Bendi IV Service Manual F-378-0804 1-11,2012

ELECTRIC
NARROW AISLE
FORKLIFT
SERVICE MANUAL
BENDI SERIES IV MODELS
B25-4/42-180D B35-4/48-180D
B30-4/42-180D B40-4/48-180D
B45-4/48-180D
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
Publication No. F-378-0804
HANDLING PRODUCTS
Table of Contents
Table of Contents
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-i
Using This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Safety · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-1
Warranty and Parts · · · · · · · · · · · · · · · · · · · · · · · · · · 2-1
Truck Overview · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-1
Receiving and Inspection · · · · · · · · · · · · · · · · · · · · · · 2-1
Operation · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-2
Preventive Maintenance · · · · · · · · · · · · · · · · · · · · · · · 2-2
Troubleshooting · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-2
Corrective Maintenance · · · · · · · · · · · · · · · · · · · · · · · 2-2
Mast IPB (illustrated parts breakdown) · · · · · · · · · · · · · · · · 2-3
Base IPB (illustrated parts breakdown) · · · · · · · · · · · · · · · · 2-3
Appendix, A through Z · · · · · · · · · · · · · · · · · · · · · · · · 2-3
Safety
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-1
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-2
Site Supervision · · · · · · · · · · · · · · · · · · · · · · · · · · · · 0-2
Operator · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 0-3
Seat Belt ...................................................................................0-4
Seat Safety Switch ..................................................................0-5
Emergency STOP Button........................................................0-5
Parking Brake ..........................................................................0-5
Tipping Hazards · · · · · · · · · · · · · · · · · · · · · · · · · · · 0-6
Longitudinal Tipping Can Occur When: ...............................0-6
Lateral Tipping Can Occur When: .........................................0-7
Traveling and Load Handling · · · · · · · · · · · · · · · · · · · · 0-7
Speed · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 0-9
Visibility · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 0-9
Bendi Series IV Forklift Operator’s Manual

i
Battery Care · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 0-9
Features....................................................................................0-9
Care.........................................................................................0-10
Service Repair · · · · · · · · · · · · · · · · · · · · · · · · · · · · 0-11
Side Shifting · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 0-12
Safety Labels · · · · · · · · · · · · · · · · · · · · · · · · · · · · 0-13
General ...................................................................................0-13
Available Options · · · · · · · · · · · · · · · · · · · · · · · · · · 0-17
Fork Positioner, Non-Side Shifting......................................0-17
Fire Extinguisher ..................................................................0-18
Rollout Battery Tray .............................................................0-18
Additional Publications · · · · · · · · · · · · · · · · · · · · · · · 0-19
Truck Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Truck Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Frame · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 1-5
Traction Drive · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 1-5
Brake System...........................................................................1-5
Parking Brake ..........................................................................1-5
Safety Interlock........................................................................1-5
Electrical System · · · · · · · · · · · · · · · · · · · · · · · · · · · 1-6
Traction ....................................................................................1-6
Main Pump Motor (Lift) ...........................................................1-6
Power Steering ........................................................................1-6
Battery ......................................................................................1-6
Hydraulic System · · · · · · · · · · · · · · · · · · · · · · · · · · · 1-7
Steering ....................................................................................1-7
Mast Controls ..........................................................................1-7
Side Shift ..................................................................................1-7
Operator’s Cab · · · · · · · · · · · · · · · · · · · · · · · · · · · · 1-8
Driver Controls ........................................................................1-8
Battery Compartment Access Cover /Latch.......................1-10
Dash Display Panel ..............................................................1-12
Mast Assemblies ...................................................................1-13
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Bendi Series IV Narrow Aisle Forklift · · · · · · · · · · · · · · · 1-16
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Models · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 1-16
EE Series (Electrical Enclosure).............................................1-16
Cold Storage (Freezer Package) ..........................................1-16
Available Options · · · · · · · · · · · · · · · · · · · · · · · · · · 1-16

ii
Fire Extinguisher ...................................................................1-16
Fork Positioner, Non-Side Shifting......................................1-17
Light and Alarms ..................................................................1-18
Rollout Battery Tray ..............................................................1-19
Receiving and Inspection . . . . . . . . . . . . . . . . . . . . . . . 2-1

Receiving Your Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Items Furnished With Your Truck · · · · · · · · · · · · · · · · · · 2-1
Items Required · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-1
Tools and Test Equipment · · · · · · · · · · · · · · · · · · · · · · 2-1
To Prepare the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Charging a Wet Battery· · · · · · · · · · · · · · · · · · · · · · · · 2-2
Using the Hydrometer.............................................................2-4
To Charge the Battery:............................................................2-4
Charging a Dry Battery · · · · · · · · · · · · · · · · · · · · · · · · 2-6
To Charge a Dry-Cell Battery: ................................................2-7
Inspection Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Visual Checks · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-8
Routine Checks · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-9
Replacing the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
To Replace a Battery · · · · · · · · · · · · · · · · · · · · · · · · 2-12
Rollout Battery Tray Option · · · · · · · · · · · · · · · · · · · · 2-14
Storage, Towing or Shipping . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Truck Storage · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-14
Battery Storage · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-15
Towing the Truck · · · · · · · · · · · · · · · · · · · · · · · · · · 2-15
To Ship the Truck · · · · · · · · · · · · · · · · · · · · · · · · · · 2-16
Using Lifting Equipment.......................................................2-17
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
To Begin Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Understanding Stability · · · · · · · · · · · · · · · · · · · · · · · 3-2
Capacity....................................................................................3-4
Serial Number Code ................................................................3-6
Load Center .............................................................................3-7
Counterweight .........................................................................3-7
Maximum Fork Height.............................................................3-8
Determining Weight of the Load............................................3-8
Working in Hazardous Environments · · · · · · · · · · · · · · · · 3-9
Atmospheric/Electrical ...........................................................3-9
Chemical Hazards ...................................................................3-9
Pre-Operation Checklist · · · · · · · · · · · · · · · · · · · · · · · 3-9
Adjusting the Driver’s Seat · · · · · · · · · · · · · · · · · · · · · 3-10
Seat Belt .................................................................................3-11
iii
Tilt Steering Column · · · · · · · · · · · · · · · · · · · · · · · · 3-12
Fork Adjustment · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-12
Manual Fork Adjust ..............................................................3-13
Fork Positioner Option - Automatic ....................................3-13
Driving the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Practice Session· · · · · · · · · · · · · · · · · · · · · · · · · · · 3-15
The Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Handling the Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
To Pick Up the Load· · · · · · · · · · · · · · · · · · · · · · · · · 3-19
To Deliver a Load · · · · · · · · · · · · · · · · · · · · · · · · · · 3-22
Fire Extinguisher Option . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
In Case of a Fire ! · · · · · · · · · · · · · · · · · · · · · · · · · · 3-27
Fork Positioner Option . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Power Steering System · · · · · · · · · · · · · · · · · · · · · · · 3-29
Mast Systems · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-30
Tilt and Shift...........................................................................3-32
Lift and Lower........................................................................3-32
Electrical Control System . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
General · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-33
Dash Displays · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-34
Preventative
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Preventative Maintenance Schedule· · · · · · · · · · · · · · · · · · 4-2
Recommended Lubricants · · · · · · · · · · · · · · · · · · · · · · · 4-3
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Tools or Equipment Required · · · · · · · · · · · · · · · · · · · · 4-8
Special Tools Required...........................................................4-8
Safety Equipment Required ...................................................4-8
Floor Access Panel - Removal · · · · · · · · · · · · · · · · · · · · 4-9
Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Check Batteries · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-10
To Check the Battery: ...........................................................4-11
Check Power Steering · · · · · · · · · · · · · · · · · · · · · · · 4-12
Check Hydraulic Functions · · · · · · · · · · · · · · · · · · · · · 4-12
Check the Return-to-Neutral · · · · · · · · · · · · · · · · · · · · 4-13
Check Primary Lift Chain · · · · · · · · · · · · · · · · · · · · · · 4-13
Inspect Tires · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-14
Chunking (Chipping) or Embedded Objects ......................4-15
Undercutting and Uneven Wear...........................................4-15
Flat-spotting...........................................................................4-16

iv
To Expand Tire Life ...............................................................4-16
Check Driver’s Seat Switch · · · · · · · · · · · · · · · · · · · · · 4-17
Weekly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Check Hydraulic Oil Level · · · · · · · · · · · · · · · · · · · · · 4-18
Check Master Cylinder Fluid Level· · · · · · · · · · · · · · · · · 4-19
Check Tilt Cylinder Racking · · · · · · · · · · · · · · · · · · · · · 4-20
Tilt Cylinder Racking and Tilt Degree Setting ....................4-20
Lubricating the Truck · · · · · · · · · · · · · · · · · · · · · · · · 4-23
Front Column Rotation Bearings/Gears .............................4-24
Tilt Cylinder Clevises ............................................................4-25
Mast Mounting Pins ..............................................................4-25
Forks and Side Shifter .........................................................4-26
Check Planetary Gear Box · · · · · · · · · · · · · · · · · · · · · 4-26
Check Lift Operation · · · · · · · · · · · · · · · · · · · · · · · · 4-29
Drive Wheel Lug Nuts · · · · · · · · · · · · · · · · · · · · · · · · 4-30
Cooling Fans· · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-30
Three Month Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Check Nuts, Bolts, and Screws · · · · · · · · · · · · · · · · · · 4-31
Change Hydraulic Oil Filter · · · · · · · · · · · · · · · · · · · · · 4-32
Check Service Disc Brakes · · · · · · · · · · · · · · · · · · · · · 4-33
To Check the Brakes.............................................................4-33
Semi-Annual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
General · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-34
Inspection Check List · · · · · · · · · · · · · · · · · · · · · · · · 4-36
Inspect Electrical Connections· · · · · · · · · · · · · · · · · · · 4-36
Fork Inspection · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-36
Replacing Motor Brushes· · · · · · · · · · · · · · · · · · · · · · 4-39
Exposing the Motors.............................................................4-39
Traction Motor Brushes........................................................4-41
Pump and Power Steering Motor Brushes .........................4-42
Annual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
Change Hydraulic Oil · · · · · · · · · · · · · · · · · · · · · · · · 4-43
Lubricate Front Steer Wheel Bearings· · · · · · · · · · · · · · · 4-45
Inspecting the Bearings, Race and Inner Seal ...................4-46
Lubricate Steer Wheel Knob · · · · · · · · · · · · · · · · · · · · 4-47
SRE Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48
General Practice · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-48
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49
Fork Positioner Lubrication, Non-Side Shifting· · · · · · · · · · 4-49
Rollout Battery Tray · · · · · · · · · · · · · · · · · · · · · · · · · 4-50
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Preliminary Procedures · · · · · · · · · · · · · · · · · · · · · · · 5-1

v
Visible Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Spills and Waste Management . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Spills of Sulfuric Acid · · · · · · · · · · · · · · · · · 5-8
Handling and Storage · · · · · · · · · · · · · · · 5-9
Waste Generation and Disposal · · · · · · · · · · · 5-9
Recycling locations · · · · · · · · · · · · · · · · · 5-10
Audible Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Performance Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Pump Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
SRE Controller Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Overview · · · · · · · · · · · · · · · · · · 5-28
Corrective Maintenance. . . . . . . . . . . . . . . . . . . . . . . . 6-1

Introduction · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-1
Tools Needed · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-1
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Lifting the Truck · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-3
Electrical Static Discharge · · · · · · · · · · · · · · · · · · · · · · 6-4
Hydraulic Fittings and Hoses · · · · · · · · · · · · · · · · · · · · 6-4
Cleaning and Inspection · · · · · · · · · · · · · · · · · · · · · · · 6-5
Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Disc Brakes · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-6
Brake Pedal · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-6
Service Brake Linkage ............................................................6-6
Brake Cut-off and Light Switch .............................................6-8
Parking Brake Handle · · · · · · · · · · · · · · · · · · · · · · · · 6-8
Adjust the Parking Brake Handle ..........................................6-9
Adjust Parking Brake Caliper...............................................6-10
Mast Lift Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Inspect Lift Chains · · · · · · · · · · · · · · · · · · · · · · · · · 6-10
Chain and Roller Adjustment · · · · · · · · · · · · · · · · · · · · 6-10
Main Pump Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
General · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-11
To Check and/or Adjust Pressure · · · · · · · · · · · · · · · · · 6-11
Steer Pump Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
General · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-14
To Check and/or Adjust Pressure · · · · · · · · · · · · · · · · · 6-15
Front Rotation Pot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
General · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-16
To Adjust and/or Replace .....................................................6-17
SRE Control Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
General · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-17
Set up· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-18

vi
Brake System - Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Changing Brakes · · · · · · · · · · · · · · · · · · · · · · · · · · 6-20
To Change Brake Pads .........................................................6-20
Replace the Brake Caliper Assembly · · · · · · · · · · · · · · · 6-23
Caliper Pistons · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-24
Disc Brake Rotors · · · · · · · · · · · · · · · · · · · · · · · · · · 6-25
Measure Thickness ...............................................................6-25
Check Lateral Run-Out (Warping) .......................................6-25
Replace Brake Rotor Assemblies........................................6-26
Master Cylinder · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-27
To Remove the Old Cylinder ................................................6-27
Bench Bleed the Master Cylinder............................................6-29
To Install the New Cylinder ..................................................6-30
Rigid Brake Line · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-30
To Replace a Damaged Line ................................................6-31
Bleeding Brakes · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-32
Parking Brake Assembly · · · · · · · · · · · · · · · · · · · · · · 6-34
Continuity test..........................................................................6-34
Replace Micro Switch ...........................................................6-35
Replacing the Brake Cable...................................................6-35
Service Brake Pedal Assembly · · · · · · · · · · · · · · · · · · · 6-37
Brake Warning Switch ..........................................................6-37
Brake Pedal............................................................................6-37
Removing Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
Steer (Load) Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
To Check · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-39
Wheel Bearings, Seals and Race· · · · · · · · · · · · · · · · · · 6-39
Replacing Tires/Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
Drive Wheels · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-41
Steer (Load) Wheels· · · · · · · · · · · · · · · · · · · · · · · · · 6-42
Console Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
Remove Left Side Cover · · · · · · · · · · · · · · · · · · · · · · 6-43
Display or Cable · · · · · · · · · · · · · · · · · · · · · · · · · · 6-44
Key Switch · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-45
Option Rocker (On/Off) Switches · · · · · · · · · · · · · · · · · 6-45
Circuit Breaker Panel · · · · · · · · · · · · · · · · · · · · · · · · 6-46
Steering Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
Steering Wheel · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-47
Steering Column (Console) · · · · · · · · · · · · · · · · · · · · · · 6-47
Orbital Steer Unit · · · · · · · · · · · · · · · · · · · · · · · · · · 6-49
To Service the Orbital Control Unit .....................................6-49
Steering Motor or Support Bearing · · · · · · · · · · · · · · · · 6-50

vii
Hints........................................................................................6-51
To Service the Motor.............................................................6-51
Steer Pump and Motor · · · · · · · · · · · · · · · · · · · · · · · 6-52
To Replace the Pump and/or Motor.....................................6-53
To Service the Steer Pump...................................................6-55
Lift Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-56
To Replace the Pump and/or Motor.....................................6-56
To Service the Lift Pump ......................................................6-59
Traction Drive - Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-60
To Begin… · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-60
To Replace Gear Unit / Motor · · · · · · · · · · · · · · · · · · · · 6-60
Hydraulic Valve Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . 6-63
Steer Control Valve · · · · · · · · · · · · · · · · · · · · · · · · · 6-63
Hydraulic Control Valve and Switches· · · · · · · · · · · · · · · 6-64
Hydraulic Lift Pot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-66
General · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-66
To Adjust and/or Replace .....................................................6-66
Linear Accelerator Module . . . . . . . . . . . . . . . . . . . . . . . . . 6-67
Module and Cable Assembly · · · · · · · · · · · · · · · · · · · · 6-67
Pedal Spring · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-69
Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-69
Replace the Switch and Cable · · · · · · · · · · · · · · · · · · · 6-70
Front End Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-70
To Begin… · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-72
Rotation Seals, Bearings or Spur Gear · · · · · · · · · · · · · · 6-72
To Remove Spur Gear Only..................................................6-73
Rotation Seals and Bearings ...............................................6-75
Hints for reassembly.............................................................6-76
The Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-76
Removing the Mast From the Truck · · · · · · · · · · · · · · · · 6-77
Tilt Cylinders· · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-80
Sideshifter · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-82
Articulation Bearing and Seal · · · · · · · · · · · · · · · · · · · 6-83
Stop Block · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-84
Horn and Direction Control . . . . . . . . . . . . . . . . . . . . . . . . . 6-85
Horn/Horn Pushbutton · · · · · · · · · · · · · · · · · · · · · · · · 6-85
Direction Control Switch · · · · · · · · · · · · · · · · · · · · · · 6-86
Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-87
To Replace a Fan · · · · · · · · · · · · · · · · · · · · · · · · · · 6-87
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-88
Lights· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-89
Back Up Alarms · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-89

viii
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-90
Appendix A - H . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-91
Appendix I - P . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-93
Appendix Q - Z . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-95

ix
Using this manual
Using This Manual

This Bendi Series IV * Service and Parts Maintenance Manual is a guide to the daily
operation and service of your Bendi Series IV Fork Lift Truck. It is designed to be used as
a reference tool in your everyday use of this truck.
Bendi is a trademark of the Landoll Corporation. All other brand and product names are
the trademarks of their respective holders.
The manual is divided into several chapters, each chapter dealing with a major function in
the care of your truck. The chapters are separated by individual index tabs. A brief
description of each chapter follows.
Safety
Always operate with safety as your number one goal.
This chapter must be carefully read, understood and adhered to strictly by all operators
and service personnel using the Bendi Series IV lift trucks. Do not use this truck until you
have thoroughly read this chapter. Failure to comply could cause risk of death or serious
injury to yourself and others.
Warranty and Parts

A copy of your Limited Warranty and Warranty and Replacement Parts Policies and
Procedures guides are found here.
Truck Overview
Chapter 1 offers a brief description of the many functions and features of your Series IV
truck. For example, traction drive, brake systems, electrical and hydraulic systems, the
operator’s compartment, specifications, and so on.
* This Service and Parts Maintenance Manual for the Bendi Series IV includes Models:
B25/42, B30/42, B35/48, B40/48, and B45/48.
Receiving and Inspection

Chapter 2 details your responsibilities upon receiving the truck, such as charging the
batteries (wet or dry), performing visual inspections and routine checks, changing
batteries, plus storage, towing or shipping information.
Bendi Series IV Forklift Service Manual

1
Using this manual
Operation
Chapter 3 explains the operation of the truck and is divided into three sections.
· Basic operation - is a complete guide to the operation of the truck, similar to the
Operator's Manual provided with every truck.
· Available options - the operating procedures for the most commonly ordered
options, such as, Fire Extinguisher, Fork Positioner, etc. are found here.
When applicable, special customer option operating instructions may also be

found here, under separate cover. Always check here or additional operating
information.
· Theory of operation - is an overview of how the hydraulic and electrical systems
work and includes a hydraulic layout diagram and schematic for a standard Series
IV truck. A fold-out electrical schematic and wiring diagram can be found inside
the front cover in this manual.
Preventive Maintenance
Chapter 4 describes the routine inspections, adjustments and settings, and lubrication
needed to keep your Bendi Series IV lift truck in optimum performance and stability, with
minimum “downtime.”
Troubleshooting
When a problem develops, see Chapter 5 for troubleshooting procedures, in chart form.
Troubleshooting procedures are defined as Visible Problems, Audible Problems,
Performance Problems, Pump Problems, or SRE Controller Problems. SRE controller
status code troubleshooting is also found here.
Once the problem is isolated, see Chapter 6, Corrective Maintenance for the adjustment
and/or repair instructions.
Corrective Maintenance
Chapter 6 details the maintenance procedures for your truck and is divided into four
sections.
· Introduction to maintenance procedures - This section must be carefully read
and understood before beginning any adjustment or repair to the Bendi Series IV
lift truck.
· Adjustments and/or setting - Instructions on performing the major adjustments
and/or settings, beyond those explained in the preventive maintenance, Chapter
4, are explained here. SRE controller setup is also included in this section.
· Mechanical repairs - This section is devoted to major mechanical repairs - how to
replace and/or repair most major mechanical parts and/or assemblies on the truck.
· Electrical control repairs - This section is devoted to major electrical repairs -
again, how to replace and/or repair most major electrical parts and/or assemblies
on the truck.

2
Using this manual
Mast IPB (illustrated parts breakdown)

The Mast Parts List(s) is an internal breakdown of the mast options available with the
Bendi Series IV forklift. This is a separate manual(s) which is included behind the Mast
IPB index tab.
Base IPB (illustrated parts breakdown)

The Bendi Series IV Parts List (F-371-___) is a separate manual which includes
breakdowns of the systems and replaceable items for the standard models and any
options available. This parts list is included behind the Base IPB index tab.
Appendix, A through Z
These three chapters contain additional service/repair manuals, in alphabetical order, for
the major systems used on the truck, such as Electrical System, Brake System, etc.
If information is not provided for a component you wish to service, contact your Landoll
service representative. Information may not be provided due to the sensitive nature of
the product, be it safety or technical requirements, or may not have been available at
time of publication.

3
Safety
Precautions
IMPORTANT !
The Bendi * Series IV trucks have been designed for
optimum safety of their operators. Please follow the safety
guidelines listed in this section and adhere to all Important,
Caution, Warning, and Danger notes found within this
manual. When the truck is in operation, always keep loose
clothing, jewelry, hair and fingers out of the restricted areas
(especially pinch areas) as labeled on the truck.
This chapter on Safety must be carefully read, understood
and adhered to strictly by all operators and service
personnel using the Bendi Series IV lift trucks. Do not use
this truck until you have thoroughly read this manual.
Failure to comply could cause risk of death or serious injury
to yourself and others.
It is the responsibility of the employer to make sure that the
operator can see, hear and has the physical and mental
ability to operate the lift truck safely. Various laws and
regulations require the employer to train lift truck operators.
These laws and regulations include:
· Occupational Safety and Health Act (USA)
· Canada Material Handling Regulations
A comprehensive operator training program is available
from Landoll Corporation. For further details, contact your
Landoll dealer for Bendi Lift Trucks.
* Landoll and Bendi are trademarks of the Landoll Corporation.

All other brand and product names are the trademarks of their
respective holders.
Series IV Bendi includes Models B25/42, B30/42, B35/48,
B40/48, and B45/48 Lift trucks.
Landoll Corporation, Bendi Series IV trucks meet or exceed
ASME B56.1 - Part III, Safety for Powered Industrial Trucks.

S-1
Safety Precautions
Safety
Site Supervision
Supervision is an essential element in the safe operation of powered industrial lift trucks.
The site supervisor must check that the Operator’s Manual is in the seat compartment on
the truck at all times. Operators must be trained on the use, maintenance and safety
aspects of the Series IV trucks under the supervision of a trained and experienced
operator.
Only those individuals trained to operate and/or service this truck may do so.
Familiarization and driving practice with a new truck must be arranged in a safe area,
away from other trucks, obstacles and people. The training program must be applied to
all new operators, regardless of previous experience.
Operator performance must be evaluated to ensure he/she has the proper skills and
knowledge to operate the truck. Operators must be retrained when new equipment is
introduced, existing equipment is modified, operating conditions change, or an operator’s
performance is determined unsatisfactory.
Warning
Do not make modifications or additions to electrical devices. Do not
tamper with or disconnect safety features or modify protective
guards (such as, overhead guards or load backrest extensions). Do
not add or remove structural parts.
Any of the above could affect truck capacity and/or safe operation of
the truck and is a serious safety violation which could cause per-
sonal injury, could weaken the construction of the truck, or could af-
fect the safe operation of the truck.
NO MODIFICATIONS OR ADDITIONS MAY BE MADE TO THIS TRUCK WITHOUT
PRIOR WRITTEN PERMISSION FROM:
Landoll Corporation
Material Handling Product Group
1900 North Street
Marysville, KS 66508 U.S.A.
Telephone: (785) 562-5381
Fax: (785) 562-4853
The truck must be inspected daily for problems or damage risking the safety of the driver
and any people in the work area, or possible damage to the truck and the load being
moved. When trucks are used on a round-the-clock basis, they must be inspected after
each shift. Problems found must be reported and corrected. The truck must be taken out
of operation until all repairs have been made and the truck has been reinspected for
safety.

S-2
Safety Precautions
Operator
Warning
Check that all directional and operational controls and levers are in
their NEUTRAL position, the brakes are set and your seat belt is fas-
tened before setting the key switch to ON (See heading ‘ Seat belt’
on page S-4).
To avoid personal injury when operating the truck, be extremely

careful that NO part of your body (head, feet, arms, legs, fingers) is
outside the operator’s cab where it could be subject to injury by aisle
supports, other trucks or any obstacle in the area.
Know the location of and be especially careful of all pinch points, as

indicated by the WARNING and DANGER labels on the truck.
Be especially careful when there are other people or moving or fixed

objects in the working area, or when the load reduces visibility (See
heading ‘ Visibility’ on page S-9). Never drive a truck up to anyone
standing in front of an object. Ensure that people stand clear of the
rear swing area before making turns.
NEVER lift, lower or transport people. NEVER allow anyone on or un-

der the forks (or load). Under no circumstances are there to be any
riders anywhere on the truck, other than the operator.
When driving in narrow aisles, make sure there is enough space for
the truck and the load, travel at reduced speeds, and where applica-
ble, request a helper to guide you safely through the area.
· The operator is responsible for observing all instructions and safety regulations in
his or her daily work routine related to the use of this truck.
· Be careful at cross aisles, doorways and other locations where people may step
into the path of travel of the truck.
· He/she must check the condition of the truck at the start of each work shift. In
particular, he/she must check the operation of the steering and brakes; the
directional control lever; the pivot and shift, tilt and lift/lower joysticks; the condition
of the batteries, parking brake, horn, and signaling devices, where applicable.
· Make sure all access/service panels, doors and covers are installed, closed and
latched tight. Do not operate the truck with panels, doors and covers removed,
opened or unlatched.
· Keep the truck clean and in good working order. Report any problems or damage
risking the safety of the driver and any people in the work area. Problems found
must be reported and corrected. The truck must be taken out of operation until all
repairs have been made and the truck has been reinspected for safety.
· Always start, stop, change direction, travel and brake smoothly so as not to shift
the load and/or overturn the truck.

S-3
Safety Precautions
· Do not indulge in stunt driving or horseplay.

· Drive carefully and slowly onto dock boards and bridge plates. Do not exceed the
rated capacity of the dock boards or bridge plates and ensure dock boards or
bridge plates are properly secured, either by being anchored or by being equipped
with devices that will prevent slipping.
· Check that dock boards have substantial contact with both the dock and the
carrier, preventing them from rocking or sliding.
· Maintain a safe distance from the edge of ramps, platforms and other similar
working surfaces.
· When leaving the operator’s cab, the forks must be lowered to the floor, the mast
must be placed in a vertical position, all controls must be in a NEUTRAL position,
the parking brake must be set and the key switch must be set to the OFF position.
Truck wheels must be blocked if the truck is parked on an incline.
Note: A powered industrial truck is considered unattended when the operator is
25 feet (7.6 m) or more away from the truck which still remains in his/her view…
or
...whenever the operator leaves the truck and it is not in view.
Seat Belt
The driver’s seat belt must always be worn when driving this truck.
· Sit up straight in the driver’s seat.
· Pull the belt across you. Do not let the belt twist.
Warning
You can be seriously injured by a twisted belt. In a crash or a tip-
over, the full width of the belt would not be available to take up the
impact forces.
· Push the latch plate into the buckle until it clicks. Pull up on the
latch plate to make sure it is secure.
· The lap part of the belt must be worn low and snug on the hips,
just touching the thighs.
IMPORTANT !
Make sure the release button on the buckle is positioned so you can unbuckle
the seat belt quickly in an emergency.

S-4
Safety Precautions
Seat Safety Switch

If the operator leaves the driver’s seat a limit switch is released. The drive and power
steering motors are disabled to prevent further truck movement.
To continue, you must first lower and sit in the seat, set the direction control lever in
NEUTRAL, then select the direction of travel.
Note: A two to three second delay is programmed into the seat switch to avoid
nuisance shutdown and interruption of normal operations. To stop the truck
quickly, use the Emergency STOP button (See page S-5).
Emergency STOP Button

Press this button to shut down the
drive and power steering motors
and all mast movement. The truck
drifts to a STOP. Immediately set
the parking brake.
To continue, pull out on the button
to reset the switch (See Figure
S-1).
BN25/B25/B30 Series
Use this button: emergency STOP button
· in case of fire, smoke or

overheating
· if a person comes between
the truck and a fixed object.
· in case an accident occurs
· in case of a short circuit or
other electrical malfunction;
for example, if the pump
motor is on continuously.
BN35/B35/B40/B45
Series emergency
disconnect
Figure S-1 Emergency STOP Button
Parking Brake
The parking brake includes a safety interlock that shuts down the drive and power
steering motors, disables the direction control lever and applies the brakes to prevent
further truck movement. To continue, you must set the direction lever to NEUTRAL,
re-lease the parking brake, then set the lever to the desired direction.

S-5
Safety Precautions
Tipping Hazards
Warning
Lift truck tip-over can cause serious injury or death to the operator or
others in the area. Every operator must be thoroughly familiar with
the tipping hazards listed in this section and must always avoid any
operation of the truck which is likely to result in tipping.
All lift trucks that elevate and tilt loads are subject to the risk of tip-
ping over, especially when accelerating or when applying the brakes
abruptly. Transporting loads off-center also increases the risk of
tip-over.
If a tip-over occurs, the operator should follow the following guidelines shown
here.
· DO NOT JUMP
· BRACE YOUR FEET FIRMLY
· HOLD ON TIGHT
· LEAN AWAY FROM THE TIP
The most likely causes of tip-over are listed in this section. However,
the operator must use good judgement based on proper training and experience to
determine turning sharpness and speed for the load being handled and the operating
surface (or road) conditions.
A truck can tip longitudinally (tipping over the front or rear wheels) or laterally (tipping
either to the left or right side).
Longitudinal Tipping Can Occur When:

· the truck is overloaded.
· the mast is tilted forward excessively, with or without a load.
· the load is raised and brakes are applied while the truck is traveling forward or
backward.
· the load is raised and the truck is accelerated while it is traveling forward or
backward.
· the truck is driven forward down a steep incline with a load.

S-6
Safety Precautions
Lateral Tipping Can Occur When:

· the truck is turned sharply while traveling rapidly in either direction, with or without
a load. An unloaded truck can tip easier than a loaded truck (with the load
lowered).
· the load is raised and the truck is being turned while traveling in either direction.
· the load is raised and the truck is being turned and accelerated or braked while
traveling forward or backward.
· the truck is turned while traveling on a ramp or other inclined surface.
· a load heavier than the rated truck capacity is lifted.
Tipping over in these conditions is made more likely by overloading, excessive mast tilt,
or off-center positioning of the load.
Soft tires can also reduce stability. The truck is equipped with tires of a size and hardness
that will provide the necessary traction and maintain a proper shape to minimize tipping.
Always replace tires with the type originally supplied by the manufacturer.
The truck can be tipped either longitudinally or laterally if it is driven:
· over objects on the floor or ground.
· off the edge of a paved surface.
· into a pothole in a paved surface.
· off the edge of a loading dock, or off the edge of a loading ramp. (It is important to
avoid driving too close to the edge of a dock or ramp).
When loading or unloading a highway truck or trailer, make sure the highway truck
cannot move away from a dock while loading is in process. Make sure the highway truck
or trailer has its brakes applied, engine turned off and, if on an incline, has the wheels
blocked.
Tipping can also occur if the truck collides with another truck or other vehicle, or if the
mast runs into an overhead obstruction.
Traveling and Load Handling

· Observe all traffic regulations. Keep to the right and maintain a safe distance from
the truck ahead based on speed of travel. Keep the truck under control at all
times.
· Yield the right of way to other people in the area.
· Slow down and sound the horn at cross aisles and other locations where visibility
is obstructed.
· Keep a clear view of the path of travel and be alert for other traffic, people and
safe clearances.
· Under all travel conditions, operate the truck at a speed that permits you to bring
the truck to a complete stop in a safe manner.
· Do not handle unstable loads. Use care when tilting forward or backward,
stacking, depositing, or retrieving a load. Never travel with the mast tilted forward.
· Never exceed the truck’s maximum lifting capacity. Refer to heading
Specifications in this manual and the capacity plate, located in the operator’s cab
(See Figure S-2).
S-7
Safety Precautions
· Pay particular attention when

picking up a new load, to ensure
the load weight and height
requirements are within the truck’s
capacity.
· Truck stability and handling may be
adversely affected.
· Do not transport loads or other
items within the operator’s cab or
other areas of the truck.
· Check that the load is properly
positioned on the forks before
lifting.
· Spread forks as far apart as the
load permits and push completely
under the load. Check that forks
and loads are centered. Use care
when handling off-center loads.
Figure S-2 Capacity Dataplate Location
· Travel with forks straight ahead,
and the mast tilted backward.
· Travel with forks or load 8” to 12”
(203 mm to 305 mm) above travel surface.
· Elevate mast or load only to pick up or deposit a load. Watch out for obstructions,
especially overhead. Watch all clearances.
· Tilt a loaded mast slowly.
· Do not release the lift control lever suddenly when lowering loads. This may cause
bouncing of the carriage which could dump the load.
· Do not allow anyone, under any circumstances, to walk or stand under the forks or
any part of the load.
· Never place any part of your body between the mast structures or any moving part
of the truck.
· Do not turn when traveling on ramps. When descending ramps, travel forward
(forks facing downhill) when empty, travel backward (forks facing uphill) when
carrying a load.
· Use care even when traveling without a load. Avoid high speeds, sharp turns and
abrupt stops.

S-8
Safety Precautions
Speed
Travel speed must be chosen according to the situation, such as, the load being handled,
road surface conditions, visibility, people working in the area, moving and fixed objects in
the area, cross aisles, and so on.
Always operate the truck at a speed that will permit it to be brought to a stop in a safe
manner.
Warning
Careless driving, such as, fast starts or abrupt braking, excessive
speed at turns or through cross aisles, sudden stops, or hard turns
at high speeds can all lead to serious personal injury and damage to
the truck and load. Always drive with safety as your number one
goal.
Visibility
Where visibility is restricted, travel at very slow speed and use the horn frequently.
Always ask for a helper to guide you safely through the area when visibility is restricted.
Always rotate in the driver’s seat to face in the direction you are traveling.
Battery Care
Overhead guard
cutout
Features
Series IV trucks include a heavy Battery compartment
gauge, pre-molded top top cover
compartment cover and a side
door to secure the battery in the
compartment.
Both covers include latches to lock Battery compartment
Top cover
the compartment. A cutout in the locking latch
overhead guard is also provided
for easy battery service (See Battery adjust-
Figure S-3). ment bracket
(both sides)
The compartment top cover and
the side door must be Side door
Battery
lowered/closed and securely compartment
locked in place whenever the
battery is installed.
Figure S-3 Battery Compartment
and OHG Cutout

S-9
Safety Precautions
Care
The truck battery contains concentrated sulfuric acid which can cause severe chemical
burns. When the battery is charging, it releases hydrogen, a colorless, odorless and
highly explosive gas which can be ignited by a spark. Eliminate all sparks or flames from
the charging area.
Shorting battery terminals can release enormous amounts of energy, causing
sparks or flame, or heating nearby components to dangerous temperatures.
The battery is very heavy, and if restraints are not replaced after maintenance,
the battery could slide out of the truck causing electrical shorts or spilling acid -
or it could cause the truck to tip over.
The battery is also used as a counterweight. A different size or weight battery could
cause the truck to become unstable and tip. Use batteries that meet the weight and size
specifications shown on the capacity plate in the operator’s cab.
Warning
Always assume the battery is emitting hydrogen and employ proper
safety precautions.
Do not smoke, use an open flame, or create arcs or sparks near the
battery.
Consult the label on your battery for information on cell-type,

ampere-hour capacity, charge rate and normal full-charge voltage.
Do not charge the battery at a current greater than 1.5 amp per 100
amp-hours capacity at the end of charge.
Packaged with every battery are specific instructions for battery

safety, care and use, and a Material Safety Data Sheet (MSDS). Read
these documents thoroughly before performing any service to the
battery.
Always disconnect the battery before performing any truck mainte-

nance and be sure to wear protective clothing and safety glasses
when working with battery acid or the battery in general.
Neutralize acid spills immediately with Bicarbonate of soda! If acid

contacts the skin or eyes, wash with water immediately and seek
medical help at once.
Never place a tool or any metal object on top of the battery where it
could possibly touch battery terminals causing a short or serious
electrical shock.
Use caution when changing battery connectors to ensure that the

polarity is not reversed.

