"Operator's Manual for Landoll Bendi 3 AC Series Electric Narrow Aisle Forklift"

ELECTRIC NARROW AISLE FORKLIFT

OPERATOR S MANUAL BENDI SERIES III MODELS B25/42E-180D B30/42E-180D B35/42E-180D

B35/48E-180D B40/48E-180D B45/48E-180D

LANDOLL CORPORATION MATERIAL HANDLING PRODUCTS

Bendi Op Manual Cover.p65

1

1900 North Street Marysville, Kansas 66508

Publication No. F-300-1099 Rev. 10/99 Printing: October 1999 (01)

10/08/1999, 10:12 AM

BENDI SERIES III NARROW AISLE ELECTRIC FORKLIFT OPERATOR S MANUAL

Reorder Part Number

110825

SERIES III MODELS B25/42E-180D / B30/42E-180D / B35/42E-180D B35/48E-180D / B40/48E-180D / B45/48E-180D LANDOLL CORPORATION - MATERIAL HANDLING PRODUCTS Marysville, Kansas 66508

Telephone (785) 562-5381

Bendi Op Manual Cover.p65

2

*110825*

Publication No. F-300-1099 Rev. 10/99 Printing: October 1999 (01)

10/08/1999, 10:12 AM

TRAINING KIT AND OPERATOR S MANUAL RE-ORDER FORM

MARYSVILLE, KANSAS

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)

-

Bill Parts Account

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Part Number

Bendi Safety and Operator Training Course

107218

$595.00

Bendi Refill Kit — Student(s)

107218RF

$ 95.00

Bendi Operator’s Manual Series II

107219

$ 15.00

Bendi Operator’s Manual Series III

110825

$ 15.00

PivotMast Safety and Operator Training Course

107220

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Send Requests to: LANDOLL CORPORATION Material Handling Product Group 1900 North Street Marysville, KS 66508-9902 Phone: (785) 562-5381 Fax: (785) 562-4853 9/99

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Table of Contents Page Safety ........................................................................................ S-1 The Meaning of Safety Statements ....................................S-2 Bendi Forklift Safety Statements ........................................S-2 Introduction .............................................................................. 1-1 Vehicle Description ............................................................ 1-2 Terminology Used in Manual .............................................. 1-2 Illustrations Used in Manual ............................................... 1-2 Questions and Comments ................................................. 1-2 Component Identification ................................................... 1-3 Identification Plate .............................................................. 1-4 Serial Number Nomenclature ............................................. 1-5 Before You Begin ..................................................................... 2-1 Operator Training ............................................................... 2-2 Operator Safety .................................................................. 2-2 Understanding Stability ...................................................... 2-2 Knowing the Rated Capacity .............................................. 2-4 Understanding Workplace Conditions ................................ 2-8 Working in Hazardous Environments ................................. 2-9 Operating Your Bendi Forklift ................................................. 3-1 Operator’s Daily Checklist .................................................. 3-2 Controls and Indicators ...................................................... 3-2 Operating Instructions – Basic Procedures ........................ 3-5 Operating Instructions – Handling a Load .......................... 3-9 Unloading Your Forklift ..................................................... 3-17 Using Lifting Equipment to Move a Forklift to Another Location ......................................... 3-20

Bendi Series III Forklift Operator’s Manual i

Table of Contents Page Inspection and Maintenance ................................................... 4-1 Inspection and Maintenance .............................................. 4-3 Inspection and Maintenance Responsibilities .................... 4-3 Inspection and Maintenance Practices .............................. 4-4 Inspecting Specially Equipped Bendi Forklift Trucks ......... 4-7 Identification Plate and Safety Warnings ........................... 4-7 Inspecting Forks ................................................................. 4-7 Repairing and Load Testing Forks ..................................... 4-9 Battery Maintenance .......................................................... 4-9 Hydraulic System Maintenance ....................................... 4-12 Transmission Fluid Change ............................................. 4-12 Power Steering System Maintenance .............................. 4-13 Mast Maintenance ............................................................ 4-14 Side Shift Circuit Maintenance ......................................... 4-16 Troubleshooting Your Bendi Forklift ...................................... 5-1 Standard Bendi Forklift Specifications .................................. 6-1 Appendix A................................................................................ A-1 Operator’s Daily Checklist ..................................................A-2 200 Hour Inspection Checklist ........................................... A-3 600 Hour Inspection Checklist ........................................... A-4 Installation Checklist ..........................................................A-5 Customer Electric Truck Installation Report .......................A-6 Routine Maintenance Schedule for Bendi Forklifts ............ A-7 Appendix B ............................................................................... B-1 Bendi Lubrication Points .................................................... B-2 Bendi Lubrication Chart ..................................................... B-2 Bendi Torque Chart ............................................................ B-3 Landoll Corporation General Torque Specifications ........... B-4 Landoll Corporation Hydraulic Fitting Torque Specifications ............................................................... B-5

Bendi Series III Forklift Operator’s Manual ii

Safety Landoll Corporation has made every effort to provide you with the safest forklift trucks on the market but wishes to indicate the proper procedures for safely operating and maintaining your lift truck.

After you review this section you will understand the meaning of the following safety symbols and safety statements:

•

Safety Alert Symbol

•

Danger

•

Warning

•

Caution

•

Note

Bendi Series III Forklift Operator’s Manual S-1

Table of Contents Safety The Meaning of 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 Alert Symbol means ATTENTION! BECOME ALERT! 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.

! 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 Forklift Safety Statements The safety statements contained in this manual relate to the operation and maintenance of Bendi forklift trucks.

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 forklift is illustrated 1 on the next page and a representation of each machine sign 2 is on the following page.

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

Bendi Series III Forklift Operator’s Manual S-2

Safety Table of Contents 17 9 29

(9 and 17 are located on inside face of control console)

25

16 4

5 11

28

2 12

27 26 23

24

8

6 22

6

1

3

7

22

27

1

12 8

18 11

BENDI 300

Bendi Series III Forklift Operator’s Manual S-3

Safety 1

2

3

5

4

6

CAUTION THIS TRUCK IS EQUIPPED WITH A ROLL/SLIDE OUT BATTERY TRAY. USE CAUTION WHEN OPENING DOOR OR REMOVING STOP 102159

7

9

8

11

PRESS BUTTON TO OVERRIDE BRAKE SWITCH DURING RAMP START

16

110816

18

12

17

HYDRAULIC OIL ONLY

24

110815

25

22

23

111009

OFF 110817

28

ON/ ACC

27 ON/ RUN

29

26

2

Bendi Series III Forklift Operator’s Manual S-4

BENDI 303

SECTION 1

Introduction Your Bendi Forklift Operator’s Manual contains basic instructions for operation and maintenance of Landoll Bendi 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 rules issued by OSHA, 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 is 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 Series III Forklift Operator’s Manual 1-1

Introduction Vehicle Description

The brake pedal (item 2) [1], is located on the floor to the left of the accelerator pedal.

The Bendi 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 battery unit. To maintain a safe counterbalance limit, a ballast weight is mounted to the rear of the truck chassis.

1

Landoll Bendi forklifts are available in capacities from 2500 to 4500 lbs. The front end can be pivoted 180 degrees. This permits the vehicle to act as a conventional as well as a narrow aisle forklift.

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. The forks are the front of the vehicle.

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

You will note that each illustration has an identifying numeral 1 on the lower left-hand corner and each item in the illustration that is referenced to the text is identified with a number 1 .

2

1

Questions and Comments If you have any questions or comments about this manual, or any procedure or description within it, please contact:

Landoll Corporation 1900 North Street Marysville, Kansas 66508 (785) 562-5381 (800) 428-5655 FAX: (785) 562-4853 www.landoll.com

In the text, illustration references appear in bold brackets [1], and the item numbers are in parenthesis (item 1). Let’s look at an example: The accelerator pedal (item 1) [1], is located on the floor to the right of the brake pedal.

Bendi Series III Forklift Operator’s Manual 1-2

BENDI 319

Introduction Component Identification

Mast Serial Number (item 7) [3]

The following illustrations will help you locate components on your Bendi forklift.

Forks (item 1) [2] Load Backrest (item 2) [2] Mast (item 3) [2] Load Wheels (item 4) [2] Drive Wheels (item 5) [2] Overhead Guard (item 6) [2]

7

6

3 3

BENDI 304

2

1 5 2

4

BENDI 314

Bendi Series III Forklift Operator’s Manual 1-3

Introduction Identification Plate The identification plate (item 1) [4] and specification data plate (item 2) [4] lists the rated capacity, serial number, and other vehicle characteristics.

These illustrations show where this information may appear on your Bendi Series III forklift. The identification plate may be in either or both of the locations shown.

1

1

!

AR W

NI

NG

MODEL:

!

G IN RN WA

!

G IN N R A W

SERIAL NO.: MAST NO.:

TRUCK TYPE:

S TA N D A R D L O A D C T R .

C A PA C I T Y A = 2 4 I N .

R AT I N G S B = 2 4 I N .

WEIGHT "C"

AUXILIARY LOAD CTR. C A PA C I T Y A = R AT I N G S B =

WEIGHT "C"

A

HEIGHT "D" B

C D

HEIGHT "D"

LANDOLL CORPORATION MARYSVILLE, KANSAS USA UNLADEN TRUCK WEIGHT W I T H O U T B AT T E R Y ( L B S . ) :

2

UNLADEN TRUCK WEIGHT W I T H M A X . B AT T E R Y ( L B S . ) : M I N . S E R V I C E W E I G H T O F B AT. :

2600 LBS.

M A X . S E R V I C E W E I G H T O F B AT. :

2900 LBS.

B AT T E R Y T Y P E : N O M I N A L T R U C K V O LTA G E :

48

COMPLIES WITH ANSI B56.I

4

Bendi Series III Forklift Operator’s Manual 1-4

BENDI 322

Introduction Serial Number Nomenclature The serial number for the Bendi forklift (item 1) [5] and mast (item 2) [5] is located on the identification plate. The following information will help decode the Bendi serial number:

Bendi Serial Number Baa/ww-ymms-xxxxx Where: aa = 25 for 2,500 lb rated capacity truck = 30 for 3,000 lb rated capacity truck = 35 for 3,500 lb rated capacity truck = 40 for 4,000 lb rated capacity truck = 45 for 4,500 lb rated capacity truck ww = 42 for 42” frame width = 48 for 48” frame width y = last digit of year of manufacture (eg., “9” means 1999, “0” means 2000) mm = month of manufacture s = component series; such as “A” xxxxx = frame number

! Caution The frame number is also located on the left side of the frame (item 1) [6]. 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.

6

1 BENDI 305

! Caution The mast serial number is also located on the left side of the mast (item 7) [3]. 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.

1 2 1

MODEL:

SERIAL NO.: MAST NO.:

2

TRUCK TYPE:

S TA N D A R D L O A D C T R .

C A PA C I T Y A = 2 4 I N .

R AT I N G S B = 2 4 I N .

