PDF Download: Landoll Bendi B3-30 ACDS Series 5 Maintenance Manual

®

Bendi B3-30 AC/DS Series 5 Articulated Counterbalance Forklift Maintenance Manual

LANDOLL COMPANY, LLC 1900 North Street Marysville, Kansas 66508 (785) 562-5381 800-428-5655 ~ WWW.LANDOLL.COM F-985-0219

02/2019 - Present

Table of Contents 1

Introduction, Safety, and Specifications Getting Started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Service Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Decal Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 General Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Lock Out / Tag Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Charging Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Mast Service Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Lifting and Blocking the Forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Emergency STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Towing the Forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 Fluid Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 General Torque Specifications (rev. 4/97) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 UNC SAE Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 UNF SAE Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 Metric Torque Specifications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 Metric Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 Hydraulic Fitting Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 Parker® Brand Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 Aeroquip® Brand Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 Gates® Brand Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

2

Planned Inspection and Maintenance Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Cleaning and Inspecting the Forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Tools and Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Safety Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Inspection Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Maintenance Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Inspection and Maintenance Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

i

Operators Daily Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Inspection Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Inspection and Maintenance Practices for Authorized Facilities ONLY . . . . . . . . . . . . . . . . . 2-3 Preparing for Inspection or Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Performance Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Completing Performance Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Operator Daily Pre-Shift Inspection Checklist - Bendi B3-30 AC/DS Series 5 . . . . . . . . . . . . . 2-5 1st 100 Hour Technicians Inspection Checklist - Bendi B3-30 AC/DS Series 5 . . . . . . . . . . . . 2-6 500 Hour Technicians Inspection Checklist - Bendi B3-30 AC/DS Series 5 . . . . . . . . . . . . . . . 2-7 2000 Hour Technician Inspection Checklist - Bendi B3-30 AC/DS Series 5 . . . . . . . . . . . . . . . 2-9 4500 Hour Technician Inspection Checklist - Bendi B3-30 AC/DS Series 5 . . . . . . . . . . . . . . . 2-9 Tires and Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Chunking (Chipping) or Embedded Objects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Undercutting and Uneven Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Flat-spotting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 To Extend Tire Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 ESD Strap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Fork Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Rated Capacity and Load Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Cracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Positioning Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Fork Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Overhead Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Hydraulic Cylinders and Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Hydraulic Hoses, Tubing and Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Check Hydraulic Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Checking the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Battery Restraint System and Roll-out (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Check the Brake Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Identification Plate and Safety Warning Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Seat Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Dash Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Accelerator Pedal, Directional Switch & Backup Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 Service Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 Mast Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 ii

F-985-1218

Tilt Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 Side Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 Mast Racking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 Speed Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 Steering - Check Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 Emergency STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 Return to Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 General Mast Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 Mast Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 Chain Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 Chain Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 Chain Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 Check Primary Lift Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 Measuring Chain Stretch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 Check Lift Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 Load Backrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 Front Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 Check Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 Side Shift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 Forklift Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 Tilt Cylinder Clevis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 Fork Positioner Lubrication (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 Steering Knob Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 Change the Pressure Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 Change Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 Service Disc Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 Wheel Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 Major Structural Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 Rust Or Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 Gear Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 Check Planetary Gear Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 Nuts, Bolts and Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 Stop Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

3

Troubleshooting General Bendi B3-30 AC/DS Troubleshooting Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 AUDIBLE PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 PERFORMANCE PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 PUMP PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

4

Corrective Maintenance Corrective Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Battery Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 iii

Battery Roll-out Option and Restraint System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Replacing the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Cleaning the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Charging a Wet Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Mast And Front End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Removing the Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Repairing Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Load Testing Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Straightness of Blade and Shank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Fork Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Difference in Height Between Fork Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Measuring Fork Thickness and Distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Adjusting Degree of Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Mast Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Removing Front Plate Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Removing the Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Floor Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Floor Plate Removal and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Tires and Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Removing/Replacing the Drive Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Replacing the Braking Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Brake System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Check Service Drum Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Checking/Changing Brake Shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Repairing Brake Wheel Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Hydraulic Brake Drums . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Parking Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Parking Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Replacing Parking Brake Lever Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Checking Parking Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Adjusting Parking Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Replacing the Parking Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Parking Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Checking Parking Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Replacing Parking Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Service Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Brake Pedal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 Replacing Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 Bench Bleed the Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Check Master Cylinder Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Bleeding Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Service Brake Pedal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 Replacing Any Other Hydraulic Brake Component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 Drivetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 Traction Motor, and Gear Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 Service the Gear Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 iv

F-985-1218

Gearbox Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 Traction Drive Motor Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 Accelerator Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 Replacing Accelerator Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 Electrical Static Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 Electrical Controls and Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 Replacing a Complete Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25 Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26 Hydraulic System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26 Changing Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26 Change the Hydraulic Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27 Checking and Adjusting Hydraulic Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28 Steering Motor Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29 Hydraulic Pump Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29 Front Rotation Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30 Hydraulic Control Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31 Steering Column/Dash Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34 Remove the Display Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34 Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35 Rocker (On/Off) Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35 Steering Wheel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36 Steering Column (Console) Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36 Steering Orbital Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37 Horn Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37 Truck Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37 Back Up Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37 Overhead Guard, Lighting and Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38 Seat Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38

5

Bendi B3/30 AC Calibration and Programming Controller Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 1314 Bendi B3/30 Controller Software Program Installation and Operation . . . . . . . . . . . . . . 5-3 Software Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 1314 Software Features and Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Tool Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Views Navigation Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Working Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Status Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Communicating with the Bendi B3-30 Series 5 Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Bendi B3-30 Series 5 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Programming Bendi B3-30 Series 5 Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Programming Bendi B3-30 Series 5 Traction and Pump Controllers . . . . . . . . . . . . . . . . . . . . 5-9 Programming Bendi B3-30 Series 5 Front I/O Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Curtis Controller Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 v

Program Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 Master Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 Landoll Traction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 Maintenance Due . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 1- Speed Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 Response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 Fine Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23 Current Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24 Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 Landoll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27 Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27 Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28 CAN Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28 Controller Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28 Controller Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28

6

Supplier Provided Documentation Lift Technologies Mast Service Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

vi

F-985-1218

Chapter 1

TABLE OF CONTENTS

Introduction, Safety, and Specifications Getting Started

The Notice, Caution, Warning and Danger safety notices and their descriptions used in this book appear as follows:

Introduction Read all of chapter 1 before performing any inspections, maintenance or repairs. This manual is intended for the service technician seeking information on product maintenance and service replacement parts. Refer to this manual for troubleshooting guides and information.

Operating Instructions Operating instructions for the Bendi B3-30 AC/DS are located in the Operator’s Manual (P/N F-958) which is shipped with every forklift. If the operator’s manual is missing on your forklift, replace immediately by calling Landoll Company, LLC at 800-423-4320 or ordering online at dealer.landoll.com.

Service Training Service Training is available for the forklift technician from Landoll Company, LLC. Topics covered include the operation, repair and maintenance of the forklift. Contact Landoll Company, LLC at www.landoll.com for more information.

NOTICE Special Notices that include helpful maintenance hints. Read and thoroughly understand.



CAUTION

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



WARNING

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



DANGER

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

Required Tools Both SAE and metric tools needed should be found in well-equipped service centers. Assorted open-end, boxend, Allen and adjustable wrenches along with assorted sockets, screwdrivers and non-marring mallets should be available to properly perform maintenance and repair.

Figure 1-1: Data Plate

1-1

TABLE OF CONTENTS INTRODUCTION, SAFETY, AND SPECIFICATIONS

Decal Identification

10 12 11 19

22

18

21 7

24 18

4

9

23

Figure 1-2: Decal Location (1 of 2) 1-2

F-985-0219

TABLE OF CONTENTS INTRODUCTION, SAFETY, AND SPECIFICATIONS

5

8

1

2

14

20 13

3

16

6

15

17 Figure 1-3: Decal Location (2 of 2)

1-3

TABLE OF CONTENTS INTRODUCTION, SAFETY, AND SPECIFICATIONS 1 2 3 4 5 6 7 8 9 10 11 12

1-4

Danger Rollover Decal Overload Warning Decal Before Operating Decal Cover Open Warning Decal Proper Vehicle Loading Decal Made in USA Flag Decal Side Shift Caution Decal Overhead Guard Decal Tire Replacement Decal Operator Warning Decal Air Bleed Decal Overhead Guard Pinch Point Decal

13 14 15 16 17 18 19 20 21 22 23 24

No Riders Decal Do Not Remove Guard Decal Drexel Yellow Bendi 8 Decal Landoll Yellow Bow-Tie Decal Brevini Oil Spec Decal Ser 4 Hyd Filter Decal Fork Hazard Warning Decal Landoll.com Gray Decal Data Plate Forklift Patents Danger Pinching Point Decal ISO 46 Hydraulic Fluid 15/13/11

F-985-0219

TABLE OF CONTENTS INTRODUCTION, SAFETY, AND SPECIFICATIONS

1

2

3

4

5

6

7

8

9

10

11

12

AIR BLEED

C A U T I O N

13

14

15

16

17

18

19

20

21

22

23

24

PP I O NI CN HT 103804

Figure 1-4: Decals

1-5

TABLE OF CONTENTS INTRODUCTION, SAFETY, AND SPECIFICATIONS

Replacement Parts The Model Number and Serial Number are required when ordering maintenance and repair parts for the Bendi B3-30 AC/DS forklift. This information is located on the data plate. See Figure 1-1. Only Landoll approved parts are to be used for service. A Landoll Parts Manual (P/N F-663) may be obtained by calling 800-423-4320 or ordering online at dealer.landoll.com.

• The data plate is located on the right side below the lift controls.

General Maintenance Instructions  •

• • •

CAUTION

Steel toe shoes and eye protection are required when maintaining or repairing a forklift.

Ear protection may also be required per OSHA standards.

Keep feet, hands and all other body parts away from all mast areas and pinch points.

Power industrial trucks may become hazardous if scheduled maintenance is neglected. Therefore adequate maintenance facilities, as well as trained personnel and procedures, should be provided.

Maintenance and inspection shall be performed in conformance with the following practices: 1. A scheduled maintenance, lubrication and inspection system shall be followed.

2. OSHA Standards require daily inspections before each shift.

3. Only qualified and authorized personnel shall be permitted to inspect, maintain or service the forklift.

4. Before operating the forklift: • Be in an operating position (faced forward, left hand on steering knob, right hand on control levers and left foot firmly planted on the floor plate).

• Turn key switch ON. • Place direction control in neutral.

• Check functions of lift systems, directional control, speed control, steering, warning devices, brakes and any attachments that are equipped.

5. Before leaving the forklift unattended:

1-6

• • • • • •

Stop the forklift.

Lower the mast completely.

Place direction controls in neutral.

Set the parking brake.

Turn key switch OFF and remove the key.

Block the wheels, especially if the forklift is on an incline.

6. Before servicing the forklift: • Locate an area with adequate clearance when evaluating performance of the forklift or attachments.

• Perform a Lock Out/Tag Out operation on the forklift.

• Raise drive wheels off the floor.

• Use chocks or other positive positioning devices.

• Block load engaging means (forks), inner mast and/or chassis (outer mast) before working under them.

7. Keep fire protection equipment present.

8. DO NOT use an open flame to check for leakage of electrolyte, fluids, or oil.

9. DO NOT use open pans of fuel or flammable cleaning fluids to clean parts.

10. Keep shop well ventilated, clean, and dry.

11. Brakes, steering mechanisms, control mechanisms, lift overload devices, guards and safety devices shall be inspected regularly and maintained in safe operating condition.

12. Data plates, operation plates, maintenance instruction plates and decals shall be maintained in legible condition.

13. All lift mechanisms and components shall be regularly inspected and properly maintained to ensure safe operating conditions.

14. All hydraulic systems and related components shall be regularly inspected and properly maintained to ensure safe operating conditions.

• Cylinders and other similar parts shall be checked to assure that “drift” has not developed to an extent that it would create a hazard.

15. Batteries, motors, controllers, limit switches, protective devices, electrical conductors and connections shall be regularly inspected and properly maintained to ensure safe operating conditions.

• Special attention shall be paid to the condition of electrical insulation.

16. The forklift shall be kept in clean condition to minimize fire hazards and facilitate detection of loose or defective parts.

F-985-0219

TABLE OF CONTENTS INTRODUCTION, SAFETY, AND SPECIFICATIONS 17. Modifications and/or additions, which affect capacity and safe forklift operation, shall not be performed by the customer or user without prior written approval of Landoll Company, LLC. In addition: capacity, operation and maintenance instruction plates along with decals, may not be removed or altered except

by Landoll Company, LLC. 18. Optional equipment shall not restrict the operator’s field of vision.

19. Optional equipment shall not interfere with safe and efficient operation of the forklift or its controls.

Lock Out / Tag Out NOTICE In the interest of operator safety and operator compliance with OSHA regulations, guidelines have been developed to perform service and maintenance on the forklift. Before performing service and maintenance on the forklift, review the following sections in this manual for additional procedures to be followed.

Anytime you are doing maintenance or repair on the B3-30 AC/DS forklift, unless it must be on for investigative testing, perform the following steps: • Remove the key from the console.

• Disconnect the battery cable connectors.

• Install Lock Out/Tag Out device at the battery connectors.

• Remove the main power fuse.

• Place Lock Out/Tag Out warning reminder on the steering wheel.

Battery Safety 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.



DANGER

 • • •

•

•

WARNING

Forklift batteries give off explosive gases during use and charging.

This gas remains in the cells long after charging is complete.

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

Keep battery vent plugs firmly in place at all times, except when adding water or taking hydrometer readings.

Keep all flame and sparks away from battery and charging area at all times.

• i.e. Lit cigarettes, striking a welding arc, etc.



WARNING

• The battery is very heavy. Be sure to replace and tighten any battery restraints which have been installed on the forklift.

• Failure to comply could result in an unbalance condition or the battery could slide out of the forklift causing electrical shorts or acid to spill - or it could cause the forklift to tip.



CAUTION

• Follow the battery manufacturer’s instructions concerning maintenance and repair.

• Only qualified and experienced personnel should perform maintenance and repair on batteries.

• Keep the battery clean. Foreign matter in the electrolyte will result in poor battery performance.

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

The battery must meet size, weight and voltage requirements of the forklift.

BATTERY FUMES ARE EXPLOSIVE!

1-7

TABLE OF CONTENTS INTRODUCTION, SAFETY, AND SPECIFICATIONS

 •

• • • • • •



WARNING

Wear protective clothing, rubber apron, boots, gloves, and full-face shield when performing any maintenance on the battery.

Batteries contain sulfuric acid which can cause severe skin and eye burns.

Avoid sulfuric acid contact with eyes, skin, clothing or the floor.

Should electrolyte be spilled on the skin, rinse promptly with clean water and soap.

If electrolyte contacts eyes, flush immediately with clean water.

If the eyes have been affected, OBTAIN MEDICAL ATTENTION IMMEDIATELY. A baking soda solution (one pound to one gallon of water) will neutralize acid spilled on clothing, floor or other surfaces.

• Apply solution until bubbling stops and rinse with clean water.

•

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

When the battery is charging, it releases hydrogen, a highly explosive gas which can be ignited by a spark.

•

Hydraulic System  • •

•

Charging Safety



CAUTION

• Consult the charger manufacturer’s manual covering your charger for operation and maintenance.

• Consult the label on the battery for information on cell-type, ampere-hour capacity, charge rate and normal full-charge voltage.

• Charge the forklift battery in a designated area with adequate ventilation.

• Make certain the charger being used matches the voltage and amperage of the forklift battery. Voltage is listed on the forklift data plate.

• Before connecting or disconnecting batteries to the charger, make sure the charger is “OFF”. Making connections while the charger is “ON” could result in serious injury to the operator and damage could occur to the charger with sparks or electrical spikes.

•

• •

DANGER

Hydraulic oil can be under very high pressure.

A pinhole leak is not easily seen and if it pierces the skin, it can cause injury and possible death.

Any fluid injected into the skin under high pressure should be considered a medical emergency despite a normal appearance of the skin.

Medical attention should be administered immediately.



WARNING

Relieve all pressure from the hydraulic system before attempting to service it.

Make sure all hydraulic lines are tight before starting the system.

Tilt Cylinder

 •

•

•

•

1-8

DANGER

WARNING

DO NOT place feet or hands in any area through the mast or in the forklift pinch points.

Servicing the tilt cylinders requires the use of an overhead hoist, hoist slings, and wheel blocks.

The overhead hoist and slings must have a rating appropriately greater for the weight of the mast being serviced.

DO NOT work under or around a forklift that is not properly secured.

F-985-0219

TABLE OF CONTENTS INTRODUCTION, SAFETY, AND SPECIFICATIONS

Mast Service Safety

 •

•

• •

WARNING

When servicing the mast or sections of the mast, hardwood blocks (4”X4”, 100 X 100mm or larger) shall be used to keep individual sections of the mast from falling.

Chains shall be used to hold the mast sections from moving, in both the vertical and horizontal directions.

The mast is EXTREMELY heavy. Extra care should be taken to minimize possible injury.

Make sure the hoist is rated for the weight of the mast.

•

Mast work is to be done in a flat designated area.

• • •

NEVER walk under or stand on the forks.

Remove forks before starting mast repairs.

NEVER reach through the upright open areas of the mast.

NEVER maintain or repair the mast without supports or while anyone is near the forklift (ASME B56.1-2000) Raise the mast and position blocks under the second stage mast.

Using an appropriate set of C-clamps, secure wooden blocks to the mast channel.

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

NEVER repair mast chains; they are to be replaced.

NEVER replace an individual mast chain. All chains are to be replaced in pairs.

•

• • • • •

Lifting and Blocking the Forklift • • • • •

Move the forklift to a level area designated for repair.

Keep forks empty and low to the ground.

Perform “Lock Out / Tag Out” procedure.

(SEE PAGE 1-7) Use a jack or hoist with a 32,000 lb. (16 ton) minimum lift capacity.

Keep the height of the lifted forklift to a minimum.

Emergency STOP B3-30 AC/DS Stop Button: Press this button to shut down the drive motor and all mast movement. The forklift drifts to a STOP. Immediately set the parking brake.

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

See Figure 1-5.

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

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

• In case an accident occurs.

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

Figure 1-5: Emergency Stop Button

Towing the Forklift If the forklift breaks down and cannot be repaired at that location, it may be towed by attaching a suitable hook and chain to the tow pin located in the cutout at the lower rear of the forklift. See Figure 1-6.

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

Set the forklift on designated hardwood blocks. Blocks are required on each of the four corners of the forklift to provide a safe and stable repair position.

1-9

TABLE OF CONTENTS INTRODUCTION, SAFETY, AND SPECIFICATIONS

 • •

• • • • • •

CAUTION

Have the parking brake applied when hooking up the tow chain.

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

Forks must be empty.

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

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

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

Always tow the forklift in the reverse direction.

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

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

3. Firmly attach the tow device from the towing vehicle to the forklift tow pin provided on the lower rear side of the forklift frame. See Figure 1-6.



CAUTION

Keep the towing speed below 2 mph.

4. The operators of the towing vehicle and the disabled forklift should maintain communication and visual contact while observing the towing operation.

NOTICE Be careful, the forklift will roll easily and steering will be difficult.

Brake functions will not be equivalent to an operational forklift.

1-10

Figure 1-6: Tow Pin

F-985-0219

TABLE OF CONTENTS INTRODUCTION, SAFETY, AND SPECIFICATIONS

Specifications Lubrication Specifications Name

Lubrication

Notes

Hydraulic System

Conoco Powerflow HE (ISO Grade 46) Filtered to Drain, flush, and refill.

ISO 4406 cleanliness code 15/13/11 or equivalent Grade oil filtered to 15/13/11.* Brake System DOT 3 Brake Fluid Fill.

Steer Wheel Bearings Alvania Grease No. 2 Clean and re-grease.

Steering Knob Light weight oil Lightly oil.

Gear Case Mobilube SHC-630 only Drain, flush, and refill.

Grease Fittings Molybdenum EP Chassis Grease Clean and re-grease.

Mast Rails Molybdenum EP Chassis Grease Clean and re-grease.

Mast Chains SAE40W oil or Bowman Heavy Load Red Grease Clean and re-oil.

General Lubrication SAE 20 Lubricating Oil Clean and re-oil. *Failure to refill with oil that meets ISO 4406 cleanliness code 15/13/11 may void warranty. Typical “NEW” oil DOES NOT meet this specification. Contact Landoll Company, LLC or your lubricant supplier for recommendation.

Torque Specifications Component

Torque

Drive Wheel Rear Wheels Fluid draining and filling plug Drive motor with vehicle frame Steering Actuator

225 ft-lbs. (305 Nm.) 20-25 in-lbs. (102 Nm.) then back off 1/2 turn 16 ft-lbs. (22 Nm.) 130 ft-lbs. (176 Nm.)

• Ringfeder Coupling

30 ft-lbs. (40.7 Nm.)

Mast

• Chain guard cap screws • Main lift cylinder plunger retainer • Free lift cylinder plunger retainer • Chain and hose sheave screws • Lift chain adjusting nuts • Backrest screws

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

Overhead Guard Bolts

170 ft-lbs. (230 Nm.)

96-125 ft-lbs. (129-169 Nm.) 275-300 ft-lbs. (373-407 Nm.) 26-30 ft-lbs. (35-41 Nm.) 50-70 ft-lbs. (68-95 Nm.) 145 ft-lbs. (197 Nm.)

Fluid Capacities Item Hydraulic Tank Brake Fluid Gear Box

Capacity-Quarts (Liters) 11 gallons (42 liters) 2 pints (1 liter) 16 oz. (0.47 liters)

1-11

TABLE OF CONTENTS INTRODUCTION, SAFETY, AND SPECIFICATIONS

General Torque Specifications (rev. 4/97) These tables provide tightening torques for general purpose applications when special torques are not specified on process or drawing. Assembly torques apply to plated nuts and cap screws 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 cap screws. Use the value in [ ] if using prevailing torque nuts.

UNC SAE Torque Specifications Size

SAE Grade 2 Ft-lbs.

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

4 [5] 8 [10] 15 [19] 24 [30] 35 [43] 55 [62] 75 [94] 130 [162] 125 [156] 190 [237] 270 [337] 380 [475] 490 [612] 650 [812]

SAE Grade 5

SAE Grade 8

Nm.

Ft-lbs.

Nm.

Ft-lbs.

Nm.

5 [7] 11 [14] 20 [26] 33 [41] 47 [58] 75 [84] 102 [127] 176 [220] 169 [212] 258 [321] 366 [457] 515 [644] 664 [830] 881 [1101]

6 [7] 13 [16] 23 [29] 35 [43] 55 [62] 80 [100] 110 [137] 200 [250] 320 [400] 408 [406] 600 [750] 840 [1050] 1010 [1375] 1460 [1825]

8 [9] 18 [22] 31 [39] 47 [58] 75 [84] 108 [136] 149 [186] 271 [339] 434 [542] 553 [686] 813 [1017] 1139 [1424] 1369 [1864] 1979 [2474]

9 [11] 18 [22] 35 [42] 55 [62] 80 [100] 110 [137] 170 [212] 280 [350] 460 [575] 680 [850] 960 [1200] 1426 [1782] 1780 [2225] 2360 [2950]

12 [15] 24 [30] 47 [57] 75 [84] 108 [136] 149 [186] 230 [287] 380 [475] 624 [780] 922 [1152] 1302 [1627] 1933 [2416] 2413 [3017] 3200 [4000]

UNF SAE Torque Specifications Size

SAE Grade 2 Ft-lbs.

1/4-28 5/16-24 3/8-24 7/16-20 1/2-20 9/16-29 5/8-18 3/4-16 7/8-14

1-12

4 [5] 9 [11] 17 [21] 27 [34] 40 [50] 60 [75] 85 [106] 150 [188] 140 [175]

Nm. 5 [7] 12 [15] 23 [28] 37 [46] 54 [68] 81 [102] 115 [144] 203 [255] 190 [237]

SAE Grade 5 Ft-lbs.

7 [9] 14 [17] 25 [31] 40 [50] 65 [81] 90 [112] 130 [162] 220 [275] 360 [450]

Nm. 9 [12] 19 [23] 34 [42] 54 [68] 88 [110] 122 [152] 176 [220] 298 [373] 488 [610]

SAE Grade 8 Ft-lbs.

10 [12] 20 [25] 35 [44] 60 [75] 90 [112] 130 [162] 180 [225] 320 [400] 500 [625]

Nm. 14 [16] 27 [34] 48 [60] 81 [102] 122 [152] 176 [220] 244 [305] 434 [542] 678 [847]

F-985-0219

TABLE OF CONTENTS INTRODUCTION, SAFETY, AND SPECIFICATIONS

UNF SAE Torque Specifications Size

SAE Grade 2 Ft-lbs.

1-14 1 1/8-12 1 1/4-12 1 3/8-12 1 1/2-12

210 [263] 300 [375] 420 [525] 560 [700] 730 [912]

SAE Grade 5

SAE Grade 8

Nm.

Ft-lbs.

Nm.

Ft-lbs.

Nm.

285 [357] 407 [508] 569 [712] 759 [949] 990 [1237]

540 [675] 660 [825] 920 [1150] 1260 [1575] 1640 [2050]

732 [915] 895 [1119] 1247 [1559] 1708 [2135] 2223 [2779]

760 [950] 1080 [1350] 1500 [1875] 2010 [2512] 2660 [3325]

1030 [1288] 1464 [1830] 2034 [2542] 2725 [3406] 3606 [4508]

Metric Torque Specifications: Coarse thread metric class 10.9 fasteners and class 10.0 nuts and through hardened flat washers, phosphate coated, Rockwell “C” 38-45. Use value in [ ] if using prevailing torque nuts.

Metric Torque Specifications Nominal thread diameter (mm) 6 7 8 10 12 14 16 18 20 24 27 30 33 36 39

Newton Meters 10 [14] 16 [22] 23 [32] 46 [60] 80 [125 125 [155] 200 [240] 275 [330] 385 [450] 670 [775] 980 [1105] 1330 [1470] 1790 [1950] 2325 [2515] 3010 [3210]

Foot Pounds 7 [10] 12 [16] 17 [24] 34 [47] 60 [75] 90 [115] 50 [180] 205 [245] 290 [335] 500 [625] 730 [825] 990 [1090] 1340 [1450] 1730 [1870] 2240 [2380]

1-13

TABLE OF CONTENTS INTRODUCTION, SAFETY, AND SPECIFICATIONS

Hydraulic Fitting Torque Specifications (REV. 10/97) 37 degree JIC, ORS, and ORB 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 cap screws 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 cap screws. Use value in [ ] if using prevailing torque nuts.

Parker® Brand Fittings Dash Size

37 Deg. JIC Ft-lbs.

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

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

Nm. 15-18 19-22 27-30 58-64 75-88 108-122 156-169 217-244 251-292 339-393

O-ring (ORS) Ft-lbs.

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

Nm. 20-23 ---------46-49 79-84 136-149 182-198 274-296 336-369 411-443 -----------

O-ring boss Ft-lbs.

13-15 21-23 25-29 40-44 58-62 75-85 109-121 213-237 238-262 310-340

Nm. 18-20 28-31 34-39 54-60 79-84 102-115 148-164 289-321 323-355 420-461

Aeroquip® Brand Fittings Dash Size

37 Deg. JIC Ft-lbs.

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

1-14

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

Nm. 15-16 20-22 24-28 52-58 77-85 108-119 ----------148-154 173-182 216-227

O-ring (ORS) Ft-lbs.

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

Nm. 14-16 ---------24-27 43-47 62-68 88-95 ----------125-136 170-190 204-224

O-ring boss Ft-lbs.

14-16 16-20 24-26 50-60 75-80 125-135 160-180 200-220 210-280 270-360

Nm. 20-22 24-27 33-35 68-78 98-110 170-183 215-245 270-300 285-380 370-490

F-985-0219

TABLE OF CONTENTS INTRODUCTION, SAFETY, AND SPECIFICATIONS

Gates® Brand Fittings Dash Size

37 Deg. JIC Ft-lbs.

-4 -5 -6 -8 -10 -12 -14 -16 -20 -24 -26

10-11 13-15 17-19 34-38 50-56 70-78 ----------94-104 124-138 156-173 219-243

Nm. 14-15 18-20 23-26 46-52 68-76 95-106 ----------127-141 168-187 212-235 297-329

O-ring (ORS) Ft-lbs.