S-10
Safety Precautions
Warning
Keep vent plugs in place and clean at all times.
When replacing this battery, use the same type battery as specified
on the truck rating nameplate. Failure to comply could result in an
unbalanced condition, resulting in tipping the truck and possible
personal injury or loss of life.
Be sure to replace, close and/or retighten any battery restraints

which have been installed on the truck.
Service Repair
When it becomes necessary to do any service repair or maintenance to the
truck, it is important to first review the following safety guidelines.
Warning
You could be injured and the truck could be damaged if you try to do
service work without proper training or equipment.
1. Be sure you have sufficient knowledge, experience and the proper tools and
replacement parts before you attempt any truck maintenance.
2. Be sure to use the proper nuts, bolts and other fasteners. Many are specifically rated;
that is, SAE Grade 5, SAE Grade 8, ISO Prop Class 8.8, etc., and must be replaced
with the identical type. It is recommended to use only Landoll authorized replacement
parts.
Warning
If you use the wrong nuts, bolts or other fasteners, parts can later
break or loosen. Serious injury could occur.
3. Whenever possible, return the truck to a service area having sufficient lighting, work
space and an assortment of tools needed to complete the service.
4. Set the key switch to OFF, set the control lever to NEUTRAL and set (engage) the
parking brake.
5. Disconnect the battery.
6. Never place a tool or any metal object on top of the battery where it could possibly
touch battery terminals causing a short or serious electrical shock.
7. Make sure all lifting devices and supports, such as, a jack or support stand, are
capable of handling the weight of the load being applied.

S-11
Safety Precautions
Warning
To be certain the truck will not move, place wedges (or blocks of
wood) at the front and back of the tires.
If you are servicing the brakes or tires, place the blocks at the front
and rear of the tire farthest away from the one being serviced. (That
would be the tire on the opposite side of the truck and at the opposite
end.)
8. Always place an appropriate support stand under the truck if it is being lifted, then
lower the truck to the stand, having both the lifting device and stand supporting the
weight of the truck.
DANGER
GETTING UNDER A TRUCK WHEN IT IS LIFTED OR JACKED IS DAN-
GEROUS AND COULD CAUSE SERIOUS INJURY OR DEATH. NEVER
GO UNDER A TRUCK THAT IS SUPPORTED ONLY BY A JACK.
9. Fully open the required truck covers and be sure they are braced to prevent
accidental closing.
Side Shifting
At least once every working shift, the side shifter must be inspected for visible damage
and defects. Any changes occurring with the side shifter or its workings must be reported
immediately to the supervisor.
Moving parts of the side shifter entail the danger of pinching, crushing or snagging. Safe
distance must be maintained at all times to prevent clothing or body parts from being
caught by the moving parts.
When side shifting, closely watch the load and forks throughout the entire operation to
prevent over shift or snagging the load on other objects.
Operate the side shift only when the load is lifted off the ground.

S-12
Safety Precautions
Safety Labels
For operator safety, a number of CAUTION, WARNING, and DANGER decals/plates are
attached to the truck, including the CAPACITY plate within the operator’s cab. A sampling
is shown below. See Figures S-4 - S-6 for safety label locations and decals.
General
WARNING or DANGER decals describe
conditions or practices which, if not strictly
observed, could result in personal injury or
possible loss of life.
CAUTION decals describe conditions or
practices which if not strictly observed or
remedied, could result in damage to, or
destruction of the equipment or property.
CAPACITY plate
This plate lists the load weights allowable for various fork heights, battery information,
and also lists the truck model number, serial number and other basic truck data. This
plate is located in the operator’s cab, next to the driver’s seat (See Figure S-2).

S-13
Safety Precautions
Figure S-4 Safety Label Location

S-14
Safety Precautions
1
2
3 5
7
4 6
11
8 10
14
12 13
17
16 18
15
19
23
20
22
29
21 25
24 31
27
28
30 40
36
34 41
32
37
35
38 39 42
Figure S-5 Safety Decal Identification

S-15
Safety Precautions
43 44
45 46
Figure S-6 Safety Decal Identification

S-16
Safety Precautions
Available Options
Fork Positioner, Non-Side Shifting
Lift trucks using automatic non-side shifting fork positioners require additional SAFETY
attention.
Warning
Pay strict attention to all safety labels affixed to the fork positioner
and backrest.
No riding or standing under any part of the load or on the forks.
NEVER reach through the backrest or between the fork positioner

mechanism.
The top of the load must not extend above the top of the backrest.
The load must never exceed the capacity of the fork positioner as
stated on the capacity plate affixed within the operator’s cab.
Daily, check the upper hook engagement, the

fasteners, the lower hook engagement and
inspect for hydraulic oil leaks (See Figure S-7).
Report any problems to your supervisor
and remove the truck from service until the
problem is corrected.
Figure S-7 Fork Check Points

S-17
Safety Precautions
Fire Extinguisher
If your truck includes a fire extinguisher it should be inspected monthly or
more frequently if circumstances dictate. The extinguisher should be
checked to see that:
· it is not damaged
· the discharge outlet is not blocked
· it is fully charged
· the seal is not broken
· the instruction pamphlet is clearly visible
Also see page 3-27 for additional operating information.
IMPORTANT !
Dry-powder extinguishers are shipped fully charged. Do not experiment with your
extinguisher since even a small amount of discharge could cause it to slowly lose
the rest of its pressure, rendering the extinguisher useless.
In case of a fire !
· Have everyone vacate the area immediately.
· Call the fire department, no matter what the size of the fire. Emergency telephone
numbers should be posted at each telephone.
· Use your extinguisher correctly, according to the directions on the label and in this
manual. Large fires should be handled by professionals.
· Be ready to leave the area in the event the fire cannot be controlled immediately.
Rollout Battery Tray

Also see page 1-19 for additional operating information.
If your truck includes the rollout battery
tray option it should be inspected at
the beginning of every shift. The
system should be checked to see that:
· The battery is secured tightly
within the battery compartment
- the proper amount of spacers
are used
· The restraint arm is locked in
place with the release handle
lowered (See Figure S-8)
· The limit switch is actuated
allowing truck operation. With
this switch released, all truck
operations must cease.
Figure S-8 Restraint Arm

S-18
Safety Precautions
Additional Publications
Additional information that describes the safe operation and use of lift trucks is available
from the following sources:
· Employment safety and health standards or regulations
(Examples: Occupational Safety and Health [USA], Canada Material Handling
Regulations)
· Safety codes and standards
(Examples: American National Standard, ANSI b56.1, Safety Standard for Low Lift
and High Lift Trucks)
· Publications from government safety agencies, government insurers, private
insurers and private organizations
(Examples: Accident Prevention Manual for Industrial Operations, from the
National Safety Council)
· Operator Safety Training Course - describes lift truck safety, good maintenance
practices, and training programs.
Available from you Landoll dealer for Bendi Lift Trucks. Landoll part no.:
12345678.

S-19
Truck Overview
Introduction
This manual provides operating and maintenance instructions for
the Landoll Corporation Bendi * Series IV Lift Trucks. The
Series IV is engineered to retain the legendary ”narrow aisle”
maneuverability of a battery-powered lift truck, while
incorporating 180° steering and front-end articulation, plus
rear-wheel drive. This gives the Bendi Series IV well suited
stability, traction and control even in the full-turn position. The
mast pivots 90° (right or left) and shifts across the front of the
truck to allow insertion and removal of loads from the right or left
hand side of the aisle. This feature makes it unnecessary to turn
the entire truck in the aisle and permits operation in storage
aisles as narrow as 66” (198 cm). One truck can handle loads
from production to storage and from storage to truck loading,
without support vehicles and without staging and dedicated
load-unload stations.
The Series IV truck also offers:
· Four-wheel configuration - dual rear wheel drive; front wheel
steering and articulation
· State-of-the-art, transistorized, electronic controls with
self-diagnostics, hour meter, battery discharge indicator and
lift interrupt.
· Joystick operation for load functions - utilizing a
three-function hydraulic control valve. A fourth (4th) function
hydraulic valve is available for an approved Class III
attachment.
· 48 volt DC battery with emergency disconnect switch,
latching battery cover with drive interlock, plus side access
compartment with slide strips or optional rollers.
· Duplex, triplex or quadplex high visibility mast
configurations.
· Lift capacity from a maximum of 2,500 lbs./1,134 kgs. up to
4,500 lbs./2,041 Kg. at 24”/600 mm load center.
· Ergonomically designed operator compartment - includes
sit-down operator position, adjustable driver’s seat,
tilt/telescoping steering wheel, hand lever direction control,
arm rest and operator supply tray

1-1
· Safety interlocks - key switch activation and operator seat
safety switch, plus an electrical lockout requiring the control
lever to be in the neutral, or center position before power
can be restored.
Landoll trucks meet or exceed ASME B56.1 - Part III, Safety for
Powered Industrial Trucks and are FMRC approved by meeting
or exceeding requirements of FRMC Class 7820, ANSI/UL-583
standard for Battery Powered Industrial Trucks, Types E, ES,
and EE.
The electrical system complies with UL-583 requirements for
type E, ES (optional), and EE (optional) Electrical
Battery-Powered, Industrial Truck construction.
Machine model, serial and option numbers (where applicable)
are stamped on the capacity nameplate affixed within the
operator’s cab (See Figure 1-1).
IMPORTANT !
Series IV truck operators and service personnel must
familiarize themselves with this manual and the Bendi
Series IV truck to provide safe and efficient operation.
Practice runs in a controlled and safe area, away from
obstacles and other personnel, are recommended.
Unauthorized driving by untrained or unskilled personnel
must be strictly prohibited.
All safety notices in this manual, those found in heading
SAFETY of this manual, and the safety regulations or
standards valid in your local area must be strictly enforced.
Figure 1-1 Capacity Dataplate Location

1-2
Truck Overview
Truck Layout
Figure 1-2 Bendi Series Overview - Left Side
1. Forks
2. Mast
3. Steering column
4. Mount/dismount handle
5. Driver’s cab
6. Seat belt
7. Access step

1-3
Truck Overview
Figure 1-3 Bendi Series Overview - Right Side
1. Electrical control cabinet

2. Overhead guard
3. Load backrest extension
4. Mast tilt indicator
5. Side Shift assembly
6. Front articulating steer tires and wheels
7. Rear drive tires and wheels
8. Battery compartment

1-4
Truck Overview
Overview
Frame
The frame consists of 3/8” to 1” thick (9.525 mm to 25.4 mm) steel panels welded
together to form the backbone of the truck (basic truck shape). A number of thick
rectangular steel shapes (counterweights) are welded within the frame to counterbalance
the truck against the weight of its load. The rear wall of the truck also includes a thick
steel plate to add additional counterbalance.
Note: The size and weight of the battery is also used as a counterbalance.
Traction Drive
Bendi Series IV trucks are dual-drive, four-wheeled trucks, having two steerable,
articulating load support wheels in the front and two independently controlled drive
wheels in the rear. The rear drive wheels consists of a gear box and a separate DC
electric motor, controlled by the SRE transistorized controller. See “Electrical System,”
page 1-6 for additional information.
Brake System
The rear drive wheels are equipped with hydraulically-actuated dry disc brakes - typical
automotive disc brake system. The brake pedal activates a master cylinder to apply
hydraulic pressure to wheel calipers, forcing the disc pads to grip the rotor.
The system is a dedicated system using standard DOT #3 brake fluid and non-asbestos
disc pads.
Parking Brake
A parking brake system is fitted to the left-side drive unit disk brake caliper and is
equipped with a cable-actuated dry disc brake (puck). The system is hand-lever
actuated, and is electrically interlocked to create a NEUTRAL condition when the brake
lever is actuated.
As the lever is raised to apply the brake, the drive and power steering motors shut down
and the directional control electrically resets to NEUTRAL, preventing further movement
of the truck.
To continue, the operator must first set the direction control lever to NEUTRAL, release
the parking brake, then set the control lever to the desired direction of travel.
Safety Interlock
Both a key lock switch (key switch) and an operator’s seat switch must be activated
before the truck can move. The seat switch is activated when the operator is seated in
the driver’s seat (Also see 'Seat Safety Switch,’ on page S-5 for additional information).

1-5
Truck Overview
Electrical System
The electrical system includes the battery, four transistorized controllers, solenoid
contactors, safety interlocks, meters, power cables, and electrical harnesses. The
electrical system complies with UL-583 requirements for type E, ES, and EE Electrical
Battery-Powered, Industrial Truck construction.
Additional information is available in the Appendix, Index tab, A - H 'Electrical System'.
Traction
Dual traction controllers are used, each having a maximum rating of 950 amps.
Controllers provide full time dual rear wheel drive with steer position sensing to
independently control the speed of each rear drive wheel during varying degrees of turn.
Inside wheel reversing occurs at full turn which also reduces the outside turning radius.
Motor amp draws and operating temperatures are greatly reduced, while speed control,
longer motor life, lower operating temperatures, increased motor torque and longer
running times are greatly improved. Ramp performance is also enhanced since there is
no bypass contactor system. The full speed range from 0 to 100% is controlled through
the controller with maximum efficiency. Starting on a ramp is also accomplished without
rollback with positive and smooth acceleration control.
Main Pump Motor (Lift)

The main pump motor (lift) is controlled by its own controller. Motor speed during lift is
varied and controlled by a potentiometer, linked to the lift lever. Maximum motor speed
during tilt and side shift is programmable to suit applications. Acceleration rates for all
functions are also programmable.
Operating temperature and amp draw of the motor is reduced and brush life is increased
affording longer run times per shift. The maximum speed of the motor for each function
is programmable, thus reducing hydraulic fluid heat and power consumption. Series IV
controllers provide more precise and smoother function speed control.
Power Steering
The power steering motor (steering) is also controlled by a separate controller. This
controller allows for programmable motor acceleration rate, greatly increasing overall
motor life and reducing brush wear.
Battery
A 48 volt lead-acid battery provides drive power, as well as power for the hydraulic
system, and power for lights and other auxiliary equipment.
For maintenance and/or emergencies, an emergency stop button (red)(B25/B30)/ quick
disconnect handle (B35/B40) is provided on the right-hand side of the driver’s
compartment. For maintenance, the driver’s seat compartment cover, a hinged side
cover, overhead guard cutout and slide strips allow easy battery removal from the right
side. As an option, rollers can be provided for additional battery maneuverability.

1-6
Truck Overview
Hydraulic System
The lift hydraulic system is powered by a variable speed DC electric motor, connected to
a vane pump. This system provides power for primary and secondary circuits for the
mast tilt (forward and backward), side shift (right-to-left) via a double-acting, double
ended cylinder, and mast lift / lower (up and down) positioning.
System cooling uses convection and conduction of heat from the reservoir, hydraulic
tubing and cylinders to maintain a safe operating temperature below 175° F (97.22° C).
A steel mesh suction filter, within the hydraulic reservoir, plus an easily accessible return
line filter (10 micron rating) with a contamination level of ISO 2943 or better is used for oil
filtration.
Additional information is available in the Operation chapter, heading, Theory of operation,
beginning on page 3-31.
Steering
The power-assisted steering system operates independently from the lift system. It
consists of a DC electric motor/pump configuration, an orbital, a motion control valve and
hydraulic power steering motor (powers the mast to pivot 0° - 90° from the front position
to the right or left side). The orbital valve meters oil to the motion control valve, then to
the power steering hydraulic motor.
Power steering is powered by a permanent magnet DC electric motor, operating at a
fixed speed.
Mast Controls
Mast positioning is achieved by operating the hydraulic control valve via the three
hydraulic control levers. Hydraulic pressure is provided by a vane pump driven by a
single DC electric motor.
Mast movements may be operated individually or together; however, when operated
together, the speed of operation is somewhat slower.
A fourth (4th) function hydraulic valve is available for an approved Class III optional
attachment.
Side Shift
The side shift circuit provides the means for moving the mast laterally (left-to-right). Side
shift movements are accomplished using a double-acting, double-ended hydraulic
cylinder (equipped with end-of-stroke cushioning) to produce a smooth, non-jerky motion.

1-7
Truck Overview
Operator’s Cab
Driver Controls
Driving controls for the Series IV truck include a steering wheel, horn button, a forward
and reverse lever, foot brake pedal, accelerator pedal for speed control, hand-actuated
parking brake lever and an emergency disconnect handle or switch (See Figure 1-4).
Figure 1-4 Operator’s Cab

1-8
Truck Overview
Warning
Driving speed of the truck must be governed by your work environ-
ment, such as, slippery floors, cross aisles, slanted driving surfaces,
load size, visibility or other people working in the area.
Never travel at speeds with or without a load that could be danger-

ous to yourself or others. Also see separate heading, Safety, in the
beginning of this manual.
· Accelerator pedal - is pressed
by the driver’s right foot to Accelerator
control the speed of the pedal
truck (See Figure 1-5).
Travel speed varies according

to the weight of the load. A
Bendi Series IV has a
maximum speed of 6.5 mph
(miles per hour)/10.5 kph
(kilometers per hour) with no
load (empty), 6.0 mph/9.7 kph
with a load.
· Brake pedal - when pressed, Brake pedal
applies the service brakes
bringing the truck to a safe
STOP (See Figure 1-5).
Figure 1-5 Pedals
Note: The Series IV is designed for
“plugging;” therefore, the service
brake pedal should only be used in an
emergency situation.
· Accessories circuit breaker panel -
Push button circuit breakers are
provided to reset the corresponding
electrical circuit should a problem
develop (See Figure 1-6).
Circuit breakers are provided for:

Lights, Reverse Access., Customer
option and 4th function (See Figure
1-6).
· Key switch - switches electrical power
to the truck On and OFF (See Figure
Figure 1-6 Steering Column Side Panel
1-6).
Warning
Circuit breakers that fail more than most indicate an electrical prob-
lem that must be immediately investigated to find the cause. The
truck must be removed from service until the problem is corrected.

1-9
Truck Overview
Battery Compartment Access Cover /Latch

The driver’s seat and side panel
are part of the pre-molded battery
compartment top cover.
The cover includes a mechanical
retention latch and pin to secure
the battery access cover to the
overhead guard when opened
(See Figure 1-7). Another hold
down latch is provided to secure
the cover closed.
Figure 1-7 Battery Cover Latch
· Direction control lever - is located on the driver’s side panel and selects the
direction of travel of the truck (forward or reverse) (See Figure 1-8).
· Horn push button - The horn is also located on the driver’s side panel.
Press in directly on the mushroom push button to sound the horn (See Figure
1-8).
Figure 1-8 Driver’s Arm Rest Control Panel
· Driver’s seat - is adjustable to accommodate the driver’s weight (seat cushion

spring tension), backrest tilt and distance from the pedals. The seat also includes
a circuit interrupt safety switch (Also see ‘Safety interlock’ on page 1-5).

1-10
Truck Overview
· Emergency STOP push button/disconnect - Activate the emergency stop

button (B25/B30) / disconnect handle (B35/B40/B45) to shut down the drive and
power steering motors and all mast movement. The truck drifts to a STOP.
Immediately set the parking brake. To continue, reset the disconnect (See Figure
S-1).
Use this button/handle:

· in case of fire, smoke or overheating
· if a person comes between the truck and a fixed object.
· in case an accident occurs
· in case of a short circuit or other electrical malfunction; for example, if the
pump motor is on continuously.
· Lift and tilt and shift - Lift, tilt, and shift movements of the mast and lift carriage
are accomplished using the three levers (joysticks) located on the driver’s side
panel. Each lever provides independent movement and each is marked with a
graphic icon to represent the function it controls (See Figure 1-8).
Also see "The Mast," page 3-16 for additional information.

· Operator switch panel - includes three on/off rocker switches to activate optional
packages installed on your truck (See Figure 1-9).
· LEFT switch - for headlights
· CENTER switch - for service brake override for ramp starting and is
standard on all trucks
· RIGHT switch - for optional attachment requiring on-dash activation
Only those options included with your truck are operable. Also see the Options section of
this chapter for more information about the options available (See Figure 1-9).
Figure 1-9 Operator Switch Panel

1-11
Truck Overview
· Parking brake pedal -

engages the parking brake
when the handled is pulled
upwards. The drive and
power steering motors shut
down and the direction
control resets to NEUTRAL
(See Figure 1-4).
To continue, the operator

must first set the direction
control lever to NEUTRAL,
release the parking brake,
then set the lever to the
desired direction.
· Rear view mirror - is
attached to the front top of Figure 1-10 Steering Column
the overhead guard. The
mirror is adjustable up and
down, and side to side.
· Tilt steering column - is pressed upwards to release the column so it may be
adjusted up or down for the driver’s comfort (See Figure 1-10).
Dash Display Panel

The instrument panel (dash display) provides easy access to truck operating information
and real-time systems diagnostics. One display is provided for each traction control.
The left side dash display records data affecting the left side drive wheel (traction
control), and indicates, via the H-BRUSH signal, when the lift pump motor brushes should
be replaced (See Figure 1-11).
The right BDI records the right
side drive wheel (traction control)
and indicates, via the H-BRUSH
signal, when the steering pump
motor brushes should be replaced
(See Figure 1-9).
Figure 1-11 Left and Right Dash Display Unit

1-12
Truck Overview
· Hour meter (LCD) - accurately accumulates and displays the active operating
hours for the appropriate drive wheel.
· Battery capacity (BDI) - monitors the capacity (or percentage) of the battery
charge remaining. F = full charge, E = empty.
When the battery drops to 10% of full charge, the lift function is disabled (by
shutting off the pump if the lift lever is operated). With this function disabled, the
operator has no choice except to return the truck to the charging station.
The main purpose of this interlock is to prevent deep discharge of the battery
(which shortens battery life), and to also protect the electric motors and other
electrical components from damage caused by low voltage.
Note: Both display units rarely read exactly the same battery capacity, but should
be within 20% of each other. This is common and should not be a concern.
· Fault indicator light - monitors the capacity (or percentage) of the battery charge
remaining. F = full charge, E = empty.
· Scroll function button - holding the button depressed for two (2) seconds enters
the fault code cycle, displaying the most recent fault code.
Tapping the button scrolls through the all fault codes recorded. To erase the
stored fault codes and reset the fault indicator light, tap the scroll button twice.
The display counts down until all faults are cleared.
To exit the fault code display, press and hold the scroll button for two (2) seconds.
This returns the display to the hour meter.
Also see Chapter 3, heading: 3.6.2 “ Instrument Panel,” on page 3-31 for additional
information.
Mast Assemblies
Various mast assembly configurations (duplex, triplex and /or quadplex) can be applied to
the Bendi Series IV trucks to provide both collapsed and extended heights suitable for
most customer requirements. The lifting capacity of the mast also varies depending on
the truck and its application. Load capacities are determined at 24” (609.6 mm) centers,
centered on the mast and include all attachments on the carriage.
The Bendi Specifications sheet at the end of this chapter lists the dimensions of standard
masts available for these trucks. Also check the capacity plate in the operator’s
compartment for the maximum lifting capabilities based on the particular truck and mast
combination (See Figure 1-1).
The trucks are counterweighted to compensate for all positions of the maximum allowed
load.

1-13
Truck Overview
Masts are engineered to distribute thrust

loads evenly between the rollers and rails.
Masts move as a unit, providing maximum
strength and endurance for the rated load
and consists of up to three pairs of
channels or rails (steel beams) rolling one
within the other on steel rollers.
The outer rails provide guidance and
support for the middle rails, which in turn
guide and support the inner rails. The
truck forks are mounted on a carriage
assembly that runs on rollers within the
inner rails (See Figure 1-12).
Figure 1-12 Mast in Collapsed Position

A primary cylinder is supported by the
inner rails and hydraulically controlled. As
the primary cylinder rod extends, a sheave
and chain assembly lift the fork/carriage
upward at twice the distance covered by
the cylinder rod.
This first stage of carriage lift is called free
lift. It is the distance of lift available
without increasing the overall height of the
mast assembly (See Figure 1-13).
A secondary cylinder, attached to the outer

rails, lifts the middle and inner rails
progressively via chains, rollers and
sheaves. The inner rails are raised at Figure 1-13 Mast in Free Lift Position
twice the rate of extension of the
secondary cylinder piston.
This upward lift continues until the
secondary cylinders are fully
extended (See Figure 1-14).
The hydraulic fluid used to lift the primary

cylinder is applied sequentially to the
secondary cylinder. When the primary
cylinder reaches full extension, the
secondary cylinder begins to extend.
Figure 1-14 Mast Fully Extended

1-14
Truck Overview
The differences in weights being supported by the cylinders, along with the differences in
cylinder diameters, ensure that the primary cylinder will be fully extended before the
secondary cylinder can begin to move. Consequently, when the mast is raised, it moves
through two phases:
· Free lift, in which only the carriage assembly moves, up to the maximum height
allowed by the inner rails (See Figure 1-13).
· Rail extension, in which both the middle and inner rails move, carrying the
carriage upward (See Figure 1-14).
Downward movement of the mast is accomplished by releasing the hydraulic fluid from
the cylinders back into the reservoir. The weight of the rails and carriage provides
enough pressure to force the fluid from the cylinders. When the secondary cylinder
piston is fully contracted, the primary cylinder begins to collapse, forcing its fluid back to
the reservoir.
The mast is supported by trunnions which allow it to tilt fore and aft. The amount of tilt is
controlled by two short hydraulic cylinders mounted between the bottom of the mast and
the pivot arm. A mast indicator gauge (pointer) is located on the left side of the mast (as
viewed from the front of the truck) to indicate when the carriage/forks are perfectly level
with the floor.
As an option, trucks may be equipped with quadplex masts which utilize four sets of rails,
referred to as Outer, Outer Intermediate, middle, and Inner rails, respectively (See Figure
1-15).
The primary cylinder and carriage operate the same as a triplex (three-rail) mast. When
the secondary cylinders extend, they lift the middle rails. Through an intricate system of
chains and sheaves, the rising middle rails pull up the outer intermediate rails at half the
middle rail speed, and push up the inner rails at twice the middle rail speed.
Figure 1-15 Quadplex Mast in Collapsed Position

1-15
Truck Overview
Technical Specifications
Bendi Series IV Narrow Aisle Forklift
Landoll Corporation’s policy is to continually improve products. We reserve the right to
change specifications and design without notice.
Technical specifications for the standard Bendi Series IV, Modes B25/42, B30/42, B35/48
and B40/48 and standard mast assemblies are listed on the Specifications sheets
provided at the end of this chapter (last two pages).
Appendix
Models
EE Series (Electrical Enclosure)
EE series or Electrical Enclosure lift trucks are used in hazardous environments requiring
protection from sparks, commonly produced by various electrical motors, contactors,
switching devices, relays, etc. EE trucks spark enclose all electrical components using
specially designed covers and/or insulated metallic-seal enclosures to insulate sparks
from the operating environment.
Cold Storage (Freezer Package)

Cold storage series lift trucks are designed to work in and out of cold storage or
freezer-type environments where moisture condensation exists. These trucks are
equipped with specially designed ductwork to divert the heat that is generated from the
pump and drive motors to the electrical compartment, keeping electrical components dry.
When the trucks are operated outside the freezer for any length of time, a
thermostatically-controlled flapper diverts the heated air to the outside.
Available Options
Fire Extinguisher
A dry-powder based fire extinguisher is mounted, using a
quick-release bracket, to the outer cage surrounding the truck
operator. Dry-powder extinguishers help fight Class B and C type
fires (oil, gas, grease, electrical, etc.).
Fire extinguishers must be inspected monthly and the results
recorded on the inspection tag attached to each extinguisher (See
Figure 1-16).
If your truck is equipped with an extinguisher, see "Fire
Extinguisher" page S-18. Also see 'Fire Extinguisher Option' page
3-27 for additional information. Figure 1-16
Fire Extinguisher

1-16
Truck Overview
Warning
Dry-powder extinguishers are shipped fully charged. Do not experi-
ment with your extinguisher since even a small amount of discharge
could cause it to slowly lose the rest of its pressure, rendering the
extinguisher useless.
Fork Positioner, Non-Side Shifting

Fork positioner options are hydraulically driven units that allow the forks to move equal
distance from each other to accommodate the size of the load being moved (See Figure
1-17).
Load Backrest
Fork Positioner
Figure 1-17 Fork Positioner Overview/ Setting
The forks start at the center of the carriage and

move equal distance to the outside and back
again as indicated by letters C and D (See
Figure 1-17).
A push button is added to the pivot and shift
joystick control (See Figure 1-18).
Figure 1-18 Joystick Push Button

1-17
Truck Overview
Light and Alarms

Various light and alarm option packages are available as follows (See Figure 1-19 for
examples):
· Audible backup alarm — sounds
(beeps or talking) when the truck is
placed in reverse to alert all personnel
in the area.
· Rear strobe light — includes 180°
blackout for operator protection and is
available with red, amber or blue lens.
· Floodlights — Two lights with guards
can be mounted on the mast or the
overhead guard on the front, rear or Back Up Alarm Strobe Light
both.
· Stop/tail lights — Two light sets can
be mounted to the back of the truck or
the overhead guard.
· Flashing backup strobe
Floodlight Turn Signal
Figure 1-19 Sample - Lights and Alarm

1-18
Truck Overview

The rollout battery tray assembly includes (See Figure 1-20):
· Roller tray
· Side restraint bracket, with spacer/shims as required
· Adjustable restraint arm, with required spacers/shims
· Limit switch for restraint arm
The battery rollout assembly reduces downtime when changing batteries by offering
quick and easy battery servicing.
With the battery rollout restraint arm installed and locked, the limit switch is actuated to
allow complete truck operation. Spacers/ shims are provided to secure the battery within
the compartment.
Releasing the rollout restraint arm handle and removing the arm, for battery removal,
releases the limit switch to shut down the truck. All operations are disabled.
Handle, rollout restraint/

release arm
Rollout restraint/
release arm, with
required spacers
Limit switch
Rollout battery
tray
Rollout battery
restraint, with required
spacers
Battery tray
btryroll
Figure 1-20 Rollout Battery Tray Assembly

1-19
Receiving Your Truck
Before shipping from the Landoll Corporation, each Bendi Series
IV truck is inspected to make sure the truck you receive is in
impeccable condition and equipped per your order. However,
we recommend that you:
· Inspect the truck for any signs of physical damage during
shipment. Note any apparent damage on the bill of lading,
and request the delivery agent to sign it. Report the
damage to your distributor and the shipping company.
· Verify that the truck configuration and options match your
purchase order. Report any discrepancies to your
distributor.
Items Furnished With Your Truck

Standard Series IV trucks are shipped from the factory with one
copy each of the Operator’s Manual and Inspection Check
Sheets, a battery disconnect handle, and a set of ignition keys
attached to the steering column.
Items Required
When the truck is received, a battery approved for use in the
truck must be installed. The battery must be replenished from a
battery charger at certain intervals.
No additional items are required to operate the truck.
Tools and Test Equipment

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

2-1
To Prepare the Truck

1. Check the hydraulic oil level. (See ‘Check Hydraulic Oil Level,’ on page 4-18).
2. Check the fluid level in the brake master cylinder reservoir. (See ‘Check Master
Cylinder Fluid Level,’ on page 4-19).
3. Check the condition of the battery. (See “Charging a Wet Battery,” on page 2-2 or
“Charging a Dry Battery,” on page 2-6).
Charging a Wet Battery

burns. When the battery is charging, it releases hydrogen, a highly explosive gas which
can be ignited by a spark. Shorting battery terminals can release enormous amounts of
energy, causing sparks or flame, or heating nearby components to dangerous
temperatures.
The battery is also very heavy, and if restraints are not replaced after maintenance, the
battery could slide out of the truck causing electrical shorts or spilling acid - or it could
cause the truck to tip.
Warning
safety precautions.
battery.
Consult the label on your battery for information on cell-type, am-

pere-hour capacity, charge rate and normal full-charge voltage. Do
not charge the battery at a current greater than 1.5 amp per 100

battery.

Neutralize acid spills immediately with Bicarbonate of Soda! If acid


2-2
Warning
electrical shock.

When replacing this battery, the truck must be equipped with a bat-
tery as specified on the rating nameplate. Failure to comply could re-
sult in an unbalanced condition, resulting in tipping the truck and
possible personal injury or loss of life.
Be sure to replace and retighten any battery restraints which have

been installed on the truck.
If the truck has been shipped with

batteries installed, first remove the
batteries from the truck. If the batteries
have been shipped with electrolyte
installed, check the specific gravity of the
electrolyte using a hydrometer to
determine if a charge is needed (See
Figure 2-1).
If the reading is between 1.280 and 1.290,
the battery is fully charged. If the reading
is down near 1.150, the battery must be
charged as described in "Charging a Wet
Battery," page 2-2 and "Charging a Dry
Battery," page 2-6.
Figure 2-1 Battery Charge State Using

a Hydrometer

2-3
Using the Hydrometer

As the battery discharges, the specific gravity of the electrolyte reduces. A hydrometer
allows you to check the specific gravity of the cells, thus the charge state of the battery
(See Figure 2-1).
Warning
1. Remove a cap from one or two of the cells. Gently squeeze (compress) the bulb of
the hydrometer.
2. Insert the tube of the hydrometer into the cell electrolyte. Slowly release the bulb to
allow fluid to draw into the hydrometer. Enough fluid must enter the hydrometer to
allow the float to move freely.
3. The specific gravity of the electrolyte is read off the scale of the float where it
emerges from the fluid (See Figure 2-1). It is a good practice to select a different cell
each time a measurement is taken and to test more than one cell.
4. When returning the electrolyte to the battery, ensure that the fluid is returned to the
cell it was taken from and be very careful not to splash the electrolyte when it is
squeezed from the hydrometer.
To Charge the Battery:

1. Remove each vent cap and check electrolyte levels. Ambient temperature should be
+77° F (+25° C) to get a proper reading. In cold weather, batteries may look dry.
2. Do not add water until an accurate level is obtained - cold weather can affect the
level. If water must be added, use only distilled water.
3. Make sure the electrolyte level is at the level indicator.
4. Charge the battery using a constant current charger set to 5% of the six-hour battery
capacity. For example, 55 amps for an 1,100 AH (ampere-hour) battery.
IMPORTANT !
Do not charge the battery at a finish current which exceeds the rating on the bat-
tery’s nameplate. Consult the label on your battery for information on cell-type,
ampere-hour capacity, charge rate and normal full-charge voltage. Do not charge
the battery at a current greater than 1.5 amp per 100 amp-hours capacity at the
end of charge.
5. Replace the vent caps. They must be secured in place during charging. Ordinarily,
the charge should take about 3 to 5 hours to complete.