AUXILIARY LOAD CTR. C A PA C I T Y A = R AT I N G S B =

WEIGHT "C"

A

HEIGHT "D" B

WEIGHT "C"

HEIGHT "D"

C D

BENDI 323

5

Bendi Series III Forklift Operator’s Manual 1-5

Introduction

Bendi Series III Forklift Operator’s Manual 1-6

SECTION 2

Before You Begin This section of your Bendi Forklift Operator’s Manual discusses the following concepts that must be thoroughly understood before you can operate a Bendi forklift: Operator Training – Discusses the operator training required

by OSHA and its implications for operators of Bendi 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 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.

Working in Hazardous Environments – You will learn about the hazards of working in explosive and flammable atmospheres and how to handle chemical hazards in this discussion.

Bendi Forklift Operator’s Manual 2-1

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 Occupational Safety and Health Administration (OSHA) 29 CFR Parts 1910, 1915, 1917, 1918, and 1926. 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 as specified by OSHA. Operating a powered industrial truck without the proper training can cause serious injury or death.

According to rules issued by OSHA, 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.

The training provided by your employer will consist of: •

• • •

Formal instruction (lecture, discussion, interactive computer learning, video tape or written material) that covers topics relating to the forklift and your workplace Demonstrations provided by an instructor Hands-on training to allow you to get some practice Evaluation of your performance in your workplace

Operator Safety Before you start using your Bendi 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.

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 forklift in a safe and efficient manner.

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.

Bendi Forklift Operator’s Manual 2-2

Before You Begin Although the Bendi forklift meets or exceeds safety guidelines established by ASME/ANSI B56.1 and EEC 89/240, accidents can still happen. According to the Occupational Safety and Health Administration (OSHA), forklift type of vehicles cause over 38,000 serious injuries and 107 fatalities annually. This is second only to vehicular highway accidents.

Studies have shown that the leading cause of these accidents is 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 are likely to tip your Bendi forklift truck which can cause serious injury or death.

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 [1] or left [2], the truck is in its least stable position. Since the large majority of accidents occur with the truck in this position, let’s examine what creates this instability.

1

4 3

Unlike an automobile which has four points of suspension, Bendi 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) [1] and (item 2) [1]. The third suspension point is the center point of the front axle (item 3) [1]. The center of gravity, an imaginary point at which all of the truck’s weight is concentrated, is located as shown (item 4) [1] when: • • •

In this position, the fulcrum, or axis around which the truck will tip, is between suspension point (item 2) [1] and (item 3) [1].

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) [1] is drawn between the three suspension points (item 1) [1], (item 2) [1], and (item 3) [1]. 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 6) [1] 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: • • •

5 2

6

• •

1

The forks are turned nearly 90° to the right No load is placed on the forks The truck is at rest.

The load exceeds the rated capacity listed on the identification plate The load exceeds the load center dimensions listed on the identification 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

BENDI 152

Bendi Forklift Operator’s Manual 2-3

Before You Begin •

The load is not distributed properly (always keep the heavier items near the load backrest) You drive across a grade You drive on a grade with the load facing downhill You use a battery that weighs less or more than the weight range listed on the identification plate

• • •

The same holds true when you turn the forks almost 90° to the left. The suspension points are (item 1) [2], (item 2) [2], and (item 3) [2]. The fulcrum is between (item 1) [2] and (item 3) [2].

The center of gravity is at (item 4) [2] when the forks are turned nearly 90° to the left, the truck is not carrying a load, and the truck is at rest. If the center of gravity shifts (item 5) [2] so it falls outside of the stability triangle, the truck will tip around the fulcrum.

Note that your truck model may have wider wheel track width for improved stability.

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 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 forklift is its rated capacity (how much weight it can safely lift). This weight is listed as the rated capacity on the identification plate. The rated capacity varies for each load depending on: • • •

1

Where the horizontal and vertical load centers are The height you plan to lift the load Attachments used

5

3 2

2

4 BENDI 154

Bendi Forklift Operator’s Manual 2-4

Before You Begin Identification Plate The following list explains each item that appears on the identification plate and specification data plate shown in Figure 4 of the Introduction.

Model (item 1) [3], The model number of your Bendi forklift appears here.

Mast No. (item 3) [3], The serial number of the mast appears here.

Rated Capacity (item 4) [3], 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.

Height (item 5) [3], This is the fork height stated in inches and centimeters. This is the distance between the ground and the top edge of the forks.

Weight (item 6) [3], The rated capacity of the forklift at various fork heights. Rated capacity stated in pounds and kilograms.

Unladen Mass Without Battery (item 7) [3], The actual weight of your Bendi forklift as built without the battery installed; stated in pounds and kilograms.

Minimum Service Weight of Battery (item 8) [3], The battery must weigh at least this much for your Bendi forklift to operate properly; stated in pounds and kilograms.

7

11 13 15

3

7 10 8 9 11 13

Truck Type (item 12) [3], This designation assigned by the Underwriter’s Laboratory (UL) Standard 583 describes the overall design of the electrical components on the truck. Type “E” offers safeguards against an inherent risk of fire and electrical shock and Types “ES and EE” adds additional safeguards to prevent emission of hazardous sparks and limits surface temperatures.

Nominal Voltage (item 13) [3], Nominal voltage indicates whether the truck uses a 48 VDC battery.

Horizontal Load Center (item 14) [3], The horizontal load center is equal to one-half the length of the rated load when the weight is evenly distributed.

Vertical Load Center (item 15) [3], The vertical load center is equal to one-half the height of the rated load when the weight is evenly distributed.

8 9 10

6 14

Maximum Unladen Mass (item 10) [3], This is the Unladen Mass Without Battery added to the Maximum Service Weight of Battery; stated in pounds and kilograms.

Battery Type (item 11) [3], This is the rating for the battery itself as designated by Underwriter’s Laboratory (UL) Standard 583. This describes the construction of the battery and battery enclosure with respect to the risk of fire, electric shock, and explosion.

Serial No. (item 2) [3], The serial number of your Bendi forklift appears here.

1 2 3 4

Maximum Service Weight of Battery (item 9) [3], The battery must not exceed the weight stated here for your Bendi forklift to operate properly; stated in pounds and kilograms.

12

1 2

5 MODEL:

SERIAL NO.:

3

MAST NO.:

TRUCK TYPE:

L A N D O L L C O R P O R AT I O N M A RY S V I L L E , K A N S A S U S A

12

UNLADEN TRUCK WEIGHT W I T H O U T B AT T E R Y ( L B S . ) :

S TA N D A R D L O A D C T R .

C A PA C I T Y A = 2 4 I N .

R AT I N G S B = 2 4 I N .

WEIGHT "C"

AUXILIARY LOAD CTR. C A PA C I T Y A = R AT I N G S B =

WEIGHT "C"

15

6 A

HEIGHT "D" B

14

C D

HEIGHT "D"

4

UNLADEN TRUCK WEIGHT W I T H M A X . B AT T E R Y ( L B S . ) : M I N . S E R V I C E W E I G H T O F B AT. :

2600 LBS.

M A X . S E R V I C E W E I G H T O F B AT. :

2900 LBS.

B AT T E R Y T Y P E : N O M I N A L T R U C K V O LTA G E :

48

COMPLIES WITH ANSI B56.I

BENDI 324

Bendi Forklift Operator’s Manual 2-5

Before You Begin 48 in (122 cm) high, has a vertical load center of 24 in (61 cm). Make sure that you do not pick up a load that is higher than twice the vertical load center.

Load Center

! 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.

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

You need to consider two types of load centers.

The horizontal load center (item 1) [4], is equal to one-half the length of the load when the weight is evenly distributed. For example, a load that is 48 in (122 cm) long has a horizontal load center of 24 in (61 cm). The farther the load center is from the fulcrum (item 2) [4], the less stable the forklift. Always make sure your load is flush against the load backrest (item 3) [4], and that unbalanced loads are loaded with the heaviest end of the load closest to the front wheels.

1

5

BENDI 110

Counterweight

1

! Warning

3 4

Never let a co-worker stand on the back of the forklift to add to the counterweight. Your co-worker can fall off the forklift, or the truck can tip backwards, causing serious injury or death.

2 4

BENDI 109

The vertical load center (item 4) [4], is equal to one-half the height of the load when the weight is evenly distributed. For example, a load that is

Your Bendi forklift has a counterweight (item 1) [5] 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.

Bendi Forklift Operator’s Manual 2-6

Before You Begin When you load at high elevations, tilt the load back far enough to seat it against the load backrest.

Maximum Fork Height

! Warning The load capacity of your forklift decreases the higher you raise the forks. Refer to the rated capacity at various heights listed on the identification plate. Failure to heed these guidelines can cause your forklift to tip over causing serious injury or death.

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

Attachments

! Warning The maximum fork height (item 1) [6], is the highest position your Bendi forklift can lift a load.

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.

Never modify your Bendi forklift in any manner. Only options and attachments approved

by Landoll Corporation 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 Corporation, 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.

Determining the Weight of the Load

1

6

In addition to the rated capacity you must determine the weight of the load before you attempt to lift it with your Bendi forklift:

BENDI 111

• • •

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

•

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

Ask your supervisor when in doubt

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

Bendi Forklift Operator’s Manual 2-7

Before You Begin Understanding Workplace Conditions ! 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.

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: • • •

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 Narrow aisle ways (should be marked according to ANSI Z53. 1) Overhead obstructions (should be marked according to ANSI Z53. 1) Poor lighting making it hard to see hazards Wet, oily, or rough terrain Other equipment or vehicles operated in the area

Remember: Do not block the following items with your Bendi forklift or materials you are moving: • • • •

Electrical panels Fire exits Emergency stop buttons Aisle ways

Dockboards (Bridge Plates) 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 dockboard must be locked in place to prevent it from rocking or sliding. Dockboards have a high friction surface designed to reduce the possibility of people or trucks slipping. Handholds or other effective means are provided on portable dockboards 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.

Trucks and Railroad Cars 1. Before you load or unload a highway truck, trailer, or railroad car, make sure it does not move unintentionally: • •

Set the brakes Block the wheels

2. In addition to setting the brakes and blocking the wheels, if a semitrailer 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 railroad cars or trailers with a Bendi forklift.

Bendi Forklift Operator’s Manual 2-8

Before You Begin Warning Devices

Atmospheric/Electrical

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

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

Your Bendi forklift may have other warning devices installed. Make sure they are in working order before you start work for the day: • • • •

An amber overhead strobe warning light Flashing backup light Rear safety light package Backup alarm (beeping or talking)

Working in Hazardous Environments Here are some types of hazards you might encounter in your workplace: • •

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

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

Check with your supervisor if you are not sure which designation is appropriate for your workplace.

Atmospheric/Electrical Chemical

! Warning

Chemical Hazards

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

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.

Bendi Forklift Operator’s Manual 2-9

Before You Begin

Bendi Forklift Operator’s Manual 2-10

SECTION 3

Operating Your Bendi Forklift This section of your Bendi Forklift Operator’s Manual discusses the following concepts that must be thoroughly understood to operate a Bendi forklift: Operator’s Daily Checklist – Inspecting your Bendi forklift before you begin your shift of work is a mandatory requirement of OSHA. 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. ASME and ITA operation sequences are also described.