10-12 ---------18-20 32-40 46-56 65-80 65-80 92-105 125-140 150-180 -----------

Nm. 14-16 ---------24-27 43-54 62-76 88-108 88-108 125-142 169-190 203-244 -----------

O-ring boss Ft-lbs.

14-16 ---------24-26 37-44 50-60 75-83 ----------111-125 133-152 156-184 -----------

Nm. 19-22 ---------33-35 50-60 68-81 102-113 ----------150-169 180-206 212-249 -----------

1-15

TABLE OF CONTENTS INTRODUCTION, SAFETY, AND SPECIFICATIONS NOTES:

1-16

F-985-0219

TABLE OF CONTENTS

Chapter 2

Planned Inspection and Maintenance Overview This section describes the routine inspections, maintenance, adjustments and lubrication necessary to ensure safe and efficient operation of the Bendi B3-30 AC/DS Series 5 forklift while minimizing downtime.

Thoroughly review this section prior to inspecting or servicing the forklift.

Inspection and maintenance schedules are provided on pages 2-5 through 2-9 of this manual and also in the Operator’s manual provided with the forklift.

These checklists include: • Operator’s Daily Inspection Checklist • 1st 100 Hour Technicians Inspection Checklist • 500 Hour Technicians Inspection Checklist • 1000 Hour Technicians Inspection Checklist • 2000 Hour Technicians Inspection Checklist • 4500 Hour Technicians Inspection Checklist Except for the Operator’s Daily Checklist, these tasks are usually performed by a service and maintenance facility that is approved by Landoll Company, LLC. These inspection sheets should be copied, completed and maintained by the forklift technicians.

Recommended lubricants, fluid levels and torque values are found on page 1-12.

IMPORTANT Read and comply with all applicable SAFETY precautions when servicing this forklift. Review “Introduction, Safety, and Specifications” on page 1-1 at the beginning of this manual.

IMPORTANT Recommended service inspections are based on normal operating conditions. If the forklift is subjected to severe or above normal operating conditions, extreme temperatures, excessive dust or wet environments, or if the forklift is around corrosive materials, service must be performed at more frequent intervals.

NOTE Common sense and standard precautions apply when servicing machinery and must always be used.

Cleaning and Inspecting the Forklift Landoll Company, LLC strongly discourages the use of power washers for cleaning forklifts. The high pressure water and soap can damage components such as electrical boards, circuitry and wiring. Water and other cleaning residue promotes the formation of rust and corrosion or may otherwise degrade some forklift components. The recommended method for dust removal is compressed air. For localized cleaning, the preferred method of cleaning is the use of a non-flammable solvent.

Carefully review manufacturer provided WARNING labels and MSDS information when using solvents or other chemicals. Follow the recommended precautions regarding use of personal protective equipment and adequate ventilation to avoid breathing toxic fumes. Adhere to the manufacturer’s instructions regarding safe use and proper disposal methods.

Before using any solvent or cleaning solution, be sure that it will not damage the part you are cleaning. For example, gasoline should NEVER be used to clean parts.

Gasoline is highly flammable and may damage some types of rubber and plastic. Hydraulic brake fluid (standard, not silicone type) is often used to clean rubber parts. It also removes paint quickly, so care should be exercised when it is used.

• Clean metal parts with a degreasing type solvent cleaner and wipe dry with a clean rag.

• Allow parts to air dry.

• DO NOT allow cleaning solvent to come in contact with rubber parts or rubber insulation, such as electrical wiring, seals, etc. to avoid corrosion.

• For non-metal parts, clean using a mild soap solution, shop vacuum for dust and loose dirt or a dust pan and brush.

• Inspect all parts thoroughly for breaks, cracks, tears, burrs, scoring, warping or sharp edges, glazing, rust pitting, flat spots, etc. Notify your supervisor of all defects and record it in the forklift log book.

• Inspect all screws and hardware for stress marks, breaks, cracks, thread defects, etc.

• Replace all damaged or questionable parts with Landoll approved replacement parts before operating the forklift.

2-1

TABLE OF CONTENTS PLANNED INSPECTION AND MAINTENANCE • Take care to properly identify and tag each part, its location and its order of removal. Use a non-destructive marker, such as a felt-tipped pen.

Take photographs and notes as necessary.

• Tag all parts for identification and location before removal and mark all mating parts for accurate reassembly.

• Protect finished surfaces from damage caused by dropped wrenches, spilled solvent, etc.

• Use a penetrating oil to loosen difficult screws, nuts or bolts. A hand-held impact driver is a handy tool when removing tight fasteners.

• Certain bolts, screws or nuts are secured with a non-permanent thread-locking compound at the factory, (i.e. Loctite Primer and Blue sealant #243 or equivalent Landoll p/n:115627). When these parts are replaced, a non-permanent thread-locking compound must be reapplied.

• No parts, except those press-fit assembled, require unusual force to disassemble. If you encounter trouble, determine the reason for the difficulty, before proceeding.

• Cover all openings caused by removing parts or sub-assemblies to keep objects from falling in where additional damage could result.

• When assembling two parts, start all of the fasteners first, then tighten them evenly and in a staggered manner. Be sure both mating surfaces are aligned, not cocked or off-center.

• Observe standard torque ratings for the size and type of fastener as listed starting on page 1-8.

• Be sure to use the proper nuts, bolts and other fasteners as rated; SAE Grade 5, SAE Grade 8, ISO Prop Class 8.8, etc.

• All fasteners must be replaced with the identical type.

Use of Landoll authorized replacement parts is recommended.

If you have any questions about parts or reassembly contact Landoll Company, LLC at 800-423-4320.

Tools and Equipment Required Read and comply with all applicable SAFETY precautions when servicing the forklift.

In addition to a good portable light source and various tools, as explained in “Required Tools” on page 1-1, the following tools and equipment may be required.

2-2

• Hydraulic jack, appropriate for the weight being raised.

• Safety stands, appropriate for the weight being supported.

• Overhead crane, appropriate for the weight being lifted and/or supported.

• Grease gun.

• Torque wrench - capable of measuring at least 500 Ft-lbs. (678 Nm.).

• Drain pan, capable of holding at least 11 gallons (41.6 liters) of hydraulic fluid.

• Angle wrenches

Safety Equipment Required The following safety equipment may be required: • Bicarbonate of soda (baking soda), to neutralize any battery acid spills.

• Safety goggles or full-face shield.

• Rubber gloves and apron.

• Dust mask (for protection against abrasive dust).

Inspection Program The inspection program recommended by Landoll Company, LLC periodically checks the integrity of forklift systems including: • Checking performance of operator functions - lift, tilt, side shift, attachment and traction systems.

• Checking for leaks.

• Checking fluid levels.

• Making sure components are securely attached.

• Checking the tires.

Maintenance Program In addition to the inspection program, Landoll Company, LLC has set up a preventative maintenance program. Preventative maintenance procedures including: • Drain, flush and fill the gear box.

• Change hydraulic oil and brake fluid.

• Clean hydraulic reservoir suction screens • Lubricate mechanical systems.

• Remove, clean and inspect battery rollers (optional).

F-985-0219

TABLE OF CONTENTS PLANNED INSPECTION AND MAINTENANCE



DANGER

Failure to follow these guidelines can cause serious injury or death: • NEVER perform maintenance or service procedures unless specifically indicated in this manual or at the specific request of supervisory personnel. All other service and maintenance on your forklift must be provided by a facility authorized by Landoll Company, LLC to perform these services.

• Wipe up any spills immediately to prevent slipping, fire, explosion or contact with hazardous materials.

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

To help avoid fire related injuries: • Have fire extinguishing equipment present in the work area.

• DO NOT allow sparks or open flames while checking fluid level, checking for leaking oil or while inspecting/servicing the battery.

• DO NOT use fuel or flammable cleaning fluids to clean parts.

Inspection and Maintenance Responsibilities Operators Daily Checklists Daily pre-shift inspection is an OSHA requirement, regulation 1910.178(q)(7).

These inspections must be documented.

The operator is required to inspect the forklift daily. This includes: • Visual inspection of the entire machine for defects.

• Visual check for any leaks.

• Check hydraulic oil, battery and brake fluid levels.

• Check that all controls and displays work properly.

A complete Operators Daily Inspection Checklist is included on page 2-5 of this section as well as in the Bendi B3-30 AC/DS Operator’s Manual (Landoll P/N F-958). Some specific guidelines follow in the next several pages to aid in the daily forklift inspection. Have a qualified technician correct all problems before operating the forklift.

Inspection Practices These guidelines will help prevent downtime for your forklift and maintain its safe operating condition: • Perform the tasks listed on the Operator’s Daily Checklist at the beginning of every shift, or if you are taking responsibility of the truck from another operator. Each operator is responsible for the condition of the forklift on their shift.

• Work together as a team with your co-workers, supervisors and authorized service facility to keep the truck in peak operating condition. Accidents happen when you assume another operator has checked out the forklift.

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



WARNING

All defects must be reported to the person in charge immediately.

Failure to do so could result in the truck becoming dangerous in operation and could lead to serious injury.

Inspection and Maintenance Practices for Authorized Facilities ONLY •

•

• •

Inspect and maintain motors, controllers, limit switches, protective devices, electrical conductors, connections and electrical insulation described in the applicable section of ASME B56.1-2000.

Only use replacement parts, including tires, that are equal to, or exceed, the quality of the parts supplies bu the original equipment manufacturer.

Install parts, including tires, according to procedures established by Landoll Company, LLC. When you remove tires, follow industry safety practices as described in the applicable section of ASME B56.1-2000.

2-3

TABLE OF CONTENTS PLANNED INSPECTION AND MAINTENANCE

Preparing for Inspection or Maintenance Before inspecting or maintaining the forklift, thoroughly read and understand the instructions and cautions described beginning on page 1-1: • Inspect the forklift in an area that has sufficient clearance to check all operator functions.

• Lower forks to the ground and tilt mast forward.

• Use wheel chocks or other positive forklift-positioning devices if drive functions will not be checked.

• Raise the drive wheels so they are not in contact with the floor when checking operator functions while leaving the forklift in a stationary position.

• Block the mast to prevent it from engaging.

• Use adequately rated hoisting equipment if the forklift will be hoisted for service.

• NEVER remove counterweights or uprights. This will change the center of gravity and can cause an unstable condition.

Performance Testing NOTE

IMPORTANT Before leaving the forklift make sure that: • The parked forklift will not cause an obstruction or safety hazard and is clear of the path of fire exits/equipment.

• The forklift will not be left unattended on an incline.

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



CAUTION

Before leaving the forklift make sure that: • The parked forklift will not cause an obstruction or safety hazard and is clear of the path of fire exits/equipment.

• The forklift will not be left unattended on an incline.

• Make sure all accessories are off before continuing.

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

Make sure all accessories are “OFF” before continuing.

Make sure: 1. The operator should be properly seated in the operator’s seat before beginning testing procedures.

2. Set the direction control lever to the neutral position.

3. Turn the key switch “ON”.

4. Set the direction switch to the forward position 5. Check functions described in the Operator’s Daily Checklist or other Checklists starting on page 2-4.

Completing Performance Testing After all tests are completed as described in the Operator’s Daily Checklist: 1.

2.

3.

4.

5.

6.

2-4

Apply the parking brake.

Tilt the mast forward.

Lower the forks to the ground Make sure all accessories are off.

Turn the key switch to the OFF position.

Remove the key.

F-985-0219

TABLE OF CONTENTS PLANNED INSPECTION AND MAINTENANCE

Operator Daily Pre-Shift Inspection Checklist - Bendi B3-30 AC/DS Series 5 Daily pre-shift inspections are an OSHA requirement. It is important that these inspections are documented.

Date

Inspector

Shift

Truck Number

Model Number

Location

Hour Meter

Hydraulic Oil Added

Battery Water Added

Brake Fluid Added

Safety & Operational Checks Tires ESD (static) Strap Forks, Retaining Pins & Heal Overhead Guard Hydraulic Cylinders and Hoses Hydraulic Oil Battery Battery Restraint (if installed) Brake Fluid Safety Warning Decals Operators Manual Data Plate Seat Adjustments Seat Belt, Buckle & Retractor Electrical Key Switch (turn power on) Dash Display Parking Brake Horn Accelerator Pedal Directional Control Backup Alarm Service Brake Seat Switch Lights Mast Controls Steering

Description

Ok

Comments

Check for damage and debris Check condition Check Condition Check for damage and cracks Check for damage and fluid leaks Check level Check water level Check charge Securely fastened Check level Attached and legible Present and legible Attached and legible Check function of all levers Check condition and operation Check wires and connectors Listen for unusual noises Check hour meter, BDI and fault codes Check operation Check function Check operation Check forward and reverse operation Check operation Check operation Check operation Check Switch and operation Check Lift/Lower Controls Check Tilt Controls Check Side-Shift Controls Check operation

During daily inspection, be sure to check the overall condition of the forklift (i.e. body/paint damage, battery cover condition, seat condition, etc). Also check the floor under and around the forklift for any signs of fluid leaks. Make a note of any conditions that are out of the ordinary and report them to your supervisor immediately.

2-5

TABLE OF CONTENTS PLANNED INSPECTION AND MAINTENANCE

1st 100 Hour Technicians Inspection Checklist - Bendi B3-30 AC/DS Series 5 To be performed after the first 100 hours or 2 weeks of truck operation, whichever comes first. In addition to the required pre-shift daily inspection. All service and repairs must be performed by a qualified technician.

Date

Inspector

Shift

Truck Number

Model Number

Location

Hour Meter

Hydraulic Oil Added

Battery Water Added

Brake Fluid Added

Description

Done

Safety & Operational Checks

Comments

Mast Chains Carriage Friction Surfaces Load Backrest Front Plate Mounting Bolts Steering actuator Hydraulic Coupling Drive Wheel (front)

Inspect, Clean & Check Tension Clean & Inspect Retorque bolts to 150 ft/lbs (205 Nm) Retorque to 760 ft/lbs (1030 Nm.) Retorque to 30 ft/lbs (41 Nm.) Retorque lug nuts to 225 lbs (305 Nm) Braking Wheels (back) Retorque lock nut to 20-25 in/lbs (102 Nm) then back off 1/2 turn Gear Box Drain, Flush and Refill Hydraulic Filter Element Replace The gear box drain/flush/refill occurring after the first 100 hours or 2 weeks of operation is CRITICAL to the life of the forklift.

NOTES:

2-6

F-985-0219

TABLE OF CONTENTS PLANNED INSPECTION AND MAINTENANCE

500 Hour Technicians Inspection Checklist - Bendi B3-30 AC/DS Series 5 To be performed every 500 hours or 2 months of truck operation, whichever comes first. In addition to the required pre-shift daily inspection. All service and repairs must be performed by a qualified technician.

Date

Inspector

Shift

Truck Number

Model Number

Location

Hour Meter

Hydraulic Oil Added

Battery Water Added

Brake Fluid Added

Safety & Operational Checks Nuts, Bolts and Screws Wheel Bearings Tires Drive Wheel (front) Braking Wheels (back) ESD (static) Strap Battery Cover Battery Battery Roll-out Tray (if equipped) Battery Restraint (if installed) Brake Fluid Safety Warning Decals Operators Manual Data Plate Seat Adjustments Seat Belt, Buckle & Retractor Electrical Key Switch (turn power on) Dash Display Parking Brake Horn Accelerator Pedal Directional Control Backup Alarm Service Brake Seat Switch Mast Controls Lights Controller Forks, Retaining Pins & Heal Load Backrest Hydraulic Hoses & Fittings

Description

Done

Comments

Check torque Clean and grease Check for damage and debris Retorque lug nuts to 225 lbs (305 Nm) Retorque lock nut to 20-25 in/lbs (102 Nm) then back off 1/2 turn Check condition Lifts smoothly and easily Check for leaks, clean and neutralize Check safety restraints and safety switch Securely fastened Check level Attached and legible Present and legible Attached, legible and accurate Check function of all levers Check condition and operation Check wires and connectors Listen for unusual noises Check hour meter, BDI and fault codes Check operation and pad wear Check function Check operation Check forward and reverse operation Check operation Check operation Check operation Check Lift/Lower Controls Check Tilt Controls Check Side-Shift Controls Check Switch and operation Check for faults Clean surface Check operation and contactor points Check condition Retorque bolts to 150 ft/lbs (205 Nm) Check for damage and fluid leaks

2-7

TABLE OF CONTENTS PLANNED INSPECTION AND MAINTENANCE Safety & Operational Checks

Mast

Rotation Stops Tilt Cylinder Lift & Side Shift Cylinders Hydraulic Pressure Filter Hydraulic Tank Breather Fans Service Brakes Gearbox

Motors

Major Structural Points (i.e. axle mount, overhead guard, rotation pins, etc

Overhead Guard

Steering

Description

Done

Comments

Clean, Check and Lube the Chain Clean, Check and Lube Carriage Check for wear Clean, Check and Lube attachment Check for Smooth Operation Check for Mast Racking Lubricate all points Check for wear and cracks Check Fwd/Rwd tilt angles Jam Nut Tight Grease pivots and end of cylinder Check for leaks and wear Replace Clean Exterior Check Operation Check for leaks and shoe wear Check for leaks Clean Clean and torque stud and bolts Clean cooling vents Check hydraulic pump motor for leaks Check for damage and cracks Check for damage and cracks Retorque Attaching Hardware Check Operation Check Steer Pot Lube steering knob Grease steering gears Check Pressure (1900 psi/13,100 kPa

NOTES:

2-8

F-985-0219

TABLE OF CONTENTS PLANNED INSPECTION AND MAINTENANCE

2000 Hour Technician Inspection Checklist - Bendi B3-30 AC/DS Series 5 To be performed every 2000 hours or 1 year of truck operation, whichever comes first. In addition to the required pre-shift daily inspection and 500 hour inspection. All service and repairs must be performed by a qualified technician.

Date

Inspector

Shift

Truck Number

Model Number

Location

Hour Meter

Hydraulic Oil Added

Battery Water Added

Brake Fluid Added

Safety & Operational Checks Mast Chains Hydraulic reservoir suction screen Gearbox Brake Fluid Front Plate Mounting Bolts Steering actuator Hydraulic Coupling

Description

Done

Comments

Inspect, Clean & Check Tension Clean with solvent Drain, Flush and Refill Change Retorque to 760 ft/lbs (1030 Nm.) Retorque to 30 ft/lbs (41 Nm.)

4500 Hour Technician Inspection Checklist - Bendi B3-30 AC/DS Series 5 To be performed every 4500 hours of truck operation. In addition to the required pre-shift daily inspection and 500 hour inspection. All service and repairs must be performed by a qualified technician.

Date

Inspector

Shift

Truck Number

Model Number

Location

Hour Meter

Hydraulic Oil Added

Battery Water Added

Brake Fluid Added

Description

Done

Safety & Operational Checks Hydraulic Oil

Comments

Change

2-9

TABLE OF CONTENTS PLANNED INSPECTION AND MAINTENANCE

Tires and Wheels

 •

•

•



CAUTION

The truck is equipped with tires of the size and hardness that provides the necessary traction and still maintain a proper shape to minimize tipping. To maintain stability and maximum reliability, you must always replace tires with the type originally supplies, as listed in the parts manual (P/N F-633).

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

Check all lug nuts after 2 to 5 hours of operation: when new lift trucks begin operation and on all lift trucks when the drive wheels have been removed and installed. Tighten the nuts in a cross pattern to the correct torque value. When nuts stay tight for 8 hours, the interval for checking the torque can be extended to 200 hours.

1. Inspect the tires for chunking (or chipping), embedded foreign material (wire, rocks, glass, metal, etc,), cuts, gouges, undercutting or uneven wear.

2. Remove any objects that will cause damage.

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

4. Make sure drive wheel nuts are tight. Tighten the lug nuts in a cross pattern to the correct torque value.

CAUTION

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

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

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

Sharp, rapid turns at quick speeds, jack-rabbit starts and stops and other such bad driving habits can cause flat spots and similar damage.

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

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

3. If tires are chunked bad enough to produce a bouncy ride, replace them immediately.

IMPORTANT Continued operation with damaged tires may result in failures of other components. This is considered abuse and is not covered under warranty.

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

Figure 2-1: Tire Tread Inspection

2-10

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

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

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

3. Correct such defects as soon as possible.

F-985-0219

TABLE OF CONTENTS PLANNED INSPECTION AND MAINTENANCE

Flat-spotting Flat-spotting occurs when: • the truck has been sitting idle for some time after heavy use and is usually caused by tires overheating.

• the truck has standing loads (loads left on the forks overnight).

• locking the brakes while traveling in either direction on grades (slopes), with or without a load, causing excessive skidding.

Polyurethane tires are extremely susceptible to this type of abuse.

1. Avoid excessive heat. Where possible, avoid hot metal or operation for long periods in hot oven rooms.

Excessive heat will break-down the tire structure.

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

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

4. Do not indulge in stunt driving or horseplay.

5. Avoid excessive hard braking, especially on grades.

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

1. Inspect tires regularly and remove embedded objects immediately.

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

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

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

5. Avoid excessive heat, overloading and standing loads.

6. Regularly check axle alignment and steering.

7. Avoid sharp turns and quick starts and stops.

8. Avoid oil, grease, gasoline and acid. Wipe these compounds off of the tires as soon as possible. Do not allow hydraulic oil to drip onto the tires.

ESD Strap The ESD Strap is installed on the bottom center of the frame of the forklift. This strap will drain all static electricity build-up that may occur on the Bendi B3-30 AC/DS forklift. ESD Strap should be in fair condition, bolted securely to the body and touching the ground.

Fork Inspection For more information on fork removal, repair and advanced inspection procedures see “Removing the Forks” on page 4-5.

 •

• •

WARNING

Never operate a forklift if you suspect the forks are damaged. Report fork damage to your supervisor immediately.

NEVER use forks repaired by welding.

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

It is recommended to use only Landoll Company, LLC replacement parts.

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



DANGER

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

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

2-11

TABLE OF CONTENTS PLANNED INSPECTION AND MAINTENANCE

Cracks Visually examine the forks for cracks and, if considered necessary, perform a non-destructive crack detection test. Pay special attention to: • Fork Heel • Welds that attach mounting components to the fork blank.

• Top clip retaining pin.

NOTE Immediately pull forklift from service and repair if cracks are found.

Hydraulic System Inspection/Maintenance 

Positioning Lock

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

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

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

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

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

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

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

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

Overhead Guard

CAUTION

Hydraulic Cylinders and Valves Check these components for damage, drift and leakage.

Refer to Landoll Company, LLC and other vendor service information for specifications.

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

Look for hydraulic hose cracks, hardening and other signs of damage or wear. Look for leaks, especially at couplings and fittings. Make sure clamps and fittings are tight. If damage, wear or leaks are found, have service repair all discrepancies immediately and check the hydraulic fluid level. DO NOT operate the forklift until service is complete.

Check Hydraulic Oil Level IMPORTANT

Check the overhead guard, making sure that it is firmly attached to the forklift and that all fasteners are secured.

The overhead guard is adjustable to accommodate various drivers and operating restrictions (low ceilings, door openings, etc.).

2-12

•

•

It is important that the proper level of properly specified oil be maintained at all times. Failure to check the oil level as recommended could cause serious mast function operating problems.

The oil level indicated on the dipstick is most accurate when the oil is at operating temperature (130°F to 200°F (54°C to 93°C)).

F-985-0219

TABLE OF CONTENTS PLANNED INSPECTION AND MAINTENANCE •

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

1. Lower the mast to within a few inches of the ground, then tilt it forward completely.

2. With the key switch OFF, turn the steering wheel left and right until it becomes difficult to turn.

3. The fill/dipstick cap is located under the floor plate.

Disconnect the battery and remove the floor plate to access the dipstick and the filter.

Full Add

Figure 2-3: Oil Level on Dipstick For information on changing the changing Hydraulic Oil see “Changing Hydraulic Oil” on page 4-26.

For information on changing the changing Hydraulic Oil Filter, see “Change the Pressure Filter” on page 2-24 Figure 2-2: Hydraulic Oil Reservoir Location 4. First clean the area around the dipstick, then pull dipstick out and wipe clean. Reinsert dipstick.

5. Remove the dipstick again, holding the dipstick tip level and check the oil level. If the oil level is at the FULL line or between the FULL and ADD lines, the level is correct and no oil is needed. If the oil is at or below the ADD line, you will need to add oil to bring it up to the FULL line (maximum).

6. Add hydraulic oil as needed. (See “Lubrication Specifications” on page 1-11) 7. If the fluid appears very dirty or dark in color, check the truck’s maintenance log for the last fluid and filter change and change accordingly.

8. Install dipstick, making sure it is seated. Attach the accelerator wiring harness and install the floor plate.

Battery 

DANGER

Before inspecting or servicing the battery, review “Battery Safety” on page 1-7 For more information about the battery refer to “Battery” on page 4-1.

When inspecting the battery, the following should be checked: 1. Battery is clean and in good condition, with no corrosion or missing vent caps.

2. Battery charge.

• For information on charging the battery see “Charging a Wet Battery” on page 4-4.

3. Battery fluid level.

Checking the Battery Using a Hydrometer As the battery discharges the specific gravity of the electrolyte lowers. A hydrometer allows you to check the specific gravity of the cells, thus the charge state of the battery.

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

2-13

TABLE OF CONTENTS PLANNED INSPECTION AND MAINTENANCE 2. Insert the tube of the hydrometer into the cell electrolyte.

3. 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.

• The specific gravity of the electrolyte is read off the scale of the float where it emerges from the fluid.

Specific Gravity Correction Temp °F

Correction

Temp °F

Correction

39-41

-0.012

101-103

+0.008

42-44

-0.011

104-106

+0.009

45-47

-0.010

107-109

+0.010

48-50

-0.009

110-112

+0.011

NOTE

51-53

-0.008

113-115

+0.012

It is a good practice to select a different cell each time a measurement is taken and to test more than one cell.

4. If the specific gravity of the battery is less than the manufactures specification at 80% discharge, you must charge the battery.

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

NOTE When returning the electrolyte to the battery, ensure that the fluid is returned to the cell from which it was taken.

Be careful not to splash the electrolyte.

Check Fluid Level

S.G = 1.280 BATTERY IN CHARGED STATE

S.G = 1.280 BATTERY IN DISCHARGED STATE

Figure 2-4: Hydrometer

Check the level in all battery cells. If the level is below the top of the battery plates, add distilled water to bring the level above the plates.

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 the battery may look dry.

2. DO NOT add water until an accurate temperature is obtained; cold weather can affect the level.

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

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

2-14

F-985-0219

TABLE OF CONTENTS PLANNED INSPECTION AND MAINTENANCE Do not overfill the battery. There must be enough room to provide space for expansion as the battery heats up during normal operation.

Battery Restraint System and Roll-out (Optional) The battery restraint should be in place at all times when a battery is installed in the forklift. A switch that detects the battery restraint will disable the forklift if the restraint is not in place.

Release Handle

Spacers

Rollout Battery Restraint Arm

Identification Plate and Safety Warning Decals 

WARNING

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

See “Decal Identification” on page 1-2 for a complete listing and location of all safety warnings.

Seat Adjustments Limit Switch Restraint Arm Mount Figure 2-5: Roll-out Battery Arm Bar

The operators seat has six levers, three on the front and three on the right side (arm rest). Check for proper function of each lever.

Check the Brake Fluid Level

Seat Adjustment

The master cylinder is located below the driver’s compartment floor plate.

1. Remove the left floor plate.

2. Clean the reservoir cap to avoid fluid contamination, then remove the filler cap and rubber gasket.

3. Additional fluid is needed when the fluid level is below the FULL line stamped inside the master cylinder housing body.