2-4
6. During the initial charge the volume of electrolyte decreases through electrolysis and
evaporation. Water approved for use in lead-acid storage batteries should be added
if the electrolyte level falls below the level indicator.
If the cell temperature rises higher than +110° F (+61.2° C) either reduce the
charging current to half the original value or stop charging until the temperature falls
below +110° F (+61.2° C). If you reduce the charging current, extend the charging
time accordingly.
7. Continue charging until the cells gas freely and the specific gravity remains constant
over a three-hour period. At the end of the charge period the cell voltages rise to
about 2.55 volts and the specific gravity rises to about 1.280, corrected to 77° F (See
Table 2-1).
8. When charging is complete, REPLACE the vented cell caps on the battery.
9. Connect battery cables and install battery in truck.
Temp oF Correction Temp oF Correction

39-41 -0.012 101-103 +0.008
42-44 -0.011 104-106 +0.009
45-47 -0.010 107-109 +0.010
48-50 -0.009 110-112 +0.011
51-53 -0.008 113-115 +0.012
54-56 -0.007 116-118 +0.013
57-60 -0.006 119-121 +0.014
61-63 -0.005 122-124 +0.015
64-66 -0.004 125-127 +0.016
67-69 -0.003 128-130 +0.017
70-72 -0.002 131-133 +0.018
73-75 -0.001 134-136 +0.019
76-78 0 137-139 +0.020
79-81 +0.001 140-142 +0.021
82-84 +0.002 143-145 +0.022
85-87 +0.003 146-148 +0.023
88-91 +0.004 149-151 +0.024
92-94 +0.005 152-154 +0.025
95-97 +0.006 155-157 +0.026
98-100 +0.007 158-160 +0.027
Table 2-1 Specific Gravity Corrections for Electrolyte Temperature

2-5
Charging a Dry Battery

burns. When the battery is charging, it releases hydrogen, a highly explosive gas which
can be ignited by a spark. Shorting battery terminals can release enormous amounts of
energy, causing sparks or flame, or heating nearby components to dangerous
temperatures.
The battery is also very heavy, and if restraints are not replaced after maintenance, the
battery could slide out of the truck causing electrical shorts or acid to spill - or it could
cause the truck to tip.
Warning
safety precautions.
battery.
Consult the label on your battery for information on cell-type,

ampere-hour capacity, charge rate and normal full-charge voltage.
Do not charge the battery at a current greater than 1.5 amp per 100

battery.
Always disconnect the battery before performing any truck

maintenance and be sure to wear protective clothing and safety
glasses when working with battery acid or the battery in general.

electrical shock.


2-6
Warning
When replacing the battery, the truck must be equipped with a

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

To Charge a Dry-Cell Battery:

1. Remove and discard plastic film seals from each cell vent hole (if present).
2. Fill the cells to the level indicator using dilute battery grade sulfuric acid with a
specific gravity between 1.260 and 1.270 corrected to +77° F (+25° C). The
temperature of the electrolyte should be no higher than 90° F (50° C).
3. Allow the cells to soak for 2 to 3 hours after filling. The electrolyte level may drop
slightly because of absorption into the plates and separators. If it does, add more
electrolyte to restore the level.
4. Charge the battery, using a constant current charger set to 5% of the six-hour battery
capacity. For example, 55 amps for an 1100 AH (ampere-hour) battery. The time
required for an initial charge is approximately 8 hours.
5. During the initial charge the volume of electrolyte decreases through electrolysis and
evaporation. Water approved for use in lead-acid storage batteries should be added
if the electrolyte level falls below the level indicator.
If the cell temperature rises higher than +110° F (+61.2° C) either reduce the
charging current to half the original value or stop charging until the temperature falls
below +110° F (+61.2° C). If you reduce the charging current, extend the charging
time accordingly.
6. Continue charging until the cells gas freely and the specific gravity remains constant
over a three-hour period. At the end of the charge period the cell voltages rise to
about 2.55 volts and the specific gravity rises to about 1.280 (corrected to 77° F)
(See Table 2-1).
7. If the specific gravity exceeds 1.290 after charging, dilute with distilled water and
continue to charge for two more hours.
8. If the specific gravity is below 1.280 after charging, add electrolyte with a specific
gravity of 1.400 until the battery has a specific gravity between 1.280 and 1.290.
Then resume charging for another two hours.
9. When charging is complete, REPLACE the vented cell caps on battery.
10. Connect battery cables and install battery in truck.

2-7
Inspection Check List

1. Before releasing the truck for use, prepare a log book or log sheet for each truck at
your site. List all services, repairs and adjustments performed, as well as equipment
or operation problems and when they are noted and repaired (hour meter reading
and date the service was performed).
Permanent logs serve as a checklist to show maintenance and repair history and to
record whether faults have been corrected.
2. Perform inspections with the truck key switch set to OFF, the control lever in the
NEUTRAL position and all brakes set.
3. Always pay strict attention to all CAUTION, WARNING, and DANGER decals affixed
to the truck and thoroughly read the SAFETY chapter of this manual.
4. If you notice or suspect a problem, immediately report it to your supervisor, record it
in the truck log book, and have it checked and/or repaired before releasing the truck
for use.
Visual Checks
Many problems can be spotted by a simple visual inspection of the truck; such as, oil
leaks, damaged tires, cracks in welds or forks, damaged covers, etc.
However, dirt, grease, oil and debris can mask some problems. If possible, the truck
should be washed on a regular basis. To remove stubborn grease accumulations, a
grease-dissolving solvent may be needed. Make sure the solvent is not harmful to
painted surfaces.
After high-pressure washing, lubricate all unprotected grease fittings and metal-to-metal
surfaces, located outside the truck (See ‘ Lubricating the Truck,’ page 4-23).
Warning
Grease solvents are often toxic and may be flammable. Use only in
accordance with the solvent manufacturer’s recommendations sup-
plied with the solvent.
For example, use only in a well-ventilated area and do not breathe

vapors. Wear protective goggles, aprons, and gloves. Avoid contact
with skin, eyes and clothes. Keep away from heat and flame. Do not
smoke when using solvents or in the area where solvents are stored.
Failure to observe these precautions may result in death or injury.

2-8
Warning
If you become dizzy while using cleaning solvents, get fresh air and
medical help immediately. If solvent contacts your eyes,
immediately treat in accordance with the manufacturer’s
recommendations supplied with the solvent.
Always read the label affixed to the solvent container for all safety
information before use.
Routine Checks
With the truck key switch set to OFF, perform a walk-around inspection. Check for
obvious damage that would require more detailed inspection. If any of the following is
apparent during your walk-around, record it in the log book for the truck and immediately
notify your supervisor and/or service
personnel.
· Battery compartment cover /
latch and pin - Check that the
battery compartment cover is
lowered into position and that
the latch is secured whenever
a battery is installed in the truck
(See Figure 2- 2).
· Battery rollout tray option - If
this option is installed, check
that the battery rollout tray
restraint arm is installed and
locked into position.
The handle must be down

(locked, the limit switch Figure 2-2 Battery Safety - Latches and Pin
actuated and the proper
spacers installed to secure the
battery within the compartment
(See Figure 2-3).
· Brake pedal - Check the
operation of the brake pedal for
smooth, firm, unobstructed
movement when pressed and
released. Problems with the
brake system must be repaired
immediately by service. Do not
use the truck.
Figure 2-3 Battery Safety - Latches and Pin

2-9
· Brakes, service - With the key switch set to ON, drive forward slowly while
steadily applying the brake pedal. The truck should stop smoothly without
noticeable side pull or vibration.
Any problems with the brake system must be repaired immediately. Do not use
the truck.
· Driver’s seat - Check the seat covering for rips or cuts. Check seat belt straps for
worn or frayed areas or cuts. Check that the seat belt is firmly attached and that
the buckle is not damaged. Check that the seat belt works properly.
The driver’s seat limit switch system includes an interlock that shuts down the
drive and power steering motors and disables the direction control (resets to
NEUTRAL) bringing the truck to a smooth STOP. The mast functions remain
operable.
To check the brake interlock,

· Sit in the driver’s seat, set the key switch to ON and release the parking
brake.
· Set the control lever to FORWARD and slowly increase motor speed until
the truck begins to move.
· Lift yourself from the seat far enough to release the seat switch. The truck
must immediately slow to a STOP, and power steering is disabled.
· If the truck continued moving forward, it must be removed from operation
and the seat switch must be replaced.
· Fasteners - Check for damaged, loose or missing screws and nuts. Tighten
and/or have service replace as needed.
· Horn, Lights, etc. - Check lights for proper on/off operation and for blown bulbs.
Check that the horn sounds when pressed. Repair and/or replace as needed.
· Hydraulic lines, loose fittings - Check underneath the truck for evidence of fluid
leaks. Look for hydraulic hose wear, damage and leaks. Make sure clamps and
fittings are tight. If leaks are found, have service repair all leaks immediately and
check the hydraulic fluid level. Do not use the truck.
· Hydraulic oil level - Check the oil level weekly. Low oil can cause operational
problems (See ‘Check Hydraulic Oil Level,’ page 4-18).
· Instruments - Inspect the instrument panel for damaged or non-working gauges.
These require the key switch to be ON and can be checked prior to beginning your
daily work routine.
· Mast operation - With the key switch turned ON, raise the mast. Check that the
primary cylinder extends fully and that the lift carriage raises to the top of the inner
rails before the secondary cylinders begin to move.

2-10
Warning
Never place your head, hands, arms or feet in the mast area! Make
sure there is sufficient room above to raise the mast safely.
· When the lift carriage reaches the top of the inner rails, the secondary
cylinders and middle rails begin lifting. Check to make sure the rails travel
smoothly and that there is no chatter or visible binding.
· With the mast fully extended, begin lowering the mast. The secondary
cylinders and middle rails fully lower first, followed by the primary cylinder
and the lift carriage.
· Check for smooth travel with no chattering or visible binding.
· If there is noticeable chatter or binding, immediately notify your immediate
supervisor or service personnel.
· DO NOT attempt to repair the mast or operate the truck until the problem is
corrected.
Warning
If the mast does not raise or lower properly or shows signs of bind-
ing, it may release or stop suddenly or move with a jerky motion and
allow the load or carriage to drop. This could result in death or seri-
ous injury to the operator or nearby persons and/or damage the load.
· Overhead Guard - Check the overhead guard and make sure that it is firmly
attached to the truck and that all fasteners are secured. The overhead guard is
adjustable to accommodate various drivers’ and operating restrictions (low
ceilings, door openings, etc.)
· Parking brake - The parking brake system includes an interlock that shuts down
the drive and power steering motors, disables the direction control (resets to
NEUTRAL) and applies the brakes to prevent further truck movement.
To check the brake interlock,

· Set the key switch to ON and release the parking brake.
· Set the control lever to FORWARD and very slowly increase motor speed.
· As the truck moves forward at slow speed, slowly raise the parking brake
handle.
· The truck must immediately slow to a STOP, and power steering is disabled.
· If the truck continues moving forward, it must be removed from operation
and repaired.
· Rust or corrosion - Check the truck frame, side and floor panels for rust and
corrosion. Clean rusty or corroded areas and repaint, if applicable. Apply a thin
coat of oil to any bare metal surface.
· Safety decals, data plates, etc. - Check for damage and missing decals. Check
that the decals are legible. Clean and/or replace as needed.

2-11
· Seat brake, optional - for basic testing, see Drivers seat, on page 1-15. In
addition, when releasing the seat switch, a clicking sound is heard as the
electro-magnetic brakes apply.
· Static discharge strap - Make sure the static discharge strap is dragging (touching)
the ground. The strap is located at the rear of the truck, between the rear wheels.
· Tires and wheels - Check tires for cuts or chunking, oil slicks, embedded foreign
material or excessive wear. Check wheels for missing lug nuts. Repair and/or
have service replace immediately. Do not use the truck.
· Welds, cracked or broken - Check for damage and reliability. Clean and repair
immediately. Do not use the truck.
· Wires or connectors - Look for damaged, cracked or broken insulation, bare
wires showing, loose or broken connectors. If electrical problems are found, have
service make repairs immediately. Do not use the truck.
Replacing the Battery

Replacing the battery requires lift and support apparatus capable of supporting the weight
and size of the battery. Check the capacity plate for battery information (See Figure 1-1).
An external battery roller tray stand is also helpful, and available through your Landoll
distributor, to allow the battery to be pushed into the compartment.
To Replace a Battery
1. Return the truck to your service
charging station area.
2. Set the key switch to OFF and
place the key in your pocket.
3. Place blocks in front of and behind
all wheels.
4. Unlatch the compartment cover
(below drivers seat) and raise the
battery compartment top cover.
5. Secure the cover to the overhead
guard latch and insert the locking
pin. Jiggle cover to be sure latch
is secured (See Figure 2-4).
6. Open the right side door by sliding
the locking lever to the right, then
swing the door fully opened.
Figure 2-4 Overhead Guard Battery
Cover Latch

2-12
Note: If your truck includes the rollout battery tray option, see “Rollout Battery
Tray Option”, page 1-19.
7. Disconnect the battery/truck cable disconnect and lay the battery cable across the
battery top (See Figure 2-5).
Models B25 and B30 Models B35 and B40
Figure 2-5 Battery Disconnects
8. Slide the compartment side Overhead guard

cutout
door spring latch towards to
the front of the truck to release
the side door. Open the door Battery compartment
top cover
(See Figure 2-6).
9. Place and connect the
appropriate lift and support
apparatus (overhead crane, Battery compartment
crossbar and chains) within Top cover
the overhead guard cutout, locking latch
then carefully lift and slide the
battery from the truck (See Battery adjust-
Figure 2-6). ment bracket
(both sides)
Side door
Battery
compartment
Figure 2-6 Removing the battery

2-13
10. To prevent roll-out, measure the width of the new battery. Adjust the retainer brackets
located on the underside of the compartment top cover to approximately 0.500” to
0.750” (12.7 mm to 19 mm) wider than the width of the battery. Tighten and torque
the screws (See General Torque, Hydraulic Fitting Torque, and Bendi Series IV
Special Torque Tables 4-3, 4-4, and 4-5).
11. When installing the battery, it must be pushed up against the rear wall panel and
centered within the battery compartment (See Figure 2-6).
12. Close and secure the compartment side door and connect the battery electrical
connector (blue). Situate the excess wiring between the battery and the side wall of
the truck, making sure the wires are not exposed causing a “pinch” condition when
the top cover is closed.
13. Release the overhead guard latch and lower and secure the top cover. Make sure
the cover latch is secured and that no wires are pinched.
Rollout Battery Tray Option

If this option is included, to remove the battery simply release the restraint arm release
handle and slide the arm from its holder. The battery is free to roll out the side of the
truck.
A limit switch is included to disable the truck while this arm is removed (battery and
motors are disabled).
When installing the battery make sure the spacers are the correct configuration for the
battery being installed. You want to restrict as much side-to-side play as possible.
Also see ‘Rollout Battery Tray,’ page 1-19, for additional information.
Storage, Towing or Shipping

Truck Storage
For long-term storage, the truck battery should be removed and stored where it can be
periodically checked and recharged every three months.
The truck should be stored indoors within a temperature range of +35° F (2° C) to +115°
F (46° C) and a relative humidity of 90%.
The truck should be raised with the tires at least 2” (51 mm) off the floor and the frame
set on large wooden blocks. Hard polyester tires, over long periods of time can develop
flat spots that may not return to normal when the truck is returned to service, rendering
the tires defective.
If the truck must be stored outside, it must be covered securely with a tarpaulin.
Continued exposure to sunlight will cause deterioration of rubber tires, gaskets and
hoses, as well as vinyl seat coverings, etc.

2-14
Battery Storage
In general, batteries that are fully charged with the electrolyte at the proper level may be
stored for up to one year. Batteries should be stored in a cool, dry, well-ventilated area,
away from direct sunlight. Batteries without covers should be covered with a
non-conductive material to protect them from dirt, moisture, etc.
IMPORTANT !
Do not drape flexible plastic sheeting over batteries as it might trap explosive
gases underneath. For batteries stored for more than one, consult the battery
manufacturer.
Consult the battery documentation or the manufacturer for storage method and routine
inspection required during the temporary storage interval.
Towing the Truck

Warning
Make sure the towing equipment is capable of handling the weight of
the truck being towed (See Figure 1-1).
Never lift a truck using straps, chains or hoists of any type.
Never connect lifting equipment to the operator’s cab overhead

guards.
Never use the truck to tow materials.
Never tow a truck that is carrying a load.
Never connect towing equipment to the mast.
For better traction, partially load the truck doing the towing.

2-15
If the truck breaks down and cannot

be repaired at that location, it may be
towed by attaching a suitable hook
and chain to the tow bar located in the
cutout at the lower rear of the truck.
(See Figure 2-7).
Also, the power steering on the
disabled truck does not operate when
the power steer motor is not running,
which makes the steering wheel
difficult to turn.
Carefully and slowly tow the truck
backwards to your service repair area.
An operator must be on the towed
truck, wearing a seat belt.
Figure 2-7 Tiedown Post Used for Towing
To Ship the Truck

1. Set the mast to its forward position (straight ahead).
2. Remove the battery. Scrape away and wipe clean any wet residue or corrosive
deposits left by the battery.
IMPORTANT !
(Also see ‘Battery care,’ on page S-9 for additional information.)
3. Connect a battery to the truck disconnect using long jumper cables and back the
truck onto its carrier so that the forks are pointed away from the forward direction of
motion. (This is usually accomplished by connecting the cables to a battery being
carried by a nurse truck and carefully driving both trucks close to the carrier.)
4. Set the mast to its forward (level) position and lower the forks to the bottom of the
mast - align the mast indicator pointer located on the left side of the mast, as viewed
from the front of the truck.
5. Disconnect the jumper cables from the truck.
6. Set the parking brake as firmly as possible.
7. Set wedges against the front and rear tires and fasten them to the floor of the carrier.
If the carrier is equipped with rings or receptacles for chains or cable rope, support
the truck as firmly as possible.
IMPORTANT !
Do not run chain or wire over the battery cover or any other finished metal sur-
face. Use padding as necessary to protect the truck finish from chains or cables.

2-16
Using Lifting Equipment

Warning
Failure to use lifting equipment of adequate capacity to lift and move
your Bendi forklift can cause lifting equipment failure, which can
lead to serious injury or death.
If you use lifting equipment, such as
elevators, cranes, or ship hoisting
gear, to move a forklift to another
location, make sure the hoisting
equipment has adequate size and
capacity to move the equipment.
If you need to use a hoist to lift your
Bendi forklift:
1. Pass a strap (1) under the truck
just in front and behind of the rear
wheels (See Figure 2-8).
2. Pass a second strap (2) under the
cross-member at the top of the
mast.
3. Make sure you place a spacer (3),
such as a 2” x 6” (5 x 15 cm) block
of wood between the overhead
guard and the lift point to avoid
damage to the truck. Figure 2-8 Setting Lift Equipment
DO NOT USE CHAINS !

2-17
Operation
This section of your Bendi Forklift Service Manual discusses the
following concepts that must be thoroughly understood to
operate the forklift. Refer to you Operator's Manual for more
in-depth instructions on operating and maintenance of your
forklift.
Basic Operation - This section describes basic information that
you must understand before operating the forklift. This includes
explanations about stability, required checklists, controls and
indicators, safe driving procedures, and proper handling of loads.
Options - This section describes operation of options such as
the fire extinguisher and fork positioner.
Theory of Operation - This section describes the hydraulic and
electrical systems as well as discusses some of the specific
features of these systems.

3-1
Operation
To Begin Operating
Warning
The Bendi Series IV lift truck is a heavy and powerful machine, capa-
ble of causing injury or death to its operator and nearby people if it is
improperly or carelessly operated. Only those individuals trained by
an experienced instructor may operate and/or service this truck.
Practice runs in a controlled area, away from other people and obsta-
cles, are recommended. Unauthorized driving by untrained or un-
skilled people must be strictly prohibited.
Do not operate this truck until this manual has been read in its
entirety, especially the section devoted to SAFETY.
Understanding Stability
Warning
First review the Safety chapter, beginning on page Safety-5 for addi-
tional information.
Never load the truck beyond its rated capacity. Loading beyond the
rated capacity can cause axles to break, the truck to tip over, the
load to fall, or serious injury or death. See the capacity plate for
rated capacity and load center information (See Figure S-2).
Never allow anyone to stand beneath or pass under the lifting

mechanism. The load could fall causing serious injury or death.
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.

3-2
Operation
Right View Left View
Figure 3-1 Right or Left 90o Stability
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 or left, the truck is in its least
stable position (See Figure 3-1).
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 (1) and (2). The third suspension point is the
center point of the front axle (3) (See Figure 3-1).
The center of gravity (4), an imaginary point at which all of the truck’s weight is
concentrated, is located as shown 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
points (2) and (3).
If you pick up a load that is too heavy the truck will tip around the fulcrum. Imagine a
triangle (5) 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. Remember, 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 (4) so it falls outside of the border of the stability triangle, the
truck will tip around the fulcrum.

3-3
Operation
The center of gravity shifts when:

· The load exceeds the rated capacity listed on the capacity plate.
· The load exceeds the load center dimensions listed on the capacity plate.
· You do not seat the forks fully into the pallet, or 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
capacity plate.
Capacity
Before you begin to operate your Bendi forklift, one of the most important facts you need
to know is its rated capacity (how much weight it can safely lift) (See Figure 3-2).
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 fall.
· The height you plan to lift the load.
· Attachments used.
Figure 3-2 Capacity Plate Capacity

3-4
Operation
The following list explains each item that appears on the capacity plate(See Figure 3-2).
1. Model: The model number of your Bendi forklift.
2. Serial number: The serial number of your Bendi forklift.
3. Mast number: The serial number of the mast.
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 distance, in inches, between the ground and the top edge of
the forks.
6. Weight: The rated capacity of the forklift at various fork heights; in pounds and
kilograms.
7. Unladen mass without battery: The actual weight of your Bendi forklift as built
without the battery installed; 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; 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; in pounds and kilograms.
10. Maximum unladen mass: This is the unladen mass without battery added to the
maximum service weight of battery; in pounds and kilograms.
11. Battery type: This is the rating for the battery as designated by Underwriter’s
Laboratory (UL) Standard 583. It describes the construction of the battery and
battery enclosure with respect to the risk of fire, electric shock, and explosion.
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 battery voltage; 48 VDC for Bendi
Series IV.
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.

3-5
Operation
Serial Number Code

The following information will help decode the Bendi Series IV serial number:
Baa/ww-ymms-xxxxx
Where:
Aa = 25 for 2,500 lb (1,134 kgs.) rated capacity truck
= 30 for 3,000 lb (1,361 kgs.) rated capacity truck
ww = 42 for 42” (107 cm.) frame width
= 48 for 48” (122 cm.) frame width
y = last digit of year of manufacture (ex. “4” means 2004, “5” means 2005)
mm = month of manufacture
s = component series; such as “A”
xxxxx = frame number (See Figure 3-3)
CAUTION
The frame number is also located on the left side of the frame (1). You
must compare the frame number listed on the capacity plate with the
frame number on the frame of the truck before you operate the
The mast serial number is also located
on the left side of the mast (2). Again,
you must compare the mast serial
number listed on the capacity plate
with the mast serial number on the
mast of the truck before you operate
the truck (See Figure 3-3).
Figure 3-3 Frame and Mast Identification

3-6
Operation
Load Center
Warning
Make sure the actual horizontal and vertical load centers do not ex-
ceed the maximum load centers stated on the capacity plate. Failure
to do this can cause the forklift to tip over causing serious injury or
death (See Figure 3-4).
You need to consider two types of load
centers. The horizontal load center (1) is
equal to one-half the length of the load
when the weight is evenly distributed (See
Figure 3-4).
For example, a load that is 48” (122 cm)
long has a horizontal load center of 24”
(61 cm). The further the load center is
from the fulcrum (2), the less stable the
forklift (See Figure 3-4).
Always make sure your load is flush
against the rear of the forks (3), and that
unevenly distributed loads are loaded with
the heaviest end of the load closest to the
front wheels (See Figure 3-4).
The vertical load center (4) is equal to
one-half the height of the load when the
weight is evenly distributed. For example,
a load that is 48” (122 cm) high has a
vertical load center of 24” (61 cm). Make Figure 3-4 Load Center Rating
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 capacity plate (See Figure 3-2).
Counterweight
Warning
Never let a coworker stand on the back of the forklift to add counter-
weight. Your coworker can fall off the forklift, or the truck can tip
backwards, causing serious injury or death.
Your Bendi forklift has a counterweight (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 (See Figure
3-4).

3-7
Operation
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 capacity
plate (See Figure 3-2).
Failure to heed these guidelines can cause your forklift to tip over
causing serious injury or death.
The maximum fork height (item 1) is the
highest position your Bendi forklift can lift a
load. This is measured from the floor to the
forks when they are raised to their highest
position. The higher the forks are raised,
the less stable the forklift becomes (See
Figure 3-5).
Figure 3-5 Maximum Lift Height
Determining 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.
· 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 immediate supervisor when in doubt.

3-8
Operation
Working in Hazardous Environments

Warning
Some atmospheric conditions encountered in the workplace are ex-
tremely 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.
Landoll Corporation also provides special Bendi forklift trucks that comply with Type ES
or EE designations. Type ES limits the emission of hazardous sparks and surface
temperatures. 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.
Pre-Operation Checklist
Perform a pre-operation inspection of the Series IV lift truck daily, before beginning your
work shift. Report all problems to your immediate supervisor. (See ‘Routine checks,’
page 2-9). Do not release the truck into operation until repairs are made.

3-9
Operation
Adjusting the Driver’s Seat

Warning
Adjust the driver’s seat only when the truck is NOT moving. You
could lose control or the sudden movement could cause you to push
a wrong pedal if you attempt to adjust the seat with the truck moving.
1. Raise the left armrest and climb into the seat. A step (cutout) is added in the side
panel to assist you into the operator’s compartment (See Figure 3-6).
2. Pull the latch lever (1) outward and slide the seat forward or backward as needed.
Release the latch lever and try to move the seat slightly to make sure that it is locked.
Warning
If the seat is not locked, it could slide forward in a sudden stop or
crash which could cause injury to the driver.
3. The rack adjustment has three positions. Lift the seat at the front corners. Adjust the
seat forward or backward until in position. Push the front corners down to lock the
position.
4. Fasten the seat belt - see “Seat Belt,”
page 3-11.
5. Lower the left armrest.
6. To dismount, release the seat belt and
raise the left armrest and dismount
using the side panel step.
7. The seat cushion is handwheel
adjustable (2) for operator comfort. A
gauge showing the adjusted level is
located to the right of the handwheel
(3) (See Figure 3-6).
Figure 3-6 Driver’s Seat Controls

3-10
Operation
Seat Belt
The driver’s seat belt must always be worn when driving this truck.
1. Sit up straight in the driver’s seat.
2. Pull the belt across you. Do not let the belt twist.
The belt may lock if you pull it across to quickly or stop too soon. If this happens, let
the belt go back slightly to unlock it. Then pull the belt across more slowly.
Warning
You can be seriously injured by a twisted belt. In a crash or a tip-
over, the full width of the belt would not be available to take up the
impact forces.
3. Push the latch plate into the buckle
until it clicks. Pull up on the latch plate
to make sure it is secure.
If the belt stops before reaching the

buckle, let it go back all the way, then
start again.
4. The lap part of the belt must be worn
low and snug on the hips, just
touching the thighs.
IMPORTANT !
Make sure the release button on the
buckle is set so you can unbuckle the
seat belt quickly in an emergency (See
Figure 3-7).
Figure 3-7 Belt Release Button

3-11
Operation
Tilt Steering Column

CAUTION !
Adjusting the steering column while driving the truck is dangerous.
The movement of the column could startle or confuse you causing
you to lose control of the truck.
Adjust the steering column only when the truck is not being driven.
1. To adjust the column, hold the
steering wheel and push up on the
locking latch (See Figure 3-8).
2. Move the steering wheel to a
comfortable level, then release the
locking latch.
3. Pull up on the steering wheel to
ensure it is firmly locked in place.
Figure 3-8 Tilt Steering Adjust
Fork Adjustment
For some loads, it may be necessary to
adjust the position of the forks by moving
them sideways (1) on the fork
carriage (See Figure 3-9).
Figure 3-9 Setting the Forks to the Pallet

3-12
Operation
Warning
Review heading Safety with regards to fork positioners for proper
safety precautions when adjusting the location of the forks on the
carriage.
Make certain the truck key switch is in the OFF position and that the
parking brake is set.
The forks must be set equal distance from the center of the fork
carriage. Setting them too far to the left or right could cause a load to
unbalance and tip the truck.
Manual Fork Adjust To

1. Measure center-to-center between the Unlock
fork openings and the pallet (2) (See
Figure 3-9).
2. The forks are locked in position by a
spring-loaded latch. To release them,
pull straight up on the release latch
knob (See Figure 3-10).
3. Slide the forks in the desired direction,
using your hand to push at the top,
and your foot to push against the tines
at the bottom. A stubborn fork may be
dislodged by alternating a push at the
top and at the bottom (See Figure
3-10).
Figure 3-10 Tilt Steering Adjust
Warning
Never pull a fork towards you as this places your hands in a possible
pinch position which could cause serious injury. Always push the
fork away from your body.
4. When the fork is in position, push the latch knob down. If necessary, push the fork a
little more to make sure the pin falls into a notch at the top of the carriage bar locking
the fork in position (See Figure 3-10).
Fork Positioner Option - Automatic

Automatic fork positioners are an option on Series IV trucks. If your truck includes a fork
positioner, see the Appendix, Index tab I-H for more information.

3-13
Operation
Driving the Truck

Warning
Only those individuals trained by an experienced instructor or opera-
tor may operate and/or service this truck. Familiarization and driving
practice with a new truck must be arranged in a protected area, away
from other personnel and obstacles.
Check that all directional and operational controls and levers are in
the NEUTRAL or center position, the brakes are set and your seat
belt is fastened before setting the key switch to on. See “Seat belt”
on page 3-17.
To avoid personal injury when operating the truck, be extremely

careful that NO part of your body (head, feet, arms, legs) is outside
the operator’s compartment where it could be subject to injury by
aisle supports, other trucks, the mast raising or lowering, or any
obstacle in the area.
As the truck operator, you are responsible for observing all speed restrictions and
traveling in accordance with aisle and work area conditions. You are responsible for
observing all instructions and safety regulations during your daily work routine related to
the use of this truck.
It is your responsibility to thoroughly read the Operator’s Manual, paying particular
attention to the chapters devoted to Safety, before attempting to operate this lift truck.
Under normal driving conditions, speed must be chosen according to the situation, such
as, surface conditions, visibility, people working in the area, moving and fixed objects in
the area, cross aisles, etc.
Where visibility is a restricted, always travel at very slow speed and ask for a helper to
guide you through the area.
Always rotate in your seat to face in the direction your are traveling.

3-14
Operation
Practice Session
1. Set the key switch to on.
The dash displays perform an internal self-diagnostic test, that lasts about ten (10)
seconds, until communications have been established with the controllers. (See
‘Dash Display Panel,’ page 1-12 for more information.)
Once communications have been established, the displays first show the battery
capacity, then show the hour meter.
IMPORTANT !
The operator should wait ten (10) seconds before actuating the traction drive or
steering to allow the self-diagnostics to execute. Failure to do this may not prop-
erly enable the traction control.
Note: Both displays indicate battery capacity as applied to each drive wheel.
They will rarely read exactly the same, but should be within 20% of each other.
This is common and should not be a concern.
2. Release the hand parking
brake - push it away from you
(down) (See Figure 3-11).
3. Move the directional control
lever to the FORWARD
position (See Figure 3-11).
Note: If you turn the key switch
off or leave your driver’s seat
while the truck is in a drive
mode, the truck automatically
reverts to the NEUTRAL mode.
The directional control lever
must then be returned to NEU-
TRAL, before selecting the de-
sired driving direction.
4. Using the LIFT lever, raise the

forks about 6” (15 cm) from
the ground. Using the TILT Figure 3-11 Armrest/Control Console
lever, tilt the mast back (3°).
This is the recommended travel position. See “The Mast” on page 3-16.
5. Slowly press the accelerator pedal. The truck begins to move in the selected
direction. Pressing the pedal produces the same effect as in an automobile; the
further the pedal is pressed, the faster the speed of travel.
However, when the pedal is release, “brake-by-plugging” activates to automatically

and bring to truck to a smooth stop. Plugging is automatic when you change
directions with the direction control lever and press the accelerator pedal.
The brake pedal is only needed for emergency stops or when you feel a quicker than
normal stop is required.

3-15
Operation
6. Steer the truck in a straight path while traveling at a SLOW speed. Practice in a
straight path and at slow speed until you are thoroughly comfortable with the action
and feel of the truck.
7. Turn right at a slow speed. Although the truck includes power steering, you must
manually return the wheel to the straight-ahead or center position.
8. Turn left at a slow speed.
9. Bring the truck to a full and smooth stop by releasing the accelerator pedal. The
brake pedal is only needed for emergency stops or when you feel a quicker than
normal stop is required.
Warning
Careless driving, such as, fast starts or sudden braking, excessive
speed at turns or through cross aisles, or hard turns at high speeds
can all lead to serious injury and damage to the truck and load. Do
not indulge in stunt driving or horseplay. Always drive with safety as
your number one goal.
10. Now move the directional control lever to the REVERSE position and repeat steps 4
through 8, at reduced speed.
Note: As an option, an audible alarm may be added to sound (beep) while you are
traveling in reverse or anytime a direction of travel is selected.
11. Continue practicing until you are comfortable with forward and reverse driving at slow
speed. When you feel you have mastered driving the truck, proceed to the next
heading the mast.
The Mast
Each mast operation is controlled by
individual control levers - LIFT, TILT
and SHIFT (See Figure 3-12).
Practice using each lever, as
explained below, until you are
comfortable with the operation of the
mast.
1. Slowly pull the LIFT lever towards
you to raise the mast. Lift the
mast only one or two feet for
practice.
2. Push the LIFT lever away from
you to lower the mast forks.
Figure 3-12 Lift, Tilt, and Shift Placard

3-16
Operation
3. Pull the TILT lever towards you to Level setting,

tilt the mast back. Rear tilt is 3° in degrees
maximum (See Figure 3-13).
4. Push the TILT lever away from 123
321
you to move the mast forward, or
to return the forks to their
horizontal position as indicated by
the tilt level gauge mounted on the
right and left sides of the
mast (See Figure 3-13).
Level indicator
5. Practice tilting the mast slowly by
feathering in the desired direction. tiltset
Feathering is the process of Tilt cylinder
moving the lever ever so slowly in
Figure 3-13 Tilt Level Gauge
the required direction to very
slowly move the load into position.
Warning
Avoid jerky movements of the mast, especially when the load is
raised. Jerky movements with the mast raised could tip the truck or
allow the load to slip from the forks, causing serious injury and/or
damage.
You should tilt the mast only at the floor level or at the load level in
the rack when depositing or picking up a load. At any other time,
forward tilting could cause the truck to tip forward or cause the load
to slide off the forks causing serious injury to yourself or anyone in
the area.
6. Tilting a loaded mast forward should be done slowly by feathering the TILT lever.
Rapid tilting might jostle a load off the forks prematurely.
7. Make sure the area to the right of the truck is clear.
8. Push the SHIFT lever forward to shift the mast to the right (See Figure 3-12).
9. Pull the SHIFT lever back to shift the mast to the left.
10. When you are thoroughly familiar with all of the control movements of the mast
levers, practice depositing and retrieving a load under the supervision of an
experienced instructor or operator.

3-17
Operation
Warning
NEVER handle loads in excess of the specified rating on the capacity
plate located in the operator’s compartment. Do not handle unstable
or loosely stacked loads. Too heavy a load may tip the truck, causing
injury to the operator. Unstable loads may fall off, injuring people
nearby.
Make sure you are thoroughly familiar with the operation of the
Bendi Series IV before you attempt to handle loads. Repeated
practice is a must! A mistake in load movement could jam the load
into the racks, causing damage, or could dislodge a load from the
forks, causing serious injury to people below.
Handling the Load

Narrow-aisles, plus the size of the truck, prevent a load from being pulled straight out of
the rack. You must pivot the front end and shift (or inch) the load in or out of the rack. A
combination of movements, where the pivot or shift actions occur with forward or
backward movements of the truck, are needed to inch the load in and out of position.
This will require some practice by the operator to be performed smoothly and effectively.
Warning
You must immediately lower the load to about 12” (30 cm) from the
floor before moving the load to another location. Lowering the load
improves driver visibility, and improves the stability of the truck by
reducing the possibility of personal injury or damage to the load
should it slip from the forks.

3-18
Operation
To Pick Up the Load

Note: Actual minimum aisle
width (5) will vary based upon
application. The following illus-
trations show a standard 40” x
48” (102 x 122 cm) pallets,
loaded on a rack with 96” (244
cm) beams. The arrow, labeled
S, shows the direction to turn
the steering wheel.
1. With the forks facing forward
approach the side of the aisle
that is opposite the load
For narrow aisles, position

the truck so it is 8” (20 cm)
from the edge of the aisle
opposite the load (2).
For wide aisles, position the

truck so it is 36” to 48” (91 to
122 cm) from the side of the Figure 3-14 Setup - Load Pick Up
aisle where the load is located
(6) (See Figure 3-14)
2. Center the forks using the shift lever. This is the normal driving position for all travel
operations.
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.
3. Drive forward until the front edge of the load wheels (3) are somewhat even with the
center of the pallet (4) on the rack (See Figure 3-14).
4. Lift (raise) the forks to the required height, then level them using the tilt lever.