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 forklift, traveling with a load, what to do in case of a tip over, going up and down an incline, and using external lifting equipment to move your Bendi forklift to a different location.

Using Lifting Equipment to Move a Forklift to Another Location – This discussion warns you to make sure lifting equipment has appropriate size and capacity for the job.

Bendi Series III Forklift Operator’s Manual 3-1

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 Bendi forklift. Failure to follow the information provided in the Before You Begin section can lead to serious injury or death.

! Warning According to rules issued by OSHA, 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 an OSHA requirement. Report any defect immediately to your supervisor!

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!

Accelerator Pedal The accelerator pedal (item 1) [1], is located on the floor to the right of the brake pedal.

ITA 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 accelerator pedal to the floor, the faster the forklift moves.

Brake Pedal

! Caution Always use your right foot for braking. Do not steer with brakes applied.

The brake pedal (item 2) [1], is located on the floor to the left of the accelerator pedal.

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

You are responsible for the daily inspection of your Bendi 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

1

Controls and Indicators 2

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

1

Bendi Series III Forklift Operator’s Manual 3-2

BENDI 319

Operating Your Bendi Forklift Note that your Bendi forklift also has a hand brake. See the discussion on “Hand Brake” for more information.

Steering Wheel The steering wheel (item 2) [3], is equipped with a steering knob (item 3) [3], which should be held firmly with your left hand at all times.

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

3

1

2

T E ON ST S W I T AR T

0F

F

E

ONRUN Y F TO DELATOO RO Y H NA M OU C R C

O AC N C O RU N N

TURN K

S

Seat Switch A seat switch (item 1) [2], tells the motor 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.

4

5

2 3

1

BENDI 315

The steering column tilt is adjustable: 1. Press the pedal (item 2) [2].

2. Adjust the angle of the steering column.

3. Release the pedal.

2

BENDI 325

Key Switch The key switch (item 1) [3], is located on the right side of the steering column. It is a three position switch (OFF, ON ACC and ON RUN). Turn the key clockwise to set the switch to the ON ACC position and further clockwise to the ON RUN position. All controls are inoperative when the key switch is in the OFF position. Turn the key fully counterclockwise to the OFF position.

Dash Display The Dash Display (item 4) [3], is above the steering column. It provides a record of operating time in hours, battery charge, or service codes.

When you turn the key switch to the ON ACC position the dash display indicates operating time.

When the key switch is in the ON RUN position, and you are sitting on the operator’s seat, the dash display indicates the battery charge or displays service codes. The battery charge is displayed as percent of full charge; “100” indicates a fully charged battery. Note that this reading may fluctuate when you first turn the key switch to ON RUN but the readings will settle down after the forklift is in operation.

Bendi Series III Forklift Operator’s Manual 3-3

Operating Your Bendi Forklift If the battery charge is less than 20 percent, the lift, tilt, side shift and other accessory controls will not function.

Note that if you see a number preceded by a “-” sign, such as “-04”, this is a service code. We have provided a list of items you can check yourself. If you cannot resolve the problem, or the code is not on this list, contact your supervisor:

ITA Operation - Pull the hand brake toward you to set it. Push it away from you to release it. You cannot drive your Bendi forklift while the parking brake is engaged. The truck will not respond to the accelerator pedal unless you push the hand brake forward all the way.

Direction Lever The direction lever (item 1) [4], is located on the front, sloped face, of the armrest.

Dash Display Service Codes Displayed Code

“-01”

“-02”

What To Do

• You are not seated on the operator’s seat and key switch is in the On position.

• Seat switch is inoperative.

• You must be on the operator’s seat when you operate your forklift.

Direction lever is in “Forward”, and accelerator pedal is pressed, when you turn key switch On.

1. Take your foot off the accelerator pedal 2. Turn key switch Off. 3. Move direction lever to neutral.

4. Turn key switch On.

Direction lever is in “Reverse”, and accelerator pedal is pressed, when you turn key switch On.

1. Take your foot off the accelerator pedal 2. Turn key switch Off. 3. Move direction lever to neutral.

4. Turn key switch On.

4 3

6 1

5

NG

• Check for debris under seat.

NI

AR W !

2 !

R WA NIN G

“-03”

What It Means

“-04”

1. Turn key switch Off. Direction lever is in “Forward” or “Reverse” 2. Move direction lever to neutral. when you turn key 3. Turn key switch On. switch On.

“-06”

Accelerator pedal is pressed and direction lever is in “neutral”.

1. Take your foot off the accelerator pedal.

2. Select direction.

3. Press accelerator pedal.

“-015”

Battery is discharged.

Charge the battery.

Hand Brake The hand brake (item 5) [3], is located to the left of the hour meter.

!

G IN N R A W

4

ITA Operation - Push the lever away from you so the truck moves forward and pull it toward you so the truck moves backward. The lever may be moved while the truck is in motion (known as “brake by plugging”). The motor will automatically come to a smooth stop and then reverse direction.

Lift Lever The first lever (item 2) [4], (closest to the operator) on the front of the armrest is the lift lever.

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

Bendi Series III Forklift Operator’s Manual 3-4

BENDI 320

Operating Your Bendi Forklift Tilt Lever The second lever (item 3) [4], on the front of the armrest is the tilt lever. A visual indicator (item 4) [2] is provided so you can easily determine the number of degrees the mast is tilted.

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

Side Shift Lever The third lever (item 4) [4], on the front of the armrest is the side shift lever. Side shift is an optional function on Bendi forklifts.

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

Attachment Lever(s) The fourth lever (item 5) [4], on the front of the armrest is an additional hydraulic lever for powered attachments. Powered attachments are optional functions on Bendi forklifts.

Horn The horn (item 6) [4], is located on the side of the armrest.

Seat Adjustments The standard Bendi Series III vinyl covered seat can be positioned as the operator requires by releasing the seat lever (item 1) [5] and moving the seat forward or back. The optional deluxe seat also has a comfort adjustment. Turn the knob (item 2) [5] to increase or decrease the firmness of the seat base suspension. The indicator (item 3) [5] will display the firmness setting. The cloth covered deluxe seat is standard on some Bendi Series III models. A vinyl cover option is available.

5

1

2

3

BENDI 316

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 Occupational Safety and Health Administration (OSHA) 29 CFR Parts 1910, 1915, 1917, 1918, and 1926. 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 as specified by OSHA. Operating a powered industrial truck without the proper training can cause serious injury or death.

Bendi Series III Forklift Operator’s Manual 3-5

Operating Your Bendi Forklift ! 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.

1

Before you operate your Bendi forklift, get used to 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 it.

2

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.

6

BENDI 326

Keep your right foot on the accelerator pedal (item 1) [6], and your left foot (item 2) [6], on the floor of the cab at all times.

Driving Position

! Warning Only operate 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.

! Caution Always use your right foot to operate the accelerator and brake pedal. Keep your left foot on the floor of the cab.

Refer to Figure [6] for proper seating position.

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

! 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. In most cases the truck will land on you causing serious injury or death.

2. Fasten your seatbelt.

Note: If you get out of your seat while the truck is moving, the seat switch opens, causing the truck to freewheel. Do not place items under the seat; they could prevent the seat switch from operating.

Starting and Traveling Note: Make sure all accessories (lights, etc.) are off before continuing.

Bendi Series III Forklift Operator’s Manual 3-6

Operating Your Bendi Forklift 1. Make sure your right foot is on the floor of the operator’s cab.

2

2. Set the direction lever (item 1) [7], to neutral.

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

3 T E ON ST S W I T AR T

0F

F

E

ONRUN Y F TO DELATOO RO Y H NA M OU C R C

O AC N C O RU N N

TURN K

4. Set the direction lever (item 1) [7], in the forward position.

S

1 3 1 NG

AR W !

NI

8

BENDI 327

9

BENDI 328

2 !

R WA NIN

G

G

IN

N

R

!

7

A W

BENDI 357

5. Use the lift lever (item 2) [7], to raise the forks 4 to 6 in (10.2 to 15.2 cm) from the ground and the tilt lever (item 3) [7], to tilt the mast back. This is the recommended traveling position.

6. Release the hand brake (item 1) [8] and hold the steering knob (item 2) [8] firmly with your left hand.

7. Note the position of the front wheels. The truck will move in the direction the front wheels are pointed.

8. Make sure the way is clear and select the direction of travel with the steering knob.

9. Gently press the accelerator pedal (item 1) [9], with your right foot. If the truck is on an incline, press the traction override button

(item 3) [8], release the brake and press the accelerator pedal simultaneously to avoid reverse motion.

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.

Bendi Series III Forklift Operator’s Manual 3-7

Operating Your Bendi Forklift When you reach an intersection:

! Warning

•

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.

•

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

Stopping

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

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

To slow down, release the accelerator, and gently apply pressure to the brake pedal with your right foot.

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

! Warning 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.

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

Stopping Distance (feet [meters])

Stopping Distance 25.00

[7.6]

20.00

[6.1]

0% Grade 4% Grade 8% Grade 12% Grade

15.00

[4.6]

10.00

[3.0]

5.00

[1.5]

0.00 1 [1.6]

2 [3.2]

3 [4.8]

4 [6.4]

5 [8.0]

6 [9.7]

7 [11.3]

Speed (mph [kph])

10

Bendi Series III Forklift Operator’s Manual 3-8

BENDI 329

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

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

To make sure you come to a safe stop: • • •

Reduce speed Reduce load size Allow adequate distance between the truck and any other vehicle, object, or person

Use Figure 10 to help determine the stopping distances in certain situations.

11 Parking

! Warning 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 Off and remove the key. Failure to properly exit and park your forklift can cause serious injury or death.

BENDI 330

Operating Instructions – Handling a Load ! Warning •

Look in the direction you will travel before you begin to drive the forklift.

•

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

•

Make sure you insert forks fully into the pallet. Do not “tip load” [11].

•

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

•

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

•

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

3. Lower the forks to the ground.

•

Never use the forklift to elevate anyone.

4. Turn the key switch to the OFF position.

•

Never carry passengers on the truck.

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.

When you park your forklift always: 1. Apply the hand brake.

2. Tilt the mast forward.

5. Remove the key.

Bendi Series III Forklift Operator’s Manual 3-9

Operating Your Bendi Forklift •

•

•

Setting the Forks

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

Before you get on the forklift make sure the spacing between the forks (item 1) [12], is properly set: 1. Measure the opening between the end stringers on the pallet (item 2) [12].

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

2. Lift the fork locks (item 3) [12], up.

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 identification plate for rated capacity and load center information.

3. Move the forks until the spacing between them is equal to one-half the opening between the end stringers on the pallet. Make sure the forks are seated in a carriage notch and equidistant from the ends of the carriage (item 4) [12].

4. Press the fork locks down to ensure locking.

3

1 2 4 12

Bendi Series III Forklift Operator’s Manual 3-10

BENDI 331

Operating Your Bendi Forklift Retrieving a Load Note: The aisle, (item 5) [13], must not be any narrower than 6.0 ft (183 cm).

Actual minimum aisle width may vary based upon application.

