the brake system must be repaired immediately. DO NOT USE THE FORKLIFT. • Driver’s Seat - Check the seat covering the rips or cuts. Check seat belt straps for worn, frayed areas, or cuts. Check that the seat belt is firmly attached and that the buckle is not damaged. Check that the seat belt works properly.

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

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

• Set the direction control lever to FORWARD and slowly increase motor speed until the forklift begins to move.

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

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

• Fasteners - Check for damaged, loose or missing screws and nuts. Tighten and/or have service replace as needed.

• Horn, Lights, Etc.- Check lights for proper on/off operation and for blown bulbs. Check that the horn sounds when pressed. Repair and/or replace as needed.

• Hydraulic Lines, Loose Fittings - Check underneath the forklift for evidence of fluid leaks. Look for hydraulic hose wear, damage and leaks. Make sure clamps and fittings are tight. If leaks are found, have service repair all leaks immediately and check the hydraulic fluid level. DO NOT USE THE FORKLIFT. • Hydraulic Oil Level - Check the oil level weekly. Low oil can cause operational problems (See “Check Hydraulic Oil Level,” in the Bendi AC/DS Maintenance Manual (F-649).

• Engage Dash Display - Inspect the engage dash display for proper operation. This requires the key switch to be ON and can be checked prior to beginning the daily work routine.

• Mast Operation- With the key switch turned ON, raise the mast. Check that the primary cylinder extends fully and that the lift carriage raises to the top of the inner rails before the secondary cylinders begin to move.



WARNING

Never place head, hands, arms or feet in the mast area! Make sure there is sufficient overhead clearance to raise the mast safely. If the mast does not raise or lower properly or shows signs of binding, it may release or stop suddenly or move with a jerky motion and allow the load or carriage to drop. This could result in death or serious injury to the operator or nearby persons and/or damage the load.

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

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

• With the mast fully extended, begin lowering the mast.

The secondary cylinders and middle rails fully lower first, followed by the primary cylinder and the lift carriage.

• Check for smooth travel with no chattering or visible binding.

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

• Overhead Guard - Check the overheard guard and make sure that it is firmly attached to the forklift and that all fasteners are secured. The overhead guard is adjustable to accommodate various drivers’ operating restrictions (low ceilings, door openings, etc.)

• Parking Brake - The parking brake system included an interlock that shuts down the drive and pump motors, disables the direction control (resets to NEUTRAL) and applies the brakes to prevent further forklift movement.

To check the brake interlock: • Set the key switch to ON and release the parking brake.

• Set the control lever to FORWARD and very slowly increase motor speed.

• As the forklift moves forward at slow speed, slowly raise the parking brake handle.

• The forklift must immediately slow tot a STOP, and steering is disabled.

• If the forklift continues moving forward, it must be removed from operation and repaired.

2-5

• Rust or Corrosion - Check the forklift frame, side and floor panes for rust and corrosion. Clean rusty or corroded areas and repaint, if applicable. Apply a thin coat of oil to any bare metal surface.

• Safety Decals, etc. - Check for damage and missing decals. Check that the decals are legible, clean and/or replace as needed.

• Seat Brake, Optional - When releasing the seat switch, a clicking sound is heard as the electro-magnetic brakes apply.

• Static Discharge Strap - Make sure the static discharge strap is dragging (touching) the ground. A strap is located on both sides of the front axle pivot point.

• Tires and Wheels - Check tires for cuts or chunking, or splits, embedded foreign material or excessive wear. Check wheels for missing lug nuts. Repair and/ or have service replace immediately. DO NOT USE THE FORKLIFT. • Welds, Cracked or Broken - Check for damage and reliability. Clean and repair immediately. DO NOT USE THE FORKLIFT.

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

Check the data plate for battery information. See Figure 1-7.

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

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

2. Set the key switch to OFF and remove key.

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

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

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

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

• Wires or Connectors - Look for damaged, cracked or broken insulation, bare wires showing, loose or broken connectors. If electrical problems are found, have service make repairs immediately. DO NOT USE THE FORKLIFT.

OVERHEAD GUARD

LATCH AND PIN LATCH BRACKET

COMPARTMENT COVER Figure 2-2: Overhead Guard Battery Cover Latch 2-6

F-648-R2

Figure 2-3: Battery Disconnects

NOTES If the forklift includes the rollout battery tray option, see “Rollout Battery Tray” on page 1-22.

OVERHEAD GUARD CUTOUT

7. Disconnect the battery/forklift cable disconnect and lay the battery cable across the battery top.

8. Slide the compartment side door spring latch towards the front of the forklift to release the side door. Open the door.

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

10. To prevent roll-out, measure the width of the new battery. Adjust the retainer brackets located on the underside of the compartments top cover to approximately.0500” to 0.750” (12.7mm to 19mm) wider than the width of the battery. Tighten and torque the screws.

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

BATTERY COMPARTMENT TOP COVER AND SEAT BATTERY COMPARTMENT TOP COVER LOCKING LATCH BATTERY ADJUSTMENT BRACKET (BOTH SIDES)

BATTERY COMPARTMENT SIDE DOOR

Figure 2-4: Removing the Battery

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

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

2-7

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

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

Rollout Battery Tray Option

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

A limit switch is included to disable the forklift while this arm is removed (battery and motors are disabled).

If this option is included, to remove the battery simply release the restraint arm release handle and slide the arm from its holder. The battery is free to roll out the side of the forklift.

When installing the battery make sure the spacers are the correct configuration for the battery being installed.

Side-to-side play should be restricted as much as possible.

ROLLOUT RELEASE ARM CATCH ROLLOUT BATTERY RESTRAINT ARM LIMIT SWITCH ROLLOUT BATTERY TRAY

ROLLOUT BATTERY RESTRAINT BATTERY TRAY

Figure 2-5: Rollout Battery Tray Option

Storage, Towing or Shipping Forklift Storage For long-term storage, the forklift battery should be removed and stored where it can be periodically checked and recharged every three months.

The forklift should be stored indoors within a temperature range of +35°F (2°C) to +115°F (46°C) and a relative humidity between 40% and 70%.

2-8

The forklift should be raised with the tires at least 2” (51mm) off the floor and the frame set on large wooden blocks. Hard polyester tires, over long periods of time can develop flat spots that may not return to normal when the forklift is returned to service, rendering the tires defective.

If the forklift must be stored outside, it must be covered securely with a tarpaulin. Continued exposure to sunlight will cause deterioration of rubber tires, gaskets and hoses, as well as vinyl seat coverings, etc.

F-648-R2

Battery Storage In general, batteries that are fully charged with the electrolyte at the proper level may be stored for up to one year. Batteries should be stored in a cool, dry, well-ventilated area, away from direct sunlight. Batteries without covers should be covered with a non-conductive material to protect them from dirt, moisture, etc.



CAUTION

Do not drape flexible plastic sheeting over batteries, as it might trap explosive gases underneath. For batteries stored for more than one year, consult the battery manufacture.

Consult the battery documentation or the manufacturer for storage method and routine inspection required during the temporary storage interval.

NOTICE Be careful, the forklift will roll easily and steering will be difficult. Brake functions will not be equivalent to an operational forklift.

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

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

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

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

Towing the Forklift If the forklift breaks down and cannot be repaired at that location, it may be towed by attaching a suitable hook and chain to the tow pin located in the cutout at the lower rear of the forklift. See Figure 2-6.

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



WARNING

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

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

Figure 2-6: Tow Pin

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

To Ship the Forklift

• Forks must be empty.

1. Set the mast to its forward position (straight ahead).

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

2. Remove the battery. Scrape away and wipe clean any wet residue or corrosive deposits left by the battery. Also See “Battery Care” on page 1-8 for additional information.

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

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

• Maximum towing speed should not exceed 2 mph.

• Always tow the forklift in the reverse direction.

3. Connect a battery to the disconnect using long jumper cables and back the forklift onto its carrier so that the forks are pointed away from the forward direction of motion. (This usually accomplished by connecting the cables to a battery being carried by a nurse forklift and carefully driving both forklifts close to the carrier.)

4. Set the mast to its forward (level) position and lower the forks to the bottom of the mast. Align the mast indicator pointer located on the right side of the mast.

