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

ELECTRIC NARROW AISLE FORKLIFT

OPERATOR’S MANUAL BENDI SERIES IV MODELS B25-4/42-180D B30-4/42-180D

B35-4/48-180D B40-4/48-180D

LANDOLL CORPORATION Material Handling Products Group 1900 North Street Marysville, Kansas 66508 Telephone (785)562-5381· FAX: (785)562-4853 www.Landoll.com · MHProd@Landoll.com MATERIAL HANDLING PRODUCTS

Publication No. F-370-0304

Table of Contents Table of Contents Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-1 Terminology Used in Manual . . . . . . . . . . . . . . . . . . . . . . . . . . S-2 Illustrations Used in Manual . . . . . . . . . . . . . . . . . . . . . . . . . . S-2 The Meaning of Safety Statements. . . . . . . . . . . . . . . . . . . . . . . S-3 Bendi Forklift Safety Statements . . . . . . . . . . . . . . . . . . . . . . . . S-3

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Vehicle Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Identification Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Operator Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Operator Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Understanding Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Tilting Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Understanding Workplace Conditions . . . . . . . . . . . . . . . . . . . . . 2-8 Working in Hazardous Environments . . . . . . . . . . . . . . . . . . . . . . 2-9

Operating Your Bendi Forklift . . . . . . . . . . . . . . . . . . . . 3-1 Operator’s Daily Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Operating Instructions - Basic Procedures . . . . . . . . . . . . . . . . . . 3-10 Operating Instructions – Handling a Load. . . . . . . . . . . . . . . . . . . 3-14 Unloading Your Forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Using Lifting Equipment to Move a Forklift to Another Location . . . . . . . 3-23

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Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . 4-1 Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Inspection and Maintenance Responsibilities . . . . . . . . . . . . . . . . . 4-3 Inspection and Maintenance Practices . . . . . . . . . . . . . . . . . . . . . 4-5 Inspecting Specially Equipped Bendi Forklift Trucks . . . . . . . . . . . . . . 4-8 Identification Plate and Safety Warnings . . . . . . . . . . . . . . . . . . . . 4-8 Repairing and Load Testing Forks . . . . . . . . . . . . . . . . . . . . . . . 4-9 Battery Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Hydraulic System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Transmission Fluid Change . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Power Steering System Maintenance . . . . . . . . . . . . . . . . . . . . . 4-14 Tire and Wheel Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Mast Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Side Shift Circuit Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Troubleshooting Your Bendi Forklift. . . . . . . . . . . . . . . . . 5-1 Standard Bendi Forklift Specifications . . . . . . . . . . . . . . . 6-1 Appendix A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 Appendix B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

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

After you review this section you will understand the meaning of the following safety symbols and safety statements: · Safety Alert Symbol · Danger · Warning · Caution · Note

Bendi Series IV Forklift Operator’s Manual S-1

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

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

You will note that each illustration has an identifying numeral Figure 1 below the illustration frame and each item in the illustration that is referenced to the text is identified with a number 1.

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

Figure S-1

The brake pedal (item 2) Figure S-1 is located on the floor to the left of the accelerator pedal.

Bendi Series IV Forklift Operator’s Manual S-2

SAFETY The Meaning of Safety Statements

Bendi Forklift Safety Statements

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

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

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

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

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

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

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

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

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

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

Bendi Series IV Forklift Operator’s Manual S-3

SAFETY

Figure S-2

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SAFETY

1 2 5

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Figure S-3 Decals

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SAFETY

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Figure S-4 Decals

Bendi Series IV Forklift Operator’s Manual S-6

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

Safe and efficient forklift operation requires skill and alertness.

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

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

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

Bendi Series IV Forklift Operator’s Manual 1-1

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

Bendi forklifts are available in capacities from 2,500 to 4,000 lbs. The front end can be pivoted 180 degrees. This permits the vehicle to act as a conventional as well as a narrow aisle forklift.

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

1. Forks 2. Load Backrest 3. Mast 4. Load Wheels

Figure 1-1

5. Drive Wheels 6. Overhead Guard 7. Steering Column

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

Bendi Series IV Forklift Operator’s Manual 1-2

SECTION 2 Before You Begin This section of your Bendi Forklift Operator’s Manual discusses the following concepts that must be thoroughly understood before you can operate a Bendi forklift: Operator training - Discusses the operator training required by legislation and its implications for operators of Bendi forklifts.

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

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

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

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

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

Bendi Series IV Forklift Operator’s Manual 2-1

BEFORE YOU BEGIN

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

Operator Training

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

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

Understanding Stability

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

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

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

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

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

Bendi Series IV Forklift Operator’s Manual 2-2

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

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

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

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

This triangle is commonly called the stability triangle.

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

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

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

Figure 2-1

Figure 2-2

Bendi Series IV Forklift Operator’s Manual 2-3

BEFORE YOU BEGIN Knowing the Rated Capacity

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

Before you begin to operate your Bendi forklift, you need to know some basic principles of how it works.

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

One of the most important facts you need to know about your Bendi forklift is its rated capacity (how much weight it can safely lift). This weight is listed as the rated capacity on the capacity plate. The rated capacity varies for each load depending on: · Where the horizontal and vertical load centers are · The height you plan to lift the load · Attachments used

Identification Plate Identification plates are provided on the truck.

The following list explains each item that appears on the identification plate (Figure 2-3).

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

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

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

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

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

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

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

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

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

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

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

Figure 2-3

Bendi Series IV Forklift Operator’s Manual 2-4

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

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

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

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

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

ww y mm s xxxxx

= 25 for 2,500 lb rated capacity truck = 30 for 3,000 lb rated capacity truck = 35 for 3,500 lb rated capacity truck = 40 for 4,000 lb rated capacity truck = 42 for 42” frame width = 48 for 48” frame width = last digit of year of manufacture (ex. “3” means 2003, “4” means 2004) = month of manufacture = component series; such as “A” = frame number

Figure 2-4

Caution The frame number is also located on the left side of the frame (item 1) Figure 2-4.

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

Caution The mast serial number is also located on the left side of the mast (item 2) Figure 2-4. You must compare the mast serial number listed on the identification plate with the mast serial number on the mast of the truck before you operate the truck.

Bendi Series IV Forklift Operator’s Manual 2-5

BEFORE YOU BEGIN Load Center

Counterweight

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

You need to consider two types of load centers. The horizontal load center (item 1) Figure 2-5, is equal to one-half the length of the load when the weight is evenly distributed. For example, a load that is 48 in. long has a horizontal load center of 24 in. The further the load center is from the fulcrum (item 2), the less stable the forklift. Always make sure your load is flush against the rear of the forks (item 3), and that unevenly distributed loads are loaded with the heaviest end of the load closest to the front wheels.

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

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

Your Bendi forklift has a counterweight (item 5) Figure 2-5 that allows it to travel with heavy loads.

When the forklift lifts a heavy load, the counterweight on the other end of the forklift keeps the center of gravity inside the stability triangle and prevents it from tipping over.

The vertical load center (item 4), is equal to one-half the height of the load when the weight is evenly distributed. For example, a load that is 48 in. high, has a vertical load center of 24 in. Make sure that you do not pick up a load that is higher than twice the vertical load center.

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

Figure 2-5

Bendi Series IV Forklift Operator’s Manual 2-6

BEFORE YOU BEGIN Maximum Fork Height

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

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

The maximum fork height (item 1) Figure 2-6, is the highest position your Bendi forklift can lift a load.

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

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

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

Attachments

Warning Never modify your Bendi forklift in any manner. Only options and attachments approved by Landoll Corporation may be installed on the truck. Other modifications will void the warranty and can cause serious injury or death.

Attachments to the forks may affect the load center.

When the factory, dealer, or distributor installs attachments approved by Landoll Corporation, an additional identification plate is attached to the truck.

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

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

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

Figure 2-6

Tilting Considerations

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

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

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

Bendi Series IV Forklift Operator’s Manual 2-7

BEFORE YOU BEGIN Understanding Workplace Conditions

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

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

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

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

· Overhead repair work Be on the defensive for anything that might present a hazard. Other situations that could present special operating conditions include: · Potholes · Pedestrian traffic · Very narrow aisle ways · Overhead obstructions · Poor lighting making it hard to see hazards · Wet, oily, or uneven terrain · Other equipment or vehicles operated in the area Remember: Do not block the following items with your Bendi forklift or materials you are moving: · Electrical panels · Fire exits · Emergency stop buttons · Aisle ways

Bendi Series IV Forklift Operator’s Manual 2-8

BEFORE YOU BEGIN Trucks

Warning

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

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

4. Do not move trailers with a Bendi forklift.

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

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

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

Some atmospheric conditions encountered in the workplace are extremely explosive and/or flammable. Make sure your Bendi forklift is designated with the type appropriate for your workplace. If you are unsure, check with your supervisor. Using the wrong type designation can cause an explosion or fire resulting in a serious injury or death.

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

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

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

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

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

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BEFORE YOU BEGIN

Bendi Series IV Forklift Operator’s Manual 2-10

SECTION 3 Operating Your Bendi Forklift This section of your Bendi Forklift Operator’s Manual discusses the following concepts that must be thoroughly understood to operate a Bendi forklift: Operator’s Daily Checklist - Inspecting your Bendi forklift before you begin your shift of work is a mandatory requirement.

The procedure for performing this inspection is explained.

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

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

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

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

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

Bendi Series IV Forklift Operator’s Manual 3-1

OPERATING YOUR BENDI FORKLIFT

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

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

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

Report any defect immediately to your supervisor!

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

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

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

Accelerator Pedal The accelerator pedal (item 1) Figure 3-1, is located on the floor to the right of the brake pedal.