Follow these steps to retrieve a load: Note: The following illustrations show standard 40 x 48 in (101.6 x 121.9 cm) pallets loaded on a rack with 96 in (243.8 cm) beams.

The arrow labeled with an “S” shows the direction you must turn the steering wheel.

1. Approach the side of the aisle that is opposite the load (item 1) [13].

2. For narrow aisles, straighten out the truck so it is 6 to 8 in (15.2 to 20.3 cm), (item 2) [13], from the edge of the aisle opposite the load.

For wider aisles, straighten out the truck so it is 36 to 48 in (91 to 122 cm), (item 6) [13], from the side of the aisle where the load is located.

3. Center the forks using the side shift lever (if you have this option).

! 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.

4. Drive forward until the front edge of the load wheels, (item 3) [13], is aligned with the center of the pallet (item 4) [13].

5 2 6 S S

1 3

13

4

BENDI 332

14

BENDI 333

Bendi Series III Forklift Operator’s Manual 3-11

Operating Your Bendi Forklift 5. Lift the forks to the proper height.

6. Stop the forklift and turn the forks 90° (turn the steering wheel counterclockwise) to align them with the load [14].

8. Turn the steering wheel clockwise 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 [16]. Only raise the load high enough to clear the rack or the load backrest may catch on the rack.

Note: When you turn the steering wheel with the truck stopped, do not apply the foot brake or hand brake.

7. Straighten out the forks (turn the steering wheel back to center) as you drive them into the load so the forks enter the load in a straight line [15].

S

S

16

15

BENDI 335

BENDI 334

Bendi Series III Forklift Operator’s Manual 3-12

Operating Your Bendi Forklift 9. Shift into reverse and slowly back away from the stack as you turn the steering wheel counterclockwise (to keep the forks straight) [17].

11. When the front right hand corner of the load (item 1) [18] 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.

S S

17

1 BENDI 336

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

If you do not have a side shift option, or 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 to 16 in (20.3 to 40.6 cm).

BENDI 337

12. Lower the forks until they are 4 to 6 in (10.2 to 15.2 cm) off the ground and slowly drive the truck to the next location observing the safety rules previously stated.

Bendi Series III Forklift Operator’s Manual 3-13

Operating Your Bendi Forklift In Case Your Forklift Tips Over

! Warning The following conditions can cause a forklift to tip over • • • • • • • •

Tip Loading [11] 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 grade Driving on a grade with the load facing downhill Using a battery that weighs less than or more than the weight range listed on the identification plate

19

BENDI 338

2. Hold on to the steering wheel [20].

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

20

BENDI 339

3. Brace your feet [21].

11

BENDI 330

If you sense your forklift is going to tip-over, follow these instructions:

21

1. Lean away from the direction the truck is tipping [19].

Bendi Series III Forklift Operator’s Manual 3-14

BENDI 340

Operating Your Bendi Forklift 4. Don’t jump [22].

22

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.

BENDI 341

Turning

Transporting a Load Follow these guidelines when you transport a load:

23

•

Do not speed.

•

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 to 6 in (10.2 to 15.2 cm) off of 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.

•

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.

BENDI 342

! Warning A lateral tip-over can occur if your truck is improperly operated [23]. Slow down before turning! Failure to slow down can cause serious injury or death.

Bendi Series III Forklift Operator’s Manual 3-15

Operating Your Bendi Forklift you must back down an incline when you are carrying a load. If vision is obscured, arrange for a “spotter” to guide you.

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.

•

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 [24].

•

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

•

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

•

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 to 6 in (10.2 to 15.2 cm) off of the ground when you clear the incline.

When you travel up or down an incline, follow these guidelines: •

•

Make sure the grade is 12% or less with a loaded Bendi forklift and 20% or less if you are not carrying a load.

Always keep the load pointed uphill [24].

Travel with the forks facing uphill whether you are going up or down an incline. That means

24

Bendi Series III Forklift Operator’s Manual 3-16

BENDI 343

Operating Your Bendi Forklift Unloading Your Forklift Note: The aisle, (item 5) [25], must not be any narrower than 6.0 ft (183 cm).

Actual minimum aisle width may vary based upon application.

Follow these steps to retrieve a load: Note: The following illustrations show standard 40 x 48 in (101.6 x 121.9 cm) pallets loaded on a rack with 96 in (243.8 cm) beams.

The arrow labeled with an “S” shows the direction you must turn the steering wheel.

off point. For wide aisles, straighten out the truck so it is 36 to 48 in (91 to 122 cm) (item 2) [25] from the side of the aisle where the load is located.

3. Center the load using the side shift lever (if you have this option).

4. Drive forward until the front edge of the load wheels, (item 3) [25], is aligned with the center of the rack opening (item 4) [25].

! 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.

1. Approach the side of the aisle that is opposite the area where you will unload the forklift (item 1) [25].

5. Lift the load to the proper height.

2. For narrow aisles, straighten out the truck so it is 6 to 8 in (15.2 to 20.3 cm), (item 2) [25], from the edge of the aisle opposite the drop

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 [26].

5 2 6 S

S 1 3

25

4

BENDI 344

26

BENDI 345

Bendi Series III Forklift Operator’s Manual 3-17

Operating Your Bendi Forklift Note: When you turn the steering wheel with the truck stopped, do not apply the foot brake or hand brake.

7. Drive forward and straighten out the load (turn the steering wheel back to center), so it is square over the stack [27].

S

S 28

BENDI 347

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

! Warning 27

BENDI 346

8. Turn the steering wheel clockwise to keep the load straight as you drive it over the stack [28].

When you lower the forks to the “no load” position (item 1) [29], make sure you do not lower the forks too far. If the forks are lowered too beyond the “no load” position, you can damage the mast, rack, or other containers on the stack. This can cause serious injury or death.

Bendi Series III Forklift Operator’s Manual 3-18

Operating Your Bendi Forklift

1

29

BENDI 348

10. Lower the forks until the load sits firmly on the stack. Continue to lower the forks until they no longer support the load (“no load” position) (item 1) [29].

! Warning Do not attempt to withdraw the forks until they have been lowered to a “no load” position. Failure to follow this guideline can cause the load to fall off the stack causing serious injury or death.

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

S

11. Shift into reverse and slowly back out of the load as you turn the steering wheel counterclockwise (to keep the forks straight) [30].

30

BENDI 349

Bendi Series III Forklift Operator’s Manual 3-19

Operating Your Bendi Forklift 12. When the front right fork (item 1) [31] 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.

Using Lifting Equipment to Move a Forklift to Another Location ! 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.

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.

S

If you need to use a hoist to lift your Bendi forklift: 1. Pass a strap (item 1) [32] under the truck just in front and behind of the rear wheels.

2. Pass a strap (item 2) [32] under the crossmember at the top of the mast.

1 31

BENDI 350

3. Make sure you place a spacer (item 3) [32] (such as a 2 x 6 in [5 x 15.2 cm] block of wood) between the overhead guard and the lift point to avoid damage to the truck.

13. Lower the forks until they are 4 to 6 in (10.2 to 15.2 cm) off the ground and slowly drive the truck to the next location observing the safety rules previously stated.

3 2

1 32

Bendi Series III Forklift Operator’s Manual 3-20

1 BENDI 351

SECTION 4

Inspection and Maintenance This section of your Bendi Forklift Operator’s Manual discusses the following concepts that must be thoroughly understood before you inspect or perform maintenance on a Bendi forklift: Inspection and Maintenance – Describes the tasks involved in performing Bendi forklift inspections and preventive maintenance.

Inspection and Maintenance Responsibilities – Details the inspection responsibilities for Bendi forklift operators and service facilities authorized by Landoll Corporation to perform preventive maintenance.

Inspection and Maintenance Practices – Describes the precautions and steps you should take when you perform inspection or preventive maintenance tasks on Bendi forklifts.

Inspecting Specially Equipped Bendi Forklift Trucks – Describes how authorized service facilities should inspect Bendi forklift trucks designed for special applications, such as Type EE trucks.

Identification Plate and Safety Warnings – Describes how to inspect the identification plate and safety warnings (decals) that are affixed to Bendi forklifts.

Inspecting Forks – Describes how authorized service facilities should inspect Bendi forklift forks.

Bendi Series III Forklift Operator’s Manual 4-1

Inspection and Maintenance Repairing and Load Testing Forks – Describes who is authorized to determine whether a fork is repairable or needs replacement and how to load test forks after they have been repaired.

Battery Maintenance – Describes how authorized service facilities should charge and care for Bendi forklift batteries.

Hydraulic System Maintenance – Describes how authorized service facilities should perform maintenance on Bendi forklift hydraulic systems.

Transmission Fluid Change – Describes how authorized service facilities should change transmission fluid.

Power Steering System Maintenance – Describes how authorized service facilities should perform maintenance on Bendi forklift power steering systems.

Mast Maintenance – Describes how authorized service facilities should perform maintenance on Bendi forklift masts including load roller and chain maintenance.

Side Shift Circuit Maintenance – Describes how authorized service facilities should perform maintenance on Bendi forklift side shift circuits.

Bendi Series III Forklift Operator’s Manual 4-2

Inspection and Maintenance Inspection and Maintenance

! Warning

Inspection Program

Never perform any maintenance or service procedures unless specifically indicated in this manual or requested by your supervisor.

All other service and maintenance on your Bendi forklift must be provided by a facility authorized by Landoll Corporation to perform these services. Failure to follow these guidelines can cause serious injury or death.

The inspection program designed by Landoll Corporation periodically checks the integrity of Bendi forklift systems such as: •

Checking performance of operator functions such as lift, tilt, side shift, attachment, and traction systems

•

Checking for leaks

•

Checking fluid levels

•

Making sure components are securely attached

•

Checking the tires

To make sure these and other systems are checked periodically, Landoll Corporation has developed a system of checklists. A blank copy of each checklist can be found in Appendix A. These checklists include: • • • • •

Operator’s Daily Checklist 200 Hour Inspection Checklist 600 Hour Inspection Checklist Installation Checklist Customer Electric Truck Installation Report

Except for the Operator’s Daily Checklist, these tasks are usually performed by a service and maintenance facility that is approved by Landoll Corporation.

Preventive maintenance tasks are usually performed by a service and maintenance facility that is approved by Landoll Corporation.

Operators may be asked to assist in some routine maintenance procedures. Never perform any of these maintenance procedures unless directed by your supervisor.

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

You are responsible for the daily inspection of your Bendi forklift: •

Maintenance Program In addition to the inspection program, Landoll Corporation has set up a preventive maintenance program. Preventive maintenance procedures include: •

Drain, flush, and refill transmission fluid

•

Clean hydraulic reservoir suction screens

•

Change hydraulic oil and filter

•

Lubricate mechanical systems

•

Remove, clean and inspect battery rollers (optional)

• • • •

Photocopy the Operator’s Daily Checklist in Appendix A in 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 If your Bendi forklift fails to perform in a safe manner during your shift, stop and park the vehicle and report the problem to your supervisor immediately.

Bendi Series III Forklift Operator’s Manual 4-3

Inspection and Maintenance 200 and 600 Hour Inspection Checklist During these inspections technicians from an authorized service and maintenance facility will inspect all mechanical and electrical systems and perform preventive maintenance operations designated by Landoll Corporation.

