Bendi Landoll Forklift B40i3 Operator’s Manual F-500-0808

Model B40i3 Operator’s Manual

LANDOLL CORPORATION 1900 North Street Marysville, Kansas 66508 (785) 562-5381 800-428-5655 ~ WWW.LANDOLL.COM F-500-0808

08/01/2008

F-500-0808 Edition

Table of Contents Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . S-1 Site Supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-2 Terminology Used in Manual . . . . . . . . . . . . . . . . . . . . . . . . . . S-3 Illustrations Used in Manual . . . . . . . . . . . . . . . . . . . . . . . . . . S-3 The Meaning of Safety Statements. . . . . . . . . . . . . . . . . . . . . . . S-4 Bendi Forklift Safety Statements . . . . . . . . . . . . . . . . . . . . . . . . S-4 Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-7 Tipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-9 Traveling and Load Handling . . . . . . . . . . . . . . . . . . . . . . . . . S-11 Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-12 Visibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-12 Gas Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-12 Service Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-13 Side Shifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-14 Available Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-14

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Vehicle Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Identification Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Traction Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Liquefied Petroleum Gas (LPG) Fuel System . . . . . . . . . . . . . . . . . 1-4 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Operator’s Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Bendi B40i3 Model Narrow Aisle Forklift . . . . . . . . . . . . . . . . . . . 1-12 Available Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Bendi B40i3 Series Forklift Operator’s Manual i

Receiving and Inspection . . . . . . . . . . . . . . . . . . . . . . . 2-1 Items Furnished With Your Truck. . . . . . . . . . . . . . . . . . . . . . . . 2-1 Tools and Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Routine Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Visual Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Truck Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Towing the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 To Ship the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Operator Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Operator Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Understanding Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Tilting Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Understanding Workplace Conditions . . . . . . . . . . . . . . . . . . . . . 3-8 Working in Hazardous Environments . . . . . . . . . . . . . . . . . . . . . . 3-8 Pre-Operation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Dockboards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Trucks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Warning Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Operating Your Bendi B40i3 Forklift . . . . . . . . . . . . . . . . . 4-1 Operator’s Daily Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Operating Precautions for LP Gas Engines . . . . . . . . . . . . . . . . . . 4-9 Operating Instructions - Basic Procedures . . . . . . . . . . . . . . . . . . 4-12 Operating Instructions – Handling a Load. . . . . . . . . . . . . . . . . . . 4-18 Unloading Your Forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26 In Case of a Fire! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30

Standard Bendi B40i3 Series Forklift Specifications . . . . . . . . 5-1 Appendix A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 Appendix B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

Bendi B40i3 Series Forklift Operator’s Manual ii

Forward To Owners, Users, and Operators The safe and efficient operation of a lift truck requires skill and alertness on the part of the operator. To develop the skill required the operator must: · receive training, pursuant to OSHA 1910.178(1) dated 12/98, in the proper operation of THIS lift truck. · understand the capabilities and limitations of the lift truck. · become familiar with the construction of the lift truck and see that it is maintained in good condition. · read and understand the warnings and operating procedures in this manual.

In addition a qualified person, experienced in lift truck operation, must guide a new operator through several driving and load handling operations before the new operator attempts to operate the lift truck alone.

It is the responsibility of the employer to make sure that the operator can see, hear, and has the physical and mental ability to operate the equipment safely.

Various laws and regulations require the employer to train lift truck operators. These laws and regulations include: ·

Occupational Safety and Health Act (USA)

·

Canada Material Handling Regulations

NOTE: A comprehensive operator training program is available from Landoll. For further details, contact your Landoll dealer for BENDI lift trucks.

This OPERATING MANUAL contains information necessary for the operation of a basic fork lift truck.

Optional equipment is sometimes installed that can change some operating characteristics described in this manual. Make sure the necessary instructions are available and understood before operating the lift truck.

Some of the components and systems described in this OPERATING MANUAL will NOT be installed on your unit. If you have a question about any item described, contact your Landoll dealer for BENDI lift trucks.

Additional information that describes the safe operation and use of lift trucks is available from the following sources: · Employment safety and health standards or regulations (Examples: “Occupational Safety and Health Standards (USA)”, “Canada Material Handling Regulations”. · Safety codes and standards (Example: American National Standard, ANSI B56.1, Safety Standard for Low Lift and High Lift Trucks. · Publications from government safety agencies, government insurers, private insurers and private organizations (Example: Accident Prevention Manual for Industrial Operations, from the National Safety Council). · “Operator Safety Training Course” describes lift truck safety, good maintenance practices, and training programs. Available from your Landoll dealer for BENDI lift trucks. Landoll Part No. 107218 NOTE: BENDI lift trucks are not intended for use on public roads.

Bendi B40i3 Series Forklift Operator’s Manual iii

Safety Precautions IMPORTANT! The Bendi B40i3 Model trucks 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. When the truck is in operation, always keep loose clothing, jewelry, hair and fingers out of the restricted areas (especially pinch areas) as labeled on the truck.

This chapter on Safety must be carefully read, understood and adhered to strictly by all operators and service personnel using the Bendi B40i3 Model lift trucks. Do not use this truck until you have thoroughly read this manual.

Failure to comply could cause risk of death or serious injury to yourself and others.

It is the responsibility of the employer to make sure that the operator can see, hear and has the physical and mental ability to operate the lift truck safely. Various laws and regulations require the employer to train lift truck operators.

These laws and regulations include: · Occupational Safety and Health Act (USA) · Canada Material Handling Regulations A comprehensive operator training program is available from Landoll Corporation. For further details, contact your Landoll dealer for Bendi Lift Trucks. * Landoll and Bendi are trademarks of the Landoll Corporation.

All other brand and product names are the trademarks of their respective holders.

Landoll Corporation, Bendi B40i3 Model trucks meet or exceed ASME B56.1 - Part III, Safety for Powered Industrial Trucks.

Bendi B40i3 Series Forklift Operator’s Manual S-1

Safety Precautions

Warning

Safety Site Supervision Supervision is an essential element in the safe operation of powered industrial lift trucks.

The site supervisor must check that the Operator’s Manual is in the seat compartment on the truck at all times. Operators must be trained on the use, maintenance and safety aspects of the Bendi B40i3 Model trucks under the supervision of a trained and experienced operator.

Only those individuals trained to operate and/or service this truck may do so. Familiarization and driving practice with a new truck must be arranged in a safe area, away from other trucks, 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 truck. Operators must be retrained when new equipment is introduced, existing equipment is modified, operating conditions change, or an operator’s performance is determined unsatisfactory.

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

Any of the above could affect truck capacity and/or safe operation of the truck and is a serious safety violation that could cause personal injury, could weaken the construction of the truck, or could affect the safe operation of the truck.

NO MODIFICATIONS OR ADDITIONS MAY BE MADE TO THIS TRUCK WITHOUT PRIOR WRITTEN PERMISSION FROM: Landoll Corporation Material Handling Product Group 1900 North Street Marysville, KS 66508 U.S.A. Telephone: Fax:

(785) 562-5381 (785) 562-4853

The truck 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 truck and the load being moved. When trucks are used on a round-the-clock basis, they must be inspected after each shift. Problems found must be reported and corrected. The truck must be taken out of operation until all repairs have been made and the truck has been reinspected for safety.

Bendi B40i3 Series Forklift Operator’s Manual S-2

Safety Precautions Terminology Used in Manual Whenever front and rear, right and left are mentioned throughout this manual, it is assumed that you are standing behind the vehicle looking toward the forks.

Illustrations Used in Manual This manual makes use of many illustrations to help you locate components on your Bendi B40i3 forklift and follow the procedures.

DRIVE PEDAL

STOP PEDAL

You will note that each illustration has an identifying Figure number below the illustration frame (See Figure S-1). bendi ic brake iso

Figure S-1 Drawing Example

Bendi B40i3 Series Forklift Operator’s Manual S-3

Safety Precautions The Meaning of Safety Statements

Bendi Forklift Safety Statements

You will find various types of safety information on the following pages and on the machine signs (decals) attached to the vehicle. This section explains their meaning.

The safety statements contained in this manual relate to the operation and maintenance of the Bendi B40i3 forklift trucks.

The Safety Alert Symbol means ATTENTION! YOUR SAFETY IS INVOLVED!

Danger Danger means a life-threatening situation exists. Death can occur if safety measures or instructions on this label are not properly followed.

Note: Make sure you read and understand the information contained in this manual and on the machine signs (decals) before you attempt to operate or maintain this vehicle.

The location of each machine sign on the Bendi B40i3 forklift is illustrated on the next page (See Figure S-2) and a representation of each machine sign is on the following page (See Figure S-3).

Make sure you check each machine sign before you operate your Bendi B40i3 forklift and replace any that are no longer legible, missing or damaged.

Warning Warning means serious injury or death can occur if safety measures or instructions on this label are not properly followed.

Caution Caution means serious equipment or other property damage can occur if instructions on this label are not properly followed.

Note: Means that failure to follow these instructions could cause damage to the equipment or cause it to operate improperly.

Bendi B40i3 Series Forklift Operator’s Manual S-4

Safety Precautions 38 14 24 32

INSIDE

1

INSIDE

5 4 3

28

19

7 17 33 15 8 23 26 31 11 9

16

25

12

6

INSIDE

3 4 18

13

22 29 30 INSIDE

11 9 21 INSIDE

23 2

27

17

15

33

31 37

19

bendi ic decals

Figure S-2 Decal Locations

Bendi B40i3 Series Forklift Operator’s Manual S-5

Safety Precautions 1 2 3

5

4

6

7

8 11 12 28

9

14

13

15

18 17

16

19 22

21

23 24

25

26

29 30

27 31 32

37

33

38

Figure S-3

Bendi B40i3 Series Forklift Operator’s Manual S-6

Safety Precautions Operator

Warning Warning

Check that all directional and operational controls and levers are in their NEUTRAL position, the brakes are set and your seat belt is fastened before setting the key switch to ON (See heading ‘ Seat belt’ on page S-8).

To avoid personal injury when operating the truck, be extremely careful that NO part of your body (head, feet, arms, legs, fingers) is outside the operator’s cab where it could be subject to injury by aisle supports, other trucks or any obstacle in the area.

Know the location of and be especially careful of all pinch points, as indicated by the WARNING and DANGER labels on the truck.

Be especially careful when there are other people or moving or fixed objects in the working area, or when the load reduces visibility (See heading ‘Visibility’ on page S-12). Never drive a truck up to anyone standing in front of an object.

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

When driving in narrow aisles, make sure there is enough space for the truck and the load, travel at reduced speeds, and where applicable, request a helper to guide you safely through the area. · The operator is responsible for observing all instructions and safety regulations in his or her daily work routine related to the use of this truck. · Be careful at cross aisles, doorways and other locations where people may step into the path of travel of the truck. · He/she must check the condition of the truck at the start of each work shift. In particular, he/she must check the operation of the steering and brakes; the directional control lever; the pivot and shift, tilt and lift/lower joysticks; the condition of the batteries, parking brake, horn, and signaling devices, where applicable. · Make sure all access/service panels, doors and covers are installed, closed and latched tight. Do not operate the truck with panels, doors and covers removed, opened or unlatched. · Keep the truck clean and in good working order. Report any problems or damage risking the safety of the driver and any people in the work area. Problems found must be reported and corrected. The truck must be taken out of operation until all repairs have been made and the truck 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 truck.

NEVER lift, lower or transport people.

NEVER allow anyone on or under the forks (or load). Under no circumstances are there to be any riders anywhere on the truck, other than the operator.

Bendi B40i3 Series Forklift Operator’s Manual S-7

Safety Precautions · Do not indulge in stunt driving or horseplay.

Seat Belt

· 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, either by being anchored or by being equipped with devices that will prevent slipping.

The driver’s seat belt must always be worn when driving this truck.

· Check that dock boards 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 cab, 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, the parking brake must be set and the key switch must be set to the OFF position. Truck wheels must be blocked if the truck is parked on an incline.

Note: A powered industrial truck is considered unattended when the operator is 25 feet (7.6 m) or more away from the truck which still remains in his/her view… or ...whenever the operator leaves the truck and it is not in view.

· Sit up straight in the driver’s seat. · Pull the belt across you. Do not let the belt twist.

Warning A twisted belt can seriously injure you.

In a crash or a tip-over, the full width of the belt would not be available to take up the impact forces. · 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.

IMPORTANT! Make sure the release button on the buckle is positioned so you can unbuckle the seat belt quickly in an emergency.

Bendi B40i3 Series Forklift Operator’s Manual S-8

Safety Precautions Seat Safety Switch If the operator leaves the driver’s seat a limit switch is released. The drive and power steering motors are disabled to prevent further truck movement.

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

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

Parking Brake The parking brake includes a safety interlock that shuts down the drives, disables the direction control lever and applies the brakes to prevent further truck movement. To continue, you must set the direction lever to NEUTRAL, release the parking brake, and then set the lever to the desired direction.

Tipping Hazards

Warning Lift truck 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 truck which is likely to result in tipping.

All lift trucks 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.

If a tip-over occurs, the operator should follow the following guidelines shown here. · DO NOT JUMP · BRACE YOUR 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 truck can tip longitudinally (tipping over the front or rear wheels) or laterally (tipping either to the left or right side).

Bendi B40i3 Series Forklift Operator’s Manual S-9

Safety Precautions Longitudinal Tipping Can Occur When: · the truck is overloaded. · the mast is tilted forward excessively, with or without a load. · the load is raised and brakes are applied while the truck is traveling forward or backward. · the load is raised and the truck is accelerated while it is traveling forward or backward. · the truck is driven forward down a steep incline with a load.

Lateral Tipping Can Occur When: · the truck is turned sharply while traveling rapidly in either direction, with or without a load. An unloaded truck can tip easier than a loaded truck (with the load lowered). · the load is raised and the truck is being turned while traveling in either direction. · the load is raised and the truck is being turned and accelerated or braked while traveling forward or backward. · the truck is turned while traveling on a ramp or other inclined surface. · a load heavier than the rated truck 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 truck 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.

The truck can be tipped either longitudinally or laterally if it is driven: · 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 cannot move away from a dock while loading is in process. Make sure the highway truck or trailer has its brakes applied, engine turned off and, if on an incline, has the wheels blocked.

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

Bendi B40i3 Series Forklift Operator’s Manual S-10

Safety Precautions Traveling and Load Handling · Observe all traffic regulations. Keep to the right and maintain a safe distance from the truck ahead based on speed of travel. Keep the truck 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.

CAPACITY PLATE

· 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 truck at a speed that permits you to bring the truck 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 truck’s maximum lifting capacity. Refer to heading Specifications in this manual and the capacity plate, located in the operator’s cab (See Figure S-4).