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

Figure 3-1

Bendi Series IV Forklift Operator’s Manual 3-2

OPERATING YOUR BENDI FORKLIFT Brake Pedal

Key Switch

CAUTION Always use your right foot for braking.

Do not steer with brakes applied.

The brake pedal (item 2) Figure 3-1, is located on the floor to the left of the accelerator pedal.

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

Your Bendi forklift will “brake by plugging” if you release the accelerator pedal, change direction with the direction lever, and press the accelerator pedal again, the motor will come to a smooth stop and then reverse direction. This process is automatic.

DO NOT press the brake pedal.

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

The key switch (item 1) Figure 3-2 is located to the right of the steering column. Insert the key and turn right to operate the truck. Make sure the parking brake is applied and the direction switch is in neutral before switching on. All load controls and the accelerator should be in neutral (i.e. not depressed) before starting. Do not depress the accelerator during starting.

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

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

3. Tighten the tilt lever.

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

Figure 3-2

Bendi Series IV Forklift Operator’s Manual 3-3

OPERATING YOUR BENDI FORKLIFT Seat Adjustments A lever (item 1) Figure 3-3, under the front of the seat releases the catch for forward or backward seat adjustment. Weight or suspension adjustment is controlled by the handwheel (item 2). A gauge showing the adjusted level is located to the right of the adjustment handwheel (item 3).

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.

There are two dash displays in the console (items 1 and 2) (Figure 3-5). The main display shows hour meter, seat switch clock, brush wear indicators, or fault codes. Use the scroll button to move through these choices. The battery discharge indicator showing battery capacity is above the main display.

The controller temperature warning light is located below the main display on the left side (Figure 3-5).

The light will come on when the controller starts going into temperature cutback (i.e. controller temperature is greater than or equal to 85oC). The light will begin flashing if the controller temperature rises above 94oC. If the light begins flashing, the forklift truck must be stopped and allowed to cool immediately.

WARNING

Dash Display The Dash (item 1) Figure 3-4 is located behind the steering wheel. It is comprised of the following gauges, displays, and switches (Figure 3-5): 1. Right Drive Display 2. Left Drive Display 3. Brake Pedal Cut-out Bypass 4. Headlights (where fitted)

When the controller temperature warning light is ILLUMINATED, the severity of the application creating this situation MUST BE REDUCED. If the controller temperature warning light begins FLASHING, the forklift truck MUST BE STOPPED to allow the controller to cool. Once the light goes off, normal operation can resume.

5. Option (where fitted)

Figure 3-3

Figure 3-4

Bendi Series IV Forklift Operator’s Manual 3-4

OPERATING YOUR BENDI FORKLIFT The left hand display provides information for the left side traction control (Figure 3-5). Should the message “D-Brush” appear on the display, the left side traction motor brushes should be replaced. The left side display also indicates the “H-Brush” signal when the lift pump motor brushes should be replaced.

The right hand display provides information on the right side traction control (Figure 3-5). “D-Brush” means the right side traction motor brushes should be replaced. The “H-Brush” signal indicates when the steering pump motor brushes should be replaced.

The display is operated by the controller and will only be turned on when the key is turned on for the controller.

On startup, the dash displays go through a self-diagnostic test which cycles through the entire display until communications have started with the controller.

IMPORTANT SHOULD THE MESSAGE “E2000” APPEAR IN EITHER, OR BOTH, OF THE DASH DISPLAYS, THERE IS A COMMUNICATIONS ERROR BETWEEN THE CONTROLLER AND THE DASH DISPLAY. SIMPLY TURN KEY OFF, WAIT FOR FIVE SECONDS, AND THEN TURN KEY ON.

IMPORTANT THE OPERATOR SHOULD WAIT FIFTEEN SECONDS BEFORE ACTUATING THE TRACTION DRIVE OR STEERING TO ALLOW SELFDIAGNOSTICS TO EXECUTE. FAILURE TO DO THIS MAY CAUSE THE TRACTION CONTROL TO NOT BE PROPERLY ENABLED. Once communications have been established, the displays will first show the battery capacity level and will then show the hour meter.

Figure 3-5

Bendi Series IV Forklift Operator’s Manual 3-5

OPERATING YOUR BENDI FORKLIFT IMPORTANT BOTH DISPLAYS INDICATE BATTERY CAPACITY. THEY WILL RARELY READ EXACTLY THE SAME, BUT SHOULD BE WITHIN 20% OF EACH OTHER. THIS IS COMMON AND SHOULD NOT BE A CONCERN.

To enter the fault code display, press and hold the “Scroll” button for 2 seconds. This will display the most recent fault code that has been recorded.

To display the next fault code, tap the “Scroll” button.

IMPORTANT

To erase the stored fault codes and reset the fault light on the display, double-tap the “Scroll” button.

The display will count down until the faults have been cleared.

ONCE THE BATTERY CAPACITY REACHES EMPTY, THE LIFT PUMP MOTOR WILL SHUT DOWN, THUS DISABLING THE LIFT FUNCTION.

To exit the fault code display, press and hold the “Scroll” button for 2 seconds. This will return the display back to the hour meter.

To switch from the hourmeter display to the lifetime clock of the controller, tap the “Scroll” button on the display.

Dash Display Fault Codes Displayed Code 4

5

10

13

What It Means Recommend Drive Controller be Replaced Battery Current Limit for Drive Exceeded

What to Do There has been an unrecoverable error in the memory of the controller. All calibration values have been lost. Please contact the Landoll Corporation for more information.

There may be a short circuit in the main motor cables. Repair.

The motor(s) may be drawing too much current from a shorted field or armature. Check the motor(s) and repair as necessary.

Both Direction Switches On One or both switches are sticking. Replace. at Same Time Switches are miswired. Correct.

A Contactor Uses More Check the polarity of the contactor coil and/or suppressor. than 2 Amps Measure contactor coil resistances using an ohmmeter. The voltage divided by the resistance will determine the amp draw. For example, a 36 volt coil should have a resistance of 18 Ohms or more to ensure less than 2 Amps.

Using the ProBit, adjust the contactor output voltage. Older contactors may draw more current. Multiplying the coil resistance by 2 will give the maximum allowable voltage. For example, a coil resistance of 15.5 Ohms will result in a maximum of 31 Volts to stay under 2 Amps.

Bendi Series IV Forklift Operator’s Manual 3-6

OPERATING YOUR BENDI FORKLIFT Dash Display Fault Codes Displayed Code

What It Means A Contactor Uses More than 2 Amps

Check the polarity of the contactor coil and/or suppressor.

Measure contactor coil resistances using an ohmmeter. The voltage divided by the resistance will determine the amp draw. For example, a 36 volt coil should have a resistance of 18 Ohms or more to ensure less than 2 Amps.

14

Check for a Welded Direction Contactor 20

Using the ProBit, adjust the contactor output voltage. Older contactors may draw more current. Multiplying the coil resistance by 2 will give the maximum allowable voltage. For example, a coil resistance of 15.5 Ohms will result in a maximum of 31 Volts to stay under 2 Amps.

Directional contactor has failed to open or is shorted Tips may be welded. Replace.

Check if Field Bar (F) Shorting to B21

No Circuit Path from A through Armature, Field and Forward Contactor

Something is shorting the contactor posts or tips.

The controller is reading a short between the motor field and B-.

The most common cause of this fault is a ground fault on the truck. As a rule of thumb, the maximum allowable voltage between the battery and the chassis is 50% of battery voltage.

The resistance measured between the chassis and motor terminals or controller bars should be in excess of 30K Ohms.

Clean up any existing ground fault and try again.

This error occurs mostly during startup. The controller is reading an open circuit across the motor when the contactor is pulled in.

The most likely cause of this fault is a poor contatct across the contactor tips, especially on the normally closed side of the directional contactor assembly. Check and correct.

23

Check the Reverse Contactor

24

What to Do

Check cable connections to the motor terminals and contactors.

There should be continuity between the “A” bar and the “F” bar when either the forward or reverse contactor is pulled in.

This error occurs mostly during startup. The controller is reading an open circuit across the motor when the contactor is pulled in.

The most likely cause of this fault is a poor contatct across the contactor tips, especially on the normally closed side of the directional contactor assembly. Check and correct.

Check cable connections to the motor terminals and contactors.

There should be continuity between the “A” bar and the “F” bar when either the forward or reverse contactor is pulled in.

Bendi Series IV Forklift Operator’s Manual 3-7

OPERATING YOUR BENDI FORKLIFT Dash Display Fault Codes Displayed Code

What It Means Check the Forward Contactor

25

27

What to Do This error occurs mostly during startup. The controller is reading an open circuit across the motor when the contactor is pulled in.

The most likely cause of this fault is a poor contatct across the contactor tips, especially on the normally closed side of the directional contactor assembly. Check and correct.

Check cable connections to the motor terminals and contactors.

There should be continuity between the “A” bar and the “F” bar when either the forward or reverse contactor is pulled in.

Battery Voltage Too High on 48 Volt battery recently charged. Surface charge has not dissipated Drive This fault can be self-correcting. On a truck with power steering, the controller, if set to do so, will pull in the steering pump briefly to dissipate the surface charge.

Ensure that the high voltage response is properly set with the ProBit. Clear the fault(s) with the ProBit. Check for a Sticky Forward The switching time of the contactor exceeds the maximum Contactor allowable value.

30 Check the plungers for free movement, the coils for shorts and anything that could physically restrict the speed of the contactor.

Check for a Sticky Reverse The switching time of the contactor exceeds the maximum Contactor allowable value.