5. Disconnect the jumper cables from the forklift.

2-9

6. Set the parking brake as firmly as possible.

7. Set wedges against the front and rear tires and fasten them to the floor of the carrier. If the carrier is equipped with rings or receptacles for chains or cable rope, support their forklift as firmly as possible.

IMPORTANT Do not run chain or wire over the battery cover or any other finished metal surface. Use padding as necessary to protect the forklift finish from chains or cables.

Using Lifting Equipment



WARNING

Failure to use lifting equipment of adequate capacity to lift and move the Bendi AC/DS forklift can cause lifting equipment failure, which can lead to serious injury or death.

TIEDOWN POST/ TOW PIN

If lifting equipment is used, such as elevators, cranes, or ship hoisting gear, to move a forklift to another location, make sure the hoisting equipment has adequate size and capacity to move the equipment.

If a hoist is needed to lift the Bendi forklift: 1. Pass a strap under the forklift just in front and behind of the rear wheels. See Figure 2-8.

2. Pass a second strap under the cross-member at the top of the mast.

Figure 2-7: Tie down Post Used for Towing

3. Make sure to place a spacer, such as a 2” x 6” (5 x 15cm) block of wood between the overhead guard and the lift point to avoid damage to the forklift.

Figure 2-8: Setting Lift Equipment 2-10

F-648-R2

Chapter 3

Understanding the Bendi AC/DS Forklift Overview and Safety A thorough understanding of the following concepts is necessary before attempting to operate a Bendi AC/DS forklift:



WARNING

Read the Operator’s Manual and machine signs (decals) before using the forklift. Failure to do so can cause serious injury or death.

• Operator training - Discusses the operator training required by legislation and its implications for operators of Bendi AC/DS forklifts.

• Operator safety - Reviews the safety guidelines operators need to be aware of before they operate a forklift.

• Understanding stability - Identifies the stability triangle and how to use it to help prevent the Bendi AC/DS forklift from tipping over.

• Knowing the rated capacity - Understanding the rated capacity and its relationship to lift the load, load center, and use of attachments is discussed along with several examples.

• Understanding workplace conditions - An awareness of potential workplace hazards is essential to avoiding accidents. Changing workplace conditions such as pedestrian traffic and potential hazards such as potholes, overhead obstructions and areas with low visibility should be considered along with proficiency in correctly loading and unloading items transported using the Bendi AC/DS forklift.

• Working in Hazardous Environments - Examine the unique hazards associated with working in potentially explosive and flammable areas and how to handle the related chemical hazards to ensure maximum safety.

Operator Training and Safety

This Operators’ Manual describes the skills and competencies necessary for safe and efficient operation of the Bendi AC/DS forklift in a variety of common workplace conditions.



WARNING

All powered industrial forklift operators must be competent to operate a powered industrial forklift safely, as demonstrated by successful completion of a relevant training course in compliance with all applicable state and federal regulations. Operating a powered industrial forklift without the proper training can cause serious injury or death.

Understanding Stability



WARNING

Never load forklift beyond its rated capacity.

Loading beyond rated capacity can cause axle failure, forklift to tip over, load to fall, serious injury, or death. See the data plate for rated capacity and load center information.

Never allow anyone to stand beneath or pass under the lifting mechanism. The load could fall causing serious injury or death.

Ensure the load is centered and the forks are fully engaged. Failure to do so can cause the load to fall, or the forklift to tip over, resulting in serious injury or death.

The leading causes of accidents involving forklifts are due to the lack of understanding of how forklifts operate, especially when it comes to stability. Understanding the principles of stability of the forklift are essential to decreasing the likelihood that the Bendi AC/DS forklift may tip over, potentially causing serious injury or death.

Before using a Bendi AC/DS forklift the operator must become familiar with its capabilities.

3-1

UNDERSTANDING THE BENDI AC/DS FORKLIFT

Basic Principles The concepts concerning stability are actually quite simple. As the angle between the forks and the body of the forklift approaches 90° to the right. See Figure 3-1. or left. See Figure 3-2. The forklift is in its least stable position.

Unlike an automobile which has four points of suspension, Bendi AC/DS forklifts operate on a three-point suspension. When the forks are turned nearly 90° to the right, two of the suspension points are on the rear axle (item 1) and (item 2). The third suspension point is the center point of the front axle (item 3).

The center of gravity, an imaginary point at which all of the forklift’s weight is concentrated, is located as shown (item 4) when: • The forks are turned nearly 90° to the right.

• No load is placed on the forks.

Figure 3-1: Right View 90° Stability

• The forklift is at rest.

In this position, the fulcrum, or axis around which the forklift will tip, is between suspension point (item 2) and (item 3).

Exceeding the rated load capacity in this position may cause the forklift to tip. Let’s see why. Imagine a triangle (item 5) is drawn between the three suspension points.

This triangle is commonly called the stability triangle.

Since the center of gravity is an imaginary point, it will shift for various reasons that we will explore in a moment.

The crucial thing to remember is, as long as the center of gravity of the forklift remains within the border of the stability triangle, the forklift will not tip.

If the center of gravity shifts (item 4) so it falls outside of the border of the stability triangle, the forklift will tip around the fulcrum.

The center of gravity will shift if: • The load exceeds the rated capacity listed on the data plate.

• The load exceeds the load center dimensions listed on the data plate.

• Forks are not fully seated in the pallet, called “tip loading”.

• There is excessive speed while turning a corner (with the forklift unloaded or loaded).

• The load remains in a raised position while being transported.

Figure 3-2: Left View 90° Stability

Load Center



WARNING

Ensure the actual horizontal and vertical load centers do not exceed the maximum load centers stated on the data plate. Failure to do this can cause the forklift to tip over causing serious injury or death.

• The load is not distributed properly (always keep the heavier items near the load backrest).

There are two types of load centers:

• Driving across a slope sideways.

Horizontal load center - which is equal to one-half the length of the load when the weight is evenly distributed.

• Driving down a slope with the load in the downhill position.

• A battery is used that weighs less or more than the weight range listed on the data plate.

3-2

For example, a load that is 48 in. long has a horizontal load center of 24 in. The further the load center is from the fulcrum, the less stable the forklift.

F-648-R2

UNDERSTANDING THE BENDI AC/DS FORKLIFT Always make sure the load is flush against the rear of the forks and that unevenly distributed loads are loaded with the heaviest end of the load closest to the front wheels.

See Figure 3-3.

Tilting Considerations

Vertical load center - is equal to one-half the height of the load when the weight is evenly distributed. For example, a load that is 48” high, has a vertical load center of 24”. Make sure that load centers fall within the rating on the data plate.

When traveling with the forklift loaded, tilt the mast rearward while keeping the load low. This will help stabilize loads with an uneven weight distribution.

The maximum horizontal and vertical load centers the Bendi AC/DS forklift is designed for are listed on the data plate.

When unloading at high elevations, only use enough tilt to place the load onto the rack or stack.

The amount of forward and rearward tilt that can be safely used if governed by the application.

When loading at high elevations, tilt the load back far enough to seat it against the load backrest or forks.

Knowing the Rated Capacity



WARNING

Never load forklift beyond its rated capacity.

Loading beyond rated capacity can cause axles to break, forklift to tip over, load to fall, or serious injury, or death. See data plate for rated capacity and load center information.

Before operating a Bendi AC/DS forklift, it is necessary to have a thorough understanding of its carrying capacity.

This includes knowing how much weight it can lift and how to properly carry a load to maintain stability.

One of the most important facts to know about a Bendi AC/DS forklift is the rated capacity (how much weight it can safely lift). This weight is listed as the rated capacity on the data plate. The rated capacity varies for each load depending on:

Figure 3-3: Load Center Rating

• Where the horizontal and vertical load centers are.

• The height to which the load will be lifted.

• Attachments used during lifting the load.

Counterweight



WARNING

Never allow anyone to stand on the back of the forklift to add counterweight creating a dangerous situation that may cause serious injury or death.

Bendi AC/DS forklifts have a counterweight that allows travel with heavy loads. When a heavy load is lifted, the counterweight on the other end of the forklift keeps the center of gravity inside the stability triangle and prevents it from tipping.

3-3

UNDERSTANDING THE BENDI AC/DS FORKLIFT

Data Plate Data plates are provided on the forklift.

The following list explains each item that appears on the data plate. (See Below.)