3-19
Operation
5. Stop the truck and turn the

forks 90°, using the steering
wheel, to align the forks to the
load (See Figure 3-15).
Note: When turning the steer-
ing wheel with the truck
stopped, do not apply the foot
brake or hand brake.
Figure 3-15 Align the Forks
6. Turn the steering wheel to

keep the forks straight as you
fully insert them into the load
and lift and side shift as
required to stabilize and
pickup the load (See Figure
3-16).
Figure 3-16 Positioning the Forks
7. Straighten out the forks using

the steering wheel as you
drive them into the load. The
forks must enter the load in a
straight line (See Figure 3-17).
If needed, raise the load

above the rack about 2” (5.1
cm) to clear the rack
horizontal members. Be
careful of any cross members
above the load.
Only raise the load high

enough to clear the rack.
Figure 3-17 Inserting the Forks into the Load

3-20
Operation
8. Tilt the mast back to make

sure the load will not slide off
the forks (See Figure 3-18).
Figure 3-18 Tilting the Load

9. Set the direction control to
REVERSE and slowly back
away from the stack as you
turn the steering wheel to
keep the forks straight (See
Figure 3-19).
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” to 16” (20 to 41
cm).
Figure 3-19 Retrieving the Pallet
10. Make sure you do not strike
any racks or objects as you
enter or leave the rack
opening.
11. When the front right hand
corner of the load (1) clears
the rack, stop backing (See
Figure 3-20).
Figure 3-20 Retrieving the Load

3-21
Operation
12. Turn the steering wheel

clockwise to straighten out the
forks so they are parallel with
the body of the truck (See
Figure 3-21).
13. Lower the forks until they are
4” to 6” (10 to 15 cm) off the
ground and slowly drive the
truck to the next location
observing all safety rules.
Figure 3-21 Normal Travel Position
Warning
Lowering the mast improves driver visibility, and improves the sta-
bility of the truck by reducing the possibility of personal injury or
damage to the load if it were to slip from the forks.
To Deliver a Load
When transporting a load, travel
with the forks 4” to 6” (10 to 15
cm) maximum from the floor and
travel at reduced speed,
comparable to your work
environment (See Figure 3-22).
Always tilt the mast back slightly to
make sure the load will not slide
off the forks (See Figure 3-22).
Figure 3-22 Tilting the Load

3-22
Operation
Note: Actual minimum aisle

width (5) will vary based upon
application. The following illus-
trations show a standard 40” x
48” (102 x 122 cm) pallets,
loaded on a rack with 96” (244
cm) beams. The arrow, labeled
S, shows the direction to turn
the steering wheel (See Figure
3-23).
Follow these steps to store a load:

1. With the forks facing forward
approach the side of the aisle
that is opposite the area
where you will deliver the load
For narrow aisles, position the Figure 3-23 Setup - Delivering a Load
truck so it is 6” to 8” (15 to 20
cm) from the edge of the aisle
opposite the drop off point (2).
For wide aisles, position the truck so it is 36” to 48” (91 to 122 cm) from the side of
the aisle where the load is located (6) (See Figure 3-23).
2. Center the load using the side shift lever.
3. Drive forward until the front edge of the load wheels are aligned with the center of the
rack opening (4) (See Figure 3-23).
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.

3-23
Operation
4. Lift the load to the proper

height.
5. Stop the forklift and turn the
load 90° (turn the steering
wheel counterclockwise) so it
points in the direction of the
drop (See Figure 3-24).
Note: When you turn the steer-
ing wheel with the truck
stopped, do not apply the foot
brake or hand brake.
Figure 3-24 Load Drop-off
6. Drive forward and straighten

out the load so it is square
over the stack (See Figure
3-25).
Figure 3-25 Straighten the Load for Drop-off
7. Turn the steering wheel to

keep the load straight as you
drive it into the opening (See
Figure 3-26).
Figure 3-26 Inserting the Load

3-24
Operation
Warning
Be careful that the load does not hit the side of the rack as it is in-
serted. You may have to move the truck forward or backward to help
provide clearance for the load to swing into the rack.
Also make sure the load is a few inches above the bottom rail of the
rack and that it does not strike any cross members above.
8. Position the load directly over
the rack beams and tilt the
mast into its vertical
position (See Figure 3-27).
Do not tilt the mast back until

the forks clear the pallet.
Figure 3-27 Leveling the Load
9. Lower the forks until the load

sits firmly on the rack.
Continue to lower the forks

until they no longer support
the load (1) (See Figure 3-28).
Figure 3-28 No-Load Position

3-25
Operation
Warning
When you lower the forks to the no load position (1) make sure you
do not lower the forks too far. If the forks are lowered beyond the no
load position, you can damage the mast, rack, or other containers on
the stack. THIS CAN CAUSE SERIOUS INJURY OR DEATH.
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.
10. Set the direction control to
REVERSE and slowly back
out of the load as you turn the
steering wheel to keep the
forks straight (See Figure
3-29).
11. When the front right fork (1)
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.
12. Lower the forks until they are
4” to 6” (10 to 15 cm) off the
ground and slowly drive the
truck to the next location
observing all safety rules. Figure 3-29 Removing the Forks
Warning
Lowering the mast improves driver visibility, and improves the sta-
bility of the truck by reducing the possibility of personal injury or
damage to the load if it were to slip from the forks.

3-26
Operation
Fire Extinguisher Option

If your truck includes a fire extinguisher it should be inspected monthly or more frequently
if circumstances dictate. The extinguisher should be checked to see that:
· it is not damaged
· the discharge outlet is not blocked
· it is fully charged
· the seal is not broken
· the instruction pamphlet is clearly visible
IMPORTANT !
Dry-powder extinguishers are shipped fully charged. Do not experi-
ment with your extinguisher since even a small amount of discharge
could cause it to slowly lose the rest of its pressure, rendering the extinguisher
useless.
In Case of a Fire !
Warning
Fumes and smoke from any fire may be dangerous and can be
deadly.
All fires should be handled by professionals. Call the fire

department, no matter what the size of the fire. Emergency telephone
numbers should be posted at each telephone.
The following directions are for general use only, intended to familiarize you with the key
functions and procedure of the fire extinguisher. Always check the extinguisher label for
specific techniques and starting distances.
1. Have everyone vacate the area immediately.
2. Hold the extinguisher upright and pull the pin.
3. Stand back from the fire the minimum distance indicated on the extinguisher label.
4. Continue to keep the extinguisher upright, compress the handles together to
discharge while sweeping the extinguisher from side to side over the fire.
5. Move closer to the areas as the fire is extinguished, BUT NOT CLOSE SO AS TO
DISPERSE BURNING MATERIAL.
6. When the fire is extinguished, beware of re-ignition.
7. Vacate and ventilate the area immediately.
8. Be equipped to leave the area in the event the fire cannot be controlled immediately.

3-27
Operation
Fork Positioner Option

The forks start at the center of the
carriage and move equal distance
to the outside and back again as
indicated by letters C and D (See
Figure 3-30).
Figure 3-30 Setting the Forks
A push button is added to the pivot and shift

joystick control (See Figure 3-31).
Press the button and push the joystick forward
to separate the forks to the outside (D).
Press the button and pull the joystick back to
bring the forks together (C).
Figure 3-31 Sample, Joystick Push

Button Option

3-28
Operation
Hydraulic System
The hydraulic system described in this section is for a standard Bendi Series IV truck. A
hydraulic layout diagram and schematic are also included. These are located under the
flap, front and/or back, of the binder cover. Your hydraulic system may vary due to
customer modifications or options purchased.
The basic hydraulic system provides power and control for truck steering and mast
system operations. The system includes two pumps (driven by electric motors), one for
power steering (steering), the other for mast operations (lift), a 3-spool control valve with
internal pressure relief valves, hydraulic cylinders for mast movement, a power steering
module and an in-line filter and two strainer.
Note: When a fourth function is needed (e.g., fork positioner) a separate solenoid
valve system is added and is activated by a push button mounted on the side
shift knob.
Power Steering System

The power steering system consists of a:
· vane pump and electric motor (the power steering pump and motor)
· steering control valve with internal pressure control
· steer motor
· power steering unit (orbital), with direction control
Steering motor
Steering
control
valve
Right Left
To
tank
Relief valve
cartridge
2,600psi (18MPa)
Steering control valve Breather
Oil
filter
Steering
pump
Strainers (2)
(A)
(B)
Figure 3-32 Power Steering Hydraulic Flow

3-29
Operation
A vane pump is coupled in series with the power steering motor. As the steering wheel is
turned, the orbital control valve switches direction of oil flow, through the steering control
valve, to the power steering motor according to the direction the wheel is turned (See
Figure 3-32).
When the steering wheel is not being moved, the control valve returns to a zero (neutral)
position directing oil flow from the pump and steer motor system directly to the hydraulic
tank, through the oil filter (See Figure 3-32).
To protect the system from excessive pressure build up (for example, when the wheel is
turned fully in one direction and held), the pump is by-passed by a pressure relief valve
set at 2,600 psi (18MPa). At 2,600 psi, the pressure valve opens to dump excess oil to
the tank, while maintaining up to 2,600 psi for power steering operation.
IMPORTANT !
Do not turn the steering wheel to its full rotation and hold it there for long peri-
ods of time. This unnecessary pressure build up applies excessive pressure to
the power steering components and causes excessive noise.
If primary pressure falls, the vane pump still meters fluid to the steering motor. However,
the operator must now supply the force ordinarily provided by the pressurized fluid.
Mast Systems
The mast system consists of a:
· gear pump and electric motor
· 3-spool hydraulic control valve with internal pressure control
· required hydraulic cylinders

3-30
Operation
Lift hydraulic
control valve
Pressure relief valve

2,600psi (18MPa) Side shift
cylindert
Side shift
Tilt
Breather Tilt cylinders
Lift
Steering
pump Lift pump
Strainers (2) 5 gpm (19 lpm)
Figure 3-33 Lift, Tilt, and Shift Circuit
The mast hydraulic system is divided into lift, tilt and side shift circuits. A single electric
motor is used to drive the 5 gpm (19Lpm) gear pump (See Figure 3-33).
A 3-spool hydraulic control valve regulates the direction of movement of the four (4)
hydraulic cylinders, and includes one (1) internal pressure relief valves, set at 2,600 psi
(for system overload protection).
Movement of the control levers operates the valve, either mechanically or hydraulically, to
direct oil flow to the cylinders. With the control levers in the NEUTRAL position, oil flow is
directed through the oil filter to tank.

3-31
Operation
Tilt and Shift

During the tilt operations, the lift pump provides oil flow to these cylinders (See Figure
3-33). Oil flow drives one side of the cylinder while relieving the pressure on the other
side. This produces smooth tilt “backward,” and shift side-to-side movements.
During tilt forward operation, an additional pressure valving (anti-cavitation 1) is provided
internally to the tilt cylinders.
1
Cavitation, the formation of partial vacuums in a liquid (such as oil) by a swiftly moving
solid body (such as a cylinder).
If a load is present on the forks, the weight of the load forces the forks downward causing
the tilt cylinders to draw fluid by suction. If the load weight is great enough, the cylinders
may move too quickly and cavitation1 occurs. This can cause severe jolting, enough to
possibly dislodge the load.
To protect against cavitation, the tilt cylinder manufacturer provides internal pressure
control to apply pressure to both sides of the cylinder thus producing a smooth downward
motion - prevent jolting.
Lift and Lower

The lift circuit consists of a primary cylinder and two secondary cylinders all driven in
parallel, a directional control valve, a velocity fuse and a flow regulator (internal to mast
assembly) (See Figure 3-33).
The primary cylinder begins lifting the forks and the load, followed by the secondary
cylinders to drive the mast rails, forks and load upward. The primary cylinder having a
larger bore than the secondary cylinders requires lower pressure to operate.
Consequently, the primary cylinder extends first. When it is extended, fluid pressure
increases to drive the secondary cylinders. As previously described, both pump cavities
are used to provide increased flow.
When the lift valve is switched to allow the forks to drop, the flow regulator (internal to the
mast assembly) governs the amount of flow (about 60 gpm) diverted to the tank, thus
controlling how quickly the forks lower.
The velocity fuse (also internal to the mast assembly) is a safety device that activates if a
line failure occurs, such as, a broken hose, split O-ring, etc., or a valve malfunctions. The
velocity fuse detects this large loss of pressure (or rapid oil flow) and immediately
activates to prevent the load from free-falling by limiting the drop speed relative to the
maximum lift capacity (3,000 lbs.).

3-32
Operation
Electrical Control System

General
For complete detailed information, separate
manuals are located in the Appendix, index
tab Q-Z, of this service manual, providing
operating and setup instructions for the
controller and the Probit hand set.
The electrical system is controlled by four (4)
SRE Mosfet Transistorized Controllers, (two
for traction, one each wheel, and one each to
power the hydraulic pump motors - lift and
steering). Motive power for the truck is
provided by series wound motors (See Figure
3-34).
Figure 3-34 SRE Controller and

Probit Hand Set

3-33
Operation
Dash Displays
The left side dash display records
data affecting the left side drive
wheel (traction control), and
indicates, via the H-BRUSH
signal, when the lift pump motor
brushes should be replaced (See
Figure 3-35).
The right BDI records the right
side drive wheel (traction control)
and indicates, via the H-BRUSH
signal, when the steering pump
motor brushes should be
replaced (See Figure 3-35).
· Hour meter (LCD) -
accurately accumulates
and displays the active
operating hours for the Figure 3-35 Dash Panel Display
appropriate drive wheel (up
to 999,999 hrs.).
· Battery capacity (BDI) - monitors the capacity (or percentage) of the battery
charge remaining. F = full charge, E = empty.
When the battery drops to 10% of full charge, the lift function is disabled (by
shutting off the pump if the lift lever is operated).
At this point, the operator has no choice except to return the truck to the charging
station. The main purpose of this interlock is to prevent deep discharge of the
battery (which shortens battery life), and to also protect the electric motors and
other electrical components from damage caused by low voltage.
Note: Both display units rarely read exactly the same battery capacity, but
should be within 20% of each other. This is common and should not be a con-
cern.
· Fault indicator light - monitors the capacity (or percentage) of the battery charge
remaining. F = full charge, E = empty.
· Scroll button - To switch from the hourmeter display to the lifetime clock of the
controller, tap the SCROLL button on the display. To enter the fault code display,
press and hold the SCROLL button for about 2 seconds. The display shows the
most recent fault code that has been recorded. To display the subsequent fault
codes, tap the SCROLL button.
To erase the stored fault codes and reset the fault light on the display, double-tap
the SCROLL button. The display counts down until the faults are cleared.
To exit the fault code display, press and hold the SCROLL button for about 2
seconds. The display returns to the hourmeter display.
‘Fault codes are explained in "SRE Troubleshooting," on page 5-29. A brief listing
follows - see Table 3-1.

3-34
Operation
· Scroll function button - holding the button depressed for two (2) seconds enters
the fault code cycle, displaying the most recent fault code.
Tapping the button scrolls through the all fault codes recorded. To erase the
stored fault codes and reset the fault indicator light, tap the scroll button twice.
The display counts down until all faults are cleared.
To exit the fault code display, press and hold the scroll button for two (2) seconds.
This returns the display to the hour meter.
Dash Display Service Codes

Displayed What It Means What to Do
Code
Recommend Drive There has been an unrecoverable error in the memory of the
4 Controller be Replaced controller. All calibration values have been lost. Please contact the
Landoll Corporation for more information.
Battery Current Limit for There may be a short circuit in the main motor cables. Repair.
Drive Exceeded
5
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 One or both switches are sticking. Replace.
10 On 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 resistance 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.
13
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.
A Contactor Uses More Check the polarity of the contactor coil and/or suppressor.
than 2 Amps
Measure contactor coil resistance 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
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.
Table 3-1 Dash Display Fault Codes

3-35
Operation

Code
Check for a Welded Directional contactor has failed to open or is shorted
Direction Contactor
20 Tips may be welded. Replace.
Something is shorting the contactor posts or tips.

Check if Field Bar (F) The controller is reading a short between the motor field and B-.
Shorting to 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
21
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.
No Circuit Path from A This error occurs mostly during startup. The controller is reading an
through Armature, Field open circuit across the motor when the contactor is pulled in.
and Forward Contactor
The most likely cause of this fault is a poor contact across the
contactor tips, especially on the normally closed side of the
23
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.
Check the Reverse This error occurs mostly during startup. The controller is reading an
Contactor open circuit across the motor when the contactor is pulled in.
24

Check the Forward This error occurs mostly during startup. The controller is reading an
Contactor open circuit across the motor when the contactor is pulled in.
25


3-36
Operation

Code
Battery Voltage Too High 48 Volt battery recently charged. Surface charge has not dissipated
on 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.
27
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
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
33 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
70 Wiring to Lift Motor an 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
74 be Replaced controller. All calibration values have been lost. Please contact the
Landoll Corporation for more information.
Battery Voltage too High Battery voltage is over 55 volts. Usually caused by surface charge
77
for Lift of a hot battery fresh off the charger.
Battery Current Limit for There may be a short circuit in the main motor cables. Repair.
Lift Exceeded
85
The motor may be drawing too much current from a shorted field or
armature. Check the motor and repair as necessary.

3-37
Preventative
Maintenance
Chapter 4 describes the routine inspections, adjustments and
lubrication necessary to keep your Bendi Series IV forklift truck
operating safely and efficiently with minimum downtime.
A maintenance schedule is provided in Table 4-1, recommended
lubricants in Table 4-2, and torque values in Tables 4-3, 4-4, and
4-5.

4-1
Preventative Maintenance
Tables
Preventative Maintenance Schedule
Table 4-1 Preventative Maintenance Schedule
WEEKS 6 12 26 52 See Section/
OPERATING HOURS 8 50 100 250 500 1,000 2,000 Page Number
Check batteries See page 4-10
Check power steering See page 4-12
Check hydraulic functions See page 4-12
Check “return-to-neutral” See page 4-13
Check primary lift chain See page 4-13
Inspect tires See page 4-14
Check driver’s seat limit switch See page 4-17
Check service brakes See page 4-33
Check hydraulic level See page 4-18
Check master cylinder fluid See page 4-19

level
Tilt cylinder racking & degree See page 4-20

adjust
Lubricating the truck See page 4-23
Front rotation column See page 4-24

bearings/ gears
Tilt cylinder clevises See page 4-25
Mast mounting pins See page 4-25
Forks and side shifter See page 4-26
Check planetary gear box See page 4-26

Check lift operation See page 4-29
Check drive wheel lug nuts See page 4-30
Cooling fans See page 4-30
Check nuts, bolts, and screws See page 4-31
Change hydraulic oil filter See page 4-32
Lubricate front steer wheel See page 4-45

bearings
Inspect lift chains See page 4-36
Chain/roller adjustment See page 4-36
Primary lift chain See page 4-36
Secondary lift chain See page 4-36
Rail channel roller See page 4-36

inspection
Carriage channel roller See page 4-36

inspection
Inspect electrical connectors See page 4-36
Fork inspection See page 4-36

4-2
WEEKS 6 12 26 52 See Section/

OPERATING HOURS 8 50 100 250 500 1,000 2,000 Page Number
Replacing motor brushes See page 4-39
Traction motors (2) See page 4-41
Pump and power See page 4-42

steering motors
Change hydraulic oil See page 4-43
Inspect wheel bearings, race, See page 4-46

seals
SRE controller, General See page 4-48

practice
Options:
Fork positioner lubrication See page 4-49
Rollout battery tray See page 4-50

lubrication
Recommended Lubricants
No. Location Type Manufacturer
Load Wheel Bearing General use Ball and Roller Texaco, Reference C & C #880
Steering Pivot Bearings Bearing Grease
1
Mast Mounting -40oF to 250oF
Sideshifter (-40oC to 121oC)
2 Front Rotation Gear Open gear lube Mobil 375 nc or equivalent
Mast Lift Chains SAE 80-90W oil, or heavy load East Falls Corporation
3
“red” grease Bowman Heavy Load Grease
4 Hydraulic Reservoir Hydraulic Fluid, 10W40 SE Amoco Rykon MV
Drive Wheel Planetary Gear Box Synthetic oil Mobil SHC 630 or equivalent
Note: See Appendix (A-H)
5
Brevini Service Manual for
additional lubricants.
Steering Knob Light general purpose machine
6
oil
Mast Uprights (Rails) Molybdenum EP Type Grease Kendall SR-12X
7 E/M Lubricants
Royal Lubricants Co., Inc.
Master Cylinder Brake Fluid, DOT #3 per Dow Chemical Co.
8
VV-B-680 Mobil Oil Co.
Table 4-2 Recommended Lubricants

4-3
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 SAE SAE SAE UNF SAE SAE SAE
Size Grade Grade Grade Size Grade Grade Grade
2 5 8 2 5 8
1/4-20 4 [5] 6 [7] 9 [11] 1/4-28 5 [6] 7 [9] 10 [12]
5/16-18 8 [10] 13 [16] 18 [22] 5/16-24 9 [11] 14 [17] 20 [25]
3/8-16 15 [19] 23 [29] 35 [43] 3/8-24 17 [21] 25 [31] 35 [44]
7/16-14 24 [30] 35 [43] 55 [62] 7/16-20 27 [34] 40 [50] 60 [75]
1/2-13 35 [43] 55 [62] 80 [100] 1/2-20 40 [50] 65 [81] 90 [112]
9/16-12 55 [62] 80 [100] 110 [137] 9/16-18 60 [75] 90 [112] 130 [162]
5/8-11 75 [94] 110 [137] 170 [212] 5/8-18 85 [106] 130 [162] 180 [225]
3/4-10 130 [162] 200 [250] 280 [350] 3/4-16 150 [188] 220 [275] 320 [400]
7/8-9 125 [156] 320 [400] 460 [575] 7/8-14 140 [175] 360 [450] 500 [625]
1-8 190 [237] 408 [506] 680 [850] 1-14 210 [263] 540 [675] 760 [950]
1-1/8-7 270 [337] 600 [750] 960 [1200] 1-1/8-12 300 [375] 660 [825] 1080 [1350]
1-1/4-7 380 [475] 840 [1050] 1426 [1782] 1-1/4-12 420 [525] 920 [1150] 1500 [1875]
1-3/8-6 490 [612] 110 [1375] 1780 [2225] 1-3/8-12 560 [700] 1260 [1575] 2010 [2512]
1/1-2-6 650 [812] 1460 [1825] 2360 [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 [ ] IF USING PREVAILING TORQUE NUTS.
Nominal Standard Torque Nominal Standard Torque

Thread Newton- Foot- Thread Newton- Foot-
Diameter Meters Pounds Diameter Meters Pounds
mm mm
6 10 [14] 7 [10] 20 385 [450] 290 [335]
7 16 [22] 12 [16] 24 670 [775] 500 [625]
8 23 [32] 17 [24] 27 980 [1105] 730 [825]
10 46 [60] 34 [47] 30 1330 [1470] 990 [1090]
12 80 [101] 60 [75] 33 1790 [1950] 1340 [1450]
14 125 [155] 90 [115] 36 2325 [2515] 1730 [1870]
16 200 [240] 150 [180] 39 3010 [3210] 2240 [2380]
18 275 [330] 205 [245]
Table 4-3 Landoll General Torque Specifications

4-4
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 Size 37 Degree (JIC) O-Ring (ORS) O-Ring Boss (ORB)
-4 11-13 15-17 13-15
-5 14-16 — 21-23
-6 20-22 34-36 25-29
-8 43-47 58-62 40-44
-10 55-65 100-110 57.5-62.5
-12 80-90 134-146 75-85
-16 115-125 202-218 109-121
-20 160-180 248-272 213-237
-24 185-215 303-327 238-262
-32 250-290 — 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 Size 37 Degree (JIC) O-Ring (ORS) O-Ring Boss (ORB)
-4 11-12 10-12 14-16
-5 15-16 — 18-20
-6 18-20 18-20 24-26
-8 38-42 32-35 50-60
-10 57-62 46-50 72-80
-12 79-87 65-70 125-135
-14 — — 160-180
-16 108-113 92-100 200-220
-20 127-133 125-140 210-280
-24 158-167 150-165 270-360
-32 245-258 — —
Table 4-4 Hydraulic Fitting Torque Specifications

4-5
Bendi Series IV Special Torque Values

Component Torque
Transmission
Wheel 130 ft. lbs. (176 Nm.)
Electric motor 17 ft. lbs. (23 Nm.)
Fluid draining and filling plug 16 ft. lbs. (22 Nm.)
Hydraulic braking unit and brake cable 37 ft. lbs. (50 Nm.)
Transmission with vehicle frame 130 ft. lbs. (176 Nm.)
Hydraulic Power Steering Motor
Bolt 5/16-24 UNF 2A 22-26 ft. lbs. (30-35 Nm.)
Bolt 3/8-24UNF 2A 45-55 ft. lbs. (61-75 Nm.)
Bolt 5/8-18 UNF 2A 140-180 ft. lbs. (190-244 Nm.)
Nut 3/4-16 UNF 2B 175-255 ft. lbs. (237-346 Nm.)
Nut 1-20 UNEF 2B 300-400 ft. lbs. (407-542 Nm.)
Nut 1-1/8-18 UNEF 2B 300-400 ft. lbs. (407-542 Nm.)
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.)
Table 4-5 Bendi Series IV Specific Torque Values

4-6
Overview
Preventive maintenance procedures are designed to extend the service life of the truck
and prevent minor problems from becoming major repairs that are expensive both in
terms of downtime and money.
IMPORTANT !
Read and comply with all applicable SAFETY precautions when servicing this
truck. See the Safety chapter at the beginning of this manual.
Recommended service intervals, as stated in Table 4-4, are based on normal op-
erating conditions. If the truck is subjected to severe or above normal operating
conditions, extreme temperatures, excessive dust or wet environments, or if the
truck is around corrosive materials, service must be performed at shorter inter-
vals.
Common sense and standard precautions usually applied when servicing machinery
must always be used.
· Before using any solvent or cleaning solution, be sure that it will not damage the
part you are cleaning. For example, gasoline should never be used to clean parts.
Gasoline is highly flammable and may damage some types of rubber and
plastic. Hydraulic brake fluid (standard, not silicone type) is often used to clean
rubber parts. It also removes paint quickly, so care should be exercised when it is
used.
· Tag all parts for identification and location before removal and mark all mating
parts for accurate reassembly.
· Protect finished surfaces from damage caused by dropped wrenches, spilled
solvent, etc.
· Use a penetrating oil to loosen difficult screws, nuts or bolts. A hand-held impact
driver is a handy tool when removing tight fasteners.
· Certain bolts, screws, or nuts are secured with a non-permanent thread-locking
compound at the factory, for example, Loctite Primer and Blue sealant #242 or
equivalent (Landoll p/n: 23749 and p/n: 23993 respectively). When these parts are
replaced, a non-permanent thread-locking compound must be re-applied.
· No parts, except those assembled with a press-fit, require unusual force to
dis-assemble. If you encounter trouble, determine the reason for the difficulty, then
proceed.
· Cover all openings caused by removing parts or sub-assemblies with clean rags to
keep objects from falling in where additional serious damage could result.
· When assembling two parts, start all of the fasteners first, then tighten them
evenly and in a staggered manner. Be sure both mating surfaces are aligned, not
cocked or off-center.
· Observe standard torque ratings for the size and type of fastener (See General
Torque, Hydraulic Fitting Torque, and Bendi Series IV Special Torque Tables 4-3,
4-4, and 4-5).
· Be sure to use the proper nuts, bolts and other fasteners. Many are specifically
rated; that is, SAE Grade 5, SAE Grade 8, ISO Prop Class 8.8, etc., and must be
replaced with the identical type. It is recommended to use only Landoll authorized
replacement parts.

4-7
Tools or Equipment Required

In addition to a good portable light source and various tightening tools, the following tools
and equipment may be required:
· Hydraulic jack, appropriate for the weight being raised.
· Safety stands, appropriate for the weight being supported.
· Overhead crane, appropriate for the weight being lifted and/ or supported.
· Grease gun.
· Torque wrench - capable of measuring at least 500 ft. lbs. (678 Nm).
· Drain pan, capable of holding at least 13 gallons (50 liters) of hydraulic fluid.
· Hydrometer with thermometer (for measuring specific gravity and temperature of
battery electrolyte).
Special Tools Required

The following special tools may be required:
· Commutator undercutting tool.
· Brush seater/commutator cleaner abrasive stone.
Safety Equipment Required

The following safety equipment may be required:
· Bicarbonate of soda (to neutralize any acid spills).
· Safety goggles or full-face shield (to guard against acid splash).
· Rubber gloves and apron (to guard against acid splash).
· Dust mask (for protection against abrasive dust when servicing commutators,
brake linings, etc.).

4-8
Floor Access Panel - Removal

This panel provides access to the linear accelerator module assembly which is mounted
to the underside of the floor plate. The master cylinder and service brake pedal and
linkage are mounted within the frame well.
Accelerator
pedal
Floor mat
Floor Access RH Floor plate,

Panel (LH Floor master cylinder well
Floor access plate)
panel
floorplt
Linear accelerator
(mounted to underside
of floor plate)
frlplt-2
Figure 4-1 Floor Access Panel, Driver’s Cab
1. Thoroughly clean the floor area using brush and dustpan or vacuum.
2. If provided, remove hardware and pull up the rubber floor mat. Be careful around the
accelerator pedal to avoid tearing the mat (See Figure 4-1).
3. Remove hardware and the access panel (LH floor plate) from the truck frame (See
Figure 4-1).
4. Remove the hardware holding the accelerator pedal to the RH floor plate. Carefully
lift the RH floor plate.
Note: The linear accelerator module electrical harness will restrict how far the
plate can be lifted. To fully remove the plate you must disconnect the electrical
harness.
5. Install all screws when the panel is reinstalled and make certain the accelerator
harness is secured to the linear accelerator. Install the rubber floor mat, if included.

4-9
Daily Inspection
Check Batteries
Warning
safety precautions.
battery.

safety, care and use, plus a Material Safety Data Sheet (MSDS). Read
these documents thoroughly before servicing the battery.
Always disconnect the battery before performing any service.
Do not lay objects on the battery as they may cause a short circuit.
Shorting battery terminals can release enormous amounts of energy,
causing electrical shock, sparks or flame, or heating nearby
components to dangerous temperatures.
Truck batteries contain concentrated sulfuric acid which can cause

severe chemical burns. When adding water to the battery, wear
rubber gloves, protective clothing and safety glasses or full-face
shield. Use a plastic container or an automatic cell filler to prevent
container breakage.

Use caution when changing battery connectors to ensure that

correct polarity is maintained.
Keep vent plugs in place, fully tightened and clean at all times.


4-10
To Check the Battery:

1. Remove a cap from one or two of the
cells. Gently squeeze (compress) the
bulb of the hydrometer.
2. Insert the tube of the hydrometer into
the cell electrolyte.
3. Slowly release the bulb to allow fluid to
draw into the hydrometer.
4. Enough fluid must enter the
hydrometer to allow the float to move
freely.
5. The specific gravity of the electrolyte is Figure 4-2 Battery Charge State Using
read off the scale of the float where it a Hydrometer
emerges from the fluid (See Figure
4-2). It is a good practice to select a
different cell each time a measurement is taken and to test more than one cell.
6. If the electrolyte temperature is above 77° F (25° C). Add a factor of 0.003 to the
specific gravity reading for every 10° F (-12.2° C) above 77° F (25° C).
7. If the specific gravity of the battery is less than the manufacturer’s specification at
80% discharge, you must charge the
battery (See "Electrical Static
Discharge," page 6-4 for charging
information).
8. When returning the electrolyte to the
battery, return it to the same cell it was
taken from and be very careful not to
splash the electrolyte as it is squeezed
from the hydrometer.
9. Check the level in all battery cells. If a
level is below the top of the battery
plates, add distilled water to bring the
level above the plates (See Figure
4-3).
High level marker indicates proper

level immediately after charging. Low Figure 4-3 Battery Electrolyte Level
level marker indicates immediate need
for additional water (See Figure 4-3).
CAUTION
Avoid over filling as it will cause overflow (flooding) of the elec-
trolyte, resulting in loss of electrolyte, battery tray corrosion, ground
paths and loss of capacity or working ability
10. Replace all the vent caps and make sure they are tight.

4-11
Check Power Steering

To conserve battery power, the power steering pump is turned off if the truck is not
moved for thirty (30) seconds.
1. Sit in the driver’s seat and set the key switch to ON and check for the 15 second time
delay.
2. While applying the service brake, release the parking brake and set the direction
control to FORWARD or REVERSE. The power steering pump motor should start
running.
3. If the motor does not start, first check that the parking brake is released.
4. While moving forward or backward slowly (to avoid flat-spotting), verify that the truck
turns left and right with a relatively smooth, easy motion.
5. While moving forward or backward slowly, turn the steering wheel completely to the
right (a full right-hand turn).
6. While moving slowly in either direction, turn the steering wheel completely to the left
(counterclockwise) while counting the number of full revolutions. The steering wheel
must complete approximately seven to nine revolutions, ±1/2 revolution, lock-to-lock.
7. Next, turn the steering wheel completely to the right (clockwise) while counting the
number of revolutions. The steering wheel must complete approximately seven to
nine revolutions, ±1/2 revolution, lock-to-lock.
8. Sit in the truck without touching the steering and check that the pump turns off after
about 15 seconds.
9. For disassembly and repair, see “Steering Assembly,” on page 6-46.
Check Hydraulic Functions

1. Pull any one of the joysticks, then abruptly release it (See Figure 4-4).
The pump must turn OFF immediately

as you release the joystick.
2. If the pump keeps running, see
“Hydraulic Control Valve and
Switches,” on page 6-64.
Figure 4-4 Checking Hydraulic Functions

4-12
Check the Return-to-Neutral

1. Sit in the driver’s seat, and turn the key switch ON.
2. Set the direction control lever to FORWARD.
3. Slowly move the truck forward, then stop by using the service brake.
4. Turn the key switch OFF, then back on again.
5. Press on the accelerator pedal.
The truck must not move. If it begins to move, see “Direction Control Switch,” on
page 6-86 to check the electrical function of the switch.
6. If the truck does not move, take your foot off the accelerator pedal. Place the
directional control lever in NEUTRAL then back to FORWARD again.
7. Slowly push on the accelerator pedal. The truck should move forward. If it does not
move, see “Direction Control Switch,” on page 6-86 to check the electrical function of
the switch.
8. Repeat preceding Steps 3 through 7, but instead of turning the key switch OFF in
Step 3, lift yourself from the driver’s seat to allow the switch interlock to release. The
truck must react as stated in Steps 5 through 7.
Check Primary Lift Chain

This adjustment procedure is for both Triplex
Level setting,
and Quad mast assemblies. in degrees
1. Park the truck on a flat, level surface, with
the parking brake engaged. 123
321
2. Set the mast in the center of the truck,

facing straight ahead, level to the floor and
empty (unloaded). Check the fork level
gauge on either side of the mast (See
Figure 4-5).
Level indicator
tiltset
Tilt cylinder
Figure 4-5 Fork Level Gauge

4-13
3. Set the key switch to OFF and place

the key in your pocket.
4. Measure the distance from the floor to
the bottom heel of the fork tine (See
Figure 4-6).
This measure must be 1/8” (3.175

mm) minimum to 1/4” (6.35 mm)
maximum.
5. If it is not within 1/8” to 1/4” (3.175 mm
to 6.35 mm), adjust the primary lift
chain accordingly. (See ‘Inspection 1/8" - 1/4"
check list,’ on page 4-36.)
Figure 4-6 Fork Heel to Floor Adjust

Inspect Tires
Warning
The truck is equipped with tires of a size and hardness that provide
the necessary traction and still maintain a proper shape to minimize
tipping. To maintain stability and maximum reliability, you must al-
ways replace tires with the type originally supplied, as listed on the
specification sheet at the beginning of this manual.
It is also recommended to replace worn tires in pairs. Treaded drive

tires must be replaced when the tread depth is less than 0.0625”
(1.6mm) at the deepest point.
1. Inspect the tires for chunking (or
chipping), embedded foreign material,
cuts, gouges, undercutting or uneven
wear (See Figure 4-7).
2. Squeaking or friction noises coming
from the tires during operation may be
caused by separation of the tire layers.
Separation is sometimes visible as a

crack around the sidewall of the tire.
Both tires must be replaced.
3. Excessive wear may be an operator
problem. Too much throttle when
starting a sharp turn causes the inside
tire to spin quicker, producing
abnormal wear.
Figure 4-7 Tire Tread Inspection
More careful driving habits can add
additional miles to tire life.