31

33

70

74 77

85

Check the plungers for free movement, the coils for shorts and anything that could physically restrict the speed of the contactor.

Direction Contactor Failed The controller has detected that the contactor tips were still closed to Drop Out after the contactor coil was dropped. Most likely the contactor tips are welded, or mechanically held closed. Correct.

Open Circuit - Check This error occurs mostly during startup. The controller is reading an Wiring to Lift Motor open circuit across the motor. Check for loose or broken motor cables.

Recommend Lift Controller There has been an unrecoverable error in the memory of the be Replaced controller. All calibration values have been lost. Please contact the Landoll Corporation for more information.

Battery Voltage too High for Battery voltage is over 55 volts. Usually caused by surface charge Lift of a hot battery fresh off the charger.

Battery Current Limit for Lift There may be a short circuit in the main motor cables. Repair.

Exceeded The motor may be drawing too much current from a shorted field or armature. Check the motor and repair as necessary.

Bendi Series IV Forklift Operator’s Manual 3-8

OPERATING YOUR BENDI FORKLIFT Hand Brake

Side Shift Lever

The hand brake (item 1) Figure 3-6, is located to the left of the control levers.

The third lever (item 5) Figure 3-6, on the front of the armrest is the side shift lever. Side shift is a standard function on Bendi forklifts.

Operation - Pull the hand brake toward you to set it.

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

Direction Lever The direction lever (item 2) Figure 3-6, is located on the front of the control pod.

Operation - Push the lever away from you for forward travel and pull it toward you for rearward travel. The lever may be moved while the truck is in motion “known as “brake by plugging”). The motor will automatically come to a smooth stop and then reverse direction. Placing the lever in neutral while traveling will bring the vehicle to a quick stop.

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

Attachment Lever(s) - Optional A fourth optional function can be fitted via a push button (item 6) Figure 3-6 controlled solenoid. The push button is mounted on the side shift lever.

Powered attachments are optional functions on Bendi forklifts.

Horn The horn (item 7) Figure 3-6, is located on the control pod.

Lift Lever The first lever (item 3) Figure 3-6, (closest to the operator) on the front of the armrest is the lift lever.

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

Tilt Lever The second lever (item 4) Figure 3-6, on the front of the armrest is the tilt lever. A visual indicator is provided so you can easily determine the number of degrees the mast is tilted.

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

Figure 3-6

Bendi Series IV Forklift Operator’s Manual 3-9

OPERATING YOUR BENDI FORKLIFT Operating Instructions - Basic Procedures

Warning Check all systems before operating this vehicle. Report unsafe conditions and correct them before operating vehicle.

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

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

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

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

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

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

IT SHOULD NEVER BE USED INSTEAD OF DRIVER TRAINING.

Bendi Series IV Forklift Operator’s Manual 3-10

OPERATING YOUR BENDI FORKLIFT Driving Position

Warning

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

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

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

1. Sit in the seat and face forward in the position outlined above (Figure 3-7).

Refer to Figure 3-7 for proper seating position.

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

This is the recommended traveling position.

1. Adjust the driving seat for comfortable operation of the forklift controls (item 1) Figure 3-7. You must be correctly seated with all body parts inside the cab.

2. Fasten your seatbelt (item 2) Figure 3-7.

Warning

2. Set the direction lever (item 2) to neutral (Figure 3-8).

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

5.

Hold the steering knob firmly with your left hand (Figure 3-8).

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

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

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

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

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

7. Gently depress accelerator pedal as required to achieve a safe operating speed. If the truck is on an incline, press the traction override button, release the brake and press the accelerator pedal simultaneously to avoid reverse motion (Figure 3-9).

Figure 3-7

Figure 3-8

Bendi Series IV Forklift Operator’s Manual 3-11

OPERATING YOUR BENDI FORKLIFT Stopping

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

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

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

Caution Figure 3-9

Turning

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

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

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

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

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

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

· Sound the horn as you reach the intersection to warn pedestrians and other equipment operators you are approaching the intersection. · Always follow the rules of the road and yield to other equipment operators and pedestrians as required.

Bendi Series IV Forklift Operator’s Manual 3-12

OPERATING YOUR BENDI FORKLIFT Stopping Distance Stopping distance changes with the incline and quality of the road surface.

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

Parking

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

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

When you park your forklift always:

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

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

1. Apply the hand brake.

2. Tilt the mast forward.

3. Lower the forks to the ground.

4. Turn the key switch to the OFF position.

5. Remove the key.

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

Bendi Series IV Forklift Operator’s Manual 3-13

OPERATING YOUR BENDI FORKLIFT Operating Instructions – Handling a Load

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

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

Make sure you insert forks fully into the pallet. Do not “tip load” (Figure 3-10).

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

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

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

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

Never carry passengers on the truck.

Figure 3-10

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

Loading the truck beyond its rated capacity can cause axle(s) to break, the truck to tip over and the load to fall.

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

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

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

Bendi Series IV Forklift Operator’s Manual 3-14

OPERATING YOUR BENDI FORKLIFT Setting the Forks Before you get on the forklift make sure the spacing between the forks (item 1) Figure 3-11, is properly set: 1. Measure the center to center between the fork openings on the pallet (item 2) Figure 3-11.

2. Lift the fork locks up (item 3) Figure3-11.

3. Move the forks until the center to center spacing is equal to the center to center distance. Make sure the forks are seated in a carriage notch and equidistant from the ends of the carriage (item 4) Figure 3-11.

4. Press the fork locks down to ensure locking.

Figure 3-11

Retrieving a Load

Follow these steps to retrieve a load:

Note: Actual minimum aisle width (item 5) Figure 3-12 will vary based upon application.

1. Approach the side of the aisle that is opposite the load (item 1) Figure 3-12.

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

2. For narrow aisles, straighten out the truck so it is 8 in., (item 2) Figure 3-12, from the edge of the aisle opposite the load. For wider aisles, straighten out the truck so it is 36 in. to 48 in., (item 6) Figure 3-12, from the side of the aisle where the load is located.

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

3. Center the forks using the side shift lever.

Warning If the forks or load jam or catch during a stacking operation, do not attempt to free them by reaching through the mast.

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

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

Figure 3-12

Bendi Series IV Forklift Operator’s Manual 3-15

OPERATING YOUR BENDI FORKLIFT 5. Lift the forks to the required height, and then level the forks using the tilt lever.

6. Stop the forklift and turn the forks 90° using the steering wheel to align them with the load (Figure 3-13).

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

7. Straighten out the forks using the steering wheel as you drive them into the load so the forks enter the load in a straight line (Figure 3-14).

8. Turn the steering wheel to keep the forks straight as you fully insert them into the load and lift, tilt, and side shift as required to stabilize and pickup the load (Figure 3-15). Only raise the load high enough to clear the rack or the load backrest may catch on the rack.

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

Figure 3-13

Figure 3-14

Figure 3-15

Bendi Series IV Forklift Operator’s Manual 3-16

OPERATING YOUR BENDI FORKLIFT 9. Shift into reverse and slowly back away from the stack as you turn the steering wheel to keep the forks straight (Figure 3-16).

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

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

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

11. When the front right hand corner of the load (item 1) Figure 3-17 clears the rack, stop backing and turn the steering wheel clockwise to straighten out the forks so they are parallel with the body of the truck (Figure 3-18).

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

Figure 3-16

Figure 3-17

Figure 3-18

Bendi Series IV Forklift Operator’s Manual 3-17

OPERATING YOUR BENDI FORKLIFT In Case Your Forklift Tips Over The following conditions can cause a forklift to tip over: · A load exceeding the stated load centers · Tip Loading (Figure 3-19) · A load that is too heavy · Taking a corner too fast · Driving with the load raised · A load that is not distributed properly (keep the heavier items near the load backrest) · Driving across a slope

Figure 3-19 2. Hold on to the steering wheel (Figure 3-21).

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

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

If you sense your forklift is going to tip-over, follow these instructions: 1. Lean away from the direction the truck is tipping (Figure 3-20).

Figure 3-21 3. Brace your feet (Figure 3-22).

Figure 3-22 Figure 3-20

Bendi Series IV Forklift Operator’s Manual 3-18

OPERATING YOUR BENDI FORKLIFT 4. Don’t jump (Figure 3-23).

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

Transporting a Load Figure 3-23

Turning

Follow these guidelines when you transport a load: · Do not speed. · Use your horn to warn others of danger. · Make sure the load is seated firmly against the load backrest. · Tilt the mast back. · Lower the load so the forks are 4 in. to 6 in. off the ground. · Be alert to overhead obstructions such as low doorways, racking, and pipes. Make sure you know the raised and lowered heights of the mast.

Figure 3-24

Warning

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

A lateral tip-over can occur if your truck is improperly operated (Figure 3-24).

Slow down before turning! Failure to slow down can cause serious injury or death.

Bendi Series IV Forklift Operator’s Manual 3-19

OPERATING YOUR BENDI FORKLIFT Traveling on Inclines

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

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

When you travel up or down an incline, follow these guidelines: · Make sure the gradient is 12% or less with a loaded Bendi forklift and 15% or less if you are not carrying a load. · Always keep the load pointed uphill (Figure 3-25). Travel with the forks facing uphill whether you are going up or down an incline.

That means you must back down an incline when you are carrying a load. If vision is obscured, arrange for a ‘Banksman’ to guide you.

Figure 3-25

· If you are not carrying a load, travel with the forks facing uphill when you are going up the incline and face the forks downhill when you are traveling down an incline (Figure 3-26). · Never travel across a grade. This can cause the truck to tip-over laterally and can cause serious injury or death. · Use the foot brake to maintain control before the truck builds up momentum. · Raise the forks as necessary to avoid damaging the forks or load as the road surface changes grade at the top or bottom of an incline. Lower the forks to 4 in. to 6 in. off the ground when you clear the incline.