4. Add fluid, DOT 3 Brake Fluid, as needed. DO NOT OVERFILL. 5. Reinstall the reservoir filler cap and rubber gasket; tighten only enough to provide a leak proof seal.

A lever under the front of the seat releases the catch for forward or backward seat adjustment. Weight or suspension adjustments is controlled by the hand wheel.

A gauge showing the adjusted level is located to the right of the adjustment hand wheel.

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.

NOTE Do not over tighten. This could crimp, split or damage the seal.

2-15

TABLE OF CONTENTS PLANNED INSPECTION AND MAINTENANCE Turn the key switch on and listen for, and investigate any unusual noises Key switch must be on to perform the daily inspection on operator controls, lights and alarms.

Dash Display With the key switch in the ON position, check for the following on the dash display: 1. Battery Discharge Indicator.

2. Speed and Direction Indicators.

3. Hour Meter • Record hours on inspection checklist.

4. Check for any fault codes.

2

4 5

6

1

3

Figure 2-6: Seat Adjustments

Seat Belt 1. Check the seat belt condition, check for fraying.

2. Push the latch plate into the buckle until it clicks.

3. Pull up on the latch plate to make sure it is secure.

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

4. Push the release button to release the seat belt.

5. Ensure the seatbelt easily and fully retracts.

Electrical Connections

Parking Brake The parking brake is located to the left of the mast control levers. See Figure 2-7 1. While in the driver's seat, set the parking brake by pulling the lever back toward the rear of the forklift.

2. Put the gear into forward or reverse and step on the accelerator slightly.

3. The parking brake should hold the forklift in place • The forklift will not respond to the accelerator pedal unless the parking brake is pushed forward all the way.

NOTICE This will cause the drive wheel to lock. DO NOT test the parking brake at high speeds.

For information on testing the parking brake switch refer to “Checking Parking Brake Switch” on page 4-16.

1. Set the key switch to off and remove the key.

2. Thoroughly check all wire connections, check for loose wires within the connectors, loose connectors, frayed or broken wires, etc.

3. If any wires or connectors are damaged, have serviced immediately before operating the forklift.

Key Switch For information on removing or replacing the key switch See “Key Switch” on page 4-35.

2-16

F-985-0219

TABLE OF CONTENTS PLANNED INSPECTION AND MAINTENANCE

Direction Control Lift/Lower Tilt

Horn Button

Directional Control Switch

Side Shift

Emergency Stop

Figure 2-7: Operator Controls

Accelerator Pedal, Directional Switch & Backup Alarm The directional control lever, located to the right of the driver seat, as well as the backup alarm can be checked at the same time as the accelerator pedal function.

1. With the key switch set to “ON”, 2. Move the direction control switch forward and gradually push on the accelerator pedal.

• The further pressed, the faster the forklift will operate.

3. Let up on the accelerator pedal and the forklift should come to a controlled stop.

4. Move the directional control switch backwards and gradually press on the accelerator pedal. Truck should move in reverse.

• Backup alarm should sound when directional control switch is pulled back.

5. Return directional control to neutral.

If any problems are detected, remove the forklift from service immediately until it is repaired.

Figure 2-8: Directional Control

Service Brakes 1. With the key switch set to “ON”, drive forward slowly and then steadily apply the brake pedal.

2. The forklift should stop smoothly without noticeable vibration.

3. Any problems with the brake system must be repaired immediately. DO NOT use the forklift until proper maintenance has been performed.

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

The switch is part of the seat as shown in Figure 2-9.

1. Start the forklift and release the parking brake.

2. The seat switch and actuator are internal to the seat cushion, located on the under side of the seat cushion between the cushion and the bottom plate.

3. Set the direction control lever in either FORWARD or REVERSE and slowly apply acceleration. As the forklift begins to slowly move in either direction, the operator should raise off of the seat just enough to disengage the switch located under the seat cushion.

• There is a few second delay programmed into the seat switch to avoid inadvertent shut down from operator normal movements.

2-17

TABLE OF CONTENTS PLANNED INSPECTION AND MAINTENANCE 4. The forklift will not come to an immediate STOP. You should lose forward direction (or reverse). The forklift may coast unless the brakes are applied.

• If the forklift doesn’t stop, take forklift out of service for repairs immediately.

5. Sit back down on the seat and press the accelerator pedal 6. The truck must not move. If it begins to move, see “The directional control switch (forward-neutral-reverse) is located on the lift lever.” on page 4-23 to check the electrical function of the lever.

• For more information see “Return to Neutral” on page 2-19.

7. If the truck does not move, take your food off the accelerator pedal. Place the directional control lever in the NEUTRUAL position then back to forward again.

SEAT SWITCH AND CABLE Figure 2-9: Seat Switch

Horn Press the horn button, located on the front side of the lift lever. See Figure 2-8. Make certain the horn sounds when the button is pushed.

Mast Controls The mast movements are controlled by three levers located to the right of the driver. See Figure 2-7

Lift 1. With the key switch turned “ON”, raise the mast by pulling back on the left lever.

2-18

•

The hydraulic motor should start running as soon as the control is moved out of the neutral position and stop as soon as the control returns to the neutral position. The motor should not run at all when lowering the mast.

2. Check that the primary mast cylinder extends fully and that the lift carriage rises to the top of the inner rails before the secondary cylinders begin to move.



WARNING

Make sure there is sufficient room above to raise the mast safely and keep all people clear.

•

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.

3. With the mast fully extended, begin lowering the mast by pushing the lever forward.

• 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 a supervisor or service personnel.

DO NOT attempt to operate the forklift until the problem is corrected.

Tilt Control 1. Tilt is controlled by using the center lever.

2. Pushing the lever forward will tilt the mast forward.

3. Pulling the lever back will tilt the mast back.

Side Shift 1. The right lever controls side shift.

2. Push the lever forward to cause the mast assembly to shift to the left.

3. Pull the lever down to cause the mast assembly to shift to the right.

Mast Racking Racking occurs when the tilt cylinder strokes are uneven.

(One cylinder bottoms before the other.)

The mast rails may twist eventually causing them to crack and separate. Proper tilt degree adjust is 3° forward and backward maximum.

F-985-0219

TABLE OF CONTENTS PLANNED INSPECTION AND MAINTENANCE



CAUTION

If this problem is left uncorrected, serious damage to the mast assembly or the tilt cylinders can occur, causing the need for extensive repair and downtime.

1. To check for racking, find a reasonably level floor area to park the forklift on and center the mast on the forklift.

2. Raise the mast to about 36” (914 mm) from the floor and tilt the mast full forward and rearward several times watching for twisting at the ends of the stroke.

3. If there is any twisting or racking, both tilt cylinder rods must be readjusted. Remove the forklift from service immediately and repair.

For more information on checking tilt angle see “Check Tilt Cylinder” on page 2-22.

Lights 1. Turn the lights on using the control switch located on the dash panel below the steering wheel.

2. Check the integrity and operation of all the lights.

Speed Switch Test to ensure that the fast and slow speed settings change the maximum speed of the forklift.

Steering - Check Operation 1. Sit in the driver’s seat and set the key switch to ON. 2. While applying the service brake, release the parking brake and set the direction control lever to forward or reverse. The power steering pump motor should start running.

3. If the motor does not start, first check that the parking brake is released.

4. While moving forward or backward slowly, verify that the truck turns left and right with relatively smooth, easy motion.

5. While moving, turn the steering wheel completely to the right until it stops.

6. While moving slowly, turn the steering wheel completely to the left (counterclockwise) while counting the number of full revolutions. The steering wheel must complete approximately seven to nine revolutions, ±1/2 revolution, lock to lock.

7. Next, turn the steering wheel completely to the right (clockwise) while counting the number of revolutions.

The steering wheel must complete approximately seven to nine revolutions, ±1/2 revolution, lock to lock.

8. Set the directional switch to neutral, without touching the steering wheel, and check that the steering pump turns off.

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

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

Return to Neutral 1. Sit in the driver’s seat, and turn the key switch ON. 2. Set the direction control lever to FORWARD. 3. Slowly move the truck forward, then stop by using the service brake.

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

5. Press on the accelerator pedal.

6. The truck must not move.

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

8. Slowly push on the accelerator pedal. The truck should move forward. If it does not move, refer to “General Bendi B3-30 AC/DS Troubleshooting Charts” on page 3-1 and “Bendi B3/30 AC Calibration and Programming” on page 5-1.

9. Repeat preceding steps, but instead of turning the key switch OFF in Step, lift yourself from the driver’s seat to allow the switch interlock to release. The truck must react as stated in Steps 4 through 8.

General Mast Inspection For more information about the mast see “Supplier Provided Documentation” on page 6-1.

Perform the following general mast inspections: 1. Check the hoist cylinder for proper sequencing.

“Mast Controls” on page 2-18.

2. Check if the unloaded mast elevates to full lift (relief should open). If mast will not go to full lift, check the hydraulic fluid level in the reservoir and add fluid if required.

2-19

TABLE OF CONTENTS PLANNED INSPECTION AND MAINTENANCE 3. With load on forks in front carry position, elevate to approximately 5 feet (1.524 meters). Lower fast to within 6 inches (152.4 mm) of floor and stop abruptly.

The mast should stop with a solid effect. if bouncy, bleed the hydraulic cylinder.

4. Check the carriage rollers and elevating channel rollers for proper contact with mating surface.

5. Look for signs of galling where the rollers contact the rail. See Figure 2-10.

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

• If galling is detected, adjust the rollers for the proper clearance over the full length of the mast rails.

6. Check for proper lift chain adjustments.

• Check for chain contact with retaining lip on sheaves.

Galling

•

• • •

•

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

Cracked side plates - Replace both chains.

Protruding or turned pins - Replace both chains.

Side wear - If pins and outside plates show signs of wear, check for misalignment of sheaves, anchors and other components. Correct the misalignment. If wear is excessive, replace both chains.

Worn, broken or misaligned chain anchors Replace or adjust as required.

Chain Lubrication



CAUTION

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

• Lubricate chains with SAE 40W oil or Bowman Heavy Load Red Grease • Each pair of chains has been factory-lubricated using heat and pressure to force the lubrication thoroughly into the chain links. Avoid removal or contamination of factory applied lubricant. Do not wash, sand blast, etch, steam clean or paint the chains.

Chain Adjustment

Figure 2-10: Channel Galling

Mast Chains

The chain must be adjusted so each strand is under equal tension for proper load distribution and mast operation. To determine whether the chains are properly adjusted: 1. Remove load from forks.

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

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

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

Each chain in a pair should have equal “give”. If tension is not equal, adjust them as described in the manufacturer’s mast service manual. “Supplier Provided Documentation” on page 6-1

Chain Inspection

Check Primary Lift Chain

Chain inspection is required after the 1st 50 hours of operation then during every 500 hour inspection. During inspection, check for the following: • Chain wear - If one chain appears to be worn, replace both chains at the same time.

2-20

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

2. Lower the empty (unloaded) forks to the floor.

3. Set the key switch to “OFF” and remove the key.

F-985-0219

TABLE OF CONTENTS PLANNED INSPECTION AND MAINTENANCE 4. Measure the distance from the floor to the bottom heel of each fork tine. See Figure 2-6. This measurement must be 1/8” (3.175 mm) minimum to 1/4” (6.35 mm) maximum. See Figure 2-11 for reference.

5. If it is not within 1/8” to 1/4” (3.175 mm to 6.35 mm), adjust the primary lift chain accordingly.

CHAIN WEAR SCALE COMPARISON BETWEEN CHAINS NEW CHAIN STRETCHED CHAIN

1/8” - 1/4”

Figure 2-12: Measuring Chain Stretch

Check Lift Operation

Figure 2-11: Fork Heel to Floor

Measuring Chain Stretch If the chains stretch beyond the recommended amount, they should be replaced in pairs. Chain stretch can be measured with a chain wear scale, as shown in Figure 2-12. The scale indicates whether the distance between two chain links is within tolerance. The shaded area in the illustration compares a stretched chain to a new chain. Measure the chains according to the instructions printed on the chain wear scale, without load on the carriage.

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

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

1. Check the lift cylinders to ensure proper sequencing.

If adjustment is needed, see “Adjusting Degree of Tilt” on page 4-6.

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

3. Load the mast and raise it approximately to 5’ (1.524 m), then quickly lower the mast until it is about 6” (1.524 mm) above the floor and stop the mast abruptly.

4. Make sure the elevating channel rollers maintain proper contact with the mast channel.

5. Look for signs of galling where the rollers contact the rail. Galling is indicated by track marks in the rails that are 1/4” to 1/2” (6.35 mm to 12.7 mm) wide running up the rail. Normal track marks are no more than 1/4” (6.35 mm) wide.

If galling is detected, adjust the rollers for the proper clearance over the full length of the mast rails. See Chapters 5 & 6 for reference.

Load Backrest Fasteners for the load backrest may loosen due to vibration. Torque the backrest fasteners to 150 ft-lbs.

(203 Nm.).

2-21

TABLE OF CONTENTS PLANNED INSPECTION AND MAINTENANCE

Front Plate The front plate mounting bolts should be re-torqued.

“General Torque Specifications (rev. 4/97)” on page 1-12.

Check Tilt Cylinder 1. To check degree of tilt, be certain the forklift is on a smooth, level surface.

2. Tilt the mast back its full stroke.

3. Place a tilt gauge against the rear outer mast rail on the right side of the forklift.

4. The gauge must read between 3.0° and 4.1° maximum.

• If equipped with a mast that has a fork height greater than 240”, available tilt is limited to 1 degree forward and 2.1 degrees back. The standard tilt is 3 degrees forward and 3.1 degrees back for masts of 239” or lower. When testing a standard truck equipped with a mast gauge, the gauge must read between 3.0 and 3.1, while the taller mast must read between 2.0 and 2.1 degrees of rear tilt .

2-22

Side Shift Cylinder

 • •

• • •

WARNING

Before you remove any hoses or tubes, relieve hydraulic system pressure.

With the truck off, open the truck auxiliary control valve several times in both directions.

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

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

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

Checking for Leaks To check side shift circuit performance: 1. Side shift completely to the left and hold the control handle in this position for 5 seconds.

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

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

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

F-985-0219

TABLE OF CONTENTS PLANNED INSPECTION AND MAINTENANCE

Mast Mounting Pins

Steering Wheel Knob

Mast Rails

Side Shift Rails

Fork Rails Tilt Cylinders Gear Box

Battery Rollers

Figure 2-13: Lubrication Locations

Forklift Lubrication In the following procedures, the location of grease fittings or surfaces to be greased are by either a grease-gun or brush. See Figure 2-13. Before brush applying grease to bearing pad surfaces, wipe out the channel to remove any foreign matter that may have accumulated since your last lubrication.



DANGER

DO NOT service the forklift and/or mast area while the key switch is “ON”. If a lever, steering wheel or accelerator pedal is accidentally moved, serious injury could occur.

2. Certain grease fittings may include protective plastic caps. Remove them before applying grease.

Remember to replace the caps when finished.

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

4. After a forklift cleaning, lubricate all unprotected grease fittings and metal-to-metal surfaces, located outside the forklift.

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

6. See “Lubrication Specifications” on page 1-11 for recommended lubricants.

1. Before lubricating the forklift, lower the forks, set the key switch to the “OFF” position.

2-23

TABLE OF CONTENTS PLANNED INSPECTION AND MAINTENANCE

Tilt Cylinder Clevis

Change the Pressure Filter

1. Set the key switch to OFF, remove the key from the key switch and place in a secure area.

2. Grease clevis fitting on end of tilt cylinder until fresh grease is squeezed from the clevis. See Figure .

3. Wipe off excess grease.

Fork Positioner Lubrication (Option) 1. Set the key switch to “OFF”, remove the key from the key switch and place in a secure area.

2. Before lubricating the positioner rails, wipe off excess lubricant and dirt buildup from within the rail channels and dirt from the top and bottom of the rail grooves.

3. Using a brush, lubricate the top areas on the fork rails, including a thin film on the front face of both rails. Using a grease gun apply grease to the lower fork rails.

4. Wipe off excess grease.



CAUTION

After prolonged forklift use, hydraulic oil will become hot and can burn the skin. Allow hydraulic oil to cool to a tolerable temperature before performing this procedure.

1.

2.

3.

4.

5.

6.

First, review “Getting Started” on page 1-1.

Park the forklift on a level surface.

Lower the forks all the way to the ground.

Apply the parking brake.

Perform “See “Lock Out / Tag Out” on page 1-7.

Make sure all the other wheels are securely blocked so that the forklift cannot move.

7. Move the lift lever in both directions to relieve hydraulic pressure.

8. Remove the floor mat and both floor plates.

9. Unplug Deutsch connector from filter indicator.

10. Remove filter body end-cap with wrench, P/N 197946, and filter element.

11. Install new filter element and reassemble in reverse order.

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

13. Check the hydraulic fluid level and reinstall the driver’s floor plate.

Figure 2-14: Fork Positioner Lubrication

Steering Knob Lubrication 1. While the truck is stationary and with the key switch OFF, apply a drop or two of light machine oil where the knob meets the steering wheel.

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

Hydraulics Dirt and other foreign materials may collect on the hydraulic pump. Any grease, dust and other grime will collect heat that the pump and motor are trying to dissipate, possibly leading to overheating issues.

Figure 2-15: High Pressure Filter 2-24

F-985-0219

TABLE OF CONTENTS PLANNED INSPECTION AND MAINTENANCE

Checking and Adjusting Hydraulic Pressure



WARNING

HIGH PRESSURE FLUIDS CAN BE DANGEROUS! Before continuing with this section, read about the warnings of pressurized hydraulic oil under “Hydraulic System” Warning page 1-7.

See “Checking and Adjusting Hydraulic Pressure” on page 4-28

Change Hydraulic Oil See “Changing Hydraulic Oil” on page 4-26

Service Disc Brakes •

•

•

The service brakes are hydraulically-actuated drum brakes, similar to an automotive drum brake system. The brake drums are installed on the two rear wheels only.

The brakes should be checked every 200 hours of operation. Normal brake shoes can last 3,000 hours of operation, but that figure can vary widely as determined by the operator and driving conditions. If you are near or beyond this time frame, you must thoroughly inspect the brakes.

New brake shoes are approximately 0.265” (6.7 mm) thick. Replace them when the shoe thickness is 0.0625” (1.588 mm) or less.

NOTE A few indications of possible brake shoe replacement are: • Excess travel of the service brake pedal.

• The truck pulling to one side when the brakes are applied.

• Squealing or grinding is heard when brakes are applied.

• Drive the truck at creep speed and apply brakes lightly, to determine if brakes pads are contacting the drum. You should feel pedal resistance as the shoes contact the drum.

• If any of the above occurs during brake inspection, see “Checking/Changing Brake Shoes” on page 4-12.

The service brake pedal must also have about 1/2” (12.7 mm) of the travel remaining when the brakes are fully applied. If less than 1/2” (12.7 mm) is available, adjust or check the shoes for wear and replace as needed.

For information on changing brake pads see “Checking/Changing Brake Shoes” on page 4-12

Wheel Bearings Clean and grease wheel bearings. For more information refer to“Disassembling and Inspecting Wheel Bearings” on page 4-26.

Major Structural Points Rust Or Corrosion Check the forklift frame, side panels, floor panels as well as mast assemblies for rust and corrosion. Clean rusty or corroded areas and repaint, if applicable. Apply a thin coat of oil to any bare metal surface.

NOTE Immediately pull forklift from service and repair if frame cracks are found.

Gear Box NOTE The planetary drive gear box assembly is filled with oil at the factory. An oil change is necessary after the first 50 hours maximum of operation in order to remove particles worn down during the running-in phase.

Thereafter, an oil change is only required once every 2000 hours or yearly, whichever comes first. Also, if the forklift has been in storage for one year or more, the oil should be changed before placing the forklift into operation.

Check Planetary Gear Box 1. First, review “Introduction, Safety, and Specifications” on page 1-1.

2. Perform “Lock Out / Tag Out” on page 1-7.

3. With the front tire raised and supported, spin the drive wheel and check for noise, rolling resistance and free play.

2-25

TABLE OF CONTENTS PLANNED INSPECTION AND MAINTENANCE 4. Rock the wheel in and out on the gearbox. If there is any noticeable movement, the gearbox must be checked or replaced.

NOTE There are no user serviceable parts for the gearbox assembly. The unit must be replaced as a complete assembly.

For information on Draining, Flushing and Filling the Gearbox see “Service the Gear Box” on page 4-21.

Stop Block The rotation stops act as a cushion when the front end is turned the full 180° in either direction See Figure 2-16.

The rotation stop is replaced by simply removing the hex socket screw (3/8”-16).

Nuts, Bolts and Screws All major mechanical and electrical connections (nuts, bolts, screws, etc.) must be checked and tightened periodically. Under severe operating conditions, checking and tightening inspection must be performed more frequently, “General Torque Specifications (rev. 4/97)” on page 1-12.

Figure 2-16: Stop Block Check and tighten the following: • •

Drive wheel lug nuts.

Drive unit gear boxes and motor mounting bolts (front wheels).

• To inspect the drive gear motor mounting bolts, you must remove the front wheels.



WARNING

When working under the truck, always use safety stands together with the lifting apparatus. Do not rely only on the lifting apparatus. The lift could leak fluid and accidentally release, allowing the truck to drop.

• Steer wheel/axle assembly mounting bolts.

• Mast tilt cylinder pin locking bolts.

• Mast mounting pin locking bolts.

• Master cylinder clevis and mounting bolts.

• All hydraulic pump and motor mounting bolts, • Hydraulic cylinder clevises.

Overhead guard mounting bolts.

2-26

F-985-0219

TABLE OF CONTENTS

Chapter 3

Troubleshooting General Bendi B3-30 AC/DS Troubleshooting Charts Shown on the following pages are general Bendi B3-30 AC/DS troubleshooting charts that will allow the service technician to diagnose areas of failure, by way of audible, performance and pump conditions and then proceed to proper chapter in this Maintenance Manual for detailed service.

Condition

Cause

Suggested Repair

AUDIBLE PROBLEMS Back up alarm does not sound.

Faulty alarm module.

Electrical problem - frayed or broken wires, faulty direction control switch or electronics.

Unusual noise when truck is in motion.

Singing noise.

Muffled grinding noise.

Clicking noise during a turn.

Rubbing or binding brake shoes in rear wheels (frozen brake cylinder).

Faulty gearbox assembly Insufficient fluid level in gearbox.

Faulty motor bearing.

Faulty wheel bearings - could be insufficient fluid or high pre-stress or excessive play on bearings.

Damaged planetary gearing could be insufficient fluid, excessive play in bearing Loose or shifting component

• Continuity check alarm module replace as needed • Check related wire harnesses and connectors for contact problems, broken wires, etc.

• Examine cable assemblies - tighten connections • Wire terminal crimps should be secured and wire stranding must not be frayed or corroded.

• Attempt to isolate cause of noise.

• Drive truck slowly, having another operator check for the unusual noise.

• Step on brakes lightly to see if brakes are biding or rubbing excessively - repair or replace.

• Replace if defective.

• Check fluid level. Check and add lubricating oil as needed.

• Repair or replace bearing or motor.

• Determine if noise is in the front or rear.

• Dismount gearbox and examine for damage.

• Try to isolate the area of the noise, then check for loose parts, misalignment, load shifting, etc.

• Check that components are in place and properly torqued.

3-1

TABLE OF CONTENTS TROUBLESHOOTING Condition Horn does not work.

Cause

Suggested Repair

Faulty horn assembly or push button.

Blown fuse.

Rubbing noise from the front wheel.

Faulty wheel bearing or damaged wheel shaft.

Scraping noise when the mast is operated.

Out of alignment.

Faulty hydraulic cylinder - lift, tilt and/or shift.

• Disconnect horn wires and push button - continuity test horn with leads connected to battery power.

• Check related wire harnesses and connectors for contact problems, broken wires, etc.

• Examine cable assemblies for tight connections.

• Wire terminal crimps should be secure and wire stranding must not be frayed, pinched or corroded.

• Check fuse.

• Check for electrical shorts in wiring or components • Dismount suspected wheel and examine bearings and shaft.

• Check for foreign material lodged inside wheel hub - remove and repair and/or replace as needed.

• Realign and shim mast rails accordingly.

• Determine which cylinder is bad rebuild or replace. (Seal kits are available for repair and can be ordered from the parts book.)

PERFORMANCE PROBLEMS No operation.

Battery disconnected or insufficient charge.

Emergency STOP (disconnect) push button is pressed.

Blown fuse.

Poor truck performance.

Battery undersized.

Undercharged battery.

Excessive electrolyte loss.

Defective battery.

3-2

• Make sure battery installed is a 48 VDC battery.

• Check battery for connection.

• Check battery for full charge.

• Check push button and if necessary, release push button.

• Place the direction switch in NEUTRAL before power on.

• Remember to wait about then (10) seconds after power on to allow diagnostic testing.

• Check main power fuses (425 Amp).

• Check for electrical short, or electrical connections.

• Refer to capacity plate for battery rating and install battery with proper ratings.

• Check/test battery characteristics.

• Adjust specific gravity at state of full charge.

• Replace battery.

F-985-0219

TABLE OF CONTENTS TROUBLESHOOTING Condition Service brakes do not stop the truck.

Cause

Suggested Repair

Low fluid level in master cylinder reservoir.

• If low, check for leaking fittings or lines - tighten and/or replace. Add brake fluid and bleed brakes if needed.

• Also check wheel cylinders for leaks - replace if needed.

• Check brake shoes for wear or defects - always replace both sides.

• Check linkage for loose nuts, broken or stressed linkage, improper adjustment - repair and re-adjust.

• If shoes are saturated, they must be replaced.

• Bleed air from brake lines indicated by bubbles in fluid during fluid bleed, or when checking the master fluid reservoir.

• Check brake system for loose fittings, cross threaded fittings and brake cylinders for leaks.

• Also check master cylinder reservoir fluid level - low level can allow air into lines.

• Examine the brake lines, wheel cylinders and master cylinder for leaks - repair immediately, then bleed the brakes.

• Also check the master cylinder piston for worn seals.

• Remove the master cylinder filler cap and “slowly” press the brake pedal. A pulse of fluid should be seen in the cylinder reservoir. If not, replace the cylinder.

• Check wheel cylinders for leaks rebuild or replace.

• Check parking brake linkage for loose nuts, broken or stressed linkage, improper adjustment - repair and readjust.

Worn brake shoes.

Brake pedal linkage adjustment.

Brake shoe contamination.

Spongy or soft service brake pedal.

Possible air in brake lines.

Faulty master cylinder.

Faulty wheel cylinders.

Parking brake does not hold the truck.

Brake cable system malfunction or out of adjustment.

3-3

TABLE OF CONTENTS TROUBLESHOOTING Condition Steering drifts/wanders or is erratic.

Cause

Suggested Repair

Low fluid or leaks in power steering system.

• Check hydraulic fluid level replenish as necessary.

• Check all related components for seal or fitting leaks - repair or replace.

• Check motion control valve cartridges for foreign material (these are replaceable cartridges and will wear out over time).

• Failed or weak orbital centering spring will cause the steering to drift - replace accordingly.

• Bad actuator - repair or replace accordingly.

• Check hydraulic pressure of 2,000 steering relief valve.

• Check actuator for seal leaks, sticking or improper adjustment repair or replace.

• Perform dash calibration.

• Check wheel bearings - replace as needed.

• Check the inlet connections to determine where air is being drawn into the system.

• Tighten loose connections.

• Check minimum drive speed which may be too slow to prime the pump.

• Bleed the hydraulic system.

• Vehicle overloaded. NEVER exceed capacity of the truck.

• Check capacity nameplate for tire specs.

• Never exceed vehicle capacity.

• Add hydraulic fluid until dipstick shows full.

• Check/fill hydraulic oil level, low flow rate or fluid pressure.

• Restriction in fluid return line or line is too small. Remove line, clean and/or replace line.

• Check pump.

• Check hydraulic pressure - 2,000 psi.

• Check for steering column, orbital, front rotation bearing noise.

• Check steer priority valve. Replace if needed.