1. Model - The model number of the Bendi AC/DS forklift appears here.

2. Serial No. - The serial number of the Bendi AC/DS forklift appears here.

3. Mast No. - The serial number of the mast appears here.

4. Rated capacity - The rated capacity is stated with the forks at various fork heights. As the load is lifted higher, the rated capacity of the forklift decreases.

5. Lift height - This is the fork height stated in inches.

This is the distance between the ground and the top edge of the forks.

6. Weight - The rated capacity of the forklift at various fork heights. Rated capacity is stated in pounds and kilograms.

7. Unladen Mass Without Battery - The actual weight of the Bendi forklift as built without the battery installed; stated in pounds and kilograms.

8. Minimum Service Weight of Battery - The battery must weigh at least this much for the Bendi forklift to operate properly; stated in pounds and kilograms.

9. Maximum Service Weight of Battery - The battery must not exceed the weight stated here for the Bendi forklift to operate properly; stated in pounds and kilograms.

10. Maximum Unladen Mass - This is the Unladen Mass Without Battery added to the Maximum Service Weight of Battery; stated in pounds and kilograms.

11. Battery Type - This is the rating for the battery itself as designated by Underwriter’s Laboratory (UL) Standard 583. This describes the construction of the battery and battery enclosure with respect to the risk of fire, electric shock, and explosion.

12. Forklift Type - This designation assigned by the Underwriter’s Laboratory (UL) Standard 583 describes the overall design of the electrical components on the forklift. Type “E” offers safeguards against an inherent risk of fire and electrical shock and Types “ES and EE” ratings add additional safeguards to prevent emission of hazardous sparks and limit excessive surface temperatures.

13. Nominal Voltage - Nominal voltage indicates that the forklift uses a 48 DC battery.

14. Horizontal Load Center - The horizontal load center is equal to one-half the length of the rated load when the weight is evenly distributed.

15. Vertical Load Center - The vertical load center is equal to one-half the height of the rated load when the weight is evenly distributed.

Maximum Fork Height



WARNING

The load capacity of the forklift decreases as the forks are raised. Refer to the rated capacity at the heights listed on the data plate. Failure to heed these guidelines can cause the forklift to tip over causing serious injury or death.

The maximum fork height is the highest position the Bendi AC/DS forklift can lift a load. See Figure 3-3. This is measured from the floor to the forks when they are raised in their highest position. The higher the forks are raised, the less stable the forklift becomes.

Attachments



DANGER

Never modify the Bendi AC/DS forklift in any manner. Only options and attachments approved

by Landoll Corporation may be installed on the forklift. Other modifications will void the warranty and may cause serious injury or death.

Attachments to the forks may affect the load center.

When the factory, dealer, or distributor installs attachments approved by Landoll Corporation, an additional data plate is attached to the forklift. The new plate identifies the type of attachment, the changes in the load centers, and the rated capacity.

Figure 3-4: Data Plate

3-4

It is illegal to use attachments for which revised capacities are not available.

F-648-R2

UNDERSTANDING THE BENDI AC/DS FORKLIFT

Determining the Weight of the Load In addition to the rated capacity the weight of the load must be determined before attempting to lift the load with the Bendi AC/DS forklift: • Weight may be listed on pallet wrapper or Bill of Lading.

• Weight is determined by multiplying the weight of each small container by the number of small containers on a pallet. Each small container should be marked with its weight.

16. Ask a supervisor when in doubt.

Bendi Serial Number Code

NOTICE The frame number is located on the left side of the frame. The mast serial number is located on the left side of the mast. (See Figure 3-5.) The frame number and mast serial number listed on the data plate should be compared with the frame number on the frame of the forklift and serial number on the mast before operating the forklift.

Understanding Workplace Conditions



The following information will help decode the Bendi serial number: Baa/wwAC/DS-yymms-xxxxx: aa

30 = 3000lb. rated capacity 40 = 4000lb. rated capacity

ww

ww frame width (43in.)

yy

last 2 digits - year of manufacture (ex. “11” = 2011)

mm

month of manufacture

s

component series; A

xxxxx

frame number

DANGER

Workplace situations are constantly changing.

Check the work area before beginning work for the day to determine any changes. If in doubt, check with a supervisor. Failure to observe new workplace conditions can lead to serious injury or death.

In addition to stability, be aware of additional potential hazards within the workplace to avoid forklift accidents.

Even when working in the same area each day, there could be changes that may affect safety, such as: • Maintenance work being performed • Wet areas

MAST SERIAL NUMBER LOCATION

• Overhead repair work Be on the defensive for anything that might present a hazard. Other situations that could present special operating conditions include: • Potholes • Pedestrian traffic • Very narrow aisle ways • Overhead obstructions • Poor lighting making it hard to see hazards • Wet, oily, or uneven terrain • Other equipment or vehicles operated in the area

FRAME NUMBER LOCATION

Remember: Do not block the following locations with the Bendi AC/DS forklift or materials being moved: • Electrical panels • Fire exits

Figure 3-5: Frame and Mast Identification

• Emergency stop buttons • Aisle ways

3-5

UNDERSTANDING THE BENDI AC/DS FORKLIFT

Dock boards Dock boards are designed and maintained so that one end contacts the dock (or loading platform) and the other end contacts the transport vehicle. When loading or unloading the transport vehicle, the dock board must be locked in place to prevent it from rocking or sliding. Dock boards have a high friction surface designed to reduce the possibility of people or forklifts slipping. Hand holds or other effective means are provided on portable dock boards to permit safe handling. Where possible, fork loops or lugs are provided for handling by forklifts.

Special rules should be followed if the workplace uses dock boards on loading docks: • Never exceed the carrying capacity marked on portable or powered dock boards.

• Portable dock boards must be secured in position, using anchors or other devices that prevent slipping.

Forklifts 1. Before loading or unloading a forklift or trailer, make sure it does not move unintentionally: — Set the brakes — Block the wheels 2. In addition to setting the brakes and blocking the wheels, if a trailer is not coupled to a tractor, make sure that all four corners are supported to prevent upending or corner dipping.

3. Maintain a safe distance from the edge of ramps, platforms, or other similar working surfaces.

4. Do not move trailers with a Bendi AC/DS forklift.

Warning Devices Sound the horn at an intersection. Stop and look for other vehicles and/or pedestrians and proceed with caution.

The Bendi AC/DS forklift may have additional optional warning devices installed. Make sure they are in working order before operating the Bendi AC/DS forklift. Optional devices may include: • An amber overhead flashing beacon.

• Flashing backup light.

• Rear safety light package.

• Back up alarm.

3-6

Working in Hazardous Environments Additional hazards in the workplace may include: • Atmospheric/Electrical • Chemical



WARNING

Some atmospheric conditions encountered in the workplace are extremely explosive and/or flammable. Make sure the Bendi AC/DS forklift is designated with the type appropriate for the working conditions. If unsure, check with the area supervisor. Using an industrial forklift that is not designed for use in a workplace with certain additional hazardous conditions can cause an explosion or fire resulting in a serious injury or death.

Atmospheric/Electrical Special atmospheric conditions are explosive and/or flammable. For example, if gasoline or kerosene is stored in the area, the vapors they produce can be flammable and explosive. Make sure the Bendi AC/DS forklift being operated meets the criteria for the workplace conditions.

The standard Bendi AC/DS forklift meets the criteria for “Type E” as described in UL 583.

The factory also provides special Bendi AC/DS forklifts that comply with “Type ES or EE” designation. In addition to the requirements of “Type E”, “Type ES” limits the emission of hazardous sparks and surface temperatures and in addition to these requirements, “Type EE” requires that the electrical equipment, including the motors, be completely enclosed.

Check with a workplace supervisor if uncertain about the correct forklift designation appropriate for the intended workplace.

Chemical Hazards Know the chemical characteristics of the substances being moved. In case of an accidental spill, stable, reactive, or flammable substances are handled differently. For example, the accidental rupture of a drum containing flammable material requires all sources of ignition to be immediately removed and may require that fire, law enforcement or EPA authorities be contacted to report the incident.

F-648-R2

Chapter4

Operating the Bendi AC/DS Forklift Overview This section of the Bendi AC/DS Forklift Operator’s Manual discusses the following concepts that must be thoroughly understood to operate a Bendi AC/DS forklift: • Operator’s Daily Checklist - Inspecting the Bendi AC/DS forklift before beginning the work shift is a mandatory requirement. The procedure for performing this inspection is explained.