Figure 3-26

Bendi Series IV Forklift Operator’s Manual 3-20

OPERATING YOUR BENDI FORKLIFT Unloading Your Forklift Note: Actual minimum aisle width may vary based upon application (item 5) (Figure 3-27).

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

Follow these steps to store a load: 1. Approach the side of the aisle that is opposite the area where you will unload the forklift (item 1) (Figure 3-27).

2. For narrow aisles, straighten out the truck so it is 6 in. to 8 in., (item 2) (Figure 3-27), from the edge of the aisle opposite the drop off point. For wide aisles, straighten out the truck so it is 36 in. to 48 in. (item 6) (Figure 3-27), from the side of the aisle where the load is located.

Figure 3-27

3. Center the load using the side shift lever.

4. Drive forward until the front edge of the load wheels, (item 3) (Figure 3-27), are aligned with the center of the rack opening (item 4) (Figure 3-27).

Warning If the forks or load jam or catch during a stacking operation, do not attempt to free them by reaching through the mast.

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

5. Lift the load to the proper height.

6. Stop the forklift and turn the load 90° (turn the steering wheel counterclockwise) so it points in the direction you will drop it off (Figure 3-28).

Figure 3-28

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

Bendi Series IV Forklift Operator’s Manual 3-21

OPERATING YOUR BENDI FORKLIFT 7. Drive forward and straighten out the load using the steering wheel so it is square over the stack (Figure 3-29).

8. Turn the steering wheel to keep the load straight as you drive it into the opening (Figure 3-30).

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

Warning When you lower the forks to the “no load” position (item 1) (Figure 3-31), make sure you do not lower the forks too far. If the forks are lowered too far beyond the “no load” position, you can damage the mast, rack, or other containers on the stack. THIS CAN CAUSE SERIOUS INJURY OR DEATH.

Figure 3-29

10. Lower the forks until the load sits firmly on the rack. Continue to lower the forks until they no longer support the load (‘no load’ position) (item 1) (Figure 3-31).

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

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

Figure 3-30

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

Figure 3-31

Bendi Series IV Forklift Operator’s Manual 3-22

OPERATING YOUR BENDI FORKLIFT 11. Shift into reverse and slowly back out of the load as you turn the steering wheel to keep the forks straight (Figure 3-32).

12. When the front right fork (item 1) Figure 3-33 clears the rack, stop backing and turn the steering wheel to straighten out the forks so they are parallel with the body of the truck.

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

Using Lifting Equipment to Move a Forklift to Another Location

Figure 3-32

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

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

If you need to use a hoist to lift your Bendi forklift: 1. Pass a strap (item 1) Figure 3-34 under the truck just in front and behind of the rear wheels.

Figure 3-33

2. Pass a strap (item 2) Figure 3-34 under the cross-member at the top of the mast.

3. Make sure you place a spacer (item 3) Figure 3-34 (such as a 2 in. x 6 in. block of wood) between the overhead guard and the lift point to avoid damage to the truck.

Figure 3-34

Bendi Series IV Forklift Operator’s Manual 3-23

OPERATING YOUR BENDI FORKLIFT

Bendi Series IV Forklift Operator’s Manual 3-24

SECTION 4 Inspection and Maintenance This section of your Bendi Forklift Operator’s Manual discusses the following concepts that must be thoroughly understood before you inspect or perform maintenance on a Bendi forklift: Inspection and Maintenance - Describes the tasks involved in performing Bendi forklift inspections and preventive maintenance.

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

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

Inspecting Specially Equipped Bendi Forklift Trucks Describes how authorized service facilities should inspect Bendi forklift trucks designed for special applications.

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

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

Bendi Series IV Forklift Operator’s Manual 4-1

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

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

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

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

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

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

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

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Inspection and Maintenance Inspection and Maintenance Inspection Program The inspection program designed by Landoll Corporation periodically checks the integrity of Bendi forklift systems such as: · Checking performance of operator functions such as lift, tilt, side shift, attachment, and traction systems · Checking for leaks · Checking fluid levels · Making sure components are securely attached · Checking the tires To make sure these and other systems are checked periodically, Landoll Corporation has developed a system of checklists. A blank copy of each checklist can be found in Appendix A. These checklists include: · Operator’s Daily Checklist · 200 Hour Inspection Checklist · 600 Hour Inspection Checklist · Installation Checklist · Customer Electric Truck Installation Report Except for the Operator’s Daily Checklist, these tasks are usually performed by a service and maintenance facility that is approved by Landoll Corporation.

Maintenance Program In addition to the inspection program, Landoll Corporation has set up a preventive maintenance program. Preventive maintenance procedures include: · Drain, flush, and refill transmission fluid · Clean hydraulic reservoir suction screens · Change hydraulic oil and filter · Lubricate mechanical systems

Warning Never perform any maintenance or service procedures unless specifically indicated in this manual or requested by your supervisor. All other service and maintenance on your Bendi forklift must be provided by a facility authorized by Landoll Corporation to perform these services. Failure to follow these guidelines can cause serious injury or death.

Preventive maintenance tasks are usually performed by a service and maintenance facility that is approved by Landoll Corporation. Operators may be asked to assist in some routine maintenance procedures. Never perform any of these maintenance procedures unless directed by your supervisor.

Inspection and Maintenance Responsibilities Operator’s Daily Checklist Note: Daily inspection is an OSHA requirement.

Report any defect immediately to your supervisor!

You are responsible for the daily inspection of your Bendi forklift: · Photocopy the Operator’s Daily Checklist in Appendix A in this manual or use the form supplied by your supervisor. · Inspect the truck and fill out the form · Report defects to your supervisor · Return the form to your supervisor · If your Bendi forklift fails to perform in a safe manner during your shift, stop and park the vehicle, remove the key, and report the problem to your supervisor immediately.

· Remove, clean and inspect battery rollers (optional)

Bendi Series IV Forklift Operator’s Manual 4-3

Inspection and Maintenance Shift Inspection

Installation Inspection

The following checks should be carried out on a machine before you start a new shift or if you take the machine over from another operator. These checks do not need to be carried out at the start of the day when the daily inspection is being performed.

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

Upon starting the shift with a new machine or when taking responsibility for a truck from another person, ensure that:

Routine Maintenance Schedule for Bendi Forklifts

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All of the controls function correctly.

The wheels are free from damage.

All warning devices are operating correctly.

The seatbelt functions.

The mast functions correctly and doesn’t get snagged or jammed.

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 CAUSE SERIOUS INJURY

200 and 600 Hour Inspection Checklist

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

Warning Never perform any maintenance or service procedures unless specifically indicated in this manual or requested by your supervisor. All other service and maintenance on your Bendi forklift must be provided by a facility authorized by Landoll Corporation to perform these services. Failure to follow these guidelines can cause serious injury or death.

Typically an authorized service and maintenance facility performs preventive maintenance procedures. At times operators may be requested to assist in performing routine maintenance, such as doing routine lubrication. If requested to do so, make sure you read and understand the guidelines discussed in the “Inspection and Maintenance Practices for Bendi Forklift Operators,” section in the is manual.

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

Bendi Series IV Forklift Operator’s Manual 4-4

Inspection and Maintenance Inspection and Maintenance Practices This section explains the general cautions and warnings you should observe during inspection and maintenance procedures. In addition, the duties of the operator and service and maintenance technician are explained. Finally, these specific procedures are explained: · Preparing for Inspection or Maintenance · Performing Testing · Completing Performance Testing

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

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

Warning Removing the counterweights or uprights will change the center of gravity of the truck and can cause the truck to tip. The battery is considered part of the truck’s counterweight. Failure to follow these guidelines can cause the truck to tip over and result in serious injury or death.

To help avoid fire hazards:

Inspection and Maintenance Practices for Bendi Forklift Operators

Have fire protection equipment present in the work area.

These guidelines will help prevent downtime for your Bendi forklift and maintain it in a safe operating condition:

Warning

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

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

FAILURE TO FOLLOW THESE GUIDELINES CAN CAUSE SERIOUS INJURY OR DEATH.

Warning Batteries produce flammable and explosive gases. Keep arcs, sparks, flames, and lighted tobacco away to prevent explosion. Keep the area well ventilated.

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

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

Accidents happen when you assume another operator has checked out the forklift. · Keep your truck clean to minimize fire hazards and facilitate detection of loose or defective parts. · Follow the procedures outlined in “Before You Inspect the Truck or Perform Service,” “Before You Check Performance,” and “After Performance Testing is Complete.”

Bendi Series IV Forklift Operator’s Manual 4-5

Inspection and Maintenance If you are asked or required to perform basic lift truck maintenance, make special note of the following: · Before you perform service or maintenance on a Bendi forklift, read and understand the Bendi Forklift Operator’s Manual, Service Manuals, and machine safety signs. · Observe the procedures and practices contained in the “The following information is provided for authorized service facilities ONLY” sections in this manual.

Inspection and Maintenance Practices for Authorized Facilities ONLY · Follow the procedures outlined in “Before You Inspect the Truck or Perform Service,” “Before You Check Performance,” and “After Performance Testing is Complete.”

· Block the mast to prevent it from engaging. · If you need to hoist the truck make sure the hoisting equipment has adequate size and capacity to move the equipment. · Never remove counterweights or uprights.

