PDF Download: Landoll Bendi AC Electric Narrow Aisle Forklift Operator’s Manual

ELECTRIC NARROW AISLE FORKLIFT

OPERATOR’S MANUAL BENDI AC MODELS B30-4/42-180D B45-4/56-180D

B40-4/48-180D B45HL-4/56-180D

LANDOLL COMPANY, LLC

MATERIAL HANDLING PRODUCTS

Material Handling Products Group 1900 North Street Marysville, Kansas 66508 Telephone (785)562-5381· FAX: (785)562-4853 www.Landoll.com · MHProd@Landoll.com Publication No. F-522-0110 January, 2010

Table of Contents Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . S-1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-2 Site Supervision · · · · · · · · · · · · · · · · · · · · · · · · · · · · S-2 Terminology Used in Manual · · · · · · · · · · · · · · · · · · · · · S-3 Illustrations Used in Manual · · · · · · · · · · · · · · · · · · · · · · S-3 The Meaning of Safety Statements · · · · · · · · · · · · · · · · · · S-4 Bendi Forklift Safety Statements· · · · · · · · · · · · · · · · · · · · S-4 Operator · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · S-7 Traveling and Load Handling · · · · · · · · · · · · · · · · · · · · · S-11 Speed· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · S-12 Visibility · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · S-12 Battery Care · · · · · · · · · · · · · · · · · · · · · · · · · · · · · S-12 Service Repair · · · · · · · · · · · · · · · · · · · · · · · · · · · · S-14 Side Shifting · · · · · · · · · · · · · · · · · · · · · · · · · · · · · S-15 Available Options · · · · · · · · · · · · · · · · · · · · · · · · · · · S-15

Bendi AC Forklift Operator’s Manual i

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Vehicle Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Component Identification· · · · · · · · · · · · · · · · · · · · · · · · 1-3 Identification (Capacity) Plate · · · · · · · · · · · · · · · · · · · · · 1-3 Truck Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Frame · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 1-4 Traction Drive · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 1-4 Electrical System · · · · · · · · · · · · · · · · · · · · · · · · · · · · 1-4 Hydraulic System · · · · · · · · · · · · · · · · · · · · · · · · · · · 1-5 Operator’s Cab · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 1-7 Technical Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 Bendi AC Narrow Aisle Forklift · · · · · · · · · · · · · · · · · · · · 1-14 Available Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 EE Series (Electrical Enclosure) · · · · · · · · · · · · · · · · · · · 1-14 Fire Extinguisher · · · · · · · · · · · · · · · · · · · · · · · · · · · 1-14

Receiving and Inspection . . . . . . . . . . . . . . . . . . . . . . . 2-1 Receiving Your Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Items Furnished With Your Truck · · · · · · · · · · · · · · · · · · · 2-1 Items Required · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-1 Tools and Test Equipment · · · · · · · · · · · · · · · · · · · · · · · 2-1 To Prepare the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Charging a Wet Battery · · · · · · · · · · · · · · · · · · · · · · · · 2-2 Charging a Dry Battery· · · · · · · · · · · · · · · · · · · · · · · · · 2-6 Routine Checks · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-8 Inspection Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Visual Checks · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-9 Replacing the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 To Replace a Battery · · · · · · · · · · · · · · · · · · · · · · · · · 2-12 Rollout Battery Tray Option · · · · · · · · · · · · · · · · · · · · · · 2-14 Storage, Towing or Shipping . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Truck Storage · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-14 Battery Storage · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-14 Towing the Truck · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-15 To Ship the Truck · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-15

Bendi AC Forklift Operator’s Manual ii

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Operator Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Operator Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Understanding Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Basic Principles · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-3 Knowing the Rated Capacity · · · · · · · · · · · · · · · · · · · · · · 3-4 Identification (Capacity) Plate · · · · · · · · · · · · · · · · · · · · · 3-4 Bendi Serial Number Code· · · · · · · · · · · · · · · · · · · · · · · 3-5 Load Center · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-6 Counterweight · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-6 Maximum Fork Height · · · · · · · · · · · · · · · · · · · · · · · · · 3-7 Tilting Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Attachments · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-7 Determining the Weight of the Load · · · · · · · · · · · · · · · · · · 3-7 Understanding Workplace Conditions . . . . . . . . . . . . . . . . . . . . . 3-8 Dockboards · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-8 Trucks · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-9 Warning Devices · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-9 Working in Hazardous Environments . . . . . . . . . . . . . . . . . . . . . . 3-9 Atmospheric/Electrical · · · · · · · · · · · · · · · · · · · · · · · · · 3-9 Chemical Hazards · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-9

Operating Your Bendi Forklift . . . . . . . . . . . . . . . . . . . . 4-1 Operator’s Daily Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Accelerator Pedal · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-2 Brake Pedal · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-3 Key Switch · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-3 Steering Wheel and Tilt Clamp· · · · · · · · · · · · · · · · · · · · · 4-3 Seat Switch· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-4 Seat Belt · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-4 Seat Adjustments · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-5 Rake Adjustment · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-5 Dash · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-6 Parking (Hand) Brake · · · · · · · · · · · · · · · · · · · · · · · · · 4-7 Direction Lever · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-7 Lift Lever · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-7 Tilt Lever · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-7 Side Shift Lever · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-7 Attachment Lever(s) - Option · · · · · · · · · · · · · · · · · · · · · 4-7 Horn · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-7

Bendi AC Forklift Operator’s Manual iii

Operating Instructions - Basic Procedures . . . . . . . . . . . . . . . . . . . 4-8 Getting On and Off the Forklift · · · · · · · · · · · · · · · · · · · · · 4-8 Driving Position· · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-9 Starting and Traveling · · · · · · · · · · · · · · · · · · · · · · · · · 4-9 Turning · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-10 Stopping · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-10 Stopping Distance · · · · · · · · · · · · · · · · · · · · · · · · · · 4-11 Parking · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-11 Mast Operation · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-11 Operating Instructions – Handling a Load. . . . . . . . . . . . . . . . . . . 4-13 Setting the Forks · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-14 Retrieving a Load · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-15 In Case Your Forklift Tips Over · · · · · · · · · · · · · · · · · · · · 4-18 Transporting a Load · · · · · · · · · · · · · · · · · · · · · · · · · 4-19 Traveling on Inclines · · · · · · · · · · · · · · · · · · · · · · · · · 4-20 Unloading Your Forklift · · · · · · · · · · · · · · · · · · · · · · · · 4-21 Using Lifting Equipment to Move a Forklift to Another Location . . . . . . . 4-23 Fire Extinguisher Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 In Case of a Fire !· · · · · · · · · · · · · · · · · · · · · · · · · · · 4-24 Fork Positioner Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26 Power Steering System· · · · · · · · · · · · · · · · · · · · · · · · 4-26 Mast Systems · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-26 Electrical Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28 General · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-28

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

Bendi AC Forklift Operator’s Manual iv

Forward To Owners, Users, and Operators The safe and efficient operation of a lift truck requires skill and alertness on the part of the operator. To develop the skill required the operator must: · receive training, in accordance to the rules provided by appropriate legislation, for the proper operation of THIS lift truck. · understand the capabilities and limitations of the lift truck. · become familiar with the construction of the lift truck and see that it is maintained in good condition. · read and understand the warnings and operating procedures in this manual.

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

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

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

Occupational Safety and Health Act (USA)

·

Canada Material Handling Regulations

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

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

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

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

Additional information that describes the safe operation and use of lift trucks is available from the following sources: · Employment safety and health standards or regulations (Examples: “Occupational Safety and Health Standards (USA)”, “Canada Material Handling Regulations”. · Safety codes and standards (Example: American National Standard, ANSI B56.1, Safety Standard for Low Lift and High Lift Trucks. · Publications from government safety agencies, government insurers, private insurers and private organizations (Example: Accident Prevention Manual for Industrial Operations, from the National Safety Council). · “Operator Safety Training Course” describes lift truck safety, good maintenance practices, and training programs. Available from your Landoll dealer (Landoll Part No. 107218).

NOTE: Forklift trucks are not intended for use on public roads.

Bendi AC Forklift Operator’s Manual v

Safety Precautions IMPORTANT! The Bendi* Model trucks have been designed for optimum safety of their operators. Please follow the safety guidelines listed in this section and adhere to all Important, Caution, Warning, and Danger notes found within this manual. When the truck is in operation, always keep loose clothing, jewelry, hair and fingers out of the restricted areas (especially pinch areas) as labeled on the truck.

This chapter on Safety must be carefully read, understood and adhered to strictly by all operators and service personnel using the Bendi Model lift trucks. Do not use this truck until you have thoroughly read this manual. Failure to comply could cause risk of death or serious injury to yourself and others.

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

These laws and regulations include: · Occupational Safety and Health Act (USA) · Canada Material Handling Regulations

A comprehensive operator training program is available from Landoll Company, LLC. For further details, contact your Landoll dealer for Bendi Lift Trucks. * Landoll and Bendi are trademarks of the Landoll Company, LLC. All other brand and product names are the trademarks of their respective holders.

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

Bendi AC Forklift Operator’s Manual S-1

Safety Precautions

Warning

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

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

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

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

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

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

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

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

The truck must be inspected daily for problems or damage risking the safety of the driver and any people in the work area, or possible damage to the truck and the load being moved. When trucks are used on a round-the-clock basis, they must be inspected after each shift. Problems found must be reported and corrected. The truck must be taken out of operation until all repairs have been made and the truck has been reinspected for safety.

Bendi AC Forklift Operator’s Manual S-2

Safety Precautions Terminology Used in Manual ACCELERATOR PEDAL

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

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

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

BRAKE PEDAL ser iv pedals

Figure S-1 Drawing Example

Bendi AC Forklift Operator’s Manual S-3

Safety Precautions The Meaning of Safety Statements

Bendi Forklift Safety Statements

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

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

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

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

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

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

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

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

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

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

Bendi AC Forklift Operator’s Manual S-4

Safety Precautions

3 38 5 2

17

24

19

INSIDE

39

41

4 32 BOTH SIDES

INSIDE

1 8

25 34

12 33 7 13 15 24 40 BOTH

SIDES

29 BOTH SIDES

36 BOTH SIDES

27 BOTH

SIDES

36

30

16 6

37 11 28 20 23 14 22 BOTH SIDES

bendi ac decals

18

21

OTHER SIDES

BOTH BOTH SIDES SIDES

31

BOTH SIDES

BOTH SIDES

BOTH SIDES

35

Figure S-2 Decal Placement

Bendi AC Forklift Operator’s Manual S-5

Safety Precautions

1 2 3

5

4

6

7

8

10

11

12

13

14

17 16 18 15 19

23

20 22 21

24

27 29 25 33

30

31 34

28 40

32

35 36 41

38

39

Figure S-3 Decals

Bendi AC Forklift Operator’s Manual S-6

37

Safety Precautions Operator

Warning Warning

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

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

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

Be especially careful when there are other people or moving or fixed objects in the working area, or when the load reduces visibility (See "Visibility" on page S-12). Never drive a truck up to anyone standing in front of an object. Ensure that people stand clear of the rear swing area before making turns.

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

NEVER lift, lower or transport people.

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

Bendi AC Forklift Operator’s Manual S-7

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

Seat Belt

· Drive carefully and slowly onto dock boards and bridge plates. Do not exceed the rated capacity of the dock boards or bridge plates and ensure dock boards or bridge plates are properly secured, either by being anchored or by being equipped with devices that will prevent slipping.

The driver’s seat belt must always be worn when driving this truck. · Sit up straight in the driver’s seat. · Pull the belt across you. Do not let the belt twist.

· Check that dock boards have substantial contact with both the dock and the carrier, preventing them from rocking or sliding. · Maintain a safe distance from the edge of ramps, platforms and other similar working surfaces. · When leaving the operator’s compartment, the forks must be lowered to the floor, the mast must be placed in a vertical position, all controls must be in a NEUTRAL position, the parking brake must be set and the key switch must be set to the OFF position. Truck wheels must be blocked if the truck is parked on an incline.

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

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

Warning A twisted belt can seriously injure you.

In a crash or a tip-over, the full width of the belt would not be available to take up the impact forces. · Push the latch plate into the buckle until it clicks. Pull up on the latch plate to make sure it is secure. · The lap part of the belt must be worn low and snug on the hips, just touching the thighs.

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

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

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

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

Bendi AC Forklift Operator’s Manual S-8

Safety Precautions

B40/B45 SERIES EMERGENCY DISCONNECT B30 SERIES EMERGENCY STOP BUTTON

emergency

Figure S-4 Emergency STOP Button

Emergency STOP Button Press this button to shut down the drive and power steering motors and all mast movement. The truck drifts to a STOP. Immediately set the parking brake.

To continue, pull out on the button to reset the switch (See Figure S-4).