4-14
Chunking (Chipping) or Embedded Objects

Chunking, or chipping is caused by repeatedly running over objects on a littered floor
which can chip away or produce deep cuts to the rubber surface of the tire.
Embedded objects, such as glass, metal chips, or nails left in a tire, and truck overloading
cause the same effect.
Sharp, rapid turns at quick speeds, jack-rabbit starts and stops and other such bad
driving habits can cause the same kind of damage (See Figure 4-7).
1. Remove any embedded foreign material from the tire as soon as it is noticed. Also
remove torn pieces of tread.
2. To avoid overloading, always center the payload on the truck to equalize the load on
all tires. Do not dangle the load on the ends of the forks. Also avoid fast cornering,
which can cause an overload affect.
3. If the tires are chunked bad enough to produce a bouncy ride, replace them (See
Figure 4-7).
Undercutting and Uneven Wear

Undercutting is caused by continuous overloads, rapid, sharp turns, operating on slopes,
a faulty steer axle, transporting loads with a high center of gravity, or transporting
off-center loads (See Figure 4-7).
Uneven tire wear is usually the result of mechanical defects, such as badly adjusted
brakes, misaligned wheels (misaligned steer axle), or a faulty drive axle.
1. Undercutting causes the rubber to bulge out over the edge of the steel band, cutting
the rubber just above the base band.
2. Check that the tires remain centered on the wheels to prevent splitting of the base
band and tread separation.
3. Correct such defects as soon as possible.

4-15
Flat-spotting
Flat-spotting occurs when:
· the truck has been sitting idle for some time after heavy use and is usually caused
by the tires overheating.
· the truck has standing loads (loads left on the forks overnight).
· locking the brakes while traveling in either direction on grades (slopes), with or
without a load, causing excessive skidding.
Polyurethane tires are extremely susceptible to this type of abuse.

1. Avoid excessive heat. Where possible, avoid contact with hot metal or operation for
long periods in hot oven rooms. Excessive heating will break-down the tire structure.
Shields which prevent heat from striking tires directly will often prolong life.
2. Avoid standing loads. Solid tires will flat-spot when loads are left standing on the
truck overnight. In extreme cases, a flat spot develops and the tire bounces with
every revolution.
3. If the tires are flat-spotted bad enough to produce a bouncy ride, replace them.
4. Do not indulge in stunt driving or horseplay where excessive hard braking is needed,
especially on grades (slopes).
To Expand Tire Life

A few simple measures can help increase tire life and reduce maintenance (downtime)
and cost of operation.
1. Inspect tires regularly and remove embedded objects immediately.
2. Check that the tires remain centered on the wheels.
3. Lubricate the truck according to the schedule provided at the beginning of this
chapter; however, avoid over lubrication.
4. Keep runways clean and maintain floors in good repair, free from breaks, ruts, cracks
and debris.
5. Avoid excessive heat, overloading and standing loads.
6. Regularly check axle alignment and steering.
7. Avoid sharp turns and quick starts and stops.
8. Avoid oil, grease, gasoline and acid. Wipe these compounds off as soon as possible.
Do not allow hydraulic oil to drip onto the tires.

4-16
Check Driver’s Seat Switch

This procedure checks the physical mechanics (actuation) of the driver’s seat switch only.
The switch is part of the seat (See Figure 4-8).
Limit Switch
and cable
Figure 4-8 Driver's Seat Switch
1. Set the key switch to ON and release the parking brake.

2. The seat switch and actuator are internal to the seat cushion, located on the under
side of the seat cushion between the cushion and the bottom plate (See Figure 4-8).
3. Set the direction control in either FORWARD or REVERSE and slowly apply
acceleration. As the truck begins to slowly move in either direction, lift yourself from
the driver’s seat just enough to release the switch in the seat cushion.
4. The truck must drift to an immediate STOP.
5. If the truck continues, see “Seat Switch,” on page 6-69.

4-17
Weekly Inspection
Check Hydraulic Oil Level
1. Lower the mast to within a few
inches of the ground, then tilt it
back completely.
2. Side shift the mast to the far right
and return it to the straight forward
position (normal carry position).
3. With the key switch OFF, turn the
steering wheel left and right until it
becomes difficult to turn.
4. The fill cap is located below the
driver’s compartment floor panel.
Remove the rubber padding, then
unscrew hardware to remove the
floor panel access cover. Also
see “Floor Access Panel -
Removal,” on page 4-9.
5. First clean the area around the fill
cap, then open the cap (turn
counterclockwise) (See Figure
4-9). Reservoir
Drain Plug Oil Level
IMPORTANT ! Dip Stick
It is important that the proper level Oil Filter and
of oil be maintained at all times. Fill Cap
Failure to check the oil level as
recommended could cause serious
mast function operating problems. Figure 4-9 Hydraulic Tank
Below Floor Panel
6. Remove it again, holding the
dipstick tip level and check the oil
FULL
level (See Figure 4-10).
If the oil level is at the FULL line or between the

FULL and ADD lines, the level is correct and no oil
is needed.
If the oil is at or below the ADD line, you’ll need to

add oil to bring it up to the FULL line (maximum).
ADD
Figure 4-10 Oil Level on Dip

Stick

4-18
7. Add hydraulic oil as needed. See Table 4-2 on page 4-3 for recommended lubricants.
Do not overfill. Having the level above the FULL line does not allow enough area for
expansion when the oil heats during normal operation.
8. If the fluid appears very dirty or dark in color, check the truck’s maintenance log for
the last fluid and filter change and change accordingly.
9. Install the fill/dipstick cap, making sure it is tight. Close the access panel and hook
the rubber latch.
Check Master Cylinder Fluid Level

The master cylinder is located
below the driver’s cab floor access
panel.
1. Remove the floor panel (See
page 4-9).
2. First clean the reservoir cap to
avoid fluid contamination, then
remove the fill cap and rubber
gasket (See Figure 4-11).
3. Additional fluid is needed
when the fluid level is below
the FULL line stamped in the
cylinder housing body.
4. Add fluid as needed. DO NOT
OVER FILL. See Table 4-2
on page 4-3 for recommended
lubricants.
Master cylinder
5. Reinstall the reservoir fill cap
and rubber gasket. Tighten Figure 4-11 Master Cylinder
only enough to provide a
leak-proof seal. Do not
overtighten and crimp or split
the seal.

4-19
Check Tilt Cylinder Racking

Warning
When checking any of the mast functions keep everyone away from
the truck. Movement of the mast or other components may injure un-
aware bystanders. Also review the Safety chapter at the beginning
of this manual.
The following adjustment procedures are critical and must be

maintained for optimum truck performance.
Check this adjustments once or twice during the first 50 hours of operation, then once
every 250 hours thereafter.
Tilt Cylinder Racking and Tilt Degree Setting

Racking occurs when the tilt cylinder strokes are uneven, (one cylinder bottoms before
the other). The mast rails then twist, eventually causing them to crack and separate.
Proper tilt degree adjust is 3° forward and 3° to 3.1° backward maximum.
Check these adjustments once or twice during the first 50 hours of operation, then once
every 250 hours thereafter.
1. To check for racking, first find a reasonably level floor area to park the truck.
2. Set the key switch to ON and shift the mast to the center of the truck, as viewed from
inside the driver’s cab.
3. Raise the forks about 36” (914 mm) from the floor and tilt the mast fully forward.
4. Tilt the mast forward and rearward a few times. Carefully watch as the mast
completes the forward and backward stroke, checking for twisting (racking).
5. If there is any twisting motion (racking) of the mast rails when the cylinders bottom,
both tilt cylinder rods must be re-adjusted. See following Step 10 “To adjust for
racking.”
CAUTION
If this is left unattended, serious damage to the mast assembly or the
tilt cylinders can occur, causing extensive repair and downtime.
6. Trial and error is the most effective way to check this adjustment. Repeat Steps 4
and 5 a few times to be sure what type of adjustment is needed. One cylinder may
need tightening while the other needs loosening, or possibly only one cylinder needs
a minor adjustment.
7. To check degree of tilt, be certain the truck is on a smooth, level surface.

4-20
8. Tilt the mast back its full stroke.

Place the tilt gauge against the
rear outer mast rail on the right
side of the truck (See Figure
4-12).
9. The gauge must read between 30
3.0° and 3.1° maximum. See Step
16 “To adjust tilt degree” if
adjustment is needed.
10. To adjust for racking, tilt the
mast fully backward.
Tilt
Gauge
Figure 4-12 Tilt Degree Adjust
Warning
Do not service the tilt cylinders while the key switch is ON. If a
joystick, steering wheel or accelerator pedal is accidentally moved,
you could be caught between the mast and the truck, causing
serious injury.
12. Bend the ears back on the lock
nut/clevis locking plate to release the
plate, then loosen the tilt cylinder lock
nut (See Figure 4-13).
13. Adjust each tilt cylinder rod
accordingly, using a 1-1/8” (28.6 mm)
open end wrench, by turning clockwise
to shorten the stroke or
counterclockwise to increase the
stroke (See Figure 4-13).
It is best to turn the rod only a 1/4 turn

at a time until the correct setting is
achieved.
Figure 4-13 Tilt Cylinder Lock Nut Bracket

4-21
14. You may have to tilt the mast a number of times (repeating Steps 10 through 13) until
the adjustment is correct.
Remember, both cylinders must bottom evenly and at the same time. Racking will
eventually render the mast assembly and/or the tilt cylinders defective.
15. When the adjustment is complete, tighten and torque both cylinder lock nuts and
bend the locking plate tab over the clevis and nut as previously installed. (See
General Torque, Hydraulic Fitting Torque, and Bendi Series IV Special Torque
Tables 4-3, 4-4, and 4-5).
16. To adjust tilt degree, tilt the mast fully backward.
17. Set the key switch to OFF and place the key in your pocket.
Warning
Do not service the tilt cylinders while the key switch is ON. If a
joystick, steering wheel or accelerator pedal is accidentally moved,
you could be caught between the mast and the truck, causing
serious injury.
18. Bend the ears back on the lock nut/clevis locking plate to release the plate, then
loosen the tilt cylinder lock nut (See Figure 4-13).
19. Place the tilt gauge against the rear outer mast rail on the right side of the truck,
about 6” (152 mm) above the pivot arm. The gauge must read between 3.0° and 3.1°
maximum (See Figure 4-12).
Warning
NEVER exceed 3.0° to 3.1° rear tilt. Rear tilt in excess of 3.1° can
cause the truck to become unstable under certain conditions.
20. Adjust each tilt cylinder rod accordingly, using a 1-1/8” (28.6 mm) open end wrench,
by turning clockwise to shorten the stroke or counterclockwise to increase the stroke.
It is best to turn the rod only a 1/4 turn at a time.
21. You may have to tilt the mast a number of times (repeating Steps 16 through 20) until
the adjustment is correct. Remember, both cylinders must bottom evenly and at the
same time or racking will occur.
22. When the adjustment is complete, tighten and torque both cylinder clevis pinch bolts.
(See General Torque, Hydraulic Fitting Torque, and Bendi Series IV Special Torque
Tables 4-3, 4-4, and 4-5).

4-22
Lubricating the Truck

1. Before lubricating the truck, lower the forks, set the key switch
to the OFF position, and set the parking brake (See Figure
4-15).
2. Certain grease fittings may include protective plastic caps.
Remove them before applying grease. Remember to replace
the caps when you are finished (See Figure 4-15).
3. In the following illustrations, the location of grease fittings or Figure 4-14
surfaces to be greased are marked by either a grease-gun or Grease Gun and
brush icon (See Figure 4-14). Brush Icon
4. Make sure all grease fittings are wiped clean before
lubricating. If any of the fittings are corroded or blocked, replace them.
Before brush-applying grease to bearing pad surfaces, wipe out the channel to
remove any foreign matter that may have accumulated since your last lubrication.
5. After high-pressure washing, lubricate all unprotected grease fittings and
metal-to-metal surfaces, located outside the truck.
Mast rails Rotation bearings
Steering gears
Chains Steering wheel
knob
Sideshift rails
Tilt cylinder
Load wheel
axle
Articulating Battery rollers

axle bearings (option)
Rotation bearings Gear box
Master cylinder Hydraulic tank
lubechas
Figure 4-15 Bendi IV Lubrication Overview

4-23
6. Interval frequency can be recorded from the running hours read on the BDI display in
the driver’s cab.
7. See Table 4-2 on page 4-3 for recommended lubricants (See Figure 4-15).
Front Column Rotation Bearings/Gears

Warning
Do not service the truck and/or mast area while the key switch is ON.
If a joystick, steering wheel or accelerator pedal is accidentally
moved serious injury could occur.
1. Set the key switch to ON and pivot
the mast straight forward. to the
normal carry position.
3. Remove the front black plastic
gear cover, button head screws
and hardware, to expose the bull
and pinion gears (See Figure
4-16).
4. Spray or brush apply and thin
layer of gear lube around the
circumference of the bull and
pinion gear teeth. Do not over
grease to prevent seepage under Figure 4-16 Front Cover / Bull and
operating temperatures. Pinion Gears
Note: Landoll recommends using

Mobil 375 nc grease (Landoll P/N
1-341-010004-1).
5. Wipe off excess grease.

6. Grease the upper and lower front
rotation bearing fittings until fresh
grease is squeezed from the lower
bearing (See Figure 4-17).
7. Wipe off excess grease at the
lower bearing.
8. Reinstall the black plastic gear
cover (button head screws and
hardware).
Figure 4-17 Front Rotation Bearings,
Upper and Lower

4-24
Tilt Cylinder Clevises

Warning
1. Set the key switch to ON and pivot
the mast straight forward. to the
normal carry position.
3. Grease clevis fittings at both ends
of each tilt cylinder and on each
side of the truck until fresh grease
is squeezed from the
clevises (See Figure 4-18).
Figure 4-18 Tilt Cylinder Clevis

Mast Mounting Pins
Warning
1. Set the key switch to ON and pivot the mast straight forward, to the normal carry
position.
3. Slide a rag or piece of cardboard
under the mast in the area of the
mounting pins to prevent oil from
dripping onto the floor.
4. Reach in between that mast and
the front end plate and apply
grease to the two grease fittings in
the lower mast mount. An
extension to the grease gun may
be required (See Figure 4-19).
5. Wipe off any excess grease.
Figure 4-19 Mast Mounting Pins

4-25
Forks and Side Shifter

Warning
1. Set the key switch to ON and
position the mast straight ahead.
3. Before lubricating the rails, wipe
off any excess lubricant and dirt
buildup from within the rail
channels.
4. Grease the two rail fittings across
the top of the carriage rail until
fresh grease is seen (See Figure
4-20).
5. Wipe off any excess grease.
6. If your truck includes the fork
positioner option, see page 4-49.
7. Also see Appendix index tab
Figure 4-20 Forks and Side Shifter
Check Planetary Gear
Box
The planetary drive gear box (right and left side) assemblies (2) are filled with oil at the
factory. An oil change is necessary after the first 100 hours maximum of operation in
order to remove particles worn down during the running-in phase. Thereafter, an oil
change is only required once every 750 hours or six (6) months, whichever comes first.
Also, if the truck has been in storage for one year or more, the oil should be changed
before placing the truck into operation.
Also see Appendix, index tab A-H 'Drive System' for installation, service, and
maintenance information.

4-26
Warning
Perform service only in a well-ventilated area. Do not breathe vapors.
Wear protective goggles, aprons, and gloves. Avoid contact with
skin, eyes and clothes. Keep away from heat and flame. Do not
smoke when using solvents or in the area where solvents are stored.
Failure to observe these precautions may result in death or injury.
If you become dizzy, get fresh air and medical help immediately. If
solvent contacts your eyes, immediately treat in accordance with the
manufacturer’s recommendations on the container.
Always read the label affixed to the fluid container for all safety
information before use.
Do not mix different types of lubricant.

1. Position the truck on a flat surface, set the parking brake and block the wheels to
prevent movement.
4. Raise the vehicle. Use jackstands, or other suitable supporting device, to support
vehicle.
5. Remove wheel from unit being serviced.
6. Thoroughly clean the area around the level and drain plugs (See Figure 4-21).
7. Raise the drive wheel of the truck being serviced just enough to allow the tire to
rotate.
Figure 4-21 Changing and/or Checking Gear Box Oil

4-27
Note: Always place an appropriate support stand under the truck if it is being
lifted. Lower the truck to the stand, having both the lifting device and stand sup-
porting the weight of the truck.
DANGER
GEROUS AND COULD CAUSE SERIOUS INJURY OR DEATH. NEVER
GO UNDER A TRUCK THAT IS SUPPORTED ONLY BY A JACK.
8. To drain, turn the wheel gear unit until drain plug in position A is at the lowest
point (See Figure 4-21).
If rotating the tire proves difficult, remove the tire and brace a 2” x 4” (5cm x 10cm)
between the mounting studs and rotate the drive gear.
9. Place a drain pan capable of storing up to 17 ounces (0.5 liters) of fluid under the
drain plug (See Figure 4-21).
10. Using a 5 mm Allen key, unscrew the drain (position A) and level (position B) plugs.
11. Drain the fluid completely into the drain pan.
CAUTION
If truck has just been in operation for a period of time the oil could be
very hot. Use special gloves or allow the truck to cool before chang-
ing the oil. It is best to drain fluid while the unit is warm, but not HOT!
Never drain oil into sewer lines.
12. Once the fluid has been drained, replace the drain plug in position A.
13. Wash the interior of the gear unit with a suitable cleaning liquid as recommended by
the lubricant manufacturer.
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 8. through 12.
14. 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 (See Figure 4-21).
15. Fill the gear unit with synthetic gear lube. See Table 4-2 on page 4-3 for
recommended lubricants. Fluid capacity is approximately 1 quart. Fill using position
B until fluid flows out from the hole in position A.
For easy oil fill, use a hose and funnel arrangement, having an outside diameter of
0.50” (12.7 mm) (See Figure 4-21).
16. Install both plugs. Tighten to 35 ft. lbs. (47 Nm). DO NOT OVERFILL.

4-28
17. Clean any contaminants from the magnetic trap and O-ring seal on the plugs.
reinstall both plugs and torque each to 15 ft. Lbs. (20 Nm).
18. Wipe off any oil spillage on the outside of the unit.
19. Turn the gear unit a few times to eliminate any air pockets and recheck fluid level.
The oil level should be checked again after a short driving period. If necessary, top
off the oil level.
Check Lift Operation

1. Check the lift cylinders to ensure
proper sequencing. If adjustment
is needed, see “The Mast,” on Channel
page 6-76. Rollers
2. Check to see that an unloaded

mast will completely lift (the relief
valve opens). If it will not, check
the hydraulic oil level in the
reservoir; add oil if necessary.
3. Load the mast and raise it
approximately 5’ (1.524 m).
Quickly lower the mast until it is
about 6” (152.4 mm) above the
floor and stop the mast abruptly.
4. Make sure the elevating channel
rollers maintain proper contact
with the mast channel (See Figure
4-22). Figure 4-22 Channel Roller Contact
5. Look for signs of galling where the

rollers contact the rail (See Figure 4-23).
Galling is indicated by track marks in the

rails that are 1/4” to 1/2” (6.35 mm to 12.7
Galling
mm) wide running up the rail. Normal
track marks are no more than 1/4” (6.35
mm) wide.
6. If galling is detected, adjust the rollers for
the proper clearance over the full length of
the mast rails (See ‘General,’ page 4-34).
Also see “Inspection Check List,” page
4-36.
Figure 4-23 Channel Galling

4-29
Drive Wheel Lug Nuts

Retorque the drive wheel lug nuts once or twice during the first 50 to 100 hours of
operation, then once every 250 hours thereafter. Also see “Check Nuts, Bolts, and
Screws,” on page 4-31.
Cooling Fans
Cooling fans (2) are provided - one to circulate air within the frame well that houses the
pumps and motors, the other to circulate air in the well below the driver’s cab floor plate.
These fans must be kept clean for proper air circulation to prevent motor overheating.
Warning
Disconnect the battery cables before working on electrical
components. An electrical short may result in arcing which could
cause serious burns.
Always wear a dust mask and eye protection when seating brushes,
cleaning commutators, and/or blowing dirt out of motors using
forced air.
1. Expose the frame well area (See Figure 4-24).
2. Set the parking brake and block the rear wheels (2).
Main pump/motor
well area drain hole
Figure 4-24 Cooling Fans - Pump/Motor Well and Driver’s Cab Areas

4-30
IMPORTANT !
The frame well area, housing the main pumps and motors, is accessible from un-
der the truck. Reach under and brush and vacuum the fan. If you must raise the
truck, see “Lifting the Truck,” on page 6-3.
Also, DO NOT use forced air as this blows the dirt back into the well area.
5. Using a brush and vacuum and wearing a face mask, brush and vacuum the cooling
fan screen to ensure proper air flow (See Figure 4-24).
6. Restricted air flow causes the motor to operate at undesirable temperatures; in turn
causing possible overheat conditions and premature wear.
Three Month Inspection

Check Nuts, Bolts, and Screws
All major mechanical and major electrical connections (nuts, bolts, screws, etc.) Must be
checked and tightened periodically. Under severe operating conditions, checking and
tightening inspection must be performed more frequently.
(See General Torque, Hydraulic Fitting Torque, and Bendi Series IV Special Torque
Tables 4-3, 4-4, and 4-5 starting on page 4-4).
Check and tighten the following:
· Drive wheel lug nuts.
· Drive unit gear boxes and motor mounting bolts (rear wheels).
To inspect the drive gear motor mounting bolts you must remove the tires. Jack
(lift) the truck and place it on safety stands.
Warning
When working under the truck, always use safety stands together
with the lifting apparatus. Do not rely only on the lifting apparatus.
The lift could leak fluid or be accidentally released, allowing the truck
to drop.
· Load wheel / axle assembly front end mounting bolts
· Mast tilt cylinder pin locking bolts.
· Mast mounting pin locking bolts.
· Master cylinder clevis and mounting bolts.
· All hydraulic pump and motor mounting bolts.
· Hydraulic cylinder clevises.
· Overhead guard mounting bolts.

4-31
Change Hydraulic Oil Filter

prevent movement.
4. Remove the driver’s cab floor plate to
expose the oil dipstick, fill cap and oil
filter combination. Also see “Floor
Access Panel - Removal,” page 4-9.
5. Before opening the filter container cap,
clean the area to avoid contamination.
6. Unscrew and remove the container Filter
cap and spring assembly (See Figure
4-25).
7. Reach in and remove the filter element
by pulling upwards while turning the
element slightly to release the bottom
O-ring seal.
8. Using a clean, lint-free cloth, clean the
inside of the cartridge bowl.
Note: All elements include the bypass
vale built into the element. As a result,
a new bypass valve is provided each Figure 4-25 Oil Filter Access
time the element is changed.
9. Coat the top and bottom O-ring seals on the new filter element with a thin film of
hydraulic oil, then insert the new element into the bowl and press down to seat the
bottom O-ring seal.
10. Align the container cap spring to the by-pass assembly pin, press down and hand
tighten the container cap. Tighten the cap an additional 1/4-turn to seal the
assembly (See Figure 4-25).
11. Operate the hydraulic system by running the mast functions and observe the filter for
oil leaks.
12. Reinstall the driver’s cab floor plate.

4-32
Check Service Disc Brakes

The service brakes are hydraulically-actuated, disc brakes, similar to an automotive disc
brake system. They are installed to the gear box / motor assembly, on the two rear drive
wheels only.
The brakes should be checked every 100 hours of operation. Normal brake pad life is
approximately 3,000 hours of operation, as determined by driving conditions. If you are
near or beyond this time frame, you must inspect the brakes.
New brake pads are approximately 0.265” (6.7 mm) thick; replace them when the pad
thickness is 0.0625” (1.588 mm) or less at the thinnest point.
A few indications of possible brake pad replacement are:
· excess travel of the service brake pedal
· the truck pulling to one side when the brakes are applied
· squealing is heard when you apply the brakes
Drive the truck at creep speed and apply brakes lightly, to determine if brakes pads are
contacting the disk (rotor). You should feel a pulsating effect as the pads contact the
disk.
If any of the above occurs during brake inspection, see “Brake System-Repair,” on page
6-19.
The service brake pedal must also have about 1/2” (12.7 mm) of the travel remaining
when the brakes are fully applied. If less than 1/2” (12.7 mm) is available, check the
pads for wear and replace as needed.
To Check the Brakes

The brakes are located in the frame well, directly below the battery. The battery and
battery lift-out tray must be removed.
1. Position the mast to the full front position, normal carry position.
3. Place blocks in front of and behind all other wheels not being serviced.
4. Disconnect the battery. Remove the battery and battery tray from the truck. See
“Replacing the Battery,” page 2-12.

4-33
5. Check the rotor for scoring,

caused be excessively worn brake
pads (See Figure 4-26).
6. Check the pad thickness using a
6” scale or micrometer (if the pads Brake
are removed). New brake pads Pad
are approximately 0.265” (6.7 mm)
thick. If the pads are 0.0625”
(1.588 mm) or less at the thinnest
point they must be replaced.
7. If replacement is needed, always 0.265”
replace pads on both sides of the 6.7 mm
truck. Also see “Brake
System-Repair,” on page 6-19.
8. Check brake lines for leaks,
Repair leaks immediately - see
“Rigid Brake Line,” on page 6-30. Figure 4-26 Checking Disc Brakes
Semi-Annual
General
To inspect and adjust the mast assembly, also see the Appendix, index tab I-P, for the
following Service Manuals:
· 30D Triple Mast Parts List F-383
· 35D Quad Mast Parts List F-385
· 45D Quad Mast Parts List F-387
· E Series Sideshift Parts List F-399

4-34
Warning
Mast adjustment procedures can produce unexpected movement of
the upright rails and other parts. Be careful and alert.
The forks must be empty. NEVER perform adjustments or

inspections with a loaded mast.
NEVER walk or stand under raised forks. NEVER stand on top of or

climb on any part of the mast rails.
NEVER reach through upright open areas.
Wood blocks used for clamping must be square on the ends and not
tapered or rounded. Use only hardwood blocks which are free from
cracks and other visual damage. Tuck blocks into the channel under
the roller where specified.
For inspection, use only an approved safety platform or step ladder.
NEVER attempt to repair a chain. If any problem is found in a chain, it

must be replaced and chains must be replace in sets. NEVER replace
only one chain.
All mast rail rollers, carriage rollers, chain sheaves and cylinder
head guide rollers (where applicable) are self-lubricating and sealed.
Roller bearing life depends on the application and conditions of
operation.
If the mast shows signs of lateral wear (excessive side play) within
the rail sections, the rollers require shimming and/or replacement. If
not properly shimmed, the rail rollers can destroy their stub shafts
and rail galling, causing extensive repair.
Do not attempt mast repair yourself. Contact your authorized Landoll

service representative. Various procedures require removing the
mast from the truck, using an approximate 3 ton overhead crane, and
placing it in a horizontal position.

4-35
Inspection Check List

· Chain stretch
· Chain and roller adjustment, triplex mast
· Primary lift chain adjustment
· Secondary lift chain adjustment
· Rail channel roller inspection
· Carriage channel roller inspection
Inspect Electrical Connections

3. Remove the rear cover (black) to
expose the electrical panel -four
screws and hardware (See Figure
4-27).
4. Thoroughly check all electrical
connections, check for loose wires
within a connector, loose
connectors, frayed or broken
wires, etc. (See Figure 4-27).
5. Repair as required. Pay special
attention to the cable and
contactor connections, located
lower access panel on the left side
of the truck, as viewed from the Figure 4-27 Electrical Control Panel
driver’s cab.
Fork Inspection
Warning
It is recommended to use only Landoll Corporation replacement
parts.
NEVER use forks repaired by welding.
Always replace both forks. Switching forks from one truck to another
can be dangerous if the capacity of the forks is not known.

4-36
prevent movement.
4. Measure fork thickness (See Figure 4-27).
5. Compare your fork measurement to the original thickness.
6. 0.0625” (1.59 mm) is the maximum acceptable wear for a standard fork size of 1-1/2”
x 4” (38.1 mm x 101.6 mm). If the fork is worn by more than 0.0625” (1.59 mm), the
acceptable limit, replace both forks.
Figure 4-28 Measuring Fork Thickness

4-37
Figure 4-29 Measuring Fork Thickness
7. Measure the distortion distance (Y) of your forks (See Figure 4-29).
8. For this measurement, use a flat bar 4” x 24” (101.6 mm by 609.6 mm), that is 2”
(50.8 mm) thick. Also use a 24” (609.6 mm) carpenter’s square (See Figure 4-29).
9. Table 4-6 shows the acceptable Y distances. If the forks exceed the distance in the
chart, replace them (See Table 4-6).
10. Next, measure the elevation of each fork tip. If the difference is more than 3/4” (19.1
mm), replace the forks (See Figure 4-29).
Blade Length Maximum “Y” Value

32” 812.8 mm 3/4” 19 mm
36” 914.4 mm 31/32” 25 mm
40” 1,016 mm 1-7/32” 31 mm
48” 1,219 mm 1-1/2” 38 mm
Table 4-6 Maximum “Y” Values
11. Check the forks for cracks, paying close attention to the heel portion of the forks. If
any cracks are found, replace the fork.
12. Every 2,400 hours, inspect the forks with magnetic particle or a dye penetrant
inspection. If no test equipment is available in-house, send the forks to a qualified
materials testin laboratory.

4-38
Replacing Motor Brushes

To check the running hours of the various motors, turn the key switch off and on and
record the hours shown on the display for the specific motor in question. Also see
“Dash Display Panel,” page 1-12.
Warning
Disconnect the battery cables before working on electrical
components. An electrical short may result in arcing which could
cause serious burns.
Always wear a dust mask and eye protection when seating brushes,
cleaning commutators, and/or blowing dirt out of motors using
forced air.
Exposing the Motors

To repair and/or replace the brushes in the main pump motor or the power steering pump
motor, the following must be either disconnected or removed:
1. Set the parking brake and all wheels not being serviced.
2. Position the mast to the front position.

4-39
Drive wheel gear box, motor

and brake assembly
Parking brake
assembly
Steer pump
Lift electric
motor
Steer electric
motor
Lift pump
Front of
truck
Drive wheel gear

box, motor and
frmwell brake assembly
Figure 4-30 Frame Well Area
5. Remove the battery - See “Replacing the Battery,” on page 2-12.

6. Remove the battery tray - 3 bolts and hardware.
7. Disconnect the electrical leads to the motor being serviced (See Figure 4-30).

4-40
Traction Motor Brushes

Traction drive motor brushes have an approximate life expectancy of 2,500 to 3,000
hours.
1. Remove the drive tires.
2. Remove all screws securing the motor
mounting bracket to the truck frame Brush
must be removed. This will allow the
unit to rotate within the truck, exposing
all brush locations (See Figure 4-30).
3. Remove the retaining screw from the
brush and screen motor cover halves.
Brush
Slide the screen off the mounting pins Spring
to expose the brush assembly.
4. Remove the screw holding the brush
pigtail wire connector to the assembly.
Figure 4-31 Pump Motor Layout and
Brushes
5. Lift the retaining spring away from the
brush, and remove the brush from its
holder (See Figure 4-31).
6. If the brush is worn to within 3/8” (9.5 mm) of the wires, replace the brush.
7. Inspect the commutator for excessive wear, cracks or burn spots. If burn spots are
found, the commutator must be cleaned (polished).
Cracks or excessive wear may require turning-down the commutator on a lathe or

possibly replacing the assembly.
8. Next, inspect the mica bar-to-bar insulation. When excessive commutator wear
results in flush or protruding mica insulation between the commutator bars, the mica
must be undercut to approximately 0.025” (0.635 mm).
Also see “Traction Drive - Rear,” on page 6-60. The motor needs to be removed
from the truck to repair the commutator or mica insulation.
9. After replacing all brushes, connect the battery and start the truck.
10. While the pump motor is running, check the brushes for proper contact with the
commutator. If arcing is suspected, it is best to seat the brushes and clean the
commutator using a brush seater/commutator cleaning stone.
11. Seating brushes - Select a stone wider than the brush. With the motor running,
press down hard on the brush with an insulated tool and apply the stone at the
leading edge of the brush for several seconds.
This allows stone material to pass under the brush. Repeat until brush is fully seated.

4-41
12. Cleaning the commutator - select a stone as large as practical. With the motor
running, hold the stone lightly against the commutator, moving the stone slowly back
and forth across the commutator face unit the excess film or burn spots are removed.
13. Turn the truck OFF. Wearing a dust mask to protect from inhaling dust particles, use
forced air and a vacuum to blow out and vacuum the dust created by seating the
brushes and the commutator.
14. Disconnect the battery, then replace the brush and screen motor covers, and the
operator’s floor panel.
Pump and Power Steering Motor Brushes

1. Read the WARNING ! note on page 4-39.
2. Expose the frame well area (See heading ‘Exposing the motors,’ page 4-39).
3. Remove the retaining screw from the brush and screen motor cover halves. Slide the
screen off the mounting pins to expose the brush assembly.
4. Remove the screw holding the brush
pigtail wire connector to the
assembly (See Figure 4-32).
Brush Wire
5. Lift the retaining spring away from the Springs Screw
brush, and remove the brush from its
holder.
6. If the brush is worn down to within 3/8”
(9.5 mm) of the wires, replace the
brush.
Brushes
7. Inspect the commutator for excessive
wear, cracks or burn spots. If burn
spots are found, the commutator must
be cleaned (polished) to remove them.
Cracks or excessive wear may require

turning-down the commutator on a
lathe or possibly replacing the
Figure 4-32 Pump and/or Power Steering
assembly.
Motor Brushes
8. Next, inspect the mica bar-to-bar
insulation. When excessive
commutator wear results in flush or protruding mica insulation between the
commutator bars, the mica must be undercut to approximately 0.025” (0.635 mm).
9. After replacing all brushes, connect the battery and start the truck.
10. While the steer motor is running, check the brushes for proper contact with the
commutator. If arcing is suspected, it is best to seat the brushes and clean the
commutator using a “brush seater/commutator cleaning stone.”

4-42
11. Seating brushes - Select a stone wider than the brush. With the motor running,
press down hard on the brush with an insulated tool and apply the stone at the
leading edge of the brush for several seconds.
This allows stone material to pass under the brush. Repeat until brush is fully
seated.
12. Cleaning the commutator - Select a stone as large as practical. With the motor
running, hold the stone lightly against the commutator, moving the stone slowly back
and forth across the commutator face until the excess film or burn spots are
removed.
13. Turn the truck OFF. Wearing a dust mask to protect from inhaling dust particles, use
forced air and a vacuum to blow out and vacuum the dust created by seating the
brushes and cleaning the commutator.
14. Disconnect the battery, then replace the install and screen motor covers.
Annual Inspection
Change Hydraulic Oil
1. The mast must be set to the normal carry position.
2. Set the parking brake and block the rear wheels (2).
5. Remove the driver’s cab floor panel (see ‘Floor Access Panel - Removal,’ page 4-9)
to expose the oil reservoir fill cap, as well as the oil filter.
6. Open the fill cap (See Figure 4-9 on page 4-18).
7. Jack (or raise) the left side of the truck (as viewed from the driver’s cab) a few
inches/centimeters to force oil to the opposite side of the truck. Also see “Lifting the
Truck,” on page 6-3.
Always place an appropriate support stand (or wood blocks) under the truck, then
lower the truck to the stand, having the lifting device and stand both support the

4-43
Hydraulic reservoir
drain plug
oildrain
Figure 4-33 Draining Oil Reservoir
DANGER
GEROUS AND COULD CAUSE SERIOUS INJURY. NEVER GO UN-
DER A LIFT TRUCK THAT IT IS SUPPORTED ONLY BY A JACK.
MAKE SURE ALL LIFTING DEVICES AND SUPPORTS, SUCH AS A

JACK OR SUPPORT STAND, BLOCKS OF WOOD, ARE CAPABLE OF
HANDLING THE WEIGHT OF THE LOAD.
8. The hydraulic reservoir (oil tank) drain plug is located in the side of the truck, near the
steering column (neck) (See Figure 4-33).
9. Slide a flat collection pan, having a capacity of 10 gallons (38 liters) minimum under
the drain plug, then remove the plug (See Figure 4-33).
10. Clean the magnetic trap on the drain plug of any contaminants. When the tank is
empty, clean and reinstall the drain plug.
11. Add hydraulic oil. See Table 4-2 on page 4-3 for recommended lubricants. Also see
“Check Hydraulic Oil Level,” page 4-18.
Note: Do not overfill. Having the level above the FULL marker on the dipstick
does not allow enough area for expansion when the oil heats during normal oper-
ation.
12. Replace the fill cap and make sure it is tightened securely.
13. Before lowering the truck, make sure the drain plug is tight enough to prevent oil
leaks, but do not over tighten.