• Controls and Indicators - The location of each control and indicator is illustrated as well as its operation.

• Operating Instructions – Basic procedures - Basic procedures such as getting on and off the forklift, driving position, starting and traveling, turning, stopping, and parking are discussed.

• Operating Instructions – Handling a load - This discussion describes the procedures necessary to load and unload the Bendi AC/DS forklift, traveling with a load, what to do in case of a tip over, and going up and down an incline.



WARNING

According to legislation, employers must make training available to ensure that operators are competent to safely operate the type of forklift that to be used in the workplace. More information on operator training requirements is included in the Getting Started section of this manual. Failure to receive proper operator training can cause serious injury or death.

Operator’s Daily Checklist NOTICE Daily inspection is a legal requirement. Report any defect immediately to the supervisor!

Operators are responsible for the daily inspection of the Bendi AC/DS forklift:

• Using Lifting Equipment to Move a Forklift to Another Location - This discussion gives warning to make sure lifting equipment has appropriate size and capacity for the job.

• Copy the “Operator’s Daily Checklist” page 5-2.

• Use in external conditions -

• Return the form to the supervisor

• Inspect the forklift and fill out the form • Report defects to the supervisor

— Normal operating conditions — Wind loads effects

Controls and Indicators

— Slippery conditions due to water, oil, etc.

This section explains how each control and indicator on the Bendi AC/DS forklift works and identifies their location with an illustration.



WARNING

First read the Getting Started section in this manual. It contains valuable information, such as stability and rated capacity, needed to know before operating the Landoll forklift. Failure to follow the information provided in the Getting Started section can lead to serious injury or death.

The operation of each control is established by the American Society of Mechanical Engineers (ASME) or Industrial Truck Association (ITA). If it is noticed that the control operation deviates from the way it is described in this manual, contact the supervisor.

4-1

OPERATING THE BENDI AC/DS FORKLIFT

Accelerator Pedal

Key Switch

The accelerator pedal is located on the floor, to the right of the brake pedal.

The key switch is located to the right of the steering column. Insert the key and turn clockwise to operate the forklift. Make sure the parking brake is applied and the direction switch is in neutral before switching on. All load controls and the accelerator should be in neutral (i.e. not depressed) before starting. Do not depress the accelerator during starting.

Depressing the pedal starts the forklift moving in the direction selected. The more the accelerator is pressed, the faster the forklift moves. Releasing the pedal brings the vehicle to a smooth stop.

Steering Wheel and Tilt Clamp The steering wheel, is equipped with a steering knob, which should be held firmly with the left hand at all times when driving. The steering column tilt and height are adjustable: 1. Loosen the tilt clamp lever.

2. Adjust the angle and height of the steering column.

3. Tighten the tilt lever.

4. Rock the column gently forward and back to ensure the clamp is tight.

Figure 4-1: Accelerator and Brake Pedals

Brake Pedal



CAUTION

The operator should always use their right foot for braking. Do not steer with brakes applied.

The brake pedal is located on the floor, to the left of the accelerator pedal.

Operation - Depress the brake pedal with right foot to activate the brakes.

The Bendi AC/DS forklift will “brake by plugging” if the accelerator pedal is released, change direction with the direction lever, and press the accelerator pedal again, the motor will come to a smooth stop and then reverse direction. This process is automatic. DO NOT press the brake pedal.

Figure 4-2: Steering Wheel Tilt Control

Seat Seat Switch A seat switch tells the hydraulic controller when the operator is present in the seat. Traction operations will shut down if the seat switch opens.

Seat Belt The driver’s seat belt must always be worn when driving this forklift.

4-2

F-648-R2

OPERATING THE BENDI AC/DS FORKLIFT



Rake Adjustment

WARNING

A twisted belt can potentially cause serious injury. In a crash or a tip-over, the full width of the belt is required to absorb the impact forces.

The rake adjustment has three adjustment positions.

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

1. Sit up straight in the driver’s seat.

2. Pull the belt across lap. Do not let the belt twist.

The belt may lock if pulled across too quickly or stopped too soon. If this happens, let the belt go back slightly to unlock it. Then pull the belt across more slowly.

3. Push the latch plate into the buckle until it clicks. Pull up on the latch plate to make sure it is secure.

4. If the belt stops before reaching the buckle, let it go back all the way, then start again.

5. The lap part of the belt must be worn low and snug on the hips, just touching the thighs.

Figure 4-4: Driver’s Seat Controls

Dash The Dash is located behind the steering wheel. See Figure 1-8. It is comprised of the following gauges, displays and switches. See Figure 1-13.

Figure 4-3: Belt Release Button

NOTICE Make sure the release button on the buckle is set so the seat belt can be unbuckled in an emergency. (See Above.)

• BDI (Battery Discharge Indicator) - shows battery capacity. See Figure 1-13. “Battery Low Lift Lockout” will display in message window when the battery condition is too low to support mast function.

NOTICE

Seat Adjustments A lever under the front of the seat releases the catch for forward or backward seat adjustment (1). Weight or suspension adjustment is controlled by the hand wheel (2). A gauge showing the adjusted level is located to the right of the adjustment hand wheel (3). See Figure 4-4.

Once the battery capacity reaches 15% the lift pump motor will shut down, thus disabling the lift function.

• Hour Meter - displays number the speed mode that the forklift has been used. Hours accumulate when the forklift is on and operator is in the seat.

4-3

OPERATING THE BENDI AC/DS FORKLIFT • Speed Indicator - displays the speed mode that the forklift is in.

• Status/Fault Display Window - displays fault messages from drives and status of drives if problems occur.

• Direction Indicator - displays the status of forward/reverse switch.

• Scroll and Enter Buttons - used to enter information into system through display. These are used by an authorized technician.

• Maintenance Hours - If enabled, the forklift hours that preventative maintenance is required is shown in this field. This must be enabled and set by an authorized technician.

The dash display is located in the center of the console.

Use the scroll button to change the intensity of the display. The battery discharge indicator showing battery capacity is below the main display.

Tilt Lever The second lever on the front of the armrest is the tilt lever. See Figure 1-8. A visual indicator is provided so the number of degrees the mast is tilted can be easily determined.

Operation - Pull back for backward tilt; push forward for forward tilt.

Side Shift Lever The third lever on the front of the armrest is the side shift lever. See Figure 1-8. Side shift is a standard function on Bendi AC/DS forklifts.

Operation - Pull back to shift to the right; push forward to shift to the left.

Attachment Lever(s) - Option

Parking (Hand) Brake

A fourth optional function can be fitted via a push button controlled solenoid. See Figure 1-8. The push button is mounted on the side shift lever. Powered attachments are optional functions on Bendi AC/DS forklifts.

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

Horn

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

The horn is located on the control pod. See Figure 1-8.

Direction Lever The direction lever is located on the front of the control pod. See Figure 1-8.

Operation - Push the lever toward the front of the forklift for forward travel, and pull it back for rearward travel. The lever may be moved while the forklift is in motion known as “brake by plugging”. The motor will automatically come to a smooth stop and then reverse direction.

Placing the lever in neutral while traveling will bring the vehicle to a quick stop.

Lift Lever The first lever (closest to the operator) on the front of the armrest is the lift lever. See Figure 1-8.

Operation - Pull back to lift the forks; push forward to lower the forks.

4-4

F-648-R2

OPERATING THE BENDI AC/DS FORKLIFT

Operating Instructions - Basic Procedures



WARNING

Check all systems before operating this vehicle.

Report unsafe conditions and correct them before operating vehicle. Do not operate vehicle unless trained and authorized to do so. Failure to follow these guidelines can result in serious injury or death.

Every forklift operator must be trained in accordance to the rules provided by OSHA, relating to Forklifts. Employers must ensure that each powered industrial forklift operator is competent to operate a powered industrial forklift safely, as demonstrated by the successful completion of the training and evaluation.

Operating a powered industrial forklift without the proper training can cause serious injury or death. It is also illegal.

The guidelines here are to give additional information relating to this specific forklift. This information is additional to that given in structured driver training.