Installation Inspection When your Bendi forklift is installed, the authorized service facility is required to complete an Installation Checklist and a Customer Electric Truck Installation Report. The installation report initiates the warranty for the vehicle.

Inspection and Maintenance Practices This section explains the general cautions and warnings you should observe during inspection and maintenance procedures. In addition, the duties of the operator and service and maintenance technician are explained. Finally, these specific procedures are explained: • • •

Preparing for Inspection or Maintenance Performance Testing Completing Performance Testing

! Warning Routine Maintenance Schedule for Bendi Forklifts The Routine Maintenance Schedule for Bendi Forklifts is located in Appendix A. Note that each task should be performed at the time interval or number of operation hours indicated, which ever comes first.

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

! Warning To help avoid fire hazards:

! Warning Never perform any maintenance or service procedures unless specifically indicated in this manual or requested by your supervisor.

All other service and maintenance on your Bendi forklift must be provided by a facility authorized by Landoll Corporation to perform these services. Failure to follow these guidelines can cause serious injury or death.

Typically an authorized service and maintenance facility performs preventive maintenance procedures. At times operators may be requested to assist in performing routine maintenance, such as doing routine lubrication.

If requested to do so, make sure you read and understand the guidelines discussed in the “Inspection and Maintenance Practices for Bendi Forklift Operators,” section in this manual.

• • •

Have fire protection equipment present in the work area.

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

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

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

! Warning Batteries produce flammable and explosive gases. Keep arcs, sparks, flames, and lighted tobacco away to prevent an explosion. Keep the area well ventilated. Failure to follow these guidelines can cause serious injury or death.

Bendi Series III Forklift Operator’s Manual 4-4

Inspection and Maintenance ! 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.

! Warning Removing the counterweights or uprights will change the center of gravity of the truck and can cause the truck to tip. The battery is considered part of the truck’s counterweight.

Failure to follow these guidelines can cause the truck to tip over and result in serious injury or death.

If you are asked or required to perform basic lift truck maintenance, make special note of the following: •

Before you perform service or maintenance on a Bendi forklift, read and understand the Bendi Forklift Operator’s Manual, Service Manuals, and machine safety signs.

•

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

Inspection and Maintenance Practices For Authorized Facilities ONLY •

Follow the procedures outlined in “Before You Inspect the Truck or Perform Service,” “Before You Check Performance,” and “After Performance Testing is Complete.”

•

Inspect and maintain motors, controllers, limit switches, protective devices, electrical conductors, connections and electrical insulation as described in the applicable section of ASME B56.1-1993.

•

Only use replacement parts, including tires, that are equal to, or exceed, the quality of the parts supplied by the original equipment manufacturer. Install parts, including tires, according to procedures established by Landoll Corporation.

•

When you remove tires, follow industry safety practices as described in the applicable section of ASME B56.1-1993.

Inspection and Maintenance Practices for Bendi Forklift Operators These guidelines will help prevent downtime for your Bendi forklift and maintain it in a safe operating condition: •

•

•

Perform the tasks listed on the Operator’s Daily Checklist even if you are taking responsibility of the truck from another operator. You are responsible for the condition of the forklift on your shift. Work together as a team with your co-workers, supervisor, and authorized service facility to keep the truck in peak operating condition. Accidents happen when you assume another operator has checked out the forklift.

Keep your truck clean to minimize fire hazards and facilitate detection of loose or defective parts.

Follow the procedures outlined in “Before You Inspect the Truck or Perform Service,” “Before You Check Performance,” and “After Performance Testing is Complete.”

Preparing for Inspection or Maintenance •

Inspect the truck in an area that has sufficient clearance to check all operator functions.

•

Lower forks to the ground and tilt mast forward.

Bendi Series III Forklift Operator’s Manual 4-5

Inspection and Maintenance •

If you will not operate the truck to check operator functions, disconnect the battery and block the wheels with chocks or other positive truck-positioning devices.

•

If you will operate the truck to perform operator functions, raise the drive wheels so they clear the floor.

•

Block the mast to prevent it from engaging.

•

If you need to hoist the truck, make sure the hoisting equipment has adequate size and capacity to move the equipment.

•

Never remove counterweights or uprights.

This will change the center of gravity and can cause an unstable condition.

4. Turn the key switch, (item 1) [2], to the ON RUN position.

1

2

Performance Testing

BENDI 130

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

5. Set the direction lever (item 1) [1], in the forward position.

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

6. Check functions described on the Operator’s Daily Checklist or 200/600 Hour Checklists.

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

3. Set the direction lever (item 1) [1], in the neutral position.

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

1. Apply the hand brake (item 1) [3].

2. Tilt the mast forward.

1

3. Lower the forks to the ground.

NG

NI

!

AR W

4. Turn the key switch to the OFF position.

5. Remove the key.

!

R WA NIN G

!

1

G IN N R A W

BENDI 352

Bendi Series III Forklift Operator’s Manual 4-6

Inspection and Maintenance Identification Plate and Safety Warnings ! Warning T E ON ST SW I T AR T

0F

Make sure that the identification plate and safety warnings (decals) located on the truck are legible and the information provided match the characteristics of the truck. Failure to follow this guideline can result in serious injury or death.

F

E

ONRUN Y F TO DELATOO RO Y H NA M OU C R C

O RU N N

TURN K

O AC N C

S

1

The following information is provided for authorized service facilities ONLY.

3

BENDI 353

Before you leave the truck make sure that: • • •

The parked truck will not cause an obstruction or safety hazard.

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

The truck is not left unattended on an incline.

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

Inspecting Specially Equipped Bendi Forklift Trucks The following information is provided for authorized service facilities ONLY. Bendi forklift trucks that were designed to meet special applications, such as Type EE construction, should be inspected and tested to make sure they meet original design criteria described by the specific agency, such as ASME B56.1-1993 and UL 583.

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

Inspecting Forks ! Warning Never operate your Bendi forklift if you suspect the forks are damaged. Report fork damage to your supervisor immediately.

Failure to follow this recommendation can cause serious injury or death.

Checks required by the Operator’s Daily Checklist: Check the top clip retaining pin and fork heel for signs of cracks and wear. Report any signs of cracks and wear to your supervisor immediately.

Bendi Series III Forklift Operator’s Manual 4-7

Inspection and Maintenance The following information is provided for authorized service facilities ONLY. Check the forks, and associated components, as required by the various checklists located in Appendix A The following discussion provides detailed procedures necessary to provide a complete fork inspection.

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

Rated Capacity and Load Center – The rated capacity of each fork must be at least half of the rated capacity stated on the identification plate.

The load center of each fork must match the load center stated on the identification plate. If the values do not match, replace the fork with one that has the correct characteristics.

Cracks – Visually examine the forks for cracks and, if considered necessary, perform a nondestructive crack detection test. Pay special attention to: •

Fork heel

•

Welds that attach mounting components to the fork blank

•

Top clip retaining pin

Straightness of Blade and Shank – Check the straightness of the upper face of each blade and the front face of each shank. If the deviation from straightness exceeds 0.5% of the length of the blade and/or the height of the shank, respectively, repair or replace the fork set.

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

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

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

Wear – Two different areas of the fork and fork attachment should be checked for wear.

Fork Blade and Shank – Check each fork blade and shank for wear, pay special attention to the area surrounding the heel of the fork. If the thickness is reduced to 90% of the original thickness, repair or replace the fork.

Fork Hooks – Check the support face of the top hook and the retaining faces of both hooks for wear, crushing, and other local deformations. If any of these deficiencies cause excessive clearance between the fork and the fork carrier, repair or replace the fork.

Fork Marking – If the fork marking is not clearly legible, it should be remarked by the fork manufacturer, or their representative, in accordance with paragraph 7.25.2 (ANSI B56.11993).

Bendi Series III Forklift Operator’s Manual 4-8

Inspection and Maintenance Repairing and Load Testing Forks The following information is provided for authorized service facilities ONLY.

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

! Warning Make sure the batteries in your Bendi forklift weigh no more than the Maximum Service Weight of Battery and no less than the Minimum Service Weight of Battery stated on the identification plate. Failure to follow these guidelines can lead to truck instability causing serious injury or death.

! Caution •

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

•

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

•

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

Load Testing Forks A fork that has undergone repairs, other than repair or replacement of the positioning lock and/ or marking, must be load tested before it is returned to service. The testing facility must test the forks according to paragraph 7.25.3 (ANSI B56.1-1993) except that the test load must be 2.5 times the rated capacity marked on the fork.

Battery Maintenance The following information is provided for authorized service facilities ONLY. Maintain the battery, and associated components, as required by the various checklists and the Routine Maintenance Schedule for Bendi Forklifts located in Appendix A. Detailed battery maintenance procedures are provided in the following paragraphs.

! Warning

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

Battery Charging The following information is provided for authorized service facilities ONLY. Charging Procedure 1. Park the truck in the charging bay and remove the key.

Batteries produce explosive gases during operation and charging. Keep your Bendi forklift in a designated area while you are charging or changing the batteries. Keep all sparks, arcs, and lighted tobacco away from the batteries. Failure to do this can cause serious injury or death.

Bendi Series III Forklift Operator’s Manual 4-9

Inspection and Maintenance 2. Raise the seat base from the right side of the Bendi: (a) Open the right side door and pull out at the rubber grommet (item 1) [4]. (b) Release the arm rest lever (item 2) [4] and raise the arm rest clear of the base (item 3) [5]. (c) Raise the seat base (item 4) [5] and lock the restraint pin (item 5) [5] into the latch (item 6) [5].

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

Note: Do not overfill - only top off after full charge.

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

2 !

5. Pull up on the “Y” handle (item 1) [6], and disconnect the truck cable (item 2) [6] from battery cable (item 3) [6].

WARNING

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

1

! Caution Connecting the charger cable to the truck cable (item 2) [6], can cause damage to the forklift.

B30

4

BENDI 317

3

6

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

9. Disconnect the charger cable and reconnect the battery cable (item 3) [6], to the truck cable (item 2) [6].

4

5

5

7. Connect the charger cable to the battery cable (item 3) [6].

BENDI 318

10. Lower the seat base from the right side of the Bendi: (a) Be sure the arm rest is raised and clear of the seat base and the right side door is open. (b) While supporting the seat base, release the restraint latch (item 6) [5] and lower the seat base. CAUTION: Grip the seat base from the side only to avoid front pinch points (Note warning decals).

Bendi Series III Forklift Operator’s Manual 4-10

Inspection and Maintenance (c) Lower and latch the arm rest. (d) Close and secure the battery compart ment door.

•

Only add distilled water to the battery cells.

Overfilling battery cells is dangerous and any spillage must be wiped up immediately.

1

•

Use only a clean glass or other non-metallic container for storing distilled water used to top off the battery fluid.

•

Keep the battery container clean and dry. Any corrosion to metal components, caused by battery acid, must be neutralized with a solution of sodium bicarbonate or diluted ammonia. Smearing the terminals with petroleum jelly and applying acid proof paint to the battery container can prevent further corrosion.