This plate lists the load weights allowable for various fork heights, battery information, and also lists the truck model number, serial number and other basic truck data. · Pay particular attention when picking up a new load, to ensure the load weight and height requirements are within the truck’s capacity. · Truck stability and handling may be adversely affected. · Do not transport loads or other items within the operator’s cab or other areas of the truck. · Check that the load is properly positioned on the forks before lifting. · 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.

bendi ic id plate

Figure S-4 Capacity Dataplate Location

· Travel with forks or load 8” to 12” (203 mm to 305 mm) above travel surface. · Elevate mast or load only to pick up or deposit a load. Watch out for obstructions, especially overhead. Watch all clearances. · Tilt a loaded mast slowly. · Do not release the lift 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. · Never place any part of your body between the mast structures or any moving part of the truck. · 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.

Bendi B40i3 Series Forklift Operator’s Manual S-11

Safety Precautions 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 truck at a speed that will permit it to be brought to a stop in a safe manner.

An ultrasonic fuel level sensor is mounted to the back mount plate. This sensor provides the operator with an accurate quantity of fuel left through the dash display.

The engine muffler is equipped with baffles to block the ejection of sparks or flame, and meets standards required by the Forest Service of the U.S. Department on Agriculture.

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 truck and load. Always drive with safety as your number one goal.

LP GAS CYLINDER

Visibility

LATCH HOOK ASSEMBLY

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

TANK STRAP

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

TANK MOUNT PLATE

Always rotate in the driver’s seat to face in the direction you are traveling.

Gas Engine Features The Bendi B40i3 Model truck is powered by a liquified petroleum gas (LPG) engine and is designed to minimize harmful emissions.

Fuel is supplied from a standard 33 or 43 lb. ICC gas cylinder tank mounted horizontally on the rear deck of the truck. The tank is held in the tank mount plate attached to the truck using a strap and latch (See Figure S-5).

ULTRASONIC FUEL LEVEL SENSOR BASE MOUNT PLATE lp tank attach

Figure S-5 Fuel Tank Attachment

Bendi B40i3 Series Forklift Operator’s Manual S-12

Safety Precautions Care

Warning

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

Do not smoke, use an open flame, or create arcs or sparks near the LPG propane tank.

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

The gas engine should be maintained per manufacturer's requirements. This includes regular oil changes, checking and replacement of belts and filters, checking coolant levels, and checking engine compression. Refer to the Service Manual for more specific information concerning proper maintenance and care of the engine.

5. Disconnect the battery.

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

Warning You could be injured and the truck could be damaged if you try to do service work without proper training or equipment.

1. Be sure you have sufficient knowledge, experience and the proper tools and replacement parts before you attempt any truck 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 you use the wrong nuts, bolts or other fasteners, parts can later break or loosen. Serious injury could occur.

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 truck will not move, place wedges (or blocks of wood) at the front and back of the tires.

If you are servicing the brakes or tires, place the blocks at the front and rear of the tire farthest away from the one being serviced. (That would be the tire on the opposite side of the truck and at the opposite end.)

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

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

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

Bendi B40i3 Series Forklift Operator’s Manual S-13

Safety Precautions Side Shifting At least once every working shift, the side shifter must be inspected for visible damage and defects.

Any changes occurring with the side shifter or its workings must be reported immediately to the supervisor.

Moving parts of the side shifter 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.

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

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

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

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 capacity plate affixed within the operator’s cab.

Daily, check the upper hook engagement, the fasteners, the lower hook engagement and inspect for hydraulic oil leaks (See Figure S-6).

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

Figure S-6 Fork Check Points

Bendi B40i3 Series Forklift Operator’s Manual S-14

Safety Precautions Fire Extinguisher

Additional Publications

If your truck includes a fire extinguisher it should be inspected monthly or more frequently if circumstances dictate. The extinguisher should be checked to see that:

Additional information that describes the safe operation and use of lift trucks is available from the following sources:

· it is not damaged · the discharge outlet is not blocked · it is fully charged · the seal is not broken

· Employment safety and health standards or regulations (Examples: Occupational Safety and Health [USA], Canada Material Handling Regulations) · Safety codes and standards (Examples: American National Standard, ANSI B56.1, Safety Standard for Low Lift and High Lift Trucks)

IMPORTANT!

· Publications from government safety agencies, government insurers, private insurers and private organizations (Examples: Accident Prevention Manual for Industrial Operations, from the National Safety Council)

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

· Operator Safety Training Course - describes lift truck safety, good maintenance practices, and training programs.

Available from your Landoll dealer for Bendi Lift Trucks. Landoll part no.: 107218.

· the instruction pamphlet is clearly visible Also see page 4-29 for additional operating information.

In case of a fire! · Have everyone vacate the area immediately. · Call the fire department, no matter what the size of the fire. Emergency telephone numbers should be posted at each telephone. · Use your 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.

Bendi B40i3 Series Forklift Operator’s Manual S-15

SECTION 1 Introduction Your Bendi B40i3 Forklift Operator’s Manual contains basic instructions for operation and maintenance of Bendi B40i3 forklifts. This information must be carefully reviewed and understood before attempting to operate the vehicle.

Safe and efficient forklift operation requires skill and alertness.

You must be familiar with the vehicle, understand its capabilities, and follow the operating procedures and safety instructions recommended in this manual.

According to legislation, your employer must make training available to ensure that you are competent to safely operate the type of forklift that you will be using in the workplace.

Safe and efficient operation also depends on correct maintenance of the vehicle. An Operator’s Daily Checklist, which outlines maintenance that must be performed each time the vehicle is put into operation, is located in Appendix A. The checklist should be part of a complete preventive Maintenance Schedule. Make certain that the vehicle is correctly maintained and is in good mechanical condition at all times, even though you may not perform all service on the vehicle yourself. Report any failure immediately for correction. Otherwise, even minor failures or damage may result in major failures, or create unsafe operating conditions.

Bendi B40i3 Series Forklift Operator’s Manual 1-1

Introduction Vehicle Description The Bendi B40i3 is a narrow aisle type lift truck. The principle of this type of truck is that the weight of the load, which is carried on the forks in front of the load wheels, is offset by the combined weight of the heavy truck chassis and its engine. To maintain a safe counterbalance limit, a ballast weight is mounted to the rear of the truck chassis.

Bendi B40i3 forklift is available in a 4,000 lb. capacity. The front end can be pivoted 180 degrees.

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

Landoll trucks 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-558 standard for Internal Combustion Engine Powered Trucks.

The Bendi B40i3 Model truck utilizes the engine and fuel system that are certified by EPA Tier III Standards.

Machine model, serial and option numbers (where applicable) are stamped on the capacity nameplate affixed within the operator’s cab (See Figure 1-1).

The Bendi B40i3 Model truck also offers: · Four-wheel configuration - dual rear wheel drive; front wheel steering and articulation · Joystick operation for load functions utilizing a three-function hydraulic control valve. A fourth (4th) function hydraulic valve is available for an approved Class III attachment. · 12-volt lead-acid battery - provides power for the lights, and other auxiliary equipment. · Triplex or quadplex high visibility mast configurations · Lift capacity 4,000 lbs/1,814 Kg. at 24"/600mm load center

IMPORTANT! The Bendi B40i3 Model truck operators and service personnel must familiarize themselves with this manual and the Bendi B40i3 Model truck 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 your local area must be strictly enforced.

· Ergonomically designed operator compartment - includes sit-down operator position, adjustable driver’s seat, tilt/telescoping steering wheel, hand lever direction control, armrest, and operator supply tray. · Safety interlocks - key switch activation and operator seat safety switch, plus an electrical lockout requiring the directional control lever to be in the neutral, or center position before power can be restored.

CAPACITY PLATE

bendi ic id plate

Figure 1-1 Capacity Dataplate Location

Bendi B40i3 Series Forklift Operator’s Manual 1-2

Introduction Component Identification The following illustration will help you locate components on your Bendi B40i3 forklift (See Figure 1-2).

1. Forks 2. Load Backrest 3. Mast 4. Load Wheels 5. Drive Wheels 6. Overhead Guard 7. LP Gas Cylinder 8. Steering Column

Identification Plate The identification plate, which lists the rated capacity, serial number and other vehicle characteristics, is located to the left of the seat (See Figure 1-3).

Figure 1-2 Component Locations

Figure 1-3 Identification Plate

Bendi B40i3 Series Forklift Operator’s Manual 1-3

Introduction

Truck 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 truck (basic truck shape). A number of thick rectangular steel shapes (counterweights) are welded within the frame to counterbalance the truck against the weight of its load. The rear wall of the truck also includes a thick steel plate to add additional counterbalance.

Traction Drive Bendi B40i3 Model trucks are dual-drive, four-wheeled trucks, having two steerable, articulating load support wheels in the front and two drive wheels in the rear. The rear drive is operated by a single hydraulic circuit consisting of a variable displacement hydraulic pump and radial piston hydraulic motors. The variable displacement hydraulic pump is controlled by the vehicle master controller (VMC).

Brake System The brake system uses two independent methods.

The use of the drive pedal to actively control hydraulic pump displacement and the stop pedal to provide a mechanical lock-up at the drive motors.

The hydrostatic drive system will act as service brake. Braking sensitivity can be controlled by releasing the drive pedal slowly or quickly.

This Bendi B40i3 forklift is equipped with a spring applied hydraulic released brake system. The stop pedal does not operate as a gentle service brake, but a firmly acting parking brake. It is to be used as for emergency stops or as parking brake. If possible do not operate the stop pedal while the forklift is in motion as this could result in the loss of the load from the forks.

Parking Brake A parking brake system is fitted to both drive units.

The system is foot pedal actuated, and is electrically interlocked to create a NEUTRAL condition when the brake lever is actuated.

The parking brake system consists of an overcenter latch to hold the stop pedal in the down position.

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 an operator’s seat switch must be activated before the truck can move. The seat switch is activated when the operator is seated in the driver’s seat (Also see 'Seat Safety Switch,’ on page S-9 for additional information).

Liquefied Petroleum Gas (LPG) Fuel System The truck is powered by a four-cylinder liquified petroleum gas (LPG) engine designed to minimize harmful emissions. See pages 4-10 - 4-11 for LPG tank removal, filling, and installation procedures.

Additional information is available in the Appendix section of the Bendi B40i3 Service Manual.

Electrical System The electrical system includes a 12-volt battery, key switch, fuses, gauges, switches, electrical harnesses, and diagnostic ports for J1939.

As the stop pedal is depressed, the drive motor shuts down and the directional control electrically resets to NEUTRAL, preventing further movement of the truck.

Bendi B40i3 Series Forklift Operator’s Manual 1-4

Introduction Battery

Steering

A 12-volt lead -acid battery provides electrical power for the engine, lights, and other auxiliary equipment.

Steering is controlled by the steering control valve, or orbital, metering oil supplied by the auxiliary pump based on the operator's input to the steering wheel.

Pressurized oil from the steering control valve is sent through a motion control valve to the hydraulic steering motor. This motor turns the gear set, which rotates the front plate and mast.

For maintenance and/or emergencies, turn off the key switch to stop power to the truck. For maintenance, the driver's seat compartment cover, a hinged side cover provides easy access to the engine compartment where the battery is located.

Hydraulic System The hydraulic system consists of two separate circuits driven by a through shaft system originating at the pump drive attached to the flywheel on the engine. The first of these circuits is the hydrostatic drive and the second is the auxiliary pump circuit.

Hydrostatic Drive The hydrostatic drive is comprised of a variable displacement pump plumbed to a fixed displacement motor for each of the two drive wheels all controlled by the Vehicle Master Controller (VMC). The operator sends a direction and throttle signal to the VMC via the operator's controls. The VMC in-turn sends a throttle signal to the engine control module and a command to the variable displacement pump.

This pump then sends oil at pressure to the wheel motors. The wheel motors then rotate the drive tires with speed and torque. Refer to the VMC section of the Service Manual for additional information and calibration instruction and procedures.

Auxiliary Pump Circuit The auxiliary pump is located on the front of the variable displacement pump. The auxiliary pump provides oil at pressure to the following: · Steering · Hydraulic Fan · Mast Valve

Hydraulic Fan The oil flow to the hydraulic fan is regulated by a proportional valve controlled by the VMC. The fan speed is controlled by varying the oil flow based on engine temperature. As engine temperature rises, the fan speed will increase to match the greater coding demand. Consequently, the hydraulic fan is shut off when full mast lift is commanded to allow all hydraulic fluid flow to the mast. However, when engine temperature is greater than 230o F mast inputs are ignored and the fan is allowed to run continuously to prevent overheating.

Mast Valve Oil supplied by the auxiliary pump, not used by steering or the hydraulic fan is directed to the 3-spool mast control valve. An inlet relief controls pressure in this branch of the auxiliary pump circuit.

The 3-spool valve directs lift circuit pressurized oil to the lift, tilt, and side shift functions based on the operator's shifting of the valve levers. In the event that an attachment or 4th function is added, oil from the side shift spool is split to go either to the side shift cylinders or the 4th function based on the signal from a push-button switch mounted to the spool control lever.

Filtration and Cooling Return oil from the steering function, hydraulic fan, and lift function are combined at the filter manifold and sent through the hydraulic cooler to be cooled.

Cooled oil from the hydraulic oil cooler is then sent through the in-tank hydraulic oil filter.

Bendi B40i3 Series Forklift Operator’s Manual 1-5

Introduction Operator’s Cab Driver Controls Driving controls for the IC Model truck include a steering wheel, horn button, a forward and reverse lever, stop pedal, and drive pedal for speed control.

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

· Drive pedal - is pressed by the driver’s right foot to control the speed of the truck (See Figure 1-4).

Pressing the pedal down starts the truck moving in the direction you selected. The closer you press the accelerator pedal to the floor, the faster the forklift moves. Releasing the pedal brings the vehicle to a smooth stop. · Stop pedal - (See Figure 1-4). · Key switch - switches electrical power to the truck ON and OFF and starts the engine.

Starter lockout prevents restart of running engine (See Figure 1-5).

Never travel at speeds with or without a load that could be dangerous to yourself or others. Also see separate heading, Safety, in the beginning of this manual.

STEERING WHEEL AND KNOB DRIVE PEDAL

STOP PEDAL

KEYSWITCH

bendi ic brake iso

bendi ic keyswitch

Figure 1-4 Pedals

Figure 1-5 Pedals

Bendi B40i3 Series Forklift Operator’s Manual 1-6

Introduction · Direction control lever - is located on the driver’s side panel and selects the direction of travel of the truck (forward or reverse) (See Figure 1-7).

OHG LATCH AND PIN

· Horn push button - The horn is also located on the driver’s side panel.

Press in directly on the mushroom push button to sound the horn (See Figure 1-7).

BATTERY COVER PIN HOLD DOWN LATCH bendi ic cover latch

Figure 1-6 Engine Cover Latch · Engine Compartment Access Cover /Latch The driver’s seat and side panel are part of the pre-molded engine 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 1-6). Another hold down latch is provided to secure the cover closed.

· Lift, tilt, and shift levers - 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 1-7) Also see "Mast Operation," page 4-16 for additional information. · Optional attachment lever - A fourth function can be fitted via a push button controlled solenoid. The push button is mounted on the side shift lever. Powered attachments are optional functions on the IC Model.