Use this button: · in case of fire, smoke or overheating · if a person comes between the truck and a fixed object. · in case an accident occurs · in case of a short circuit or other electrical malfunction; for example, if the pump motor is on continuously.

Tipping Hazards If a tip-over occurs, the operator should follow the following guidelines shown here. · DO NOT JUMP · BRACE YOUR FEET FIRMLY · HOLD ON TIGHT

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

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

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

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

· LEAN AWAY FROM THE TIP

Bendi AC Forklift Operator’s Manual S-9

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

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

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

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

The truck can be tipped either longitudinally or laterally if it is driven: · over objects on the floor or ground. · off the edge of a paved surface. · into a pothole in a paved surface. · off the edge of a loading dock, or off the edge of a loading ramp. (It is important to avoid driving too close to the edge of a dock or ramp).

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

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

Bendi AC Forklift Operator’s Manual S-10

Safety Precautions Traveling and Load Handling · Observe all traffic regulations. Keep to the right and maintain a safe distance from the truck ahead based on speed of travel. Keep the truck under control at all times. · Yield the right of way to other people in the area. · Slow down and sound the horn at cross aisles and other locations where visibility is obstructed. · Keep a clear view of the path of travel and be alert for other traffic, people and safe clearances. · Under all travel conditions, operate the truck at a speed that permits you to bring the truck to a complete stop in a safe manner. · Do not handle unstable loads. Use care when tilting forward or backward, stacking, depositing, or retrieving a load. Never travel with the mast tilted forward. · Never exceed the truck’s maximum lifting capacity. Refer to "Standard Bendi Forklift Specifications" beginning on page 5-1 and the identification (capacity) plate located in the operator's cab (See Figure S-5).

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

IDENTIFICATION (CAPACITY) PLATE ser iv caploc2

Figure S-5 Capacity Plate Location

· Travel with forks or load in recommended traveling position. · Elevate mast or load only to pick up or deposit a load. Watch out for obstructions, especially overhead. Watch all clearances. · Tilt a loaded mast slowly. · Do not release the lift/tilt joystick control lever suddenly when lowering loads. This may cause bouncing of the carriage, which could dump the load. · Do not allow anyone, under any circumstances, to walk or stand under the forks or any part of the load. · Never place any part of your body between the mast structures or any moving part of the truck. · Do not turn when traveling on ramps. When descending ramps, travel forward (forks facing downhill) when empty, travel backward (forks facing uphill) when carrying a load. · Use care even when traveling without a load.

Avoid high speeds, sharp turns and abrupt stops.

· Travel with forks straight ahead, and the mast tilted backward.

Bendi AC Forklift Operator’s Manual S-11

Safety Precautions Speed

Care

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

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

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

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

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

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

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

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

Both covers include latches to lock the compartment. A cutout in the overhead guard is also provided for easy battery service (See Figure S-6).

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

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

The battery is very heavy, and if restraints are not replaced after maintenance, the battery could slide out of the truck causing electrical shorts or spilling acid - or it could cause the truck to tip over.

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

OVERHEAD GUARD CUTOUT BATTERY COMPARTMENT TOP COVER AND SEAT BATTERY COMPARTMENT TOP COVER LOCKING LATCH BATTERY ADJUSTMENT BRACKET (BOTH SIDES) BATTERY COMPARTMENT SIDE DOOR btry compartment

Figure S-6 Battery Compartment and OHG Cutout

Bendi AC Forklift Operator’s Manual S-12

Safety Precautions

Warning

Warning

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

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

Consult the label on your battery for information on cell-type, ampere-hour capa c it y, ch ar g e r at e an d n o rm a l full-charge voltage. Do not charge the battery at a current greater than 1.5 amp per 100 amp-hours capacity at the end of charge.

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

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

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

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

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

Keep vent plugs in place and clean at all times.

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

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

Bendi AC Forklift Operator’s Manual S-13

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

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

1. Be sure you have sufficient knowledge, experience and the proper tools and replacement parts before you attempt any truck maintenance.

2. Be sure to use the proper nuts, bolts and other fasteners. Many are specifically rated; that is, SAE Grade 5, SAE Grade 8, ISO Prop Class 8.8, etc., and must be replaced with the identical type. It is recommended to use only Landoll authorized replacement parts.

Warning If you use the wrong nuts, bolts or other fasteners, parts can later break or loosen. Serious injury could occur.

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

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

5. Disconnect the battery.

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

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

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

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

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

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

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

Bendi AC Forklift Operator’s Manual S-14

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

Daily, check the upper hook engagement, the fasteners, the lower hook engagement and inspect for hydraulic oil leaks (See Figure S-7).

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

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

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

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

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

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

Figure S-7 Fork Check Points

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

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

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

The load must never exceed the capacity of the fork positioner as stated on the identification (capacity) plate affixed within the operator’s cab.

Bendi AC Forklift Operator’s Manual S-15

Safety Precautions Fire Extinguisher

Additional Publications

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

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

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

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

IMPORTANT!

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

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

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

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

· the instruction pamphlet is clearly visible Also see page 4-24 for additional operating information.

In case of a fire! · Have everyone vacate the area immediately. · Call the fire department, no matter what the size of the fire. Emergency telephone numbers should be posted at each telephone. · Use your extinguisher correctly, according to the directions on the label and in this manual.

Professionals should handle large fires. · Be ready to leave the area in the event the fire cannot be controlled immediately.

Bendi AC Forklift Operator’s Manual S-16

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

Safe and efficient operation also depends on correct maintenance of the vehicle. An Operator’s Daily Checklist, which outlines maintenance that must be performed each time the vehicle is put into operation, is located in Appendix A. The checklist should be part of a complete planned 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 AC Forklift Operator’s Manual 1-1

Introduction

Vehicle Description 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.

Bendi forklifts are available in capacities from 3,000 to 4,000 lbs. The front end can be pivoted 180 degrees. This permits the vehicle to act as a conventional as well as a narrow aisle forklift.

The Bendi AC truck also offers: · Four-wheel configuration - dual rear wheel drive; front wheel steering and articulation · High efficiency, field oriented motor controller the enables smooth low speed control including zero speed position hold. Controller includes thermal protection based on motor and controller temperature. · Joystick operation for load functions - utilizing a three-function hydraulic control valve. A fourth (4th) function hydraulic valve is available for an approved Class II attachment. · 48 volt DC battery with emergency disconnect switch, latching battery cover with drive interlock, plus side access compartment with slide strips or optional rollers.

Landoll trucks meet or exceed ASME B56.1 - Part III, Safety for Powered Industrial Trucks and are FMRC approved by meeting or exceeding requirements of FRMC Class 7820, ANSI/UL-583 standard for Battery Powered Industrial Trucks, Types E, ES, and EE. The electrical system complies with UL-583 requirements for type E, ES (optional), and EE (optional) Electrical Battery-Powered, Industrial Truck construction.

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

IMPORTANT !

Bendi AC truck operators and service personnel must familiarize themselves with this manual and the Bendi AC truck to provide safe and efficient operation. Practice runs in a controlled and safe area, away from obstacles and other personnel, are recommended. Unauthorized driving by untrained or unskilled personnel must be strictly prohibited.

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

· Duplex, triplex or quadplex high visibility mast configurations. · Lift capacity from a maximum of 3,000 lbs./1,361 kgs. up to 4,000 lbs./1,814 Kg. at 24”/600 mm load center. · Ergonomically designed operator compartment - includes sit-down operator position, adjustable driver’s seat, tilt/telescoping steering wheel, hand lever direction control, arm rest and operator supply tray · Safety interlocks - key switch activation and operator seat safety switch, plus an electrical lockout requiring the control lever to be in the neutral, or center position before power can be restored.

IDENTIFICATION (CAPACITY) PLATE ser iv caploc2

Figure 1-1 Capacity Dataplate Location

Bendi AC Operator’s Manual 1-2

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

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

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

Figure 1-2 Component Locations

Figure 1-3 Identification (Capacity) Plate

Bendi AC Forklift Operator’s Manual 1-3

Introduction

Truck Overview Frame The frame consists of 3/8” to 1” thick (9.525 mm to 25.4 mm) steel panels welded together to form the backbone of the truck (basic truck shape). A number of thick rectangular steel shapes (counterweights) are welded within the frame to counterbalance the truck against the weight of its load. The rear wall of the truck also includes a thick steel plate to add additional counterbalance.

Note: The size and weight of the battery is also used as a counterbalance.

Traction Drive Bendi AC trucks are dual-drive, four-wheeled trucks, having two steerable, articulating load support wheels in the front and two independently controlled drive wheels in the rear. The rear drive wheels consists of a gear box and a separate AC electric motor, controlled by the transistorized controller.

See “Electrical System,” on this page for additional information.

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

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

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

Safety Interlock Both a key lock switch (key switch) and an operator’s seat switch must be activated before the truck can move. The seat switch is activated when the operator is seated in the driver’s seat (Also see 'Seat Safety Switch,’ on page S-8 for additional information).

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

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

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

Additional information is available in the Appendix, of the Bendi AC Service Manual (F-526-___).

Bendi AC Operator’s Manual 1-4

Introduction Traction

Hydraulic System

Dual traction controllers are used, each having a maximum rating of 350 amps. Controllers provide full time dual rear wheel drive with steer position sensing to independently control the speed of each rear drive wheel during varying degrees of turn.

Inside wheel reversing occurs at full turn which also reduces the outside turning radius. Motor amp draws and operating temperatures are greatly reduced, while speed control, longer motor life, lower operating temperatures, increased motor torque and longer running times are greatly improved. The full speed range from 0 to 100% is controlled through the controller with maximum efficiency. Starting on a ramp is also accomplished without rollback with positive and smooth acceleration control.

The system uses a single pump to generate pressure and flow to meet the needs of both the steering system and the mast system. Only the amount of oil needed by the steering system is provided to the steering system. The amount of oil diverted to the steering system is based on operator input, allowing the excess oil to return to tank at a lower pressure, reducing the demands on the battery. The hydraulic pump motor is speed controlled to provide adequate steering response and is enabled through the selection of truck direction. Additional pump flow is provided linearly with the actuation of the lift function. Actuation of both the tilt and side shift functions provide step increases in pump flow to meet the demands of the function while ensuring adequate flow to the steering system.

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

For maintenance and/or emergencies, an emergency stop button (red)(B30)/ quick disconnect handle (B40) is provided. The emergency stop button (red) (B30) is located on the right-hand side of the driver’s compartment. The quick disconnect handle (B40) is located to the left side of the seat (See Figure S-4).

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

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

Additional information is available beginning on page 4-26.

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

Bendi AC Forklift Operator’s Manual 1-5

Introduction Steering

Side Shift

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

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

Mast Controls Mast positioning is achieved by operating the hydraulic control valve via the three hydraulic control levers. Hydraulic pressure is provided by a vane pump driven by a single AC electric motor. The pump operates continuously, ensuring enough oil for the steer circuit operation of lift, tilt, and sideshift cause an increase in pump speed, allowing no decrease in mast performance.

Mast movements may be operated individually or together; however, when operated together, the speed of operation is somewhat slower.

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

Bendi AC Operator’s Manual 1-6

Introduction Operator’s Cab

Warning

Driver Controls Driving controls for the Bendi AC truck include a steering wheel, horn button, a forward and reverse lever, foot brake pedal, accelerator pedal for speed control, hand-actuated parking brake lever and an emergency disconnect handle or switch (See Figure 1-4).

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

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

HORN BUTTON CONTROL LEVERS (LIFT, TILT, SHIFT)

DIRECTION CONTROL (FORWARD/REVERSE)

PARKING (HAND) BRAKE KEY SWITCH STEERING WHEEL W/ KNOB

-

TILT STEERING COLUMN

+

%

DASH DISPLAY

OPERATOR’S SWITCH PANEL (3) EMERGENCY BATTERY DISCONNECT (B40/B45 MODELS) DRIVER’S CAB ACCESS STEP

DRIVER’S TRAY DRIVER’S SEAT

drivecab2

Figure 1-4 Operator’s Cab

Bendi AC Forklift Operator’s Manual 1-7

Introduction · Accelerator pedal - is pressed by the driver’s right foot to control the speed of the truck (See Figure 1-5).

ACCELERATOR PEDAL

Travel speed varies according to the weight of the load. A Bendi AC has a maximum speed of 6.5 mph (miles per hour)/10.5 kph (kilometers per hour) with no load (empty), 6.0 mph/9.7 kph with a load. · Brake pedal - when pressed, applies the service brakes bringing the truck to a safe STOP (See Figure 1-5).

Note: The Bendi AC is designed for “plugging;” therefore, the service brake pedal should only be used in an emergency situation. · Key switch - switches electrical power to the truck On and OFF (See Figure 1-6).

BRAKE PEDAL

Warning

ser iv pedals

Figure 1-5 Pedals

Circuit breakers that fail more than most indicate an electrical problem that must be immediately investigated to find the cause. The truck must be removed from service until the problem is corrected.