It SHOULD NEVER BE USED INSTEAD OF DRIVER TRAINING. Look in the direction of travel before beginning to drive the forklift. Failure to look in the direction of traveling can cause serious injury or death.

Before operating the Bendi AC/DS forklift, become familiar with the controls and indicators and practice going forward, backward, turning, stopping and parking without a load on the forklift. After becoming familiar with the forklift’s operation, learn how to load and unload the forklift.

Getting On and Off the Forklift • Always maintain a three-point contact when getting on and off the forklift.

• Use the steps and hand holds provided for this purpose.

Driving Position



DANGER

The operator should remain in the seat with the seat belt fastened while the forklift is moving. The seat belt will help the operator remain inside of the forklift should it tip over. Never jump from the forklift if it begins to tip. The forklift may land on the operator causing serious injury or death.



WARNING

Only operate the vehicle from the operator’s seat with the seat belt fastened. Do not place any body part outside the vehicle. Do not carry passengers. Failure to follow these guidelines can result in serious injury or death.

For Proper Seating Position. See Figure 4-5.

1. Adjust the driving seat for comfortable operation of the forklift controls. The operator must be correctly seated with all body parts inside the cab.

2. Fasten the seat belt.

Starting and Traveling Failure to follow this procedure will result in traction not being enabled.

1. Sit in the seat and face forward in the position outlined above. See Figure 4-5.

2. Set the direction lever to neutral.

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

4. Use the lift lever to raise the forks 4 to 6 in. from the ground and the tilt lever to tilt the mast back. This is the recommended traveling position.

5. Operator should hold the steering knob firmly with left hand.

6. Note the direction in which the forks are facing. The forklift will travel in that direction – make sure that it is clear. Release the parking brake and set the direction of travel.

7. Gently depress accelerator pedal as required to achieve a safe operating speed. If the forklift is on an incline, release the brake and press the accelerator pedal simultaneously to avoid reverse motion. See Figure 4-1.

4-5

OPERATING THE BENDI AC/DS FORKLIFT When reaching an intersection: • Slow down. Even if the forklift is not carrying a load it can tip-over if turning at a high rate of speed!

• Sound the horn as reaching the intersection to warn pedestrians and other equipment operators the forklift is approaching the intersection.

• Always follow the rules of the road and yield to other equipment operators and pedestrians as required.

Stopping



ADJUST SEAT FASTEN SEATBELT Figure 4-5: Proper Seating Position

WARNING

When stopping, stay inside the cab until the forklift comes to a complete stop. Failure to stay inside the cab can cause serious injury or death.

Do not apply brakes abruptly with the load raised or tilted forward. If stopped abruptly the load may dislodge from the forks causing serious injury or death.



CAUTION

Always use right foot for braking. Do not ride the brakes. Do not apply brakes while steering.

To slow down, release the accelerator, and the forklift will automatically stop.

Figure 4-6: Parking Brake and Direction Level

Turning



For an emergency stop, release the accelerator and press hard on the foot brake pedal with the right foot.

WARNING

• Do not turn the steering wheel to its full rotation and hold it there for long periods of time. This unnecessary pressure build up applies excessive pressure to the steering components, cause excessive noise, and may result in a blown pump motor fuse.

• A lateral tip-over can occur if the forklift is improperly operated. Slow down before turning! Failure to slow down can cause serious injury or death.

4-6

The Bendi AC/DS forklift will also “brake by plugging” by releasing the accelerator pedal, changing direction with the direction lever, and pressing the accelerator pedal again. The forklift will come to a smooth stop and then reverse direction. This process is automatic, DO NOT press the brake pedal.

Stopping Distance Stopping distance changes with the incline and quality of the road surface.

To make sure the forklift comes to a safe stop: • Reduce speed.

• Allow adequate distance between the forklift and any other vehicle, object, or person.

F-648-R2

OPERATING THE BENDI AC/DS FORKLIFT

Parking

M



WARNING

When exiting the vehicle, place controls in neutral and set the hand brake. If leaving the forklift unattended, fully lower the mast, turn key OFF and remove the key. Failure to properly exit and park the forklift can cause serious injury or death.

Before parking the vehicle make sure: • The parked forklift will not cause an obstruction or safety hazard.

• The forklift is clear of fire exits, fire equipment, and stairways.

• The forklift is not left unattended on an incline.



WARNING

NEVER handle loads in excess of the specified rating on the data plate located in the operator’s compartment. Do not handle unstable or loosely stacked loads. Too heavy a load may tip the forklift, causing injury to the operator. Unstable loads may fall off, injuring people nearby.

Be thoroughly familiar with the operation of the Bendi AC/DS forklifts before attempting to handle loads. Repeated practice is a must! A mistake in load movement could jam the load into the racks, causing damage, or could dislodge a load from the forks, causing serious injury to people below.

1. Slowly pull the LIFT lever back to raise the mast. Lift the mast only one or two feet for practice.

• If the forklift is inoperative and must be left parked on an incline, securely block the wheels and remove the key.

2. Push the LIFT lever forward to lower the mast forks.

When parking the forklift always:

4. Push the TILT lever forward to move the mast forward, or to return the forks to their horizontal position as indicated by the tilt level gauge mounted on the right and left sides of the mast.

1. Apply the hand brake.

2. Tilt the mast forward.

3. Lower the forks to the ground.

4. Turn off all accessories e.g., lights.

5. Turn the key switch to the OFF position.

6. Remove the key.

3. Pull the TILT lever back to tilt the mast back. Rear tilt is 3° maximum. See Figure 4-8.

5. Practice tilting the mast slowly by “feathering” in the desired direction. Feathering is the process of moving the lever very slowly in the desired direction to accurately move the load into position.

Mast Operation Each mast operation is controlled by individual control levers - LIFT, TILT and SHIFT. See Figure 4-7. Practice using each lever, as explained below, until comfortable with the operation of the mast.



WARNING

Avoid jerky movements of the mast, especially when the load is raised. Jerky movements with the mast raised could tip the forklift or allow the load to slip from the forks, causing serious injury and/or damage.

The mast should only be tilted at the floor level or at the load level in the rack when depositing or picking up a load. At any other time, forward tilting could cause the forklift to tip forward or cause the load to slide off the forks causing serious injury to personnel in the area.

Figure 4-7: Lift, Tilt and Shift Placard

4-7

OPERATING THE BENDI AC/DS FORKLIFT

Operating Instructions – Handling a Load



WARNING

Look in the direction of travel before beginning to drive the forklift.

Make sure forks are set so the spacing between them is equal to one-half the opening between the end stringers on the pallet.

Make sure to insert forks fully into the pallet. Do not “tip load”. See Figure 4-9.

Read and understand the information in the “Getting Started” section before operating a Bendi AC/DS forklift.

Figure 4-8: Tilt Level Gauge 6. Tilting a loaded mast forward should be done slowly by feathering the TILT lever. Rapid tilting might jostle a load off the forks prematurely.

7. Make sure the area to the right of the forklift is clear.

8. Push the SHIFT lever forward to shift the mast to the right. See Figure 4-7.

9. Pull the SHIFT lever back to shift the mast to the left.

10. When thoroughly familiar with all of the control movements of the mast levers, practice depositing and retrieving a load under the supervision of an experienced instructor or operator.

Do not handle unstable or loosely stacked loads.

Use caution when handling long, high or wide loads.

Do not allow anyone to stand beneath or pass under the mast.

Never use the forklift to elevate anyone without the use of an approved attachment.

Never carry passengers on the forklift.

Never load the Bendi AC/DS forklift beyond its rated capacity. Rated capacity is stated on the forklift’s data plate. Loading the forklift beyond its rated capacity can cause axle(s) to break, the forklift to tip over and the load to fall.

Make sure the load center of the load does not exceed the load center rating stated on the forklift’s data plate.

If the mast continues to raise after the control lever is released, turn off the key switch.

FAILURE TO FOLLOW THESE GUIDELINES CAN CAUSE SERIOUS INJURY OR DEATH. SEE DATA PLATE FOR RATED CAPACITY AND LOAD CENTER INFORMATION.

Figure 4-9: Tipping a Load

4-8

F-648-R2

OPERATING THE BENDI AC/DS FORKLIFT

Setting the Forks

Retrieving a Load

Before getting on the forklift make sure the spacing between the forks is properly set.