DIRECTION CONTROL LEVER HORN PUSH BUTTON

LIFT LEVER

ATTACHMENT LEVER (OPTION) TILT LEVER

SIDE SHIFT LEVER

bendi ic armrest

Figure 1-7 Driver’s Arm Rest Control Panel

Bendi B40i3 Series Forklift Operator’s Manual 1-7

Introduction · Driver’s seat - is adjustable to accommodate the driver’s weight (seat cushion spring tension), backrest tilt and distance from the pedals (See Figure 1-8). The seat also includes a circuit interrupt safety switch (Also see ‘Safety interlock’ on page 1-4).

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 handwheel.

A gauge showing the adjusted level is located to the right of the adjustment handwheel. · Rake Adjustment - The rake adjustment has three adjustment positions.

Operation - Lift seat at the front corners.

Adjust seat forward or backward until in position. Push front corners of seat down to lock in place.

FORWARD/BACKWARD SEAT ADJUSTMENT LEVER WEIGHT/SUSPENSION ADJUSTMENT HANDWHEEL ADJUSTMENT LEVEL GAUGE seat adjustment

Figure 1-8 Seat Adjustments

· Rear view mirror - is attached to the front top of the overhead guard. The mirror is adjustable up and down, and side to side. · Steering Wheel and Tilt clamp - is equipped with a steering knob, which should be held firmly with your left hand at all times. The steering column tilt and height are both adjustable (See Figure 1-9). · Operator switch panel - includes three on/off rocker switches to activate optional packages installed on your truck (See Figure 1-10).

• LEFT switch - for headlights

TILT STEERING ADJUST LEVER

• CENTER switch - differential lock is standard on all trucks • RIGHT switch - for optional attachment requiring on-dash activation Only those options included with your truck are operable. Also see the Options section of this chapter for more information about the options available (See Page 1-12).

tiltster

Figure 1-9 Steering Column

Bendi B40i3 Series Forklift Operator’s Manual 1-8

Introduction STEERING WHEEL

DASH DISPLAY

DISPLAY FUNCTION BUTTONS

HEADLIGHT TOGGLE SWITCH

m146696 op

NOT USED

KEYSWITCH

12V AUXILIARY TOGGLE SWITCH

CAN DIAGNOSTIC PORT

Figure 1-10 Operator Switch and Dash Display Panel · Dash Display - The Dash Display is located on the dash behind the steering wheel. It is comprised of the following gauges, displays, and buttons (See Figures 1-10 and 1-11): • Engine Coolant Temperature Gauge • Fuel Gauge • Hour Meter - accurately displays the active operating hours • Clock

BATTERY ICON

ENGINE OIL PRESSURE ICON

SEATBELT/SEAT SWITCH ICON

HYD OIL TEMP ICON

PARKING ICON

FAULT ICON

FUEL GAUGE

- +

P F

H

• Warning Icons E

• Display Function Buttons · Dash Toggle Switches - The Dash Toggle Switches are located below the steering wheel. Note that the center switch is not used. The toggle switches are used for the following applicaations: • Headlight Toggle Switch (where fitted) • 12V Auxiliary Toggle Switch (where fitted)

L 4:56

PM

HRS

0

CLOCK HOUR METER DISPLAY FUNCTION BUTTONS

DRIVE FILTER STATUS ICON

ENGINE COOLANT TEMPERATURE GAUGE

m146074

Figure 1-11 Dash Display

Bendi B40i3 Series Forklift Operator’s Manual 1-9

Introduction Mast Assemblies Various mast assembly configurations (duplex, triplex and /or quadplex) can be applied to the Bendi B40i3 Model trucks to provide both collapsed and extended heights suitable for most customer requirements. The lifting capacity of the mast also varies depending on the truck and its application.

Load capacities are determined at 24” (609.6 mm) centers, centered on the mast and include all attachments on the carriage.

The Bendi Specifications sheet at the end of this chapter lists the dimensions of standard masts available for these trucks. Also check the capacity plate in the operator’s compartment for the maximum lifting capabilities based on the particular truck and mast combination (See Figure 1-1).

Figure 1-12 Mast in Collapsed Position

The trucks 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 consist of up to three pairs of channels or rails (steel beams) rolling one within the other on steel rollers.

The outer rails provide guidance and support for the middle rails, which in turn guide and support the inner rails. The truck forks are mounted on a carriage assembly that runs on rollers within the inner rails (See Figure 1-12).

Figure 1-13 Mast in Free Lift Position 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 1-13).

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.

Figure 1-14 Mast Fully Extended

This upward lift continues until the secondary cylinders are fully extended (See Figure 1-14).

Bendi B40i3 Series Forklift Operator’s Manual 1-10

Introduction 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 1-13). · Rail extension, in which both the middle and inner rails move, carrying the carriage upward (See Figure 1-14).

Figure 1-15 Quadplex Mast in Collapsed Position

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.

The mast is supported by trunnions, which allow it to tilt fore and aft. Two short hydraulic cylinders mounted between the bottom of the mast and the pivot arm control the amount of tilt. A mast indicator gauge (pointer) is located on the left side of the mast (as viewed from the front of the truck) to indicate when the carriage/forks are perfectly level with the floor.

As an option, trucks 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 1-15).

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.

Bendi B40i3 Series Forklift Operator’s Manual 1-11

Introduction

Technical Specifications

Appendix

Bendi B40i3 Model Narrow Aisle Forklift

Available Options

Landoll Corporation’s policy is to continually improve products. We reserve the right to change specifications and design without notice.

Technical specifications for the standard Bendi B40i3 Model and standard mast assemblies are listed in the Specifications section (See Section 5).

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

Fire extinguishers must be inspected monthly and the results recorded on the inspection tag attached to each extinguisher (See Figure 1-16).

Figure 1-16 Fire Extinguisher

If your truck is equipped with an extinguisher, see "Fire Extinguisher" page S-15. Also see 'Fire Extinguisher Option' page 4-29 for additional information.

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

Bendi B40i3 Series Forklift Operator’s Manual 1-12

Introduction

Load Backrest

Fork Positioner

Figure 1-17 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 of the load being moved (See Figure 1-17).

The forks start at the center of the carriage and move equal distance to the outside and back again as indicated by letters C and D (See Figure 1-17).

A push button is added to the pivot and shift joystick control (See Figure 1-18).

Figure 1-18 Joystick Push Button

Bendi B40i3 Series Forklift Operator’s Manual 1-13

Introduction Light and Alarms Various light and alarm option packages are available as follows (See Figure 1-19 for examples): · Audible backup alarm — sounds (beeps or talking) when the truck is placed in reverse to alert all personnel in the area. · Rear LED strobe light — includes 180° blackout for operator protection and is available with red, amber or blue lens.

BACK UP ALARM

STROBE LIGHT

HEADLIGHT

TAIL LIGHT

· 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 truck or the overhead guard. · Flashing backup strobe

alrm

Figure 1-19 Sample - Lights and Alarm

Bendi B40i3 Series Forklift Operator’s Manual 1-14

SECTION 2 Receiving and Inspection Receiving Your Truck Before shipping from the Landoll Corporation, each Bendi B40i3 Model truck is inspected to make sure the truck you receive is in impeccable condition and equipped per your order. However, we recommend that you: · Inspect the truck 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 your distributor and the shipping company. · Verify that the truck configuration and options match your purchase order.

Report any discrepancies to your distributor.

Items Furnished With Your Truck Standard Bendi B40i3 Model trucks are shipped from the factory with one copy each of the Operator’s Manual and Inspection Check Sheets, and a set of ignition keys attached to the steering column.

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.

Bendi IC/HT Series Forklift Operator’s Manual 2-1

Receiving and Inspection

To Prepare the Truck

Routine Checks

1. Check the hydraulic oil level. (See ‘Check Hydraulic Oil Level,’ in the Service Manual).

With the truck key switch set to OFF, perform a walk-around inspection. Check for obvious damage that would require more detailed inspection. If any of the following is apparent during your walk-around, record it in the log book for the truck and immediately notify your supervisor and/or service personnel.

2. Check the engine oil level. (See “Checking the Oil Level,” in the Service Manual).

Warning If you become dizzy while using cleaning solvents, get fresh air and medical help immediately. If solvent contacts your eyes, immediately treat in accordance with the manufacturer’s recommendations supplied with the solvent.

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

· Battery compartment cover / latch and pin - Check that the battery compartment cover is lowered into position and that the latch is secured whenever a battery is installed in the truck (See Figure 2-1). · Stop pedal - Check the operation of the stop pedal for smooth, firm, unobstructed movement when pressed and released.

Problems with the brake system must be repaired immediately by service. Do not use the truck.

OHG LATCH AND PIN

BATTERY COVER PIN HOLD DOWN LATCH bendi ic cover latch

Figure 2-1 Battery Safety - Latches and Pin

Bendi IC/HT Series Forklift Operator’s Manual 2-2

Receiving and Inspection

Inspection Check List

Visual Checks

1. Before releasing the truck for use, prepare a log book or log sheet for each truck at your site. List all services, 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).

Many problems can be spotted by a simple visual inspection of the truck; such as, oil leaks, damaged tires, cracks in welds or forks, damaged covers, etc.

Permanent logs serve as a checklist to show maintenance and repair history and to record whether faults have been corrected.

2. Perform inspections with the truck key switch set to OFF, the control lever in the NEUTRAL position and all brakes set.

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

4. If you notice or suspect a problem, immediately report it to your supervisor, record it in the truck log book, and have it checked and/or repaired before releasing the truck for use.

IMPORTANT! Appendix A contains an Operator's Daily Checklist, which should be used as a guideline when inspecting the truck.

However, dirt, grease, oil and debris can mask some problems. If possible, the truck should be washed on a regular basis. To remove stubborn grease accumulations, a grease-dissolving solvent may be needed. Make sure the solvent is not harmful to painted surfaces.

After high-pressure washing, lubricate all unprotected grease fittings and metal-to-metal surfaces, located outside the truck. See page B-2 for lube points and lubrication table. Refer to the Service Manual for lubrication instructions.

Warning Grease solvents are often toxic and may be flammable. Use only in accordance with the solvent manufacturer’s recommendations supplied with the solvent.

For example, use only i n 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.

Bendi IC/HT Series Forklift Operator’s Manual 2-3

Receiving and Inspection · Driver’s seat - Check the seat covering for rips or cuts. Check seat belt straps for worn or 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 power steering motors and disables the direction control (resets to NEUTRAL) bringing the truck 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 control lever to FORWARD and slowly increase motor speed until the truck begins to move.

• Lift yourself from the seat far enough to release the seat switch. The truck must immediately slow to a STOP, and power steering is disabled.

• If the truck 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 truck 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 truck.

· Hydraulic oil level - Check the oil level weekly. Low oil can cause operational problems (See ‘Check Hydraulic Oil Level,’ in the Service Manual. · Instruments - Inspect the instrument panel for damaged or non-working gauges. These require the key switch to be ON and can be checked prior to beginning your 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 your head, hands, arms or feet in the mast area! Make sure there is sufficient room above to raise the mast safely.

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

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

• With the mast fully extended, begin lowering the mast. The secondary cylinders and middle rails fully lower first, followed by the primary cylinder and the lift carriage.

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

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

• DO NOT attempt to repair the mast or operate the truck until the problem is corrected.

Bendi IC/HT Series Forklift Operator’s Manual 2-4

Receiving and Inspection

Warning 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. · Overhead Guard - Check the overhead guard and make sure that it is firmly attached to the truck and that all fasteners are secured. The overhead guard is adjustable to accommodate various drivers’ and operating restrictions (low ceilings, door openings, etc.) · Parking brake - The parking brake system includes an interlock that shuts down the drive and power steering motors, disables the direction control (resets to NEUTRAL) and applies the brakes to prevent further truck movement.

· Rust or corrosion - Check the truck 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. · Safety decals, data plates, etc. - Check for damage and missing decals. Check that the decals are legible. Clean and/or replace as needed. · Tires and wheels - Check tires for cuts or chunking, oil slicks, embedded foreign material or excessive wear. Check wheels for missing lug nuts. Repair and/or have service replace immediately. Do not use the truck. · Welds, cracked or broken - Check for damage and reliability. Clean and repair immediately. Do not use the truck. · 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 truck.

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 truck moves forward at slow speed, slowly depress the stop pedal.

• The truck must immediately slow to a STOP. • If the truck continues moving forward, it must be removed from operation and repaired.

Bendi IC/HT Series Forklift Operator’s Manual 2-5

Receiving and Inspection OVERHEAD GUARD

Replacing the Battery 1. Return the truck to your service charging station area.

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

LATCH AND PIN

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.

LATCH BRACKET

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).

COMPARTMENT COVER

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

latch

Figure 2-2 Overhead Guard Battery Cover Latch

7. Disconnect the positive and negative battery/truck cables and lay the cables to the side (See Figure 2-3).

8. Undo the 2 - 3/8-16 hex lock nuts and remove battery clamp bracket. The battery should be free to move.

POSITIVE BATTERY CABLE

9. When installing the battery, it must be pushed up against the rear wall panel and centered within the battery compartment (See Figure 2-3).

NEGATIVE BATTERY CABLE

10. Connect the positive battery cable (red) to the positive terminal on the new battery and the negative battery cable (black) to the negative terminal on the new battery.

BATTERY CLAMP BRACKET

11. Close left side door.

12. 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.

3/8-16 HEX LOCK NUTS battery disconnect

Figure 2-3 Battery Disconnects

Bendi IC/HT Series Forklift Operator’s Manual 2-6

Receiving and Inspection

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

The truck should be stored indoors within a temperature range of +35° F (2° C) to +115° F (46° C) and a relative humidity of 90%.

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

If the truck 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.

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, non-conductive material to protect them from dirt, moisture, etc.

IMPORTANT! 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 manufacturer.

Towing the Truck

Warning Make sure the towing equipment is capable of handling the weight of the truck being towed (See Figure 1-1).

Never connect lifting equipment to the operator's cab overhead guards..

Never use the truck to tow materials.

Never tow a truck that is carrying a load.

Never connect towing equipment to the mast.

For better traction, partially load the truck doing the towing.

Should it become necessary to tow the forklift, the towing instructions decal located on the truck must be followed (See Figure 2-4).

Figure 2-4 Towing Instruction Decal

Bendi IC/HT Series Forklift Operator’s Manual 2-7

Receiving and Inspection To Ship the Truck TIE DOWN POST / TOW PIN

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

2. Back the truck onto its carrier so that the forks are pointed away from the forward direction of motion.

3. 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 left side of the mast, as viewed from the front of the truck.

4. Set the parking brake.

bendi ic towpin

Figure 2-5 Tiedown Post Used for Towing

5. 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 the truck as firmly as possible.

IMPORTANT! If the truck breaks down and cannot be repaired at that location, it may be towed by attaching a suitable hook and chain to the tow bar located in the cutout at the lower rear of the truck (See Figure 2-5).

Do not run chain or wire over the seat base or any other finished metal surface. Use padding as necessary to protect the truck finish from chains or cables.