3

2

! Warning 6

BENDI 321

Batteries produce explosive gases during operation and charging. Keep your Bendi forklift in a designated area while you are charging or changing the batteries and make sure you latch the battery cover in the Up position. Keep all sparks, arcs, and lighted tobacco away from the batteries. Failure to do this can cause serious injury or death.

Battery Care The following information is provided for authorized service facilities ONLY. The information below is only intended as a guide for battery care. For further information on the safe operation of batteries, refer to the applicable battery manufacturer’s guide.

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

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

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

•

Keep all sparks, arcs, and lighted tobacco away from the batteries.

•

Make sure the filler plugs are tight and the vents are clear.

•

If you take a truck out of service for any length of time, disconnect and remove the battery.

•

Disconnect the battery when you transport the truck.

•

Keep the battery fully charged while it is in storage.

Bendi Series III Forklift Operator’s Manual 4-11

Inspection and Maintenance •

Store spare batteries in a cool, dry place.

Maintain the cells by topping off with distilled water and give it an equalizing charge each month.

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

•

Spare and replacement batteries must be the same type and weight as the original unit unless authorized by Landoll Corporation.

•

Make sure that lifting chains, slings, hooks, tools, and other metallic objects do not come into contact with the battery terminals.

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

•

Never operate a truck with the battery cover (seat base) removed.

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

•

Never remove the charging connector by pulling the lead. This could result in damage to the insulation inside the connector.

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

•

Never use or charge a battery that has a damaged connector and/or defective insulation. Repair or replace the connector.

Hydraulic System Maintenance The following information is provided for authorized service facilities ONLY. Maintain the hydraulic system, and associated components, as required by the various checklists and the Routine Maintenance Schedule for Bendi Forklifts located in Appendix A. Guidelines for hydraulic system maintenance is provided in the following paragraphs.

! Caution Do not allow hydraulic fluid level to drop significantly or allow the reservoir to run dry.

This will induce air into the system and cause damage to hydraulic system components.

Transmission Fluid Change The following information is provided for authorized service facilities ONLY. Change the transmission fluid as required in the Routine Maintenance Schedule for Bendi Forklifts located in Appendix A. The detailed transmission fluid change procedure follows: 1. Disconnect the battery.

2. Place the vehicle on a level floor and block opposing wheels.

3. Raise the vehicle.

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

5. Remove wheel.

6. Thoroughly clean the area around the fill (item 1) [7], level (item 2) [7], and drain (item 3) [7] plugs.

Bendi Series III Forklift Operator’s Manual 4-12

Inspection and Maintenance 7. Place a drain pan under the drain plug.

8. Using a 3/8 inch Allen key, unscrew the fill, level and drain plugs.

Power Steering System Maintenance The following information is provided for authorized service facilities ONLY.

1

Perform maintenance on the power steering system as required by the 200 and 600 hour checklists and Routine Maintenance Schedule for Bendi Forklifts located in Appendix A. Guidelines are provided in the following paragraphs.

•

Fluid for the hydraulic power steering system comes from the central hydraulic reservoir.

•

Always use a puller to remove the steering wheel. Do not use a hammer, torch, or crow bar.

•

Investigate and immediately correct any play, rattle, shimmy, misalignment or other unusual occurrence in the steering system.

9. Drain the fluid completely into the drain pan.

•

Report any malfunction or accident that may have damaged a steering system part.

10. Clean the magnet on the drain plug and reinstall in bottom hole. Tighten to 35 ft. lbs. (47 Nm).

•

11. Fill the transmission with synthetic gear lube as indicated in the Lubrication Chart located in Appendix B. Fluid capacity is approximately 1 pint (0.47 L). Fill through fill plug until fluid is at the level plug. Install both plugs. Tighten to 35 ft. lbs. (47 Nm). DO NOT OVERFILL.

Do not attempt to weld any broken steering component. Replace the component with original equipment only. Do not cold straighten, hot straighten, or bend any steering part.

•

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

•

Investigate and correct any external leak in the steering system, no matter how minor the leak.

2

3 7

BENDI 354

Bendi Series III Forklift Operator’s Manual 4-13

Inspection and Maintenance outer (item 3) [8], or inner intermediate upright assemblies (item 4) [8], is 1/16 in. (1.5 mm).

Filling and Air Bleeding the System Fill and air bleed the power steering system per the schedule shown on the Routine Maintenance Schedule for Bendi Forklifts.

1. Fill the reservoir until it reaches the FULL mark on the dipstick. DO NOT OVERFILL.

3. To check the clearance, insert a pry bar between the upright and roller (item 5) [8], and measure the clearance at the “XXX” (item 1) [8].

2. Run the steering through three complete cycles by turning the steering wheel all the way in one direction, then all the way the other direction.

4

3. Check and refill the reservoir after each cycle.

3

2

5

4. Add fluid until it reaches the FULL mark on the dipstick.

1

Mast Maintenance The following information is provided for authorized service facilities ONLY. Perform maintenance on the mast as required by the 200 and 600 hour checklists and Routine Maintenance Schedule for Bendi Forklifts located in Appendix A. Guidelines are provided in the following paragraphs.

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

8

BENDI 355

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

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

Load Roller Maintenance

Measuring Chain Stretch

1. Check for proper load roller shimming as required by the Routine Maintenance Schedule for Bendi Forklifts.

Inspect the chains as required by the 200 and 600 hour checklists and Routine Maintenance Schedule for Bendi Forklifts. Check for the following:

2. The maximum side-to-side clearance (item 1) [8], between load rollers (item 2) [8], and the

•

Chain wear. If one strand appears to be worn replace both strands of the pair.

Bendi Series III Forklift Operator’s Manual 4-14

Inspection and Maintenance Rust and corrosion. If chain joints become tight from rust and corrosion, loosen them with SAE 40W oil or penetrating oil. If they cannot be loosened, or if the tight joints are caused by bent pins, plates, or peened plate edges, replace both strands of chain.

To determine whether the chains are properly adjusted:

•

Cracked side plates. Replace both strands of chain.

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

•

Protruding or turned pins. Replace both strands of chain.

•

Side wear. If pins and outside plates show signs of wear, check for misalignment of sheaves, anchors or other components.

Correct the misalignment. If wear is excessive, replace both strands of chain.

4. Each chain in a pair should have equal “give”.

If tension is not equal, adjust them as described in the manufacturer’s mast service manual.

•

•

Worn, broken or misaligned chain anchors.

Replace or adjust as required.

Chain Lubrication

! Caution The chains must be coated with a film of lubricant at all times.

•

•

1. Remove load from forks.

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

Measuring Chain Stretch If the chains stretch beyond the recommended amount, they should be replaced in pairs. Chain stretch can be measured with a chain wear scale (item 1) [9]. The scale indicates whether the distance between two chain links is within tolerance. The shaded area in the illustration (item 2) [9], compares a stretched chain (item 3) [9], to a new chain (item 4) [9]. Measure the chains according to the instructions printed on the chain wear scale, without a load on the carriage.

Lubricate the chains as required by the 200 and 600 hour checklists and Routine Maintenance Schedule for Bendi Forklifts. Use lubricant listed on the Lubrication Chart located in Appendix B. Each pair of chains has been factory-lubricated using heat and pressure to force the lubricant thoroughly into the chain links. Avoid removal or contamination of this factory applied lubricant. Do not wash, sand blast, etch, steam clean, or paint the chains.

2 1

4 3

Chain Adjustment The chains must be adjusted so each strand is under equal tension for proper load distribution and mast operation.

9

BENDI 356

Bendi Series III Forklift Operator’s Manual 4-15

Inspection and Maintenance •

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

•

Check the hydraulic system pressure at the carriage hose terminal. Refer to the truck service manual for details on measuring hydraulic system pressure. The minimum recommended pressure is 2000 psi (140 bar).

System pressure must not exceed 3500 psi (245) bar.

•

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

Side Shift Circuit Maintenance

•

Check the hydraulic system flow volume at the carriage hose terminal. The recommended flow volume is 2 GPM (7.5 L/min.).

The following information is provided for authorized service facilities ONLY.

Checking For Leaks To check side shift circuit performance:

Perform maintenance on the side shift circuit as required by the 200 and 600 hour checklists and Routine Maintenance Schedule for Bendi Forklifts located in Appendix A. Guidelines are provided in the following paragraphs.

1. Side shift completely to the left and hold the control handle in this position for 5 seconds.

Check for external leaks at the cylinder, fittings and hoses.

! Warning

2. Side shift completely to the right and hold the control handle in this position for 5 seconds.

Check for external leaks at the cylinder, fittings and hoses.

•

•

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

Check for hydraulic fluid leaks using a piece of cardboard or wood. Do not use your bare hands. Remember to wear safety glasses.

Hydraulic oil can be under very high pressure. A pinhole leak is not easily seen and if it pierces your skin, can cause gangrene, and possibly death, if not treated immediately by a physician familiar with this type of injury.

Troubleshooting Side Shift System 1. Disconnect the right hand cylinder hose from the hose terminal or internal reeving fitting.

2. Cap the supply fitting.

3. Place the hose end in a bucket.

4. Start the truck.

5. Actuate the side shift right control handle for five seconds.

6. If there is oil flow out of the hose, the cylinder seals are defective and require service. Refer to the manufacturer’s side shift service manual.

7. If there is no oil flow out of the hose, the problem is not in the hydraulic system.

Bendi Series III Forklift Operator’s Manual 4-16

SECTION 5

Troubleshooting Your Bendi Forklift This section of your Bendi Forklift Operator’s Manual includes a Troubleshooting Guide to help you quickly locate problems that can happen using your Bendi forklift. Follow all safety precautions stated in the previous chapters when making any adjustments to your machine.

Bendi Series III Forklift Operator’s Manual 5-1

Troubleshooting Your Bendi Forklift Symptom

Possible Cause: Remedy Battery disconnected or discharged: Connect and/ or charge the battery Control fuses blown: Replace fuses Power fuse blown: Replace fuses Shut down by emergency switch: Use EV100LX diagnostics in the Service Manual Improper start-up sequence: Put the unit in neutral, then turn the key on

Sluggish performance, erratic switching, slow lift

Loose connection (power wiring): Tighten connections Motor brushes are worn: Replace the brushes Brake is dragging: See brake adjustment in Service Manual Load wheels are binding: Check for clearance Defective EV100LX: Refer to EV100LX section of the Service Manual

Improper creep speed - improper acceleration in EV100LX range - bypass or inadequate power

EV100LX system is misadjusted: Adjust EV100LX; refer to Service Manual

Does not lift (motor runs) Direction control O.K.