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

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

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

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

3. Set the direction lever (item 1) Figure 4-1, in the neutral position.

· Inspect and maintain motors, controllers, limit switches, protective devices, electrical conductors, connections, and electrical insulation as described in the applicable section of ASME B56.1-2000. · Only use replacement parts, including tires, that are equal to, or exceed, the quality of the parts supplied by the original equipment manufacturer. Install parts, including tires, according to procedures established by Landoll Corporation. · When you remove tires, follow industry safety practices as described in the applicable section of ASME B56.1-2000.

Preparing for Inspection or Maintenance · Inspect the truck in an area that has sufficient clearance to check all operator functions. · Lower forks to the ground and tilt mast forward.

Figure 4-1

· If you will not operate the truck to check operator functions, block the wheels with chocks or other positive truck-positioning devices. · If you will operate the truck to perform operator function, raise the drive wheels so they clear the floor.

Bendi Series IV Forklift Operator’s Manual 4-6

Inspection and Maintenance 4. Turn the key switch to the ON RUN position (item 1) Figure 4-2.

Completing Performance Testing

5. Set the direction lever (item 2) Figure 4-2, in the forward position.

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

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

1. Apply the hand brake (item 1) Figure 4-3.

2. Tilt the mast forward.

3. Lower the forks to the ground.

4. Turn the key switch to the OFF position 5. Remove the key.

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

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

Figure 4-2

Figure 4-3

Bendi Series IV Forklift Operator’s Manual 4-7

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

Identification Plate and Safety Warnings

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

The following information is provided for authorized service facilities ONLY. Contact Landoll Corporation if any accessories that modify the capacity and truck operation are planned.

After the factory reviews your request, new identification tags will be issued to update the rated capacity and other operation characteristics.

Inspecting Forks

Warning Never operate your Bendi forklift if you suspect the forks are damaged. Report fork damage to your supervisor immediately. Failure to follow this recommendation can cause serious injury or death.

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

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

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

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

Cracks - Visually examine the forks for cracks and, if considered necessary, perform a non-destructive crack detection test. Pay special attention to: · Fork heel · Welds that attach mounting components to the fork blank · Top clip retaining pin Straightness of Blade and Shank - Check the straightness of the upper face of each blade and the front face of each shank. If the deviation from straightness exceeds 0.5% of the length of the blade and/or the height of the shank, respectively, repair or replace the fork set.

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

Bendi Series IV Forklift Operator’s Manual 4-8

Inspection and Maintenance 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.

Repairing and Load Testing Forks

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

Repairing Forks

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.

The following information is provided for authorized service facilities ONLY.

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

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

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

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

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

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

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

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

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

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

Battery Charging The following information is provided authorized service facilities ONLY.

Charging Procedure 1. Park the truck in the charging bay and remove the key.

2. Unlatch and raise the seat base from the right side of the Bendi: 3. Check the electrolyte levels and top off with distilled water as necessary. Add sufficient amount of distilled water to keep the acid level visible. Many types of cells have an indicator rib or similar projection above the separator guard.

Do not fill above this marker. Refer to manufacturer’s instructions.

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

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

5. Pull the connector attached to the battery leads (item 1) from the connector attached to the forklift truck (item 2) (Figures 4-4 and 4-5).

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

Bendi Series IV Forklift Operator’s Manual 4-10

for

Inspection and Maintenance

Caution Connecting the charger cable to the truck cable (item 2) can cause damage to the forklift (Figures 4-4 and 4-5).

7. Connect the charger cable to the battery cable (item 1) (Figures 4-4 and 4-5).

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

9. Disconnect the charger cable and reconnect the connector attached to the battery leads (item 1) to the connector attached to the forklift truck (item 2) (Figures 4-4 and 4-5).

Figure 4-4

10. Lower the seat base from the right side of the Bendi: a. Be sure the arm rest is raised and clear of the seat base and the right side door is open. b. While supporting the seat base, release the restraint latch and lower the seat base.

CAUTION: Grip the seat base from the side only to avoid front pinch points. (Note warning decals). c. Lower and latch the arm rest. d. Close and secure the battery compartment door.

Figure 4-5

Bendi Series IV Forklift Operator’s Manual 4-11

Inspection and Maintenance Battery Care

Warning

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

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

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

If electrolyte is taken internally, drink large quantities of water or milk! DO NOT induce vomiting. Get prompt medical attention. · Only add distilled water to the battery cells.

Overfilling battery cells is dangerous and any spillage must be wiped up immediately. · Use only a clean glass or other non-metallic container for storing distilled water used to top off the battery fluid. · Keep the battery container clean and dry. Any corrosion to metal components, caused by battery acid, must be neutralized with a solution of sodium bicarbonate or diluted ammonia. Smearing the terminals with petroleum jelly and applying acid proof paint to the battery container can prevent further corrosion.

Batteries produce explosive gases during operation and charging. Keep your Bendi forklift in a designated area while you are charging or changing the batteries and make sure you latch the battery cover in the UP position. Keep all sparks, arcs, and lighted tobacco away from the batteries. Failure to this can cause serious injury or death. · Keep all sparks, arcs, and lighted tobacco away from the batteries. · Make sure the filler plugs are tight and the vents are clear. · If you take a truck out of service for any length of time, disconnect and remove the battery. · Disconnect the battery when you transport the truck. · Keep the battery fully charged while it is in storage. · Store spare batteries in a cool, dry place.

Maintain the cells by topping off with distilled water and give it an equalizing charge each month. · Spare and replacement batteries must be the same type and weight as the original unit unless authorized by Landoll Corporation. · Make sure that lifting chains, slings, hooks, tools, and other metallic objects do not come into contact with the battery terminals. · Never operate a truck with the battery cover (seat base) removed. · Never remove the charging connector by pulling the lead. This could result in damage to the insulation inside the connector. · Never use or charge a battery that has a damaged connector and/or defective insulation. Repair or replace the connector.

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

Caution Do not allow hydraulic fluid level to drop significantly or allow the reservoir to run dry. This will induce air into the system and cause damage to hydraulic system components.

Caution

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

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

3. Raise the vehicle.

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

5. Remove wheel.

6. Thoroughly clean the area around the level and drain plugs (Figure 4-6).

7. To drain, turn the wheel gear unit until drain plug in position A is at the lowest point (Figure 4-6).

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

8. Place a drain pan under the drain plug.

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

10. Drain the fluid completely into the drain pan.

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

12. Wash the interior of the gear unit with a suitable cleaning liquid as recommended by the lubricant manufacturer.

9. Using a 5 mm Allen key, unscrew the drain (position A) and level (position B) plugs.

11. Once the fluid has been drained, replace the drain plug in position A.

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

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

Figure 4-6

Bendi Series IV Forklift Operator’s Manual 4-13

Inspection and Maintenance a. Put liquid into the gear unit and then replace the filler plug. b. Run the gear unit for a few minutes as a high speed. c. Drain the cleaning liquid from the gear unit in the same way as described for draining the oil in steps 7. through 11.

13. To fill the gear unit, turn the wheel gear unit until the level hole in position A is about 15o below the center line of the gear unit (Figure 4-6).

14. Fill the gear unit with synthetic gear lube as indicated in the Lubrication Chart located in Appendix B. Fluid capacity is approximately 1 quart. Fill using position B until fluid flows out from the hole in position A. 15. Install both plugs. Tighten to 35 ft. lbs. (47 Nm).

DO NOT OVERFILL. 16. Turn the gear unit a few times to eliminate any air pockets and check the various levels.

Power Steering System Maintenance

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

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

1. Fill the reservoir until it reaches the FULL mark on the dipstick. DO NOT OVERFILL. 2. Run the steering through three complete cycles by turning the steering wheel all the way in one direction, then all the way the other direction.

3. Check and refill the reservoir after each cycle.

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

The following information is provided for authorized service facilities ONLY. Perform maintenance on the power steering system as required by the 200/600 Hour Checklists and Routine Maintenance Schedule for Bendi Forklifts located in Appendix A. Guidelines are provided in the following paragraphs. · Fluid for the hydraulic power steering system comes from the central hydraulic reservoir. · Always use a puller to remove the steering wheel. Do not use a hammer, torch, or crow bar. · Investigate and immediately correct any play, rattle, shimmy, misalignment, or other unusual occurrence in the steering system. · Report any malfunction or accident that may have damaged a steering system part. · Do not attempt to weld any broken steering component. Replace the component with original equipment only. Do not cold straighten, hot straighten, or bend any steering part.

Figure 4-7

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

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Inspection and Maintenance Tire and Wheel Maintenance

Mast Maintenance

Inspect solid rubber tires for wire, rocks, glass, pieces of metal, holes, cuts, and other damage.

(Figure 4-7). Remove any object that will cause damage. Check for loose or missing hardware.

Remove any wire strapping or other material that is wrapped around the axle.

The following information is provided for authorized service facilities ONLY.

Make sure the drive wheel nuts are tight. Tighten the wheel nuts in a cross pattern to the correct torque value shown in the Routine Maintenance Schedule located in Appendix A.

Warning Check all wheel 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 shown in the Routine Maintenance Schedule located in Appendix A. When the nuts stay tight for eight hours, the interval for checking the torque can be extended to 200 hours.

Perform maintenance on the mast as required by the 200/600 Hour Checklists and Routine Maintenance Schedule for Bendi Forklifts located in Appendix A. Guidelines are provided in the following paragraphs.

Warning Never work on the mast with a load on the forks or attachment in the raised position without supports or while anyone is near the lift truck control handles per ASME B56.1-2000.

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

2. The maximum side-to-side clearance (item 1) Figure 4-8, between load rollers (item 2) Figure 4-8, and the outer (item 3) Figure 4-8, or inner intermediate upright assemblies (item 4) Figure 4-8, is 1/16 in. (1.5 mm).