Also, the power steering on the disabled truck does not operate when the power steer motor is not running, which makes the steering wheel difficult to turn.

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

Bendi IC/HT Series Forklift Operator’s Manual 2-8

Receiving and Inspection Using Lifting Equipment

SPACER

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

LOCATION OF 2ND STRAP

If you use 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.

LOCATION OF 1ST STRAP

If you need to use a hoist to lift your Bendi forklift: 1. Pass a strap under the truck just in front and behind of the rear wheels (See Figure 2-6).

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

bendi ic move fork

Figure 2-6 Using Lift Equipment

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

DO NOT USE CHAINS!

Bendi IC/HT Series Forklift Operator’s Manual 2-9

SECTION 3 Before You Begin This section of your Bendi B40i3 Forklift Operator’s Manual discusses the following concepts that must be thoroughly understood before you can operate a Bendi B40i3 forklift: Operator training - Discusses the operator training required by legislation and its implications for operators of Bendi B40i3 forklifts.

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

Understanding stability - In this discussion you will learn about the stability triangle and how to use it to help prevent your Bendi B40i3 forklift from tipping over.

Knowing the rated capacity - The meaning of rated capacity and how it relates to how high you lift the load, the load center, and attachments used is discussed in detail using several examples.

Understanding workplace conditions - This discussion makes you aware of hazards in the workplace that you must understand to avoid accidents. You need to stay aware of changing conditions in your workplace such as potholes, overhead obstructions, and pedestrian traffic that may change on a daily basis. You also need to understand how to load and unload transport vehicles.

Bendi B40i3 Series Forklift Operator’s Manual 3-1

Before You Begin

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

Warning Every forklift operator must be trained in accordance to the rules provided by appropriate legislation. Your employer must ensure t hat each pow ered industrial truck operator is competent to operate a powered industrial truck safely, as demonstrated by t he successful completion of the relevant training course. Operating a powered industrial truck without the proper training can cause serious injury or death.

Operator Safety Before you start using your Bendi B40i3 forklift you must become familiar with its capabilities and thoroughly read and understand the material contained in this Operator’s Manual and the various machine signs (decals) found on your vehicle.

Understanding Stability

Warning Never load truck beyond its rated capacity. Loading beyond rated capacity can cause axles to break, truck to tip over, load to fall, or serious injury or death. See identification plate for rated capacity and load center information.

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

Warning Make sure that the load is centered and the forks are fully engaged. Failure to do so can cause the load to fall, or the truck to tip over, resulting in serious injury or death The leading causes of accidents involving forklift trucks are due to the lack of understanding of how forklift trucks operate, especially when it comes to stability. If you don’t understand the concepts of stability, you may tip over your Bendi B40i3 forklift truck, which can cause serious injury or death.

Whether you are a new operator or have used forklifts for many years, read through the following guidelines. They provide step-by-step instructions to help you operate your Bendi B40i3 forklift in a safe and efficient manner.

Bendi B40i3 Series Forklift Operator’s Manual 3-2

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

Unlike an automobile, which has four points of suspension, Bendi B40i3 forklift trucks 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 truck’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 · The truck is at rest.

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

If you try to pick up a load that is too heavy, the truck will tip around the fulcrum. Let’s see why. Imagine a triangle (item 5) is drawn between the three suspension points.

1

4

2

5

3

bendi ic stability rt

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 truck remains within the border of the stability triangle, the truck will not tip.

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

The center of gravity will shift if: · The load exceeds the rated capacity listed on the identification plate. · The load exceeds the load center dimensions listed on the capacity plate. · You do not seat the forks fully into the pallet, called “tip loading”. · You take a corner too fast (with the truck unloaded or loaded). · You drive with the load raised. · The load is not distributed properly (always keep the heavier items near the load backrest). · You drive across a slope. · You drive on a slope with the load facing downhill.

1

5

2

4

3

bendi ic stability lt

Figure 3-1 Right View 90o Stability

Figure 3-2 Left View 90o Stability

Bendi B40i3 Series Forklift Operator’s Manual 3-3

Before You Begin Knowing the Rated Capacity

Warning Never load truck beyond its rated capacity. Loading beyond rated capacity can cause axles to break, truck to tip over, load to fall, or serious injury or death. See identification plate for rated capacity and load center information.

Before you begin to operate your Bendi B40i3 forklift, you need to know some basic principles of how it works. This includes knowing how much weight it can carry and how to properly carry a load to maintain stability.

One of the most important facts you need to know about your Bendi B40i3 forklift is its rated capacity (how much weight it can safely lift). This weight is listed as the rated capacity on the capacity plate.

The rated capacity varies for each load depending on: · Where the horizontal and vertical load centers are · The height you plan to lift the load · Attachments used

Identification Plate Identification plates are provided on the truck.

The following list explains each item that appears on the identification plate (See Figure 3-3).

1. Model. The model number of your Bendi B40i3 forklift appears here.

2. Serial No. The serial number of your Bendi B40i3 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 you lift the load 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 stated in pounds and kilograms.

7. Unladen mass. The actual weight of your Bendi B40i3 forklift as built; stated in pounds and kilograms.

8. Truck Type. This designation assigned by the Underwriter’s Laboratory (UL) Standard 558 describes the overall design of the components for the internal combustion engine powered truck. Type “LP” designated units are liquefied petroleum gas units having minimum acceptable safeguards against inherent fire hazards. Type “LPS” designated units are similar to the “LP” units with additional safeguards to the exhaust, fuel, and electrical systems.

9. Nominal Voltage. Nominal voltage indicates that the truck uses a 12 VDC battery.

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

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

Figure 3-3 Identification Plate Capacity

Bendi B40i3 Series Forklift Operator’s Manual 3-4

Before You Begin Bendi Serial Number Code The following information will help decode the Bendi serial number:

MAST SERIAL NO. LOCATION

Baa/ww-ymms-xxxxx Where: aa ww y mm s xxxxx

= 40 for 4,000 lb rated capacity truck = 48 for 48” frame width = last digit of year of manufacture (ex. “8” means 2008, “9” means 2009) = month of manufacture = component series; such as “A” = frame number

Caution The frame number is also located on the left side of the frame (See Figure 3-4).

You must compare the frame number listed on the identification plate with the frame number on the frame of the truck before you operate the truck.

FRAME NO. LOCATION bendi ic frame and mast id

Figure 3-4 Frame and Mast Identification

Caution The mast serial number is also located on the left side of the mast (See Figure 3-4). You must compare the mast serial number listed on the identification plate with the mast serial number on the mast of the truck before you operate the truck.

Bendi B40i3 Series Forklift Operator’s Manual 3-5

Before You Begin Load Center

Counterweight

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

You need to consider two types of load centers. The horizontal load center is equal to one-half the length of the load when the weight is evenly distributed. 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. Always make sure your 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 3-5).

Warning Never let anyone stand on the back of the forklift to add counterweight. They can fall off the forklift, or the truck can tip backwards, causing serious injury or death.

Your Bendi B40i3 forklift has a counterweight that allows it to travel with heavy loads. When the forklift lifts a heavy load, the counterweight on the other end of the forklift keeps the center of gravity inside the stability triangle and prevents it from tipping over (See Figure 3-5).

HORIZONTAL LOAD CENTER

The 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 in. high has a vertical load center of 24 in. Make sure that you do not pick up a load that is higher than twice the vertical load center.

The maximum horizontal and vertical load centers your Bendi B40i3 forklift can handle is listed on the identification plate.

COUNTERWEIGHT FULCRUM REAR OF FORKS

bendi ic load center rating

VERTICAL LOAD CENTER

Figure 3-5 Load Center Rating

Bendi B40i3 Series Forklift Operator’s Manual 3-6

Before You Begin Maximum Fork Height

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

Warning The load capacity of your forklift decreases the higher you raise the forks.

Refer to the rated capacity at the heights listed on the identification plate. Failure to heed these guidelines can cause your forklift to tip over causing serious injury or death.

The maximum fork height is the highest position your Bendi B40i3 forklift can lift a load (See Figure 3-6).

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.

When you unload at high elevations, make sure you only use enough tilt to place the load onto the rack or stack.

Attachments

Warning Never modify your Bendi B40i3 forklift in any manner. Only options and attachments approved by Landoll may be installed on the truck. Other modifications will void the warranty and can 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, an additional identification plate is attached to the truck. The new plate identifies the type of attachment, the changes in the load centers, and the rated capacity.

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

MAXIMUM FORK HEIGHT

Determining the Weight of the Load In addition to the rated capacity you must determine the weight of the load before you attempt to lift it with your Bendi B40i3 forklift: · Weight is listed on pallet wrapper · Weight is listed on Bill of Lading

bendi ic max fork height

Figure 3-6 Maximum Lift Height

Tilting Considerations

· 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. · Ask your supervisor when in doubt

The amount of forward and rearward tilt you should use is governed by the application.

When you travel with the truck loaded, you should tilt the mast rearward as well as keep the load low. This will help stabilize loads with an uneven weight distribution.

Bendi B40i3 Series Forklift Operator’s Manual 3-7

Before You Begin Understanding Workplace Conditions

Warning

Working in Hazardous Environments

Warning

Workplace situations are constantly changing. Check your area before beginning work for the day. If in doubt, check with your supervisor. Failure to observe new workplace conditions can lead to serious injury or death.

Some atmospheric conditions encountered in the workplace are extremely explosive and/or flammable. Make sure your Bendi forklift is designated with the type appropriate for your workplace.

In addition to stability, you need to be aware of special situations in your workplace to avoid forklift accidents. Even if you work in the same area each day, there could be changes that would affect your safety, such as:

If you are unsure about the forklift, check with your supervisor. Using the wrong type designation can cause an explosion or fire resulting in a serious injury or death.

· Contractors doing maintenance · Wet areas · 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

Chemical Hazards You should know the chemical characteristics of the substances you are moving. In case of an accident you would handle stable, reactive, or flammable substances differently. For example, if you puncture a drum that contains flammable material, you need to turn off all sources of ignition and contact the proper authorities.

· 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 Remember: Do not block the following items with your Bendi B40i3 forklift or materials you are moving: · Electrical panels · Fire exits · Emergency stop buttons · Aisle ways

Bendi B40i3 Series Forklift Operator’s Manual 3-8

Before You Begin Pre-Operation Checklist

Trucks

Perform a pre-operation inspection of the Bendi B40i3 Model lift truck daily, before beginning your work shift. Report all problems to your immediate supervisor. (See ‘Routine checks,’ page 2-2). Do not release the truck into operation until repairs are made.

1. Before you load or unload a truck or trailer, make sure it does not move unintentionally:

Dockboards Dockboards are designed and maintained so that one end contacts the dock (or loading platform) and the other end contacts the transport vehicle. When you load or unload 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 trucks slipping. Handholds 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 fork trucks.

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

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

· 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 B40i3 forklift.

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

Your Bendi B40i3 forklift may have other warning devices installed. Make sure they are in working order before you start work for the day: · An amber overhead flashing beacon · Flashing backup light · Rear safety light package · Back up alarm

Bendi B40i3 Series Forklift Operator’s Manual 3-9

SECTION 4 Operating Your Bendi B40i3 Forklift This section of your Bendi B40i3 Forklift Operator’s Manual discusses the following concepts that must be thoroughly understood to operate a Bendi B40i3 forklift: Operator’s Daily Checklist - Inspecting your Bendi B40i3 forklift before you begin your shift of work 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 your Bendi B40i3 forklift, traveling with a load, what to do in case of a tip over, and going up and down an incline.

Theory of operation - is an overview of how the hydraulic and electrical systems work and includes a hydraulic layout diagram and schematic for a standard Bendi Series IC truck. A foldout electrical schematic and wiring diagram can be found inside the front cover in this manual.

Bendi B40i3 Series Forklift Operator’s Manual 4-1

Operating Your Bendi Forklift

Warning If you haven’t done so already, please read the Before You Begin section in this manual. It contains valuable information, such as stability and rated capacity, you need to know before you operate your Landoll forklift. Failure to follow the information provided in the Before You Begin section can lead to serious injury or death.

Warning According to legislation your employer must make training available to ensure that you are competent to safely operate the type of forklift that you will be using in the workplace. More information on operator training requirements is included in the Before You Begin section of this manual. Failure to receive proper operator training can cause serious injury or death.

Operator’s Daily Checklist Note: Daily inspection is a legal requirement.

Report any defect immediately to your supervisor!

You are responsible for the daily inspection of your Bendi B40i3 forklift: · Photocopy the Operator’s Daily Checklist in Appendix A of this manual or use the form supplied by your supervisor. · Inspect the truck and fill out the form · Report defects to your supervisor · Return the form to your supervisor

Controls and Indicators This section explains how each control and indicator on your Bendi B40i3 forklift works and identifies their location with an illustration.

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

Bendi B40i3 Series Forklift Operator’s Manual 4-2

Operating Your Bendi Forklift Drive Pedal

Stop Pedal

The drive pedal is located on the floor to the right of the stop pedal (See Figure 4-1).

The Stop pedal is located on the floor to the left of the drive pedal (See Figure 4-1).

Operation - Pressing the pedal down starts the truck moving in the direction you selected, see discussion of the “Direction Lever.” The closer you press the drive pedal to the floor, the faster the forklift moves.

Releasing the pedal brings the vehicle to a smooth stop.

Operation - Pressing the pedal down stops the truck movement.

Seat Switch A seat switch tells the hydraulic controller when you are in the operator’s seat. Traction operations will shut down if the seat switch opens signaling that you are not in the operator’s seat.

DRIVE PEDAL

STOP PEDAL

bendi ic brake iso

Figure 4-1 Drive and Stop Pedals

Bendi B40i3 Series Forklift Operator’s Manual 4-3

Operating Your Bendi Forklift Key Switch The key switch is located to the right of the steering column (See Figure 4-2). Insert the key and turn right to operate the truck. 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.

Steering Wheel and Tilt Clamp

STEERING WHEEL AND KNOB

KEYSWITCH

Caution Adjusting the steering column while driving the truck is dangerous. The movement of the column could startle or confuse you causing you to lose control of the truck.

bendi ic keyswitch

Figure 4-2 Steering Wheel Components

Adjust the steering column only when the truck is not being driven.

The steering wheel, is equipped with a steering knob, which should be held firmly with your left hand at all times (See Figure 4-2). The steering column tilt and height are adjustable: 1. Loosen the tilt clamp (or lever) (See Figure 4-3).

STEERING WHEEL AND KNOB TILT CLAMP

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 lever is tight.

bendi ic tilt clamp

Figure 4-3 Tilt Clamp Location

Bendi B40i3 Series Forklift Operator’s Manual 4-4

Operating Your Bendi Forklift Seat Adjustments A lever, under the front of the seat releases the catch for forward or backward seat adjustment (See Figure 4-4). Weight or suspension adjustment is controlled by the handwheel. A gauge showing the adjusted level is located to the right of the adjustment handwheel.