Worn or out-of-adjustment steer assembly.

Insufficient hydraulic pressure.

Steering potentiometer misaligned.

Worn, loose wheel bearings.

Hard steering effort in one or both directions.

Air in the hydraulic system.

Vehicle overloaded.

Low hydraulic fluid.

Low flow rate or fluid pressure.

Components in steering linkage binding or making noise.

3-4

F-985-0219

TABLE OF CONTENTS TROUBLESHOOTING Condition

Cause

Suggested Repair

Lost motion at the steering wheel.

Steering wheel loose on column or stripped.

Air in the hydraulic system.

• Check and re-torque the steering wheel locking nut.

• Check the inlet connections to determine where air is being drawn into the system.

• Tighten loose connections.

• Check the minimum drive speed which may be too slow to prime the pump.

• Bleed hydraulic system.

• Check that the hydraulic pump/motor is activated when the operator is on the seat and the direction is selected.

• Check battery charge state and recharge battery, if necessary. A discharged battery reduces effective voltage across the traction motors and control circuits. Slow travel speeds and erratic contactor operation may result.

• Verify encoder is operational.

• Replace accelerator switch module.

• If overheating is suspected, turn OFF the truck, and allow time for the system to cool. While the truck is cooling, check the following: • Check motor compartment cooling fans to ensure they are operating and clean.

• Look at dash display to check for errors. Record fault code to determine problem - refer to chapter 6 for calibration and programming fault code definition.

• Check battery charge state and recharge battery if necessary.

• Check dash display for fault condition. Refer to controller troubleshooting if fault is present.

• Check that the direction control forward-neutral-reverse control is functioning properly.

• Repair accelerator switch

Truck does not turn.

Hydraulic pump not activated.

Truck moves slowly.

Battery may be too low.

Traction motor encoder error.

Faulty accelerator switch module.

Overheated motor or motor controller (thermal cutback).

Truck has gone into LOS Mode (“Loss of Sensor” also known as “Limp Home Mode”.)

Truck does not move.

Battery charge state too low.

System fault is present.

Faulty direction control lever.

Creep speed or acceleration sluggish.

Faulty accelerator switch assembly.

Open armature on traction motor.

Control panel system is improperly adjusted.

• Repair or replace.

• Re-adjust the control panel.

3-5

TABLE OF CONTENTS TROUBLESHOOTING Condition Mast does not lift load.

Cause

Suggested Repair

Attempting to lift a load in excess of the truck’s capacity.

• NEVER attempt to lift a load heavier than the specified rating of the truck.

• Replace lift potentiometer.

• Check battery charge state and recharge battery if necessary.

• Low levels can cause the cylinder to “cavitate” and not permit full lift of the mast. Add hydraulic oil.

• Bent or damage plunger, worn internal seals - repair or replace as needed.

• Check hydraulic pressure of system relief valves. Try re-adjusting the pressure relief valves. Maximum system pressure must not exceed 2,800 psi.

• Check valve for seal leaks, sticking or misadjustment.

• Repair or replace and/or readjust accordingly.

• If problem persists, replace the relief valve cartridge.

• Check settings.

• Replace the pump.

• Determine which cylinder is leaking or binding - rebuild or replace. Seal kits are available.

• Check lift pump control fuse.

• Check mast for damage and signs of improper adjustment.

• NEVER attempt to lift a load heavier than the specified rating of the truck.

• Adjust or replace.

• Check battery charge state and recharge if necessary.

• Check settings.

• Check settings.

• • Repair or replace.

• Repair or replace.

Faulty lift potentiometer.

Battery charge state may be too low.

Low hydraulic oil.

Faulty hydraulic control valve.

Insufficient system pressure.

Faulty pump.

Note: If the pump were faulty, other mast functions would also be affected.

Blown fuse.

Mechanical damage to mast.

Mast lifts slowly - loss of lift speed

Attempting to lift a load in excess of the truck’s capacity.

Faulty lift potentiometer.

Battery charge state may be too low.

Controller output incorrect.

Insufficient pump or relief valve pressure setting.

Mechanical damage of the mast.

Hydraulic cylinders leaking.

3-6

F-985-0219

TABLE OF CONTENTS TROUBLESHOOTING Condition Mast drifts downward.

Mast does not tilt.

Cause

Suggested Repair

Excessive load - attempting to lift loads beyond the capacity of the truck.

Pressure relief valve malfunction.

Lift hydraulic cylinders leaking or binding.

Faulty lift control valve

• NEVER exceed forklift’s lift ratings.

Inoperative tilt directional control valve.

Faulty switch.

Insufficient pump or relief valve pressure.

Inadequate lubrication or worn bearings.

Lower mounting hooks installed incorrectly.

Restricted or leaking supply hoses.

Hydraulic cylinder leaking or binding.

Controller output incorrect.

• Adjust system pressure.

• Oil may be bypassing between the spool and body - repair or replace directional control valve.

• The spool is not centering properly or is broken - repair or replace the directional control valve.

• Check the Appendix for vendor service information, where applicable.

• Repair or replace.

• Continuity test switch. Replace if defective.

• Check settings and adjust pressure.

• Follow recommended maintenance schedule.

• Check the Appendix for vendor service information, where applicable.

• Locate restriction or replace hose.

Tighten fittings to seal any leaks.

• Shift cylinder is leaking or binding rebuild or replace. Seal kits are available for most cylinders.

• Check settings via the 1314 software program.

PUMP PROBLEMS No hydraulic pressure.

Pump driven in the wrong direction of rotation after servicing.

Coupling or shaft sheared or disengaged.

Fluid viscosity too heavy to pick up prime.

• Change the drive direction immediately to prevent seizure.

• Correct the pump cartridge ring position for each direction of rotation.

• Check the Appendix for vendor service information, where applicable.

• Disassemble the pump and check the shaft and cartridge for damage.

• Check all strainers and filters for dirt and sludge - clean and replace.

• Completely drain the system.

• Add new filtered oil of the proper viscosity.

3-7

TABLE OF CONTENTS TROUBLESHOOTING Condition Leaking fluid.

Cause

Suggested Repair

Cracked or cut hoses, where applicable.

Loose or faulty hose clamps, where applicable.

Loose or faulty hydraulic fittings.

• Replace, NEVER attempt to patch a hydraulic hose.

• Tighten and/or replace.

• Tighten and/or replace. Be careful not to strip the threads, rendering the fitting defective.

• Disassemble the unit and replace the oil seals.

• Service the hydraulic tank intake strainer.

• Check the fluid condition and, if necessary drain and flush the hydraulic system. Refill with clean oil.

• Check intake lines (hoses and fittings) and seals for leaks. Repair all leaks.

• Repair and/or replace.

• Check for faulty relief valve and adjust or replace as required.

• Check for and repair worn pump.

• Check for correct oil.

• Locate excessive heat source (usually a restriction) in the system and correct the condition.

• Disassemble unit and replace worn rotor set.

• Disassemble unit and replace worn rotor set, drive link and coupling shaft.

Oil seals deteriorated.

Pump making noise.

Significant loss of speed under load.

Pump intake partially blocked.

Air leaks at the intake or shaft seal.

(Oil in reservoir would possibly be foamy.)

Damaged pump/motor mounting.

Lack of sufficient oil supply.

Excessive heat source.

High internal pump leakage.

Severely worn or damaged internal splines.

3-8

F-985-0219

Chapter 4

TABLE OF CONTENTS

Corrective Maintenance Corrective Maintenance This section is divided by features. For each feature, major adjustment and/or settings, mechanical repairs, and electrical control system repairs are addressed.

NOTE As a safety reminder, duplicate safety Information and precautions from Chapter 1 will be shown.

It is important to always locate the section which pertains to your needs, then read the entire procedure before attempting to adjust, repair, and/or replace parts.





DANGER

Read and understand all safety warnings located in “Battery Safety” on page 1-7.



WARNING

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

WARNING

• Injury to personnel and/or damage to the forklift will result if service work is attempted without proper qualified experience.

• It is recommended to always use Landoll replacement parts when performing any forklift maintenance.

• Failure to use correct replacement parts may result in a failure which may cause serious injury or death.



Battery

CAUTION

To be certain the forklift will not move, place wedges or blocks of wood at the front and back of the tires. When servicing the brakes or tires, place the block at all tires not being serviced.

• Be sure to use the proper nuts, bolts and other fasteners. Many are specifically rated: SAE Grade 5, SAE Grade 8, ISO Prop Class 8.8, etc. must be replaced with the identical type.

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

• Set the key switch to the “OFF” position and remove the key from the console.

• Set the direction control lever to NEUTRAL and set the parking brake.

Read and follow the safety and standards information in chapter 1. (SEE PAGE 1-1)

NOTICE 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.

Bendi B3-30 AC/DS Series 5 forklifts 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 4-4 The compartment top cover and the side door must be lowered/closed and securely locked in place whenever the battery is installed.

It is important to properly maintain the battery to ensure long life, strong voltage potential and safety of the battery.

For Battery Inspection information refer to Daily Inspection “Battery” on page 2-13

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.

4-1

TABLE OF CONTENTS CORRECTIVE MAINTENANCE



CAUTION

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

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

Battery Roll-out Option and Restraint System Roll-out Battery Tray Option If the roll-out battery tray is installed, to remove the battery simply release the restraint arm release handle and slide the arm from its holder. The battery is free to roll out the side of the forklift.

A limit switch is included to disable the forklift battery and drive motor while this arm is removed.

The battery restraint arm should be in place at all times when a battery is installed in the forklift.

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

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

Release Handle

Spacers

Rollout Battery Restraint Arm

3. Open the right hand door.

4. If using a roll-out stand, position the battery stand next to the forklift. Align stand with battery compartment. Battery roller stand should be at the same height as the forklift 5. Push battery into the forklift’s battery compartment or lower if using a hoist.

6. Install the roll-out battery arm bar, or the forklift will not operate. See Figure 4-1.

7. Connect the battery.

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

BATTERY TRAY

Figure 4-2: Roll-out Battery Tray Option

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.

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

 Limit Switch Restraint Arm Mount

Figure 4-1: Roll-out Battery Restraint

Roll-out Battery Removal 1. Remove the safety retainer bar, deactivating the safety switch.

2. Position battery roll out stand next to the forklift and align the stand with the path of the battery.

3. Roll the battery onto the stand.

Roll-out Battery Installation

CAUTION

Battery Removal: • Never remove the battery partially from the forklift without a roller stand in place.

• Lower forks completely.

• DO NOT allow any electrically conductive object to come in contact with the top of the battery. This may cause a short circuit when removing or transporting the battery.

• Use an insulator (such as plywood) to cover the top of the battery during removal.

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

2. Check to be sure the key is “OFF”.

4-2

F-985-0219

TABLE OF CONTENTS CORRECTIVE MAINTENANCE

To Replace a Battery:

Overhead Guard

Removal: 1. Return the forklift to service charging station area.

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

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

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

5. Secure the cover to the overhead guard latch. See Figure 4-5.

6. Open the right side door by sliding the locking lever to the right, then swing the door fully opened. See Figure 4-4 7. Disconnect the battery/forklift cable disconnect and lay the battery cable across the battery top.

8. Slide the compartment side door spring latch towards the front of the forklift to release the side door. Open the door. See Figure 4-4.

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

Latch Battery Cover

Battery Tray

Side Door/Spring Latch Figure 4-4: Removing the Battery

Figure 4-5: Overhead Guard Battery Cover Latch

Figure 4-3: Battery Disconnects

4-3

TABLE OF CONTENTS CORRECTIVE MAINTENANCE

Installation: 1. 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.

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

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

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

4. Release the overhead guard latch, lower the battery cover and secure the latch located below the operators seat. Make sure that no wires are pinched.

Cleaning the Battery When properly maintained, the battery will remain relatively clean and dry. Occasionally it may be necessary to remove excessive electrolyte. If this happens, remove the battery from the truck and clean with a solution of baking soda and water. (one pound baking soda to 1 gallon of water) Rinse the battery off with water and allow to air dry.

Charging a Wet Battery



DANGER

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

• DO NOT smoke, use an open flame or create arcs or sparks near the battery.

• Be sure to replace and re-tighten any battery restraints which have been installed on the forklift • Failure to comply could result in an unbalanced condition, resulting in tipping the forklift and possible personal injury or loss of life.

4-4



CAUTION

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

1. Remove each vent cap and check electrolyte levels.

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

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

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

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.

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

Distilled water should be added if the electrolyte level falls below the level indicator.

• If the cell temperature rises higher than +110° F (+43.3° C) either reduce the charging current to half the original value or stop charging until the temperature falls below +110° F (+43.3° C). If the charging current is reduced, extend the charging time accordingly.

5. See “Specific Gravity Correction” on page 2-14 for correction factors dependent upon electrolyte temperature.

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 (25° C).

7. Connect battery cables and install battery in forklift.

F-985-0219

TABLE OF CONTENTS CORRECTIVE MAINTENANCE

Mast And Front End Removing the Forks 1.

2.

3.

4.

5.

6.

First, review “Getting Started” on page 1-1.

Park the forklift on a level surface.

Lower the forks all the way to the ground.

Apply the parking brake.

Perform “Lock Out / Tag Out” on page 1-7 Slide the fork so the hook on the fork lines up with the notch on the bottom of the front plate.

7. Pull the fork tine upward until the hook is free of the carriage. See Figure 4-6.

ROTATE AND LIFT TO UNLOCK

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

Load Testing Forks The following information is provided for authorized service facilities ONLY. A fork that has undergone repairs, other than repair or replacement of the positioning lock and/or marking, must be load tested before it is returned to service. The testing facility must test the forks according to paragraph 7.25.3 (ASME B56.1-2000) except that the test load must be 2.5 times the rated capacity marked on the fork.

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

Fork Angle

Figure 4-6: Changing Forks

NOTE As an alternate method, raise the forks a few inches from the floor and place a block of wood under the fork. Slowly lower the forks. The block of wood lifts the fork to unhook if from the front plate.

8. Lift the fork off of the front plate. Various forks can be heavy - use adequate lifting apparatus or ask for a helper as needed.

9. To replace forks, perform steps 9 through 11 in reverse order.

Repairing Forks The following information is provided for authorized service facilities ONLY.

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

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

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

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

3. Measure fork thickness. See Figure 4-7

4-5

TABLE OF CONTENTS CORRECTIVE MAINTENANCE

Figure 4-8: Fork Distortion Distance Figure 4-7: Measuring Fork Thickness 4. Compare your fork measurement to the original thickness.

• When 10% of the original fork thickness is worn away, it must be replaced. On a standard fork size of 2” x 6” (50 mm x 152 mm) the fork must be replaced if 1/ 5" (5mm) of material is missing. A 10% reduction of material results in 20% capacity reduction.

5. Measure the distortion distance (Y) of your forks.

6. For this measurement, use a flat bar 4” x 24” (101.6 mm by 609.6 mm), that is 2” (50.8 mm) thick. Also use a 24” (609.6 mm) carpenter’s square (See Figure 4-8).

Blade

Length

Maximum Tip

“Y” Value

32” 36” 40” 48”

812.8 mm 914.4 mm 1,016 mm 1,219 mm

3/4” 31/32” 1-7/32” 1-1/2”

19mm 25 mm 31mm 38”

Adjusting Degree of Tilt To check tilt see “Check Tilt Cylinder” on page 2-22.

1. To adjust the degree of tilt, tilt the mast fully backward.

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



CAUTION

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

4-6

7. If the deviation from straightness exceeds 0.5% of the length of the blade they must be replaced. Table 2-1 shows the acceptable Y distances. If the forks exceed the distance in the chart, replace them.

8. Next, measure the elevation of each fork tip. If the difference in tip heights exceeds 3% of the length of the blade, the set of forks shall not be returned to service until repaired.

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

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

3. Loosen the tilt cylinder adjuster bolt.

4. Continue to loosen the tilt cylinder adjuster bolt until there is no bolt pressure on the tilt cylinder clevis.

5. Place the tilt gauge against the rear outer mast rail on the right side of the truck, about 6” (152 mm) above the mast cross member.



CAUTION

NEVER exceed 3.0° to 3.1° rear tilt for 239” or shorter masts. Never exceed 2.0° to 2.1° rear tile for 240” or taller masts. Actual rear tilt in excess of recommended tilt can cause the truck to become unstable under certain conditions.

F-985-0219

TABLE OF CONTENTS CORRECTIVE MAINTENANCE 6. Relieve the hydraulic pressure on the tilt cylinder.

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

7. You may have to tilt the mast a number of times, repeating steps 4 through 9, until the adjustment is correct.

To remove the mast, the work area must be clean and clear of obstacles, large enough to lay the mast horizontally, have a concrete floor and an overhead crane and frame rated to at least 3 tons and 3 or 4 6” x 6” x 48” (152 mm x 152 mm x 1,219 mm) solid planks of wood.

It is recommended to thoroughly steam clean the mast, removing all dirt, debris and grease.

NOTICE Do Not steam clean the chain.

NOTE At this time, make sure all hydraulic hoses, electrical wiring and all parts of the mast move smoothly and clear the frame when the mast is going through the complete tilt movement. Also check and correct mast flex, a misadjustment of the tilt cylinders that causes one tilt cylinder to bottom out before the other one has completed travel.

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

9. Tighten and torque the tilt cylinder adjuster bolt against the cylinder clevis. (See “Torque Specifications” on page 1-11)

Mast Removal



WARNING

• The mast may swing from the lift forklift, be alert and cautious!

• Only trained and experienced technicians or your Landoll service representative must be allowed to service the mast assembly.

• NEVER place any part of one’s body into the working area of the mast.

• NEVER work on the mast while it is loaded; remove the load first.

• Observe all safety precautions while operating the overhead crane and lifting apparatus.

• Be careful! If the top of the mast is lower than the bottom of the mast when laying flat, the carriage will slide to the top, causing damage to the mast or even injury.

• It is recommended to secure the carriage to the mast if possible.

Record the roller clearances and chain adjustments before removing the front plate or rails.

Make notes as you disassemble the mast while referring to “Lift Technologies Mast Service Manual” on page 6-1.

1. First, review “Getting Started” on page 1-1.

2. Park the forklift on a level surface.

3. Lower the forks all the way to the ground.

4. Apply the parking brake.

5. Perform “Lock Out / Tag Out” on page 1-7 6. Remove the forks.

7. Remove the two bolts and hardware holding the backrest to the mast. Carefully remove the backrest; it can be heavy - use adequate lifting apparatus or ask for a helper.

8. Attach an overhead crane and strap, rated to 3 tons, and apply slight lift to the mast. See Figure 4-9.

9. Visually inspect the chains for cracks, stretched or stressed links and broken pins. When raising the mast, listen for usual chain noise and watch the action of the chain for anything unusual. Watch for unusual pulley movement or pulley wobble that would indicate a worn mast bearing.

10. At the mast, disconnect the lift cylinder hose.

See other precautions see “Mast Service Safety” on page 1-9.

4-7

TABLE OF CONTENTS CORRECTIVE MAINTENANCE 9. Remove the 7/8-9 X 2-1/4” bolts securing the Front Plate Assembly to the frame.

Removing the Tilt Cylinder

STRAP

NOTES Only apply these steps if the mast has been removed.

40D, 45D, & 50D SERIES Figure 4-9: Supporting the Mast 11. Oil will drain from the cylinder lines and the hoses.

Have shop rags handy to clean oil spills. Plug and/or cap the cylinder ports and hoses to prevent further oil drainage. Tag each hose for identification.

12. Remove the four hex head cap screws (5/8-11 x 2-1/2”), the lower mast pins and hardware.

13. Raise the mast enough to release the mast hooks from their supports.

14. Lay the mast horizontally, carriage side facing up, across three or four 6” x 6” x 48” (152 mm x 152 mm x 1,219 mm) planks of wood.

15. Dismantle, clean and inspect the mast assemblies and sub-assemblies as instructed in “Supplier Provided Documentation” on page 6-1.

16. Reassemble the mast in reverse order, using your notes as necessary.

17. Before returning the mast to service, perform all adjustment procedures listed in enclosed “Lift Technologies Mast Service Manual” on page 6-1.

Removing Front Plate Assembly 1.

2.

3.

4.

5.

6.

First, review “Getting Started” on page 1-1.

Park the forklift on a level surface.

Lower the forks all the way to the ground.

Apply the parking brake.

Perform “Lock Out / Tag Out” on page 1-7 Complete steps 2-10 of “Mast Removal” on page 4-7.

7. Hook up a hoist to the front plate assembly and put slight tension on the strap.

8. Remove and mark the hoses to the tilt cylinder. Cap and plug the hoses and cylinder to keep dirt out.

4-8

1.

2.

3.

4.

5.

6.

First, review “Getting Started” on page 1-1.

Park the forklift on a level surface.

Lower the forks all the way to the ground.

Apply the parking brake.

Perform “Lock Out / Tag Out” on page 1-7 Disconnect the two hydraulic hoses from the tilt cylinder.

7. Cap and plug the hoses and cylinder ports. Also, tag the hoses for identification. Have rags handy to soak up oil spills.

8. Mark the location of the cylinder jam nut for reassembly to the new cylinder.

NOTE The jam nut is usually at the end of the threads closest to the barrel of the cylinder.

9. On the mast end of the cylinder, remove the bolt and hardware from the tilt cylinder pin weldment and remove the pin from the tilt cylinder clevis. .

NOTE If mast has not been removed, the mast and masthead weldment will fall forward to main rotation pin placement.

10. On the front rotation plate side, remove the bolt and hardware holding the tilt cylinder in on the front rotation plate.

NOTE To repair the tilt cylinder, replace seals, wiper, O-rings, etc., see Parts Manual (Landoll P/N F-663).

11. Reconnect cylinder to mast assembly in reverse order.

F-985-0219

TABLE OF CONTENTS CORRECTIVE MAINTENANCE

Floor Plate NOTE While not absolutely necessary for many of the repairs described in this section, sometimes the removal of the floor plate can decrease the required downtime needed for maintenance work. The floor plate removal and reassembly takes only a few minutes, and for this reason, it is described early in this chapter.

When instructions are given for repairs in this chapter, it will automatically be assumed that the floor plate has been removed.

3

6

7

Floor Plate Removal and Assembly This panel provides access to the accelerator assembly which is mounted to the underside of the floor plate. The master cylinder and service brake pedal and linkage are mounted within the frame well, easily accessible when the floor plate has been removed.

1. Thoroughly clean the floor area using a vacuum.

2. Lift up the rubber floor mat, carefully separating it from the accelerator and brake pedal.

See Figure 4-10.

3. Remove the 5/16”-18 floor plate fasteners.

4. Remove the left floor plate from the truck frame.

5. Carefully lift up the right floor plate a few inches. The accelerator pedal assembly will still be attached to the floor plate by the accelerator wiring harness.

Unhook the accelerator harness and lift away the floor plate.

6. Assemble in reverse procedure.

2

4

5

1

Figure 4-10: Floor Plate Assembly

4-9

TABLE OF CONTENTS CORRECTIVE MAINTENANCE

Tires and Wheels



CAUTION

Replacing pressed-on tires should be done only by technicians who have been specifically trained for this procedure and have the specific tools to perform this job.

8. Replace tire only with Landoll approved replacement part.

9. Press the replacement tire onto hub. The replaced tire gets pressed off during this procedure. Make sure the outside of the new tire is flush with the hub.

10. Install tire/hub assembly onto the truck and torque lug nuts to 225 ft. lbs. (305 Nm.) in a cross-cross pattern. See Figure 4-11.

Figure 4-11: Tire Tightening Sequence

Removing/Replacing the Drive Wheel 1. Review “Introduction, Safety, and Specifications” on page 1-1.

2. Apply the parking brake.

3. Perform “Lock Out / Tag Out” on page 1-7.

4. Block both rear wheels so the truck cannot move.

5. Lift and support the truck so that the drive wheel is clear of the floor by about an inch.

6. Remove the lug nuts.

7. Using adequate support, remove the drive wheel.

NOTE Wheel and tire combination weigh over 200 lbs. (90.7 kg)

 •

• •

•

4-10

CAUTION

Make sure that replacement drive tires are of the same size and composition as what was originally supplied by Landoll Company, LLC. Tire composition can affect braking, capacity, turning and operator safety.

Landoll Bendi B3-30 AC/DS tires are an interference type, meaning the tires are pressed on and pressed off.

The front drive tire can be replaced individually, but the two follower tires should be replaced in pairs to maintain performance and stability.

Disassembling and Inspecting Rear Wheel Bearings 1. First, review “Introduction, Safety, and Specifications” on page 1-1.

2. Lift axle and support wheel so it is free to rotate.

3. If the diameter of the tire is less than 13”, Landoll recommends that the tire be replaced.

4. Remove hub cap, 1-1/4” hex slot nut, lock washer, and outer bearing. (“Rear Wheel Bearing Assembly” on page 4-11.)

5. Slide hub/wheel assembly from spindle. Remove inner bearing cone and seal from hub.

6. Clean bearing cones and seal. Clean bearing cups inside hub.

7. Examine for damage and replace bearing if needed.

8. Replace bearing cones if cones are cracked or pitted.

9. Replace seal if worn or damaged.

NOTE You should pre-pack the bearings with grease before replacing. Bearing components get replaced as a set.

Replacing the Braking Tires NOTE Rear braking tires must be replaced in pairs, but do this procedure one tire at a time. Replacement braking tires must have same size and composition as factory tires.

1. Follow steps 1-3 on“Removing/Replacing the Drive Wheel” on page 4-10.

2. Continue with steps 2-9 on “Disassembling and Inspecting Rear Wheel Bearings” on page 4-10.

F-985-0219

TABLE OF CONTENTS CORRECTIVE MAINTENANCE 3. Press the replacement tire onto the hub. The replaced braking tires gets pressed off as the new tire gets pressed on. Make sure the outside of the new tire is flush with the hub.

4. Continue with all steps of “Assembling Rear Wheel Bearings” on page 4-11.

5 3

Assembling Rear Wheel Bearings 1. If bearing cones are replaced, clean hub and press new bearing cones into hub. See Figure 4-12 2. Pack wheel bearings with grease.

3. Place outside face of wheel down on bench. Insert inner bearing (item 4) and carefully drive seal (item 5) in until flush with hub.

4. Carefully slide hub, bearing and seal assembly onto spindle.

IMPORTANT Avoid damaging the grease seal. A damaged seal must be replaced.

5. Put a moderate amount of wheel bearing grease in the hub cavity area between the inner and outer bearing space.

6. Insert the outer bearing cone (item 6) and washer (item 7). Tighten hex slot nut (item 8) against spindle washer by hand.

7. Adjust bearing preload by slowly rotating hub while tightening hex slot nut until resistance is felt.

8. While turning the wheel or rim counterclockwise, apply 240 - 260 in. lbs. (27.1 - 29.4 Nm) of torque to the spindle nut.

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

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

11. Apply a thin layer of grease to the hub cap o-ring (item 2) and press hub cap (item 1) into hub.

2

8

7

4

6

1

Figure 4-12: Rear Wheel Bearing Assembly

Brake System The drum brakes are self-adjusting and should require no maintenance after the initial technician setup.

See Figure 4-13 for typical brake assembly for reference.

IMPORTANT • •

•

• •

•

•

• •

Safety must always be paramount when working on brake system components.

Parts that are not in perfect working condition should not be used. It is recommended to only use genuine Landoll parts.

Whenever servicing a brake component, it is recommended to service both sides of the truck to ensure that both sides have equal braking and to prevent premature wear and uneven braking action.

If you are unsure about a procedure, contact Landoll Service Department for assistance.

Wear eye protection. If brake fluid comes in contact with eyes, immediately rinse with water and seek medical attention.

Use only DOT3 brake fluid. Brake fluid will damage paint. Cover all body parts and be careful not to spill brake fluid during brake maintenance.

DO NOT use petroleum based solvents to clean brake parts. Use only brake cleaner or denatured alcohol.

DO NOT used compressed air to blow particles from the brake assembly.