Excessive load: Check the load Air lock: Bleed the hydraulic cylinder Pump(s) are defective: Check oil pressure - repair or replace if necessary Low oil supply: Add oil Plugged suction screen: Clean the screen, flush and refill the reservoir

Does not lift (motor does not run)

Battery low (lift lockout): Recharge battery Valve switch misadjusted: Adjust the valve switch Valve switch is defective: Replace valve switch Valve is not operating: Check linkage Control wiring is open (pump contactor does not energize): Refer to Service Manual Power wiring is open (pump contactor does energize): Refer to Service Manual

Slow lift

Battery low: Recharge battery Excess load: Check the load Leaks in lift cylinder: Tighten or replace cylinder packing Plug suction screen: Clean the screen, flush and refill the reservoir Worn pump/motor unit(s): Check oil pressure (rebuild or replace)

No operation

Bendi Series III Forklift Operator’s Manual 5-2

Troubleshooting Your Bendi Forklift Symptom Does not lower

Possible Cause: Remedy Control valve linkage is broken: Inspect and repair Mechanical binding: Inspect mast Flow valve is defective: Replace

Lowers excessively slow

Mast Flow valve is defective: Clean or replace valve Mast Flow valve is undersized: Replace valve with correct size valve

Does not tilt (motor runs)

Excess load: Check the load Plugged orifice: Inspect orifices in hydraulic valve

Slow or erratic tilt

Orifices are plugged: Clean orifices in valve and tilt cylinder

Hydraulic system leaks oil

Defective hose: Replace the hose Loose fittings: Tighten

Lift or tilt cylinder leaking

Seals or wiper damaged: Replace Rod is damaged: Inspect and replace

Oil in breather line (lift cylinder)

Leakage in cylinder packing (some gradual accumulation is normal): Tighten or replace cylinder packing

Steering is slack

Worn bushings: Replace Backlash in gears: Replace if worn Loose keys, etc.: Inspect linkage

Steers hard

Low hydraulic pressure: Inspect and adjust

Battery rollers stick (Battery rollers optional)

Corroded: Remove, clean and lubricate

Not enough brake

Improper adjustment: See Service Manual

Too much brake

Improper adjustment: See Service Manual Transmission (see Service Manual for repair procedures)

Knocking conditional on speed

Gearing of helical gear step has been damaged when mounting motor: Dismount electric motor.

Check drive pinion and helical gear for damage

Singing noise

Motor connection is not correct: Check motor connection Insufficient fluid level: Check fluid level Motor bearing is faulty: Check motor bearing

Bendi Series III Forklift Operator’s Manual 5-3

Troubleshooting Your Bendi Forklift Symptom Muffled grinding noise

Possible Cause: Remedy Wheel bearings faulty - due to insufficient fluid level - inadmissible high pre-stress of bearings: Have bearings checked in a workshop Gearing of planetary step damage - due to insufficient fluid level - due to excessive play of wheel bearings: Have wheel set of planetary step and wheel bearings checked in a workshop

Leakage in breather valve

Excessive fluid level: Check fluid level

Leakage in motor

O-ring seal faulty: Dismount electric motor, check O-ring and sealing surfaces for damages Faulty bearing seal on electric motor: Dismount electric motor, check O-ring and sealing surfaces for damages

Leakage in wheel shaft

Faulty seal ring on wheel shaft: Check radial shaft seal ring and wheel shaft for damages in the sealing area; Consult workshop

Leakage when transmission warms up

Fluid level is either too high or too low: Check fluid level Wheel bearings with an excessive pre-stress: Consult workshop

Hydraulic Power Steering Motor (see Service Manual for repair procedures) Oil leakage

Oil seal rings deteriorated by excess heat: Replace oil seal rings by disassembling motor unit Special bolt loose or its sealing area deteriorated by corrosion: Loosen then tighten single bolt to torque specification or replace bolt Internal shaft seal worn or damaged: Replace seal. Disassembly of motor unit necessary Worn coupling shaft and internal seal: Replace coupling shaft and seal by disassembling motor unit

Low mechanical efficiency or undue high pressure required to operate motor unit

Line blockage: Locate blockage source and repair or replace Internal interference: Disassemble motor unit, identify and remedy cause and repair, replacing parts as necessary

Bendi Series III Forklift Operator’s Manual 5-4

Troubleshooting Your Bendi Forklift Symptom

Possible Cause: Remedy

Battery (see Service Manual for repair procedures) Unequal or low specific gravity

Electrolyte spillage during watering: Avoid over watering, neutralize and clean Electrolyte flooding: Water cells during end of charge Insufficient charge: Extend charging time Internal short: Replace cell

Excessive water requirement

Overcharging: Select a properly sized charger.

Check charging time and average battery temperature.

Jar leakage: Replace or repair cell

Excessive cell temperatures

Overcharging: Check charger size and charging time Battery overworked: Reduce to one cycle/day or 300/yr. Maximum Battery being charged more than once per day: Reduce charging to once per day Battery temperature too high at start of charge: Allow battery to cool down before starting charge Shorted cell(s): Replace defective cell(s)

Poor truck performance

Battery undersized: Install higher capacity battery Undercharged battery: Extend charging time Discharge indicator malfunction: Reset discharge indicator for 80% Defective charging connector: Replace or repair cable and/or connector Excessive loss of electrolyte: Adjust specific gravity at state of full charge. Check for leakage.

Hydrostatic Steering System (see Service Manual for repair procedures) Clicking noise during a turn

Loose or shifting component: Check that components are in place and torqued correctly

Steering wander

Different size tires: Replace tires of incorrect size Loose, worn, or out of adjustment parts: Check for loose or worn steering linkage parts or wheel bearings

High steering effort in one direction

Vehicle overloaded: Do not exceed capacity of vehicle Low hydraulic system pressure: Check other components of system Excessive heat: See excessive heat checklist

Bendi Series III Forklift Operator’s Manual 5-5

Troubleshooting Your Bendi Forklift Symptom High steering effort in both directions

Possible Cause: Remedy Different size tires: Replace tires of incorrect size Vehicle overloaded: Do not exceed capacity of vehicle Low hydraulic fluid level: Add hydraulic fluid Low flow or pressure from pump: Check pump Components in steering linkage binding: Find source of binding and correct Restriction in fluid return line, or line too small: Clear or replace fluid return line

Lost motion at the steering wheel

Steering wheel loose on column: Tighten steering wheel Air in hydraulic system: Bleed hydraulic system

Mast and Side Shifter (see manufacturer’s mast or side shift service manual for repair procedures) Cylinders do not lift-empty

Plugged inlet hose: Unplug hose or replace Insufficient oil: Check the truck hydraulic system for correct oil level in tank, defective pump or pump drive, leaks in the lines or disconnected control valve linkage. Repair or replace as necessary.

Bent or jammed plunger: Repair or replace as necessary

Cylinders do not lift-loaded

Plugged piston check valve: Unplug check valve or replace Truck relief valve setting low: Raise truck relief setting to specified level Over capacity: Reduce load to specified capacity Mechanical bind due to bent plunger or bad rollers: Remove mechanical load by replacing/ freeing plunger and rollers

Cylinders drift

External leak in pressure line: Tighten or replace as necessary Truck valve defective-cycle to full lift height to verify: Repair or replace truck valve.

External leaks at retainer: Replace all cylinder seals.

Piston check valve leaking: Replace check valve

Bendi Series III Forklift Operator’s Manual 5-6

Troubleshooting Your Bendi Forklift Symptom Spongy or jerky action

Possible Cause: Remedy Sticky or defective truck relief valve: Remove and check the truck relief valve. If contaminated oil caused the malfunction, drain and flush the system, change the filter and refill with fresh oil.

Bent or damaged cylinder: Disassemble, check and repair cylinder assembly plunger Load rollers not properly adjusted or defective: Adjust or repair as necessary Mast channels improperly lubricated: Lubricate mast Low battery charge: Charge battery Low pump volume: Install accumulator Low oil level: Fill oil reservoir Insufficient hydraulic tank capacity or baffles: Install larger tank or baffles Air in hydraulic system: Bleed hydraulic system

Attachment will not side shift or side shifts slowly

Inadequate upper bearing lubrication or worn bearings: Lubricate or replace bearings Kinked supply hoses: Locate kink and straighten hose External leaks: Locate source of leakage Incorrect hydraulic pressure/volume from the truck: Check and adjust pressure and volume Lower mounting hooks installed incorrectly: See Service Manual for correct installation procedure Worn or defective cylinder seals: Replace cylinder seals

Bendi Series III Forklift Operator’s Manual 5-7

Troubleshooting Your Bendi Forklift

Bendi Series III Forklift Operator’s Manual 5-8

SECTION 6

Standard Bendi Forklift Specifications This section of your Bendi Forklift Operator’s Manual includes the standard specifications for the following Bendi forklift trucks: • • • • • •

B25/42E-180D B30/42E-180D B35/42E-180D B35/48E-180D B40/48E-180D B45/48E-180D

Bendi Series III Forklift Operator’s Manual 6-1

Standard Bendi Forklift Specifications Mast Dimensions

Mast Type

A Max. Fork Height

B Collapsed Height

C Free Lift Height

D Max.Overall Height

in

cm

in

cm

in

cm

in

cm

Triple Triple Triple Triple Triple* Triple* Quad* Quad* Quad* Quad* Quad*

188 198 216 230 251 272 240 258 276 294 312

478 503 549 584 638 691 610 655 701 747 792

83 87 95 101 112 121 83 89 95 101 107

211 221 241 257 284 307 211 226 241 257 272

61 65 73 79 86 99 58 64 70 76 82

155 165 185 201 218 251 147 163 178 193 208

236 246 264 278 299 320 288 306 324 342 360

599 625 671 706 759 813 732 777 823 867 914

Above dimensions are based on 3" clearance under the mast. * Not available for B25/42E-180D.

Truck Dimensions B25/42E-180D in cm

E 7 18

F 66 168

G 22 56

H 95 241

I 10 25

J 38 97

K 87 221

L 42 107

M 31 79

N 4 10

O 29 74

P 18°

Q 11°

R 40 102

S 48 122

T 74 188

U 19 48

V 43 109

W 96 244

X 28 71

B30/42E-180D in cm

E 7 18

F 66 168

G 22 56

H 95 241

I 10 25

J 39 99

K 87 221

L 43 42 107

M 31 79

N 4 10

O 29 74

P 18°

Q 11°

R 40 102

S 48 122

T 74 188

U 19 48

V 43 109

W 96 244

X 28 71

B35/42E-180D in cm

E 10 25

F 66 168

G 22 56

H 98 249

I 10 25

J 39 99

K 87 221

L L* 50 48 122

M 31 79

N 4 10

O 29 74

P 18°

Q 11°

R 40 102

S 48 122

T 74 188

U 19 48

V 43 109

W 96 244

X 28 71

B35/48E-180D in cm

E 7 18

F 66 168

G 25 64

H 98 249

I 10 25

J 39 99

K 87 221

L 48 122

M 31 79

N 4 10

O 29 74

P 18°

Q 11°

R 40 102

S 48 122

T 78 198

U 19 48

V 43 109

W 101 257

X 28 71

B40/48E-180D in cm

E 10 25

F 66 168

G 25 64

H 101 257

I 10 25

J 39 99

K 87 221

L 48 137

M 31 79

N 4 10

O 29 74

P 18°

Q 11°

R 40 102

S 48 122

T 78 198

U 19 48

V 43 109

W 101 257

X 28 71

B45/48E-180D in cm

E 10 25

F 66 168

G 25 64

H 101 257

I 10 25

J 39 99

K 87 221

L* 54 137

M 31 79

N 4 10

O 29 74

P 18°

Q 11°

R 40 102

S 48 122

T 78 198

U 19 48

V 43 109

W 101 257

X 28 71

BENDI 310

Bendi Series III Forklift Operator’s Manual 6-2

Standard Bendi Forklift Specifications W

T R

L

L*

O

L* = Models B35/42 and B45/48 only

M

D

J A K

C B S

V U I

Q E

P

N F

X

G H BENDI 311

Bendi Series III Forklift Operator’s Manual 6-3

Standard Bendi Forklift Specifications Standard Specifications Gradeability Empty Loaded