Warning Adjust the driver’s seat only when the truck is NOT moving. You could lose control or the sudden movement could cause you to push a wrong pedal if you attempt to adjust the seat with the truck moving.

1. Raise the left armrest and climb into the seat. A step (cutout) is added in the side panel to assist you into the operator’s compartment.

2. Pull the latch lever outward and slide the seat forward or backward as needed. Release the latch lever and try to move the seat slightly to make sure that it is locked (See Figure 4-4).

Warning If the seat is not locked, it could slide forward in a sudden stop or crash, which could cause injury to the driver.

3. The rake adjustment has three positions. Lift the seat at the front corners. Adjust the seat forward or backward until in position. Push the front corners down to lock the position.

4. Fasten the seat belt - see “Seat Belt,” page 4-6.

5. Lower the left armrest.

6. To dismount, release the seat belt and raise the left armrest and dismount using the side panel step.

7. The seat cushion is handwheel adjustable for operator comfort. A gauge showing the adjusted level is located to the right of the handwheel (See Figure 4-4).

FORWARD/BACKWARD SEAT ADJUSTMENT LEVER WEIGHT/SUSPENSION ADJUSTMENT HANDWHEEL ADJUSTMENT LEVEL GAUGE seat adjustment

Figure 4-4 Driver's Seat Controls

Bendi B40i3 Series Forklift Operator’s Manual 4-5

Operating Your Bendi Forklift Seat Belt The driver’s seat belt must always be worn when driving this truck.

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

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

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

Warning A twisted belt can seriously injure you.

In a crash or a tip-over, the full width of the belt would not be available to take up the impact forces.

Figure 4-5 Belt Release Button

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

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

DASH DISPLAY

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

IMPORTANT! Make sure the release button on the buckle is set so you can unbuckle the seat belt quickly in an emergency (See Figure 4-5).

bendi ic dash display

Figure 4-6 Dash Display Location

Bendi B40i3 Series Forklift Operator’s Manual 4-6

Operating Your Bendi Forklift STEERING WHEEL

DASH DISPLAY

DISPLAY FUNCTION BUTTONS

HEADLIGHT TOGGLE SWITCH

m146696 op

NOT USED

KEYSWITCH

12V AUXILIARY TOGGLE SWITCH

CAN DIAGNOSTIC PORT

Figure 4-7 Dash Display Gauges

Dash Display The Dash Display is located on the dash behind the steering wheel (See Figure 4-6). It is comprised of the following gauges, displays, and switches (See Figures 4-7 and 4-8): 1. Engine Coolant Temperature Gauge

BATTERY ICON

ENGINE OIL PRESSURE ICON

SEATBELT/SEAT SWITCH ICON

HYD OIL TEMP ICON

PARKING ICON

FAULT ICON

2. Fuel Gauge 3. Hour Meter

FUEL GAUGE

4. Clock

- +

P F

5. Warning Icons

L

6. Display Function Buttons

Dash Toggle Switches The Dash Toggle Switches are located below the steering wheel (See Figure 4-7). Note that the center switch is not used.The toggle switches are used for the following applicaations: 1. Headlight Toggle Switch (where fitted) 2. 12V Auxiliary Toggle Switch (where fitted)

H

E

4:56

PM

HRS

0

CLOCK HOUR METER DISPLAY FUNCTION BUTTONS

DRIVE FILTER STATUS ICON

ENGINE COOLANT TEMPERATURE GAUGE

m146074

Figure 4-8 Dash Display Location

Bendi B40i3 Series Forklift Operator’s Manual 4-7

Operating Your Bendi Forklift Direction Lever

Tilt Lever

The direction lever is located on the front of the control pod (See Figure 4-9).

The second lever, on the front of the armrest is the tilt lever (See Figure 4-9).

Operation - Push the lever away from you for forward travel and pull it toward you for rearward travel. Placing the lever in neutral while traveling will bring the vehicle to a quick stop.

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

Lift Lever

The third lever, on the front of the armrest is the side shift lever (See Figure 4-9). Side shift is a standard function on Bendi B40i3 forklifts.

The first lever, (closest to the operator) on the front of the armrest is the lift lever (See Figure 4-9).

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

Side Shift Lever

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

Attachment Functions - Optional A fourth optional function can be fitted via a push button controlled solenoid (See Figure 4-9). The push button is mounted on the side shift lever.

Powered attachments are optional functions on Bendi B40i3 forklifts.

Horn The horn is located on the control pod (See Figure 4-9).

DIRECTION CONTROL LEVER HORN PUSH BUTTON

LIFT LEVER

ATTACHMENT LEVER (OPTION) TILT LEVER

SIDE SHIFT LEVER

bendi ic armrest

Figure 4-9 Control Levers

Bendi B40i3 Series Forklift Operator’s Manual 4-8

Operating Your Bendi Forklift Operating Precautions for LP Gas Engines IMPORTANT SAFETY FIRST! The following caution hints have been prepared for your safety and the safety of your fellow workers and should be strictly adhered to. Carefully read and understand each one before attempting to operate the truck. · DO NOT run at low idle for prolonged periods. · Never operate engine at more than the regular governed speed. Excessive speeds are harmful. · The governor is set at the factory and needs no adjustment. · Immediately after engine starts, ensure the low oil pressure icon has gone out. If it is not, stop engine and inspect oil system to find the cause of failure. If you are unable to find the cause, be sure to consult your service person before operating the engine. Under no circumstances attempt operation without oil pressure. · Make sure all gauges are in the normal operating zone.

“Frequent reading of the instrument panel must become a habit.” · Follow Recommended Schedules of Maintenance - This will avoid trouble, which can cause expensive breakdowns. Maintain your lift truck for dependable and economical operation.

Liquefied Petroleum Gas (LPG) There is a fuel gauge that is part of the LCD dash display. The gauge provides an indication of fuel in the tank. The fuel icon flashes when there is less than 10% remaining in the tank.

Warning Close the shut-off valve on the tank when parking the lift truck more than momentarily. Do not park the lift truck near heat or ignition sources.

Do not store LPG tanks near heat or an open flame. For complete instructions on the storage of LPG fuels, refer to ANSI/NFPA 58 and 505.

LPG is extremely flammable. When checking or filling an LPG tank: No smoking. Stop engine.

Frost on the surface of the tank, the valves or fittings and the odor of LPG fuel indicates a leak. Inspect the LPG system and repair a leak immediately.

An LPG fuel leak creates an explosion and fire hazard. Do not attempt to start the engine if there is a leak in the LPG fuel system.

Only trained and authorized personnel are permitted to operate filling equipment. LPG tanks are heavy. The weight of an LPG tank can exceed the maximum recommended weight for safe lifting by an individual. Get assistance when lifting or lowering an LPG tank.

Use correct lifting procedures.

Fill LPG tanks outdoors. Stay at least 50 feet (15 meters) from buildings, motor vehicles, electrical equipment, or other ignition sources. Stay at least 15 feet (5 meters) from LPG storage tanks.

Bendi B40i3 Series Forklift Operator’s Manual 4-9

Operating Your Bendi Forklift Use the following procedure to remove the LPG tank: 1. Removable LPG tanks can be replaced indoors only if the lift truck is a minimum of 25 feet (8 meters) from any open flame or ignition source.

2. Move the lift truck to the area where LPG tanks are changed.

3. Turn the tank shut-off valve clockwise until the fuel valve is completely closed.

4. Run the engine until it stops, then turn the key switch to the OFF position.

NOTE: The following instructions are general procedures. There is a variation in equipment for filling LPG tanks. The local authorities that have jurisdiction have specific rules and regulations for filling LPG tanks. Make sure these rules and regulations are available and understood.

1. Check the LPG tank to make sure it needs filling. During the fill operation, the LPG tank must be in a position so that the liquid level indicator will always be in the vapor space above the liquid level.

5. Disconnect the quick disconnect fitting.

2. Open the liquid outlet valve and by-pass return valve on the storage tank.

6. Release the tank latch and remove the tank from the bracket.

3. Start the pump.

Warning Use only an approved LPG tank. Do not use an LPG tank that is damaged. A damaged LPG tank must be removed from service.

Use the following procedure to fill the LPG tank:

Warning Read and follow all the refueling precautions and instructions under Liquefied Petroleum Gas (LPG).

4. Connect the supply hose to the quick disconnect fitting on the LPG tank. If the LPG tank has an auxiliary fill fitting, connect the supply hose to this fitting. Make sure the correct adapter is used to connect the supply hose to the auxiliary fill fitting.

5. Open the vent valve on the liquid level indicator.

6. Open the shut-off valve on the LPG tank.

7. Open the valve on the end of the supply hose.

8. Watch for a discharge from the vent valve on the liquid level indicator. When a cloud of visible vapor appears, the LPG tank is full. Do not fill the LPG tank more than the maximum level indicated by the liquid level indicator.

Immediately close the valve at the end of the supply hose.

9. Close the vent valve on the LPG tank.

10. Close the shut-off valve on the LPG tank.

11. Disconnect the supply hose.

12. Stop the pump.

13. Close the liquid outlet valve and the by-pass return valve on the storage tank.

Bendi B40i3 Series Forklift Operator’s Manual 4-10

Operating Your Bendi Forklift Use the following procedure to install the LPG tank:

LP Gas

1. Before the LPG tank is installed on the lift truck, check the operation of the fuel gauge. Look at the fluid gauge and move the tank. If the gauge needle does not move, a new tank must be installed.

Natural Gas Processors Association Specifications HD-5

Warning Make sure the alignment pin extends through the correct hole in the rim of the LPG tank. The hose or the fittings can be damaged if the LPG tank is not installed in the correct position. A damaged hose or fitting can release LPG fuel and cause an explosion and fire hazard.

2. Install the LPG tank in its bracket so that the alignment pin is in the correct hole. Close the latch on the tank bracket.

3. Connect the quick disconnect fitting to the shut-off valve on the LPG tank. Use your hand to tighten the fitting.

4. Turn the shut-off valve counterclockwise to open the valve.

5. Inspect the fuel system for leaks when the fuel valve is open. Frost on the surface of the tank, valves or fittings or a strong odor of LPG fuel indicates a leak.

Engine Coolant The coolant level is checked by checking the level in the plastic reserve tank - not by removing the radiator cap.

When required, coolant must be added to the system only at the reserve tank - not by removing the radiator cap. When adding coolant, use the proper anti-freeze solution. Anti-freeze protection must be provided for and checked in both the radiator and reserve tank.

NOTE: The cooling system is filled with an Dexcool Anti-Freeze solution for protection to -10oF(-2oC). Always fill or replace with the same mixture or with a solution of higher concentration for operating in temperatures below -10oF(-2oC).

Caution Never operate the engine without a thermostat as severe engine damage can result through incorrect cooling.

Bendi B40i3 Series Forklift Operator’s Manual 4-11

Operating Your Bendi 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.

Warning Every forklift operator must be trained in accordance to the rules provided by OSHA, relating to Forklift Trucks. Your employer must ensure that each powered industrial truck operator is competent to operate a powered industrial truck safely, as demonstrated by the successful completion of the training and evaluation. Operating a powered industrial truck 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 truck. This information is additional to that given in structured driver training.

IT SHOULD NEVER BE USED INSTEAD OF DRIVER TRAINING.

Warning To avoid personal injury when operating the truck, be extremely careful that NO part of your body (head, feet, arms, legs) is outside the operator’s compartment where it could be subject to injury by aisle supports, other trucks, the mast raising or lowering, or any obstacle in the area.

Warning Look in the direction you will travel before you begin to drive the forklift. Failure to look in the direction you are traveling can cause serious injury or death.

Before you operate your Bendi B40i3 forklift, become familiar with the controls and indicators and practice going forward, backward, turning, stopping and parking without a load on the truck. After you become familiar with the truck’s operation, learn how to load and unload the forklift.

As the truck operator, you are responsible for observing all speed restrictions and traveling in accordance with aisle and work area conditions.

You are responsible for observing all instructions and safety regulations during your daily work routine related to the use of this truck.

It is your responsibility to thoroughly read the Operator’s Manual, paying particular attention to the chapters devoted to Safety, before attempting to operate this lift truck.

Under normal driving conditions, speed must be chosen according to the situation, such as, surface conditions, visibility, people working in the area, moving and fixed objects in the area, cross aisles, etc.

Where visibility is a restricted, always travel at very slow speed and ask for a helper to guide you through the area.

Always rotate in your seat to face in the direction you are traveling.

Getting On and Off the Forklift · Always maintain a three-point contact when you get on and off the forklift. · Use the steps and handholds provided for this purpose.

Bendi B40i3 Series Forklift Operator’s Manual 4-12

Operating Your Bendi Forklift Driving Position

Warning Only operate the vehicle from the operator’s seat with the seat belt fastened.

Do not place any part of your body outside the vehicle. Do not carry passengers. Failure to follow these guidelines can result in serious injury or death.

Refer to Figure 4-10 for proper seating position.

1. Adjust the driving seat for comfortable operation of the forklift controls (See Figure 4-10). You must be correctly seated with all body parts inside the cab.

2. Fasten your seatbelt (See Figure 4-10).

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

1. If the lift truck uses LPG fuel, open the fuel valve on the LPG tank.

Warning LPG is very flammable. An odor of LPG fuel can indicate a leak in the fuel system. DO NOT start the engine until the fuel leak is repaired.

2. On LPG units, make sure the LPG tank is properly mounted and connected. Open tank valve slightly until pressure equalizes. Then, open the valve the rest of the way.

Warning Remain in your seat with the seatbelt fastened while the truck is moving.

Your seatbelt will help you remain inside of the truck should it tip over.

Never jump from the truck if it begins to tip. The truck may land on you causing serious injury or death.

Caution Never open valve quickly, as this will cause the safety check valve to close.

3. Sit in the seat and face forward in the position outlined above (See Figure 4-10).

4. Make sure that the direction lever is in neutral (See Figure 4-11).

DIRECTION CONTROL LEVER

ADJUST SEAT FASTEN SEATBELT bendi ic direction control

bendi ic driving position

Figure 4-10 Proper Seating Position

Figure 4-11 Direction Control Lever

Bendi B40i3 Series Forklift Operator’s Manual 4-13

Operating Your Bendi Forklift 5. Insert the key into the key switch and turn it to start the engine. Do not depress accelerator while starting.

Caution Do not engage the starter for more than 30 seconds at a time. If the engine does not start, turn the key switch to OFF. Wait 60 seconds before engaging the starter again.

6. If the engine does not start after four attempts, get help from authorized service personnel.

7. As soon as the engine starts, release the ignition key, which will automatically return to the “ON” position. Check that all gauges are functioning.

8. After starting a cold engine, the engine will operate at a speed faster than idle (approximately 1000 RPM) for a few minutes until the oil pressure and coolant temperature are in the normal area. This warm-up period will permit oil to reach all bearing surfaces, thus reducing the possibility of scoring and premature wear of internal engine parts. Then, operate all controls to make sure they are functioning properly. Stop the engine and make a visual inspection for oil, coolant, or fuel leaks.