Make sure you strictly adhere to all clearances and torque specifications.

4-11

TABLE OF CONTENTS CORRECTIVE MAINTENANCE •

•

When you are finished working on the brakes, test them carefully under controlled conditions before releasing truck for operation.

If a problem is suspected, do not release or drive the truck until the problem is corrected.

Brake System Service NOTE Braking of the Bendi B3-30 AC/DS truck is accomplished two different ways. When the accelerator pedal is released, the moving motion of the truck is restrained by the drive motor in both the forward and reverse direction.

Stopping the truck can also be done by the normal pressing of the brake pedal.

Check Service Drum Brakes •

•

•

The service brakes are hydraulically-actuated drum brakes, similar to an automotive drum brake system. The brake drums are installed on the two rear wheels only.

The brakes should be checked every 500 hours of operation. Normal brake shoes can last 3,000 hours of operation, but that figure can vary widely as determined by the operator and driving conditions. If you are near or beyond this time frame, you must thoroughly inspect the brakes.

New brake shoes are approximately 0.265” (6.7 mm) thick. Replace them when the shoe thickness is 0.0625” (1.588 mm) or less.

NOTE A few indications of possible brake shoe replacement are: • Excess travel of the service brake pedal.

• The truck pulling to one side when the brakes are applied.

• Squealing or grinding is heard when brakes are applied.

• If any of the above occurs during brake inspection, see Checking/Changing Brake Shoes below.

The service brake pedal must also have about 1/2” (12.7 mm) of the travel remaining when the brakes are fully applied. If less than 1/2” (12.7 mm) is available, adjust or check the shoes for wear and replace as needed.

4-12

Checking/Changing Brake Shoes The brakes are located in the rear drum/wheel assembly and are attached to a backing plate. See “Drum Shoe Assembly” on page 4-13 for typical brake assembly for reference.

1. First, review “Introduction, Safety, and Specifications” on page 1-1.

2. Set the key switch to OFF, remove the key from the key switch and secure key in a safe place.

3. Perform “Lock Out / Tag Out” on page 1-7.

4. Place blocks in front of and behind all other wheels not being serviced.

5. Raise and block the side of the truck being serviced.

6. Remove the hub cap and o-ring.

7. Lift lock washer tang, and remove the lock nut.

8. Remove the integrated brake drum/wheel assembly.

NOTE If the wheel will not come off, make sure the parking brake is completely released. In extreme cases of wear, the brake shoes must be fully returned (retracted) before the wheel can be removed. Brake fluid will damage paint.

Have a container and shop rags handy to soak up any spilled brake fluid. Cover all body parts and be careful not to spill fluid during this procedure.



WARNING

DO NOT use forced air to clean brake parts.

9. Check the inside contact surfaces of the drums for cracks, score marks, deep grooves, a raised lip on the outer edge, and signs of overheating. If the drums show blue spots, indicating overheated areas, the drum must be replaced. Also, look for surface glazing, grease or brake fluid on the shoe contact surfaces. Grease and brake fluid can be removed from metal surfaces, but if the shoes are contaminated, they must be replaced. Surface glazing, which is a glossy, highly polished finish, can be removed with medium grit emery cloth. (100-120 grit) 10. Before removing the internal brake components, wash (spray) them with brake cleaner and allow to dry. Position a container under the brake assembly to catch the excess residue.

11. Pull or press to release the star wheel adjuster latches and turn the star wheel to retract both the front and rear brake shoes.

12. Loosen one clamp hold-down screw and remove the other screw to allow the clamp to drop down making it easier to remove the front and rear return springs.

13. Unhook and remove both return springs.

F-985-0219

TABLE OF CONTENTS CORRECTIVE MAINTENANCE 14. Press in on the hold-down spring and pop it to one side (opposite of where hook is attached) to free the spring hook from the rear of the brake backing plate.

This will require some force to compress the spring to pop it free.

15. Remove both hold down screws and the hold down clamp. Carefully separate the front and rear shoes from the wheel cylinder and parking brake lever assembly.

16. Clean the area and check the wheel cylinder for leaks. Pull back on the bottom portion of the rubber boot on both sides of the cylinder. If it is not dry, see “Repairing Brake Wheel Cylinders” on page 4-14.

NOTE Check the brake lines for cracking, splits, or any apparent weakness - replace as needed.

17. SPARINGLY lubricate the brake shoe contact areas of the backing plate with high temperature grease.

Install the new brake shoes and install the brake drum (two outer hex head screws and hardware). Do not allow any grease to come on contact with braking area of the shoe. Torque the screws to specifications shown in “Torque Specifications” on page 1-11.

18. Install the new brake shoes by following the above instruction in reverse order. Be sure that all springs are properly hooked at both ends and that they hold-down clamp screws are tight.

19. Wiggle the brake assembly to ensure that the shoes are centered on the backing plate.

20. Reinstall components in reverse order. See “Assembling Rear Wheel Bearings” on page 4-11.

21. Bleed the brakes. (SEE PAGE 4-19) 22. Pump the brakes several times to seat the new brake shoes.

Make a few normal stops in forward and reverse to allow the brakes to further seat themselves. DO NOT lock the brakes which could cause flat spots.

8

6 4

7

9

10

5

11 12

3 2 1

13

17

16 15 14 Figure 4-13: Drum Shoe Assembly

4-13

TABLE OF CONTENTS CORRECTIVE MAINTENANCE

Repairing Brake Wheel Cylinders

Hydraulic Brake Drums

NOTE

NOTE

The wheel cylinder, if it freezes-up or shows signs of leakage, must be replaced before returning the truck to operation.

1. Perform “Lock Out / Tag Out” on page 1-7 2. Raise the side of the truck being serviced.

3. Remove the wheel. See “Replacing Brake Drum Assemblies” on page 4-14.

4. Remove the brake shoes. See “Checking/Changing Brake Shoes” on page 4-12.

5. Using a flare-nut wrench, disconnect the brake fluid inlet line from the wheel cylinder. Have shop rags handy to soak up any spilled fluid. See Figure 4-13.

6. DO NOT pull the brake line away from the cylinder.

Plug the end to reduce fluid loss and contamination.

7. Remove the two bolts holding the cylinder to the backing plate.

8. Install the new cylinder and tighten fasteners to the specified torque as shown in “Torque Specifications” on page 1-11.

9. Connect the brake inlet line and install the brake shoe assembly and drum. To avoid stripping the brass threads, do not over tighten the brake line fittings. See “Checking/Changing Brake Shoes” on page 4-12.

10. Reinstall the components in reverse order.

11. Bleed the brakes. See “Bleeding Brakes” on page 4-19.

Whenever servicing and/or replacing a brake drum assembly, you must service both sides of the truck to prevent premature wear and uneven braking action. The drum and the wheel is an integrated assembly.

NOTE When replacing a brake assembly, a wheel cylinder or a master cylinder, it is advisable to purge the entire brake system of old, possibly contaminated fluid.

Measure Brake Drum Diameter Repeat steps 1 through 8 of preceding section “Checking/Changing Brake Shoes” on page 4-12.

Check the drums for scoring, cracks, deep grooves, a raised lip on the outer edge, signs of overheating, out of round or other damage.

Drum diameter measurements may be checked with the drum removed from the truck. Using a brake drum gauge, measure the diameter at four or more points on the drum and make sure all measurements are taken at the same distance in from the outer edge of the drum.

Thickness variations of more then 0.005” (0.13 mm) can cause pedal pulsation and/or vibration when applying the brakes. A drum that does not meet these specifications must be turned or replaced.

Replacing Brake Drum Assemblies 1. Repeat Steps 1 through 9 of preceding section “Checking/Changing Brake Shoes” on page 4-12.

2. Check the brake lines for cracks, splits or any apparent weaknesses. Replace as needed.

3. Loosen the locknut and hardware from the spindle.

DO NOT remove the nut from the assembly at this time.

4. Rock the drum back and forth while gently pulling on the drum.

5. If needed, using the rubber mallet (dead-blow hammer), hit the drum on the opposite side, driving it towards the loosened nut.

6. Repeatedly hit the drum evenly in a circular motion until it pops free, then remove the nut.

7. Remove the drum and tire assembly.

NOTE

Figure 4-14: Wheel Cylinder Repair

4-14

When handling the new drum, protect the finish surfaces from damage, such as nicks, deep scratches, dents from dropping, corrosion, etc. Damage to the braking surfaces renders the brake drum defective. The tire must be pressed on the new drum before assembly.

8. Install the new drum and tire assembly to the spindle, being careful not to damage the grease seal during assembly. Make sure the spindle is clean and free of dirt and grease and then install.

F-985-0219

TABLE OF CONTENTS CORRECTIVE MAINTENANCE 9. Adjust bearing preload by slowly rotating hub while tightening hex slot nut to 20 - 25 in. lbs. (2.26 - 2.82 Nm). Back nut off 1/2 of a turn or then further until a notch aligns with the lock nut tab.

10. Reassemble in reverse order.

11. Repeat Steps 20 through 23 of preceding section “Checking/Changing Brake Shoes” on page 4-12.

Parking Brake 

CAUTION

DO NOT release or operate the truck if you are in doubt about the effectiveness of the parking brake system. Contact your Landoll service representative for assistance.

Parking Brake Assembly The parking brake assembly is used for holding the forklift in place while unattended; it is activated by pulling the park brake lever.

The parking brake assembly includes: • Parking Brake Lever • Parking Brake Cable • Parking Brake Switch

Parking Brake Lever NOTE The amount of travel of the parking brake lever should allow the lever to move from the released position to the brake position, having the brake fully applied before handle travel is at its maximum.

Replacing Parking Brake Lever Assembly 1. First, review “Introduction, Safety, and Specifications” on page 1-1.

2. Set the key switch to OFF, then remove the key from the key switch and place in a secure area.

3. Perform “Lock Out / Tag Out” on page 1-7 4. Make sure all the other wheels are securely blocked so that the truck cannot move.

5. Remove the battery.

6. Remove floor plates.

NOTE The parking brake lever assembly is located to the left of the hydraulic control valves & to the right of the operator.

7. Disconnect the clevis end brake cable.

8. Replace with new parking brake lever assembly.

9. Remove brake linkage and brake switch cam from old lever assembly and install on the new lever.

10. Reassemble in reverse order.

11. Adjust park brake.

Checking Parking Brake Adjustment

 • •

•

CAUTION

Make sure you are wearing work gloves.

Before reaching in to turn the wheel, make sure the truck has sat idle long enough to cool. Various parts can get extremely hot during operation.

Adjusting the parking brake lever too tight will overheat the brake shoes and cause premature wear or overheat the brake drums, causing premature failure.

1. Set the key switch to OFF, remove the key from the key switch and disconnect the battery.

2. Block the front wheel and the left wheel.

3. Raise and block the right side of the truck until the right braking tire clears the floor by no more than 1” (25.4 mm).

4. While sitting on the seat, pull on the parking brake lever as far as possible using moderate force. The lever should apply pressure on the right drum before the handle moves to the rear most position. When the parking brake is applied, the right wheel should not turn when attempting to turn by hand.

5. Release the parking brake by pushing the button as the lever is pulled toward you. Then allow the handle to move toward the front of the truck.

6. To adjust, loosen the Allen head adjustment setscrew located on the park brake lever. Turning the lever clockwise tightens the setting; counterclockwise loosens the setting. After adjustment, tighten Allen head adjustment setscrew.

IMPORTANT DO NOT OVERTIGHTEN. You will separate the cable from the clevis ends.

4-15

TABLE OF CONTENTS CORRECTIVE MAINTENANCE 7. Apply and release the parking brake five or six times to stretch (seat) the cable, then double check your adjustment.

8. If this fails to properly adjust the park brake.

Adjusting Parking Brake Cable 1. First, review “Introduction, Safety, and Specifications” on page 1-1.

2. Perform “Lock Out / Tag Out” on page 1-7.

3. Make sure all the other wheels are securely blocked so that the truck cannot move.

4. Remove the floor plates.

5. Loosen adjustment bolt jam nut.

6. Remove emergency brake yoke pin.

7. Turn emergency brake yoke to adjust desired brake cable tension.

8. Replace yoke pin nut and tighten.

IMPORTANT The adjustment should be set that so when the park brake lever is screwed all the way out (completely counterclockwise) and the lever is pulled to its full vertical position, the parking brake holds the wheel as stated in the section “Checking Parking Brake Adjustment” on page 4-15.

9. Tighten adjustment bolt jam nut.

10. Reassemble in reverse order.

IMPORTANT The parking brake cable assembly and bracket will be loose when hardware is removed. Remove the parking brake assembly carefully so that the actuator pins, yoke and parking brake springs do not fall out.

8. At the park lever, pull the pin that connects the cable to the park brake linkage and remove old cable.

9. Remove the cable from the truck noting how the cable is positioned.

10. Route the new cable from the parking brake lever to the rear drum brake assembly in the same manner as the original cable, then connect both ends.

11. Adjust the parking brake cable.

12. Reassemble in reverse order.

Parking Brake Switch The parking brake switch electrically disables the truck from driving when applied and is located on the park brake handle assembly.

Checking Parking Brake Switch 1. Set the key switch to OFF, remove the key from the key switch and store the key in a secure area.

2. Disconnect the battery.

3. Make sure all the wheels are securely blocked so that the truck cannot move.

4. Remove the hydraulic control valve cover.

5. Remove the floor plates.

6. Disconnect e-brake cutout switch connector.

7. Connect the ohm meter leads to the switch wires.

NOTE The meter should show less than 1 ohm.

8. Slowly pull back on the brake lever. The meter should not indicate continuity, indicating the switch is released before the lever reaches its full locking position.

IMPORTANT

Replacing the Parking Brake Cable 1. First, review “Introduction, Safety, and Specifications” on page 1-1.

2. Set the key switch to OFF, remove the key from the key switch and place in a secure area.

3. Disconnect the battery.

4. Perform “Lock Out / Tag Out” on page 1-7.

5. Make sure all the other wheels are securely blocked so that the truck cannot move.

6. Remove the hydraulic valve cover to expose the parking brake mechanism.

7. Remove the floor plates.

4-16

If the meter indicates continuity when the switch in not activated, the switch is defective and requires replacement.

9. Disconnect the ohm meter.

10. Reassemble in reverse order.

Replacing Parking Brake Switch 1. Review “Introduction, Safety, and Specifications” on page 1-1.

2. Set key to OFF, remove the key from the key switch and store in a secure area.

3. Apply the parking brake and disconnect the battery.

4. Perform “Lock Out / Tag Out” on page 1-7.

5. Make sure wheels are blocked.

F-985-0219

TABLE OF CONTENTS CORRECTIVE MAINTENANCE 6. Remove the floor plates and control valve cover to expose the parking brake components.

7. Disconnect the switch at the Deutsch connector and remove the two screws holding the switch to the frame.

8. Install the new switch in reverse order.

9. Connect the switch at the connector.

NOTE A plunger within the handle activates the switch and has no adjustment. It is always activated in the resting position.

To check the operation of this switch:

1. Start the truck and release the parking brake.

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

3. As the truck is moving forward at slow speed, slowly pull up on the brake lever.

4. The truck must immediately slow to a STOP. 5. If the truck continues moving forward, recheck the setting and operation of the switch.

Service Brakes

ROTARY BRAKE SENSOR

BRAKE SWITCH

Figure 4-15: Brake Pot and Switch

Brake Pedal Assembly

Brake Pedal

NOTE

The service brake pedal has about 1" maximum free-play before any pressure is applied to the brakes, (or before the pedal moves the master cylinder plunger).

The two piece floor plate gets removed to provide access to the brake pedal and accelerator pedal which is mounted to the underside of the floor plate. The master cylinder and service brake pedal and linkage are mounted within the frame well.

4-17

TABLE OF CONTENTS CORRECTIVE MAINTENANCE The pedal also has a maximum range of travel of up to only 0.500” (12.7 mm) before it contacts the positive stop hex screw, and includes a brake light switch that energizes the brake STOP lights, where applicable, and has a switch for disengaging traction drive. The brake light/accelerator switch is factory set to trip just as the brake pedal begins its downward stroke.

Service Brake Linkage NOTE The linkage between the brake pedal and the master cylinder is non-adjustable.

Some other areas that can affect the braking system include: • Low fluid level in the master cylinder reservoir.

• Air or leaks in the system.

• Worn brake shoes “Checking/Changing Brake Shoes” on page 4-12.

Any of these conditions can affect pedal free-play.

Proceed to the appropriate heading for repairs.

Service Brake Switch Brake Light/Accelerator Switch Adjustment 1. First, review “Introduction, Safety, and Specifications” on page 1-1.

2. Perform “Lock Out / Tag Out” on page 1-7.

3. Slightly loosen both brake switch hex head screws See Figure 4-14.

4. Disconnect the wiring harness and connect an Ohm meter to the connectors of the switch that is being tested.

5. Slowly push down on the brake pedal. Before you feel pedal resistance, the meter must read one of the following: 6. The meter must not indicate continuity with the pedal fully released for brake lights (2 black wires).

7. The meter must indicate continuity <1 Ohm with pedal fully released for brake switch (2 green wires).

8. The switch can be adjusted forward or rearward to achieve proper actuation of the switches as the brake pedal is depressed.

9. Carefully torque the screws (8 to 10 ft. lbs.; 11-14 Nm) to secure the switch without moving the setting, then release the brake pedal to verify the setting.

10. Disconnect the ohm meter and reconnect the wiring harness.

11. Connect the battery and start the truck.

4-18

12. Depress the brake pedal and verify that the brake lights (if equipped) operate and travel of the truck is interrupted when the brake pedal id depressed =>.5 inches.

Master Cylinder Replacing Master Cylinder 1. First, review “Introduction, Safety, and Specifications” on page 1-1.

2. Perform “Lock Out / Tag Out” on page 1-7.

3. Apply the parking brake, disconnect the battery and block the wheels.

4. Remove the master cylinder fill cap and rubber diaphragm by loosening the two round head screws.

NOTE Siphon out as much fluid as possible. Install and tighten the fill cap and diaphragm before removing the cylinder.

5. Place rags under the brake line connections. Have a plastic cap or bag handy to cover the end of the line to limit fluid spillage.

IMPORTANT Brake fluid will damage paint. Cover truck body parts and be careful not to spill fluid during this procedure.

6. Using a flare-nut wrench, disconnect the brake fluid line at the rear of the cylinder.

NOTE Flare-nut wrenches should be used to prevent rounding off the corners of the brake line fitting.

7. Carefully pull the brake line away from the cylinder.

Seal or plug the brake line and master cylinder port to prevent fluid loss and/or contamination.

8. Disassemble the yoke from the master cylinder crank plate (one 5/16-18 screw and hardware).

9. Remove the two master cylinder mounting bolts and remove the cylinder from the truck.

10. Remove the reservoir cap and discard any fluid remaining in the reservoir.

11. Mark the push rod lock nut setting, then remove the yoke and lock nut from the old cylinder and install it to the new cylinder, maintaining the same lock nut setting.

NOTE The push rod lock nut should be installed so that when the pedal is completely retracted, the yoke to the master cylinder crank plate hardware is loose, when it is completely assembled.

F-985-0219

TABLE OF CONTENTS CORRECTIVE MAINTENANCE NOTE Whenever the master cylinder is removed and/or replaced, the hydraulic brake system must be bled. See “Bench Bleed the Master Cylinder” on page 4-19.

12. Install the new master cylinder in reverse order.

IMPORTANT Brake fluid will damage paint. Wipe up any spilled fluid immediately, then flush the area with clean water.

NOTE Since high pressure is not involved in the bench bleed procedure, your finger can be used to plug the cylinder hole and prevent the intake of air. Wash hands after this procedure or wear protective latex glove. Kits to aid in the bench-bleeding of master cylinders are also available at your local auto parts store.

Bench Bleed the Master Cylinder 1. Support the cylinder in a vise while allowing you to push the internal piston with the push rod See Figure 4-16.

2. Fill the cylinder with DOT 3 brake fluid.

3. Slowly push in on the rubber boot and cylinder plunger (push rod) assembly to force air from the cylinder, then hold the push rod in See Figure 4-16.

4. Press your finger tightly over the outlet port to prevent air from being drawn back into the cylinder when you release the push rod. Wait several seconds to allow fluid to be drawn from the reservoir to the cylinder bore, then repeat this step. When you push the rod in again, it will force your finger from the master cylinder outlet port to expel any trapped air.

Place rags underneath to soak up any fluid loss.

5. When only brake fluid is expelled, hold the push rod in and seal the master cylinder outlet port with an appropriate threaded plug or plastic cap, then release pressure on the push rod.

6. Fill the master cylinder reservoir and install the filler cap and gasket.

Figure 4-16: Bench Bleeding the Master Cylinder

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

1. Remove the left floor plate See “Floor Plate Removal and Assembly” on page 4-9.

2. First clean the reservoir cap to avoid fluid contamination, then remove the fill cap and rubber gasket See Figure 4-16.

3. Additional fluid is needed when the fluid level is below the FULL line stamped in the master cylinder housing body.

4. Add fluid as needed. DO NOT OVER FILL. Use only DOT3 brake fluid from a clean, sealed source.

5. Reinstall the reservoir fill cap and rubber gasket.

Tighten only enough to provide a leak-proof seal.

NOTE DO NOT over tighten. This could crimp, split, or damage the seal.

Bleeding Brakes NOTE Bleeding the brake system is necessary to remove any air that is trapped when replacing brake lines, brake calipers or the master cylinder. To avoid extensive damage to the system, use only DOT 3 brake fluid.

4-19

TABLE OF CONTENTS CORRECTIVE MAINTENANCE



CAUTION

Wear eye protection. If brake fluid comes in contact with your eyes, immediately rinse them with water and seek medical attention.

NOTE Check the fluid level often during the bleeding operation and add fluid as needed to prevent the level from falling low enough to allow air bubbles into the master cylinder.

Use only new DOT 3 brake fluid from a sealed container.

NEVER use old or used brake fluid. It contains moisture which will deteriorate the brake system components.

IMPORTANT It is necessary to bleed both wheels if air has entered the system. Air in the brake system can be caused by low fluid level or if a brake line has been leaking or disconnected. If the brake pedal feels spongy when pressed and travels almost to the mechanical stop but regains height when pumped, air has entered the system. The system must be bled. If no fittings were recently opened for service, check for leaks that would have allowed air into the system and repair leaks before attempting to bleed the system. DO NOT allow fluid to go inside of the brake drum and onto the brake pad. It will contaminate the brake shoes and cause failure.

IMPORTANT Be careful when handling bleeder screws. Rust may cause the fitting to break. Spray the fitting with penetrating oil before attempting to loosen. Use a 6-sided wrench or socket instead of a 12-sided.

13. Loosen the cylinder bleed screw until fluid starts to flow. Watch for air bubbles at the immersed end of the tube.

14. When the brake pedal bottoms, tighten the bleed screw, then release the pedal. DO NOT release pressure on the pedal until the bleed screw is tightened.

15. Repeat Steps 8 through 11 as many times as needed until the fluid draining in the container is free of air bubbles.

16. Fill the master cylinder fluid level and add as needed before bleeding the other side.

17. Check the operation of the brakes. The pedal should feel solid when depressed, with no softness. If necessary, repeat this procedure.

NOTE Have an assistant available, as well as a supply of brake fluid, an empty container, a length of 3/16” clear plastic or vinyl tubing to fit over the cylinder bleeder fitting and a six point wrench to open and close the fitting.

6. Perform “Lock Out / Tag Out” on page 1-7.

7. Block the wheels so that the truck can’t move.

8. Start with the right wheel (the wheel farthest from the master cylinder).

9. Loosen the bleeder fitting slightly, then tighten it where it is snug but can be loosened quickly and easily.

10. Fit a length of tubing over the bleed screw and immerse the other end in the container of new brake fluid. Check that the tubing fits tightly over the bleeder fitting. See Figure 4-17.

11. Check fluid level in the master cylinder. Fill before you begin.

12. Have someone slowly press on the brake pedal several times to build pressure in the system, then hold the pedal down.

Figure 4-17: Bleeding Brakes

Service Brake Pedal Assembly NOTE The service brake assembly (brake pedal) includes the mechanical brake pedal assembly, containing a pivot bushing. The only normal repair items are the switch, the pivot bushing or the brake return spring.

Replacing Any Other Hydraulic Brake Component 1. First, review “Introduction, Safety, and Specifications” on page 1-1.

4-20

F-985-0219

TABLE OF CONTENTS CORRECTIVE MAINTENANCE 2. Perform “Lock Out / Tag Out” on page 1-7.

3. Apply the parking brake.

4. Make sure all the other wheels are securely blocked so that the truck cannot move.

5. Remove covers as needed.

6. Replace the damaged component.

Traction Motor, and Gear Box For information on removing and replacing the Drive Tire, see “Removing/Replacing the Drive Wheel” on page 4-10

NOTE Wheel and tire combination weigh over 200 lbs. (90.7 kg) For information on inspecting the gear box see “Check Planetary Gear Box” on page 2-25

Service the Gear Box

 • • •

• •

• •

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



Drivetrain

•

5. Thoroughly clean the area around the fill and drain/level plugs.

WARNING

Perform service only in a well-ventilated area. DO NOT breathe vapors.

Wear protective goggles, aprons and gloves.

Avoid contact with skin, eyes and clothes.

Keep away from heat and flame. Failure to observe these precautions may result in death or injury.

If you become dizzy, get fresh air and medical help immediately.

If solvent contacts your eyes, immediately treat in accordance with the manufacturer’s recommendations on the container.

DO NOT mix different types of lubricants.

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

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

2. Perform “Lock Out / Tag Out” on page 1-7.

3. Raise the front wheel of the vehicle. Use jack stands, or a suitable supporting device, to support vehicle to allow the drive tire to rotate.

4. Remove wheel from unit being serviced.

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.

6. To drain, turn the gear box so that one of the drain plugs is at the lowest point. If rotating the gear box proves difficult, brace a 2” x 4” (5cm x 10cm) between the wheel studs and rotate.

See Figure 4-18.

7. Place a drain pan capable of storing up to 32 ounces (1.0 liter) of fluid under the drain plug.

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

9. Drain the fluid completely into the drain pan.



CAUTION

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

10. Once the fluid has been drained, replace the drain/level plug in position A. 11. Wash the interior of the gear box with a suitable cleaning liquid as recommended by the lubricant manufacturer.

• Put liquid into the gear box through the fill plug and replace the fill plug.

• Run the gear box for a few minutes at a high speed.

• Drain the cleaning liquid from the gear box in the same way as described for draining the oil.

• Clean any contaminants from the magnetic trap and O-ring seal on the plugs.

12. To fill the gear box, turn until the drain/level hole in position A is about 15º below the horizontal center line of the gear box.

4-21

TABLE OF CONTENTS CORRECTIVE MAINTENANCE 13. Fill the gear box with synthetic gear lube through position B until fluid flows out from position A. Fluid capacity is approximately 1 pint(16 oz.).

“Lubrication Specifications” on page 1-11) • DO NOT OVERFILL. 14. Install both plugs. Tighten to 25 ft. lbs. (34 Nm).

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

16. Turn the gear box a few times to eliminate any air pockets and recheck fluid level. The oil level should be checked again after a short driving period. If necessary, re-fill the oil.

4MM HEX SOCKET FILL PLUG

5MM HEX SOCKET BOLT

B

B

5MM HEX SOCKET BOLT

5MM HEX SOCKET BOLT

4MM HEX SOCKET FILL PLUG

15 o

A

4MM HEX SOCKET DRAIN/ LEVEL PLUG

5MM HEX SOCKET BOLT

A

4MM HEX SOCKET DRAIN/ LEVEL PLUG

Figure 4-18: Servicing the Gear Box

Gearbox Replacement To repair and/or replace the traction motors: 1. Review “Introduction, Safety, and Specifications” on page 1-1.