KEY SWITCH breaker

Figure 1-6 Steering Column Side Panel

Bendi AC Operator’s Manual 1-8

Introduction Battery Compartment Access Cover /Latch COVER HOLD DOWN LATCH

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

The cover includes a mechanical retention latch and pin to secure the battery access cover to the overhead guard when opened (See Figure 1-7).

Another hold down latch is provided to secure the cover closed. · Direction control lever - is located on the driver’s side panel and selects the direction of travel of the truck (forward or reverse) (See Figure 1-8). · Horn push button - The horn is also located on the driver’s side panel.

OHG LATCH AND PIN BATTERY COVER PIN

cvrlatch

Figure 1-7 Battery Cover Latch

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

LIFT LEVER

HORN PUSH BUTTON

TILT LEVER ATTACHMENT LEVER (OPTION)

DIRECTION CONTROL LEVER

SIDE SHIFT LEVER

PARKING (HAND) BRAKE

Figure 1-8 Driver’s Arm Rest Control Panel

Bendi AC Forklift Operator’s Manual 1-9

Introduction · Emergency STOP push button/disconnect - Activate the emergency stop button (B30) / disconnect handle (B40) to shut down the drive and power steering motors and all mast movement. The truck drifts to a STOP. Immediately set the parking brake. To continue, reset the disconnect (See Figure S-4).

Use this button/handle: • in case of fire, smoke or overheating • if a person comes between the truck and a fixed object.

TILT STEERING ADJUST LEVER

• in case an accident occurs • in case of a short circuit or other electrical malfunction; for example, if the pump motor is on continuously. · Lift, tilt, and shift - Lift, tilt, and shift movements of the mast and lift carriage are accomplished using the three levers (joysticks) located on the driver’s side panel.

Each lever provides independent movement and each is marked with a graphic icon to represent the function it controls (See Figure 1-8).

Also see "Mast Operation," page 4-11 for additional information. · Parking brake pedal - engages the parking brake when the handled is pulled upwards.

The drive and power steering motors shut down and the direction control resets to NEUTRAL (See Figure 1-4).

To continue, the operator must first set the direction control lever to NEUTRAL, release the parking brake, then set the lever to the desired direction. · Rear view mirror - is attached to the front top of the overhead guard. The mirror is adjustable up and down, and side to side.

Bendi AC Operator’s Manual 1-10

Figure 1-9 Steering Column

· Tilt steering column - is pressed upwards to release the column so it may be adjusted up or down for the driver’s comfort (See Figure 1-9). · Operator switch panel - includes three on/off rocker switches to activate optional packages installed on your truck (See Figure -).

• LEFT switch - for headlights • CENTER switch - for factory or user supplied accessories • RIGHT switch - for speed mode toggles between fast and slow. Slow mode used for training and in confined spaces. Speeds can be adjusted by authorized technicians.

Note: Only those options included with your truck are operable. Also see the Options section of this chapter beginning on page 1-14 for more information about the options available.

Introduction Hourmeter - displays number of hours that the forklift has been used.

Hours accumulate when truck is on and operator is in seat.

Engage Display Panel - The Engage Display is located on the dash behind the steering wheel. It is comprised of the following gauges, displays, and switches (See Figure 1-10).

Speed Indicator - displays the speed mode that the truck is in.

BDI (battery discharge indicato-r) shows battery capacity (Figure 4-6).

"Battery Low Lift Lockout" will display in message window once battery capacity reaches 15%. At this point, t.he truck must be returned to the charger for a full charge cycle immediately.

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

Direction Indicator - displays the status of forward/reverse switch Scroll and Enter Buttons - used to enter information into system through display. These are used by an authorized technician.

IMPORTANT ONCE THE BATTERY CAPACITY REACHES 15% AND THE FORKLIFT ENTERS LIFT LOCKOUT, THE OPERATOR SHOULD CEASE ALL MAST FUNCTIONS IMMEDIATELY. THE PUMP MOTOR WILL STILL OPERATE WHEN A DIRECTION IS SELECTED IN ORDER TO PROVIDE STEER PRESSURE. IF THE OPERATOR NOTICES THE MAST LIFT SPEED DOES NOT INCREASE WHEN THE LIFT LEVER IS PULLED ALL THE WAY BACK, THEN THIS IS AN INDICATION THE FORKLIFT HAS ENTERED LIFT LOCKOUT AND MUST BE CHARGED IMMEDIATELY. THE REDUCTION IN PERFORMANCE, ALONG WITH THE MESSAGE DISPLAYED ON THE DASH, INDICATE THAT THE BATTERY NEEDS TO BE CHARGED.

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

STATUS/ FAULT DISPLAY SPEED INDICATOR

DIRECTION INDICATOR -

-

+ %

50

0

666.2

HOUR METER ENTER BUTTON BATTERY DISCHARGE INDICATOR ac dash display

+ %

hrs

ACCESSORY SWITCH

100

666 SVC

SPEED MODE SWITCH SCROLL BUTTONS MAINTENANCE HOURS, IF ENABLED

HEADLIGHT/TAILLIGHT TOGGLE SWITCH (WHERE FITTED)

Figure 1-10 Operator Switch Panel

Bendi AC Forklift Operator’s Manual 1-11

Introduction Mast Assemblies Various mast assembly configurations (duplex, triplex and /or quadplex) can be applied to the Bendi AC trucks to provide both collapsed and extended heights suitable for most customer requirements.

The lifting capacity of the mast also varies depending on the truck and its application. Load capacities are determined at 24” (609.6 mm) centers, centered on the mast and include all attachments on the carriage.

The Bendi Specifications list the dimensions of standard masts available for these trucks. Also check the identification (capacity) plate in the operator’s cab for the maximum lifting capabilities based on the particular truck and mast combination (See Figure 1-1).

Figure 1-11 Mast in Collapsed Position

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

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

The outer rails provide guidance and support for the middle rails, which in turn guide and support the inner rails. The truck forks are mounted on a carriage assembly that runs on rollers within the inner rails (See Figure 1-11).

Figure 1-12 Mast in Free Lift Position

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

This first stage of carriage lift is called free lift. It is the distance of lift available without increasing the overall height of the mast assembly (See Figure 1-12).

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

This upward lift continues until the secondary cylinders are fully extended (See Figure 1-13).

Bendi AC Operator’s Manual 1-12

Figure 1-13 Mast Fully Extended

Introduction The hydraulic fluid used to lift the primary cylinder is applied sequentially to the secondary cylinder.

When the primary cylinder reaches full extension, the secondary cylinder begins to extend.

As an option, trucks may be equipped with quadplex masts which utilize four sets of rails, referred to as Outer, Outer Intermediate, middle, and Inner rails, respectively (See Figure 1-14).

The differences in weights being supported by the cylinders, along with the differences in cylinder diameters, ensure that the primary cylinder will be fully extended before the secondary cylinder can begin to move. Consequently, when the mast is raised, it moves through two phases:

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

· Free lift, in which only the carriage assembly moves, up to the maximum height allowed by the inner rails (See Figure 1-12). · Rail extension, in which both the middle and inner rails move, carrying the carriage upward (See Figure 1-13).

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

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

Figure 1-14 Quadplex Mast in Collapsed Position

Bendi AC Forklift Operator’s Manual 1-13

Introduction

Technical Specifications Bendi AC Narrow Aisle Forklift Landoll Corporation’s policy is to continually improve products. We reserve the right to change specifications and design without notice.

Technical specifications for the standard Bendi AC, Models B30/42 and B40/48 and standard mast assemblies are listed in the Specifications section (See Page 5-1).

Available Options EE Series (Electrical Enclosure) EE series or Electrical Enclosure lift trucks are used in hazardous environments requiring protection from sparks, commonly produced by various electrical motors, contactors, switching devices, relays, etc.

EE trucks spark enclose all electrical components using specially designed covers and/or insulated metallic-seal enclosures to insulate sparks from the operating environment.

Cold Storage (Freezer Package) Cold storage consist of treatment of electrical connections to inhibit corrosion. Harness connections are sealed against moisture.

Bendi AC Operator’s Manual 1-14

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

Fire extinguishers must be inspected monthly and the results recorded on the inspection tag attached to each extinguisher (See Figure 1-15).

If your truck is equipped with an extinguisher, see "Fire Extinguisher" page S-16. Also see 'Fire Extinguisher Option' page 4-24 for additional information.

Figure 1-15 Fire Extinguisher

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

Introduction

Load Backrest

Fork Positioner

Figure 1-16 Fork Positioner Overview/ Setting

Fork Positioner, Non-Side Shifting Fork positioner options are hydraulically driven units that allow the forks to move equal distance from each other to accommodate the size of the load being moved (See Figure 1-16).

The forks start at the center of the carriage and move equal distance to the outside and back again as indicated by letters C and D (See Figure 1-16).

A push button is added to the pivot and shift joystick control (See Figure 1-17).

Figure 1-17 Joystick Push Button

Bendi AC Forklift Operator’s Manual 1-15

Introduction Light and Alarms Various light and alarm option packages are available as follows (See Figure 1-18 for examples): · Audible backup alarm — sounds (beeps or talking) when the truck is placed in reverse to alert all personnel in the area. · Rear LED strobe light — includes 180° blackout for operator protection and is available with red, amber or blue lens.

BACK UP ALARM

STROBE LIGHT

HEADLIGHT

TAIL LIGHT

· Headlights — Two LED lights with guards can be mounted on the mast or the overhead guard on the front, rear or both. · Stop/tail lights — Two LED light sets can be mounted to the back of the truck or the overhead guard. · Flashing backup strobe

alrm

Figure 1-18 Sample - Lights and Alarm

Bendi AC Operator’s Manual 1-16

Introduction Rollout Battery Tray The rollout battery tray assembly includes (See Figure 1-19): · Roller tray · Side restraint bracket, with spacer/shims as required · Adjustable restraint arm, with required spacers/shims · Limit switch for restraint arm

The battery rollout assembly reduces downtime when changing batteries by offering quick and easy battery servicing.

With the battery rollout restraint arm installed and locked, the limit switch is actuated to allow complete truck operation. Spacers/ shims are provided to secure the battery within the compartment.

Releasing the rollout restraint arm handle and removing the arm, for battery removal, releases the limit switch to shut down the truck. All operations are disabled.

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

ROLLOUT BATTERY RESTRAINT BATTERY TRAY

rollout battery tray

Figure 1-19 Rollout Battery Tray Assembly

Bendi AC Forklift Operator’s Manual 1-17

SECTION 2 Receiving and Inspection Receiving Your Truck Before shipping from the Landoll Company, LLC, each Bendi AC truck is inspected to make sure the truck you receive is in impeccable condition and equipped per your order. However, we recommend that you: · Inspect the truck for any signs of physical damage during shipment. Note any apparent damage on the bill of lading, and request the delivery agent to sign it.

Report the damage to your distributor and the shipping company. · Verify that the truck configuration and options match your purchase order.

Report any discrepancies to your distributor.

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

Items Required When the truck is received, a battery approved for use in the truck must be installed. The battery must be replenished from a battery charger at certain intervals.

No additional items are required to operate the truck.

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

Bendi AC Forklift Operator’s Manual 2-1

Receiving and Inspection

Warning

To Prepare the Truck 1. Check the hydraulic oil level. (See ‘Check Hydraulic Oil Level,’ in the Bendi AC Planned Maintenance Manual (F-527-___)).

2. Check the fluid level in the brake master cylinder reservoir. (See ‘Check Master Cylinder Fluid Level,’ Bendi AC Planned Maintenance Manual (F-527-___)).

3. Check the condition of the battery. (See “Charging a Wet Battery,” on page 2-2 or “Charging a Dry Battery,” on page 2-6).

Charging a Wet Battery The truck battery contains concentrated sulfuric acid which can cause severe chemical burns. When the battery is charging, it releases hydrogen, a highly explosive gas which can be ignited by a spark.

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

The battery is also very heavy, and if restraints are not replaced after maintenance, the battery could slide out of the truck causing electrical shorts or spilling acid - or it could cause the truck to tip.

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

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

Consult the label on your battery for information on cell-type, ampere-hour cap a c i t y, c h a rg e ra t e a n d n o r m a l full-charge voltage. Do not charge the battery at a current greater than 1.5 amp per 100 amp-hours capacity at the end of charge.

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

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

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

Bendi AC Forklift Operator’s Manual 2-2

Receiving and Inspection

Warning Keep vent plugs in place and clean at all times.

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

If the truck has been shipped with batteries installed, first remove the batteries from the truck. If the batteries have been shipped with electrolyte installed, check the specific gravity of the electrolyte using a hydrometer to determine if a charge is needed (See Figure 2-1).

If the reading is between 1.280 and 1.290, the battery is fully charged. If the reading is down near 1.150, the battery must be charged as described in "Charging a Wet Battery," page 2-2 and "Charging a Dry Battery," page 2-6.