NOTE: Do not idle LPG engines for more than 5 minutes after starting. Cold fouling of spark plugs can result and lubrication in cold weather can be inadequate. Do not run the engine at maximum power continuously until engine is fully warmed up.

Caution Close the fuel valve on the LPG tank when parking the lift truck more than momentarily.

9. Raise the forks 12 in. or so from the ground and tilt them fully back. This is the recommended traveling position.

10. Hold the steering wheel with the left hand. Use the knob provided to facilitate quick turning of the wheel (See Figure 4-11).

11. Note the direction in which the forks are facing.

The truck will travel in that direction – so make sure that it is clear. Set the direction of travel.

12. Release the parking brake operation of the stop pedal. To release: Depress catch lever and pedal at once to release locking hook from catch pin.

Notice This Bendi IC forklift is equipped with a spring applied hydraulically released brake system. The pedal does not operate a gentle service brake, but a firmly acting parking brake. It is to be used for emergency stops or as a parking brake.

If possible, do not operate this pedal while the Bendi IC forklift is in motion as this could result in the loss of the load from the forks.

13. Move the direction control lever (See Figure 4-11) to the desired direction of travel.

14. Gently depress the drive pedal and the truck will begin to move away (See Figure 4-12). Depress the drive pedal as required to achieve a safe operating speed.

Warning Inching requires coordinated movement of the drive pedal. New operators must practice this procedure before attempting to handle loads.

Warning LP Gas is a combustible vapor that is heavier than air. Escaping gas can accumulate in low areas.

Bendi B40i3 Series Forklift Operator’s Manual 4-14

Operating Your Bendi Forklift When you reach an intersection: · Slow down. Even if the forklift is not carrying a load it can tip-over if you turn at a high rate of speed! · Sound the horn as you reach the intersection to warn pedestrians and other equipment operators you are approaching the intersection.

DRIVE PEDAL

STOP PEDAL

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

Stopping

Warning

bendi ic brake iso

Figure 4-12 Drive and Stop Pedals

When you stop, stay inside the cab until the truck comes to a complete stop.

Failure to stay inside the cab can cause serious injury or death.

To slow down, release the accelerator, and the truck will automatically slow down to a stop.

Turning

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

Your Bendi B40i3 forklift will also “brake by plugging” if you release the drive pedal, change direction with the direction lever, and press the drive pedal again, the truck will come to a smooth stop and then reverse direction. This process is automatic, DO NOT press the brake pedal.

For an emergency stop, release the drive pedal and press hard on the stop pedal with your right foot or put the directional lever in the neutral position.

Bendi B40i3 Series Forklift Operator’s Manual 4-15

Operating Your Bendi Forklift Stopping Distance Stopping distance changes with the incline and quality of the road surface.

To make sure you come to a safe stop: · Reduce speed · Allow adequate distance between the truck and any other vehicle, object, or person

Parking

Warning

Figure 4-13 Lift, Tilt, and Shift Placard

When you exit the vehicle, place controls in neutral and set the hand brake.

If you leave the truck unattended, fully lower the mast, turn engine Off and remove the key. Failure to properly exit and park your forklift can cause serious injury or death.

LEVEL SETTING, IN DEGREES

321

123

Before you park the vehicle make sure: · The parked truck will not cause an obstruction or safety hazard. · The forklift is clear of fire exits, fire equipment, and stairways. · The truck is not left unattended on an incline.

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

LEVEL INDICATOR TILT CYLINDER

tiltset

Figure 4-14 Tilt Level Gauge

When you park your forklift always:

Mast Operation

1. Apply the stop pedal.

Each mast operation is controlled by individual control levers - LIFT, TILT and SHIFT (See Figure 4-13). Practice using each lever, as explained below, until you are comfortable with the operation of the mast.

2. Tilt the mast forward.

3. Lower the forks to the ground.

4. Turn the key switch to the OFF position.

5. Remove the key.

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

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

2. Push the LIFT lever away from you to lower the mast forks.

3. Pull the TILT lever towards you to tilt the mast back. Rear tilt is 3° maximum (See Figure 4-14).

Bendi B40i3 Series Forklift Operator’s Manual 4-16

Operating Your Bendi Forklift 4. Push the TILT lever away from you 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 (See Figure 4-14).

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

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

You should tilt the mast only 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 truck to tip forward or cause the load to slide off the forks causing serious injury to yourself or anyone in the area.

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 and left of the truck is clear.

8. Push the SHIFT lever forward to shift the mast to the right (See Figure 4-13).

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

10. When you are 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.

Warning NEVER handle loads in excess of the specified rating on the capacity plate located in the operator’s compartment.

Do not handle unstable or loosely stacked loads. Too heavy a load may tip the truck, causing injury to the operator. Unstable loads may fall off, injuring people nearby.

Make sure you are thoroughly familiar with the operation of the Bendi B40i3 Model before you attempt 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.

Bendi B40i3 Series Forklift Operator’s Manual 4-17

Operating Your Bendi Forklift Operating Instructions – Handling a Load Narrow-aisles, plus the size of the truck, prevent a load from being pulled straight out of the rack. You must pivot the front end and shift (or inch) the load in or out of the rack. A combination of movements, where the pivot or shift actions occur with forward or backward movements of the truck, are needed to inch the load in and out of position. This will require some practice by the operator to be performed smoothly and effectively.

Figure 4-15 Tipping a Load

Warning You must immediately lower the load to about 12” (30 cm) from the floor before moving the load to another location.

Lowering the load improves driver visibility, and improves the stability of the truck by reducing the possibility of personal injury or damage to the load should it slip from the forks. Look in the direction you will travel before you begin to drive the forklift.

Warning 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 you insert forks fully into the pallet. Do not “tip load” (See Figure 4-15).

Read and understand the information in the Before You Begin section before you operate a Bendi B40i3 forklift.

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

Never carry passengers on the truck.

Never load your Bendi B40i3 forklift beyond its rated capacity. Rated capacity is stated on the truck’s capacity plate.

Loading the truck beyond its rated capacity can cause axle(s) to break, the truck 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 truck’s capacity 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 CAPACITY PLATE FOR RATED CAPACITY AND LOAD CENTER INFORMATION.

Do not handle unstable or loosely stacked loads. Use caution when you handle high or wide loads.

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

Bendi B40i3 Series Forklift Operator’s Manual 4-18

Operating Your Bendi Forklift Setting the Forks

Warning Review heading Safety with regards to fork positioners for proper safety precautions when adjusting the location of the forks on the carriage.

FORK LOCK FORK SPACING

Make certain the truck key switch is in the OFF position and that the parking brake is set.

The forks must be set equal distance from the center of the fork carriage.

Setting them too far to the left or right could cause a load to unbalance and tip the truck.

CARRIAGE NOTCH CENTER TO CENTER BETWEEN FORK OPENINGS

bendi ic setting the forks

Before you get on the forklift make sure the spacing between the forks is properly set (See Figure 4-16):

Figure 4-16 Setting the Forks

1. Measure the center to center between the fork openings on the pallet (See Figure 4-16).

ROTATE AND LIFT TO UNLOCK

2. Rotate and lift the fork locks up (See Figure 4-16).

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 (See Figure 4-16).

Warning Never pull a fork toward you as this places your hands in a possible pinch position, which could cause serious injury. Always push the fork away from your body.

frkrls

Figure 4-17 Manual Fork Adjust

4. Press the fork locks down to ensure locking.

Bendi B40i3 Series Forklift Operator’s Manual 4-19

Operating Your Bendi Forklift Retrieving a Load Note: Actual minimum aisle width (item 5) Figure 4-18 will vary based upon application.

Note: The following illustrations show standard 40 in. x 48 in. (W x L) pallets loaded on a rack with 96 in. beams.

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

Follow these steps to retrieve a load:

1

S

4

2

3

1. Approach the side of the aisle that is opposite the load (item 1) Figure 4-18.

2. For narrow aisles, straighten out the truck so it is 8 in., (item 2) Figure 4-18, from the edge of the aisle opposite the load. For wider aisles, straighten out the truck so it is 36 in. to 48 in., (item 6) Figure 4-18, from the side of the aisle where the load is located.

3. Center the forks using the side shift lever.

Warning

6 5

bendi ic load retrieve 1

Figure 4-18 Setup - Load Pick Up

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.

4. Drive forward until the center of the load wheels, (item 3) Figure 4-18, are aligned with the center of the pallet (item 4) Figure 4-18.

S

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 4-19).

bendi ic load retrieve 2

Figure 4-19 Align the Forks

Bendi B40i3 Series Forklift Operator’s Manual 4-20

Operating Your Bendi Forklift Note: When you turn the steering wheel with the truck stopped, do not apply the stop pedal.

7. Straighten out the forks using the steering wheel as you drive them into the load so the forks enter the load in a straight line (See Figure 4-20).

S

8. Turn the steering wheel to keep the forks straight as you fully insert them into the load and lift, tilt, and side shift as required to stabilize and pickup the load (See Figure 4-21). Only raise the load high enough to clear the rack or the load backrest may catch on the rack.

Note: All movement may be controlled to a greater extent by the use of the inching feature.

9. Tilt the mast back to make sure the load will not slide off the forks (See Figure 4-22).

bendi ic load retrieve 3

Figure 4-20 Positioning the Forks

S

stckngc

Figure 4-22 Tilting the Load bendi ic load retrieve 4

Figure 4-21 Inserting the Forks into the Load

Bendi B40i3 Series Forklift Operator’s Manual 4-21

Operating Your Bendi Forklift 10. Shift into reverse and slowly back away from the stack as you turn the steering wheel to keep the forks straight (See Figure 4-23).

11. You may need to side shift as you back out the load to clear the rack.

12. If you still are unable to get enough clearance, drive forward and try the removal process again.

To get more clearance, don’t start turning the forks until you have backed out 8 in. to 16 in.

13. When the first corner of the load (item 1) Figure 4-24 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 truck (See Figure 4-25).

S

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

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

bendi ic load retrieve 5

Figure 4-23 Retrieving the Pallet

1

S

bendi ic load retrieve 6

Figure 4-24 Retrieving the Load

S

bendi ic load retrieve 7

Figure 4-25 Normal Travel Position

Bendi B40i3 Series Forklift Operator’s Manual 4-22

Operating Your Bendi Forklift In Case Your Forklift Tips Over The following conditions can cause a forklift to tip over: · A load exceeding the stated load centers · Tip Loading (See Figure 4-26) · A load that is too heavy · Taking a corner too fast · Driving with the load raised · A load that is not distributed properly (keep the heavier items near the load backrest) · Driving across a slope

Figure 4-26 2. Hold on to the steering wheel (See Figure 4-28).

· Driving on a slope with the load facing downhill

Warning Failure to follow these guidelines can cause serious injury or death.

If you sense your forklift is going to tip-over, follow these instructions: 1. Lean away from the direction the truck is tipping (See Figure 4-27).

Figure 4-28 3. Brace your feet (See Figure 4-29).

Figure 4-27

Figure 4-29

Bendi B40i3 Series Forklift Operator’s Manual 4-23

Operating Your Bendi Forklift 4. Don’t jump (See Figure 4-30).

Follow these rules when you carry a load to help prevent the truck from tipping: · Slow down. Your forklift can tip over if you turn at a high rate of speed! · Sound the horn as you reach the intersection to warn pedestrians and other equipment operators you are approaching the intersection. · Always follow the rules of the road and yield to other equipment operators and pedestrians as required.

Transporting a Load Figure 4-30

Follow these guidelines when you transport a load: · Do not speed.

Turning

· Use your 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 you know the raised and lowered heights of the mast.

Figure 4-31

Warning

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

A lateral tip-over can occur if your truck is improperly operated (See Figure 4-31). Slow down before turning! Failure to slow down can cause serious injury or death.

Bendi B40i3 Series Forklift Operator’s Manual 4-24

Operating Your Bendi Forklift Traveling on Inclines

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 you travel up or down an incline, follow these guidelines: · Make sure the gradient is 12% or less with a loaded Bendi B40i3 forklift and 15% or less if you are not carrying a load. · Always keep the load pointed uphill (See Figure 4-32). Travel with the forks facing uphill whether you are going up or down an incline. That means you must back down an incline when you are carrying a load. If vision is obscured, arrange for a ‘Banksman’ to guide you.

bendi ic load uphill

Figure 4-32 Traveling Uphill

· If you are not carrying a load, travel with the forks facing uphill when you are going up the incline and face the forks downhill when you are traveling down an incline (See Figure 4-33). · Never travel across a grade. This can cause the truck to tip-over laterally and can cause serious injury or death. · 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 you clear the incline.

Caution Do not roll down inclines with the engine not running. Severe damage to the hydrostatic drive can occur.

bendi ic downhill

Figure 4-33 Traveling Down an Incline

Should the engine stall while traversing an incline, immediately press hard on the brake pedal to stop the truck. Put the direction lever in neutral and restart the engine. Next, shift the direction lever to the desired direction, depress the drive pedal, release the brake pedal, and resume travel.

Bendi B40i3 Series Forklift Operator’s Manual 4-25

Operating Your Bendi Forklift Unloading Your Forklift Note: Actual minimum aisle width may vary based upon application (item 5) (See Figure 4-34).

Note: 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 you must turn the steering wheel.

Follow these steps to store a load:

1

S

4

2

3

1. Approach the side of the aisle that is opposite the area where you will unload the forklift (item 1) (Figure 4-34).

2. For narrow aisles, straighten out the truck so it is 6 in. to 8 in., (item 2) (Figure 4-34), from the edge of the aisle opposite the drop off point. For wide aisles, straighten out the truck so it is 36 in. to 48 in. (item 6) (Figure 4-34), from the side of the aisle where the load is located.

3. Center the load using the side shift lever.

6

bendi ic unload retrieve 1

5

Figure 4-34 Setup - Delivering a Load

4. Drive forward until the center of the load wheels, (item 3) (Figure 4-34), are aligned with the center of the rack opening (item 4) (Figure 4-34).

Warning 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.

S

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 you will drop it off (See Figure 4-35).

Note: When you turn the steering wheel with the truck stopped, do not apply the stop pedal.

bendi ic unload 2

Figure 4-35 Load Drop-off

Bendi B40i3 Series Forklift Operator’s Manual 4-26

Operating Your Bendi Forklift 7. Drive forward and straighten out the load using the steering wheel so it is square over the stack (See Figure 4-36).

8. Turn the steering wheel to keep the load straight as you drive it into the opening (See Figure 4-37).

S

Warning Be careful that the load does not hit the side of the rack as it is inserted. You may have to move the truck forward or backward to help provide clearance for the load to swing into the rack.

Also make sure the load is a few inches above the bottom rail of the rack and that it does not strike any cross members above. bendi ic unload 3

9. Position the load directly over the rack beams and tilt the mast into its vertical position (See Figure 4-38).

Figure 4-36 Straighten the Load for Drop-off

S

stckngb bendi ic unload 4

Figure 4-37 Inserting the Load

Figure 4-38 Leveling the Load

Bendi B40i3 Series Forklift Operator’s Manual 4-27

Operating Your Bendi Forklift

Warning

“NO LOAD” POSITION

When you lower the forks to the “no load” position, make sure you do not lower the forks too far (See Figure 4-39).