2. Perform “Lock Out / Tag Out” on page 1-7.

3. Support the unit as the mounting screws are removed.

4. Remove the eight M16-2 X 30 hex socket screws and hardware holding the gear box to the truck frame.

5. Evenly support the gear box and allow the shaft to slide free from the motor.

6. Place the gear box on a sturdy work bench. Use wood blocks balance and support the assembly while on the work bench.

7. Reassemble the gear box to the truck by following the preceding steps in reverse order.

8. Fill the gear box with synthetic gear lube through position B until fluid flows out from position A. Fluid capacity is approximately 1 pint(16 oz.).

“Lubrication Specifications” on page 1-11 • DO NOT OVERFILL! 9. Tighten and torque the M16-2 X 30 screws. “Torque Specifications” on page 1-11.

Figure 4-19: Gear Box Cover Removal

4-22

F-985-0219

TABLE OF CONTENTS CORRECTIVE MAINTENANCE

Traction Drive Motor Service 1. Repeat steps 1-8 in “Gearbox Replacement” on page 4-22.

2. Support the unit as the mounting bolts are removed.

3. Remove the twelve 1/2-20 X 2 hex socket screws and hardware holding the motor to the motor mount weldment.

4. With the motor supported, rotate the motor to align the electrical connecting terminals to the slots machined in the motor mount weldment.

5. Slide the motor out far enough to install a second strap around the motor. This strap is to support the motor from outside the truck frame.

6. Place the assembly on a sturdy work bench. Use wood planks to balance and support the assembly while on the workbench.

7. Assemble the new motor by following the preceding steps in reverse.

8. Tighten and torque the screws.

4. Remove the fasteners and hardware securing the accelerator to the floor panel. See Figure 4-10.

5. Disassemble the accelerator from the floor plate and install the replacement accelerator in its place.

6. Refer to Landoll Setup Procedure, located in “Bendi B3/30 AC Calibration and Programming” on page 5-1 to re-calibrate the accelerator module.

Electrical Fuses Various size fuses are located in the controller compartments located on the right side of the forklift as well as on the rear. Exact size and amperage rating must but be retained when replacing.

Electrical Static Discharge IMPORTANT •

•

Figure 4-20: Tire, Gear Box and Motor Exploded View

•

Accelerator Pedal

Normal precautions concerning the handling of electronic components are applicable in order to minimize the risk of damage to these devices by ELECTRICAL STATIC DISCHARGE. Avoid contact with the pins of these devices and ensuring that when they are removed from a printed circuit board (PCB), the pins are strapped together with conductive tape. Immediately place the PCB in static-free bubble wrap or ESD bag.

ESD smocks over normal clothing must be worn to discharge high voltage potentials caused by friction during normal wear.

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

NOTE The accelerator assembly consists of the linear potentiometer, harness, and accelerator pedal.

Electrical Controls and Levers The directional control switch (forward-neutral-reverse) is located on the lift lever.

Replacing Accelerator Module 1. First, review “Introduction, Safety, and Specifications” on page 1-1.

2. Perform “Lock Out / Tag Out” on page 1-7.

3. Remove the floor plates “Floor Plate Removal and Assembly” on page 4-9.

Replacing Levers 1.

2.

3.

4.

First, review “Before You Begin” on page 1-1.

Park the forklift on a level surface.

Lower the forks all the way to the ground.

Apply the parking brake.

4-23

TABLE OF CONTENTS CORRECTIVE MAINTENANCE 5. Set the key switch to the “OFF” position and remove the key from the console.

6. Disconnect the battery.

7. Perform “Lock Out / Tag Out” on page 1-7.

8. Make sure all the other wheels are securely blocked so that the forklift cannot move.

9. Remove the operator data placard from around the hydraulic control levers.

Figure 4-22: Remove Cover

Figure 4-21: Remove Placard 10. Remove the linkage cover plate. (NOTE: You may need to remove the battery. There are two screws that secure the cover that cannot be reached without removing the battery.)

11. Rotate the lift and sideshift lever towards the center.

12. Remove the control lever cover.

13. Remove the center lever to allow easier rotation of lift lever.

14. Disconnect 6 pin Deutsch connector on lever harness and remove the two nylon ties the secure the harness to the lift linkage.

15. Loosen the bolts that hold the linkage pivot pin to the truck to allow the harness to be pulled free.

16. Unscrew the lift lever from its rocker block.

17. Transfer jam nut from old lift lever to new lift lever, noting position of nut on old lever.

18. Screw new lift lever into lift linkage rocker block.

Screw lever until jam nut touches rocker block.

4-24

Figure 4-23: Center Lever Removed

F-985-0219

TABLE OF CONTENTS CORRECTIVE MAINTENANCE 19. Slide lever harness past the front of the linkage pivot pin, alongside the lift linkage link.

20. Tighten the bolts that hold the pivot pin to the truck.

21. Connect lever harness to truck harness and secure harness to linkage with nylon ties.

22. Replace control lever cover.

23. Rotate levers to match original orientation. Tighten jam nuts to secure.

24. Replace linkage over plate 25. Replace operator data placard.

26. Test for proper operation.

27. Replace the control lever cover.

Replacing a Complete Control Panel 1. First, review “Introduction, Safety, and Specifications” on page 1-1.

2. Set the key switch to OFF, remove the key from the key switch and place in a secure area.

3. Perform “Lock Out / Tag Out” on page 1-7.

4. Make sure all the other wheels are securely blocked so that the truck cannot move.

5. Remove the control compartment cover located either on the right side or rear of the forklift, depending on which controller is being replaced.

6. Mark and remove all cables connected to high current terminals of the panel and disconnect the main harness.

7. Remove mounting hardware that secures the assembly to the truck and remove the panel or single component from the truck. See Figure 4-25.

8. Reassemble in reverse order. All cables installed on the motor controllers must use all the required Landoll approved fasteners and be in the correct assembled order. See Figure 4-24. Refer to the Bendi B3-30 AC/DS Parts Manual for replacement parts.

9. Tighten cables connected to the high current terminals, identified on the controller housing as B+, B-, U, V and W to 90 +/- 1- in-lbs(10.2 +/- 1.1 Nm).

Refer to view shown below for high current cables.

NOTE After replacing the controller it must be reprogrammed.

See Chapter 5 Bendi B3/30 AC Calibration and Programming.

HIGH CURRENT CONNECTIONS DEFFINITION: B+ = Positive Battery to Controller.

B- = Negative Battery to Controller.

U = Motor phase U. V = Motor phase V. W = Motor phase W.

0 %2/7 PP 0,1 '(37+

+,*+ /2$' 6$)(7< :$6+(5

/8*

0 7(50,1$/ PP 0$; '(37+

6(&7,21 9,(:

(;3/2'(' 9,(:

Figure 4-24: Heavy Cable Hardware and Assembly

4-25

TABLE OF CONTENTS CORRECTIVE MAINTENANCE

AC Motor



CAUTION

DO NOT allow: • Hydraulic fluid level to drop significantly or allow the reservoir to run dry. This will induce air into the system and cause damage to hydraulic system components.

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

Cylinders and Valves: Check these components for drift and leakage. Refer to Landoll Company, LLC and other vendor service information for specifications.

AC Pump Controller Hydraulic Pump Figure 4-25: AC Motor, Pump and Controller

Hydraulic Components

Hoses and Tube lines: Check for cracks, hardening, or other signs of wear. Reroute any usable hoses that are kinked, severely bent, or rest against hot parts.

Look for leaks, especially at couplings and fittings.

Replace any hoses or tube lines that do not meet system flow and pressure ratings.

Hydraulic Fluid: Check fluid level and look for air bubbles. Check the filter. See “Changing Hydraulic Oil” on page 4-26.

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

NOTE

NOTE

This section explains the following: • Hydraulic System Maintenance • Changing Hydraulic Oil • Changing the Hydraulic Filter • Checking Hydraulic Pressure • Servicing the Lift Motor and Pump 1. First, review “Introduction, Safety, and Specifications” on page 1-1.

2. Apply the parking brake.

3. Perform “Lock Out / Tag Out” on page 1-7 4. Make sure all the other wheels are securely blocked so that the truck cannot move.

5. Remove the floor plate, if necessary.

The hydraulic pump in your Bendi truck is powered by an AC non-serviceable motor. The pump supplies hydraulic pressure for steering and mast lift.

Hydraulic System Maintenance Maintain the hydraulic system, and associated components, as required by the various checklists (SEE PAGE 2-5).

4-26



CAUTION

After prolonged truck use, hydraulic oil will be hot and can burn human skin. Allow hydraulic oil to cool to a temperature that does not burn skin before performing this procedure.

Changing Hydraulic Oil For this section See Figure 4-26 for component locations.

Hydraulic oil can damage paint, have plenty of rags handy to clean up any spills immediately.

1. Review “Introduction, Safety, and Specifications” on page 1-1.

2. Park the truck on a level, designated service area.

3. Set the parking brake and block the rear wheels.

4. Perform “Lock Out / Tag Out” on page 1-7.

F-985-0219

TABLE OF CONTENTS CORRECTIVE MAINTENANCE 5. Remove the floor panels.

6. Open the fill/dipstick cap.

7. The hydraulic reservoir drain plug is located on the right side of the forklift directly under the control panel cover.

8. Slide a flat collection pan, (minimum 11 gallons (42 liters)) under the drain plug, then remove the plug.

9. If still installed, remove the battery and battery tray.

10. Remove and clean the suction screen.

11. Reinstall suction screen.

12. Remove magnetic plug, clean of any contaminants and replace.

13. Replace the high pressure filter element (located under the floor plates).(See “Change the Hydraulic Oil Filters” on page 4-27) 14. Reinstall drain plug.

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

15. Refill the Hydraulic System.

• See “Lubrication Specifications” on page 1-11.

• DO NOT overfill.

16. Replace the fill/dipstick cap, turn clockwise, and make sure it is tightened securely.

17. Operate mast to check for leaks.

18. With the forklift OFF and the forks down, check the oil level on the dipstick and add oil accordingly.

• See “Check Hydraulic Oil Level” on page 2-12

Change the Hydraulic Oil Filters



CAUTION

After prolonged truck use, hydraulic oil will be hot and can burn human skin. Allow hydraulic oil to cool to a temperature that does not burn skin before performing this procedure.

1. Park the truck on a level, designated service area, set the parking brake and block the wheels.

2. Perform “Lock Out / Tag Out” on page 1-7.

3. Remove the floor plates.

4. Using a clean, lint-free cloth, clean the area around the filter element housing.

5. Disconnect the filter switch, accessed through the port on the right hand front of the frame.

6. Remove the filter body end cap and filter element.

7. Clean the filter body and end cap. Lubricate new filter element and install into filter body.

8. Coat the end cap o-ring seal with a thin film of hydraulic oil, then screw the end cap onto the housing.

9. Reconnect the filter switch.

10. Check hydraulic fluid level.

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

12. Reinstall the floor plate.

Filter Switch / End Cap

Dipstick

Magnetic Plug Hydraulic Reservoir

Drain Plug Suction Screen

Figure 4-26: Hydraulic Reservoir

Figure 4-27: High Pressure Filter 4-27

TABLE OF CONTENTS CORRECTIVE MAINTENANCE

Checking and Adjusting Hydraulic Pressure



WARNING

HIGH PRESSURE FLUIDS CAN BE DANGEROUS! Before continuing with this section, read about the warnings of pressurized hydraulic oil under “Hydraulic System” on page 1-8.

NOTE For ease of checking hydraulic pressure, Landoll offers a Pressure Check Kit (P.N. 0018152) which includes a 5000 p.s.i. (344.7 bar) gauge, hose and a quick-coupler assembly. If you are using your own system, have shop rags, oil absorbent and a small container ready to collect any oil spills.

1. For this test, make sure that the hydraulic tank has plenty of oil.

2. Perform “Lock Out / Tag Out” on page 1-7.

3. Remove the floor plates.

4. Connect the pressure check kit quick-coupler (female end) to the coupler (male end) on the control valve.

• If you are not using the pressure check kit, remove the quick-coupler and install an appropriate fitting to accept your pressure gauge arrangement • Have rags handy to collect any oil leakage.

• Install your 5000 psi (344.7 bar) gauge arrangement to the tee fitting.

• All parts connected to the gauge port must be capable of handling up to 5000 p.s.i. (344.7 bar).

• Remove the control panel cover on the right side of the forklift.

• To adjust pressure, the truck (pump) must be running to create hydraulic pressure. Always pay careful attention when servicing while the truck is running.

To check or set the pressure, you must pull the tilt lever to dead head the cylinder to build pressure, then set the relief valve.

5. Loosen the relief valve jam nut.

6. Start the truck.

7. Adjust the valve stem by turning clockwise to increase pressure, counterclockwise to decrease pressure. This procedure adjusts the pressure relief valve setting.

8. Release the lever immediately once the pressure is set at 2600 psi. (179 bar)

IMPORTANT DO NOT hold a hydraulic joystick (bottomed out) for excessive periods of time. Extreme pressure is applied to the system which can, over periods of time, generate heat and damage oil and internal components.

9. If the pressure is low and cannot be adjusted to the proper value, check the pump and make sure there are no leaks in the hydraulic system. If the pressure is too high and cannot be adjusted to the proper pressure, replace the relief valve.

10. Tighten the relief valve lock nut.

11. Set the key to OFF, remove the key from the key switch, and disconnect the battery.

12. Operate the function joysticks momentarily to relieve system pressure.

13. Remove the pressure gauge quick-coupler or remove your gauge arrangement.

14. Start the truck.

15. Lift and lower the mast a few times to check the hydraulic system for leaks.

16. Set the key to OFF and disconnect the battery.

17. Reassemble all covers and panels that were previously removed.

Quick-Coupler

Figure 4-28: Pressure Testing 4-28

F-985-0219

TABLE OF CONTENTS CORRECTIVE MAINTENANCE

Steering Motor Service

•

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



NOTE When performing any steering motor service, it is important to have the proper tools and clean facilities to complete a successful repair. Also make sure that when doing a motor repair that all related components are correctly working and that clean oil and filters are to be used. Dirt, grease and old oil will not only hurt motor performance, but shorten the motor’s life as well.

CAUTION

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

Hydraulic Pump Service NOTE

Load Sense Steering System The Bendi B3/30 lift truck uses a load sense priority flow control (See Figure 4-29) to meter hydraulic oil flow to the steering system. As the operator turns the wheel, a fluid signal from the steering control unit (orbital), shifts a load sense valve in the main control valve that meters fluid from the control valve to the steering orbital. This system provides fluid to the steering system as needed and allows the fluid to flow back to the tank at a low pressure when steering is not needed, thereby reducing power consumption.

Load Sense Steering Section

Figure 4-29: Load Sense Section of Hydraulic Spool

Power Steering System Maintenance Guidelines to perform maintenance on the power steering system is provided in the following paragraphs.

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

• Some hydraulic repair will need the steering wheel pulled. Always use a puller to remove the steering wheel. DO NOT use a hammer, torch, or crow bar.

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

The hydraulic lift pump used on the Bendi B3/30 has no serviceable parts and is repaired by replacement only.

When replacing the lift pump, make sure that the hydraulic oil is clean and that the hydraulic system has a new clean filter. (See Changing Hydraulic Oil and “Change the Hydraulic Oil Filters” on page 4-27)

Replacing the Hydraulic Pump and Motor NOTE The AC motor and pump are located in the rear of the truck, surrounded by the counterweight and are accessible by removing the rear cover.

1. Perform “Lock Out / Tag Out” on page 1-7.

2. Remove the rear enclosure cover. See Figure 4-30.

3. Move the hydraulic levers back and forth to relieve pressure from the lines.

4. Disconnect and cup the suction and pressure hoses from the hydraulic pump, item #1. Place shop rags under the connections to catch hydraulic oil.

5. Disconnect the 2 snap electrical connectors, item #2.

6. Mark and disconnect the 3 heavy gauge electrical cables, item #3.

7. Assembly is awkward and heavy. Use crane or seek the assistance or another technician during removal.

8. Assembly is fastened with studs. Place wood blocks below pump. Use a pry bar to support assembly once the final nut has been removed from the mounting plate.

9. Support assembly with a sling or with the aid of another technician. “Walk” the assembly from studs and remove from truck.

NOTE Assembly is very heavy.

10. Assemble in reverse procedure.

4-29

TABLE OF CONTENTS CORRECTIVE MAINTENANCE

2

3

1 Hydraulic Pump

Figure 4-30: Hydraulic Motor and Pump Assembly

Front Rotation Assembly This section explains servicing the: • Steering Actuator.

• Stop blocks.

• Steer potentiometer You will need a 2 to 3 ton (1,814-2,722 kg.) overhead crane to support the mast and/or the front end weldment, when you separate it from the forklift front rotation arm.

You will also need hydraulic jacks or large block of wood and a portable hydraulic press.

This service is best performed at your service center as opposed to the customer facility.

3. Apply the parking brake and block all wheels.

4. Relieve hydraulic pressure in the system by turning the steering wheel two times to the left, then two times to the right and move the joysticks in both directions.

5. Perform “Lock Out / Tag Out” on page 1-7.

6. Support the front end of the forklift (between the front rotation arm and the forklift frame) using support stands or blocks of wood capable of handling the weight.

7. Connect a strap from the overhead crane around the top center cross member of the mast and apply slight tension only.

8. Remove the steering sensor, sensor bracket and sensor rod.

9. Remove all screws in the top Ringfeder bearing.

Screw these into their adjacent threaded holes to push-off the outer ring.

10. Remove the bearing and set aside on a clean surface.

11. Remove the upper bearing spacer and pry bearing upwards.

12. Remove the four hex head screws holding the Upper actuator mount in place and remove mount.

13. Repeat step 9, 10 and 11 for the bottom Ringfeder bearing.

14. Remove hoses and cap to prevent spills.

15. Replace or repair the actuator and reassemble in reverse order.

Removing the Steering Actuator NOTE Before any assembly or disassembly of components, clean actuator shaft ends and coupling pockets in mount plates using brake parts cleaner DO NOT use anything containing molybdenum disulphide.

1. First, review “Introduction, Safety, and Specifications” on page 1-1.

2. Park the forklift on a clean, flat, level surface with enough room to work in the area safely.

4-30

Figure 4-31: Rotation Assembly F-985-0219

TABLE OF CONTENTS CORRECTIVE MAINTENANCE Hints for Reassembly

To Center the Steer Sensor

1. To install the actuator, you must align all parts. The overhead crane may have to be adjusted a fraction of an inch to allow the actuator to slide in place.

2. Remember to install the bottom spacer before you move the front end weldment back into place.

3. Starting at the top of the assembly, carefully install the steer actuator. Align the shaft bottom through hole to the hole in the front plate weldment yoke.

See Figure 4-31.

4. Port P2 should be above port P1.

5. The compression coupling should be completely bottomed out in their respective pockets. If they aren’t, reposition as necessary.

6. Tighten all compression coupling locking screws alternating sides (like a car’s lug nuts) and torque to 30 ft lb (40.7 Nm).

7. Loosen plugs in P1 and P2 and slowly rotate the actuator 90°, until the ports face directly forward (towards the mast) and retighten P1 and P2.

8. Install the 3/4-16 hex head screw and hardware.

Tighten and torque accordingly, see page 1-19.

9. Install the top portion of the assembly. Tighten and torque accordingly, see “Torque Specifications” on page 1-11.

10. Apply additional grease at the two grease fittings.

See “Lubrication Specifications” on page 1-11 for recommended lubrication.

1. Loosen 10-32 x 3/4 hex head cap screws connecting steer pot bracket to rotation switch bracket.

2. Adjust steer sensor bracket until centered over the sensor drive rod, located in the top of the front rotation shaft. See Figure 4-32.

Steer (Front Rotation) Sensor The steer (front rotation) sensor is replaced as a complete unit and is electrically checked, See Figure 4-32. For any troubleshooting and calibration information, see Chapter 4.

NOTE Once centered you must calibrate the sensor, see “Bendi B3/30 AC Calibration and Programming” on page 5-1.

3. Tighten down the set screw.

To Adjust and/or Replace the Steer Sensor 1. First, review “Introduction, Safety, and Specifications” on page 1-1 2. Perform “Lock Out / Tag Out” on page 1-7.

3. Remove the plastic front rotation cover to expose the internal gearing and steer rotation sensor assembly.

4. Loosen the two #10-32 X 3/4 hex head cap screws and “evenly” position the steer rotation sensor assembly until rotation sensor is centered over the drive rod, located in the top of the rotation shaft.

5. If the sensor is being replaced, disconnect the electrical connector and remove the #8-32 x 1-1/2 round head bolts and hardware.

6. Install the new sensor assembly in reverse order.

7. Tighten and torque the screws accordingly, refer to torque specification charts in “Torque Specifications” on page 1-11.

Hydraulic Control Valve Assembly General While a leaky control valve may be fixed by installing a service kit, if there are more serious problems to the hydraulic spool, Landoll recommends a complete hydraulic valve replacement.

The following procedure explains how to replace a specific valve should a sluggish or sticking valve spool be suspect.

Figure 4-32: Front Rotation Sensor

4-31

TABLE OF CONTENTS CORRECTIVE MAINTENANCE

Hydraulic Control Valve and Switches Removal

Figure 4-33: Control Valves If you remove the valve from the truck for servicing (hex head screws and hardware), when reinstalling the valve be certain to tighten the mounting screws in a staggering fashion while applying equal pressure to all screws. If the screws are not tightened and torqued evenly, you could create a stress crack, thus internal oil leaks, rendering the valve defective.

NOTE •

• •

The main hydraulic pump for lift, tilt, pivot, and shift (mast functions) is a fixed displacement gear pump.

System pressure must not exceed 3,000 psi, ±65 psi (207 bar, ±5 bar) maximum.

The main pump pressure relief valve is part of the hydraulic control valve.

A pressure gauge port is provided, with a “quick-coupler,” (pressure service kit, Landoll p.n.

0018152) for reading the pump pressure on the hydraulic control valve. The pressure check port on the forklift is attached to the inlet port on the hydraulic control valve.



CAUTION

Before you service this valve for possible pressure problems, make sure there are no leaks in the hydraulic system and that there is sufficient oil in the tank. Both conditions can contribute to low pressure problems.

4-32

1. First, review “Introduction, Safety, and Specifications” on page 1-1.

2. Perform “Lock Out / Tag Out” on page 1-7 3. Apply the hand brake and block the wheels.

4. Relieve pressure in the system by moving the hydraulic levers back and forth a few times.

5. Remove the floor plate.

6. Remove valve cover.

7. Inspect the spool actuator end (upper) and the switch actuator end (lower) for leakage. Also inspect valve for leakage between valve sections.

8. If leakage is found, the spool seals can be replaced.

If there is leakage within the spools, as determined by drift in the hydraulic actuator, the valve may need to be replaced. If leakage is found between sections, replace o-ring between the section.

9. Remove the valve from the truck by first identifying and marking all hoses, disconnecting and plugging all hydraulic tubes. Be prepared to manage spills.

10. Disconnect the lift pot from the truck wiring harness and switches from the truck wiring harness at the Deutsche connector.

11. Remove the push/pull linkage from the spools by removing the linkage pins and pulling the pins from the spools.

12. Remove the bolts holding the valve to the valve mounting bracket.

F-985-0219

NOTE During this time close inspection should be given looking for leaks between the sections. If there have been sectional leaks, simply unbolt the three bolts that hold the sections together, replace the leaking o-ring and tighten up the bolts holding the sections together. (See “Hydraulic Control Valve” in F-663 Bendi B3-30 parts manual) 13. Remove the spool and end mechanism from the bore.

14. Remove the seal, wiper and seal plate from the tang/clevis end of the spool. A dental pick can be used to remove the wiper and o-ring. Use caution to avoid nicking the bore.

15. Remove the end mechanism from the cap end of the spool.

16. Remove all foreign material from the spool and seal counter bores.

17. Lubricate the seal groove bores on the cap and tang/clevis ends of the housing.

F-985-0219

TABLE OF CONTENTS CORRECTIVE MAINTENANCE 18. Re-assemble the cap end of the spool with the new seals per the applicable end mechanism repair instruction.

19. Carefully reinsert the spool.

20. Install the new seal and wiper on the tang/clevis end of the spool using the seal plate to push them in prior to completing the seal plate cap screw installation and torque.

21. Assemble the switch pot brackets to the other end of the valve.

22. Apply grease (NLSI #2 Texaco #880) to actuator end prior to assembly of the spool actuator.

23. Reassemble valve to truck.

24. Attach and tighten all hoses.

25. Operate valve functions and check for leaks.

6. Once load check poppet has been properly installed, place load check spring in hollow cavity inside check poppet.

Figure 4-35: Hydraulic Valve Disassembly

Hydraulic Lift Sensor NOTE The hydraulic lift sensor is replaced as a complete unit with the wiring harness. See Figure 4-34.

Replacing Lift Sensor

Figure 4-34: Hydraulic Valve Switches

Spool Section Rebuild NOTE The inlet assembly will include an o-ring, and the spool sections will include an o-ring, load check poppet and load check spring.

1. For proper reassembly alignment, lay valve components on a clean, hard, flat surface.

2. Thread tie rod nuts onto the short threaded end of each of the individual tie rods with the nuts threaded up the entire length of the threads.

3. Insert tie rods through tie rod holes of inlet housing, lay inlet on end with tie rods pointing up and install o-ring into groove. Special care must be taken to ensure o-ring has been completely installed in groove.

4. Place first spool section over inlet section with o-ring groove facing upward and install o-ring into groove.

5. Install load check poppet into load check cavity, nose first.

1. First, review “Introduction, Safety, and Specifications” on page 1-1.

2. Set the key switch to OFF, remove the key from the key switch and put in a secure area.

3. Apply the parking brake, perform a Lock Out/Tag Out procedure, disconnect the battery and block the wheels.

4. Relieve pressure in the system by turning the steering wheel two times to the left, then two times to the right and move the joysticks in both directions.

5. Remove the floor plate to allow removal of the valve cover.

6. Disconnect the lift sensor from the main truck harness at the Deutsche connector.

7. Remove the lift sensor bracket from the end of valve.

8. Remove the two screws holding the lift sensor from the bracket.

9. Install new sensor and reassemble the pot to the bracket.

10. Reassemble pot mount bracket to valve.

11. Reinstall valve on truck.

12. Attach and tighten hydraulic hoses.

13. Start truck, operate hydraulic system, and check for leaks.

4-33

TABLE OF CONTENTS CORRECTIVE MAINTENANCE 14. Calibrate lift sensor input to controller. (Refer “Bendi B3/30 AC Calibration and Programming” on page 5-1 for controller calibration.) This adjustment is actually completed through the controller electronically.

15. Reinstall brake assembly.

16. Install floor plates and valve cover.

Hydraulic Fittings and Hoses 1. First, review “Introduction, Safety, and Specifications” on page 1-1.

2. Perform “Lock Out / Tag Out” on page 1-7.

3. Block the wheels.

4. Before disconnecting any hydraulic fittings or hose assemblies, relieve the system pressure, down to zero psi. This is accomplished by turning the steering wheel a few times in both directions, and moving the control levers in both directions after the key switch is turned OFF.



WARNING

High pressure hydraulic oil leaks can pierce the body and cause SEVERE injury to personnel.

Always reduce pressure before opening any hydraulic pressure line.



CAUTION

Oil spills can cause falls. To avoid injury, make sure all spills are cleaned well with oil dry/wipes.

5. Remove the hose coupling from the defective fitting.

Use two wrenches; one wrench to loosen the hose coupling, and one to prevent the fitting from turning.

Be prepared to clean up any oil spillage.

6. Always tag the hoses and fittings for identification. If necessary, keep notes and put markings on parts using a non-destructive marker.

7. Remove the defective fitting and replace with a new fitting. Use two wrenches; one wrench to tighten the hose coupling, and one to prevent the fitting from turning.

NOTE SAE fittings do not need a thread sealant. They are straight thread and include an O-ring seal.

Figure 4-36: Tightening Hydraulic Connections

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

2. Check hydraulic fluid level.

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

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

5. Pull either joystick to see if hydraulics are working.

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

7. Pump troubleshooting tips can be found in “PUMP PROBLEMS” on page 3-7.

Steering Column/Dash Assembly This procedure replaces the steering wheel, steering column, and components.