4-44
Lubricate Front Steer Wheel Bearings

1. Position the truck on a flat surface, set the parking brake and block the wheels not
being serviced to prevent movement.
2. Raise the mast about five feet (1.5m) to expose the inner wheel frame area and the
wheel bearing grease fittings.
5. Jack (lift) and block the truck so that the steer wheel being greased is clear of the
floor. Place a support stand appropriately under the truck.
Always place an appropriate support stand (or wood blocks) under the truck, then
lower the truck to the stand, having the lifting device and stand both support the
DANGER
GEROUS AND COULD CAUSE SERIOUS INJURY. NEVER GO UNDER
A LIFT TRUCK THAT IT IS SUPPORTED ONLY BY A JACK.
MAKE SURE ALL LIFTING DEVICES AND SUPPORTS, SUCH AS A

JACK OR SUPPORT STAND, BLOCKS OF WOOD, ARE CAPABLE OF
HANDLING THE WEIGHT OF THE LOAD.
6. Make sure the other wheels are
securely blocked so that the truck
cannot move.
7. Remove the wheel hub cap - pry
off using flat blade
screwdriver (See Figure 4-34).
8. Clean out all excess grease from
the spindle/wheel hub area.
9. Using a grease gun, lubricate the
steer axle fitting, located on the
inside of the front axle weldment
plate until fresh grease is seen.
10. Wipe off excess grease and
replace the hub cap using a Clean out
rubber mallet. excess grease
Note: Make sure the breather hole
Breather
is clear of grease and dirt, other- port
wise the hub will fall off with heat
and air expansion (See Figure Wheel hub cap
4-34). wheelasy
Figure 4-34 Steering Wheel Bearings

4-45
Inner bearing
Hub cap Outer bearing cone
cup (race)
O-ring seal
Inner bearing
Cotter pin and cup(race)
hex slot nut
Outer bearing Spindle

cone
Inner grease
seal
Load wheel
Spindle Washer assembly
Breather port
wheelasy
Figure 4-35 Exposing Wheel Bearing Cones, Cups (Races), and Inner Seals
Inspecting the Bearings, Race and Inner Seal

If inspection of the bearing cones, cups (race), and inner seal is deemed necessary,
proceed as follows:
· Bend back the tangs of the cotter pin and remove the pin from the wheel
spindle (See Figure 4-35).
· Remove the spindle nut and bearing washer, then carefully pull out on the wheel
to loosen the bearing.
· As the wheel is removed, remove the outer wheel bearing cone, which pops free
as the wheel is pulled away.
Be careful not to damage the inner seal as the wheel is removed (See Figure
4-35).
· If the inner seal is damaged, use a screwdriver to pry the seal from the wheel.
Note how the seal is installed.
· Remove the inner bearing cone.
Note: If the bearings must be replaced, use a standard puller to remove the inner
and outer bearing cup (race) from the wheel rim.
· Wash the bearing in a solvent. Examine it for damage or wear. Allow the parts to
air dry.
· Spin the bearings and check for unusual sounds indicating rough surfaces or
non-rotating rollers. Replace bearings if they are noisy or appear rough.
Also see “Steering Assembly,” on page 6-46.

· Pack the bearings with high-temperature bearing grease making sure the grease
penetrates the rollers, cone and cage from the back side. See Table 4-2 on page
4-3 for recommended lubricants.

4-46
· Clean the spindle and examine it for wear or scoring damage.

· Install a new grease seal and, if not damaged, the original inner bearing cone.
Note: Install new bearing cup (race) by pressing into wheel rim. Apply an even
force to prevent cracking the cup (race) during installation. Be sure that each
bearing cup (race) is fully seated (bottomed out) against the shoulder in the rim
bore.
· Carefully set the wheel over the grease seal and spindle and install the outer
bearing cone, steel washer, then the spindle nut (See Figure 4-35).
· While turning the wheel or rim counterclockwise, apply 240 to 260 in. lbs. of torque
to the spindle nut.
· Spin the wheel to make sure it turns free, then back off the wheel nut 1/2 turn.
While turning the wheel, apply 20 to 25 in. lbs. (2.26 to 2.82 Nm) of torque to the
nut. Again, check to make sure the wheel turns freely.
· Back-off the nut slightly as necessary to align it with the nearest hole. Insert and
bend back the legs of the cotter pin
· Install the hub cap.
Lubricate Steer Wheel

Knob
1. While the truck is stationary and with
the key switch OFF, apply a drop or
two of light machine oil where the
knob meets the steering wheel (See
Figure 4-36).
2. Spin the knob a few times and wipe off
excess oil.
Figure 4-36 Steering Wheel Knob

4-47
Figure 4-37 SRE Controller Overview
SRE Controller
The SRE transistor control units, like all electrical apparatus, exhibits some thermal
losses. The semi-conductor junctions have finite temperature limits above which these
devices may be damaged (See Figure 4-37).
For these reasons, normal maintenance should guard against any action that could
expose the components to excessive heat, such as steam cleaning; and/or that which
could reduce heat dissipating ability of the control, such as restricting air flow.
Note: For additional information on the SRE Controller, see the Appendix, index
tab A - H, 'Electrical System'.
General Practice
· Before performing any maintenance to the SRE controller you must disconnect the
battery.
· Any controls that are be used in ambient temperatures of 100° F (38° C) or above
must be brought to the immediate attention of the Landoll Corporation.

4-48
· Never steam clean the control.
In dusty areas, use low-pressure forced air to blow off the control. In oily or
greasy areas, a mild solution of detergent or denatured alcohol may be used to
wash off the control. Then, using low-pressure forced air, blow the unit completely
dry. The control may also be cleaned using an electrical contact-type degreaser.
· The use of a heat-transfer grease, such as Dow Corning #340, is recommended
when re-installing the SRE panel. The grease helps dissipate heat.
· Thermal boards and other exposed SRE control parts should be kept free of dirt
and paint that might change the effective resistance between points.
· Use a lead-acid battery with a voltage and ampere hour rating specific for the
vehicle. Follow normal battery maintenance procedures recharging the battery
before 80% discharge and with equalizing charges capability.
Options
Fork Positioner Lubrication, Non-Side Shifting
1. Set the key switch to ON and position the mast straight ahead.
WARNING
Do not service the fork positioner while the key switch is ON. If the
pivot or tilt joystick is accidentally moved, serious injury could oc-
cur.
3. Before lubricating the positioner rails,
wipe off excess lubricant and dirt
buildup from within the rail channels
and dirt from the top and bottom of the
rail grooves.
4. Using a brush, lubricate the shaded
areas on the fork rails, including a thin
film on the front face of both rails (See
Figure 4-38).
Figure 4-38 Fork Positioner, Non-Side

Shifting

4-49

1. Set the parking brake and block
the rear wheels (2).
3. Disconnect and remove the
battery. See page 2-12 for
instructions on replacing the
battery.
4. Using a brush and vacuum, clean
the roller tray and restraint release
arm area of any dirt or battery acid
residue.
5. Remove the rollout restraint and
brush apply a thin film of grease to
the mating surfaces of the
restraint arm and inside of
bracket (See Figure 4-39).
6. Apply a drop or two of light Figure 4-39 Rollout Battery Tray Lubrication
machine oil to the rollers. Spin
each roller and wipe off excess oil.
DO NOT over oil.
7. Also apply a drop or two of light machine oil to the release handle. DO NOT over oil.

4-50
Troubleshooting
This chapter contains troubleshooting procedures to help
diagnose and solve problems. Once the problem is isolated you
must refer to Chapter 6, Corrective maintenance for the repair
instructions.
Troubleshooting procedures are arranged as:

· Visible problems, including battery troubleshooting
· Spills and waste management
· Audible problems
· Performance problems
· Pump problems
· SRE controller troubleshooting
Preliminary Procedures
· Thoroughly review the problem with the operator so you
have a complete description of what is wrong.
· Check the operator’s driving practices and operating
procedures to see if operator error could be the problem.
If you suspect operator error, review the operating

procedures of this manual with the operator, or have the
operator read the Operator’s Manual provided with each
truck.
· If you are sure it is operator error, return the truck to service
and see that the operator is properly retrained before being
allowed to drive the truck.
· Check the preventive maintenance log to make sure that the
log is up-to-date and the problem is recorded. If it is not, or if
there is no log, begin one and start by performing a
preventive maintenance inspection of the truck (See Table
4-1).
· After the problem has been corrected, operate the truck
again to verify the repair and to ensure there are no
additional problems. If no other problems exist, return the
truck to operation. If other problems are found, troubleshoot
and repair them before returning the truck to operation.

5-1
Troubleshooting
Visible Problems
Chart - Visible Problems
# Problem Cause Suggested Repair
1. Cracked or exceptionally Fatigue, age, excessive lifting of • When replacing forks - Forks
worn forks. overweight loads, straightness must be replaced in pairs.
of blade and shank, fork angle • Check straightness of the upper face
or height differences between of each blade and the front face of
fork tips. each shank. If deviation exceeds
WARNING 0.5% of the length of the blade
• If you find any defect in and/or height of shank respectively,
the forks or mounting replace forks.
components, take the
forklift out of service • Check angle between upper face of
until the forks are re- fork blade and load face of each
paired. Failure to do so shank. If deviation exceeds 3° from
can cause the load to original specification, replace forks.
fall resulting in serious • Check difference in height between
injury or death. each fork blade (measured at the tip
with the fork mounted on the
carriage). If difference in tip heights
exceeds 3% of the length on the
blade, replace the forks.
• See “Removing Forks,” on page
6-38.
Excessive wear or defective • Check each fork, especially at the
hooks. heal area. If thickness is reduced to
90% of original thickness, replace
the forks.
• Check support face of the top hook
and the retaining faces of both
hooks for wear, crushing or other
deformations. Excessive clearance
between fork and carriage requires
fork replacement.
WARNING
• Forks requiring repair must be returned to the original manufac-
turer.
• Never try to repair surface cracks or wear by welding. If a fork is re-
set, make sure it is heat treated before it is returned to service.
• A fork that has undergone repairs must be load tested before it is
returned to service. The test facility must test 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.
2. Leaking fluid. Cracked, split, or cut hoses. • Replace. NEVER attempt to patch a
hose.
• See “Hydraulic Fittings and Hoses,”
on page 6-4.

5-2
Troubleshooting

Loose or faulty hydraulic • Tighten and/or replace. Be careful
fittings. not to strip the threads, rendering
the fitting defective.
on page 6-4.
Pump or motor oil seals, rings, • Replace seals in bad unit or replace
gaskets, etc. deteriorated by unit.
excessive heat or corrosion. • Check appropriate “Appendix” index
tab for vendor service information,
where applicable.
3. Puddles/leakage in area Loose plug or faulty seal/gasket • Locate source of leak - gear box.
of rear drive wheels. in gear box. • Replace seals in suspected unit or
replace unit.
• See “Traction Drive - Rear,” on
page 6-60.
• Check appropriate “Appendix” index
where applicable.
Gear box leaks when warmed • Check fluid level- too high. See
up. “Check Planetary Gear Box,” on
page 4-26.
Faulty seals/gaskets in main • Check the hydraulic pump assembly
hydraulic pump. for excessive wear, oil leaks, loose
or defective fittings.
• Replace seals or replace unit.
• See Figure 6-38 on page 6-57.
• Also see “Pump Problems,” on
page 5-26.
where applicable.
Loose or faulty hydraulic • Locate source of leak. Tighten
fittings. and/or replace fittings.
• Be careful not to strip the threads,
rendering the fitting defective.
on page 6-4.

5-3
Troubleshooting

Loose brake line fittings. • Locate source of leak. Tighten
and/or replace fittings.
• Brake line fittings are made of soft
metal. Be careful not to strip the
threads, rendering the fitting
defective.
• See “Rigid Brake Line,” on page
6-30.
• See “Bleeding Brakes,” on page
6-32.
Leaking brake caliper. • Rebuild or replace caliper.
• See “Replace the Brake Caliper
Assembly,” on page 6-23.
6-32.
4. Leakage in motor. Faulty O-ring or bearing seal on • Disassemble electric motor and
electric motor. check O-ring and bearing seals and
sealing surfaces for damage -
replace accordingly.
• See “Traction Drive - Rear,” on page
6-60.
5. Grease blotches around Faulty grease seal in steer • Check seal rings and wheel shaft for
front steer wheels wheel assembly. damage in seal area.
(especially on inside of • Replace the inner grease seal.
wheel rim).
• See “Wheel Bearings, Seals, and
Races,” on page 6-39.
6. Puddles/leakage near Faulty oil seal/gasket in power • Rebuild or replace the power
center area (neck) of the steering motor. steering pump.
truck. Internal shaft seal worn or • See “Steering Assembly,” on page
damaged. 6-46.
Worn coupling shaft and internal
seal.
Loose hose or hydraulic fitting. • Locate source of leak, example,
pump or cylinder, oil tank drain line
fitting, etc. Tighten and/or replace
fittings.
on page 6-4.
Leakage in breather valve. • Excessive hydraulic fluid level.
• See “Check Hydraulic Oil Level,” on
page 4-18.

5-4
Troubleshooting

7. Puddles/leakage near Leaking cylinder - lift, tilt and/or • Determine bad cylinder - rebuild
mast. sideshift. and/or replace.
• See “The Mast,” on page 6-76.
• Seal kits are available for most
cylinders - see IPB for part
numbers.
Loose hose or hydraulic fitting. • Locate source of leak, cylinder,
manifold hose, cylinder hoses, etc.
Tighten and/or replace fittings.
on page 6-4.
8. Frayed or broken wires. This may be caused by • Repair or replace wires and
improperly secured wires or harnesses and secure properly.
harnesses allowing pinching or • See “Inspect Electrical
excessive movement Connections,” on page 4-36.
(vibration).
• Make sure wires do not come in
contact with any moving parts or are
not pinched in access doors or
cover panels.
9. Lights do not work. Blown bulb. • Replace the bulb.
• See “Lights,” on page 6-89.
Bad fuse. • Check Fuse SRE#1 and C.B. #3.
• Check circuit breaker or DC
converter.
Electrical problem - frayed or • Check related wire harnesses and
broken wires, faulty switch or connectors for contact problems,
electronics. broken wires, etc.
• Continuity check on/off switches -
replace as needed.
• See “Intermittent Electrical
Problems,” on page 5-5.
10. Intermittent electrical Loose electrical connections. • Check for excessive vibration or
problems. poor maintenance procedures.
• Tighten contacts as needed.
• Examine cable assemblies for tight
connections.
• Wire terminal crimps should be
secure and wire stranding must not
be frayed or corroded.
11. Scraping marks on the Rail misalignment. • Realign rails. See “The Mast,” on
mast. page 6-76.

5-5
Troubleshooting

12. Excessive tire wear. Hard starting and stopping. • Examine operator’s driving habits
and train operator accordingly.
• Excessive “hard” stops and starts
contribute to abnormal brake and tire
wear.
• See “Check Service Disc Brakes,”
on page 4-33.
• See “Inspect Tires,” on page 4-14.
Excessive overloading or • NEVER lift loads in excess of what is
improper weight distribution. recorded on the capacity nameplate
(See Figure 1-1).
• Excessive overloading or improper
weight distribution placed on the
drive train will eventually render the
gear box defective and could cause
wheel traction problems; in turn,
premature tire wear.
• Also see “Understanding Stability,”
on page 3-2.
Faulty gear box bearings • Check appropriate “Appendix” index
causing alignment problems. tab for vendor service information,
where applicable.
Worn steer wheel bearings. • Replace. See “Wheel Bearings,
Seals, and Races,” on page 6-39.
Improper tire durometer. • Repair only with Landoll
recommended spare parts.
13. Battery troubleshooting. WARNING
• Only personnel who have been trained in battery installation, charg-
ing and maintenance should work on the battery. Also see “Spills
and Waste Management,” on page 5-8.
13a. Excessive battery water Overcharging. • See dataplate on battery for

needed. important information.
• Select a proper sized battery
charger.
• Check charge time and average
battery temperature.
• See “Charging a Wet Battery,” on
page 2-2.
Jar leakage. • Repair or replace.
• See “Replacing the Battery,” on
page 2-12.
13b. Excessive battery cell Overcharging. • See “Excessive battery water
temperature. needed,” on page 5-6.

5-6
Troubleshooting

Overworked. • Reduce to one cycle per day or 300
per year maximum.
• Reduce charging to once a day.
• Allow battery to cool down before
charging.
Shorted cell(s). • Repair or replace. Use only an
authorized battery repair service
center.
13c. Unequal or low specific Electrolyte spillage during • Avoid over watering.
gravity - battery. watering. • Immediately neutralize and clean
using Bicarbonate of Soda.
page 2-2.
Electrolyte flooding. • Add water during the end of the
charge.
page 2-2.
Insufficient charge. • Extend charging time - see
dataplate on battery for important
information.
Internal short. • Repair or replace. Use only an
authorized battery repair service
center.

5-7
Troubleshooting
Spills and Waste Management

Warning
Also refer to the MSDS (Material Safety Data Sheet) manual, which
should be located in your battery charging area for important infor-
mation on safely handling chemical products, such as sulfuric acid,
and personal treatment should an accident occur.
Spills of Sulfuric Acid

Spills of sulfuric acid should be handled with consideration for the following:
· Do not touch spilled material without appropriate personal protective equipment
(e.g., face shield, acid resistant gloves and apron, etc.).
· If possible, stop the flow of spilled acid with sand or other noncombustible
absorbent and/or neutralize with bicarbonate of soda, lime or other neutralizing
agent.
· Place spill residue into compatible containers. If spill occurs from a battery, waste
should be tested for presence of hazardous constituents prior to disposal.
· Residue from spilled, unused sulfuric acid which has been neutralized (pH 6.0-9.0)
can be safely disposed of in municipal trash, unless local or state regulations
specify otherwise.
· Do not allow the discharge of any neutralized acid into sanitary or storm sewers.
· Spills which enter the environment (through sewers, waterways or soil) must be
reported, as applicable, to city, state, or federal environmental agencies, including
local emergency planning committee (LEPC). As a guide, the federal reportable
quantity (RQ) for 100% sulfuric acid is 1,000 pounds; the reportable quantity for
lead is one (1) pound.
· Spills which occur during transportation of batteries should be reported to
CHEMTREC (1-800-424-9300), a 24-hour service for emergency assistance.

5-8
Troubleshooting
Handling and Storage

· Batteries and battery components should be handled only in accordance with the
safety procedure outlined in "Waste Generation and Disposal," page 5-9.
· All batteries, as well as other hazardous substances, should be stored under
cover and on an impervious surface with adequate containment to prevent
dispersion of contaminants to the environment.
· Batteries and acids should be stored away from sewer and storm drains and from
sources of heat.
· Leaking and cracked batteries and cells must be provided with adequate
containment during storage and transportation.
· Generally, there are no storage time restrictions for batteries or for spent lead-acid
batteries which are destined for recycling. However, state regulations and local fire
and health ordinances should be consulted for special restrictions on the storage
of hazardous substances, including batteries and acid.
· Sulfuric acid is listed as an extremely hazardous substance under the Federal
Emergency Planning and Community Right-to-Know Act (EPCPA). Notification
and/or reporting to state and local agencies may be required if specific quantity
limitations are exceeded. The threshold planning quantity (TPQ) and reportable
quantity (RQ) for sulfuric acid is 1,000 pounds.
Waste Generation and Disposal

· Spent lead-acid batteries which are destined for recycling are not regulated under
federal hazardous waste regulations or by most state regulations. Contact your
state environmental agency for additional information.
· Under federal land ban restrictions and individual state battery recycling laws,
spent lead-acid batteries can be disposed of only by recycling/reclamation at
permitted secondary lead smelters or other authorized recycling facilities. Spent
batteries should be sent only to facilities which have obtained EPA or state
hazardous waste permits for the storage of spent batteries prior to recycling. Also
see Table 5-1.
· Acid which is removed from spent batteries is a regulated hazardous waste.
Facilities which generate spent acid may be subject to state or federal regulations
for large or small quantity generators applicable to labeling, manifesting,
transportation, and reporting.

5-9
Troubleshooting
Recycling locations
District City/State Telephone
Boston Hollis, NH 603-886-5900
Syracuse, NY 305-437-1789
Reading/Philadelphia Reading, PA 215-921-4480
Warminster, PA 215-443-0912
Pittsburgh, PA 412-788-1613
Glen Burnie, MD 410-768-5586
Cincinnati Cincinnati, OH 513-831-3838
Cleveland, OH 216-241-6231
Columbus, OH 800-582-1363
Atlanta Norcross, GA 404-446-8663
Birmingham, AL 205-591-0606
Chicago Countryside, IL 708-352-3665
Peoria, IL 309-699-3900
Detroit Auburn Hills, MI 313-852-1500
Grand Rapids, MI 616-531-1120
Los Angeles City of Industry, CA 818-333-3060
San Francisco Hayward, CA 510-887-8080
Seattle, WA 206-575-3090
Dallas Dallas, TX 214-869-1855
Memphis, TN 901-365-6944
Houston, TX 713-690-8700
San Antonio, TX 512-661-5497
Kansas City Kansas City, MO 816-231-1414
Omaha, NE 412-592-1760
Roseville, MN 612-631-2150
Table 5-1 Recycle Locations

5-10
Troubleshooting
Audible Problems
Chart - Audible Problems
1. Back up alarm does not Faulty alarm module. • Continuity check alarm module -
sound. replace as needed.
• See “Back Up Alarms,” on page
6-89.
Electrical problem - frayed or • See “Inspect Electrical
broken wires, faulty direction Connections,” on page 4-36.
control switch or electronics. • Check related wire harnesses and
connectors for contact problems,
broken wires, etc.
connections.
• See “Intermittent electrical
problems,” on page 5-5.
2. Unusual noise when Rubbing or binding brake pads • Try to isolate the cause of the noise.
truck is in motion. in rear wheels (possible frozen • Drive truck slowly having another
caliper). operator check for the unusual
noise.
• Step on brakes lightly to see if
brakes are binding or rubbing
excessively - repair or replace.
• See “Brake System - Repair,” on
page 6-19.
Faulty gear box assembly. • If unit is suspected, it must be
removed from the truck and either
repaired or replaced.
• See “Traction Drive - Rear,” on
page 6-60.
tab A-H, for vendor service
information, where applicable.
3. Knocking, conditional Helical gear step has been • Dismount electric motor.
on speed. damaged when mounting • See “Traction Drive - Rear,” on
motor. page 6-60.
• Check drive pinion and helical gear
for damage.
• Repair or replace.
4. Singing noise. Incorrect motor connection. • Check motor connection. See
electrical diagram, p/n 130945.

5-11
Troubleshooting

Insufficient fluid level. • Check fluid level. See “Check
Planetary Gear Box,” on page 4-26.
Faulty motor bearing. • Repair or replace motor. See
“Traction Drive - Rear,” on page
6-60.
5. Muffled grinding noise. Faulty wheel bearings - could • Determine if noise is in the front or
be insufficient fluid or high rear.
pre-stress or excessive play on • For front - See “Wheel Bearings,
bearings. Seals, and Races,” on page 6-39.
• For rear - See “Traction Drive -
Rear,” on page 6-60.
• See “Check Planetary Gear Box,”
on page 4-26.
Damaged planetary step • Dismount gear box and examine for
gearing - could be insufficient damage.
fluid, excessive play in bearing. • See “Traction Drive - Rear,” on page
6-60.
• See “Check Planetary Gear Box,”
on page 4-26.
6. Clicking noise during a Loose or shifting component. • Try to isolate the area of the noise,
turn. then check for loose parts,
misalignment, load shifting, etc.
• Check that components are in place
and properly torqued.
• See Table 4-5 on page 4-6.
7. High RPM in drive motor. Most commonly caused by • Check motor coil for a short -
shorted field coil. remove and either rebuild or replace
the suspected drive motor.
8. Horn does not work. Faulty horn assembly or • Disconnect horn wires and
pushbutton. pushbutton - continuity test horn with
leads connected to battery power.
• Check related wire harnesses and
connectors for contact problems,
broken wires, etc.
connections.
• See “Intermittent electrical
Blown fuse. • Check fuse FUSRE6.
• Check for electrical short - in horn or
electrical connections.

5-12
Troubleshooting

9. Rubbing noise from the Faulty wheel bearing or • Dismount suspected wheel and
front wheels. damaged wheel shaft. examine bearings and shaft.
Races,” on page 6-39.
• Check for foreign material lodged
inside wheel hub - remove and
repair and/or replace as needed.
10. Scraping noise when Out of alignment. • Re-align and shim mast rails
the mast is operated accordingly.
Faulty hydraulic cylinder - lift, • Determine which cylinder is bad -
tilt and/or shift. rebuild or replace.
cylinders - see Chapter 7 “IPB” for
part numbers.
11. Pump making noise or See “Pump Problems,” beginning on page 5-26.
running continuously.

5-13
Troubleshooting
Performance Problems
Chart - Performance Problems
1. NO operation! Battery disconnected or • Make sure battery installed is a 48
insufficient charge. VDC battery.
• Check battery for connection.
• See “Replacing the Battery,” on
page 2-12.
• Check battery for full charge.
page 2-2.
Emergency STOP (disconnect) • Check pushbutton and if necessary,
pushbutton is pressed. release pushbutton.
Improper start-up sequence. • Place the direction switch in
NEUTRAL before power on.
• Remember to wait about ten (10)
seconds after power on to allow
diagnostic testing.
• See “Practice Session,” on page
3-15.
Blown fuse. • Check main power fuses (200amp) -
FUSRE7 and FUSRE8.
• Check for electrical short, or
electrical connections.
2. Poor truck performance. Battery undersized. • Refer to capacity plate for battery
rating and install battery with proper
ratings.
• See “Capacity,” on page 3-4.
Undercharged battery. • Return truck to charging station and
check battery characteristics.
• See “To Prepare the Truck,” on
page 2-2.
• Check charging connector and
discharge indicator for malfunction.
Repair or replace.
• Reset discharge indicator for 80%.
Excessive loss of electrolyte. • Adjust specific gravity at state of full
charge.
page 2-2.

5-14
Troubleshooting

3. Service brakes do not Low fluid level in master • See “Check Service Disc Brakes,”
stop the truck. cylinder reservoir. on page 4-33.
• If low, check for leaking fittings or
lines - tighten and/or replace.
• Brake line fittings are made of soft
metal. Be careful not to strip the
threads, rendering the fitting
defective.
• See “Rigid Brake Line,” on page
6-30.
• Also check wheel calipers for leaks -
rebuild or replace.
• See “Replace the Brake Caliper
Worn brake pads. • Check brake pads for wear or
defects -always replace both sides.
on page 4-33.
• See “Changing Brakes,” on page
6-20.
Brake pedal linkage • Check linkage for loose nuts,
adjustment. broken or stressed linkage,
misadjustment - repair and
re-adjust.
• See “Service Brake Pedal
Brake pad contamination. • If hydraulic oil, brake fluid or grease
come in contact with the pads, they
must be wiped clean and the pads
must be sanded using a fine emery
cloth.
• If the pads are saturated, they must
be replaced.
Excessive armature movement. • Make sure caliper is free to float
with disc.
on page 4-33.
• Replace motor.

5-15
Troubleshooting

4. Spongy or soft service Possible air in brake lines. • Bleed air from brake lines - indicated
brake pedal. by bubbles in fluid during fluid
bleed, or when checking the master
fluid reservoir.
6-32.
• Check brake system for loose
fittings, cross threaded fittings and
brake calipers for leaks.
• Also check master cylinder reservoir
fluid level - low level can allow air
into lines.
on page 4-33.
Faulty seals in master cylinder • Examine the brake lines, wheel
or low fluid level. calipers and master cylinder for
leaks - repair immediately, then
bleed the brakes.
• Also check master cylinder piston for
worn seals.
• Remove the master cylinder filler
cap and “slowly” press the brake
pedal. A pulse of fluid should be
seen in the cylinder reservoir. If not,
replace the cylinder.
• See “Master Cylinder,” on page
6-27.
Faulty seals in wheel caliper. • Check brake caliper for leaks -
rebuild or replace.
• See “Caliper Pistons,” on page
6-24.
5. Parking brake does not Brake cable system malfunction • Check parking brake linkage for
hold the truck. or out of adjustment. loose nuts, broken or stressed
linkage, misadjustment - repair and
re-adjust.
• See "Parking Brake Assembly,” on
page 6-34.
Service brakes not working • See “Service brakes do not stop the
properly. truck,” on page 5-15.

5-16
Troubleshooting

6. Power steering electric Loose or defective power • Check cables for excessive wear.
motor does not start. cables. • See “Intermittent electrical
• Check ”fault” lights and repair as
determined by fault instructions.
• See “SRE Controller Problems,”
Possible internal motor short, • Check motor - repair or replace.
worn brushes, etc. • See “Steer Pump and Motor,” on
page 6-52.
• See “Replacing Motor Brushes,” on
page 4-39.
Faulty interlock seat switch. • Seat switch must trip when driver is
seated - check operation and
replace if bad.
• See “Check Driver's Seat Switch,”
on page 4-17.
• See “Seat Switch,” on page 6-69.
Faulty hydraulics and/or • Check hydraulic pressure -
damaged steering pump. 2,600psi.
• A damaged pump can cause a
reduction in system performance
which slows steering response.
• Severe conditions could cause a
total loss of powered steering.
• See “Steer Pump and Motor,” on
page 6-52.
where applicable.
Faulty electrical system. • Check line contactor for proper
activation.
• Blown fuse - check FUSRE10.
• Examine power cable assemblies
for continuity and tight
connections.
• Check steer pump controller - See
“SRE Controller Problems,”

5-17
Troubleshooting

7. Steering drifts/wanders Improperly sized tires. • Check capacity nameplate for tire
or is erratic. specs (See Figure 1-1).
• See Figure 4-7.
Low fluid or leaks in power • Check hydraulic fluid level -
steering system. replenish as necessary.
• See “Check Hydraulic Oil Level,” on
page 4-18.
• Check all related components for
seal or fitting leaks - repair or
replace.
Worn or out-of-adjustment steer • Check motion control valve
assembly. cartridges for foreign material (these
are replaceable cartridges and will
wear out over time).
• See “Steering Assembly,” on page
6-46.
• Failed or weak orbitrol centering
spring will cause the steering to drift
- replace accordingly.
• Check if steer pinion gear is seated
properly on steer motor.
• Make sure the shaft woodruff key,
between steer pinion gear and steer
motor is installed correctly.
• Bad steer motor - repair or replace
accordingly.
where applicable.
Insufficient hydraulic pressure • Check hydraulic pressure of steering
at the steering pump. relief valve (2,600 psi).
page 6-52.
• Check steering motor for seal leaks,
sticking or misadjustment - repair or
replace.
page 6-52.
• Check appropriate Appendix index
where applicable.

5-18
Troubleshooting

Loose steering pump and • Check and tighten mounting
motor assembly mounting. brackets and mounting between
motor and pump.
• See “Steer Pump and Motor,” page
6-52.
Worn or loose wheel bearings. • Check wheel bearings - replace as
needed.
Races,” page 6-39.
• See “Drive Wheels,” page 6-41.
Air in the hydraulic system. • Check the inlet connections to
determine where air is being drawn
into the system.
• Tighten loose connections.
• Check the minimum drive speed
which may be too slow to prime the
pump.
• Bleed hydraulic system.
8. Hard steering effort in Improperly sized tires. • See Figure 4-7 on page 4-14.
one or both directions.
Vehicle overloaded. • NEVER exceed capacity of the
truck. Check capacity nameplate for
tire specs.
• See “Capacity,” page 3-4.
• Also see “Understanding Stability,”
page 3-2.
Low hydraulic fluid. • See “Check Hydraulic Oil Level,” on
page 4-18.
Low flow rate or fluid pressure. • Restriction in fluid return line or line
is too small. Remove line, clean
and/or replace line.
• Check pump. See “Steer Pump and
Motor,” page 6-52.
• Check hydraulic pressure -
2,600psi.

5-19
Troubleshooting

Components in steering linkage • Find source of problem and repair,
binding or making noise. such as -
Steering column - See “Steering

Column,” on page 6-47.
Orbital steering unit - See “Orbital

Steer Unit,” on page 6-49.
Front rotation neck upper and/or

lower bearings - See "Rotation
Seals, Bearings, or Spur Gear," on
page 6-72.
Inside drive wheel not dropping • Check steer pot settings. Adjust or
out replace - See 'Front Rotation Pot,'
page 6-16.
9. Lost motion at the Steering wheel loose on column • Check and re-torque the steering
steering wheel. or stripped. wheel locking nut.
• See “Steering Wheel,” on page
6-47.
Air in the hydraulic system. • Check the inlet connections to
determine where air is being drawn
into the system.
• Tighten loose connections.
• Check the minimum drive speed
which may be too slow to prime the
pump.
• Bleed hydraulic system.
10. Truck turns too slowly. See “Steering drifts/wanders or is erratic,” on page 5-18.
11. Truck does not turn. Steering pump not activated. • First check that the steering
pump/motor are activated when the
wheel is turned.
• See previous heading “Power
steering electric motor does not
start,” on page 5-17.
12. Truck moves slowly. Battery may be too low. • Check battery charge state and
recharge battery, if necessary. A
discharged battery reduces effective
voltage across the traction motors
and control circuits. Slow travel
speeds and erratic contactor
operation may result.
page 2-2.

5-20
Troubleshooting

Faulty accelerator switch • Check switch for excessive wear or
module. misadjustment which can cause
speed problems - repair or replace
as needed.
• A damaged or bent accelerator foot
pedal or misadjustment can cause
the switch to remain open.
• Remove the accelerator module
from the truck and examine for worn
or damaged linkage.
• See “Linear Accelerator Module,”
on page 6-67.
Overheated motor or motor • If overheating is suspected, turn
controller (thermal cutback). OFF the truck, and allow time for the
system to cool. While the truck is
cooling, check the following:
• Check motor compartment cooling
fans to ensure they are operating
and clean. See “Traction Drive -
Rear,” on page 6-60.
• Check the SRE controller unit for
overheating or possible problems.
beginning on page 5-28
Drive motor commutator and • Repair or replace. See “Replacing
brushes are worn or faulty. Motor Brushes,” on page 4-39.
Short field winding on traction • Repair or replace. See “Replacing
motor. Motor Brushes,” on page 4-39.
13. Truck does not move. Battery charge state may be • Check battery charge state and
too low. recharge battery if necessary.
• See “Check Batteries,” on page
4-10.
Faulty direction control lever. • Check that the direction control
forward-neutral-reverse control is
functioning properly.
• Continuity test showing that the
contacts are opening and closing as
required - repair or replace.
• Check coil resistance to see if coil is
opening - repair or replace.
• Check mechanics of the direction
control switch assembly - repair or
replace.
• See “Direction Control Switch,” on
page 6-86.