If the forks are lowered too far beyond the “no load” position, you can damage the mast, rack, or other containers on the stack. THIS CAN CAUSE SERIOUS INJURY OR DEATH. 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 4-39).

Warning Do not attempt to withdraw the forks until they have been lowered to a “no load” position.

bendi ic no load

Figure 4-39 No-Load Position

FAILURE TO FOLLOW THIS GUIDELINE CAN CAUSE THE LOAD TO FALL OFF THE STACK CAUSING SERIOUS INJURY OR DEATH. S

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

11. Shift into reverse and slowly back out of the load as you turn the steering wheel to keep the forks straight (See Figure 4-40).

bendi ic unload 5

Figure 4-40 Backing Away from the Load

Bendi B40i3 Series Forklift Operator’s Manual 4-28

Operating Your Bendi Forklift 12. When the first fork (item 1) (See Figure 4-41) clears the rack, stop backing and turn the steering wheel to straighten out the forks so they are parallel with the body of the truck.

1

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

S

Fire Extinguisher Option If your truck 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 · it is fully charged · the seal is not broken

bendi ic unload 6

Figure 4-41 Removing the Forks

· the instruction pamphlet is clearly visible

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

Bendi B40i3 Series Forklift Operator’s Manual 4-29

Operating Your Bendi Forklift In Case of a Fire!

Warning Fumes and smoke from any fire may be dangerous and can be deadly.

Professionals should handle all fires.

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

The following directions are for general use only, intended to familiarize you with the key functions and procedure of the fire extinguisher. Always check the extinguisher label for specific techniques and starting distances.

1. Have everyone vacate the area immediately.

2. Hold the extinguisher upright and pull the pin.

3. Stand back from the fire the minimum distance indicated on the extinguisher label.

4. Continue to keep the extinguisher upright, compress the handles together to discharge while sweeping the extinguisher from side to side over the fire.

5. Move closer to the area, as the fire is extinguished, BUT NOT CLOSE SO AS TO DISPERSE BURNING MATERIAL.

Figure 4-42 Setting the Forks

Fork Positioner Option The forks start at the center of the carriage and move equal distance to the outside and back again as indicated by letters C and D (See Figure 4-42).

A push button is added to the pivot and shift joystick control (See Figure 4-43).

Press the button and push the joystick forward to separate the forks to the outside (D).

Press the button and pull the joystick back to bring the forks together (C).

6. When the fire is extinguished, beware of reignition.

7. Vacate and ventilate the area immediately.

8. Be equipped to leave the area in the event the fire cannot be controlled immediately.

Figure 4-43 Sample, Joystick Push Button Option

Bendi B40i3 Series Forklift Operator’s Manual 4-30

SECTION 5 Standard Bendi B40i3 Series Forklift Specifications This section of your Bendi B40i3 Forklift Operator’s Manual includes the standard specifications for the following Bendi forklift trucks: · B40i3

Bendi B40i3 Series Forklift Operator’s Manual 5-1

Standard Bendi Forklift Specifications

Mast Type

Mast Dimensions B Collapsed Height

A Max. Fork Height

C Free Lift Height

D (A + S) Max. Overall Height

In.

Cm.

In.

Cm.

In.

Cm.

In.

Cm.

Triple

188

478

83

211

61

155

224

569

Triple

198

503

87

221

65

165

234

594

Triple

216

549

95

241

73

185

252

640

Triple

224

569

98

249

74

188

260

660

Triple

240

610

106

269

82

208

276

701

Triple

258

655

115

292

91

231

294

746

Triple

276

701

122

310

98

249

312

792

Triple

294

747

128

325

104

264

330

838

Triple

312

792

132

335

108

274

348

883

Quad

250

635

87

221

62

145

2886

726

Quad

258

655

89

226

64

163

3294

746

Quad

276

701

95

241

70

178

312

8792

Quad

294

747

101

257

76

193

330

838

Quad

312

792

107

272

82

208

348

883

Above dimensions are based on 3” mast underclearance.

Truck Dimensions B40/48IC-180D

E

F

G

H

J

K

L

M

N

O

P

Q

R

S

T

U

V

W

X

In.

12

69

28

109

I 10

33

89

49

37

4

31

18o

12o

40

36

75

19

44

110

26

Cm.

30

176

72

277

27

84

226

123

94

10

79

102

91

189

49

112

279

67

Bendi B40i3 Series Forklift Operator’s Manual 5-2

Standard Bendi Forklift Specifications W

T R

L

O

M

J

D A

B

K C

S

V X U

I Q E bendi ic spec dim

P

N F

G

H

Bendi B40i3 Series Forklift Operator’s Manual 5-3

Standard Bendi Forklift Specifications Standard Specifications Model

B40/48IC-180D

Rated Capacity at 24” Load Center

4,000 lb (1,814 kg)

Rated Capacity to 198” w/ Sideshifter

4,000 lb (1,814 kg)

Mast Tilting Angle Forward Reverse

3o 3o

Traveling Speed Forward Reverse

8 mph (13 kph) 8 mph (13 kph)

Total Truck Weight

13,140 lb (5,966 kg)

Front Truck Weight

3,500 lb (1,589 kg)

Rear Truck Weight

9,640 lb (4,377 kg)

Engine GM 2.4L HP Rating Fuel Battery Voltage Traction

4 cyl.

60 hp @ 2,400 rpm LPG 12 volt Hydrostatic

Gradeability

15%

Poly Load Tire (Front)

14 x 5 x 8 in (36 x 13 x 20 cm)

Rubber Cushion Tire (Rear)

18 x 7 x 12 in (46 x 18 x 30 cm)

Fork Size (Standard) ITA Class II Carriage

1-1/2 x 4 x 40 in 3.8 x 10 x 1000

Lifting Speed Empty Loaded

90 ft/min (27 m/min) 70 ft/min (21 m/min)

Lowering Speed Empty Loaded

60 ft/min (18 m/min) 90 ft/min (27 m/min)

Bendi B40i3 Series Forklift Operator’s Manual 5-4

Appendix A This section of your Bendi B40i3 Forklift Operator’s Manual includes the following checklists and maintenance schedules: · Operator’s Daily Checklist · Installation Checklist · Customer Bendi B40i3 Truck Installation Report · Routine Maintenance Schedule for Bendi B40i3 Forklifts These checklists and schedules should be used to help maintain the truck and keep it in the best working order. For more information on using these checklists and schedules, see the Bendi B40i3 Service Manual.

Bendi IC/HT Series Forklift Operator’s Manual A-1

Appendix A BENDI B40i3 Operator’s Daily Checklist Daily pre-shift inspection is an OSHA requirement. It is important that these inspections are documented.

Date _____________________ Truck No. _________________ Location __________________ Shift _____________________

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

SAFETY & OPERATIONAL CHECKS Have a qualified mechanic correct all problems.

Record Fluids Added: Coolant ____________________ Hydraulic Oil ________________ Engine Oil __________________

O.K. (X)

Need Maintenance

Fuel Odor - If present, do not start truck! Report immediately!

Forks, Top Clip Retaining Pin and Heel - Condition Load Backrest Extension - Attached Lift and Lowering Control - Functioning smoothly Tilt Control - Forward and Back - Functioning smoothly Sideshift Control - Functioning smoothly Hang-on Attachment- Functioning smoothly, securely attached, fittings attached Steering Operation - Functioning smoothly Accelerator and Stop Pedal - Functioning smoothly Controls (Turn Power On); Investigate unusual noises immediately Dash Display - Functioning properly Horn, Lights, Seat Switch - Functioning properly Parking Brake - Holds truck in stopped position Drive Control - Forward/Reverse - Functioning smoothly Engine Air Cleaner - Squeeze rubber dirt trap; Clean and check Engine Belt - Check for wear Battery Hood and Seat Latch - Function properly Operator’s Compartment Capacity Plate Attached - Info. matches Model, Serial No., and Attachments; Operator’s Manual in Case Seat Belt, Buckle, and Retractors - Functioning smoothly Overhead Guard - Properly mounted and attached Radiator - Check Level in Overflow Tank LPG Hoses - Check for damage, kinks and correct fitting LPG Tank - Securely attached; free of rust, corrosion, and damage Overall machine - Keep clean and tidy appearance Engine Oil, Hydraulic Fluid - Check levels Tires - Check for debris; Drive Tire Lug Nuts - Torque to 205 ft.lbs.

(275 Nm) Major Structural Points (Front Rotation, Mast Braces, Overhead Guard) - Check for cracks Hydr. Cylinders, Pump, Valve - Check for leaks, noise, proper function Safety Warnings - Attached (Refer to Operator’s Manual for Location)

Bendi B40i3 Series Forklift Operator’s Manual A-2

Appendix A BENDI B40i3 Installation Checklist QUALITY CONTROL SHEET

Date _____________________ Truck No. _________________ Location __________________ Shift _____________________

Remit Copy to Landoll Corporation

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

SAFETY & OPERATIONAL CHECKS Have a qualified mechanic correct all problems.

Record Fluids Added: Coolant ____________________ Hydraulic Oil ________________ Engine Oil __________________

O.K. (X)

Need Maintenance

Forks, Top Clip Retaining Pin and Heel - Condition Load Backrest Extension - Attached Tilt Control - Forward and Back - Functioning Smoothly Hoist and Lowering Control - Functioning Smoothly Attachment Control - Operational Hydraulic Hoses, Mast Chains and Stops - Check Visually (Note Bracket Location) Steering Operation - Functioning Smoothly Accelerator - Functioning Smoothly Parking Brake - Holds truck in stopped position Dash Display - Functioning properly Lights - Functioning Drive Control - Forward/Reverse - Functioning Smoothly Hydraulic Fluid Level Engine Oil Level Operator’s Compartment Capacity Plate Attached - Information Matches Model, Serial No., and Attachments Seat Belt, Buckle, and Retractors - Functioning Smoothly Horn - Functioning Radiator Coolant Level Controls (Turn Power On); Investigate Unusual Noises Immediately Safety Warnings - Attached (Refer to Operator’s Manual for Location) Overhead Guard - Attached Tires - Check for Debris; Drive Tire Lug Nuts - Torque to 205 ft. lbs.

(275 Nm) Leaks - Hydraulic Oil, Battery, Brake Fluid

Bendi B40i3 Series Forklift Operator’s Manual A-3

Appendix A LANDOLL CORPORATION 1900 North Street · Marysville, KS 66508 Phone: (785)562-5381· Fax: (785)562-4853

Customer Bendi B40i3 Truck Installation Report CUSTOMER ______________________________ ADDRESS _______________________________ INSTALLATION DATE ______________________ 24 MONTH WARRANTY END DATE __________ 36 MONTH WARRANTY END DATE __________

TRUCK SERIAL NO.________________________ CITY, STATE, ZIP __________________________ Before any warranty claim can be honored for new equipment being installed, this form must be filled out completely and properly signed by the dealer/branch representative and responsible customer official. Installation report must be submitted within five days after delivery. The installation date will initiate the warranty.

NOTE: CUSTOMER MUST FILE CLAIM WITH CARRIER FOR ANY DAMAGES RECEIVED DURING TRANSIT. List damages: CHECK OPERATION AND ADJUST WHERE NECESSARY

1.

Upright and Fork Carriage a.

Forks or Parts . . . . . . . . . . . . . . . . . . . . . . . c b.

Chain Adjustment of Lift Tie Bar Assembly . . . . . . . . c

2.

Load Backrest . . . . . . . . . . . . . . . . . . . . . . . . . . c

3.

Door Adjustment . . . . . . . . . . . . . . . . . . . . . . . . c

4.

Tires: a.

Drive Tires. . . . . . . . . . . . . . . . . . . . . . . . . c b.

Steer Tires . . . . . . . . . . . . . . . . . . . . . . . . c

5.

Wheel Bolts: Torque to 205 ft.-lbs. (275 Nm) . . . . . . . . . . c

6.

Seat Adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . c

7.

Brakes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . c

8.

Horn and Lights: (Head-Spot-Tail). . . . . . . . . . . . . . . . . . . . . . . . . c

9.

Drive Controls: a.

Direction Master Switch (Forward, Reverse, and Neutral). c b.

Accelerator Pedal . . . . . . . . . . . . . . . . . . . . . c

10. Steering: a.

Power Steer Operation . . . . . . . . . . . . . . . . . . c b.

Steering Stops . . . . . . . . . . . . . . . . . . . . . . c 11. Hour Meter Reading . . . . . . . . . . . . . . . . . . . . . . . c 12. Hydraulic Controls a.

Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . c b.

Tilt (Angle and Alignment) . . . . . . . . . . . . . . . . . c c.

Attachment . . . . . . . . . . . . . . . . . . . . . . . . c

13. Electrical Controls: . . . . . . . . . . . . . . . . . . . . . . . c a.

Inching Pedal . . . . . . . . . . . . . . . . . . . . . . . c b.

Switches (Brake-Seat-Steer Position) . . . . . . . . . . . c c.

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . c d.

Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . c e.

Warning Lights . . . . . . . . . . . . . . . . . . . . . . c 14. Hydraulic System - Oil Leaks: a.

Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . b.

Control Valve . . . . . . . . . . . . . . . . . . . . . . . c.

Hydrostatic Motors . . . . . . . . . . . . . . . . . . . . d.

Hydrostatic Pumps . . . . . . . . . . . . . . . . . . . . e.

Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . f.

Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . g.

Attachment Cylinders . . . . . . . . . . . . . . . . . . . h.

Hydraulic Lines and Fittings . . . . . . . . . . . . . . . .

15. Test Run Was truck operator instructed? . . . . . . . . . . . Yes c Was truck manual delivered?. . . . . . . . . . . . Yes c Was maintenance department instructed? . . . . . Yes c Was truck already in service? . . . . . . . . . . . Yes c Were caution/warning plates reviewed with operator? . . . . . . . . . . . . . . . . . . . Yes c

c c c c c c c c

No c No c No c No c No c

16. Fluid and Lube: a.

Hydraulic Oil; Check Dipstick . . . . . . . . . . . . . . . b.

Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . c.

Radiator Fluid . . . . . . . . . . . . . . . . . . . . . . . d.

Lube Points . . . . . . . . . . . . . . . . . . . . . . . .

c c c c

COMMENTS TRUCKS SHOULD BE GIVEN GENERAL INSPECTION - PARTICULARLY APPEARANCE - BOLTS, COTTER PINS, ETC. DISTRIBUTION Original - Landoll Corporation Part 2 - Dealer Copy Part 3 - Customer Copy

I hereby certify that this machine has been thoroughly checked and found to be in good mechanical and operating condition.