The console assembly includes the following and are accessible by removing the right side steering assembly cover (black) - ten (10) screws and hardware: • Auxiliary power rocker switch (fan, scanner, etc.)

• Headlights (rocker switch, where fitted) • Standard/Ramp mode (Allows current to increase in the ramp mode) • Tilt steering lever • Key switch

Remove the Display Panel 1. First, review “Introduction, Safety, and Specifications” on page 1-1.

4-34

F-985-0219

TABLE OF CONTENTS CORRECTIVE MAINTENANCE 2. Set the key switch to OFF, remove the key from the key switch and place in a secure area.

3. Apply the parking brake, perform a Lock Out/Tag Out procedure and disconnect the battery. Make sure all the wheels are securely blocked so that the truck cannot move.

4. Remove the right side cover of the steering column to expose the internal components of the steering column by removing the 2 cover screws and hardware. See Figure 4-37.

5. Remove the four large screws and hardware.

See Figure 4-37.

6. Remove the bellows (rubber boot) free of the steering column cover.

7. Reach inside the steering column and disconnect the appropriate display wire connectors from the main wire harness.

8. Install the new display by reversing the above steps.

9. Connect the wire connector to the display and close the steering column by reversing the steps outlined in 4 through 8.

Key Switch 1. First, review “Introduction, Safety, and Specifications” on page 1-1.

2. Perform “Lock Out / Tag Out” on page 1-7.

3. Make sure all the wheels are securely blocked so that the truck cannot move.

4. Remove the right side cover to expose the internal components of the steering column as described on page 4-1.

5. Reach inside the steering column and disconnect the appropriate switch connector from the main wire harness.

6. Unscrew the knurled switch collar ring to separate the switch from the base plate. See Figure 4-38.

7. Disconnect the wires from the switch terminals noting how they are connected to ensure proper orientation when connecting the new switch.

8. Install the key switch by reversing the preceding steps.

Figure 4-38: Key Switch Assembly

Rocker (On/Off) Switches NOTE

Figure 4-37: Dash and Steering Console Assembly

Rocker switches are dash mounted and are used to control various light packages and accessories.

1. Repeat preceding sections 1-4 in Key Switch.

2. Reach inside the steering column and disconnect the appropriate accessory switch connector from the main wire harness.

3. The accessory on/off rocker switches are held by locking tabs. Compress the tabs on one side at a time to release the switch body, then push up and lift out of the slot. See Figure 4-38.

4-35

TABLE OF CONTENTS CORRECTIVE MAINTENANCE NOTE Be careful when compressing and pushing the switch in or out. The tabs could break off if the procedure is not done carefully and evenly on all sides.

4. Detach the wires from the defective switch, noting the connection arrangement for when installing the new rocker switch.

5. Insert the replacement switch in the slot and compress the tabs as needed to allow it to insert.

6. Connect the cable connector to the wire harness and close the steering column by reversing the steps outlined in the above section.

7. Close the steering column by installing the right side cover.

Figure 4-40: Steering Wheel and Knob

Steering Column (Console) Removal NOTE

Figure 4-39: Rocker Switch Removal

Steering Wheel Removal 1. Pry the plastic cover from the steering wheel using your finger tips. If you cannot grab the cover, you can start it by carefully using a medium sized flat blade screw driver and gently prying upwards. DO NOT force it or the cover may crack.

2. Loosen the steering wheel nut.

3. Remove the steering wheel.

NOTE If the steering wheel is difficult to remove, use a commercial puller. With this tool, it should remove easily.

4. Install the steering wheel by placing it over the shaft, aligning the wheel and shaft splines and pushing downward evenly until the nut can be installed.

5. Tighten the nut.

4-36

This is a two man operation, due to weight of steering column (approximately 30 pounds/14 kgs.). If an overhead crane is available, the crane could be strapped to the steering wheel for support.

1. Remove floor plates. (See “Floor Plate Removal and Assembly” on page 4-9) 2. Remove the lower dash cover weldment.

3. Disconnect the plugs that connect the dash harness to the main harness and any optional lighting harnesses.

4. Relieve hydraulic pressure in the system by turning the steering wheel a few times to the left and right.

5. Also pry (up) the bellows (rubber boot) free of the bellows retainer plate. This exposes the mounting plate for the steering column and the orbital control unit.

IMPORTANT Four screws secure the assembly to the orbital steering mount bracket for stability. Once removed the unit is supported by the hydraulic hoses only.

6. Remove the four bolts and hardware securing the orbital control unit to the steering column.

7. Remove the four bolts and hardware securing the steering column console to the bellows retainer plate.

See Figure 4-41.

8. With help, lift the steering column upwards to disengage the shaft from the orbital unit, then remove the steer column from the truck.

F-985-0219

TABLE OF CONTENTS CORRECTIVE MAINTENANCE 9. When installing the new steer column, you must turn the steering shaft until it aligns with the orbital unit and drops into place.

10. Continue by reversing the preceding steps making sure to tighten and torque all mounting screws (See “Torque Specifications” on page 1-11)

Horn Service NOTE The horn button is located to the right of the direction control lever.

Removing the horn 1. Turn the key switch is OFF, remove the key, perform Lock Out/Tag Out procedure and disconnect battery.

2. Remove front rotation cover plate.

3. Disconnect the electrical wires.

4. Remove the hex screws and hardware to separate the horn from the frame.

5. Install the new horn by reversing the preceding steps.

6. Connect the battery and test the horn.

Truck Lighting Trucks equipped with optional lighting, flashing or spot lights may contain replaceable bulbs or the housing may be replaced as a whole. Lighting replacement varies according to the manufacturer.

Figure 4-41: Steering Column Removal

Headlights

Steering Orbital Control Unit 1. Remove floor plates (See “Floor Plate Removal and Assembly” on page 4-9).

2. Remove the lower dash cover weldment.

3. Relieve hydraulic pressure in the system by turning the steering wheel a few times to the left and right.

4. Tag the port locations of each hydraulic line and fitting, then disconnect the four lines from the unit.

5. Review section “Hydraulic Fittings and Hoses” on page 4-34.

NOTE Immediately plug and cap all hose ends and tag each for identification. Be prepared to clean up any oil spills.

6. If the unit is being replaced, or the fittings are defective, notice the placement angle of the hose fittings before removing them.

7. Install the new steering orbital control unit to the steering column by following the preceding steps in reverse order.

8. Check oil level in the hydraulic tank and fill as needed.

These lights have non-replaceable LED elements and are replaced as an entire unit.

Brake and Tail Lights 1. Set the key switch to OFF and remove the key.

2. Perform “Lock Out / Tag Out” on page 1-7..

3. The complete LED light assembly must be replaced to repair a faulty light assembly.

4. Pull off the complete LED light assembly. Exercise care to avoid breaking the LED assembly.

5. Disconnect the wire connector and remove the bracket that is attached to the overhead guard.

6. If shielding or guard covers are involved, make certain that the guard is replaced after the repair.

Reassemble in reverse order.

Back Up Alarms 1. First, review “Introduction, Safety, and Specifications” on page 1-1.

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

3. Apply the parking brake and disconnect the battery.

4. To access the alarm assembly, raise the seat base as it is located under the arm rest.

4-37

TABLE OF CONTENTS CORRECTIVE MAINTENANCE 5. To replace the alarm assembly, disconnect the wire connector and remove the mounting hardware holding the alarm to the mounting bracket.

Overhead Guard, Lighting and Alarms Trucks equipped with optional LED flood / headlights, tail and stop lights, flashing or spot lights (strobe lights), etc. do not contain replaceable bulbs. Bulb replacement must be done as a complete assembly.

Seat Switch Replacement The driver's seat micro switch and cable assembly are mounted to the bottom of the seat cushion.

To check the function of the seat switch see “Seat Switch” on page 2-17.

Replacing the Switch and Cable 1. Set the key switch to OFF, remove the key from the key switch and place in a secure area.

2. Perform “Lock Out / Tag Out” on page 1-7.

3. Block all wheels.

4. Remove the hardware securing the front portion of the seat slide rails to the cover. Then loosen the back two sets of hardware.

5. Raise the front of the seat up to expose the switch and cable mounting.

6. Have a helper disconnect the switch cable from the main harness, then unscrew the switch assembly.

7. Install the new switch and cable by performing the preceding steps in reverse order.

8. Before placing the truck back into operation, test it to be sure the switch functions properly. (See “Seat Switch” on page 2-17.)

4-38

F-985-0219

TABLE OF CONTENTS

Chapter 5

Bendi B3/30 AC Calibration and Programming Controller Theory of Operation The Bendi B3/30 truck uses Curtis controllers that convert DC battery power to 3-phase AC power by precisely controlling the induction drive for high bandwidth, efficiency and low ripple torque generation.

Below is shown the Dash Display for reference: Button #1 “Enter Key” - Used to Enter the Calibration Mode and to make selections after they are located.

Display directions: Hold the enter button down until the change is accepted.

Button #2 “Up Key” - Moves “Up” through the selections.

Button #3 “Down Key” -Move “Down” through the selections.

The following parameters can be adjusted through the dash display: • Maintenance Monitor - Used to set the hour meter value at which the operator will be alerted that service is required, NXT SVC DUE. When the truck meets or exceeds the value entered in this section, “SERVICE DUE” will be shown on the display. If this feature is not desired, set the value to the factory default of 99900 hrs. Use the Up/Down arrows to manipulate the values by the hundreds.

• Steer Potentiometer (POT) Setup - Used to calibrate the steering position potentiometer.

• Accelerator Potentiometer (POT) Setup - Used to calibrate the accelerator potentiometer.

• Lift Potentiometer (POT) Setup - Used to calibrate the lift potentiometer.

• Brake Potentiometer (POT) Setup - Used to calibrate the brake potentiometer.

• Lift Lockout Setup - This parameter allows for adjustment of the battery capacity percentage where lift lockout is initiated.

IMPORTANT When replacing the steering, brake, acceleration or lift potentiometer maintenance has been performed, re-calibration of the Bendi B3/30 is required.

Figure 5-1: Dash Display

5-1

TABLE OF CONTENTS BENDI B3/30 AC CALIBRATION AND PROGRAMMING Truck calibration is performed by activating the key switch and performing the following procedure: Follow flow chart in Figure 5-1.

1. At the Main Screen, press and hold the ENTER button for approximately 5 seconds. This will open the main menu. “TRUCK SETUP”.

2. An “Asterisk” will show your selection - Use the Up/Down arrows to move to the next selection.

Hold down ENTER to select.

3. Truck Setup now will display the password screen.

4. To enter the password, use the Up/Down arrows to manipulate the value to the desired digit and press ENTER. Repeat this process for each digit. After entering the correct password, the truck setup menu will be displayed.

Note: The default password is: 4 2 3 1.

5. If use of Maintenance Monitor is desired, navigate to “MAINT MONITOR” selection and adjust the Service Due Hour Meter value as you require.

6. STEER POT SETUP: Navigate to Steer POT SETUP on the main menu and press enter. Press ENTER again to begin calibration • The asterisk moves to the right indicating your selection. (The location of (*) defines current stage of calibration) • Steer truck fully left and press ENTER. Turn Steer to straight selection and hit ENTER. Steer the truck to the right position & press ENTER. • This completes the STEER POT SETUP. 7. ACCEL POT SETUP: Navigate to ACCEL POT SETUP on the main menu and press enter. Press ENTER again to begin calibration.

• ACCEL ZERO calibration - Ensure the foot pedal is in the up position and press ENTER. • ACCEL FULL - Press the pedal to the floor and press ENTER. Monitor the accelerator pot voltage on the screen; ensure this value is changing with movement of the pedal between .1VDC and 5.2VDC. • This completes the ACCELERATOR POT SETUP. 8. LIFT POT SETUP: Select LIFT POT SETUP from the truck setup menu and press ENTER. Press ENTER again to begin calibration.

• LIFT LEVER ZERO - Ensure the lift lever is in the neutral position and press ENTER. • LIFT LEVER FULL - Pull the lift lever back completely and press ENTER. Monitor the lift pot voltage on the screen; ensure this value is changing with movement of the lever between .1VDC & 5.2V. 9. BRAKE POT SETUP: Select BRAKE POT SETUP from the truck setup menu and press ENTER. Press ENTER again to begin calibration.

5-2

•

BRAKE PEDAL ZERO - Ensure the brake pedal is in the up position and press ENTER. • BRAKE PEDAL FULL - Press the brake pedal to the floor and press ENTER. Monitor the brake pot voltage on the screen; ensure this value is changing with movement of the pedal between .1VDC and 5.1VDC. This completes the BRAKE POT SETUP. 10. LIFT/LOCKOUT SETUP: Select LIFT LOCKOUT from the truck setup menu and press enter. Press ENTER again to begin editing.

11. Use the Up/Down arrows to manipulate the value to the desired percentage and press enter to store the new value. This completes the LIFT/LOCKOUT. 0DLQ 0HQX 758&. 6(783 /&' &2175$67 (;,7 3$66:25' (;,7 ³3DVVZRUG 2N´ /&' &2175$67 $'-867 &2175$67 (;,7

0$,17 021,725 67((5 327 6(783 $&&(/ 327 6(783 /,)7 327 6(783 %5$.( 327 6(783 /,)7 /2&.287 6(783 (;,7 9(+,&/( +56 1;7 69& '8( (;,7

0DLQW 0RQLWRU 6XE 0HQX

67((5 )8// /()7 67((5 &(17(5 67((5 )8// 5,*+7 67((5 327 9'& (;,7

6WHHU 3RW 6HWXS 6XE 0HQX

$&&(/(5$725 =(52 $&&(/(5$725 )8// $&&(/ 327 9'& (;,7

$FFHO 3RW 6HWXS 6XE 0HQX

/,)7 /(9(5 =(52 /,)7 /(9(5 )8// /,)7 327 9'& (;,7

/LIW 3RW 6HWXS 6XE 0HQX

%5$.( 3('$/ =(52 %UDNH 3RW 6HWXS %5$.( 3('$/ )8// 6XE 0HQX %5$.( 327 9'& (;,7 /,)7 /2&.287 (;,7

Figure 5-2: Display Hierarchy

F-985-0219

TABLE OF CONTENTS BENDI B3/30 AC CALIBRATION AND PROGRAMMING

1314 Bendi B3/30 Controller Software Program Installation and Operation The 1314 Controller Software is used to monitor, configure and diagnose the Bendi B3/30 Forklift performance and functions.

The following sections will guide you through the installation of the 1314 Controller Programming Station and explain the software program functionality.

The Curtis 1309 Dongle is used to connect your laptop computer to the forklift controllers. See Figure 5-3

Figure 5-4: Serial Communication Ports

Curtis 1309 Dongle Figure 5-3: Curtis 1309 Dongle The serial communication ports (Pump Serial and Traction Serial) are located in the fuse panel on the right side of the forklift. See Figure 5-4

5-3

TABLE OF CONTENTS BENDI B3/30 AC CALIBRATION AND PROGRAMMING

Software Installation Procedure In order to work with the controllers used on the Bendi B2-30 Series 5 forklift, Curtis 1314 software version 4.6.5 or later must be used. To download the software, log into the dealer portal website on www.landoll.com. If you do not have a log in, you can request one on the Landoll website.

• -> Bendi_B3-30_AC_DS_Series_5 • -> Software.

3. Click on the folder “1314-4402-OEM_4_6_5” to download the installation file.

4. Once the installation file is downloaded, double click it to run the software setup.

Follow the on-screen prompts to install the 1314 software.

Once on the dealer portal: 1. Click on the Dealer Resources tab.

2. Select: • Forklift Service Materials

5-4

F-985-0219

TABLE OF CONTENTS BENDI B3/30 AC CALIBRATION AND PROGRAMMING

1314 Software Features and Functionality

1.

2.

3.

4.

5.

Menu Bar Tool Bar Views Navigation Bar Working Area Status Bar

Menu The Menu Bar provides you with the functions available. Depending on the access level, some menus are not available.

While connected to the system or while the program is loaded, not all menus are activated.

5-5

TABLE OF CONTENTS BENDI B3/30 AC CALIBRATION AND PROGRAMMING

5-6

Tool Bar

Views Navigation Bar

1. Connect • Connect the 1314 software to an active controller.

2. Disconnect • Disconnect the 1314 software from an active controller.

3. Refresh • Refresh the data from the connected controller.

4. Open • Open a previously saved .cpf parameter file.

5. Save • Save the parameters of the currently connected controller to the .cpf file.

6. Save to Connected System • Save the opened .cpf file parameter values to the currently connected controller.

• Also called “cloning” a program.

1. System Information • Gives information about the connected system, such as controller model (pump, traction) and code revision.

2. Parameters • Shows all the parameters available to monitor for tuning and editing.

3. Monitor • Shows all parameters available to monitor for tuning and diagnostics.

4. Diagnostics • Shows all the active and historic vehicle faults.

F-985-0219

TABLE OF CONTENTS BENDI B3/30 AC CALIBRATION AND PROGRAMMING

Working Area The content of this area varies depending on the selected view. This is the area used to view and edit parameters and diagnostic values.

Status Bar This area displays the status of the connected controller.

5-7

TABLE OF CONTENTS BENDI B3/30 AC CALIBRATION AND PROGRAMMING

Communicating with the Bendi B3-30 Series 5 Controllers To initiate communication with the Bendi B-3-30 Series 5 Controllers, first make sure that the Curtis 1309 Dongle is connected between the correct diagnostic port on the truck harness and our laptop and that the forklift is powered on.

Bendi B3-30 Series 5 Parameters (See spreadsheets at the end of this chapter for a list of all available parameters for each of the controllers on the Bendi B3-30 Series 5 forklift.)

Programming Bendi B3-30 Series 5 Controllers To program the Bendi B3-30 Series 5 Controllers, first download the correct software files from the Landoll Dealer Portal Website. (Note: the image below is just an example, the actual file names may differ from what is shown below.)

5-8

F-985-0219

TABLE OF CONTENTS BENDI B3/30 AC CALIBRATION AND PROGRAMMING

Programming Bendi B3-30 Series 5 Traction and Pump Controllers Connect the Curtis 1309 Dongle to the diagnostic port on the forklift harness that corresponds to the controller you wish to flash. Make sure the forklift is powered on. Locate the correct software file and double click to open the programming software (See Image Below). Before the software can load, a Security Warning box may pop-up, if so, click run.

Click on the Comms Button, select “Set Comm Port” and then select the Comm port that your Curtis 1309 Dongle is connected to. If you are unsure which port to select, you will be able to change this later and can try different ports until you locate the correct one.

Next click on the Flash button. If you have selected to correct Comm port the flashing process will start. If not, repeat the previous step and select a different Comm port. Repeat this as necessary until the flashing process starts.

Once the flashing process is complete, click on Defaults and then select “Update both user and OS defaults”. Once the defaults have been successfully updated, continue updating other controllers as needed. Once all controllers have been programmed (as needed), key the forklift off then back on.

5-9

TABLE OF CONTENTS BENDI B3/30 AC CALIBRATION AND PROGRAMMING

Programming Bendi B3-30 Series 5 Front I/O Modules Connect the Curtis 1309 Dongle to the diagnostic port on the forklift harness that corresponds to the controller you wish to flash. Make sure the forklift is powered on. Open the Curtis 1314 software.

Note: The 1314 software must be version 4.6.5 or later to work with the Bendi Series 6 forklift controller software.

Once the software is opened, click on the “Connect” button from the Tool Bar to connect to the controller. Click on the “Open” button from the Tool Bar.

When the pop up box appears, locate the correct downloaded software file for the controller you wish to program, select it and click “Open”.

Once the file is opened, click on the “Clone” button in the Tool Bar

5-10

F-985-0219

TABLE OF CONTENTS BENDI B3/30 AC CALIBRATION AND PROGRAMMING A pop-up window will appear, click the check box next to “Advanced Cloning”. (Below left image).

When you click on the check box, another pop-up will appear, click OK to close it. (Above right image.)

On the “Cloning” pop-up, click OK. (Below left image.)

\

A final pop-up box will appear, click OK to begin the cloning process. (Above right image.)

5-11

TABLE OF CONTENTS BENDI B3/30 AC CALIBRATION AND PROGRAMMING During the cloning process, the box on the screen will tell you to turn the truck off. When this happens, turn the truck key switch off.

Wait until the screen tells you to turn the truck back on, then turn the truck key switch on.

5-12

F-985-0219

TABLE OF CONTENTS BENDI B3/30 AC CALIBRATION AND PROGRAMMING When the cloning process is complete, the screen will tell you it was successfully cloned. Click “Close” to close the cloning pop up box.

Curtis Controller Troubleshooting IMPORTANT The following troubleshooting chart provides information on the Curtis controller faults: • Fault code • Fault name displayed on the Dash Display • The effect of the fault • Possible causes of the fault • Fault set conditions • Fault clear conditions •

NOTE Whenever a fault is encountered and no wiring or vehicle fault can be found, shut off the key switch and turn it back on to see if the fault clears. If it does not, shut off the key switch and remove the 35-pin connector. Check the connector for corrosion, damage, or unseated terminals.

Clean, and if necessary, re-insert it.

TYPES OF LED DISPLAY

Display Neither LED illuminated Yellow LED flashing Yellow and red LED’s both on solid Red LED on solid

Red LED and yellow LED flashing alternately

Status Controller is not powered on; or vehicle has dead battery; or sever damage.

Controller is operating normally.

Controller is in Flash program mode.

Watchdog failure or no software loaded. Cycle key switch to restart, and if necessary load software.

Controller has detected a fault.

2-digit code is flashed by yellow LED identifies the specific fault; one or two flashes by red LED indicate whether first or second code digit will follow.

5-13

TABLE OF CONTENTS BENDI B3/30 AC CALIBRATION AND PROGRAMMING

Program Troubleshooting Chart C O D E 12

13

14

15

16

17

PROGRAMMER LCD DISPLAY Controller Overcurrent ShutdownMotor; ShutdownMainContactor; ShutdownEMBrake; ShutdownThrottle; FullBrake; ShutdownPump Current Sensor Fault ShutdownMotor; ShutdownMainContactor; ShutdownEMBrake; ShutdownThrottle; FullBrake; ShutdownPump.

Precharge Failed ShutdownMotor; ShutdownMainContactor; ShutdownEMBrake; ShutdownThrottle; FullBrake; ShutdownPump.

Controller Severe Undertemp ShutdownMotor; ShutdownMainContactor; ShutdownEMBrake; ShutdownThrottle; FullBrake; ShutdownPump.

Controller Severe Overtemp ShutdownMotor; SutdownMainContactor; ShutdownEMBrake; ShutdownThrottle; FullBrake; ShudownPump.

Severe Undervoltage Reduced drive torque.

T P X

X

POSSIBLE CAUSE 1. External short of phase U, V, or W 2.

3.

X

X

1. Leakage to vehicle frame from

2.

X

X

X

X

3.

4.

X

Temperature.

Controller is operating in an extreme environment.

Excessive load on vehicle.

Improper mounting of controller.

1. Battery Menu parameters are 2.

3.

4.

5.

6.

5-14

Temperature.

Controller is operating in an extreme environment.

1. See Monitor menu » Controller: 2.

X

Capacitor Voltage.

External load on capacitor bank (B+ connection terminal) that prevents the capacitor bank from charging.

1. See Monitor menu » Controller: 2.

X

phase U, V, or W (shot in motor stator).

Controller defective.

1. See Motor menu » Battery: 2.

X

motor connections.

Motor parameters are mis-tuned.

Controller defective.

misadjusted.

Non-controller system drain on battery.

Battery resistance too high.

Battery disconnected while driving.

See Monitor menu » Battery: Capacitor Voltage.

Blown B+ fuse or main contactor did not close.

SET/CLEAR CONDITIONS Set: Phase current exceeded the current measurement limit.

Clear: Cycle key switch.

Set: Controller current sensors have invalid offset reading.

Clear: Cycle key switch.

Set: Precharge failed to charge the capacitor bank to the key switch voltage.

Clear: Cycle Interlock input or use VCL function Precharge.

Set: Heatsink temperature above +95° C. Clear: Bring heatsink temperature above -40° C, and cycle interlock or key switch.

Set: Heatsink temperature above +95° C. Clear: Bring heatsink temperature below +95° C, and cycle interlock or key switch

Set: Capacitor bank voltage dropped below the Severe Undervoltage limit with FET bridge enabled.

Clear: Bring capacitor voltage above Severe Undervoltage limit.

F-985-0219

TABLE OF CONTENTS BENDI B3/30 AC CALIBRATION AND PROGRAMMING C O D E 18

22

PROGRAMMER LCD DISPLAY

T P

Severe Overvoltage ShutdownMotor; ShutdownMainContactor; ShutdownEMBrake; ShutdownThrottle; FullBrake; ShutdownPump.

X

Controller Overtemp Cutback Reduced drive and brake torque.

X

X

POSSIBLE CAUSE

SET/CLEAR CONDITIONS

1. See Monitor menu » Battery:

Set: Capacitor bank voltage exceeded the Severe Overvoltage limit with FET bridge enabled.

Clear: Bring capacitor voltage below Severe Overvoltage limit, and then cycle key switch.

2.

3.

4.

X

1.

2.

3.

23

Undervoltage Cutback Reduced drive torque.

X

X

4.

5.

1.

2.

3.

4.

5.

6.

7.

24

Overvoltage Cutback Reduced brake torque.

X

X

1.

2.

3.

4.

5.

25

+5V Supply Failure None, unless a fault action is programmed in VCL.

X

X

1.

2.

Capacitor Voltage.

Battery menu parameters are misadjusted.

Battery resistance too high for given regen current.

Battery disconnected while regen braking.

See Monitor menu » Controller: Temperature.

Controller is performance-limited at this temperature.

Controller is operating in an extreme setting.

Excessive load on vehicle.

Improper mounting of controller.

Normal Operation. Fault shows that the batteries need recharging.

Controller is performance limited at this voltage.

Battery parameters are misadjusted.

Non-controller system drain on battery.

Battery resistance too high.

Battery disconnected while driving.

See Monitor menu » Battery: Capacitor Voltage.

Blow B+ fuse or main contactor did not close.

Normal operation. Fault shows that regen braking currents elevated the battery voltage during regen braking. Controller is performance limited at this voltage.

Battery parameters are misadjusted.

Battery resistance too high for given regen current.

Battery disconnected while regen braking.

See Monitor menu » Battery: Capacitor Voltage.

External load impedance on the +5V supply (pin 26) is too low.

See Monitor menu » Outputs: 5 Volts and Ext Supply Current.

Set: Heat sink temperature exceeded 85° C. Clear: Bring heat sink temperature below 85° C.

Set: Capacitor bank voltage dropped below the Undervoltage limit with the FET bridge enabled.

Clear: Bring capacitor voltage above the undervoltage limit.

Set: Capacitor bank voltage exceeded the Overcoltage limit with the FET bridge enabled.

Clear: Bring capacitor voltage below the Overvoltage limit.

Set: +5V supply (pin 26) outside the +5V ± 10% range.

Clear: Bring voltage within range.

5-15

TABLE OF CONTENTS BENDI B3/30 AC CALIBRATION AND PROGRAMMING C O D E 28

PROGRAMMER LCD DISPLAY MotorTemp Hot Cutback Reduced drive torque.

T P X

POSSIBLE CAUSE

SET/CLEAR CONDITIONS

X

1. Motor temperature is at or above

Set: Motor temperature is at or above the Temperature Hot parameter setting.

Clear: Bring the motor temperature within range.

X

the programmed Temperature Hot setting, and the requested current is being cut back.

Motor Temp Control Menu parameters are mis-tuned.

See Monitor menu » Motor: Temperature and » Inputs: Analog2.

If the application doesn’t use a motor thermistor, Temp Compensation and Temp Cutback should be programmed Off. Motor thermistor is not connected properly.