3. To check the clearance, insert a pry bar between the upright and roller (item 5) Figure 4-8, and measure the clearance at the “XXX” (item 1) Figure 4-8.

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

Figure 4-8

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Inspection and Maintenance Chain Maintenance Regular inspection and lubrication of the chains will increase their service life and reduce downtime.

When you perform chain maintenance, make sure you follow the guidelines in “Chain Inspection”, “Chain Lubrication”, “Chain Adjustment”, and “Measuring Chain Stretch”.

Measuring Chain Stretch Inspect the chains as required by the 200/600 Hour Checklists and Routine Maintenance Schedule for Bendi Forklifts. Check for the following: · Chain wear. If one strand appears to be worn replace both strands of the pair. · Rust and corrosion. If chain joints become tight from rust and corrosion, loosen them with SAE 40W oil or penetrating oil. If they cannot be loosened, or if the tight joints are caused by bent pins, plates, or peened plate edges, replace both strands of chain. · Cracked side plates. Replace both strands of chain.

Chain Lubrication

Caution The chains must be coated with a film of lubricant at all times. · Lubricate the chains as required by the 200/600 Hour Checklists and Routine Maintenance Schedule for Bendi Forklifts located in Appendix A. Use lubricant listed on the Lubrication Chart located in Appendix B. · Each pair of chains has been factorylubricated using heat and pressure to force the lubricant thoroughly into the chain links.

Avoid removal or contamination of this factory applied lubricant. Do not wash, sand blast, etch, steam clean, or paint the chains.

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

· Protruding or turned pins. Replace both strands of chain.

To determine whether the chains are properly adjusted:

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

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

1. Remove load from forks.

· Worn, broken or misaligned chain anchors.

Replace or adjust as required.

2. Extend 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.

4. Each chain in a pair should have equal “give”. If tension is not equal, adjust them as described in the manufacturer’s mast service manual.

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Inspection and Maintenance Measuring Chain Stretch If the chains stretch beyond the recommended amount, they should be replaced in pairs. Chain stretch can be measured with a chain wear scale (item 1) Figure 4-9. The scale indicates whether the distance between two chain links is within tolerance.

The shaded area in the illustration (item 2) Figure 4-9, compares a stretched chain (item 3) Figure 4-9, to a new chain (item 4) Figure 4-9. 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.

Side Shift Circuit Maintenance The following information is provided for authorized service facilities ONLY. Perform maintenance on the side shift circuit as required by the 200/600 Hour Checklists and Routine Maintenance Schedule for Bendi Forklifts located in Appendix A. Guidelines are provided in the following paragraphs.

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

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

Hydraulic oil can be under very high pressure. A pinhole leak is not easily seen and if it pierces your skin, can cause gangrene, and possibly death, if not treated immediately by a physician familiar with this type of injury. · Check the hydraulic system pressure at the carriage hose fitting. Refer to the truck service manual for details on measuring hydraulic system pressure. The minimum recommended pressure is 2000 psi (140 bar).

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

Figure 4-9

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

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Inspection and Maintenance Checking for Leaks

Troubleshooting Side Shift System

To check side shift circuit performance.

1. Disconnect the right hand cylinder hose from the hose terminal or internal reeving fitting.

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.

2. Cap the supply fitting.

3. Place the hose end in a bucket.

4. Start the truck.

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

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

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

Bendi Series IV Forklift Operator’s Manual 4-18

SECTION 5 Troubleshooting Your Bendi Forklift This section of your Bendi Forklift Operator’s Manual includes a Troubleshooting Guide to help you quickly locate problems that can happen using your Bendi forklift. Follow all safety precautions stated in the previous chapters when making any adjustments to your machine.

Bendi Series IV Forklift Operator’s Manual 5-1

Troubleshooting Your Bendi Forklift Symptom

Possible Cause: Remedy

No operation

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

Sluggish performance, erratic switching, slow lift

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

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

Control panel system is misadjusted: Adjust control panel; refer to Service Manual

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

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

Does not lift (motor does not run)

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

Slow lift

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

Does not lower

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

Lowers excessively slow

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

Bendi Series IV Forklift Operator’s Manual 5-2

Troubleshooting Your Bendi Forklift Symptom

Possible Cause: Remedy

Does not tilt (motor runs)

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

Slow or erratic tilt

Orifices are plugged: Clean orifices in valve and tilt cylinder

Hydraulic system leaks oil

Defective hose: Replace the hose Loose fittings: Tighten

Lift or tilt cylinder leaking

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

Oil in breather line (lift cylinder)

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

Steering is slack

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

Steers hard

Low hydraulic pressure: Inspect and adjust

Battery rollers stick (Battery rollers optional)

Corroded: Remove, clean and lubricate

Not enough brake

Improper adjustment: See Service Manual

Too much brake

Improper adjustment: See Service Manual

Transmission (see Service Manual for repair procedures) Knocking conditional on speed

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

Check drive pinion and helical gear for damage.

Singing noise

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

Muffled grinding noise

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

Leakage in breather valve

Excessive fluid level: Check fluid level

Leakage in motor

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

Leakage in wheel shaft

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

Bendi Series IV Forklift Operator’s Manual 5-3

Troubleshooting Your Bendi Forklift Symptom Leakage when transmission warms up

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

Hydraulic Power Steering Motor (see Service Manual for repair procedures) Low mechanical efficiency or undue high pressure required to operate motor unit

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

Oil leakage

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

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

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

Excessive water requirement

Overcharging: Select a properly sized charger Check charging time and average battery temperature Jar leakage: Replace or repair cell

Excessive cell temperatures

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

Poor truck performance

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

Bendi Series IV Forklift Operator’s Manual 5-4

Troubleshooting Your Bendi Forklift Symptom

Possible Cause: Remedy

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

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

Steering wander

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

High steering effort in one direction

Vehicle overloaded: Do not exceed capacity of vehicle Low hydraulic system pressure: Check other components of system

High steering effort in both directions

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

Lost motion at the steering wheel

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

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

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

Bent or jammed plunger: Repair or replace as necessary

Cylinders do not lift-loaded

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

Cylinders drift

External leak in pressure line: Tighten or replace as necessary Truck valve defective-cycle to full lift height to verify: Repair or replace truck valve External leaks at retainer: Replace all cylinder seals Piston check valve leaking: Replace check valve

Bendi Series IV Forklift Operator’s Manual 5-5

Troubleshooting Your Bendi Forklift Symptom

Possible Cause: Remedy

Spongy or jerky action

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

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

Attachment will not side shift or side shifts slowly

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

Bendi Series IV Forklift Operator’s Manual 5-6

SECTION 6 Standard Bendi Forklift Specifications This section of your Bendi Forklift Operator’s Manual includes the standard specifications for the following Bendi forklift trucks: · B25-4/42-180D · B30-4/42-180D · B35-4/48-180D · B40-4/48-180D

Bendi Series IV Forklift Operator’s Manual 6-1

Standard Bendi Forklift Specifications

Mast Type

Mast Dimensions B Collapsed Height

A Max. Fork Height

C Free Lift Height

D Max. Overall Height

In.

Cm.

In.

Cm.

In.

Cm.

In.

Cm.

Triple

188

478

83

211

61

155

236

599

Triple

198

503

87

221

65

165

246

625

Triple

216

549

95

241

73

185

264

671

Triple

230

691

121

307

99

251

320

813

Triple*

251

638

112

284

86

218

299

759

Triple*

272

691

121

307

99

251

320

813

Quad*

240

610

83

211

58

147

288

732

Quad*

258

655

89

226

64

163

306

777

Quad*

276

701

95

241

70

178

324

823

Quad*

294

747

101

257

76

193

342

867

Quad*

312

792

107

272

82

208

360

914

Above dimensions are based on 3” mast underclearance. * Not Available for B25-4/42-180D

Truck Dimensions B25-4/42-180D

E (1)

F

G

H

I

J

K (2)

L

M (3)

N

O

P

Q

In.

13

63

27

102

13

38

87

45

--

3

25

18o

11o

Cm.

33

160

68

259

33

97

221

114

--

10

64

B30-4/42-180D

E

F

G

H

In.

13

63

27

102

13

J

K

L

M

N

O

P

38

87

45

--

3

25

18o

Cm.

33

160

68

259

33

97

221

114

--

10

64

B35-4/48-180D

E

F

G

H

In.

13

63

29

104

13

J

K

L

M

N

O

P

38

87

50

--

3

25

18o

Cm.

33

160

73

264

33

97

221

130

--

10

64

B40-4/48-180D

E

F

G

H

In.

13

63

29

104

13

J

K

L

M

N

O

P

38

87

50

--

3

25

18o

Cm.