The following illustrations show standard 40 in. x 48 in.

(W x L) pallets loaded on a rack with 96 in. beams.

1. Measure the center to center between the fork openings on the pallet. See Figure 4-10.

The arrow labeled with an ‘S’ shows the direction to turn the steering wheel.

2. Lift the fork locks up. See Figure 4-11.

Actual minimum aisle width, (item 5) See Figure 4-12, will vary based upon application.

3. Move the forks until the center to center spacing is equal to the center to center distance. Make sure the forks are seated in a carriage notch and equidistant from the ends of the carriage.

4. Press the fork locks down to ensure locking.



If the forks or load jam or catch during a stacking operation, do not attempt to free them by reaching through the mast. Failure to follow this guideline can cause serious injury or death.

 FORK LOCK FORK SPACING

DANGER

WARNING

Lowering the mast improves driver visibility, and improves the stability of the forklift by reducing the possibility of personal injury or damage to the load if it were to slip from the forks.

Follow these steps to retrieve a load:

CARRIAGE NOTCH CENTER TO CENTER BETWEEN FORK OPENINGS Figure 4-10: Centering the Forks

1. Approach the side of the aisle that is opposite the load (item 1). See Figure 4-12.

2. For narrow aisles, straighten out the forklift so it is 8 in., (item 2) See Figure 4-12, from the edge of the aisle opposite the load. For wider aisles, straighten out the forklift so it is 36 in. to 48 in., (item 6), from the side of the aisle where the load is located.

3. Center the forks using the side shift lever.

4. Drive forward until the front edge of the load wheels, (item 3) See Figure 4-12), are aligned with the center of the pallet (item 4).

5. Lift the forks to the required height, and then level the forks using the tilt lever.

6. Stop the forklift and turn the forks 90° using the steering wheel to align them with the load. See Figure 4-13.

Figure 4-11: Setting the Forks

4-9

OPERATING THE BENDI AC/DS FORKLIFT

NOTICE When turning the steering wheel with the forklift stopped, do not apply the foot brake or hand brake.

9. Shift into reverse and slowly back away from the stack while turning the steering wheel to keep the forks straight. See Figure 4-16.

10. There may be need to side shift while backing out the load to clear the rack.

If there’s still not enough clearance, drive forward and try the removal process again. To get more clearance, don’t start turning the forks until having backed out 8 in. to 16 in.

1

S

4

2

S

3

6 5

Figure 4-12: Setup - Load Pickup Figure 4-14: Positioning the Forks 11. When the front right hand corner of the load (item 1) See Figure 4-17, clears the rack, stop backing and turn the steering wheel clockwise to straighten out the forks so they are parallel with the body of the forklift. See Figure 4-18.

S

12. Lower the forks until they are 4 in. to 6 in. off the ground and slowly drive the forklift to the next location observing the safety rules previously stated.

S Figure 4-13: Align the Forks 7. Straighten out the forks using the steering wheel as the forks are driven into the load so the forks enter the load in a straight line. See Figure 4-14.

8. Turn the steering wheel to keep the forks straight as they are fully inserted into the load and lift, tilt, and side shift as required to stabilize and pickup the load.

See Figure 4-15. Only raise the load high enough to clear the rack or the load backrest may catch on the rack.

4-10

Figure 4-15: Inserting the Forks into the Load F-648-R2

OPERATING THE BENDI AC/DS FORKLIFT

S S

Figure 4-16: Retrieving the Pallet

Figure 4-18: Normal Travel Position

Follow these guidelines when transporting a load:

• Make sure the load is not wider than the width of the gangways or aisles, especially if backing a bulky load down an incline.

• Do not travel with excess speed.

Traveling on Inclines

Transporting a Load

• Use the horn to warn others of danger.

• Make sure the load is seated firmly against the load backrest.

• Tilt the mast back.

• Lower the load so the forks are 4 in. to 6 in. off the ground.

• Be alert to overhead obstructions such as low doorways, racking, and pipes. Make sure to know the raised and lowered heights of the mast.

1



WARNING

Use extra caution when operating on ramps.

Travel slowly, and do not turn. Travel with load uphill. Travel with empty forks downhill. Failure to follow these guidelines can cause serious injury or death.

When traveling up or down an incline: • Make sure the gradient is 12% or less with a load and 15% or less if not carrying a load.

• Always keep the load pointed uphill. See Figure 4-19.

Travel with the forks facing uphill, whether going up or down an incline. The forklift must back down an incline when carrying a load. If vision is obscured, arrange for a ‘Banksman’ to help guide.

S

• If not carrying a load, travel with the forks facing uphill when going up the incline, and face the forks downhill when traveling down an incline. See Figure 4-20.

• Never travel across a grade. This can cause the forklift to tip-over laterally and can cause serious injury or death.

• Use the foot brake to maintain control before the forklift builds up momentum.

Figure 4-17: Retrieving the Load

• Raise the forks as necessary to avoid damaging the forks or load as the road surface changes grade at the top or bottom of an incline. Lower the forks to 4 in. to 6 in. off the ground when clearing the incline.

4-11

OPERATING THE BENDI AC/DS FORKLIFT



DANGER

• If the forks or load jam or catch during a stacking operation, do not attempt to free them by reaching through the mast. Failure to follow this guideline can cause serious injury or death.

• When lowering the forks to the “no load” position, make sure not to lower the forks too far. (See Figure 4-25.) If the forks are lowered too far beyond the “no load” position, damage of the mast, rack, or other containers on the stack can occur. THIS CAN CAUSE SERIOUS INJURY OR DEATH. Figure 4-19: Traveling Uphill

• Do not attempt to withdraw the forks until they have been lowered to a “no load” position. FAILURE TO FOLLOW THIS GUIDELINE CAN CAUSE THE LOAD TO FALL OFF THE STACK CAUSING SERIOUS INJURY OR DEATH. Follow these steps to store a load: 1. Approach the side of the aisle that is opposite the area where the forklift will be unloaded (item 1). See Figure 4-21.

Figure 4-20: Traveling Down an Incline

Unloading The Forklift The following illustrations show standard 40 in. x 48 in.

(W x L) pallets loaded on a rack with 96in. beams. The arrow labeled with an ‘S’ shows the direction that the steering wheel must be turned.

Actual minimum aisle width may vary based upon application (item 5). See Figure 4-21.

4-12

2. For narrow aisles, straighten out the forklift so it is 6 in. to 8 in., (item 2) See Figure 4-21, from the edge of the aisle opposite the drop off point. For wide aisles, straighten out the forklift so it is 36 in. to 48 in. (item 6), from the side of the aisle where the load is located.

3. Center the load using the side shift lever.

4. Drive forward until the front edge of the load wheels, (item 3), are aligned with the center of the rack opening (item 4).

5. Lift the load to the proper height.

6. Stop the forklift and turn the load 90° (turn the steering wheel counterclockwise) so it points in the direction to be dropped off. See Figure 4-22.

F-648-R2

OPERATING THE BENDI AC/DS FORKLIFT 10. Lower the forks until the load sits firmly on the rack.

Continue to lower the forks until they no longer support the load (‘no load’ position). See Figure 4-25.

1

S

NOTICE 4

2

3

Do not tilt the mast back until the forks clear the pallet.

6

S 5

Figure 4-21: Setup - Delivering a Load

Figure 4-23: Straighten the Load for Drop-Off

S

S Figure 4-22: Load Drop-Off

NOTICE When turning the steering wheel with the forklift stopped, do not apply the foot brake or hand brake.

7. Drive forward and straighten out the load using the steering wheel so it is square over the stack. See Figure 4-23.

Figure 4-24: Inserting the Load

8. Turn the steering wheel to keep the load straight as it is driven it into the opening. See Figure 4-24.

9. Position the load directly over the rack beams and tilt the mast into its vertical position.

4-13

OPERATING THE BENDI AC/DS FORKLIFT

“NO LOAD” POSITION

1

S

Figure 4-25: No-Load Position 11. Shift into reverse and slowly back out of the load as the steering wheel is turned to keep the forks straight. See Figure 4-26.

12. When the front fork (item 1) See Figure 4-27, clears the rack, stop backing and turn the steering wheel to straighten out the forks so they are parallel with the body of the forklift.

13. Lower the forks until they are 4 in. to 6 in. off the ground and slowly drive the forklift to the next location observing the safety rules previously stated.