5-21
Troubleshooting

Faulty accelerator switch • See “Faulty accelerator switch
assembly. module,” on page 5-21.
Faulty commutator or worn • Repair or replace. See “Replacing
motor brushes. Motor Brushes,” on page 4-39
Open armature on traction • Repair or replace. See “Traction
motor. Drive - Rear,” on page 6-60.
14. Creep speed or Control panel system is • Re-adjust the control panel.
acceleration sluggish. misadjusted. • See Appendix, index tab A - H
'Electrical System'.
15. Mast does not lift load. Attempting to lift a load in • NEVER attempt to lift a load heavier
excess of the truck’s capacity. than the specified rating of the truck.
• Also see “Traveling and Load
Handling,” on page S-7 for
addittional information.
Faulty lift pot. • Adjust or replace - See "Hydraulic
Lift Pot," page 6-66.
Battery charge state may be too • Check battery charge state and
low. recharge battery if necessary.
4-10.
Low hydraulic oil. • Low levels can cause the cylinder to
“cavitate” and not permit full lift of the
mast. See “Check Lift Operation,”
on page 4-29.
• Check reservoir oil level. Replenish
as needed. See “Check Hydraulic
Oil Level,” on page 4-18.
Faulty hydraulic control valve. • Bent or damage plunger, worn
internal seals - repair or replace as
needed.
tab, for vendor service information,
where applicable.

5-22
Troubleshooting

Insufficient system pressure. • Check hydraulic pressure of system
relief valves. For an overview of the
system, see “Hydraulic System ,”
on page 3-29.
• Try re-adjusting the pressure relief
valves. Maximum system pressure
must not exceed 2,800 psi.
• See “To Check and/or Adjust
Pressure,” on page 6-11.
• Check valves for seal leaks, sticking
or misadjustment.
• Repair or replace and/or re-adjust
accordingly.
• If problem persists, replace the relief
valve cartridge.
tab, for vendor service information,
where applicable.
Controller output incorrect. • Check settings via the Probit.
Faulty pump. • The hydraulic pump sections may
be damaged - replace the pump.
Note: If the pump were faulty, • Check appropriate “Appendix” index
other mast functions would also be tab for vendor service information,
affected. where applicable.
Hydraulic cylinders leaking or • Determine which cylinder is leaking
binding. or binding - rebuild or replace.
cylinders - see Bendi Series IV
Parts List (F-371-___).
Blown fuse. • Check lift pump control fuse,
FUSRE9.
Mechanical damage of the • Check mast for damage and signs
mast. of misadjustment. See “Check Lift
Operation,” on page 4-29
16. Mast lifts slowly - loss of Attempting to lift a load in • NEVER attempt to lift a load heavier
lift speed. excess of the truck’s capacity. than the specified rating of the truck.
• Also see “Traveling and Load
Handling,” on page S-7 for
addittional information.
Faulty lift pot. • Adjust or replace - See "Hydraulic
Lift Pot," page 6-66.

5-23
Troubleshooting

Battery charge state may be to • Check battery charge state and
low. recharge battery if necessary.
4-10.
Insufficient pump or relief valve • See “Mast does not lift load,” on
pressure. page 5-22.
Mechanical damage of the • See “Mast does not lift load,” on
mast. page 5-22.
Hydraulic cylinders leaking or • See “Mast does not lift load,” on
binding. page 5-22.
17. Mast drifts downward. Excessive load - attempting to • See “Mast does not lift load,” on
lift loads beyond the capacity of page 5-22.
the truck.
Pressure relief valve • See “Insufficient system pressure,”
malfunction. on page 5-23.
Lift hydraulic cylinders leaking • Determine which cylinder is leaking
or binding. or binding - rebuild or replace.
• See “Mast does not lift load,” on
page 5-22.
cylinders - see Bendi Series IV Parts
List (p/n F-371-____).
Faulty lift control valve. • Oil may be bypassing between the
spool and body - repair or replace
directional control valve.
• The spool is not centering properly
or is broken - repair or replace
directional control valve.
where applicable.
18. Mast does not tilt. Inoperative tilt directional • Repair or replace.
control valve. • See 'Tilt Cylinders' page 6-77.
tabs for vendor service information,
where applicable.
Faulty switch. • Continuity test switch.
• See 'Hydraulic Control Valve and
Switches', page 6-64.

5-24
Troubleshooting

Insufficient pump or relief valve • See section “Insufficient pump or
pressure. relief valve pressure,” beginning on
page 5-24.
Hydraulic cylinders leaking or • Tilt cylinder is leaking or binding -
binding. rebuild or replace.
cylinders - see Bendi Parts List
F-371.
• See “Tilt Cylinders,” on page 6-77.
19. Carriage does not shift, Inoperative shift motor. • Repair or replace.
or side shifts too slowly. • Check appropriate “Appendix” index
where applicable.
• See “Side Shifter,” on page 6-82.
Faulty switch. • Continuity test switch.
where applicable.
Insufficient pump or relief valve • See section “Insufficient pump or
pressure. relief valve pressure ,” beginning on
page 5-24.
Inadequate lubrication or worn • See “Forks and Side Shifter,” on
bearings. page 4-26.
• Replace bearings.
where applicable.
Lower mounting hooks installed • Check appropriate “Appendix” index
incorrectly. tab for vendor service information,
where applicable.
Kinked or leaking supply • Locate kink and straighten.
hoses. • Repair or replace defective hose.
• Tighten fittings to seal any leaks.
on page 6-4.

5-25
Troubleshooting
Pump Problems
1. No hydraulic pressure. Pump driven in the wrong • Change the drive direction
direction of rotation after immediately to prevent seizure.
servicing. • Correct the pump cartridge ring
position for each direction of
rotation.
where applicable.
Coupling or shaft sheared or • Disassemble the pump and check
disengaged. the shaft and cartridge for
damage.
Oil intake line is restricted. • Check all strainers and filters for dirt
and sludge - clean or replace.
• See “Change Hydraulic Oil Filter,”
on page 4-32.
Fluid viscosity too heavy to pick • Completely drain the system.
up prime. • Add new filtered oil of the proper
viscosity.
• See Table 4-2 on page 4-3 for
recommended lubricants.
• See “Change Hydraulic Oil Filter,”
on page 4-32.
2. Leaking fluid. Cracked or cut hoses, where • Replace. NEVER attempt to patch a
applicable. hose.
on page 6-4.
Loose or faulty hose clamps, • Tighten and/or replace.
where applicable.
Loose or faulty hydraulic • Tighten and/or replace. Be careful
fittings. not to strip the threads, rendering
the fitting defective.
on page 6-4.
Oil seals deteriorated. • Disassemble the unit and replace
the oil seals.
where applicable.
3. Main pump runs Faulty hydraulic control valve. • Repair or replace.
continuously. • See “Hydraulic Valve Assemblies,”
on page 6-63.

5-26
Troubleshooting

Faulty electrical control circuit. • Check switches and pots.
• See 'Hydraulic Control Valve and
Switches', page 6-64.
4. Pump making noise. Pump intake partially blocked. • Service the hydraulic tank intake
strainer.
• Check the fluid condition and, if
necessary drain and flush the
hydraulic system. Refill with clean
oil.
• See “Change Hydraulic Oil,” on
page 4-43.
Air leaks at the intake or shaft • Check intake lines (hoses and
seal. (Oil in reservoir would fittings) and seals for leaks. Repair
possibly be foamy.) all leaks.
Damaged pump/motor • Repair and/or replace.
mounting.
5. Significant loss of Lack of sufficient oil supply. • Check for faulty relief valve and
speed under load. adjust or replace as required.
• Check for and repair worn pump.
• Check for correct oil - See Table 4-2
on page 4-3.
Excessive heat source. • Locate excessive heat source
(usually a restriction) in the system
and correct the condition.
High internal motor leakage. • Disassemble unit and replace worn
rotor set.
where applicable.
Severely worn or damaged • Disassemble unit and replace worn
internal splines. rotor set, drive link and coupling
shaft.
where applicable.

5-27
Troubleshooting
SRE Controller Problems

For standard Bendi Series IV lift trucks, the SRE Controls / ProBit Manual for Version 1.2
the Faults and Settings for SRE ProBit PB-200 and the Menu Layout instructions are
provided in this chapter (separate documents), beginning after page ___.
Overview
If misoperation on the truck occurs, a service status code is displayed on the dash
display.
With the status code number, follow the procedures outlined in the status codes
instruction manual to determine the problem and corrective action (See Table 3-1 starting
on page 3-35 for detailed description or Table 5-2 for quick reference).
Also see “SRE Troubleshooting,” on page 5-29.
Code # Description Code # Description

4 Replace Drive Controller. 25 Check forward contactor.
5 Battery current for drive exceeded. 27 Battery voltage too high on drive.
10 Both direction switches on at 30 Check for a sticky forward

same time. contactor.
12 Contactor exceeds 2 amps. 31 Check for a sticky reverse

contactor.
14 Contactor exceeds 2 amps. 33 Direction contactor failed to drop

out.
20 Check for welded direction 70 Open circuit - check wiring to lift

contactor. motor.
21 Check field bar F shorted to B-. 74 Replace lift controller.
23 No circuit path from A through 77 Battery voltage too high for lift.
armature, field and forward
contactor.
24 Check reverse contactor. 85 Battery current limit for lift
exceeded.
Table 5-2 Dash Display Fault Codes

5-28
Troubleshooting
SRE Troubleshooting
The following SRE/Probit Manual information is located in the Appendix, index tab A - H
"Electrical System":
· Probit Manual Version 1.2
· SRE ProBit PB-200, Faults and Settings Explained
· Menu Layout for Probit
· PSM Module Troubleshooting Manual

5-29
Introduction
Chapter six (corrective maintenance) is divided into four
sections:
Major adjustments and/or settings - showing the adjustments
and/or settings needed to maintain a reliable truck.
Mechanical repairs - how to replace and/or repair most major
parts and/or assemblies.
Electrical control system repairs - how to replace and/or repair
electrical contactors, fuses and the SRE controllers.
Options - how to adjust, replace and/or repair the most
commonly ordered option features.
It is important to always locate the section which pertains to your
needs, then read the entire procedure before attempting to
adjust, repair and/or replace parts.
It is recommended to always use genuine Landoll replacement
parts to maintain the overall high quality performance and
guarantee maximum truck stability and to minimize downtime.
Tools Needed
The tools required to service the Bendi Series IV lift truck are
those found in a well-equipped service center, both English and
Metric sizes. For example, an assortment of open-end and box
wrenches, socket and Allen wrenches with drivers, adjustable
wrenches, flat blade and Phillips head screw drivers, and
non-marring type mallets should be available.
Additionally, you should carry a flashlight and drop light, drum
brake adjusting wrench, feeler gauges, a calibrated torque
wrench and a standard ohm meter, analog or digital.

6-1
Before You Begin

When it becomes necessary to do an electrical or mechanical service repair or
maintenance procedure, it is important to review and practice the following safety
suggestions.
Warning
You could be injured and the truck could be damaged if you try to do
service work without qualified experience.
If you use the wrong grade replacement parts, in time, they can break
or loosen. Serious injury could occur. It is recommended to use
Landoll replacement parts before you attempt any truck
maintenance.
· Be sure to use the proper nuts, bolts and other fasteners. Many are specifically
rated; that is, SAE Grade 5, SAE Grade 8, ISO Prop Class 8.8, etc., and must be
replaced with the identical type.
· Whenever possible, return the truck to a service area having sufficient lighting,
work space and an assortment of tools needed to complete the repair.
· Set the key switch to OFF and place the key in your pocket.
· Set the direction control lever to NEUTRAL and set the parking brake.
CAUTION
To be certain the truck will not move, place wedges (or blocks of
wood) at the front and back of the tires. If you are servicing the
brakes or tires, place the block at the front and rear of the tire farthest
away from the one being serviced, that is, the tire on the opposite
side of the truck and at the opposite end.
· Disconnect the battery.
· Never place a tool or any metal object on top of the battery where it
electrical shock.

6-2
Lifting the Truck

1. Always place an appropriate support stand or blocks of wood (8” square; 204 mm
square minimum) under the truck if it is being lifted, then lower the truck to the
support, having the lifting device and support both support the weight of the
DANGER
GEROUS AND COULD CAUSE SERIOUS INJURY. NEVER GO UNDER
A LIFT TRUCK THAT IT IS SUPPORTED ONLY BY A JACK.
Crane
Block of wood Support blocks

to prevent roll of wood
Figure 6-1 Jack and Support the Truck
1. Make sure all lifting devices and supports, such as a jack or support stand, blocks of
wood, are capable of handling the weight of the load.
2. Remove the required truck cover doors for easy access.

6-3
Electrical Static Discharge

Normal precautions concerning the handling of metaloxide semi-conductors (MOS)
components are applicable in order to minimize the risk of damage to these devices by
ELECTRICAL STATIC DISCHARGE. This entails avoiding contact with the pins of these
devices and ensuring that when they are removed from a printed circuit board (PCB), the
pins are strapped together with conductive tape. Immediately place the PCB in static-free
bubble wrap or bag.
Any external clothing, overalls, etc. manufactured of nylon or a similar material must not
be worn as they are capable of reaching extremely high voltage potentials caused by
friction during normal wear.
Use a grounding wrist band to protect microprocessors from static electricity and always
touch a metal surface (other than the truck) before touching a PCB. These precautions
are especially necessary in respect of microprocessor devices, found on the hydraulic
control PCB, of this truck.
Hydraulic Fittings and Hoses

2. Disconnect the battery and block the wheels.
Warning
Before disconnecting any hydraulic fittings or hose assemblies, re-
lieve the system pressure, down to zero (0) psi. This is accomplished
by turning the steering wheel a few times in both directions, and
moving the control levers in both directions after the key switch is
turned OFF.
HIGH PRESSURE HYDRAULIC OIL LEAKS CAN PIERCE THE BODY

AND CAUSE SEVERE INJURY TO PERSONNEL. ALWAYS REDUCE
PRESSURE BEFORE OPENING ANY HYDRAULIC PRESSURE LINE.
Oil is slippery and can cause falls. To avoid injury, wipe up spilled oil
with shop rags, or apply an oil-dry and clean up after it has soaked
up the spill.

6-4
3. Remove the hose coupling from the

defective fitting. Use two wrenches;
one wrench to loosen the hose
coupling, and one to prevent the fitting
from turning.
Have rags handy to soak up any oil

spillage (See Figure 6-2).
4. Always tag the hoses and fittings for
identification. If necessary, keep notes
and put markings on parts using a
non-destructive marker, such as a
felt-tipped pen.
5. Remove the defective fitting and
replace with a new fitting. Use two
wrenches; one wrench to tighten the Figure 6-2 Removing Hoses/ Fittings
hose coupling, and one to prevent the
fitting from turning (See Figure 6-2).
Note: SAE fittings do not need a thread sealant. They are straight thread and in-
clude an O-ring seal.
Cleaning and Inspection

· Always clean all metal parts with a de-greasing-type cleaner solvent and wipe dry
with a clean shop rag.
· Allow parts to air dry.
· Do not allow cleaning solvent to come in contact with rubber parts or rubber
insulation, such as electrical wiring, seals, etc.
IMPORTANT !
Cleaning solvents can be TOXIC and FLAMMABLE. Pay particular attention to all
WARNING labels provided by the solvent manufacturer, such as, protection dur-
ing use, personal health precautions and ventilation to avoid breathing vapors.
· For non-metal parts, clean using a mild soap solution, shop vacuum for dust and
loose dirt and a dust pan and brush.
· Inspect all parts thoroughly for breaks, cracks, tears, burrs, scoring, warping or
sharp edges, glazing, rust pitting, flat spots, etc. Notify your immediate supervisor
of all defects and record it in the truck log book.
· Inspect all screws and hardware for stress marks, breaks, cracks, thread defects,
etc.
· Replace all damaged or questionable parts.
· Take care to properly identify and tag each part and its order of removal. If
necessary, keep notes and put markings on parts using a non-destructive marker,
such as a felt-tipped pen.

6-5
Brake System
Disc Brakes
The rear disc brakes are inherently self-adjusting. NO adjustments are necessary or
provided.
Brake Pedal
The service brake pedal has about 0.0625” to 0.125” (1.588 mm - 3.175 mm) maximum
free-play before any pressure is applied to the brakes, (or before the pedal moves the
master cylinder plunger). It is important to have free-play to prevent applying constant
pressure to the master cylinder.
The pedal also has a maximum range of travel of up to only 0.500” (12.7 mm) before it
contacts the positive stop hex screw, and includes a brake warning micro switch that
deactivates the drive motors (and energizes the brake STOP lights, where applicable).
The brake warning micro switch is factory set to trip just as the brake pedal begins its
downward stroke.
Service Brake Linkage

1. First, review “Before You Begin,” page 6-2.
2. Set the key switch to OFF, place the key in your pocket, and disconnect the
battery.
3. Before doing any adjustment, check for:
· low fluid level in the master cylinder reservoir (See ‘Check Master Cylinder Fluid
Level,’ page 4-19).
· air or leaks in the system
· worn brake pads (See ‘Check Service Disc Brakes,’ page 4-33).
Any of these conditions can affect pedal free-play. Proceed to the appropriate
heading for repairs.
4. Remove the driver’s cab floor access panel to expose the brake pedal linkage and
master cylinder (See ‘Floor Access Panel - Removal,’ page 4-9).

6-6
Master cylinder Master cylinder

cover
Cylinder push rod
Push rod
lock nut
Yoke
Normally
closed 1.0
Crank
plate
Common
mstrcyl1 Brake switch
Figure 6-3 Master Cylinder and Brake Switch Assembly
5. Loosen 5/16” (7.94 mm) lock nut on the master cylinder push rod (See Figure 6-3).
6. Turn the rod clockwise to increase free play on the pedal; turn counterclockwise to
decrease free-play.
Tighten the adjustment lock nut against the brake pedal yoke.
The brake pedal must have about 0.0625” to 0.125” (1.588 mm - 3.175 mm)
maximum free-play before any pressure is applied to the brakes (or before the pedal
moves the master cylinder plunger).
7. Check the downward travel of the pedal to ensure there is no more than a 0.500”
(12.7 mm) stroke before the pedal contacts the positive stop screw (See Figure 6-3).
8. Install the driver’s cab floor access panel.
9. Connect the battery and check for proper brake operation as follows:
· Raise and block the truck off the ground.
· Accelerate the forklift to full speed.
· Apply the brakes to quickly STOP the wheels.
· Release the brake pedal after the wheels stop, then accelerate again to full speed.
· Release the accelerator pedal to allow the truck to coast to a stop.
· Both wheels should stop very closely together (around the same time).
· Repeat this procedure two times in forward and in reverse directions.
10. If the forklift does not perform as stated above, re-inspect the brake calipers for wear.
(See 'Check Service Disc Brakes,’ on page 4-33).

6-7
Brake Cut-off and Light Switch

battery.
3. Slightly loosen both brake switch hex head screws (See Figure 6-3).
4. Connect the ohm meter leads to the COMMON and colored wires - one set is
normally closed, the other normally open.
The meter must show a reading of less than 1 ohm for the cut-off, the light should be
open.
5. Slowly push down on the brake pedal. Before the pedal reaches its first locking
position the meter must read OPEN, indicating the switch is released.
6. Slide the brake switch forward or backward to locate the switch at this position - to
just trip as the pedal begins its downward stroke (See Figure 6-3).
7. Carefully tighten and torque the screws (8 to 10 ft. lbs.; 11-14 Nm) to secure the
switch without moving the setting, then release the brake pedal to verify the setting.
8. Disconnect the ohm meter.
9. Apply the brakes while checking that the drive motors deactivate and that the lights
turn ON before pressure is applied to the master cylinder.
10. Connect the battery and perform a road test. Road test the truck by getting up to
speed and apply the brakes ten (10) times in forward and reverse.
Do not lock the brakes when stopping to avoid “flat-spotting.”
Parking Brake Handle

The amount of vertical travel of the parking brake handle should allow the handle to move
from the horizontal position up to the vertical position, having the brake fully applied in the
vertical position.
CAUTION
Adjusting the parking brake handle too tight will overheat the tires,
causing them to separate from the rims; overheat brake shoes caus-
ing premature wear; or overheat the drive motors, causing prema-
ture failure.

6-8
Adjust the Parking Brake

Handle
1. First, review “Before You Begin,” Applied
page 6-2.
o
90 travel
2. Set the key switch to OFF, then
place the key in your pocket and Adjustment
disconnect the battery. setscrew
3. Block all wheels.

Released
4. Raise the left side of the truck until the
rear drive tire clears the floor by no
more than 1” (25.4 mm) - see “Before
You Begin,” page 6-2.
5. Pull up on the parking brake handle as
far as possible using moderate
force (See Figure 6-4).
The amount of vertical travel should Figure 6-4 Parking Brake Vertical Travel
allow the handle to snap into the full
vertical position. The left rear wheel
should not turn when attempting to
turn by hand.
Warning
BEFORE REACHING IN TO TURN THE WHEEL, MAKE SURE THE
TRUCK HAS SAT IDLE LONG ENOUGH TO COOL. VARIOUS PARTS
CAN GET EXTREMELY HOT DURING OPERATION. ALSO MAKE
SURE YOU ARE WEARING WORK GLOVES.
6. Release the parking brake by pushing downward as far as the lever will travel.
7. To adjust, tighten or loosen the Allen head adjustment setscrew accordingly.
Turning clockwise tightens the setting; counterclockwise loosens the setting.
Note: Do not overtighten. You will separate the cable from the clevis ends.
8. Apply and release the parking brake five or six times to stretch (seat) the cable, then
double check your adjustment.
9. If this fails to properly adjust the brake, see “Adjust Parking Brake Caliper,” page
6-10.

6-9
Adjust Parking Brake Caliper

New brake pads are approximately 0.265” (6.7 mm) thick; replace them when the pad
thickness is 0.0625” (1.588 mm) or less at the thinnest point (See Figure 6-5).
CAUTION
Adjusting the parking brake too tight will overheat the brake pads
and caliper, causing premature wear; or overheat the drive motors,
causing premature failure.
The lining should be at least 0.03125” (0.794 mm) above the pad mounting screw head.
1. First, review “Before You Begin,” page
6-2. Brake caliper
2. Set the key switch to OFF, place the key
in your pocket, and disconnect the
battery.
Hex adjustment
3. Remove the battery and the battery tray to
screw
expose the parking brake linkage and
caliber (See ‘Replacing the Battery,’ page
2-12).
4. Block the wheels and release the parking
brake.
5. Loosen the adjustment nut and turn the
hex screw until the disk pad (puck) is prkbrake
against the rotor (See Figure 6-5).
6. Back off the nut approximately ¼ turn for Figure 6-5 Parking Brake Caliper
an approximate 0.020” (0.508 mm)
clearance.
7. Check this clearance by inserting a feeler gauge between the brake puck and rotor.
Re-adjust accordingly.
8. Tighten the adjustment locknut and recheck the setting using the feeler gauge.
9. Apply the hand brake a few times to ensure proper setting and operation.
Mast Lift Chains

Inspect Lift Chains
(See ‘Inspection Check List,’ page 4-36)
Chain and Roller Adjustment

(See ‘General,’ page 4-34)

6-10
Main Pump Relief Valve

General Lift, tilt, and shift
levers
The main hydraulic pump for lift,
tilt and shift (mast functions) is a
single cavity pump (5 gpm).
System pressure varies from Control valve
2,650 psi, ±65 psi (18 MPa, ±0.45 cover
MPa) minimum, up to 3,000 psi,
±65 psi (21 MPa, ±0.45 MPa) Service (parking)
maximum. Actual pressure is brake lever
determined by mast size, load
requirements and lift speed. Hydraulic control
valve
Check with your Landoll service
representative for actual setting.
The main pump pressure relief
valve is located in the hydraulic
control valve, which is located
beneath the control valve cover, in
front of the driver’s arm rest (See
Figure 6-7).
hydvlvlo
A pressure gauge port is provided,
with a “quick-coupler,” (pressure
service kit, Landoll p/n: 0018152) Figure 6-6 Control Valve Location
for reading the main pump
pressure (See Figure 6-8).
Note: Before you service this valve for possible pressure problems, make sure
there are no leaks in the hydraulic system and that there is sufficient oil in the
tank. Both conditions can contribute to low pressure problems.
(Also see ‘Mast Systems,’ page 3-30 for additional circuit information.)
To Check and/or Adjust Pressure

battery.
3. For ease in checking pressure Landoll Service offers a Pressure Check Kit (p/n:
0018152) which includes a 3,000 psi (21 MPa) pressure gauge, hose and
quick-coupler).
4. If you are using your own system, have shop rags and a small container handy to
collect any oil spills.
5. Remove the control valve cover, located to the right of the driver’s seat (See Figure
6-6).

6-11
Figure 6-7 Connecting Pressure Gauge
6. Operate the function joysticks briefly to relieve system pressure - allows oil to drain.
7. Connect the pressure check kit quick-coupler (female end) to the coupler (male end)
on the control valve (See Figure 6-7).
· If you are not using the pressure check kit, remove the quick-coupler and install an
appropriate fitting to accept your pressure gauge arrangement.
· Have rags handy to collect the oil leakage.
· Install your 3,000 psi (21 MPa) pressure gauge arrangement to the T fitting (See
Figure 6-7).
CAUTION
All parts connected to the gauge port must be capable of handling up
to 3,000 psi (21 Mpa).
To adjust pressure, the truck (pump) must be running to create

hydraulic pressure. Always pay attention to what you are doing when
servicing the truck while it is running.
8. Connect the battery and set the key switch to ON.

6-12
9. To check and/or set pressure, you

must hold the LIFT/LOWER
joystick in the lower position to
build pressure, then set the relief
valve.
10. Loosen the relief valve jam Loosen
nut (See Figure 6-8). Lock Nut Clockwise
11. Adjust the valve stem by turning to Increase
clockwise to increase pressure,
counterclockwise to decrease
pressure (See Figure 6-8).
Counter Clockwise
12. Release the joystick immediately to Decrease
once the pressure is set (2,600
psi, + 65 psi, - 0 psi; 18 MPa, +
0.45, - 0 MPa minimum, up to Figure 6-8 Relief Valve Setting
3,000 psi; 21 MPa, + 0.45, - 0
MPa).
IMPORTANT !
Do not hold the joystick (bottomed out) for long periods of time. Excessive pres-
sure is applied to the circuit which can, over long periods of time, damage inter-
nal components.
13. If the pressure is low and cannot be adjusted to the proper value, check the pump
and make sure there are no leaks in the hydraulic system.
If the pressure is too high and cannot be adjusted to the proper value, replace the
relief valve.
14. Tighten the valve lock nut.
battery.
16. Operate the function joysticks briefly to relieve system pressure - allows oil to drain.
17. Remove the pressure gauge quick-coupler...or...remove your gauge arrangement
and install the quick-coupler.

6-13
19. Lift and lower the mast from a few feet a few times to check the hydraulic system for
leaks.
20. Set the key switch to OFF and disconnect the battery.
21. Reassemble all items previously removed.
Steer Pump Relief Valve

General
The steering hydraulic pump is a single cavity vane pump. Pressure is controlled by a
pressure relief valve, located in the hydraulic manifold beneath the driver’s cab floor
access panel.
Power steering pressure is set at 2,600 psi ±65 psi (18 MPa, ±0.3 MPa) (See Figure 6-9).
A pressure gauge port is provided, with a “quick-coupler,” (pressure service kit, Landoll
p/n: 0018152) for reading the steer pump pressure.
Note: Before you service this valve for possible pressure problems, make sure
there are no leaks in the hydraulic system and that there is sufficient oil in the
tank. Both conditions can contribute to low pressure problems.
(Also see ‘Power Steering System,’ page 3-29 for additional circuit information.)
Figure 6-9 Steering Hydraulic Valve Assembly

6-14
To Check and/or Adjust Pressure

battery.
3. Remove the driver’s cab floor panel (See ‘Floor Access Panel - Removal,’ page 4-9).
4. For ease in checking pressure Landoll Service offers a Pressure Check Kit (p/n:
0018152) which includes a 3,000 psi (21 MPa) pressure gauge, hose and
quick-coupler).
If you are using your own system, have shop rags and a small container handy to
collect any oil spills.
5. Turn the steering wheel briefly from one side to the other to relieve system pressure -
allow oil to drain.
6. Connect the pressure check kit quick-coupler (female end) to the coupler (male end)
on the control valve (See Figure 6-9).
· If you are not using the pressure check kit, remove the quick-coupler and install an
appropriate fitting to accept your pressure gauge arrangement.
· Have rags handy to collect the oil leakage.
· Install your 3,000 psi (21 MPa) pressure gauge arrangement to the T fitting.
CAUTION
To adjust pressure, the truck (pump) must be running to create hy-
draulic pressure. Always pay attention to what you are doing when
servicing the truck while it is running.
8. Turn the steering wheel fully to the right and hold the wheel to allow pressure buildup.
The pressure reading must be 2,600 psi, 65 psi (18 MPa, ±0.3 MPa) maximum.
9. Release the steering wheel.
IMPORTANT !
Do not hold the steering wheel (bottomed out) for long periods of time. Excessive
pressure is applied to the circuit which can, over long periods of time, damage in-
ternal components.

6-15
10. Adjust the internal relief valve head (5/32” Allen wrench) by turning clockwise to
increase pressure or counterclockwise to decrease pressure.
If the pressure is low and cannot be adjusted to the proper value, check the pump
and make sure there are no leaks in the hydraulic system.
If the pressure is too high and cannot be adjusted to the proper value, replace the
relief valve.
11. With pressure set at 2,600 psi, 65 psi (18 MPa, ±0.3 MPa) maximum, set the key
switch to OFF and disconnect the battery.
12. Turn the steering wheel briefly from one side to the other to relieve system pressure -
allow oil to drain.
14. Turn the steering wheel from one side to check the hydraulic connections for leaks.
15. Install the driver’s cab floor access panel (See ‘Replacing the Battery,’ on page
2-12).
Front Rotation Pot

General
The front rotation sensor potentiometer is replaced as a complete unit, is electrically
checked using the Landoll Setup Procedures of the SRE Controllers, and requires only a
distance setting between the actuating cam and the actuator arm roller of ¼”
(6.4mm) (See Figure 6-10).
1/4” (6.4mm) Actuating arm roller
Adjustment bolts (2)
Rotation sensor
(Pot)
rotapot Actuating cam
Figure 6-10 Rotation Sensor Potentiometer Adjustment

6-16
To Adjust and/or Replace

1. Position the forks (mast) straight ahead.
5. Remove the plastic front rotation cover to expose the internal gearing and pot
assembly.
6. Loosen the two 3/8” hex shoulder bolts and “evenly” position the pot assembly until a
¼” (6.4mm) gap exist between the actuating arm roller and the actuating cam (See
Figure 6-10).
If the pot is being replaced, disconnect the electrical connector and remove the
shoulder bolts and hardware. Install the new pot assembly in reverse order.
7. Tighten and torque the screws accordingly (See Table 4-3 on page 4-4).
8. Refer to the Landoll Setup Procedure, located in the Appendix, index tab A - H
'Electrical System'.
SRE Control Adjust

General
SRE controllers are factory set, via the ProBit handset and should not need adjustment
under normal operation. Up to four (4) setup procedures are provided, determined by
your drive configuration. You setup version is identified by a label affixed inside the
control panel and will be one of the following:
· Recalibrate with program Bendi 1
IMPORTANT !
When setup is required, contact your Landoll service representative for assis-
tance. Failure to follow proper set up instructions could result in misoperation or
damage to the control system.
To replace an SRE control unit, see the Appendix, index tab A - H 'Electrical System'.
Adjustable features (or functions) are displayed and programmed into the two motor
controllers and the steering controller using the ProBit handset. See the Appendix, index
tab A - H 'Electrical System' for a complete functional description of the ProBit and its
use.

6-17
Manuals included:
· DSPL-01 Dash display guide
· SRE ProBit PB-200 Faults and Settings Explained
· ProBit Manual Version 1.2
· Menu Layout, for ProBit
· PSM Module Troubleshooting Manual
IMPORTANT !
Before making any adjustments to the controller read the inclosed in its entirety.
If you are not sure of the procedures outlined in the manuals, contact your Lan-
doll service representative for assistance. Failure to set proper values could
cause misoperation of the truck or damage to the drive motor or control system.
Set up
WARNING
Voltages and currents capable of causing heavy arcing may exist in
the controllers, and operation of the controllers could cause
unexpected movement of the truck.
Before connecting or disconnecting the ProBit handset, turn OFF the

key switch, make sure the directional control lever is in NEUTRAL,
disconnect the battery, and jack up the drive wheels of the truck
(raise wheel approximately 1” from ground).
1. First, review “Before You Begin,”
page 6-2.
2. Remove the rear (Landoll)
compartment access panel to
access the SRE controllers and
electrical panel.
3. At the SRE control unit, connect
the ProBit handset to the
connector (See Figure 6-11).
4. Connect the battery. Make sure
the directional control lever is in
NEUTRAL and release the
parking brake.
Note: The truck can be operated Figure 6-11 Plug Connection
with the handset connected.
5. Follow the step-by-step instructions for the ProBit handset/SRE programming, found
in the Appendix, index tab A - H 'Electrical System'.

6-18
Brake System - Repair

WARNING
Safety must always be paramount when working on brake system
components.
Do not use parts that do not appear to be in perfect working

condition. It is recommended to use only Landoll genuine
replacement parts.
Whenever servicing a brake component, it is recommended to

service both sides of the truck to prevent premature wear and
uneven braking action.
If you are unsure about a procedure, seek professional help. Contact

your Landoll service representative.
Wear eye protection. If brake fluid comes in contact with your eyes,
immediately rinse them with water and seek medical attention.
Use only DOT #3 brake fluid.
Brake fluid will damage paint. Cover all body parts and be careful not
to spill fluid during this procedure.

6-19
Changing Brakes
WARNING
Brake pads must be replaced on both wheels at the same time.
NEVER replace the pads on only one wheel.
Do not, under any circumstances, use petroleum-based solvents to

clean brake parts. Use only brake cleaner or denatured alcohol.
Do not use compressed air to blow dust particles from the brake
assembly.
Make sure you strictly adhere to all clearances and torque

specifications.
When you are finished working on the brakes, test them carefully
under controlled conditions before releasing the truck for operation.
If the contact surfaces of the rotor show cracks, score marks, deep
grooves, a raised lip on the outer edge, or signs of overheating or
warping, the rotor must be replaced.
If a problem is suspected, do not release or drive the truck until the

problem is corrected.
To Change Brake Pads

3. Apply the hand brake and disconnect the battery.
4. Make sure all the other wheels are securely blocked so that the truck cannot move.
5. Remove the battery and battery tray (See “Replacing the Battery,” page 2-12).

6-20
Floating brake
calipers
Tire
Brake caliper
mount
Drive motor
Rotor
Mounting
diskbrke bolts (2)
Figure 6-12 Disc Brake Assembly Overview
6. Remove the two mounting bolts securing the brake caliper assembly to its mounting
plate (See Figure 6-12).
7. If preferred, although not necessary, disconnect the brake lines, using a flare-nut
wrench. Plug or cap the ends to avoid fluid loss and contamination (See ‘Rigid Brake
Line,’ on page 6-30).
Have a container and shop rags handy to soak up any spilled brake fluid. DO NOT
spill brake fluid over the caliper housing.
Note: Flare-nut wrenches should be used as they wrap around the nut to prevent
rounding off the flats.
IMPORTANT !
Brake fluid will damage paint. Cover all body parts and be careful not to spill fluid
during this procedure.

6-21
Caliper half mounting

screws and hardware (4)
Grease (each side)
Brake caliper
outer plate
Guide pins, one

Caliper half each side
mounting
hardware (4)
Bleed fittings
Brake caliper
caliper mounting bolts
Figure 6-13 Disk Brake Assembly
8. Remove the caliper outer plate (four hex head screws and hardware), then separate
both halves (See Figure 6-13).
9. Remove both old disk brake pads.
10. Push the piston into the caliper bore to provide clearance between the new brake
pads and the rotor during assembly.
11. Check the contact surfaces of the rotor for cracks, score marks, deep grooves, a
raised lip on the outer edge, signs of overheating or rotor run-out. If any of these are
present, the rotor must be replaced (See ‘Disc Brake Rotors,’ on page 6-25).
Also look for surface glazing, grease or brake fluid on the brake pad contact
surfaces. Grease and brake fluid can be removed using denatured alcohol or brake
cleaner. However, the shoes must be replaced if they are contaminated.
Surface glazing, which is a glossy, highly polished finish, can be removed with
medium grit emery cloth (100-120 grit).
12. Check the brake lines for cracking or splits, any apparent weakness - replace as
needed (See ‘Rigid Brake Line,’ on page 6-30).
13. Check both brake caliper pistons for signs of fluid leakage, indicating a defective seal
which must be repaired.
14. Install the new brake pads and reassembly the caliper (four hex head screws and
hardware). Torque the screws (See Table 4-3 on page 4-4).