33

160

73

264

33

97

221

130

--

10

64

I

I

I

R

S (4)

V

W

X

40

--

74

19

43

100

29

--

188

48

109

250

73

Q

R

S

T

U

V

W

X

11o

40

--

74

19

43

100

29

102

--

188

48

109

250

73

Q

R

S

T

U

V

W

X

11o

40

--

76

19

44

102

29

102

--

193

48

112

259

73

Q

R

S

T

U

V

W

X

11o

40

--

76

19

44

102

29

102

--

193

48

112

259

73

DIMENSION W/ SIDESHIFTER AND 45D QUAD MAST 87” STANDARD HEIGHT VARIES PER CUSTOMER SETTINGS VARIES PER CUSTOMER SPECS

Bendi Series IV Forklift Operator’s Manual 6-2

U

102

NOTE: ALL DIMENSIONS ROUNDED TO THE NEAREST WHOLE NUMBER. (1) (2) (3) (4)

T

Standard Bendi Forklift Specifications

Bendi Series IV Forklift Operator’s Manual 6-3

Standard Bendi Forklift Specifications Standard Specifications Gradeability Empty Loaded

20% 12%

Rated Capacity at 24”(61 cm) Load Center B25-4/42-180D B30-4/42-180D B35-4/48-180D B40-4/48-180D

2,500 lb (1,136 kg) 3,000 lb (1,364 kg) 3,500 lb (1,814 kg) 4,000 lb (1,814 kg)

Mast Tilting Angle Forward Reverse

3o 3o

Fork Size (Standard) ITA Class II Carriage

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

Lifting Speed Empty Loaded

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

Lowering Speed Empty Loaded

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

Traveling Speed Forward Reverse

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

Truck Weight With Battery B25-4/42-180D B30-4/42-180D B35-4/48-180D B40-4/48-180D

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

Minimum Battery Weight

2,600 lb (1,182 kg)

Poly Load Tire (Front) B25-4/42-180D; B30-4/42-180D; B35-4/48-180D; B40-4/48-180D

12 x 5 x 8 in (30 x 13 x 20 cm) or 14 x 5 x 8 in (36 x 13 x 20 cm)

Solid Rubber Drive Tire (Rear) B25-4/42-180D; B30-4/42-180D; B35-4/48-180D; B40-4/48-180D

18 x 6 x 12-1/8 in (46 x 15 x 31 cm) 18 x 7 x 12-1/8 in (46 x 18 x 31 cm)

Battery

48 Volt Type EO

Bendi Series IV Forklift Operator’s Manual 6-4

Appendix A This section of your Bendi Forklift Operator’s Manual includes the following checklists and maintenance schedules: · Operator’s Daily Checklist · 200 Hour Inspection Checklist · 600 Hour Inspection Checklist · Installation Checklist · Customer Electric Truck Installation Report · Routine Maintenance Schedule for Bendi Forklifts

Bendi Series IV Forklift Operator’s Manual A-1

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

Date _____________________ Truck No. _________________ Location __________________ Shift _____________________

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

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

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

O.K. (X)

Need Maintenance

Overall machine - Keep clean and tidy appearance Hydraulic Oil, Battery, Brake Fluid - Check for leaks Tires - Check for debris; Drive Tire Lug Nuts - Torque to 225 ft.lbs. (300 Nm) Forks, Top Clip Retaining Pin and Heel - Condition Load Backrest Extension - Attached Hydraulic Hoses, Mast Chains and Stops - Check Visually (Note Bracket Location) Finger Guards - Attached Major Structural Points (Front Rotation, Mast Braces, Overhead Guard) - Check for cracks Overhead Guard - Properly mounted and attached Safety Warnings - Attached (Refer to Operator’s Manual for Location) Battery - Check water/electrolyte level and charge Hydraulic Fluid Level Transmission Fluid Leaks Operator’s Compartment Capacity Plate Attached - Info. matches Model, Serial No., and Attachments; Operator’s Manual in Case Battery Restraint System - Adjust and Fasten Seat Belt, Buckle, and Retractors - Functioning smoothly Brake Fluid - Check levels Controls (Turn Power On); Investigate unusual noises immediately Accelerator and Brake/Inching Pedal - Functioning smoothly Parking Brake and Service Brake - Functioning smoothly Steering Operation - Functioning smoothly Drive Control - Forward/Reverse - Functioning smoothly Tilt Control - Forward and Back - Functioning smoothly Lift and Lowering Control - Functioning smoothly Sideshift Control - Functioning smoothly Hang-on Attachment- Functioning smoothly, securely attached, fittings attached Attachments - Check for any oil leaks Horn, Lights, Seat Switch - Functioning properly Hood and Seat Latch - Function properly Gauges - Hour Meter - Functioning properly Battery Discharge Indicator - Functioning Instrument Monitors - Functioning

Bendi Series IV Forklift Operator’s Manual A-2

BENDI 200 Hour Inspection Checklist To be performed after each 200 hours of truck operation in addition to the required pre-shift daily inspection.

Date _____________________ Truck No. _________________ Location __________________ Shift _____________________

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

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

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

O.K. (X)

Need Maintenance

Leaks - Hydraulic Oil, Battery, Brake Fluid Tires - Check for Debris; Drive Tire Lug Nuts - Torque to 225 ft.lbs.

(300 Nm) Forks, Top Clip Retaining Pin and Heel - Condition Load Backrest Extension - Attached Hydraulic Hoses and Connections - Check for Wear Mast Chains - Lube with SAE 40 wt. Oil or Bowman Heavy Load Red Grease Check Torque on Gear Box Bolts Check All Connections for Proper Torque Hydraulic Fluid Level - Check and Fill Transmission Fluid Leaks Operator’s Compartment Capacity Plate Attached - Info. matches Model, Serial No., and Attachments; Operator’s Manual in Case Battery Restraint System - Adjust and Fasten Seat Belt, Buckle, and Retractors - Functioning smoothly Brake Fluid - Check levels Controls (Turn Power On); Investigate unusual noises immediately Accelerator and Brake/Inching Pedal - Functioning smoothly Parking Brake and Service Brake - Functioning smoothly Steering Operation - Functioning smoothly Drive Control - Forward/Reverse - Functioning smoothly Tilt Control - Forward and Back - Functioning smoothly Lift and Lowering Control - Functioning smoothly Sideshift Control - Functioning smoothly Hang-on Attachment- Functioning smoothly, securely attached, fittings attached Attachments - Check for any oil leaks Horn, Lights, Seat Switch - Functioning properly Hood and Seat Latch - Function properly Gauges - Hour Meter - Functioning properly Battery Discharge Indicator - Functioning Instrument Monitors - Functioning

Bendi Series IV Forklift Operator’s Manual A-3

BENDI 600 Hour Inspection Checklist To be performed after each 600 hours of truck operation in addition to the required pre-shift daily inspection and the 200 hour inspection.

Date _____________________ Truck No. _________________ Location __________________ Shift _____________________

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

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

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

O.K. (X)

Need Maintenance

Inspect Electrical Contactors - Replace if Necessary Tires - Check for Debris; Drive Tire Lug Nuts - Torque to 225 ft.lbs.

(300 Nm) Forks, Top Clip Retaining Pin and Heel - Condition Load Rollers - No Greater than 1/16” Hydraulic Hoses and Connections - Check for Wear Mast Chains - Lube with SAE 40W oil or Bowman Heavy Load Red Grease - Check for Wear and Stretch Gear Box - Check Oil Level and Check for Proper Torque on Gear Box nuts - Check Motor Mount Bolts Torque and Brushes Check All Connections for Proper Torque Hydraulic Return Filter - Change element and check for Proper Level Check Pressures Transmission Fluid Leaks Operator’s Compartment Capacity Plate Attached - Information Matches Model, Serial No., and Attachments Battery Restraint System - Adjust and Fasten Seat Belt, Buckle, and Retractors - Functioning Smoothly Brake Fluid - Check Level Controls (Turn Power On); Check Card Adjustments Accelerator - Functioning Smoothly Parking Brake and Service Brake - Functioning Smoothly Steering Operation - Functioning Smoothly; Lubricate Steering Knob Drive Control - Forward/Reverse - Functioning smoothly Tilt Control - Forward and Back - Functioning smoothly Lift and Lowering Control - Functioning smoothly Sideshift Control - Functioning smoothly Hang-on Attachment- Functioning smoothly, securely attached, fittings attached Attachments - Check for any oil leaks Horn, Lights, Seat Switch - Functioning properly Hood and Seat Latch - Function properly Gauges - Hour Meter - Functioning properly Battery Discharge Indicator - Functioning Instrument Monitors - Functioning

Bendi Series IV Forklift Operator’s Manual A-4

BENDI Installation Checklist QUALITY CONTROL SHEET

Date _____________________ Truck No. _________________ Location __________________ Shift _____________________

Remit Copy to Landoll Corporation

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

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

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

O.K. (X)

Need Maintenance

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

Bendi Series IV Forklift Operator’s Manual A-5

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

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

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

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

Upright and Fork Carriage a.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

e.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Make & Model____________________________________ b.

Service Weight____________________________________

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

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

SERVICEMAN_____________________

DATE______________

DEALER/BRANCH_________________________________________ ADDRESS_______________________________________________

LAN-0054 REV-000 May 2003

ACCEPTANCE BY COMPANY OFFICAL CUSTOMER_____________________

DATE______________

SIGNATURE_____________________

TITLE______________

Bendi Series IV Forklift Operator’s Manual A-6

ROUTINE MAINTENANCE SCHEDULE FOR BENDI FORKLIFTS

Operation

*Time

First 2 wks

First month

Hours

50100

1st 200

Monthly Quarterly 200

600

SemiAnnually Annually 1000

Check that terminal studs and mounting bolts on motor are clean and tight

X

Clean cooling holes on motor of debris or restrictions

X

Check traction motor brushes for pressure and wear, and surface on commutator for roughness

X

Clean dust from traction motors

X

Check resistance between truck body and negative/positive terminal of battery

X

Check operation of contactor points and micro switches

X

X

Check resistance of contactor coils

X

Clean control panel surface

X

X

Clean commutator on traction motor

X

Thoroughly scrub battery

X

Thoroughly clean machine and controls (do not steam clean where control panel could get wet)

X

Check all wire and connections, bolts and nuts

X

Check brake/inching pedal free play

X

X

Check hand brake

X

X

Check lift chain tension

X

X

X

Check lift bracket rollers for damage

X

Check lift and tilt cylinder fittings

X

Check lift and tilt cylinders are working together correctly and in unison

X

X

Check hydraulic oil pump operation

X

X

Drain, flush, and refill transmission

X

Retorque lug nuts on drive wheels

X

X

X

X X

Clean hydraulic reservoir suction screens with solvent

X

Service all grease fittings

X

Check power steering pump operation Fill and air bleed power steering system

2000

X

X

X

X

Check brake fluid level

X

Remove, clean, and repack battery rollers

X

Investigate Registered Fault Codes; Clear Fault Codes When Resolved

Bendi Series IV Forklift Operator’s Manual A-7

ROUTINE MAINTENANCE SCHEDULE FOR BENDI FORKLIFTS

Operation

*Time

First 2 wks

First month

Hours

50100

1st 200

Monthly Quarterly 200

Check brushes for pressure or wear, and surface of commutator for roughness (Hydraulic oil pump and power steering pump)

X

Clean dust from motors (Hydraulic oil pump and power steering pump)

X

600

Change hydraulic oil and filter

X

Inspect the mast mechanism

X

Lubricate steering knob.