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

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

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

Figure 2-1 Battery Charge State Using a Hydrometer

Bendi AC Forklift Operator’s Manual 2-3

Receiving and Inspection Using the Hydrometer

To Charge the Battery:

As the battery discharges, the specific gravity of the electrolyte reduces. A hydrometer allows you to check the specific gravity of the cells, thus the charge state of the battery (See Figure 2-1).

1. Remove each vent cap and check electrolyte levels. Ambient temperature should be +77° F (+25° C) to get a proper reading. In cold weather, batteries may look dry.

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

1. Remove a cap from one or two of the cells.

Gently squeeze (compress) the bulb of the hydrometer.

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

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

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

2. Do not add water until an accurate level is obtained - cold weather can affect the level. If water must be added, use only distilled water.

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

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

IMPORTANT !

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

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

Bendi AC Forklift Operator’s Manual 2-4

Receiving and Inspection 6. During the initial charge the volume of electrolyte decreases through electrolysis and evaporation. Water approved for use in lead-acid storage batteries should be added if the electrolyte level falls below the level indicator.

7. Continue charging until the cells gas freely and the specific gravity remains constant over a three-hour period. At the end of the charge period the cell voltages rise to about 2.55 volts and the specific gravity rises to about 1.280, corrected to 77° F (See Table 2-1).

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

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

Temp oF

Correction

Temp oF

Correction

39-41

-0.012

101-103

+0.008

42-44

-0.011

104-106

+0.009

45-47

-0.010

107-109

+0.010

48-50

-0.009

110-112

+0.011

51-53

-0.008

113-115

+0.012

9. Connect battery cables and install battery in truck.

54-56

-0.007

116-118

+0.013

57-60

-0.006

119-121

+0.014

61-63

-0.005

122-124

+0.015

64-66

-0.004

125-127

+0.016

67-69

-0.003

128-130

+0.017

70-72

-0.002

131-133

+0.018

73-75

-0.001

134-136

+0.019

76-78

0

137-139

+0.020

79-81

+0.001

140-142

+0.021

82-84

+0.002

143-145

+0.022

85-87

+0.003

146-148

+0.023

88-91

+0.004

149-151

+0.024

92-94

+0.005

152-154

+0.025

95-97

+0.006

155-157

+0.026

98-100

+0.007

158-160

+0.027

Table 2-1 Specific Gravity Corrections for Electrolyte Temperature

Bendi AC Forklift Operator’s Manual 2-5

Receiving and Inspection Charging a Dry Battery The truck battery contains concentrated sulfuric acid which can cause severe chemical burns. When the battery is charging, it releases hydrogen, a highly explosive gas which can be ignited by a spark.

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

The battery is also very heavy, and if restraints are not replaced after maintenance, the battery could slide out of the truck causing electrical shorts or acid to spill - or it could cause the truck to tip.

Warning Keep vent plugs in place and clean at all times.

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

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

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

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

Consult the label on your battery for information on cell-type, ampere-hour cap a c i t y, c h a rg e ra t e a n d n o r m a l full-charge voltage. Do not charge the battery at a current greater than 1.5 amp per 100 amp-hours capacity at the end of charge.

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

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

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

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

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

Bendi AC Forklift Operator’s Manual 2-6

Receiving and Inspection To Charge a Dry-Cell Battery: 1. Remove and discard plastic film seals from each cell vent hole (if present).

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

3. Allow the cells to soak for 2 to 3 hours after filling. The electrolyte level may drop slightly because of absorption into the plates and separators. If it does, add more electrolyte to restore the level.

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

5. During the initial charge the volume of electrolyte decreases through electrolysis and evaporation. Water approved for use in lead-acid storage batteries should be added if the electrolyte level falls below the level indicator.

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

6. Continue charging until the cells gas freely and the specific gravity remains constant over a three-hour period. At the end of the charge period the cell voltages rise to about 2.55 volts and the specific gravity rises to about 1.280 (corrected to 77° F) (See Table 2-1).

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

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

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

10. Connect battery cables and install battery in truck.

Bendi AC Forklift Operator’s Manual 2-7

Receiving and Inspection

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

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

Routine Checks

COVER HOLD DOWN LATCH

OHG LATCH AND PIN BATTERY COVER PIN

cvrlatch

Figure 2-2 Battery Safety - Latches and Pin

With the truck key switch set to OFF, perform a walk-around inspection. Check for obvious damage that would require more detailed inspection. If any of the following is apparent during your walk-around, record it in the log book for the truck and immediately notify your supervisor and/or service personnel. · Battery compartment cover /seat latch and pin - Check that the battery compartment cover is lowered into position and that the seat latch is secured whenever a battery is installed in the truck (See Figure 2-2). · Battery rollout tray option - If this option is installed, check that the battery rollout tray restraint arm is installed and locked into position.

RELEASE HANDLE RESTRAINT ARM

LIMIT SWITCH SPACERS rollarm1

Figure 2-3 Battery Safety - Latches and Pin

The handle must be down (locked, the limit switch actuated and the proper spacers installed to secure the battery within the compartment (See Figure 2-3). · Brake pedal - Check the operation of the brake pedal for smooth, firm, unobstructed movement when pressed and released.

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

Bendi AC Forklift Operator’s Manual 2-8

Receiving and Inspection

Inspection Check List

Visual Checks

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

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

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

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

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

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

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

After high-pressure washing, lubricate all unprotected grease fittings and metal-to-metal surfaces, located outside the truck. See page B-2 for lube points and lubrication table. Refer to the Bendi AC Planned Maintenance Manual (F-527-___) for lubrication instructions.

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

For example, use only in a well-ventilated area and do not breathe vapors.

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

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

Bendi AC Forklift Operator’s Manual 2-9

Receiving and Inspection · Brakes, service - With the key switch set to ON, drive forward slowly while steadily applying the brake pedal. The truck should stop smoothly without noticeable side pull or vibration.

Any problems with the brake system must be repaired immediately. Do not use the truck. · Driver’s seat - Check the seat covering for rips or cuts. Check seat belt straps for worn or frayed areas or cuts. Check that the seat belt is firmly attached and that the buckle is not damaged. Check that the seat belt works properly.

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

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

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

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

• If the truck continued moving forward, it must be removed from operation and the seat switch must be replaced. · Fasteners - Check for damaged, loose or missing screws and nuts. Tighten and/or have service replace as needed. · Horn, Lights, etc. - Check lights for proper on/off operation and for blown bulbs. Check that the horn sounds when pressed. Repair and/or replace as needed.

· Hydraulic oil level - Check the oil level weekly. Low oil can cause operational problems (See ‘Check Hydraulic Oil Level,’ in the Bendi AC Planned Maintenance Manual (F-527-___). · Engage Dash Display - Inspect the engage dash display for proper operation. This requires the key switch to be ON and can be checked prior to beginning your daily work routine. · Mast operation - With the key switch turned ON, raise the mast. Check that the primary cylinder extends fully and that the lift carriage raises to the top of the inner rails before the secondary cylinders begin to move.

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

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

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

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

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

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

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

· Hydraulic lines, loose fittings - Check underneath the truck for evidence of fluid leaks. Look for hydraulic hose wear, damage and leaks. Make sure clamps and fittings are tight. If leaks are found, have service repair all leaks immediately and check the hydraulic fluid level. Do not use the truck.

Bendi AC Forklift Operator’s Manual 2-10

Receiving and Inspection

Warning If the mast does not raise or lower properly or shows signs of binding, it may release or stop suddenly or move with a jerky motion and allow the load or carriage to drop. This could result in death or serious injury to the operator or nearby persons and/or damage the load. · Overhead Guard - Check the overhead guard and make sure that it is firmly attached to the truck and that all fasteners are secured. The overhead guard is adjustable to accommodate various drivers’ and operating restrictions (low ceilings, door openings, etc.) · Parking brake - The parking brake system includes an interlock that shuts down the drive and power steering motors, disables the direction control (resets to NEUTRAL) and applies the brakes to prevent further truck movement.

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

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

· Rust or corrosion - Check the truck frame, side and floor panels for rust and corrosion.

Clean rusty or corroded areas and repaint, if applicable. Apply a thin coat of oil to any bare metal surface. · Safety decals, data plates, etc. - Check for damage and missing decals. Check that the decals are legible. Clean and/or replace as needed. · Seat brake, optional - when releasing the seat switch, a clicking sound is heard as the electro-magnetic brakes apply. · Static discharge strap - Make sure the static discharge strap is dragging (touching) the ground. The strap is located at the rear of the truck, between the rear wheels. · Tires and wheels - Check tires for cuts or chunking, oil slicks, embedded foreign material or excessive wear. Check wheels for missing lug nuts. Repair and/or have service replace immediately. Do not use the truck. · Welds, cracked or broken - Check for damage and reliability. Clean and repair immediately. Do not use the truck. · Wires or connectors - Look for damaged, cracked or broken insulation, bare wires showing, loose or broken connectors. If electrical problems are found, have service make repairs immediately. Do not use the truck.

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

• The truck must immediately slow to a STOP, and power steering is disabled.

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

Bendi AC Forklift Operator’s Manual 2-11

Receiving and Inspection OVERHEAD GUARD

Replacing the Battery Replacing the battery requires lift and support apparatus capable of supporting the weight and size of the battery. Check the identification (capacity) plate for battery information (See Figure 1-1).

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

LATCH AND PIN LATCH BRACKET

To Replace a Battery 1. Return the truck to your service charging station area.

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

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

COMPARTMENT COVER latch

Figure 2-4 Overhead Guard Battery Cover Latch

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

5. Secure the cover to the overhead guard latch and insert the locking pin. Jiggle cover to be sure latch is secured (See Figure 2-4).

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

Bendi AC Forklift Operator’s Manual 2-12

Receiving and Inspection BATTERY HANDLE

BATTERY CABLE DISCONNECT

BATTERY CONNECTOR

TRUCK CONNECTOR

TRUCK IDENTIFICATION (CAPACITY) PLATE HANDLE MUST BE INSTALLED AND USED FOR SAFE OPERATING CONDITIONS AND COMPLIANCE W/ UL58

TRUCK CABLE DISCONNECT

Model B30

Model B40

Figure 2-5 Battery Disconnects

Note: If your truck includes the rollout battery tray option, see “Rollout Battery Tray Option”, page 1-17.

OVERHEAD GUARD CUTOUT

7. Disconnect the battery/truck cable disconnect and lay the battery cable across the battery top (See Figure 2-5).

BATTERY COMPARTMENT TOP COVER AND SEAT

8. Slide the compartment side door spring latch towards to the front of the truck to release the side door. Open the door (See Figure 2-6).

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

BATTERY COMPARTMENT TOP COVER LOCKING LATCH BATTERY ADJUSTMENT BRACKET (BOTH SIDES) BATTERY COMPARTMENT SIDE DOOR btry compartment

Figure 2-6 Removing the Battery

Bendi AC Forklift Operator’s Manual 2-13

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

Tighten and torque the screws (See General Torque, Hydraulic Fitting Torque, and Bendi AC Special Torque Tables on pages B-3 through B-5).

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

12. Close and secure the compartment side door and connect the battery electrical connector (blue). Situate the excess wiring between the battery and the side wall of the truck, making sure the wires are not exposed causing a “pinch” condition when the top cover is closed.

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

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

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

When installing the battery make sure the spacers are the correct configuration for the battery being installed. You want to restrict as much side-to-side play as possible.

Also see ‘Rollout Battery Tray,’ page 1-17, for additional information.

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

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

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

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

Battery Storage In general, batteries that are fully charged with the electrolyte at the proper level may be stored for up to one year. Batteries should be stored in a cool, dry, well-ventilated area, away from direct sunlight.

Batteries without covers should be covered with a non-conductive material to protect them from dirt, moisture, etc.

IMPORTANT !

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

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

Bendi AC Forklift Operator’s Manual 2-14

Receiving and Inspection Towing the Truck

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

TIEDOWN POST/ TOW PIN

Never lift a truck using straps, chains or hoists of any type.

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

Never use the truck to tow materials.

Figure 2-7 Tiedown Post Used for Towing

Never tow a truck that is carrying a load.

Never connect towing equipment to the mast.

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

If the truck breaks down and cannot be repaired at that location, it may be towed by attaching a suitable hook and chain to the tow bar located in the cutout at the lower rear of the truck (See Figure 2-7).

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

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

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

2. Remove the battery. Scrape away and wipe clean any wet residue or corrosive deposits left by the battery.

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

4. Set the mast to its forward (level) position and lower the forks to the bottom of the mast - align the mast indicator pointer located on the left side of the mast, as viewed from the front of the truck.

5. Disconnect the jumper cables from the truck.

6. Set the parking brake as firmly as possible.

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

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

IMPORTANT! (Also see ‘Battery Care,’ on page S-12 for additional information.)

Bendi AC Forklift Operator’s Manual 2-15

Receiving and Inspection Using Lifting Equipment

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.