Figure 4-27: Removing the Forks

In Case of Forklift Overturning



DANGER

A tip-over can occur if the forklift is improperly operated. Failure to follow these guidelines can cause serious injury or death.

The following conditions can cause a forklift to tip over: • A load exceeding the stated load centers.

• Tip Loading See Figure 4-9.

• A load that is too heavy.

• Taking a corner too fast.

S

• Driving with the load raised.

• A load that is not distributed properly (keep the heavier items near the load backrest).

• Driving across a slope.

• Driving on a slope with the load facing downhill.

• Using a battery that weighs less than or more than the weight range listed on the data plate.

If there is a sense of the forklift tipping-over, follow these instructions:

Figure 4-26: Backing Away from the Load

1. Lean away from the direction the forklift is tipping.

2. Hold on to the steering wheel.

3. Brace feet.

4. Don’t jump.

4-14

F-648-R2

OPERATING THE BENDI AC/DS FORKLIFT

Using Lifting Equipment to Move a Forklift to Another Location



DANGER

Failure to use lifting equipment of adequate capacity to lift and move the Bendi AC/DS forklift can cause lifting equipment failure, which can lead to serious injury or death.

If using lifting equipment, such as elevators, cranes, or ship hoisting gear, to move a forklift to another location, make sure the hoisting equipment has adequate size and capacity to move the equipment.

If a hoist is needed to lift the Bendi AC/DS forklift: 1. Pass a strap under the forklift just in front and behind of the rear wheels.

2. Pass a strap under the cross-member at the top of the mast.

3. Make sure to place a spacer (such as a 2 in. x 6 in. block of wood) between the overhead guard and the lift point to avoid damage to the forklift.

Figure 4-28: Using Lifting Equipment to Move Forklift

4-15

OPERATING THE BENDI AC/DS FORKLIFT Table provided for general use.

NOTES:

4-16

F-648-R2

Chapter 5

Checklists and Specifications Inspections Overview Both daily and scheduled maintenance procedures are designed to extend the service life of the forklift and prevent major problems causing costly downtime.

The Daily Checklist is provided describing routine inspections, adjustments and lubrication necessary to keep the Bendi AC/DS Series forklift operating safely, followed by details to facilitate the specific checks.

Maintenance Schedule A detailed and rigorous full inspection maintenance schedule must be followed and is explained in the “Bendi AC/DS Series Maintenance Manual,” (P/N F-649).

NOTICE Read and comply with all applicable SAFETY precautions explained in “Getting Started” on page 1-1. Recommended service inspections are based on normal operating conditions. In environments with excessive dust/wetness, or if around corrosive materials, service must be performed more often.

Daily Checklist Daily pre-shift inspection is an OSHA requirement.

Report any defect immediately to the supervisor.

The operator is responsible for the daily inspection of the Bendi AC/DS Series forklift: • Photocopy the “Operator’s Daily Checklist” on the following page or use the form supplied by the supervisor.

• Inspect the forklift and fill out the form.

• Report defects and return the form to the supervisor.

5-1

CHECKLISTS AND SPECIFICATIONS

Date

Inspector

Shift

Location

Forklift Number

Model Number

Serial Number

Hr. Meter

Battery Fluid Added

Hyd. Oil Added

Operator’s Daily Checklist Safety and Operational Checks

Description

Safety Warnings and Operator’s Manual

Attached and legible

Data Plate

Attached and legible

Tires

Check for debris

Static straps

Check presence and condition

Parking brake

Check operation

Service brakes

Check operation and fluid fill level

Forks, top clip retaining pin, and heel

Check condition

Mast racking

Check for proper lift operation

Hydraulic oil

Check fluid level

Hydraulic cylinders

Check for leaks

Battery

Check water/electrolyte level and charge

Battery restraint system

Adjust and fasten

Structural Points

Check for damage and cracks

Turn power on

Investigate unusual noises

Dash display

Status

Bendi AC/DS

Pass/Fail

Comments

Check hour meter/BDI Check for fault codes

Steering

Check operation Check accelerator operation Check lift/lower control operation Check tilt control operation Check side-shift control operation

Controls

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

Lights and backup alarm (if equipped)

Check switch operation

Seat switch

Check seat switch operation

Seat belt, buckle, and retractors

Check operation

Seat adjustments

Check Lumbar and slide operation Check Rake operation

5-2

F-648-R2

CHECKLISTS AND SPECIFICATIONS

Checking Chassis Components This section of the Bendi AC/DS Series Forklift Operator’s Manual details the procedures and information needed to successfully inspect and maintain the forklift on a daily basis.

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

Data Plate The data plate should be checked to verify capacity ratings and lift heights. Also check the serial number of the forklift and mast to make sure they match up with the corresponding numbers on the data plate. See Figure 1-7.

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

The forklift is equipped with tires of a size and hardness that provide the necessary traction and still maintain a proper shape to minimize tipping. To maintain stability and maximum reliability, tires must always be replaced with the type originally supplied, as listed on the specification sheet at the end of this manual. It is also recommended to replace worn tires in pairs. Drive tires with tread must be replaced when the tread depth is less than 1/16” (1.6mm) at the deepest point.



CAUTION

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

Figure 5-1: Tire Wear and Damage 1. Inspect the tire for chunking or embedded objects.

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

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

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

2. Inspect tires for undercutting and uneven wear.

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

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

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

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

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

6. Torque drive wheel lug nuts to 75 ft. lbs. (101.7Nm) and make sure no lug nuts are missing.

5-3

CHECKLISTS AND SPECIFICATIONS

ESD Straps

Service Brakes

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

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

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



CAUTION

• Do not service carriage forks while the key switch is on. If the joystick is accidentally moved, serious injury could occur.

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

• Never use forks repaired by welding.

• Always replace both forks.

Figure 5-2: Static Discharge Straps

Parking Brake The parking brake system on a Bendi AC/DS Series forklift is automatically controlled by the forklift’s control system.



CAUTION

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

To check the park brake: 1. Sit in the operator’s seat and turn the key switch to ON. 2. Put the directional switch in the forward position and drive forward at a very slow speed.

3. While forklift is creeping forward, turn the key switch to the off position.

4. The park brake should click on immediately after the key switch is turned OFF, bringing the forklift to an abrupt stop.

5. If any problems are found with the operation of the park brake, immediately pull the forklift from service and repair. DO NOT USE THE FORKLIFT.

5-4

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

Mast Racking With the key switch turned ON, tilt the unloaded mast rearward. The mast should stop when the tilt cylinders bottom with no evidence of mast twist (racking).

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

1. Lower the mast.

2. Open the access door on the front of the forklift and pull the dipstick and ensure the oil level reads between the marks.

3. Add oil if level is low.

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

Look for hydraulic hose wear, damage, and leaks. Make sure clamps and fittings are tight. If leaks are found, remove the forklift from service immediately until all leaks are repaired.

F-648-R2

CHECKLISTS AND SPECIFICATIONS

Battery

Specific Gravity Correction

If the forklift has been shipped with batteries installed, first remove the batteries from the forklift. If the batteries have been shipped with electrolyte installed, check the specific gravity of the electrolyte using a hydrometer to determine if a charge is needed.

Temp °F

Correction

Temp °F

Correction

39-41

-0.012

101-103

+0.008

42-44

-0.011

104-106

+0.009

45-47

-0.010

107-109

+0.010

If the reading is between 1.280 and 1.290, the battery is fully charged. If the reading is down near 1.150, the battery must be charged as described in “Charging a Wet Cell Battery.”

48-50

-0.009

110-112

+0.011

51-53

-0.008

113-115

+0.012

54-56

-0.007

116-118

+0.013

57-60

-0.006

119-121

+0.014

Using a Hydrometer

61-63

-0.005

122-124

+0.015

64-66

-0.004

125-127

+0.016

67-69

-0.003

128-130

+0.017

70-72

-0.002

131-133

+0.018

73-75

-0.001

134-136

+0.019

76-78

0

137-139

+0.020

79-81

+0.001

140-142

+0.021

82-84

+0.002

143-145

+0.022

85-87

+0.003

146-148

+0.023

88-91

+0.004

149-151

+0.024

92-94

+0.005

152-154

+0.025

95-97

+0.006

155-157

+0.026

98-100

+0.007

158-160

+0.027

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

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

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

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

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

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

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

2. Cold weather can affect the level. If water must be added, use only distilled water.

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

4. Replace the vent caps. They must be secured in place during charging. Ordinarily, the charge should take about 3 to 5 hours to complete.