SERVICEMAN_____________________

DATE______________

DEALER/BRANCH_________________________________________ ADDRESS_______________________________________________ ACCEPTANCE BY COMPANY OFFICAL

LAN-0054 REV-000 May 2003

CUSTOMER_____________________

DATE______________

SIGNATURE_____________________

TITLE______________

Bendi B40i3 Series Forklift Operator’s Manual A-4

Appendix A ROUTINE MAINTENANCE SCHEDULE FOR BENDI B40i3 FORKLIFTS

Operation

*Time

First 2 wks

First month

Hours

50100

1st 200

Monthly Quarterly 200

600

SemiAnnually Annually 1000

2000

FOR ENGINE ROUTINE MAINENANCE SCHEDULE, SEE ENGINE OPERATOR'S MANUAL Forks, Top Clip Retaining Pin and Heel - Condition Load Rollers - No Greater than 1/16” Mast - Inspect all friction surfaces and check lift chain tension Mast chains - Inspect, Clean, and Lubricate Mast, Carriage, or Attachment Friction Surfaces Clean, inspect for wear or damage, and lubricate Lift and Tilt Cylinder Fittings - Check; Be sure they work together and in unison Lift Chains - Clean and lubricate Extend Mast - Check for Excessive Wear Attachment Control - Operational Mast Chains - Lube with SAE 40W oil or Bowman Heavy Load Red Grease - Check for Wear and Stretch Drive Wheels - Retorque lug nuts Wheel Bearings - Clean and fill with grease Vacuum Hoses - Check for cracks and leaks Power Steering System - Fill and Air Bleed Power Steering Pump - Check Operation Steering Operation - Functioning Smoothly; Lubricate Steering Knob Power Steering System - Fill and Air Bleed Accelerator - Functioning Smoothly Controls (Turn Power On); Investigate Unusual Noises Immediately Instrument Monitors - Functioning Stop Pedal - Functioning Parking and Service Brakes - Check for effectiveness Parking and Service Brakes - Functioning Smoothly, Check Pads for Excessive Wear Hydraulic Oil Pump - Check Operation Air Cleaner Element - Clean Air Cleaner Element - Replace Vacuum Hoses - Check for cracks and leaks Hydraulic Fluid Level - Check and Fill Hydraulic Oil Filter - Change element and check for Proper Level - Check Pressures Exterior of Hydraulic Tank and Oil Tank Breather Clean Hydraulic Oil - Change

X X X X X X X X X X

X X X X X X X X X X X X X X X X X X X X X

Bendi B40i3 Series Forklift Operator’s Manual A-5

Appendix A ROUTINE MAINTENANCE SCHEDULE FOR BENDI B40i3 FORKLIFTS

Operation

*Time

First 2 wks

First month

Hours

50100

1st 200

Hydraulic Reservoir Suction Screens - Clean with Solvent Operator’s Compartment Capacity Plate Attached Information Matches Model, Serial No., and Attachments Engine Oil and Filter - Change Engine Compartment - Clean Engine Oil and Filter - Replace Alternator and Starter - Clean with compressed air; Check brushes and springs, check power terminals Battery - Thoroughly Clean Muffler and Exhaust System - Check for leaks LPG System - Check pressure hoses and fitting seals LPG Filter - Change Seat Belt, Buckle, and Retractors - Functioning Smoothly Radiator - Use air to clean fins; correct cap and tighten; check hoses and clamps Radiator - Clean Cooling Holes and Oil Cooler of Debris or Restrictions Tires - Check for Debris; Drive Tire Lug Nuts Torque to 205 ft. lbs. (275 Nm) Leaks - Hydraulic Oil, Battery, Brake Fluid, Complete Transmission Hydraulic Hoses and Connections - Check for Wear Switches (interlock, direction, parking/seat, key, pressure, and temperature) - Check Operation Wire connections and sending units - Check Grease Fittings - Service Check All Connections for Proper Torque

Monthly Quarterly 200

SemiAnnually Annually

600

1000

X X

X X X X X X X X

X X X X X X

X X

X X X X

X

X

Note: The above measures do not comprise a complete service schedule.

It is essential that your forklift truck is regularly serviced by Bendi approved personnel. Recommended service intervals are as follows: Single shift*

Every quarter

Single to double shift

Every other month

Continuous use

Monthly

* Single shift is 40 hrs./ week * Perform maintenance at interval or hours of operation, which ever occurs first.

Bendi B40i3 Series Forklift Operator’s Manual A-6

2000

Appendix B This section of your Bendi B40i3 Forklift Operator’s Manual includes the following lubrication and torque specification charts: · Bendi Lubrication Points · Bendi Lubrication Chart · Bendi Torque Chart · Landoll Corporation General Torque Specifications · Landoll Corporation Hydraulic Fitting Torque Specifications

Bendi IC/HT Series Forklift Operator’s Manual B-1

Appendix B

7

1

2

3

6

4

8

5 10

9 bendi ic lube

Name 1

Chain

2

Upright Rail

3 4 5 6 7

Rotation Bearings Steering Knob Engine Steering Gears Hydraulic Reservoir

8 9 10

Tilt Cylinders Articulating Axle Bearings Load Wheel Axle

Lubrication SAE 40W oil or Bowman Heavy Load Red Grease Chassis Lube or Kendall SR-12X Texaco Ref. C & C #880 Light weight oil SAE 30W oil Texaco Ref. C & C #880 Transdraulic Fluid Mobil 424 (ISO Grade 68) Texaco Ref. C & C #880 Texaco Ref. C & C #880 Texaco Ref. C & C #880

Notes Clean and reoil Lubricate inner sides of upright rails Use standard lubrication gun Lightly oil Drain, flush, and refill Brush or spray on lubricant Drain, flush, and refill Use standard lubrication gun Use standard lubrication gun Use lubrication gun and adapter for flush type fittings

Bendi B40i3 Series Forklift Operator’s Manual B-2

Appendix B Component

Torque Transmission

Wheel

205 ft. lbs. (275 Nm.)

Fluid draining and filling plug

16 ft. lbs. (22 Nm.)

Hydraulic braking unit and brake cable

37 ft. lbs. (50 Nm.)

Drive motor with vehicle frame

130 ft. lbs. (176 Nm.) Hydraulic Power Steering Motor

Bolt 5/16-24 UNF 2A

22-26 ft. lbs. (30-35 Nm.)

Bolt 3/8-24UNF 2A

45-55 ft. lbs. (61-75 Nm.)

Bolt 5/8-18 UNF 2A

140-180 ft. lbs. (190-244 Nm.)

Nut 3/4-16 UNF 2B

175-255 ft. lbs. (237-346 Nm.)

Nut 1-20 UNEF 2B

300-400 ft. lbs. (407-542 Nm.)

Nut 1-1/8-18 UNEF 2B

300-400 ft. lbs. (407-542 Nm.) Hydrostatic Steering Control Unit

Plug and o-ring assy #8 SAE fitting

44-48 ft. lbs. (60-65 Nm.)

Steering control unit assy bolt (M8 X1.0)

18-23 ft. lbs. (24-31 Nm.)

Mounting bolts

23-25 ft. lbs. (31-34 Nm.) Mast and Sideshifter

Chain guard capscrews

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

Main lift cyl. plunger retainer

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

Free lift cyl. plunger retainer

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

Carriage roller capscrews

70-80 ft. lbs. (95-108 Nm.)

Chain and hose sheave screws

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

Lift chain adjusting nuts

50-70 ft. lbs. (68-90 Nm.)

Backrest screws

145 ft. lbs. (197 Nm.)

Side shift mounting hooks

115-125 ft. lbs. (156-170 Nm.)

Fluid Capacities Item

Capacity quarts (liters)

Hydraulic Tank

10 gallons (40 liters)

Fuel Tank

11.5 gallons (43.5 liters)

Engine Oil (GM 2.4L)

4.5 quarts (4.3 liters)

Cooling System (50% Water/50% Dexcool)

2.9 gallons (11.0 liters)

Bendi B40i3 Series Forklift Operator’s Manual B-3

Appendix B LANDOLL CORPORATION GENERAL TORQUE SPECIFICATIONS (REV. 4/97) THIS CHART PROVIDES TIGHTENING TORQUES FOR GENERAL PURPOSE APPLICATIONS WHEN SPECIAL TORQUES ARE NOT SPECIFIED ON PROCESS OR DRAWING. ASSEMBLY TORQUES APPLY TO PLATED NUTS AND CAPSCREWS ASSEMBLED WITHOUT SUPPLEMENTAL LUBRICATION (AS RECEIVED CONDITION). THEY DO NOT APPLY IF SPECIAL GRAPHITE MOLY-DISULFIDE OR OTHER EXTREME PRESSURE LUBRICANTS ARE USED. WHEN FASTENERS ARE DRY (SOLVENT CLEANED), ADD 33% TO AS RECEIVED CONDITION TORQUE. BOLT HEAD IDENTIFICATION MARKS INDICATE GRADE AND MAY VARY FROM MANUFACTURER TO MANUFACTURER. THICK NUTS MUST BE USED ON GRADE 8 CAPSCREWS. USE VALUE IN [

] IF USING PREVAILING TORQUE NUTS.

TORQUE IS SPECIFIED IN FOOT POUNDS UNC Size 1/4-20

SAE Grade SAE Grade SAE Grade 2 5 8 4 [5] 6 [7] 9 [11]

5/16-18

8

[10]

13

[16]

18

[22]

3/8-16

15

[19]

23

[29]

35

[43]

7/16-14

24

[30]

35

[43]

55

[62]

1/2-13

35

[43]

55

[62]

80

[100]

9/16-12

55

[62]

80

[100]

110

[137]

5/8-11

75

[94]

110

[137]

170

3/4-10

130

[162]

200

[250]

7/8-9

125

[156]

320

1-8

190

[237]

408

1-1/8-7

270

[337]

1-1/4-7

380

1-3/8-6 1/1-2-6

UNF Size 1/4-28

SAE Grade SAE Grade SAE Grade 2 5 8 5 [6] 7 [9] 10 [12]

5/16-24 9 3/8-24 17

[11]

14

[17]

20

[25]

[21]

25

[31]

35

[44]

7/16-20 27 1/2-20 40

[34]

40

[50]

60

[75]

[50]

65

[81]

90

[112]

[75]

90

[112]

130

[162]

[212]

9/16-18 60 5/8-18 85

[106]

130

[162]

180

[225]

280

[350]

3/4-16

150

[188]

220

[275]

320

[400]

[400]

460

[575]

7/8-14

140

[175]

360

[450]

500

[625]

[506]

680

[850]

1-14

210

[263]

540

[675]

760

[950]

600

[750]

960

[375]

660

[825]

1080

[1350]

[475]

840

[1050] 1426

[1200] 1-1/8-12 300 [1782] 1-1/4-12 420

[525]

920

[1150] 1500

[1875]

490

[612]

110

[1375] 1780

[700]

1260

[1575] 2010

[2512]

650

[812]

1460

[1825] 2360

[2225] 1-3/8-12 560 [2950] 1/1-2-12 730

[912]

1640

[2050] 2660

[3325]

METRIC COARSE THREAD METRIC CLASS 10.9 FASTENERS AND CLASS 10.0 NUTS AND THROUGH HARDENED FLAT WASHERS, PHOSPHATE COATED, ROCKWELL “C” 38-45.

USE VALUE IN [

Nominal Thread Diameter mm 6 7 8 10 12 14 16 18

] IF USING PREVAILING TORQUE NUTS.

Standard Torque NewtonFootMeters Pounds 10 16 23 46 80 125 200 275

[14] [22] [32] [60] [101] [155] [240] [330]

7 12 17 34 60 90 150 205

[10] [16] [24] [47] [75] [115] [180] [245]

Nominal Thread Diameter mm 20 24 27 30 33 36 39

Standard Torque NewtonFootMeters Pounds 385 670 980 1330 1790 2325 3010

[450] [775] [1105] [1470] [1950] [2515] [3210]

Bendi B40i3 Series Forklift Operator’s Manual B-4

290 500 730 990 1340 1730 2240

[335] [625] [825] [1090] [1450] [1870] [2380]

Appendix B LANDOLL CORPORATION HYDRAULIC FITTING TORQUE SPECIFICATIONS 37o JIC, ORS, & ORB (REV. 07/2008) THIS CHART PROVIDES TIGHTENING TORQUES FOR HYDRAULIC FITTING APPLICATIONS WHEN SPECIAL TORQUES ARE NOT SPECIFIED ON PROCESS OR DRAWING. ASSEMBLY TORQUES APPLY TO PLATED CARBON STEEL AND STAINLESS STEEL FITTINGS ASSEMBLED WITHOUT SUPPLEMENTAL LUBRICATION (AS RECEIVED CONDITION). THEY DO NOT APPLY IF SPECIAL GRAPHITE MOLY-DISULFIDE OR OTHER EXTREME PRESSURE LUBRICANTS ARE USED. BRASS FITTINGS AND ADAPTERS - 65% OF THE TORQUE VALUE FOR STEEL. STAINLESS STEEL, ALUMINUM AND MONEL - THREADS ARE TO BE LUBRICATED. TORQUE IS SPECIFIED IN FOOT POUNDS AEROQUIP BRAND FITTINGS Dash Size 37 Degree JIC O-Ring (ORS) -4 11-12 10-12 -5 15-16 — -6 18-20 18-20 -8 38-42 32-35 -10 57-62 46-50 -12 79-87 65-70 -14 — — -16 108-113 92-100 -20 127-133 125-140 -24 158-167 150-165 -32 245-258 — GATES BRAND FITTINGS Dash Size 37 Degree JIC O-Ring (ORS) -4 10-11 10-12 -5 13-15 — -6 17-19 18-20 -8 34-38 32-40 -10 50-56 46-56 -12 70-78 65-80 -14 — 65-80 -16 94-104 92-105 -20 124-138 125-140 -24 156-173 150-180 -32 219-243 — PARKER BRAND FITTINGS Dash Size 37 Degree JIC O-Ring (ORS) -4 11-13 15-17 -5 14-16 — -6 20-22 34-36 -8 43-47 58-62 -10 55-65 100-110 -12 80-90 134-146 -16 115-125 202-218 -20 160-180 248-272 -24 185-215 303-327 -32 250-290 —

O-Ring Boss (ORB) 14-16 18-20 24-26 50-60 72-80 125-135 160-180 200-220 210-280 270-360 — O-Ring Boss (ORB) 14-16 — 24-26 37-44 50-60 75-83 — 111-125 133-152 156-184 — O-Ring Boss (ORB) 13-15 21-23 25-29 40-44 57.5-62.5 75-85 109-121 213-237 238-262 310-340

Bendi B40i3 Series Forklift Operator’s Manual B-5

Appendix B

Bendi B40i3 Series Forklift Operator’s Manual B-6

Document Control Revision Log: Date

Revision

Improvement(s) Description and Comments

08/01/08

F-500-0808

Initial Release

nn/nn/nn

F-

nn/nn/nn

F-

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

Model B40i3 Operator’s Manual

Re-Order Part Number F-500-0808

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

Copyright 2011. Landoll Corporation "All rights reserved, including the right to reproduce this material or portions thereof in any form"

F-500-0808

08/01/2008