If you need to use a hoist to lift your Bendi forklift: 1. Pass a strap under the truck just in front and behind of the rear wheels (See Figure 2-8).

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

Figure 2-8 Setting Lift Equipment

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

DO NOT USE CHAINS!

Bendi AC Forklift Operator’s Manual 2-16

SECTION 3 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 legislation 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 AC Forklift Operator’s Manual 3-1

Before You Begin

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

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

Operator Safety Before you start using your Bendi 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 (capacity) plate for rated capacity and load center information.

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

Warning Make sure that the load is centered and the forks are fully engaged. Failure to do so can cause the load to fall, or the truck to tip over, resulting in serious injury or death.

The leading causes of accidents involving forklift trucks are due to the lack of understanding of how forklift trucks operate, especially when it comes to stability. If you do not understand the concepts of stability, you may tip over your Bendi forklift truck which can cause serious injury or death.

Bendi AC Forklift Operator’s Manual 3-2

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

Unlike an automobile which has four points of suspension, Bendi forklift trucks operate on a three-point suspension. When the forks are turned nearly 90° to the right, two of the suspension points are on the rear axle (item 1) and (item 2). The third suspension point is the center point of the front axle (item 3) . The center of gravity, an imaginary point at which all of the truck’s weight is concentrated, is located as shown (item 4) when: · The forks are turned nearly 90° to the right · No load is placed on the forks · The truck is at rest.

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

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

This triangle is commonly called the stability triangle.

Since the center of gravity is an imaginary point, it will shift for various reasons that we will explore in a moment. The crucial thing to remember is, as long as the center of gravity of the truck remains within the border of the stability triangle, the truck will not tip.

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

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

Figure 3-1 Right View 90o Stability

Figure 3-2 Left View 90o Stability

Bendi AC Forklift Operator’s Manual 3-3

Before You Begin Knowing the Rated Capacity

Warning

Identification (Capacity) Plate Identification (capacity) plates are provided on the truck.

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 (capacity) plate for rated capacity and load center information.

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

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.

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

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

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

2. Serial No. The serial number of your Bendi forklift appears here.

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

5. Lift height. This is the fork height stated in inches. This is the distance between the ground and the top edge of the forks.

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

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

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

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

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

Figure 3-3 Identification (Capacity) Plate

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

Bendi AC Forklift Operator’s Manual 3-4

Before You Begin 12. Truck Type. 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.

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

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

13. Nominal Voltage. Nominal voltage indicates whether the truck uses a 48 DC battery.

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

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

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

Bendi Serial Number Code MAST SERIAL NO. LOCATION

The following information will help decode the Bendi serial number: Baa/ww-ymms-xxxxx Where: Aa

ww

y mm s xxxxx

= 30 for 3,000 lb rated capacity truck = 40 for 4,000 lb rated capacity truck = 45 for 4,500 lb rated capacity truck = 42 for 42” frame width = 48 for 48” frame width = 56 for 56” frame width = last digit of year of manufacture (ex. “8” means 2008, “9” means 2009) = month of manufacture = component series; such as “A” = frame number

serno

FRAME NO. LOCATION

Figure 3-4 Frame and Mast Identification

Bendi AC Forklift Operator’s Manual 3-5

Before You Begin Load Center

Counterweight

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

You need to consider two types of load centers. The horizontal load center, is equal to one-half the length of the load when the weight is evenly distributed. For example, a load that is 48 in. long has a horizontal load center of 24 in. The further the load center is from the fulcrum, the less stable the forklift. Always make sure your load is flush against the rear of the forks, and that unevenly distributed loads are loaded with the heaviest end of the load closest to the front wheels (See Figure 3-5).

Warning Never let a co-worker stand on the back of the forklift to add counterweight.

Your co-worker can fall off the forklift, or the truck can tip backwards, causing serious injury or death.

Your Bendi forklift has a counterweight that allows it to travel with heavy loads (See Figure 3-5). 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.

The vertical load center, is equal to one-half the height of the load when the weight is evenly distributed. For example, a load that is 48 in. high, has a vertical load center of 24 in. Make sure that you do not pick up a load that is higher than twice the vertical load center.

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

HORIZONTAL LOAD CENTER

COUNTERWEIGHT FULCRUM REAR OF FORKS VERTICAL LOAD CENTER

ser iv box

Figure 3-5 Load Center Rating

Bendi AC Forklift Operator’s Manual 3-6

Before You Begin Maximum Fork Height

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

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

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

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

This is measured from the floor to the forks when they are raised in their highest position. The higher the forks are raised, the less stable the forklift becomes.

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

Attachments

Warning Never modify your Bendi forklift in any manner. Only options and attachments approved by Landoll Company, LLC may be installed on the truck. Other modifi-cations 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 Company, LLC, an additional identification plate is attached to the truck.

The new plate identifies the type of attachment, the changes in the load centers, and the rated capacity.

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

MAXIMUM FORK HEIGHT

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

ser iv lift

Figure 3-6 Maximum Lift Height

Tilting Considerations

· Weight is determined by multiplying the weight of each small container by the number of small containers on a pallet. Each small container should be marked with its weight. · Ask your supervisor when in doubt

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

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

Bendi AC Forklift Operator’s Manual 3-7

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

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

Special rules should be followed if your workplace uses dockboards on loading docks: · Never exceed the carrying capacity marked on portable or powered dockboards. · Portable dockboards must be secured in position, using anchors or other devices that prevent slipping.

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

Bendi AC Forklift Operator’s Manual 3-8

Before You Begin Trucks

Warning

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

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

4. Do not move trailers with a Bendi forklift.

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

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 flashing beacon · Flashing backup light · Rear safety light package · Back up alarm

Working in Hazardous Environments Here are some types of hazards you might encounter in your workplace: · Atmospheric/Electrical · Chemical

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.

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

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

Bendi AC Forklift Operator’s Manual 3-9

SECTION 4 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.

The procedure for performing this inspection is explained.

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

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

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

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.

Use in external conditions Normal operating conditions Wind loads effects Slippery conditions due to water, oil, etc.

Bendi AC Forklift Operator’s Manual 4-1

Operating Your Bendi Forklift

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

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

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

Report any defect immediately to your supervisor!

You are responsible for the daily inspection of your Bendi forklift: · Photocopy the Operator’s Daily Checklist in the Bendi AC Planned Maintenance Manual (F-527-___) or use the form supplied by your supervisor. · Inspect the truck and fill out the form · Report defects to your supervisor · Return the form to your supervisor

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

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

ACCELERATOR PEDAL

Accelerator Pedal The accelerator pedal, is located on the floor to the right of the brake pedal (See Figure 4-1).

Operation - Pressing the pedal down starts the truck moving in the direction you selected, see discussion of the “Direction Lever.” The closer you press the accelerator pedal to the floor, the faster the forklift moves. Releasing the pedal brings the vehicle to a smooth stop.

BRAKE PEDAL ser iv pedals

Figure 4-1 Accelerator and Brake Pedals

Bendi AC Forklift Operator’s Manual 4-2

Operating Your Bendi Forklift Brake Pedal

Key Switch

CAUTION Always use your right foot for braking.

Do not steer with brakes applied.

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

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

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.

The key switch is located to the right of the steering column (See Figure 4-2). Insert the key and turn right to operate the truck. Make sure the parking brake is applied and the direction switch is in neutral before switching on. All load controls and the accelerator should be in neutral (i.e. not depressed) before starting. Do not depress the accelerator during starting.

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

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

ENGAGE DASH DISPLAY

STEERING WHEEL -

+ %

0

666.2

50

hrs

100

666 SVC

KEY SWITCH

3. Tighten the tilt lever.

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

TILT CLAMP str column and dash

Figure 4-2 Steering Wheel Components

Bendi AC Forklift Operator’s Manual 4-3

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

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

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

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

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

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

IMPORTANT! Make sure the release button on the buckle is set so you can unbuckle the seat belt quickly in an emergency (See Figure 4-3).

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

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

Warning A twisted belt can seriously injure you.

In a crash or a tip-over, the full width of the belt is required to absorb the impact forces.

Figure 4-3 Belt Release Button

Bendi AC Forklift Operator’s Manual 4-4

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

Rake Adjustment The rake adjustment has three adjustment positions.

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

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

Figure 4-4 Driver's Seat Controls

Bendi AC Forklift Operator’s Manual 4-5

Operating Your Bendi Forklift Dash The Dash is located behind the steering wheel (See Figure 4-5). It is comprised of the following gauges, displays, and switches (See Figure 4-6):

ENGAGE DASH DISPLAY

STEERING WHEEL -

+ %

0

666.2

1. Engage Dash Display

50

hrs

100

666 SVC

KEY SWITCH

2. Speed Mode Switch 3. Headlights (where fitted) 4. Option (where fitted) The dash display is located in the center of the console (See Figure 4-6). The main display shows hour meter, brush wear indicators, and drive motor over temperature. Use the scroll button to change the intensity of the display The battery discharge indicator showing battery capacity is above the main display.

TILT CLAMP str column and dash

Figure 4-5 Dash Display Location

STATUS/ FAULT DISPLAY SPEED INDICATOR

DIRECTION INDICATOR -

-

+ %

0

666.2

HOUR METER ENTER BUTTON BATTERY DISCHARGE INDICATOR ac dash display

+ %

50

hrs

ACCESSORY SWITCH

100

666 SVC

SPEED MODE SWITCH SCROLL BUTTONS MAINTENANCE HOURS, IF ENABLED

HEADLIGHT/TAILLIGHT TOGGLE SWITCH (WHERE FITTED)

Figure 4-6 Dash Display

Bendi AC Forklift Operator’s Manual 4-6

Operating Your Bendi Forklift Parking (Hand) Brake

Side Shift Lever

The parking (hand) brake is located to the left of the control levers (See Figure 4-7).

The third lever on the front of the armrest is the side shift lever (See Figure 4-7). Side shift is a standard function on Bendi forklifts.

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

Direction Lever The direction lever is located on the front of the control pod (See Figure 4-7).

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

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

Attachment Lever(s) - Option A fourth optional function can be fitted via a push button controlled solenoid (See Figure 4-7). The push button is mounted on the side shift lever.

Powered attachments are optional functions on Bendi forklifts.

Horn The horn is located on the control pod (See Figure 4-7).

LIFT LEVER

HORN PUSH BUTTON

Lift Lever

TILT LEVER

The first lever (closest to the operator) on the front of the armrest is the lift lever (See Figure 4-7).

ATTACHMENT LEVER (OPTION)

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

SIDE SHIFT LEVER

DIRECTION CONTROL LEVER

Tilt Lever The second lever on the front of the armrest is the tilt lever (See Figure 4-7). A visual indicator is provided so you can easily determine the number of degrees the mast is tilted.

PARKING (HAND) BRAKE

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

Figure 4-7 Control Levers

Bendi AC Forklift Operator’s Manual 4-7

Operating Your Bendi Forklift

Operating Instructions Basic Procedures Warning Check all systems before operating this vehicle. Report unsafe conditions and correct them before operating vehicle.

Do not operate vehicle unless trained and authorized to do so. Failure to follow these guidelines can result in serious injury or death.

Warning Every forklift operator must be trained in accordance to the rules provided by OSHA, relating to Forklift Trucks. Your employer must ensure that each powered industrial truck operator is competent to operate a powered industrial truck safely, as demonstrated by the successful completion of the training and evaluation. Operating a powered industrial truck without the proper training can cause serious injury or death. It is also illegal.

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

Before you operate your Bendi 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 the forklift.

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.

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

IT SHOULD NEVER BE USED INSTEAD OF DRIVER TRAINING.

Bendi AC Forklift Operator’s Manual 4-8

Operating Your Bendi Forklift Driving Position

Starting and Traveling

Warning

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

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

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

1. Sit in the seat and face forward in the position outlined above (See Figure 4-8).

Refer to Figure 4-8 for proper seating position.

4. Use the lift lever to raise the forks 4 to 6 in. from the ground and the tilt lever to tilt the mast back.

This is the recommended traveling position.

1. Adjust the driving seat for comfortable operation of the forklift controls (See Figure 4-8). You must be correctly seated with all body parts inside the cab.

2. Fasten your seatbelt (See Figure 4-8).

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

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

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

2. Set the direction lever to neutral (See Figure 4-9).

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

5.

Hold the steering knob firmly with your left hand (See Figure 4-9).

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

The truck will travel in that direction – so make sure that it is clear. Release the parking brake and set the direction of travel.

7. Gently depress accelerator pedal as required to achieve a safe operating speed. If the truck is on an incline, release the brake and press the accelerator pedal simultaneously to avoid reverse motion (See Figure 4-10).

PARKING (HAND) BRAKE

-

DIRECTION LEVER

+ %

0

666.2

50

hrs

100

666 SVC

ac st-trvl

Figure 4-8 Proper Seating Position

Figure 4-9 Parking Brake and Direction Lever

Bendi AC Forklift Operator’s Manual 4-9

Operating Your Bendi Forklift ACCELERATOR PEDAL

Stopping

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.