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

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

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

Figure 5-3: Using a Hydrometer

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

5-5

CHECKLISTS AND SPECIFICATIONS 8. Refer to “Specific Gravity Correction” on page 5-5 for Specific Gravity correction factors dependent upon electrolyte temperature.

9. Continue charging until the cells gas freely and the specific gravity remains constant over a three-hour period. At the end of the charge period the cell voltages rise to about 2.55 volts and the specific gravity rises to about 1.280, corrected to 77° F. 10. When charging is complete, ensure the vented cell caps on the battery are secure.

11. Connect battery cables and install battery in forklift.

9. When charging is complete, REPLACE the vented cell caps on battery.

10. Connect battery cables and install battery in forklift.

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

Check the data plate for battery information. See Figure 1-7.

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

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

2. Fill the cells to the level indicator using dilute battery grade sulfuric acid with a specific gravity between 1.260 and 1.270 corrected to +77° F (+25° C). The temperature of the electrolyte should be no higher than 90° F (50° C).

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

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

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

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

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

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

5. Secure the cover to the overhead guard latch and insert the locking pin. Jiggle cover to be sure latch is secured. See Figure 5-4.

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

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

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

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

8. Slide the compartment side door spring latch towards to the front of the forklift to release the side door.

Open the door. See Figure 5-4.

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

7. Disconnect the battery/forklift cable disconnect and lay the battery cable across the battery top. See Figure 5-5.

9. Place and connect the appropriate lift and support apparatus (overhead crane, crossbar and chains) within the overhead guard cutout, then carefully lift and slide the battery from the forklift. See Figure 5-4.

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

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

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

5-6

F-648-R2

CHECKLISTS AND SPECIFICATIONS

OVERHEAD GUARD CUTOUT

BATTERY COMPARTMENT TOP COVER AND SEAT BATTERY COMPARTMENT TOP COVER LOCKING LATCH BATTERY ADJUSTMENT BRACKET (BOTH SIDES)

BATTERY COMPARTMENT SIDE DOOR

Figure 5-4: Removing the Battery

Figure 5-5: Battery Disconnects

5-7

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

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

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

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

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

Rollout Battery Tray Option If this option is included, to remove the battery simply release the restraint arm release handle and slide the arm from its holder. The battery is free to roll out the side of the forklift.

A limit switch is included to disable the forklift while this arm is removed (battery and motors are disabled).

When installing the battery make sure the spacers are the correct configuration for the battery being installed.

Side-to-side play should be restricted as much as possible.

COVER HOLD DOWN LATCH

OHG LATCH AND PIN BATTERY COVER PIN Figure 5-6: Overhead Pin

RELEASE HANDLE RESTRAINT ARM

LIMIT SWITCH SPACERS Figure 5-7: Battery Latch

Check Structural Points Rust or Corrosion Check the forklift frame, side, and floor panels for rust and corrosion. Clean rusty or corroded areas and repaint, if applicable. Apply a thin coat of oil to any bare metal surface. Immediately pull forklift from service and repair if cracks are found.

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

The overhead guard is adjustable to accommodate various drivers’ and operating restrictions (low ceilings, door openings, etc.).

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

Dash Display Check for proper operation. If the instrument does not operate or shows signs of damage, return the forklift to service for repair.

Steering Before operating the forklift, check the steering system to make sure it operates correctly.

To check the steering system: 1. Enter the operators compartment and turn the key switch to the ON position.

5-8

F-648-R2

CHECKLISTS AND SPECIFICATIONS 2. Next, while moving forward or backwards slowly, turn the steering mechanism clockwise until the steering wheel locks. The front steer wheels should have turned clockwise. Repeat turning the steering arm counterclockwise and the front steer wheels should turn counterclockwise.

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

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

Racking occurs when the tilt cylinder strokes are uneven.

(One cylinder bottoms before the other).

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



CAUTION

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

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

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

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

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



WARNING

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

Side-Shift Control

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

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

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

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

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

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

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

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

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

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

Direction Control Check the direction control switch in both positions.

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

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

5-9

CHECKLISTS AND SPECIFICATIONS

Speed Switch

Rake Adjustment

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

The rake adjustment has three adjustment positions.

Return to Neutral

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

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

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

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

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

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

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

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

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

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

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

5-10

F-648-R2

CHECKLISTS AND SPECIFICATIONS

Specifications Tables Lubrication Specifications Name

Lubrication

Notes

Hydraulic System

Mobil DTE13 or similar ISO grade 32 hydraulic oil

Brake System

DOT 3 Brake Fluid

Drain, flush, and refill Fill

Steer Wheel Bearings

Alvania Grease No. 2

Clean and re-grease

Steering Knob

Light weight oil

Lightly oil

Battery Rollers (optional)

SAE 30W oil

Clean and re-oil

Gear Case

Mobilube SHC-630 only

Drain, flush, and refill

Grease Fittings

Molybdenum EP Chassis Grease

Clean and re-grease

Mast Rails

Molybdenum EP Chassis Grease

Clean and re-grease

Mast Chains

SAE40W oil or Bowman Heavy Load Red Grease

Clean and re-oil

General Lubrication

SAE 20 Lubricating Oil

Clean and re-oil

General Specifications Model

Bendi 30 AC/DS

Bendi 40 AC/DS

Capacity @ 24” Load Centers

3,000 lbs.

(1,363 Kg)

4,000 lbs.

(1,818 Kg)

Power Source

Battery, Electric 48V

Battery, Electric 48V

Total Weight w/ Battery

12,800 lbs.(5,818 Kg)

13,770 lbs.(6,259 Kg)

Travel Speed Loaded Unloaded

6.5 mph / 10.5 kph 7 mph / 11.3 kph

6.5 mph / 10.5 kph 7 mph / 11.3 kph

Lift Speed Loaded Unloaded

90 fpm / 27.4 mpm 110 fpm / 33.5 mpm

90 fpm / 27.4 mpm 110 fpm / 33.5 mpm

Lower Speed Loaded Unloaded

100 fpm / 30.4 mpm 90 fpm / 27.4 mpm

100 fpm / 30.4 mpm 90 fpm / 27.4 mpm

Mast Tilt Up to 293” (7.44 m) Higher than 294” (7.5 m)

3° Front / 3° Back 2° Front / 1° Back

3° Front / 3° Back 2° Front / 1° Back

Standard Forks (ITA Class II)

42 x 4 x 1.5in. / 1016 x 101 x 38mm

42 x 4 x 1.5in. / 1016 x 101 x 38mm

Gradeability (Loaded)

15%

15%

Motor Rating

12 kW

12 kW

Traction Motor Rating

5.1 kW each

5.6 kW

Wheel Sizes: Front (2 each)

14 x 5 x 8 in. (355x229x203mm)

14 x 5 x 8 in. (355x229x203mm)

Rear (2 each)

18 x 7 x 8 in. (267x229x203mm)

18 x 7 x 8 in. (267x229x203mm)

Battery Recommended - 48V

Min Weight 2,550 lbs (1,159 kg) Max Weight 3,100 lbs (1,409 kg) 680 AmpHr

Min Weight 2,550 lbs (1,159 kg) Max Weight 3,100 lbs (1,409 kg) 680 AmpHr

AC AC

AC AC

Control Type Traction Hydraulic

5-11

CHECKLISTS AND SPECIFICATIONS Table provided for general use.

NOTES:

5-12

F-648-R2

Document Control Revision Log: Date

Revision

Improvement(s) Description and Comments

05/15/12

F-648-R1

Initial Release

06/05/12

F-648-R2

Revised

10/17/14

F-648-R2

Complete Revision- Lani

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

Bendi AC/DS Operator’s Manual Re-Order Part Number F-648-R2

LANDOLL CORPORATION 1900 North Street Marysville, Kansas 66508 (785) 562-5381 800-428-5655 ~ WWW.LANDOLL.COM

Copyright 2012. Landoll Corporation “All rights reserved, including the right to reproduce this material or portions thereof in any form.”

F-648-R2