If the application doesn’t use a motor and motor thermistor, Motor Temp Sensor Enable shoudl be programmed Off. See Monitor menu » Motor: Temperature and » Inputs: Analog2.

Open or short on driver load.

Dirty connector pins.

Bad crimps or faulty wiring.

2.

3.

4.

29

MotorTemp Sensor Fault MaxSpeed reduced (LOS, Limited Operating Strategy), and motor temperature cutback disabled.

X

1.

2.

3.

31

Coil1 Driver Open/Short ShutdownDriver1.

X

X

1.

2.

3.

36

Encoder Fault ShutdownEMBrake.

X

X

1. MotorCoil3 Driver Open/Short ShutdownDriver3. encoder failure.

2. Bad crimps or faulty wiring.

3. See Monitor menu » Motor: Motor 37

38

5-16

Motor Open ShutdownMotor; ShutdownMainContactor; ShutdownEMBrake; ShutdownThrottle; FullBrake; ShutdownPump.

Main Contactor Welded ShutdownMotor; ShutdownMainContactor; ShutdownEMBrake; ShutdownThrottle; FullBrake; ShutdownPump.

RPM. Motor phase is open.

Bad crimps or faulty wiring.

X

X

1.

2.

X

X

1. Main contactor tips are welded 2.

3.

closed.

Motor phase U or V is disconnected or open.

An alternate voltage path (such as an external precharge resistor) is providing a current to the capacitor bank (B+ connection terminal).

Set: Motor thermistor input (pin8) is at the votlage rail (0 or 10V).

Clear: Bring the motor thermistor input voltage within range.

Set: Main contactor driver (pin 6) is either open or shorted. This fault can be set only when Main Enable = Off Clear: Bring the motor thermistor input voltage within range.

Set: Motor encoder phase failure detected.

Clear: Cycle key switch.

Set: Motor phase U, V, or W detected open.

Clear: Cycle key switch.

Set: Just prior to the main contactor closing, the capacitor bank voltage (B+ connection terminal) was loaded for a short time and the voltage did not discharge.

Clear: Cycle key switch.

F-985-0219

TABLE OF CONTENTS BENDI B3/30 AC CALIBRATION AND PROGRAMMING C O D E 39

41

PROGRAMMER LCD DISPLAY

T P

Main Contactor Didn’t close ShutdownMotor; ShutdownMainContactor; Shutdown EMBrake; ShutdownThrottle; Fullbrake; ShutdownPump

X

Throttle Wiper High ShutdownThrottle.

X

X

POSSIBLE CAUSE

SET/CLEAR CONDITIONS

1. Maincontactor did not close.

2. Main contactor tips are oxidized,

Set: With the main contactor commanded closed, the capacitor bank voltage (B+ connection terminal) did not charge to B+.

Clear: Cycle key switch.

3.

X

4.

1.

2.

42

Throttle Wiper Low ShutdownThrottle;

X

X

burned, or not making good contact.

External load on capacitor bank (B+ connection terminal) that prevents capacitor bank from charging.

Blown B+ fuse.

See Monitor menu >> Inputs: Throttle Pot. Throttle pot wiper voltage too high.

1. See Monitor menu >> Inputs: ThrottlePot.

2. Throttle pot wiper voltage too high.

43 44 45

Pot2 Wiper High FullBrake.

Pot2 Wiper Low FullBrake.

Pot Low Overcurrent ShutdownThrottle. FullBrake ShutdownSteer

X

1. Refer to Curtis

X

1. Refer to Curtis

EEPROM Failure ShutdownMotor; ShutdownMainContactor; Shutdown EMBrake; ShutdownThrottle; ShutdownInterlock;Shutdow nDriver1 ShutdownDriver2;Shutdown driver3; ShutdownDriver4;Shutdown PD; Fullbrake; ShutdownPump; TrimDisable;SevereDual; ShutdownSteer; LOSDual HPD/Sequecing Fault.

Shutdown Throttle

X

X

X

1. See Monitor menu » Outputs: Pot Low.

2. Combined pot resistance connected to pot low is too low.

46

47

X

1. Failure to write to EEPROM memory. This can be caused by EEPROM memory writes initiated

by VCL, by the CAN bus, by adjusting parameters with the programmer, or by loading new software into the controller.

1. KSI, interlock, direction, and

2.

throttle inputs applied in incorrect sequence.

Bad crimp, faulty wiring or KSI switch. See Monitor menu » Inputs.

Set: Throttle pot wiper (pin 16) voltage is higher than the high fault threshold (can be changed with the VCL function SETUP POT FAULTS) Clear: Bring throttle pot wiper voltage above the fault threshold.

Set: Throttle pot wiper (pin 16) voltage is higher than the high fault threshold (can be changed with the VCL function Setup_Pot_Faults). Clear: Bring throttle pot wiper voltage below the fault threshold.

Return Controller to Landoll Company, LLC for evaluation.

Return Controller to Landoll Company, LLC for evaluation.

Set: Pot low (pin 18) current exceeds 10mA. Clear: Clear pot low overcurent condition and cycle key switch.

Set: Controller operating system tried to write to EEPROM memory and failed.

Clear: Download the correct software (OS) and matching parameter default settings into the controller and cycle key switch.

Set: HPD (High Pedal Disable) or sequencing fault caused by incorrect sequence if key switch, interlock, direction and throttle inputs.

Clear: Reapply correct input sequence.

5-17

TABLE OF CONTENTS BENDI B3/30 AC CALIBRATION AND PROGRAMMING C O D E 49

52

68

69

71

72

5-18

PROGRAMMER LCD DISPLAY Parameter Change Fault ShutdownMotor; ShutdownEMBrake; Shutdown Throttle; Fullbrake; ShutdownPump Battery Rollout Switch Fault in Left traction controller.

VCL Run Time Error ShutdownMotor; ShutdownMainContactor; ShutdownEMBrake; ShutdownThrottle; ShutdownInterlock; ShutdownDriver1; ShutdownDriver2; ShutdownDriver3: ShutdownDriver4; ShutdownPD; FullBrake; ShutdownPump.

ShutdownPump: TrimDisable; SevereDual; ShutdownSteer; LOSDual.

External Supply Out of Range None, unless a fault action is programmed in VCL;

OS General ShutdownMotor; ShutdownMainContactor; ShutdownEMBrake; ShutdownThrottle; ShutdownInterlock; ShutdownDriver1;Shutdown Driver2; ShutdownDriver3;Shutdown Driver4; ShutdownPD; FullBrake:Shutdown Pump; TrimDisable; SevereDual;Shutdown Steer; LOSDual PDO TImeout Shutdown Interlock; CAN NMT State set to Pre-operational

T P X

X

X

X

POSSIBLE CAUSE 1.

SET/CLEAR CONDITIONS Set: Adjustment of a parameter setting that requires cycling of key switch.

Clear: Cycle key switch.

1. This is a safety fault caused by a change in certain parameter settings so that the vehicle will not operate until KSI is cycled. For example, if a user changes the Throttle Type, this fault will appear and require cycling KSI before the vehicle can operate.

X

X

X

X

1. Internal Controller fault.

X

X

1. Time between CAN PDO messages received exceeded the PDO Timeout Period.

Return Controller to Landoll Company, LLC for evaluation.

Set: Runtime VCL code error condition.

Clear: Edit VCL application software to fix this error condition; flash the new compiled software and matching parameter defaults; cycle key switch.

Set: The external supply current (combined current used by the 5V supply [pin 26} and 12V supply {pin 25}) is either greater than the upper current threshold or lower than the low current threshold. The two thresholds are defined by the External Supply Max and External Supply Min parameter settings.

Clear: Bring the external supply current within range.

Set: Internal controller fault detected.

Clear: Cycle key switch.

Set: Time between CAN PDO messages received exceeded the PDO Timeout Period.

Clear: Cycle key switch or receive CAN NMT message.

F-985-0219

TABLE OF CONTENTS BENDI B3/30 AC CALIBRATION AND PROGRAMMING C O D E 73

74

75

91

93

PROGRAMMER LCD DISPLAY

T P X

POSSIBLE CAUSE 1.

2.

3.

4.

Stall Detected ShutdownMotor; SevereDual; ShutdownEMBrake; Control Mode changed to LOS (Limited Operating Strategy)

X

Fault On other Traction Controller For information on this fault, plug the programmer into the other controller.

Dual Severe Fault ShutdownMotor; ShutdownMainContactor ShutdownEMBrake; Shutdown Throttle; FullBrake; Shutdown Pump Other controller: Same effects as this controller.

VCL/OS Mismatch ShutdownMotor; ShutdownMainContactor; ShutdownEMBrake; ShutdownThrottle; ShutdownInterlock; ShutdownDriver1; ShutdownDriver2; ShutdownDriver3; ShutdownDriver4; ShutdownPD; FullBrake; ShutdownPump Encoder LOS (LimitedOperatingStrategy).

Enter LOS control mode.

X

X

1.

X

X

1. Both traction controllers have

5.

active severe faults and therefore both will be disabled.

1. The VCL software in the controller does not match the OS software in the controller.

1.

1. 1. Limited Operating Strategy

2.

3.

4.

98

Illegal Model Number ShutdownMotor; ShutdownMainContactor; ShutdownEMBrake; ShutdownThrottle; FullBrake; ShutdownPump.

Stalled motor.

Motor encoder failure.

Bad crimps or faulty wiring.

Problems with power supply for the motor encoder.

See Monitor menu » Motor: Motor RPM. A fault is active on the other traction controller.

X

X

(LOS) control mode has been activated, as a result of either an Encoder Fault (Code 36) or a Stall Detect Fault (Code 73).

Motor encoder failure.

Bad crimps or faulty wiring.

Vehicle is stalled.

1. Model_Number variable contains

2.

3.

illegal value (not 1234, 1236, 1238, or 1298).

Software and hardware do not match.

Controller defective.

SET/CLEAR CONDITIONS Set: No motor encoder movement detected.

Clear: Either cycle key switch, or detect valid motor encoder signals while operating in LOS mode and return Throttle Command=) and Motor RPM=0.

Set: In a Dual Drive traction system, any fault in the other traction controller will cause this fault to be set.

Clear: Clear all the active faults in the other traction controller.

Set: A severe fault in each traction controller will cause this fault to be set.

Clear: Correct the severe fault(s) in either controller to clear the Dual Severe Fault; of course, you will want to clear all faults on both controllers.

Set: VCL and OS software do not match when key switch cycles, a check is made to verify that they match and a fault is issued when they don’t.

Clear: Download the correct VCL and OS software into the computer.

Set: Encoder Fault (Code 36) or Stall Detect Fault (Code 73) was activated, and Brake or Interlock has been applied to activate LOS control mode, allowing limited motor control.

Clear: Cycle key switch or, if LOS mode was activated by the Stall Fault, clear by ensuring encoder senses proper operation, Motor RPM=0, and Throttle Command=0.

Set: Illegal Model_Number variable; when KSI cycles, a check is made to confirm a legal Model_Number, and a fault is issued if one is not found.

Clear: Download appropriate software for your controller model.

5-19

TABLE OF CONTENTS BENDI B3/30 AC CALIBRATION AND PROGRAMMING

Master Controller Parameter

Definition

Range

Default

The time (in seconds) that the seat switch input can be false until an SRO (return to neutral) fault occurs.

The time (in seconds) that the pump will continue to run after the seat switch input is false.

The level of battery discharge at which lift lockout occurs.

0.0 - 5.0 Seconds

2.0

0.0 - 30.0 Seconds

10.0

0 - 99%

20

0 - 100%

100

0 - 100%

16

0 - 100%

91

0 - 100%

16

Program Landoll Traction HPD Sequencing Delay

Steering Off Delay Lift Lockout LevelF-985-0219

Multimode Functions Rabbit Fwd Max Speed Turtle Fwd Max Speed Rabbit Rev Max Speed Turtle Rev Max Speed

5-20

The maximum forward vehicle speed when the mode switch is in Rabbit Mode.

The maximum forward vehicle speed when the mode switch is in Turtle Mode.

The maximum reverse vehicle speed when the mode switch is in Rabbit Mode.

The maximum reverse vehicle speed when the mode switch is in Turtle Mode.

F-985-0219

TABLE OF CONTENTS BENDI B3/30 AC CALIBRATION AND PROGRAMMING

Hour Meter Set Total HM

10s of Hours

Remaining HRs in Mins

Sets the reset hourmeter flag to send the hourmeter parameters to the other controllers.

The value of truck hours/10. This parameter works in conjunction with "Remaining HRs in Mins" to set the total truck hours. EX. To set the truck hours to 1507.3, you would set this parameter to 150 (1507.3/10=150 with a remainder of 7.3), along with setting the "Remaining HRs in Mins" parameter as explained below.

The value of truck hours that are less than 10. This parameter works in conjunction with the "10s of Hours" parameter to set the total truck hours. Ex. To set the truck hours to 1507.3, you would set this parameter to 438 (the remaining hours from the parameter above are 7.3, so 7.3 hrs x 60 min/hr = 438 minutes).

Off - On

Off

0 - 20,000 Hours

0

0 - 600 Minutes

0

0 - 99900 hours

500

0.1 - 30.0 Seconds

3.0

0.1 - 30.0 Seconds

3.0

Maintenance Due

Next Service Due

1- Speed Mode Response Full Accel Rate HS

Full Accel Rate LS

When the hourmeter is equal to this parameter, "SRVC DUE" will be displayed on the dash display. IN addition, if "Active Maintenance” parameter is set to "ON", then the lift will be disabled until this parameter is reset. Setting this parameter to 99900 effectively sets it to off.

Note: Any changes made to the parameters in this menu must be made to both the traction and slave controllers in order to ensure smooth, safe forklift operation.

The rate (in seconds) at which the speed command increases when full throttle is applied at high vehicle speeds. Larger values represent slower response..

The rate (in seconds) at which the speed command increases when full throttle is applied at low vehicle speeds. Larger values represent slower response.

5-21

TABLE OF CONTENTS BENDI B3/30 AC CALIBRATION AND PROGRAMMING

Low Accel Rate

Neutral Decel Rate HS

Neutral Deccel Rate LS

Full Brake Rate HS

Full Brake Rate LS

Low Brake Rate

5-22

The rate (in seconds) at which the speed command increases when a small amount of throttle is applied. This rate is typically adjusted to affect low speed maneuverability.

The rate (in seconds) that is used to slow down the vehicle when the throttle is released to neutral at high vehicle speeds.

Larger values represent a less aggressive response.

The rate (in seconds) that is used to slow down the vehicle when the throttle is released to neutral at slow vehicle speeds.

Larger values represent a less aggressive response.

The rate (in seconds) that is used to slow down the vehicle when full brake is applied or when full throttle is applied in the opposite direction at high vehicle speeds.

Larger values represent a less aggressive response.

The rate (in seconds) that is used to slow down the vehicle when full brake is applied or when full throttle is applied in the opposite direction at slow vehicle speeds.

Larger values represent a less aggressive response.

The rate (in seconds) at which the vehicle slows down at all speeds when a small amount of brake is applied or when a small amount of throttle is applied in the opposite direction. Larger values represent a less aggressive response.

0.1 - 30.0 Seconds

10.0

0.1 - 30.0 Seconds

2.5

0.1 - 30.0 Seconds

7.0

0.1 - 30.0 Seconds

1.0

0.1 - 30.0 Seconds

2.5

0.1 - 30.0 Seconds

6.0

F-985-0219

TABLE OF CONTENTS BENDI B3/30 AC CALIBRATION AND PROGRAMMING

Fine Tuning Partial Decel Rate

HS (High Speed)

LS (Low Speed)

Reversal Soften

Max Speed Accel

Max Speed Decel

Current Limits

Drive Current Limit

The rate (in seconds) that is used to slow down the vehicle when the throttle is reduced without being released to neutral.

Larger values represent slower response.

Sets the percentage of the Typical Max Speed above which the HS parameters will be used.

Sets the percentage of the Typical Max Speed below which the LS parameters will be used.

Larger values create a softer reversal from regen braking to drive when near zero speed. This helps soften the transition when the regen and drive current limits are set to different values.

The rate (in seconds) at which the maximum speed setpoint is allowed to change when the value of Max Speed is raised. The rate set by this parameter is the time to ramp from 0 rpm to Typical Max Speed rpm. EX. Suppose the Max Speed is raised from 1000 rpm to 4000 rpm. If Typical Max Speed is 5000 rpm and the rate is set to 1.0 seconds, it will take 1.0 * (4000-1000) / 5000 = 0.6 seconds to ramp from 1000 rpm to 4000 rpm.

The rate (in seconds) at which the maximum speed setpoint is allowed to change when the value of Max Speed is lowered. The rate set by this parameter is the time to ramp from Typical Max Speed rpm to 0 rpm. EX. Suppose the Max Speed is lowered from 4500 rpm to 2500 rpm. If Typical Max Speed is 5000 rpm and the rate is set to 10.0 seconds, it will take 10.0 * (4500-2500) / 5000 = 4.0 seconds to ramp from 4500 rpm to 2500 rpm

0.1 - 30.0 Seconds

30.0

0-100%

70

0 - 100%

30

0 - 100%

20

0.1 - 30.0 Seconds

1.0

0.1 - 30.0 Seconds

10.0

5 - 100%

79

Note: Any changes made to the parameters in this menu must be made to both the traction and slave controllers in order to ensure smooth, safe forklift operation.

The maximum RMS current the controller will supply to the motor during drive operation, as a percentage of the controllers' full rated current. Reducing this value will reduce the maximum drive torque..

5-23

TABLE OF CONTENTS BENDI B3/30 AC CALIBRATION AND PROGRAMMING

Battery

Resets Volts Per Cell

Full Volts Per Cell

Empty Volts Per Cell

Discharge Time

BDI Reset Percent

5-24

This parameter determines the key switch voltage level that is considered 100% state of charge. Full Voltage Level = Full Volts Per Cell x # of battery cells. DO NOT modify this parameter. Changing this value from the default may result in damage to the forklift controllers.

This parameter determines the key switch voltage level that is considered 100% state of charge. Full Voltage Level = Full Volts Per Cell x # of battery cells. DO NOT modify this parameter. Changing this value from the default may result in damage to the forklift controllers.

This parameter sets the keyswitch voltage that is considered to be 0% state of charge.

Empty Voltage Level = Empty Volts Per Cell x # of battery cells. DO NOT modify this parameter. Changing this value from the default may result in damage to the forklift controllers.

The minimum time for the BDI algorithm to count down the BDI Percentage from 100% to 0%. State of Charge Level = ((Full Voltage Level - Empty Voltage Level) x BDI Percentage / 100) + Empty Voltage Level When KSI is first powered on, the BDI percentage variable will reset to 100% only if (Key Switch Voltage > Reset Voltage Level) and (BDI Percentage < BDI Reset Percent).

.90 - 3.00

2.090

.90 - 3.00

2.040

.90 - 3.00

1.710

.90 - 3.00

60

0 - 100%

75

F-985-0219

TABLE OF CONTENTS BENDI B3/30 AC CALIBRATION AND PROGRAMMING

Monitor Landoll Lift Cutout Flag Steer Pump Speed Flag Seat Switch Motor Temp Sensor Analog

On when the forklift is in Lift Lock-Out On when the direction switch is in either Forward or Reverse AND the driver is on the seat (seat switch is closed

On - Off On - Off

On when the driver is on the seat Analog input of the motor temp sensor

On - Off ?? - ?? V

On when Deep Reach has been enabled On when Hi-Lift has been enabled The steer angle (in degrees) calculated by the controller based on the steer sensor input On when Left Steer coil is active (Deep Reach Only) On when Right Steer coil is active (Deep Reach Only) On when the Reach Limit Switch is active (Reach is fully retracted, Deep Reach Only) Coil current of the extension relay (Deep Reach Only)

On - Off On - Off -90 - 90°

Deep Reach/Hi-Lift Deep Reach Enabled Hi-Lift Enabled Steer Angle Left Steer Coil Active Flag Right Steer Coil Active Flag Reach Limit Switch Flag Extension Relay Value

On - Off On - Off On - Off ?? - ?? mA

Learned Throttle and Brake Parameters Throttle Deadband Throttle Max Brake Deadband Brake Max Steer Pot Min Steer Pot Zero Steer Pot Max

Calibrated throttle minimum voltage Calibrated throttle maximum voltage Calibrated brake minimum voltage Calibrated brake maximum voltage Calibrated steer pot minimum voltage Calibrated steer pot voltage at 0 degrees Calibrated steer pot maximum voltage

1356 I/O Module

Note: These inputs are wired into the 1356 I/O module, and then the input values are sent over the CAN bus to the master controller

Battery Roll Out Switch

On when the battery retainer is correctly installed (Optional) On when the filter is full and requires service On when the parking brake is engaged On when the Lift Limit height has been reached (Optional) On when the Battery connector gate is open On when the Lift Limit Override button is pressed (Optional) Input voltage of the throttle IVS sensor. This input should be ~0.50V when the throttle is in neutral and go to ~4.50V when the throttle is moved from neutral

Filter Switch Parking Brake Switch Lift Limit Switch Battery Gate Switch Lift Limit Override Switch Throttle Sensor Ivs

0.00 - 5.00 V 0.00 - 5.00 V 0.00 - 5.00 V 0.00 - 5.00 V 0.00 - 5.00 V 0.00 - 5.00 V 0.00 - 5.00 V

On - Off On - Off On - Off On - Off On - Off On - Off 0.00 - 5.00 V

5-25

TABLE OF CONTENTS BENDI B3/30 AC CALIBRATION AND PROGRAMMING

Monitor Landoll Throttle Sensor Analog

Brake Sensor Analog

Steer Sensor Analog

Input voltage of the throttle Analog sensor.

This input should sweep from ~0.50V at neutral to ~4.50V as the throttle is pressed to the maximum position Input voltage of the brake hall effect sensor.

This input should sweep from ~0.50V at neutral to ~4.50V as the brake is pressed.

Input voltage of the steer hall effect sensor.

This input should sweep from ~0.50V to ~4.50V as the steer wheel is turned lock to lock.

0.00 - 5.00 V

0.00 - 5.00 V

0.00 - 5.00 V

1356 Valve Module

Note: These inputs are wired into the 1356 Valve module, and then the input values are sent over the CAN bus to the master controller

Forward Switch

On when the direction switch is engaged in the forward direction On when the direction switch is engaged in the reverse direction.

On when the horn switch is pressed.

On when the tilt lever is activated On when the sideshift lever is activated.

On when the auxiliary hydraulic function button is pressed. (Optional) Input voltage of the hall effect lift sensor.

Reverse Switch Horn Switch Tilt Switch SideShift Switch Aux Switch Lift Sensor Analog

On - Off On - Off On - Off On - Off On - Off On - Off 0.00 - 5.00 V

Inputs Throttle Command

Mapped Throttle

Brake Command

Mapped Brake

Steer Angle (deg) Interlock

The amount of throttle command (in percentage) that is being requested of the controller The amount of throttle command (in percentage) that is being requested of the motors, factoring in the speed settings, angle of the steer pot, etc.

The amount of brake command (in percentage) that is being requested of the controller The amount of brake command (in percentage) that is being requested of the motors, factoring in the speed settings, angle of the steer pot, etc.

The steer angle (in degrees) calculated by the controller based on the steer sensor input On if the interlock is set

-100 - 100 %

Traction Contactor PWM output The voltage of the 5V supply for the left traction motor encoder

0 - 100% 0.00 - 6.25 V

-100 - 100 %

-100 - 100 %

-100 - 100 %

-90 - 90° On - Off

Outputs Traction Contactor PWM 5 Volts

5-26

F-985-0219

TABLE OF CONTENTS BENDI B3/30 AC CALIBRATION AND PROGRAMMING

Monitor Landoll 12 Volts Ext Supply Current

The voltage of the 12V supply for the master comm port The combined current of the external 12V and 5V supplies

0.00 - 12.00 V 5 - 200 mA

Battery BDI Capacitor Voltage Keyswitch Voltage

The battery's state of charge The voltage at the controller's B+ terminal The voltage at the KSI input (pin 1)

0 - 100% 0-105 V 0-105 V

Motor Motor RPM Temperature MotorSpeed A MotorSpeed B

The motor speed The motor temperature, based on the input from the motor temp sensor The right traction motor encoder phase A speed. This should be equal to MotorSpeed B. The right traction motor encoder phase B speed. This should be equal to MotorSpeed A.

-12000 - 12000 RPM -100 - 300°

RMS curren tof the controller, taking all three phases into account Controller internal temperature

0 - 1000 A

0 - 12000 RPM 0 - 12000 RPM

Controller Current (RMS) Temperature Main State

Regen VCL Error Module VCL Error

Main Contactor State: 0 = Open 1 = Precharge 2 = WeldCheck 3 = ClosingDelay 4 = MissingCheck 5 = Closed (when Main Enable = On) 6 = Delay 7 = ArcCheck 8 = OpenDelay 9 = Fault 10 = Closed (when Main Enable = On) On when regen braking is taking place; Off when it is not Shows the value of a VCL Runtime Error (Fault code 68) Shows the value of a VCL Runtime Error (Fault code 68)

-100 - 300 °C 0 - 10

On - Off 0 - 65536 0 - 65536

Cutbacks

Note: For any cutback parameter, a value of 100% indicates no cutback in current.

Motor Temp Cutback

Available current as a result of the motor temperature cutback function.

0 - 100%

5-27

TABLE OF CONTENTS BENDI B3/30 AC CALIBRATION AND PROGRAMMING

Monitor Landoll Controller Temp Cutback Undervoltage Cutback Overvoltage Cutback

Available current as a result of the controller temperature cutback function Available current as a result of the undervoltage cutback function Available current as a result of the overvoltage cutback function

0 - 100% 0 - 100% 0 - 100%

Vehicle Vehicle Speed

Vehicle speed. For accurate speed estimates, the Speed to RPM parameter must be set correctly

-327.7 - 327.7

CAN Status CAN Node ID CAN NMT State

Displays the controller's Node ID Controller CAN NMT state: 0 = Initialization 4 = Stopped 5 = Operational 127 = Pre-Operational

0 - 127 0 - 127

Controller Maintenance

Controller Cleaning

There are no user serviceable parts in the Curtis 1234/36/38 controllers. No attempt should be made to open, repair, or modify the controller. Modifying the controller will void the warranty. It is recommended that the controller and connection be kept clean and dry and that the controller’s fault history file be checked and cleared during service.

Periodically cleaning the controller exterior will help protect it against corrosion and possible electrical problems created by dirt that is part of the operating environment and that normally exists in battery powered systems. When working around any battery powered system, proper safety precautions should be taken. These include, but are not limited to: proper training, wearing eye protection, and avoiding loose clothing and jewelry.

IMPORTANT Never use a pressure washer to clean the controller.

Use the following cleaning procedure for routine maintenance: 1. Remove power by disconnecting the battery.

2. Discharge the capacitors in the controller by connecting a load across the controller’s B+ and B terminals.

3. Remove any dirt or corrosion from the power and signal connector areas. The controller should be wiped clean with a moist rag. Dry it before reconnecting the battery.

4. Make sure the connections are tight.

5-28

F-985-0219

TABLE OF CONTENTS

Chapter 6

Supplier Provided Documentation Disclaimer: The documentation provided here within Chapter 9, “Supplier Provided Documentation,” has been appended to this Landoll Maintenance Manual for reference only.

The specific contents of this information is not the responsibility of Landoll Company, LLC or any of it’s affiliates.

Lift Technologies Mast Service Manual Models 30D/35D/40D/50D/55D/60D

6-1

TABLE OF CONTENTS SUPPLIER PROVIDED DOCUMENTATION

6-2

F-985-0219

Date

Revision

Improvement(s) Description and Comments

01/31//2019

F-985-0219

New Manual - GG

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

Bendi B3-30AC/DS Series 5 Maintenance Manual

Re-Order Part Number F-985-0219

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

®

Copyright 2019. Landoll Company, LLC “All rights reserved, including the right to reproduce this material or portions thereof in any form.”

F-985-0219