Warning 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.

BRAKE PEDAL

Caution

ser iv pedals

Figure 4-10 Accelerator and Brake/Inching Pedals

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

Turning

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

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.

When you reach an intersection: · Slow down. Even if the forklift is not carrying a load it can tip-over if you turn at a high rate of speed!

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

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

· 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 AC Forklift Operator’s Manual 4-10

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

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

Parking

Warning

Figure 4-11 Lift, Tilt, and Shift Placard

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

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

LEVEL SETTINGS, IN DEGREES

Before you park the vehicle make sure:

TILT CYLINDER

· 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.

TILT INDICATOR

tiltset

Figure 4-12 Tilt Level Gauge

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

Mast Operation

When you park your forklift always:

Each mast operation is controlled by individual control levers - LIFT, TILT and SHIFT (See Figure 4-11). Practice using each lever, as explained below, until you are comfortable with the operation of the mast.

1. Apply the hand brake.

2. Tilt the mast forward.

3. Lower the forks to the ground.

4. Turn the key switch to the OFF position.

5. Remove the key.

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

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

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

3. Pull the TILT lever towards you to tilt the mast back. Rear tilt is 3° maximum (See Figure 4-12).

Bendi AC Forklift Operator’s Manual 4-11

Operating Your Bendi Forklift 4. Push the TILT lever away from you to move the mast forward, or to return the forks to their horizontal position as indicated by the tilt level gauge mounted on the right and left sides of the mast (See Figure 4-12).

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

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

You should tilt the mast only at the floor level or at the load level in the rack when depositing or picking up a load.

At any other time, forward tilting could cause the truck to tip forward or cause the load to slide off the forks causing serious injury to yourself or anyone in the area.

6. Tilting a loaded mast forward should be done slowly by feathering the TILT lever. Rapid tilting might jostle a load off the forks prematurely.

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

8. Push the SHIFT lever forward to shift the mast to the right (See Figure 4-11).

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

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

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

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

Make sure you are thoroughly familiar with the operation of the Bendi AC trucks before you attempt to handle loads. Repeated practice is a must! A mistake in load movement could jam the load into the racks, causing damage, or could dislodge a load from the forks, causing serious injury to people below.

Bendi AC Forklift Operator’s Manual 4-12

Operating Your Bendi Forklift

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” (See Figure 4-13).

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.

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

Never carry passengers on the truck.

Figure 4-13 Tipping a Load

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

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

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

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

Bendi AC Forklift Operator’s Manual 4-13

Operating Your Bendi Forklift Setting the Forks Before you get on the forklift make sure the spacing between the forks is properly set (See Figure 4-14): 1. Measure the center to center between the fork openings on the pallet (See Figure 4-14).

2. Lift the fork locks up (See Figure 4-14).

3. Move the forks until the center to center spacing is equal to the center to center distance. Make sure the forks are seated in a carriage notch and equidistant from the ends of the carriage (See Figures 4-14 and 4-15).

4. Press the fork locks down to ensure locking.

Figure 4-14 Setting the Forks

ROTATE AND LIFT TO UNLOCK

frkrls

Figure 4-15 Setting the Forks

Bendi AC Forklift Operator’s Manual 4-14

Operating Your Bendi Forklift Retrieving a Load Note: Actual minimum aisle width (item 5) Figure 4-16 will vary based upon application.

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

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

Follow these steps to retrieve a load: 1. Approach the side of the aisle that is opposite the load (item 1) Figure 4-16.

2. For narrow aisles, straighten out the truck so it is 8 in., (item 2) Figure 4-16, from the edge of the aisle opposite the load. For wider aisles, straighten out the truck so it is 36 in. to 48 in., (item 6) Figure 4-16, from the side of the aisle where the load is located.

Figure 4-16 Setup - Load Pick Up

3. Center the forks using the side shift lever.

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) Figure 4-16, are aligned with the center of the pallet (item 4) Figure 4-16.

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

6. Stop the forklift and turn the forks 90° using the steering wheel to align them with the load (See Figure 4-17).

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

Figure 4-17 Align the Forks

Bendi AC Forklift Operator’s Manual 4-15

Operating Your Bendi Forklift 7. Straighten out the forks using the steering wheel as you drive them into the load so the forks enter the load in a straight line (See Figure 4-18).

8. Turn the steering wheel to keep the forks straight as you fully insert them into the load and lift, tilt, and side shift as required to stabilize and pickup the load (See Figure 4-19). Only raise the load high enough to clear the rack or the load backrest may catch on the rack.

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

9. Shift into reverse and slowly back away from the stack as you turn the steering wheel to keep the forks straight (See Figure 4-20).

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

Figure 4-18 Positioning the Forks If you still are unable to get enough clearance, drive forward and try the removal process again.

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

Figure 4-19 Inserting the Forks into the Load

Figure 4-20 Retrieving the Pallet

Bendi AC Forklift Operator’s Manual 4-16

Operating Your Bendi Forklift 11. When the front right hand corner of the load (item 1) Figure 4-21 clears the rack, stop backing and turn the steering wheel clockwise to straighten out the forks so they are parallel with the body of the truck (See Figure 4-22).

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

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

Figure 4-21 Retrieving the Load

Figure 4-22 Normal Travel Position

Bendi AC Forklift Operator’s Manual 4-17

Operating Your Bendi Forklift In Case Your Forklift Tips Over The following conditions can cause a forklift to tip over: · A load exceeding the stated load centers · Tip Loading (See Figure 4-23) · A load that is too heavy · Taking a corner too fast · Driving with the load raised · A load that is not distributed properly (keep the heavier items near the load backrest) · Driving across a slope

Figure 4-23 2. Hold on to the steering wheel (See Figure 4-25).

· Driving on a slope with the load facing downhill · Using a battery that weighs less than or more than the weight range listed on the identification plate

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

Figure 4-25

If you sense your forklift is going to tip-over, follow these instructions: 1. Lean away from the direction the truck is tipping (See Figure 4-24).

3. Brace your feet (See Figure 4-26).

Figure 4-26 Figure 4-24

Bendi AC Forklift Operator’s Manual 4-18

Operating Your Bendi Forklift 4. Don’t jump (See Figure 4-27).

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

Transporting a Load

Figure 4-27

Follow these guidelines when you transport a load:

Turning

· 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 in. to 6 in. off the ground. · Be alert to overhead obstructions such as low doorways, racking, and pipes. Make sure you know the raised and lowered heights of the mast. · 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.

Figure 4-28

Warning A lateral tip-over can occur if your truck is improperly operated (See Figure 4-28). Slow down before turning! Failure to slow down can cause serious injury or death.

Bendi AC Forklift Operator’s Manual 4-19

Operating Your Bendi Forklift Traveling on Inclines

Warning Use extra caution when operating on ramps. Travel slowly and do not turn.

Travel with load uphill. Travel with empty forks downhill. Failure to follow these guidelines can cause serious injury or death.

When you travel up or down an incline, follow these guidelines: · Make sure the gradient is 12% or less with a loaded Bendi forklift and 15% or less if you are not carrying a load. · Always keep the load pointed uphill (See Figure 4-29). Travel with the forks facing uphill whether you are going up or down an incline. That means you must back down an incline when you are carrying a load. If vision is obscured, arrange for a ‘Banksman’ to guide you.

Figure 4-29 Traveling Uphill

· If you are not carrying a load, travel with the forks facing uphill when you are going up the incline and face the forks downhill when you are traveling down an incline (See Figure 4-30). · 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 in. to 6 in. off the ground when you clear the incline.

Figure 4-30 Traveling Down an Incline

Bendi AC Forklift Operator’s Manual 4-20

Operating Your Bendi Forklift Unloading Your Forklift Note: Actual minimum aisle width may vary based upon application (item 5) (Figure 4-31).

Note: The following illustrations show standard 40 in. x 48 in. (W x L) pallets loaded on a rack with 96in. beams. The arrow labeled with an ‘S’ shows the direction you must turn the steering wheel.

Follow these steps to store a load: 1. Approach the side of the aisle that is opposite the area where you will unload the forklift (item 1) (Figure 4-31).

2. For narrow aisles, straighten out the truck so it is 6 in. to 8 in., (item 2) (Figure 4-31), from the edge of the aisle opposite the drop off point. For wide aisles, straighten out the truck so it is 36 in. to 48 in. (item 6) (Figure 4-31), from the side of the aisle where the load is located.

Figure 4-31 Setup - Delivering a Load

3. Center the load using the side shift lever.

4. Drive forward until the front edge of the load wheels, (item 3) (Figure 4-31), are aligned with the center of the rack opening (item 4) (Figure 4-31).

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.

5. Lift the load to the proper height.

6. Stop the forklift and turn the load 90° (turn the steering wheel counterclockwise) so it points in the direction you will drop it off (See Figure 4-32).

Figure 4-32 Load Drop-Off

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

Bendi AC Forklift Operator’s Manual 4-21

Operating Your Bendi Forklift 7. Drive forward and straighten out the load using the steering wheel so it is square over the stack (See Figure 4-33).

8. Turn the steering wheel to keep the load straight as you drive it into the opening (See Figure 4-34).

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

Warning When you lower the forks to the “no load” position, make sure you do not lower the forks too far (See Figure 4-35).

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

Figure 4-33 Straighten the Load for Drop-off

10. Lower the forks until the load sits firmly on the rack. Continue to lower the forks until they no longer support the load (‘no load’ position) (See Figure 4-35).

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.

Figure 4-34 Inserting the Load “NO LOAD” POSITION

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

Figure 4-35 No-Load Position

Bendi AC Forklift Operator’s Manual 4-22

Operating Your Bendi Forklift 11. Shift into reverse and slowly back out of the load as you turn the steering wheel to keep the forks straight (See Figure 4-36).

12. When the front right fork (item 1) Figure 4-37 clears the rack, stop backing and turn the steering wheel to straighten out the forks so they are parallel with the body of the truck.

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

Using Lifting Equipment to Move a Forklift to Another Location

Figure 4-36 Backing Away from the Load

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.

If you need to use a hoist to lift your Bendi forklift: 1. Pass a strap under the truck just in front and behind of the rear wheels (See Figure 4-38).

Figure 4-37 Removing the Forks

2. Pass a strap under the cross-member at the top of the mast (See Figure 4-38).

3. Make sure you place a spacer (such as a 2 in. x 6 in. block of wood) between the overhead guard and the lift point to avoid damage to the truck (See Figure 4-38).

Figure 4-38 Using Lifting Equipment to Move Forklift

Bendi AC Forklift Operator’s Manual 4-23

Operating Your Bendi Forklift

Fire Extinguisher Option If your truck includes a fire extinguisher it should be inspected monthly or more frequently if circumstances dictate. The extinguisher should be checked to see that: · it is not damaged · the discharge outlet is not blocked · it is fully charged · the seal is not broken · the instruction pamphlet is clearly visible

IMPORTANT !

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

In Case of a Fire !

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

All fires should be handled by professionals. Call the fire department, no matter what the size of the fire. Emergency telephone numbers should be posted at each telephone.

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

1. Have everyone vacate the area immediately.

2. Hold the extinguisher upright and pull the pin.

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

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

5. Move closer to the areas as the fire is extinguished, BUT NOT CLOSE SO AS TO DISPERSE BURNING MATERIAL. 6. When the fire is extinguished, beware of reignition.

7. Vacate and ventilate the area immediately.

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

Bendi AC Forklift Operator’s Manual 4-24

Operating Your Bendi Forklift

Fork Positioner Option The forks start at the center of the carriage and move equal distance to the outside and back again as indicated by letters C and D (See Figure 4-39).

Figure 4-39 Setting the Forks

A push button is added to the pivot and shift joystick control (See Figure 4-40).

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

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

Figure 4-40 Sample, Joystick Push Button Option

Bendi AC Forklift Operator’s Manual 4-25

Operating Your Bendi Forklift

Hydraulic System The hydraulic system described in this section is for a standard Bendi AC truck. A hydraulic layout diagram and schematic are also included with the Service Manual. These are located under the flap, front and/or back, of the binder cover. Your hydraulic system may vary due to customer modifications or options purchased.

The system uses a single pump to generate pressure and flow to meet the needs of both the steering system and the mast system. Only the amount of oil needed by the steering system is provided to the steering system. The amount of oil diverted to the steering system is based on operator input, allowing the excess oil to return to tank at a lower pressure, reducing the demands on the battery. The hydraulic pump motor is speed controlled to provide adequate steering response and is enabled through the selection of truck direction. Additional pump flow is provided linearly with the actuation of the lift function. Actuation of both the tilt and side shift functions provide step increases in pump flow to meet the demands of the function while ensuring adequate flow to the steering system.

Note: When a fourth function is needed (e.g., fork positioner) a separate solenoid valve system is added and is activated by a push button mounted on the side shift knob.