20% 12%

Rated Capacity at 24 in. (61 cm) Load Center B25/42E-180D B30/42E-180D B35/42E-180D; B35/48E-180D B40/48E-180D B45/48E-180D

2,500 lb (1,136 kg) 3,000 lb (1,364 kg) 3,500 lb (1,591 kg) 4,000 lb (1,818 kg) 4,500 lb (2,045 kg)

Mast Tilting Angle Forward Reverse

3° 3°

Fork Size (Standard) ITA Class II Carriage

1.5 x 4 x 36 in (3.81 x 10 x 91 cm)

Lifting Speed Empty Loaded

90 ft/min (27.4 m/min) 70 ft/min (21.3 m/min)

Lowering Speed Empty Loaded

60 ft/min (18.3 m/min) 90 ft/min (27.4 m/min)

Traveling Speed Empty Loaded

6.5 mph (10.5 kph) 6.0 mph (9.7 kph)

Truck Weight With Battery B25/42E-180D B30/42E-180D B35/48E-180D B35/42E-180D B40/48E-180D B45/48E-180D

11,810 lb (5,365 kg) 12,340 lb (5,609 kg) 13,150 lb (5,977 kg) 12,440 lb (5,655 kg) 13,320 lb (6,055 kg) 13,880 lb (6,309 kg)

Minimum Battery Weight

2,600 lb (1,182 kg)

Poly Load Tire (Front) B25/42E-180D; B30/42E-180D; B35/48E-180D; B40/48E-180D B35/42E-180D; B45/48E-180D Solid Rubber Drive Tire (Rear) B25/42E-180D B30/42E-180D; B35/42E-180D; B35/48E-180D; B40/48E-180D B45/48E-180D Battery

12 x 5 x 8 in (30 x 13 x 20 cm) 14 x 5 x 8 in (36 x 13 x 20 cm) 18 x 6 x 12-1/8 in (46 x 15 x 31 cm) 18 x 7 x 12-1/8 in (46 x 18 x 31 cm) 18 x 8 x 12-1/4 in (46 x 20 x 31 cm) 48 Volt Type EO

Bendi Series III Forklift Operator’s Manual 6-4

Appendix A This section of your Bendi Forklift Operator’s Manual includes the following checklists and maintenance schedules: • • • • • •

Operator’s Daily Checklist 200 Hour Inspection Checklist 600 Hour Inspection Checklist Installation Checklist Customer Electric Truck Installation Report Routine Maintenance Schedule for Bendi Forklifts

Bendi Series III Forklift Operator’s Manual A-1

A-2

A-3

A-4

A-5

A-6

Routine Maintenance Schedule for Bendi Forklifts Operation

Time*

First 2 Weeks 1st 50 - 100

First Month 1st 200

Monthly

Quarterly

SemiAnnually 1000 X

Hours* 200 500 Check that terminal studs and mounting bolts on motor are clean and tight Clear cooling holes on X motor of debris or restrictions Check traction motor X brushes for pressure and wear, and surface of commutator for roughness Clean dust from X traction motors Check resistance X between truck body and negative/positive terminal of battery Check operation of X X contactor points and micro switches Check resistance of contactor coils Clean SCR surface X X Clean commutator on X traction motor Thoroughly scrub X battery X Thoroughly clean machine (do not steam clean where EV100LX could get wet) X Check wiring, bolts and X nuts X Check brake pedal free X play X Check hand brake X Check lift chain tension X X Check lift bracket X rollers for damage Check lift and tilt X X cylinder fittings X Check lift and tilt X cylinder operation X Check hydraulic oil X pump operation Drain, flush and refill X X X transmission * Perform maintenance at interval or hours of operation, which ever occurs first

Annually 2000

X

A-7

Routine Maintenance Schedule for Bendi Forklifts Operation

Time*

First 2 Weeks 1st 50 - 100 X

First Month 1st 200

Monthly

Quarterly

SemiAnnually 1000

200 500 Hours* Retorque lug nuts on X drive wheels Clean hydraulic reservoir suction screens with solvent Service all grease X fittings X Check power steering X pump operation Fill and air bleed power X X steering system Check brake fluid level X Remove, clean and X repack battery rollers Check brushes for X pressure or wear, and surface of commutator for roughness (Hydraulic oil pump and power steering pump) Clean dust from motors X (Hydraulic oil pump and power steering pump) Change hydraulic oil X and filter Inspect the mast X mechanism Lubricate steering knob X Check steering X backlash Inspect all tires and X wheels Inspect and lubricate X X the mast chains Shim rollers X Check chains for wear X and stretch Check brake pads for X excessive wear * Perform maintenance at interval or hours of operation, which ever occurs first

A-8

Annually 2000 X

Appendix B This section of your Bendi 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 Series III Forklift Operator’s Manual B-1

Appendix B 6 1 2

BENDI 312

4

12 3

5

13 11 10

7

Name

1 2 3 4 5 6 7 8 9 10 11 12 13

Lubrication Chain SAE 40W oil or Bowman Heavy Load Red Grease Upright Rail Chassis Lube or Kendall SR-12X Rotation Bearings Texaco Ref. C & C #880 Steering Knob Light weight oil Battery Rollers (opt.)

Texaco Ref. C & C #880 Reservoir Cap 30W oil Hydraulic Reservoir Amoco Rykon MV Gear Case Mobilube SHC-634 Master Cylinder Heavy duty brake fluid Articulating Axle Bearings Texaco Ref. C & C #880 Load Wheel Axle Texaco Ref. C & C #880 Steering Gears Texaco Ref. C & C #880 Tilt Cylinders Texaco Ref. C & C #880

9

8 Notes

Clean and reoil Lubricate inner sides of upright rails Use standard lubrication gun Lightly oil Use standard lubrication gun Clean in solvent and reoil Drain, flush, and refill Drain, flush, and refill Check level and add if necessary Use standard lubrication gun Use lubrication gun and adapter for flush type fittings Use standard lubrication gun Use standard lubrication gun

Bendi Series III Forklift Operator’s Manual B-2

BENDI 313

Appendix B Component

Torque Transmission

Wheel 130 ft. lbs. (176 Nm.) Electric motor 17 ft. lbs. (23 Nm.) Fluid draining and filling plug 16 ft. lbs. (22 Nm.) Hydraulic braking unit and brake cable 37 ft. lbs. (50 Nm.) Transmission with vehicle frame 100 ft. lbs. (136 Nm.) Hydraulic Power Steering Motor Bolt 5/16 24 UNF 2A 22-26 ft. lbs. (30-35 Nm.) Bolt 3/8 24 UNF 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.) Electric Motors Motor terminals 12 ft. lbs. (16 Nm.) Pole pieces screws 20-25 ft. lbs. (27-34 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 x 1.0) 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. lbs. (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.)

Bendi Series III Forklift Operator’s Manual B-3

Appendix B Landoll Corporation General Torque Specifications (Rev. 4/97) This chart provides tightening torques for general purpose application 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

SAE Grade 2

SAE Grade 5

SAE Grade 8

UNC Size

SAE Grade 2

SAE Grade 5

SAE Grade 8

1/4-20 5/16-18 3/8-16 7/16-14 1/2-13 9/16-12 5/8-11 3/4-10 7/8-9 1-8 1-1/8-7 1-1/4-7 1-3/8-6 1-1/2-6

4 8 15 24 35 55 75 130 125 190 270 380 490 650

6 [7] 13 [16] 23 [29] 35 [43] 55 [62] 80 [100] 110 [137] 200 [250] 320 [400] 408 [506] 600 [750] 840 [1050] 110 [1375] 1460 [1825]

9 18 35 55 80 110 170 280 460 680 960 1426 1780 2360

1/4-28 5/16-24 3/8-24 7/16-20 1/2-20 9/16-18 5/8-18 3/4-16 7/8-14 1-14 1-1/8-12 1-1/4-12 1-3/8-12 1-1/2-12

5 9 17 27 40 60 85 150 140 210 300 420 560 730

7 [9] 14 [17] 25 [31] 40 [50] 65 [81] 90 [112] 130 [162] 220 [275] 360 [450] 540 [675] 660 [825] 920 [1150] 1260 [1575] 1640 [2050]

10 20 35 60 90 130 180 320 500 760 1080 1500 2010 2660

[5] [10] [19] [30] [43] [62] [94] [162] [156] [237] [337] [475] [612] [812]

[11] [22] [43] [62] [100] [137] [212] [350] [575] [850] [1200] [1782] [2225] [2950]

[6] [11] [21] [34] [50] [75] [106] [188] [175] [263] [375] [525] [700] [912]

[12] [25] [44] [75] [112] [162] [225] [400] [625] [950] [1350] [1875] [2512] [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 [ ] if using prevailing torque nuts.

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

Standard Torque NewtonMeters 10 16 23 46 80 125 200 275

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

FootPounds 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 NewtonMeters 385 670 980 1330 1790 2325 3010

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

Bendi Series III Forklift Operator’s Manual B-4

FootPounds 290 500 730 990 1340 1730 2240

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

Appendix B Landoll Corporation Hydraulic Fitting Torque Specifications 37° JIC, ORS, & ORB (Rev. 10/97)

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 Parker Brand Fittings Dash Size

37 Degree JIC

O-Ring (ORS)

O-Ring Boss (ORB)

-4 -5 -6 -8 -10 -12 -16 -20 -24 -32

11-13 14-16 20-22 43-47 55-65 80-90 115-125 160-180 185-215 250-290

15-17 – 34-36 58-62 100-110 134-146 202-218 248-272 303-327 –

13-15 21-23 25-29 40-44 57.5-62.5 75-85 109-121 213-237 238-262 310-340

Landoll Corporation Hydraulic Fitting Torque Specifications 37° JIC, ORS, & ORB (Rev. 10/97)

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.

Torque is specified in foot pounds Aeroquip Brand Fittings Dash Size

37 Degree JIC

O-Ring (ORS)

O-Ring Boss (ORB)

-4 -5 -6 -8 -10 -12 -14 -16 -20 -24 -32

11-12 15-16 18-20 38-42 57-62 79-87 – 108-113 127-133 158-167 245-258

10-12 – 18-20 32-35 46-50 65-70 – 92-100 125-140 150-165 –

14-16 18-20 24-26 50-60 72-80 125-135 160-180 200-220 210-280 270-360 –

Bendi Series III Forklift Operator’s Manual B-5

Appendix B

Bendi Series III Forklift Operator’s Manual B-6