X

Check steering backlash.

X

Inspect all tires and wheels.

X

Inspect, clean, and lubricate the mast chains.

X

X

Shim rollers.

X

Check chains for wear and stretch.

X

Check brake pads for excessive wear Check operation of switches (interlock, direction, parking/seat, key, pressure/temperature)

X X

X

Neutralize and clean battery box and connectors

X

Check water/electrolyte level in battery

X

Check structure and electrical conditions of battery

X

Inspect friction surfaces of carriage or attachment

X

Inspect friction surfaces of mast

X

Extend mast to check for excessive wear on roller track

X

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

Bendi Series IV Forklift Operator’s Manual A-8

SemiAnnually Annually 1000

2000

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

Bendi Series IV Forklift Operator’s Manual B-1

Appendix B

Chain

Name

Notes Clean and reoil

2 3 4 5 6 7 8 9 10 11

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

Texaco Ref. C & C #880 Reservoir Cap 30W oil Hydraulic Reservoir Amoco Rykon MV Gear Case Mobilube SHC-630 Master Cylinder Heavy duty brake fluid DOT 3 Articulating Axle Bearings Texaco Ref. C & C #880 Load Wheel Axle Texaco Ref. C & C #880

12 13

Steering Gears Tilt Cylinders

Lubricate inner sides of upright rails Use standard lubrication gun Lightly oil Use standard lubrication gun Clean in solvent and re-oil Drain, flush, and refill Drain, flush, and refill Check level and add if necessary Use standard lubrication gun Use lubrication gun and adapter for flush type fittings Brush or spray on lubricant Use standard lubrication gun

1

Texaco Ref. C & C #880 Texaco Ref. C & C #880

Bendi Series IV Forklift Operator’s Manual B-2

Appendix B Component

Torque Transmission

Wheel

225 ft. lbs. (300 Nm.)

Electric motor

17 ft. lbs. (23 Nm.)

Fluid draining and filling plug

16 ft. lbs. (22 Nm.)

Hydraulic braking unit and brake cable

37 ft. lbs. (50 Nm.)

Transmission with vehicle frame

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

Bolt 3/8-24UNF 2A

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

Bolt 1/2-20 UNF 2A

80-100 ft. lbs. (190-244 Nm.) Electric Motors

Motor terminals

12 ft. Lbs. (16 Nm)

Pole pieces screws

20-25 ft. Lbs. (27-34 Nm.) Hydrostatic Steering Control Unit

Plug and o-ring assy #8 SAE fitting

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

Steering control unit assy bolt (M8 X1.0)

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

Mounting bolts

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

Chain guard capscrews

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

Main lift cyl. plunger retainer

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

Free lift cyl. plunger retainer

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

Carriage roller capscrews

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

Chain and hose sheave screws

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

Lift chain adjusting nuts

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

Backrest screws

145 ft. lbs. (197 Nm.)

Side shift mounting hooks

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

Bendi Series IV Forklift Operator’s Manual B-3

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

] IF USING PREVAILING TORQUE NUTS.

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

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

5/16-18

8

[10]

13

[16]

18

[22]

3/8-16

15

[19]

23

[29]

35

[43]

7/16-14

24

[30]

35

[43]

55

[62]

1/2-13

35

[43]

55

[62]

80

[100]

9/16-12

55

[62]

80

[100]

110

[137]

5/8-11

75

[94]

110

[137]

170

3/4-10

130

[162]

200

[250]

7/8-9

125

[156]

320

1-8

190

[237]

408

1-1/8-7

270

[337]

1-1/4-7

380

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

UNF Size 1/4-28

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

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

[11]

14

[17]

20

[25]

[21]

25

[31]

35

[44]

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

[34]

40

[50]

60

[75]

[50]

65

[81]

90

[112]

[75]

90

[112]

130

[162]

[212]

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

[106]

130

[162]

180

[225]

280

[350]

3/4-16

150

[188]

220

[275]

320

[400]

[400]

460

[575]

7/8-14

140

[175]

360

[450]

500

[625]

[506]

680

[850]

1-14

210

[263]

540

[675]

760

[950]

600

[750]

960

[375]

660

[825]

1080

[1350]

[475]

840

[1050] 1426

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

[525]

920

[1150] 1500

[1875]

490

[612]

110

[1375] 1780

[700]

1260

[1575] 2010

[2512]

650

[812]

1460

[1825] 2360

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

[912]

1640

[2050] 2660

[3325]

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

USE VALUE IN [

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

] IF USING PREVAILING TORQUE NUTS.

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

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

7 12 17 34 60 90 150 205

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

Nominal Thread Diameter mm 20 24 27 30 33 36 39

Standard Torque NewtonFootMeters Pounds 385 670 980 1330 1790 2325 3010

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

Bendi Series IV Forklift Operator’s Manual B-4

290 500 730 990 1340 1730 2240

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

Appendix B LANDOLL CORPORATION HYDRAULIC FITTING TORQUE SPECIFICATIONS 37o JIC, ORS, & ORB (REV. 10/97) THIS CHART PROVIDES TIGHTENING TORQUES FOR HYDRAULIC FITTING APPLICATIONS WHEN SPECIAL TORQUES ARE NOT SPECIFIED ON PROCESS OR DRAWING. ASSEMBLY TORQUES APPLY TO PLATED CARBON STEEL AND STAINLESS STEEL FITTINGS ASSEMBLED WITHOUT SUPPLEMENTAL LUBRICATION (AS RECEIVED CONDITION). THEY DO NOT APPLY IF SPECIAL GRAPHITE MOLY-DISULFIDE OR OTHER EXTREME PRESSURE LUBRICANTS ARE USED. BRASS FITTINGS AND ADAPTERS - 65% OF THE TORQUE VALUE FOR STEEL. STAINLESS STEEL, ALUMINUM AND MONEL - THREADS ARE TO BE LUBRICATED.

TORQUE IS SPECIFIED IN FOOT POUNDS PARKER BRAND FITTINGS Dash 37 Degree O-Ring Size JIC (ORS) -4 11-13 15-17 -5 14-16 — -6 20-22 34-36 -8 43-47 58-62 -10 55-65 100-110 -12 80-90 134-146 -16 115-125 202-218 -20 160-180 248-272 -24 185-215 303-327 -32 250-290 —

O-Ring Boss (ORB) 13-15 21-23 25-29 40-44 57.5-62.5 75-85 109-121 213-237 238-262 310-340

LANDOLL CORPORATION HYDRAULIC FITTING TORQUE SPECIFICATIONS 37o JIC, ORS & ORB (REV. 10/97) THIS CHART PROVIDES TIGHTENING TORQUES FOR HYDRAULIC FITTING APPLICATIONS WHEN SPECIAL TORQUES ARE NOT SPECIFIED ON PROCESS OR DRAWING. ASSEMBLY TORQUES APPLY TO PLATED CARBON STEEL AND STAINLESS STEEL FITTINGS ASSEMBLED WITHOUT SUPPLEMENTAL LUBRICATION (AS RECEIVED CONDITION). THEY DO NOT APPLY IF SPECIAL GRAPHITE MOLY-DISULFIDE OR OTHER EXTREME PRESSURE LUBRICANTS ARE USED. BRASS FITTINGS AND ADAPTERS - 65% OF THE TORQUE VALUE FOR STEEL.

TORQUE IS SPECIFIED IN FOOT POUNDS. AEROQUIP BRAND FITTINGS Dash 37 Degree O-Ring Size JIC (ORS) -4 11-12 10-12 -5 15-16 — -6 18-20 18-20 -8 38-42 32-35 -10 57-62 46-50 -12 79-87 65-70 -14 — — -16 108-113 92-100 -20 127-133 125-140 -24 158-167 150-165 -32 245-258 —

O-Ring Boss (ORB) 14-16 18-20 24-26 50-60 72-80 125-135 160-180 200-220 210-280 270-360 —

Bendi Series IV Forklift Operator’s Manual B-5

Appendix B

Bendi Series IV Forklift Operator’s Manual B-6

BENDI NARROW AISLE ELECTRIC FORKLIFT OPERATOR’S MANUAL SERIES IV MODELS B25-4/42-180D/B30-4/42-180D B35-4/48-180D/B40-4/48-180D LANDOLL CORPORATION Material Handling Products Group 1900 North Street Marysville, Kansas 66508 Telephone (785)562-5381· FAX: (785)562-4853 www.Landoll.com · MHProd@Landoll.com

Reorder Part Number

F-370-0304 March, 2004