Power Steering System The power steering system consists of a: · Dynamic Load Sense Steering Control Unit (orbital) · Steer motor · Load sense diverter valve, part of main control valve. · Main Hydraulic Pump and Motor · Hydraulic Pump Motor Controller

The steering system operates with the selection of a truck direction. This switch closure signals the hydraulic pump motor controller to operate the motor at a speed that is defined in the controller as Steer Speed. The Bendi AC power steering system uses a dynamic load sense steering control unit to control oil flow to the steering motor at the front of the truck.

As the steering wheel is turned, the load sense orbital sends a signal to the load sense diverter valve within the main control valve causing oil to be sent to the orbital.

When the steering wheel is not being turned, the oil returns to tank at with very little increase in pressure.

To protect the system from excessive pressure build up (for example, when the wheel is turned fully in one direction and held), the pump is by-passed by a pressure relief valve set at 2,600 psi (18MPa). At 2,600 psi, the pressure valve opens to dump excess oil to the tank, while maintaining up to 2,600 psi for power steering operation.

IMPORTANT !

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

If primary pressure falls, the orbital acts as a pump providing fluid to the steering motor. However, the operator must now supply the force ordinarily provided by the pressurized fluid.

Mast Systems The mast hydraulic system consists of a: · Main Hydraulic Pump and Motor · 3 spool valve · Hydraulic Cylinders The mast hydraulic system is divided into lift, tilt and side shift circuits. A single 1.53 cu in per rev pump is coupled to the hydraulic pump motor.

The 3 spool valve controls the flow to the lift cylinders, tilt cylinders, and sideshift cylinders.

System pressure is controlled at 2800 psi to protect cylinders and hoses.

Bendi AC Forklift Operator’s Manual 4-26

Operating Your Bendi Forklift Tilt and Shift

Lift and Lower

During the tilt operations, the lift pump provides oil flow to these cylinders. Oil flow drives one side of the cylinder while relieving the pressure on the other side. This produces smooth tilt “backward,” and shift side-to-side movements.

The lift circuit consists of a primary cylinder and two secondary cylinders all driven in parallel, a directional control valve, a velocity fuse and a flow regulator (internal to mast assembly).

During tilt forward operation, an additional pressure valving (anti-cavitation 1) is provided internally to the tilt cylinders.

If a load is present on the forks, the weight of the load forces the forks downward causing the tilt cylinders to draw fluid by suction. If the load weight is great enough, the cylinders may move too quickly and cavitation1 occurs. This can cause severe jolting, enough to possibly dislodge the load.

To protect against cavitation, the tilt cylinder manufacturer provides internal pressure control to apply pressure to both sides of the cylinder thus producing a smooth downward motion - prevent jolting.

The primary cylinder begins lifting the forks and the load, followed by the secondary cylinders to drive the mast rails, forks and load upward. The primary cylinder having a larger bore than the secondary cylinders requires lower pressure to operate.

Consequently, the primary cylinder extends first.

When it is extended, fluid pressure increases to drive the secondary cylinders. As previously described, both pump cavities are used to provide increased flow.

When the lift valve is switched to allow the forks to drop, the flow regulator (internal to the mast assembly) governs the amount of flow (about 25 gpm) diverted to the tank, thus controlling how quickly the forks lower.

The velocity fuse (also internal to the mast assembly) is a safety device that activates if a line failure occurs, such as, a broken hose, split O-ring, etc., or a valve malfunctions. The velocity fuse detects this large loss of pressure (or rapid oil flow) and immediately activates to prevent the load from free-falling by limiting the drop speed relative to the maximum lift capacity.

1

Cavitation, the formation of partial vacuums in a liquid (such as oil) by a swiftly moving solid body (such as a cylinder).

Bendi AC Forklift Operator’s Manual 4-27

Operating Your Bendi Forklift

Electrical Control System General Curtis Instruments 1236 and 1238 AC induction motor controllers control the traction drives and pump motor. They provide flexibility and power through inclusion of a field-programmable logic controller embedded in each motor controller.

The embedded logic controller runs a fully functional field-oriented AC motor control operating system (OS) that can be user-tailored via parameter modification. The OS also contains logic to execute OEM developed software called VCL (Vehicle Control Language), which is used to customize the controllers to the dual drive Bendi. A CAN bus communicates between the two traction controllers, the pump controller and the dash display.

Figure 4-41 Electrical Control System

Bendi AC Forklift Operator’s Manual 4-28

SECTION 5 Standard Bendi Forklift Specifications This section of your Bendi Forklift Operator’s Manual includes the standard specifications for the following Bendi forklift trucks: · B30-4/42-180D · B40-4/48-180D · B45-4/56-180D · B45HL-4/56-180D

Bendi AC Forklift Operator’s Manual 5-1

Standard Bendi Forklift Specifications

Mast Type

N Max. Fork Height In. Cm.

Mast Dimensions P Collapsed Height In. Cm.

Q Free Lift Height In. Cm.

R Max. Overall Height In. Cm.

Triple Triple Triple Triple Triple Triple Triple Triple Triple Triple Triple Triple Triple Triple Quad Quad Quad Quad

188 198 216 224 240 258 276 294 312 322 360 374 417 433 250 276 294 312

83 87 95 98 106 115 122 128 132 137 156 166 180 185 87 95 101 107

61 65 73 74 82 91 98 104 108 113 132 142 156 161 62 70 76 82

236 246 264 272 288 306 324 342 360 370 408 422 465 481 298 324 342 360

478 503 549 569 610 655 701 747 792 818 914 950 1059 1100 635 701 747 792

211 221 241 249 269 292 310 325 335 348 396 422 457 470 221 241 257 272

155 165 185 188 208 231 249 264 274 287 335 361 396 409 157 178 193 208

599 625 671 691 732 777 823 869 914 940 1036 1068 1176 1217 757 823 867 914

B30-4/42-180D

A

B

Truck Dimensions C D E

F

G

H

M

In.

12

63

100

3

31

51

87

43

180o

Cm.

31

160

254

8

79

130

221

109

B40-4/48-180D

A

B

C

D

E

F

G

H

M

In.

12

63

103

3

31

51

87

48

180o

Cm.

31

160

262

8

79

130

221

122

B45-4/56-180D

A

B

C

D

E

F

G

H

M

In.

12

63

103

3

31

51

87

55

180o

Cm.

31

160

262

8

79

130

221

140

B45HL-4/56-180D

A

B

C

D

E

F

G

H

M

In.

12

63

103

3

31

51

87

55

180o

Cm.

31

160

262

8

79

130

221

140

Aisle Dimensions Load Depth x Width (J x I) 40" x 48" (1,000 x 1,200 mm) 48" x 40" (1,200 x 1,000 mm) Min. Clear Transfer Aisle

Minimum Clear Aisle (K) 70" (1,778 mm) 78" (1,981 mm) 108" (2,743 mm)

Bendi AC Forklift Operator’s Manual 5-2

Standard Bendi Forklift Specifications

I

J H K

M

R N P G

Q F E

A

B

D C

ser iv se spec dim

Figure 5-1 Bendi AC Forklift Truck Dimensions

Bendi AC Forklift Operator’s Manual 5-3

Standard Bendi Forklift Specifications Standard Specifications Gradeability B30-4/42-180D; B40-4/48-180D; B45-4/56-180D 15% Unloaded 15% Loaded B45HL-4/56-180D Unloaded 10% Loaded 8% Rated Capacity at 24”(61 cm) Load Center B30-4/42-180D 3,000 lb (1,364 kg) B40-4/48-180D 4,000 lb (1,814 kg) B45-4/56-180D 4,500 lb. (2,045 l\kg) B45HL-4/56-180D 4,000 lb (1,814 kg) Mast Tilting Angle Forward/Reverse (B30-4/42-180D) 3o/3" Forward/Reverse (B40-4/42-180D) Forward/Reverse (B40-4/42-180D)

3o /3" below 240 in (610 cm) 1o/ 2" above 240 in (610 cm)

Forward/Reverse (B45-4/56-180D) Forward/Reverse (B45-4/56-180D)

3o /3" below 276 in (701 cm) 1o/ 3" above 276 in (701 cm)

Forward/Reverse (B45HL-4/56-180D)

1o/3" 1-1/2 x 4 x 36 in (3.81 x 10 x 91 cm)

Fork Size (Standard) ITA Class II Carriage Lifting Speed Unloaded Loaded Lowering Speed Unloaded Loaded Traveling Speed Unloaded Loaded Truck Weight With Battery B30-4/42-180D B40-4/48-180D B45-4/56-180D B45HL-4/56-180D Minimum Battery Weight Poly Load Tire (Front) Solid Rubber Drive Tire (Rear) B30-4/42-180D B40-4/48-180D; B45-4/56-180D B45HL-4/56-180D Battery B30-4/42-180D B40-4/48-180D; B45-4/56-180D; B45HL-4/56-180D

110 ft/min (33.5 m/min) 90 ft/min (27.4 m/min) 90 ft/min (27.4 m/min) 100 ft/min (30.5 m/min) 7.0 mph (11.3 kph) 6.5 mph (10.5 kph) 12,800 lb (5,818 kg) 13,770 lb (6,259 kg) 14,350 lb.(6,522 kg) 14,936 lb. (6,789 kg) 2,600 lb (1,182 kg) 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 12-1/8 in (46 x 18 x 31 cm) 24-85-17, 48 Volt, 680 AHC 24-85-19, 48 Volt, 765 AHC

Bendi AC Forklift Operator’s Manual 5-4

Appendix A This section of your Bendi Forklift Operator’s Manual includes the following checklists and maintenance schedules: · Installation Checklist · Customer Electric Truck Installation Report · Routine Maintenance Schedule for Bendi Forklifts

These checklists and schedules should be used to help maintain the truck and keep it in the best working order. Photocopy both of the installation checklists, fill out, and return the completed copies to the Landoll Company, LLC. For more information on using the Routine Maintenance Schedule and procedures for maintaining the forklift, see the Bendi AC Service Manual (F-526-___)

Bendi AC Forklift Operator’s Manual A-1

BENDI AC Installation Checklist QUALITY CONTROL SHEET

Date _____________________ Truck No. _________________ Location __________________ Shift _____________________

Remit Copy to Landoll Company, LLC

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

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

O.K. (X)

Forks, Top Clip Retaining Pin and Heel - Condition Load Backrest Extension - Attached Tilt Control - Forward and Back - Functioning Smoothly Lift Control - Up and Down - Functioning Smoothly Sideshift Control - Right and Left - Functioning Smoothly Attachment Control - Operational Hydraulic Hoses, Mast Chains and Stops - Check Visually (Note Bracket Location) Steering Operation - Functioning Smoothly Accelerator - Functioning Smoothly Parking Brake and Service Brake - Functioning Smoothly Brake Fluid - Check Level Lights - Functioning Drive Control - Forward/Reverse - Functioning Smoothly Internal Checks: Battery - Water Electrolyte Level and Charge Battery Restraint System - Adjust and Fasten Battery Discharge Indicator - Functioning Hydraulic Fluid Level Transmission Fluid Leaks Operator’s Compartment Capacity Plate Attached - Information Matches Model, Serial No., and Attachments Seat Belt, Buckle, and Retractors - Functioning Smoothly Horn - Functioning Controls (Turn Power On); Investigate Unusual Noises Immediately Investigate Registered Fault Codes; Clear Fault Codes When Resolved Instrument Monitors - Functioning Safety Warnings - Attached (Refer to Operator’s Manual for Location) Overhead Guard - Attached Finger Guards - Attached Tires - Condition; Drive Tire Lug Nuts - Torque to 225 ft.lbs. (300 Nm) Leaks - Hydraulic Oil, Battery, Brake Fluid

Bendi AC Forklift Operator’s Manual A-2

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

Need Maintenance

LANDOLL Company, LLC 1900 North Street · Marysville, KS 66508 Phone: (785)562-5381· Fax: (785)562-4853

Customer ELECTRIC TRUCK Installation Report CUSTOMER ______________________________ ADDRESS _______________________________ INSTALLATION DATE ______________________ 12 MONTH WARRANTY END DATE __________ 36 MONTH WARRANTY END DATE __________

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

NOTE: CUSTOMER MUST FILE CLAIM WITH CARRIER FOR ANY DAMAGES RECEIVED DURING TRANSIT. List damages: CHECK OPERATION AND ADJUST WHERE NECESSARY 1.

Upright and Fork Carriage a.

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

Chain Adjustment of Lift Tie Bar Assembly . . . . . . . . c 2. Load Backrest . . . . . . . . . . . . . . . . . . . . . . . . . . c 3. Sheet Metal (battery compartment) . . . . . . . . . . . . . . . c 4. Tires: a.

Drive Tires; Torque wheel nuts to 225 ft. Lbs. (300 Nm) . c b.

Steer Tires . . . . . . . . . . . . . . . . . . . . . . . . c 5. Wheel Bolts: Tighten . . . . . . . . . . . . . . . . . . . . . . c 6. Seat Adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . c 7. Brakes: a.

Pedal Firmness . . . . . . . . . . . . . . . . . . . . . . c b.

Pedal Free Play . . . . . . . . . . . . . . . . . . . . . . c c.

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . c 8. Horn and Lights: (Head-Spot-Tail). . . . . . . . . . . . . . . . . . . . . . . . . c 9. Drive Controls: a.

Direction Master Switch (Return to Neutral) . . . . . . . . c b.

Accelerator Switch . . . . . . . . . . . . . . . . . . . . c 10. Speed Control: a.

Review control panel settings . . . . . . . . . . . . . . . c b.

Plugging . . . . . . . . . . . . . . . . . . . . . . . . . . c 11. Steering: a.

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

Motor Locks . . . . . . . . . . . . . . . . . . . . . . . . c 12. Hour Meter Reading . . . . . . . . . . . . . . . . . . . . . . . c 13. Electrical Controls: . . . . . . . . . . . . . . . . . . . . . . . c a.

Contactor . . . . . . . . . . . . . . . . . . . . . . . . . c b.

Drive Motors. . . . . . . . . . . . . . . . . . . . . . . . c c.

Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . c d.

Switches (limit-brake-seat-valve) . . . . . . . . . . . . . c

e.

Battery care and charging . . . . . . . . . . . . . . . . . c 14. Hydraulic Controls a.

Hoist. . . . . . . . . . . . . . . . . . . . . . . . . . . . c b.

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

Attachment . . . . . . . . . . . . . . . . . . . . . . . . c d.

Limit Switches . . . . . . . . . . . . . . . . . . . . . . . c 15. Hydraulic System - Oil Leaks: a.

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

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

Hoist Cylinder . . . . . . . . . . . . . . . . . . . . . . . c d.

Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . c e.

Attachment Cylinders . . . . . . . . . . . . . . . . . . . c f.

Hydraulic Lines and Fittings . . . . . . . . . . . . . . . . c 16. Test Run Was truck operator instructed? . . . . . . . . . . . Yes c No c Was truck manual delivered?. . . . . . . . . . . . Yes c No c Was maintenance department instructed? . . . . . Yes c No c Was truck already in service? . . . . . . . . . . . Yes c No c Were caution/warning plates reviewed with operator? . . . . . . . . . . . . . . . . . . . Yes c No c 17. Battery Specific Gravity: a.

Voltage and water level (lead acid) . . . . . . . . . . . . c 18. Fluid and Lube: a.

Master Brake Cylinder. . . . . . . . . . . . . . . . . . . c b.

Hydraulic Oil; Check Dipstick . . . . . . . . . . . . . . . c c.

Transmission(s) . . . . . . . . . . . . . . . . . . . . . . c d.

Lube Points . . . . . . . . . . . . . . . . . . . . . . . . c 19. Battery: a.

Make & Model____________________________________ b.

Service Weight____________________________________

COMMENTS TRUCKS SHOULD BE GIVEN GENERAL INSPECTION - PARTICULARLY APPEARANCE - BOLTS, COTTER PINS, ETC. DISTRIBUTION

Original - Landoll Company, LLC Part 2 - Dealer Copy Part 3 - Customer Copy

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

SERVICEMAN_____________________

DATE______________

DEALER/BRANCH_________________________________________ ADDRESS_______________________________________________

LAN-0054 REV-000 May 2003

ACCEPTANCE BY COMPANY OFFICIAL CUSTOMER_____________________

DATE______________

SIGNATURE_____________________

TITLE______________

Bendi AC Forklift Operator’s Manual A-3

ROUTINE MAINTENANCE SCHEDULE FOR BENDI FORKLIFTS

Operation

*Time

First 2 wks

First month

Hours

50100

1st 200

Mast Chains - Inspect, Clean, and Lubricate Drive Wheels - Retorque Lug Nuts Power Steering System - Fill and Air Bleed Gear Box - Drain, Flush, and Refill Mast - Inspect All Friction Surfaces and Check Lift Chain Tension Lift/Tilt and Pivot/Shift Cylinder Fittings - Check; Be Sure They Work Together and in Unison Brake Pedal - Check For Free Play Parking and Service Brakes - Check for Effectiveness Hydraulic Oil Pump - Check Operation Check Operation of Contactor Points and Micro Switches Clean control panel surface Switches (direction, parking/seat, key, pressure/temperature) - Check Operation Wire Connections and Sending Units - Check Check all Connections for Proper Torque Mast, Carriage, or Attachment Friction Surfaces Clean, Inspect for Wear or Damage, and Lubricate Lift Chains - Clean and Lubricate Extend Mast - Check for Excessive Wear Attachment Control - Operational Steer Wheel Bearings - Clean and Fill with Grease Accelerator - Functioning Smoothly Controls (Turn Power On); Investigate Unusual Noises Immediately Instrument Monitors - Functioning Parking and Service Brakes - Functioning Smoothly, Check Pads for Excessive Wear Hydraulic Fluid Level - Check Exterior of Hydraulic Tank and Oil Tank Breather Clean Battery - Thoroughly Clean Tires - Check for Debris; Drive Tire Lug Nuts Torque to 225 ft. lbs. (305 Nm) Leaks - Hydraulic Oil, Battery, Brake Fluid, Complete Transmission Hydraulic Hoses and Connections - Check for Wear Grease Fittings - Service Check Brushes for Pressure or Wear Neutralize and Clean Battery Box and Connectors Check Water/Electrolyte Level in Battery Check Structure and Electrical Conditions of Battery Clean Dust from Motors (Hydraulic Oil Pump and Power Steering Pump)

X X X X

Monthly Quarterly 600

X X

X X

X

X X X X

1000

X

X

X X X

X X

Bendi AC Forklift Operator’s Manual A-4

200

SemiAnnually Annually

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

2000

ROUTINE MAINTENANCE SCHEDULE FOR BENDI FORKLIFTS

Operation

*Time

First 2 wks

First month

Hours

50100

1st 200

Monthly Quarterly

Seat Belt, Buckle, and Retractors - Functioning Smoothly Forks, Top Clip Retaining Pin and Heel - Condition Load Rollers - No Greater than 1/16" clearance Mast Chains - Lube with SAE 40W oil or Bowman Heavy Load Red Grease - Check for Wear and Stretch Steering Operation - Functioning Smoothly; Lubricate Steering Knob.

Brake Fluid - Check Level Hydraulic Oil Filter - Change Element and Check for Proper Level Operator's Compartment Capacity Plate Attached Information Matches Model, Serial No., and Attachments Check Resistance Between Truck Body and Negative/Positive Terminal of Battery Remove, Clean, and Repack Battery Rollers Power Steering System - Fill and Air Bleed Check that Terminal Studs and Mounting Bolts on Motors are Clean and Tight Clean Cooling Holes on Motors of Debris or Restrictions Hydraulic Oil - Change Hydraulic Reservoir Suction Screens - Clean with Solvent Check Resistance of Contactor Coils

200

600

SemiAnnually Annually 1000

2000

X X X X

X X X X

X X X X X X X X

* Perform maintenance at interval or hours of operation, which ever occurs first.

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

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

Every quarter

Single to double shift

Every other month

Continuous use

Monthly

* Single shift is 40 hrs./ week

Bendi AC Forklift Operator’s Manual A-5

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 Company, LLC General Torque Specifications · Landoll Company, LLC Hydraulic Fitting Torque Specifications

Bendi AC Forklift Operator’s Manual B-1

Appendix B

6

1

2

12

5

4

13 3 11

10

9

7

8

ser iv se lube

Chain

Name

Notes Clean and reoil

2 3 4 5 6 7 8 9 10 11

Lubrication SAE 40W oil or Bowman Heavy Load Red Grease Upright Rail Chassis Lube or Kendall SR-12X Rotation Bearings Mobil XHP222 Steering Knob Light weight oil Battery Rollers (opt.)

Mobil XHP222 Reservoir Cap 30W oil Hydraulic Reservoir Amoco Rykon MV Gear Case Mobilube SHC-630 Master Cylinder Heavy duty brake fluid DOT 3 Articulating Axle Bearings Mobil XHP222 Load Wheel Axle Mobil XHP222

12 13

Steering Gears Tilt Cylinders

Lubricate inner sides of upright rails Use standard lubrication gun Lightly oil Use standard lubrication gun Clean in solvent and re-oil 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 Brush or spray on lubricant Use standard lubrication gun

1

Mobil XHP222 Mobil XHP222

Bendi AC Forklift Operator’s Manual B-2

Appendix B Component

Torque Transmission

Wheel

225 ft. lbs. (305 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

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

Bolt 3/8-24UNF 2A

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

Bolt 1/2-20 UNF 2A

80-100 ft. lbs. (108-136 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 X1.0)

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

Mounting bolts

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

Chain guard capscrews

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

Main lift cyl. plunger retainer

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

Free lift cyl. plunger retainer

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

Carriage roller capscrews

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

Chain and hose sheave screws

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

Lift chain adjusting nuts

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

Backrest screws

145 ft. lbs. (197 Nm.)

Side shift mounting hooks

115-125 ft. lbs. (156-169 Nm.)

Bendi AC Forklift Operator’s Manual B-3

Appendix B LANDOLL COMPANY, LLC

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

] IF USING PREVAILING TORQUE NUTS.

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

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

5/16-18

8

[10]

13

[16]

18

[22]

3/8-16

15

[19]

23

[29]

35

[43]

7/16-14

24

[30]

35

[43]

55

[62]

1/2-13

35

[43]

55

[62]

80

[100]

9/16-12

55

[62]

80

[100]

110

[137]

5/8-11

75

[94]

110

[137]

170

3/4-10

130

[162]

200

[250]

7/8-9

125

[156]

320

1-8

190

[237]

408

1-1/8-7

270

[337]

1-1/4-7

380

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

UNF Size 1/4-28

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

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

[11]

14

[17]

20

[25]

[21]

25

[31]

35

[44]

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

[34]

40

[50]

60

[75]

[50]

65

[81]

90

[112]

[75]

90

[112]

130

[162]

[212]

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

[106]

130

[162]

180

[225]

280

[350]

3/4-16

150

[188]

220

[275]

320

[400]

[400]

460

[575]

7/8-14

140

[175]

360

[450]

500

[625]

[506]

680

[850]

1-14

210

[263]

540

[675]

760

[950]

600

[750]

960

[375]

660

[825]

1080

[1350]

[475]

840

[1050] 1426

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

[525]

920

[1150] 1500

[1875]

490

[612]

110

[1375] 1780

[700]

1260

[1575] 2010

[2512]

650

[812]

1460

[1825] 2360

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

[912]

1640

[2050] 2660

[3325]

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

USE VALUE IN [

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

] IF USING PREVAILING TORQUE NUTS.

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

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

7 12 17 34 60 90 150 205

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

Nominal Thread Diameter mm 20 24 27 30 33 36 39

Bendi AC Forklift Operator’s Manual B-4

Standard Torque NewtonFootMeters Pounds 385 670 980 1330 1790 2325 3010

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

290 500 730 990 1340 1730 2240

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

Appendix B LANDOLL COMPANY, LLC

HYDRAULIC FITTING TORQUE SPECIFICATIONS 37o 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 AEROQUIP BRAND FITTINGS Dash Size 37 Degree JIC O-Ring (ORS) -4 11-12 10-12 -5 15-16 — -6 18-20 18-20 -8 38-42 32-35 -10 57-62 46-50 -12 79-87 65-70 -14 — — -16 108-113 92-100 -20 127-133 125-140 -24 158-167 150-165 -32 245-258 — GATES BRAND FITTINGS Dash Size 37 Degree JIC O-Ring (ORS) -4 10-11 10-12 -5 13-15 — -6 17-19 18-20 -8 34-38 32-40 -10 50-56 46-56 -12 70-78 65-80 -14 — 65-80 -16 94-104 92-105 -20 124-138 125-140 -24 156-173 150-180 -32 219-243 — PARKER BRAND FITTINGS Dash Size 37 Degree JIC O-Ring (ORS) -4 11-13 15-17 -5 14-16 — -6 20-22 34-36 -8 43-47 58-62 -10 55-65 100-110 -12 80-90 134-146 -16 115-125 202-218 -20 160-180 248-272 -24 185-215 303-327 -32 250-290 —

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

Bendi AC Forklift Operator’s Manual B-5

Appendix B

Bendi AC Forklift Operator’s Manual B-6

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

Models B30-4/42-180D B40-4/48-180D B45-4/56-180D B45HL-4/56-180D Operator’s Manual Re-Order Part Number F-522-0110 LANDOLL COMPANY, LLC 1900 North Street Marysville, Kansas 66508 (785) 562-5381 800-428-5655 ~ WWW.LANDOLL.COM

Copyright 2010. Landoll Company, LLC “All rights reserved, including the right to reproduce this material or portions thereof in any form.”

F-522-0110