6-22
15. Lubricate the guide pin contact areas with a high temperature silicone grease (See
Figure 6-13).
16. Install the brake caliper to its mounting bracket (See Figure 6-12).
17. Top off the master cylinder with brake fluid (See ‘Check Master Cylinder Fluid Level,’
page 4-19). Pump the brakes several times to seat the new brake pads.
18. Reassemble and check the truck. Connect the battery and check for proper brake
operation as follows:
· Raise and block the truck off the ground.
· Accelerate the forklift to full speed.
· Apply the brakes to quickly STOP the wheels.
· Release the brake pedal after the wheels stop, then accelerate again to full speed.
· Release the accelerator pedal to allow the truck to coast to a stop.
· Both wheels should stop very closely together (around the same time).
· Repeat this procedure two times in forward and in reverse directions.
19. If the forklift does not perform as stated above, re-inspect the brake calipers for wear
(See ‘Check Service Disc Brakes,’ page 4-33).
20. Make a few normal stops in forward and reverse to allow the brakes to further seat
themselves. DO NOT lock the brakes which could cause flat spots.
Replace the Brake Caliper Assembly

IMPORTANT !
Whenever servicing or replacing a caliper assembly, it is recommended to service
both sides of the truck to prevent premature wear and uneven braking action.
1. Repeat Steps 1 through 12 of preceding section “Changing Brakes”, beginning on

page 6-20.
2. Install the new caliper assembly in reverse order making sure the brake pads are
properly installed and the brake guide pins are lightly greased using a silicone
high-temperature grease (See Figure 6-12).
3. Repeat Steps 19 through 22 of preceding section “To Change Brake Pads”,
4. Bleed the brakes (See ‘Bleeding Brakes,’ on page 6-32).
It is recommended when replacing a brake caliper assembly to purge the entire brake
system of old, possibly contaminated fluid.
5. Repeat Steps 18 through 20 of preceding section “To Change Brake Pads”,

6-23
Caliper Pistons
The brake caliper piston, if it freezes-up or shows signs of leakage, must be repaired or
replaced before returning the truck to operation.
WARNING
Whenever servicing and/or replacing a caliper assembly or internal
parts, you must service both sides of the truck to prevent premature
wear and uneven braking action.
1. Repeat Steps 1 through 9, including IMPORTANT ! of preceding section “Changing
Brakes” , beginning on page 6-20.
2. Remove the brake caliper assembly from the truck and place on your workbench.
3. Stuff shop rags and a block of wood into the caliper to catch the piston, then lightly
apply compressed air to the inlet port.
IMPORTANT !
DO NOT apply too much air pressure to the bore, or the piston may jump out,
causing damage to the piston and/or yourself. Be absolutely sure to keep your
fingers away from the piston while air is being applied.
4. Once the piston pops free, remove the O-ring seals and discard. Be careful not to
scratch metal surfaces. Do not use metal tools when removing the seal.
5. Remove both bleeder screws.
6. Inspect the piston and the caliper housing bore for corrosion, worn plating, scoring,
nicks, etc. Crocus cloth can be used to polish out light corrosion only. Beyond that,
you must replace the entire brake caliper assembly.
7. Thoroughly wipe out the bore area and clean all parts, then lubricate the pistons,
caliper and O-ring seal with fresh, clean Dot #3 brake fluid (See Table 4-2 on page
4-3 for recommended lubricants).
8. Install the O-ring seal to the pistons and slide the pistons into the housing bore. Make
sure the O-ring seals do not twist as the piston is inserted.
9. Bottom the piston into the bore, then install new brake pads.
10. Repeat Steps 14 through 19 of preceding section “Changing Brakes” , beginning on
page 6-20.

6-24
Disc Brake Rotors

WARNING
Whenever servicing and/or replacing a rotor assembly, you must
service both sides of the truck to prevent premature wear and un-
even braking action.
Repeat steps 1 through 5 of preceding section “To Change Brake Pads”, beginning on
page 6-20.
Check the rotors for scoring, cracks, deep grooves, a raised lip on the outer edge, signs
of overheating, rotor run-out or other damage. Rotor run-out should be measured while
the rotor is installed.
Rotor thickness measurements may be checked with the rotor installed or removed from
the truck. Use a dial gauge to check run-out. Use a calibrated micrometer, calibrated in
ten-thousandths of an inch, to check thickness.
Measure Thickness
Measure thickness, using a micrometer, at four or more points on the rotor and make
sure all measurements are taken at the same distance in from the outer edge of the rotor.
Thickness variations of more then 0.0005” (0.013 mm) can cause pedal pulsation and/or
vibration when applying the brakes. A rotor that does not meet these specifications, must
be replaced.
Check Lateral Run-Out (Warping)

1. Raise, jack up, and block the side of the truck being
checked to allow the drive wheel to rotate freely (See
‘Lifting the Truck,’ on page 6-3).
2. Secure the dial indicator to the drive wheel electric motor
casing so the indicator button contacts the rotor at about
0.50” (13 mm) from the outer edge of the rotor. Set the dial
indicator to zero.
3. Turn the rotor (wheel/tire) by hand one or two complete
revolutions and observe the total indicated run-out.
4. If the run-out exceeds 0.0031” (0.08mm), replace the rotor.
Do not resurface the rotor - see “Replace Brake Rotor
Assemblies,” beginning on page 6-26.

6-25
Replace Brake Rotor Assemblies

1. To remove the caliper assembly, repeat Steps 1 through 4 of preceding section
“Replace the Brake Caliper Assembly” , beginning on page 6-23.
IMPORTANT !
To remove the rotor, you will need a pry bar and a rubber mallet (dead-blo ham-
mer). DO NOT USE an unprotected hammer. You will damage the rotor rendering
it unserviceable.
2. Loosen the flanged hex nut (¾-16, Grade

Caliper assembly
8) and hardware from the gear box
Must be removed
shaft (See Figure 6-14).
DO NOT remove the nut from the

assembly at this time. Flanged nut
3. Drive pry bar between non-machined

surface of the rotor and the drive motor,
where the brake caliper is mounted (See
Figure 6-14). Unmachined
surface
4. Using the rubber mallet (dead-blo
hammer), hit the rotor on the opposite rotor
side, driving it towards to loosened nut.
5. Repeatedly hit the rotor evenly in a circular
motion until it pops free, then remove the Figure 6-14 Rotor Assembly
nut.
6. Slide the rotor assembly from the keyed
drive shaft and discard. Do not lose the woodruff key.
IMPORTANT !
When handling the new rotor, protect the finish surfaces from damage, such as
nicks, deep scratches, dents from dropping, corrosion, etc. Damage to the brak-
ing surfaces renders the rotor defective.
7. Install the new rotor to the keyed drive shaft. Install, tighten and torque the flanged
hex nut (See Table 4-5).
Make sure there is no grease on the shaft/nut area before installing and torquing the
nut.
8. Repeat Steps 16 through 19 of preceding section “Changing Brakes” , beginning on
page 6-20.

6-26
Master Cylinder
To Remove the Old Cylinder
3. Apply the hand brake, disconnect the battery and block the wheels.
4. Remove the driver’s cab floor panel (See ‘Floor Access Panel - Removal,’ page 4-9).
5. Remove the master cylinder fill cap and rubber diaphragm (two round head screws).
Siphon out as much fluid as possible. Install and tighten the fill cap and diaphragm
before removing the cylinder (See Figure 6-15).
Figure 6-15 Master Cylinder Assembly
6. Place rags under the brake line fitting. Have a plastic cap or bag handy to cover the
end of the line to limit fluid spillage.
IMPORTANT !
during this procedure.

6-27
Master cylinder
Master cylinder cover
Cylinder push rod Mounting bolts (2)

and hardware Elbow fitting
Push rod
lock nut
Brake line
Yoke
Crank Brake pedal

base plate
cylinder remove
Figure 6-16 Cylinder Removal
7. Using a flare-nut wrench, disconnect the brake fluid line at the rear of the cylinder
(See Figure 6-16).
Note: Flare-nut wrenches should be used as they wrap around the nut to prevent
rounding off the flats.
8. Carefully pull the brake line away from the cylinder. Seal or plug the brake line and
master cylinder port to prevent fluid loss and/or contamination.
9. Disassemble the yoke from the master cylinder crank plate (one 5/16-18 and
hardware) (See Figure 6-16).
10. Remove the two master cylinder mounting bolts (3/8-16) and remove the cylinder
from the truck.
11. Remove the reservoir cap and discard any fluid remaining in the reservoir.
12. Mark the push rod lock nut setting, then remove the yoke and lock nut from the old
cylinder and install it to the new cylinder, maintaining the same lock nut setting.
13. Discard the old cylinder and/or rebuild the cylinder using only genuine Landoll
replacement parts.
Also see the Appendix, index tab A - H 'Brake System'.

6-28
Note: Whenever the master cylinder is removed and/or replaced, the hydraulic
brake system must be bled. The time required to bleed the system can be re-
duced and made easier if the master cylinder is filled with brake fluid and bench-
bled before installing the cylinder into the truck (See ‘Bench Bleed the Master
Cylinder,’ on page 6-29).
IMPORTANT !
during this procedure. Wipe up any spilled fluid immediately, then flush the area
with clean water.
Bench Bleed the Master Cylinder

Since high pressure is not involved in the bench bleed procedure, your finger can be
used to plug the cylinder hole and prevent air intake.
1. Support the cylinder (in a vise) to prevent fluid spillage while allowing you to push the
internal piston (See Figure 6-17).
2. Remove the filler cap and fill the cylinder with DOT #3 brake fluid.
3. Slowly push in on the rubber boot and cylinder plunger (push rod) assembly to force
air from the cylinder, then hold the piston in (See Figure 6-17).
Figure 6-17 Support and Bench Bleed the Cylinder

6-29
4. Press your finger tightly over the brake line inlet port to prevent air from being drawn
back into the cylinder when you release the piston, or feed a separate line (flexible
tubing) from the cylinder port(s) and immerse the other end in the container of new
brake fluid.
Wait several seconds to allow fluid to be drawn from the reservoir to the cylinder
bore, then repeat this step. When you push the piston in again it will force your finger
from the hole to expel any trapped air (See Figure 6-17).
Place rags under the brake line fitting to soak up any fluid lose.
5. When only brake fluid is expelled from the inlet port, hold the piston in and seal the
inlet port with an appropriate threaded plug or plastic cap, then release pressure on
the piston.
6. Fill the master cylinder reservoir and install the filler cap and gasket. Install the rubber
boot and plunger assembly.
To Install the New Cylinder

Install the new master cylinder by reversing the steps in “To Remove the Old Cylinder,”
page 6-27 noting the following:
· Make sure the cylinder mounting bolts are properly seated and tightened to the
specified torque (See Table 4-5 on page 4-6).
· Assemble the push rod yoke to the brake pedal crank plate.
· Bleed the system (See ‘Bleeding Brakes,’ on page 6-32).
· Readjust the brake pedal - see “Service Brake Linkage,” beginning on page 6-6.
Rigid Brake Line

The brake line assembly, from the master cylinder to the rear drive wheels, consists of:
· Two lines joined by a T fitting starting below the driver’s cab back to the frame well
area.
· One line running from the master cylinder to the center front T fitting.
· Two brake hoses each between the right and left hard tubing to the calipers
All tubing lines are secured to the truck frame using cable clamps (3/8”/1cm) - four
per side.
Prefabricated brake lines are available and recommended (See Figure 6-18).

6-30
Master cylinder
Rigid brake line

(tubing)
Master cylinder
brake line
To RIGHT brake
caliper
To LEFT brake
caliper
brakelin
Figure 6-18 Brake Line Layout
To Replace a Damaged Line

3. Apply the hand brake and disconnect the battery and block the wheels.
4. Remove the driver’s cap floor panel (See ‘Floor Access Panel - Removal,’ page 4-9).
5. Remove the battery and the battery tray (See ‘Replacing the Battery,’ on page 2-12).
6. Replace the damaged line (See Figure 6-18).
Use flare-nut wrenches to remove these lines. Do not overtighten the fittings to avoid
stripping the brass threads.
7. Bleed the brakes (See ‘Bleeding Brakes,’ page 6-32).

6-31
Bleeding Brakes
Bleeding the brake system is necessary to remove any air that is trapped when replacing
brake lines, wheel calipers or the master cylinder. To avoid extensive damage to the
system, use only DOT #3 brake fluid.
WARNING
Wear eye protection. If brake fluid comes in contact with your eyes,
immediately rinse them with water and seek medical attention.
Check the fluid level often during the bleeding operation and add
fluid as needed to prevent the level from falling low enough to allow
air bubbles into the master cylinder.
Use only fresh (new) DOT #3 brake fluid. NEVER use old or used
brake fluid. It contains moisture which will deteriorate the brake
system components.
It is necessary to bleed both wheels if air has entered the system due to low fluid level or
if a brake line has been disconnected at the master cylinder or at the T fitting.
If the brake pedal feels spongy when pressed and goes almost to the mechanical stop
but regains height when pumped, air has entered the system. It system must be bled. If
no fittings were recently opened for service, check for leaks that would have allowed air
into the system and repair leaks before attempting to bleed the system.
Have an assistant handy, as well as a supply of brake fluid, an empty container, a length
of 3/16” (4.763 mm) clear plastic or vinyl tubing to fit over the cylinder bleeder fitting and a
flare-nut wrench to open and close the fitting.
WARNING
DO NOT allow fluid to run down the inside of the backing plate and
into the brake and drum area. It will contaminate the brake lining ma-
terial causing an unsafe brake condition and unnecessary repair.
4. Block the wheels, remove the battery and battery tray (See ‘Replacing the Battery,’
page 2-12).
5. Start with the rear right wheel as viewed from inside the driver’s cab (the wheel
farthest from the master cylinder).
6. Loosen the bleeder fitting slightly, then tighten it to a point where it is snug but can be
loosened quickly and easily.

6-32
7. Fit a length of tubing over the bleed

screw and immerse the other end in
the container of new brake fluid.
Check that the tubing fits tightly over
the bleeder fitting (See Figure 6-19).
8. Check fluid level in the master
cylinder. Fill as needed before you
begin.
9. Have someone slowly press on the
brake pedal several times to build
pressure in the system, then hold the
pedal down.
IMPORTANT !
Be careful when handling bleeder
screws. Rust may cause the fitting to
easily break off if forced. Installing a
new bleeder screw may include over-
haul or replacement of the caliper. Figure 6-19 Bleeding Brakes
Spray the fitting with penetrating oil
before attempting to loosen it to help
prevent problems.
10. Loosen the cylinder bleed screw until fluid starts to flow. Watch for air bubbles at the
immersed end of the tube.
11. When the brake pedal bottoms, tighten the bleed screw, then release the pedal. DO
NOT release pressure on the pedal until the bleed screw is tightened.
12. Repeat Steps 8 through 11 as many times as needed until the fluid draining in the
container is free of air bubbles.
13. Check the master cylinder fluid level and fill as needed before beginning the other
side.
14. Check the operation of the brakes. The pedal should feel solid when depressed, with
no sponginess. If necessary, repeat this procedure.

6-33
Parking Brake Assembly

The parking brake assembly
includes:
· one cable from the hand
lever to the parking brake
caliper Park brake
handle
· a drive interlock switch that
shuts down the drive and
power steering motors, Switch
disables the direction actuator *
control (electrically resets
to NEUTRAL) Switch
plunger
· The mechanical brake Park brake
caliper assembly mount frame
Switch
1. First, review “Before You Connector
Begin,” page 6-2. hanger
2. Set the key switch to OFF Brake cable * Switch actuator also
and place the key in your connecting link
pocket. parkswch for brake cable.
3. Disconnect the battery, block

the wheels and release the
hand brake.
Figure 6-20 Parking Brake Switch
4. Remove the arm rest/ valve
console cover to expose the
hand parking brake
mechanics (See Figure 6-20).
Continuity test
· Connect the ohm meter leads to the COMMON and NORM CLOSED switch wires.
The meter must show a reading of less than 1 ohm.

· Slowly pull up on the brake handle. Before the brake handle reaches its full
locking position (full vertical position), the meter reading must OPEN, indicating
the switch is released.
· Disconnect the ohm meter.

6-34
Replace Micro Switch

3. Disconnect the battery, block the wheels and release the hand brake.
4. Remove the arm rest/valve console cover to expose the hand parking brake
5. Disconnect the switch at the cable connector and unscrew the switch (two jam nuts)
from the park brake handle frame.
6. Install the new switch in reverse order and tighten the jam nuts (See Figure 6-20).
7. Connect the switch at the connector.
8. The plunger is preset and has no adjustment. It is always activated in the resting
position.
9. To check the operation of this switch:
· Set the key switch to ON and release the parking brake.
· Set the control lever to FORWARD and very slowly increase motor speed.
· As the truck is moving forward at slow speed, slowly pull up on the brake handle.
· The truck must immediately slow to a STOP, and power steering is disabled.
· If the truck continues moving forward, recheck the setting and operation of the
switch.
WARNING
DO NOT release or operate the truck if you are in doubt about the ef-
fectiveness of the parking brake system. Contact your Landoll ser-
vice representative for assistance.
Replacing the Brake Cable

1. Repeat Steps 1 through 3 of preceding section “Replace Micro Switch”, page 6-35.
2. Remove the battery and battery tray (See Figure 2-6)
3. Remove the Driver’s cab floor panel (See section ‘Floor Access Panel - Removal,’
page 4-9).
Also remove the arm rest/valve console cover to expose the hand parking brake
4. Mark the location of the lock nuts on the existing brake cable at caliper end. Then
loosen the nuts.
5. Remove the hand lever cotter pin and mounting pin (switch plunger actuator) and
separate the old brake cable from the lever assembly (See Figure 6-20).

6-35
6. Disassemble the cable from the Lock nut

parking brake caliper yoke and
Cable adjustment
remove the cable from the truck
noting how the cable is positioned Tension spring
(See Figure 6-21). (return)
7. Feed the new cable from the hand
lever to the brake caliper in the
same manner as the one
removed, then connect both ends. Brake cable
8. Adjust the parking brake cable -

see “Adjust Parking Brake Yoke
Caliper,” beginning on page 6-10.
brakcbl1
Figure 6-21 Parking Brake Cable -

Caliper End
WARNING
DO NOT release or operate the truck if you are in doubt about the ef-
fectiveness of the parking brake system. Contact your Landoll ser-
vice representative for assistance.
Pedal pad (rubber)
Pedal weldment
Pivot bushing
Crank
plate
Brake lgt/accel
cutout switch
Brake pedal
base weldment
Brake return
brkpdeal spring
Figure 6-22 Brake (Service) Pedal Assembly

6-36
Service Brake Pedal Assembly

The service brake assembly (brake pedal) includes:
· A warning interlock switch that shuts down the drive and power steering motors,
disables the direction control (electrically resets to NEUTRAL) and applies the
mechanical brake option to prevent further truck movement
· The mechanical brake pedal assembly, containing a pivot bushing
The only normal wear repair would be the switch or the pivot bushing (See Figure 6-22).
Brake Warning Switch

1. First, review “Before You
Begin,” page 6-2.
Crank plate
2. Set the key switch to OFF
and place the key in your
pocket.
3. Disconnect the battery, block
the wheels and release the
hand brake.
4. Remove the driver’s cab floor
panel (See section ‘Floor
Access Panel - Removal,’ on
page 4-9).
5. Unscrew and remove the Brake lgt/accel
switch assembly from the cutout switch
brake pedal frame and install Adjustment
the new switch (See Figure slots
6-23). brkswtch
6. To set the switch (See Section

‘Brake Cutoff and Light Figure 6-23 Brake Switch
Switch,’ on page 6-8).
Brake Pedal
1. Repeat Steps 1 through 4 of preceding section “Brake Warning Switch”, beginning on
page 6-37.
2. Pedal pad - To replace the brake pedal pad, simply pry the old pad from the pedal
base and discard. Then install the replacement pad (See Figure 6-22).

6-37
3. Remove the hex head screw Pedal pad

and hardware (3/8-16) (rubber)
securing the pedal assembly,
Pivot bushing
through brake pedal base, to
the crank plate (See Figure
6-24).
4. Examine the pivot bushing,
the machined hex on the
pedal shaft and the mating Crank
hex in the crank plate. Repair plate
and/or replace accordingly.
5. Reassemble the brake pedal. Brake pedal
Then check the brake pedal base weldment
for proper play - see “Brake
Pedal,” beginning on page Brake return
6-6. spring
pedal
Also check the warning light
for proper operation and Figure 6-24 Pedal Pushing
setting - see “Brake Cut-off
and Light Switch,” beginning
on page 6-8.
Removing Forks
To
page 6-2. Unlock
2. Slide the fork so the hook on the
fork lines up with the notch on the
bottom of the carriage.
3. Pull the fork tine upward until the
hook is free of the carriage (See
Figure 6-25).
Note: As an alternate method, raise
the forks a few inches from the
floor and place a block of wood
under the fork. Slowly lower the
forks. The block of wood lifts the
fork to unhook it from the carriage.
4. Lift the fork off the carriage. Figure 6-25 Changing Forks
Various forks can be heavy - use
adequate lifting apparatus or ask for a helper as needed.
5. To replace the forks, perform steps 1 through 3 in reverse order.

6-38
Steer (Load) Wheels

To Check
1. First, review “Lifting the Truck,” beginning on page 6-3.
2. With the truck raised and supported, spin each wheel and check for noise, rolling
resistance and free play.
3. Rock the wheel in and out on the spindle. If there is any noticeable movement, the
bearings should be checked and then repacked with grease and/or replaced.
Wheel Bearings, Seals and Race

3. Apply the hand brake and disconnect the battery. Make sure all the other wheels are
securely blocked so that the truck cannot move.
4. Lift and support the truck so that the wheel being serviced is clear of the floor by no
more than 1” (25.4 mm). Review “Lifting the Truck,” on page 6-3.
5. Remove (pry off using flat blade screwdriver) the wheel rim cover (hub cap). Clean
excess grease from around the spindle (See Figure 6-26).
6. Remove the cotter pin. Unscrew the hex slot nut (use open-end wrench) and remove
the nut and spindle washer (See Figure 6-26).
Inner bearing
Hub cap Outer bearing cone
cup (race)
O-ring seal
Inner bearing
Cotter pin and cup(race)
hex slot nut
Outer bearing Spindle

cone
Inner grease
seal
Load wheel
Spindle Washer assembly
Breather port
wheel-1
Figure 6-26 Removing the Hub Cap and Wheel

6-39
7. Pull the wheel rim out slightly to release the outer bearing cone. Remove the outer
bearing cone. Then, pull the wheel from the spindle.
8. Turn the tire over, face down, to remove the inner bearing cone and inner grease
seal. Use a screwdriver to pry the old grease seal from the wheel. Note how the seal
is installed (See Figure 6-26).
9. Remove the inner bearing cone.
10. Place a punch or wood block in the grooves in the wheel and tap out the front inner
bearing cup (race). Turn the wheel over and remove the outer bearing cup (race).
Note: The bearing cone and bearing cup (race) are a matched set and must al-
ways be replaced as a set.
11. Use an approved solvent to remove all traces of old grease from the bearings, wheel
rim and spindle. Allow the parts to air dry. Also see “Cleaning and Inspection,” on
page 6-5.
12. Inspect the bearing for cracks, heat discoloration, worn rollers, etc. Check the
bearing race for wear and/or damage.
13. Install a new inner and outer bearing cup (race) (one each) in the wheel rim. A seal
and race tool is recommended to press in the race.
Note: Take care to apply an even force to the bearing cup (race) to prevent
cracking during installation. Be sure that each bearing cup (race) is fully seated
(bottomed out) against the shoulder in the bore.
14. Pack the bearings with high-temperature bearing grease making sure the grease
penetrates the rollers, cone and cage from the back side (See Table 4-2 on page 4-3
for recommended lubricants).
Also apply a thin coat of grease to the spindle at the outer bearing seat, and to the
inner surfaces of the race.
Note: If your truck is cold storage equipped you must use the appropriate grease
for cold storage applications. DO NOT mix greases as they will counteract each
other.
15. Place the grease-packed inner bearing cone into the rear of the wheel and apply a
little grease around the outer edge of the bearing.
16. Place the new grease seal over the inner bearing cone and tap the seal evenly into
place using the seal and race tool. The seal must be flush with the wheel rim.
17. Carefully install the wheel rim to the spindle, push the outer bearing cone into
position, and install the spindle washer and hex slot nut. Support the wheel rim to
avoid dragging the inner grease seal across the threads on the spindle.
18. Tighten the nut only slightly. Spin the wheel in a forward direction to seat the
bearings and remove any excess grease. While spinning the wheel, tighten the hex
slot nut to the specified torque (22 [ 2] ft. lbs./30 [ 3] Nm.) (See Table 4-5 on page
4-6).

6-40
19. Loosen the nut ½ turn - no more, then tighten the nut again and torque as specified.
20. Insert a new cotter pin. Back-off the nut slightly as needed to align the notches to the
hole in the spindle.
21. Install the hub cap and road test the truck before placing it back into operation.
Replacing Tires/Wheels
WARNING
The truck is equipped with tires of a size and hardness that provide
the necessary traction and still maintain a proper shape to minimize
tipping. To maintain stability and maximum reliability, you must al-
ways replace tires with the type originally supplied, as listed on the
specification sheet at the beginning of this manual.
It is also recommended to replace worn tires in pairs. Treaded drive

tires must be replaced when the tread depth is less than 0.0625”
(1.6mm) at the deepest point.
Drive Wheels
1. First, review “Before You Begin,” Tire lift support - connected
page 6-2. to overhead crane
2. Set the key switch to OFF and Gear box
3. Apply the hand brake and
disconnect the battery. Make sure
the other wheels are securely
blocked so that the truck cannot
move.
4. Lift and support the truck so that
the load wheel being serviced is
clear of the floor by no more than
1” (25.4 mm). Also see “Lifting the Tire and wheel
Truck,” on page 6-3. assembly
5. Remove the 6 hex nuts and Lug nuts (6)

hardware (See Figure 6-27).
wheel-2
Figure 6-27 Removing Drive Wheels

6-41
6. Using an overhead crane and

adequate lifting apparatus, remove
the wheel.
The wheel and tire weigh

approximately 100 lbs. (45.4 kg.).
7. When installing the new wheel,
tighten and torque the six hex nuts
and hardware in a staggering
fashion, following the numbering
pattern (See Figure 6-28).
8. Tighten to 130 ft. lbs. (176 Nm)
(See Table 4-5).
Figure 6-28 Removing Drive Wheels

Steer (Load) Wheels
To remove one of the steer (load) wheels, see the appropriate steps in section “Wheel
Bearings, Seals and Race” on page 6-39.
Console Assembly
The console assembly includes the following:
· Two pump, traction control displays, including BDI
· Tilt steering lever
· Key switch
· Circuit breakers, for lights and options
· Light/options off/on rocker switches
The above parts are accessed by removing the left side steering assembly cover (black) -
seven (7) screws and hardware.

6-42
Steering knob
(B) cover screws - Steering wheel

3 each half
Wheel nut
(A) cover screws -

4 (2 each side) Steering console
Key switch
Tilt steering location
lever
Circuit breaker
location
Left side cover
Rubber boot
Orbital mount
sterclm3 plate
Figure 6-29 Remove Left Side Cover
Remove Left Side Cover

3. Apply the hand brake and disconnect the battery. Make sure the other wheels are
4. Loosen the Allen set screw in the tilt steering lever and remove the lever from the
stem (See Figure 6-29).
5. Remove the four large screws and hardware marked (A) (See Figure 6-29).
6. Remove the three left side top cover screws and hardware marked (B) (See Figure
6-29).
7. Pry the bellows (rubber boot) free of the steering column cover.
8. Remove the left side cover to expose the internal components of the steering column.

6-43
Dash display
panel (4 button
head screws)
Key switch (2 button

head screws)
Circuit breaker
panel (2 button
head screws)
Key switch
display locknut
Figure 6-30 Console Dash Display Panel
Display or Cable
1. Repeat preceding section “Remove Left Side Cover” , beginning on page 6-43.
2. Remove the four screws securing the dash panel to the steering console (See Figure
6-30).
3. Reach inside the steering column and disconnect the appropriate display cable
connector from the main wire harness, then lift the panel out.
4. Remove the two knurled nuts and hardware holding the display to the panel.
5. Install the new display by reversing the above steps.
6. Connect the cable connector to the wire harness and close the steering column by
reversing the steps outlined in section “Remove Left Side Cover” , on page 6-43.

6-44
Key Switch
1. Repeat preceding section
“Remove Left Side Cover” ,
2. Reach inside the steering column
and disconnect the appropriate
switch connector from the main Key
wire harness. Switch
3. Unscrew the knurled switch collar
ring to separate the switch from
the base plate (See Figure 6-31).
Collar
4. Disconnect the wires from the Ring
switch terminals noting how they
are connected to ensure proper Figure 6-31 Key Switch
orientation when connecting the
new switch.
Note: If you are replacing the wire harness, disconnect the two leads on the
steering column, again noting orientation and disconnect the cable connector.
5. Install the key switch and/or wire harness by reversing the preceding steps.
6. Close the steering column by reversing the steps outlined in section “Remove Left
Side Cover” , beginning on page 6-43.
Option Rocker (On/Off) Switches

Optional rocker switches are also used
to control various light packages, or
other accessories. When an option is
installed, the switch is activated.
1. Repeat preceding section
“Remove Left Side Cover” ,
2. Reach inside the steering column
and disconnect the appropriate
accessory switch connector from
the main wire harness.
3. The accessory on/off rocker
switches are held by knurled
plastic wings (or tabs). Compress
the wings (or tabs) on one side at
a time to release the switch body, Figure 6-32 Option Rocker Switches
then push it up and out of the slot
(See Figure 6-32).
Be careful when compressing and pushing the switch in or out. The wings (tabs)
could break off if the procedure is not done evenly on all sides.

6-45
4. Detach the wires from the defective switch, noting the connection arrangement for
when installing the new rocker switch.
5. Insert the replacement switch in the slot and compress the wings (or tabs) as
necessary to allow it to pop into place.
6. Connect the cable connector to the wire harness and close the steering column by
reversing the steps outlined in section “Remove Left Side Cover” , beginning on page
6-43.
Circuit Breaker Panel

1. Repeat preceding section “Remove Left Side Cover” , beginning on page 6-43.
2. Reach inside the steering column and disconnect the appropriate circuit breaker
connector from the main wire harness.
3. Remove the two round head screws securing the breaker panel to the dash panel
cover (See Figure 6-30).
4. Pull the circuit breaker panel out and disconnect the wire harness from the defective
breaker.
5. Replace the defective breaker and install the panel by reversing the preceding steps.
6. Close the steering column by reversing the steps outlined in section “Remove Left
Side Cover” , beginning on page 6-43.
Steering Assembly
Satisfactory performance of any hydraulic system requires a well-engineered installation.
The hydraulics must meet the design features of the vehicle and contribute to the
operation for which the vehicle was built.
Make no changes to the steering system without first consulting qualified Landoll factory
service personnel.
This procedure replaces the steering wheel and the steering column, pump and motor.
· Before disassembling or disconnecting any part of the system, thoroughly clean off
all outside dirt, especially from around fittings and tube connections.
· First, review “Before You Begin,” page 6-2.
· Apply the hand brake and disconnect the battery. Make sure the other wheels are

6-46
Steering Wheel
1. Pry the plastic cover from the steering wheel using your finger tips. If you cannot
grab the cover, you can start it by carefully using a medium sized flat blade screw
driver and gently prying upwards. DO NOT force it or you may crack the cover.
2. Loosen the wheel nut (See Figure 6-29).
3. Pry the steering wheel upwards by wiggling and pulling straight up. It is important to
pull up evenly on both sides of the wheel.
Note: If the wheel is difficult to remove, tap the wheel nut using a dead-blo ham-
mer a few times. The wheel should remove easily.
4. Install the steering wheel by placing it over the shaft, aligning the wheel and shaft
splines and pushing downward evenly until the nut can be installed.
5. Tighten the nut, keeping in mind the tighter the nut the more difficult it will be to
remove the steering wheel later on.
Steering Column (Console)

This is a two man operation, due to weight of steering column (approximately 30
pounds/14 kgs.). If an overhead crane is available, the crane could be strapped to the
steering wheel for support.
1. Repeat preceding section “Remove Left Side Cover” , beginning on page 6-43. This
exposes the main cable harness that must be disconnected to allow the column to be
removed.
2. Relieve hydraulic pressure in the system by turning the steering wheel a few times to
the left and right.

6-47
Steering column
assembly
Connects steer column

to truck frame
(4 screws & hardware)
Bellows retainer
mount plate
Connects orbital to
steer column (4 bolts
& lock washers)
Access opening
Steer assembly mount

column (truck frame)
Orbital control unit
Figure 6-33 Steer Control System
3. Also pry (up) the bellows (rubber boot) free of the bellows retainer plate. This
exposes the mounting plate for the steering column and the orbital control unit (See
Figure 6-33).
IMPORTANT !
Four screws secure the assembly to the orbital steering mount bracket for stabil-
ity. Once removed the unit is supported by the hydraulic tubing only. Exercise
care not to apply excessive force and bend the tubing.
4. Remove the plastic front rotation cover to expose the orbital control unit.
5. Remove the four bolts and hardware securing the orbital control unit to the steering
column (See Figure 6-33).
6. Remove the four bolts and hardware securing the steering column (console) to the
bellows retainer plate. Two bolts are accessed through the cutout in the main frame
(access opening) (See Figure 6-33).

6-48
7. With help, lift the steering column upwards to disengage the shaft form the orbital
unit, then remove the steer column from the truck.
8. When installing the new steer column, you must turn the steering shaft until it aligns
with the orbital unit and drops into place.
9. Continue by reversing the preceding steps making sure to tighten and torque all
mounting screws (See Table 4-3 on page 4-4).
Orbital Steer Unit

Orbital control
1. Repeat Steps 1 through 5 of unit
preceding section “Steering
Column (Console)”, beginning
on page 6-47.
V1 - Orbital
2. Tag the port locations of each right hand
hydraulic line and fitting, then
disconnect the four lines from V2 - Orbital
the unit (See Figure 6-34). left hand
P1 - Orbital
Review previous section pressure
“Hydraulic Fittings and
Hoses,” on page 6-4. Have
D2 - Orbital
shop rags handy to soak up return
any fluid spills.
3. If the unit is being replaced, or Steering control
the fittings are defective, valve
notice the placement (angle)
of the hose fittings then
remove them. Thread them
into the new orbital unit (or
replace).
4. Immediately cap the ports in
the control unit to prevent oil
spills.
To oil filter
5. Install the new orbital control
orbital
unit to the steering column by
following the preceding steps
in reverse order (See Figure
6-34).
Figure 6-34 Orbital Control Unit
6. Check oil level in the hydraulic
tank and fill as needed (See
‘Check Hydraulic Oil Level,’ on page 4-18).
To Service the Orbital Control Unit

To service the orbital control unit, see the Appendix, index tab Q - Z 'Steer System'.

6-49
Sensor position
pot assembly
Pinion mounting
hardware
Pinion retainer
plate
Pinion gear
Motor support
bearing
Steer motor
mounting plate
Spur gear
M2 - Steer motor
line (tube)
Steer motor
M1 - Steer motor
line (tube)
D1 - Steer case
drain line (tube)
stermotor
Figure 6-35 Steer Motor Assembly
Steering Motor or Support Bearing

3. Apply the hand brake and disconnect the battery. Make sure all wheels are securely
blocked so that the truck cannot move.
4. Tag the port locations of the three hydraulic lines to the steer motor, then disconnect
them from the motor fittings (See Figure 6-35).
Review previous section “Hydraulic Fittings and Hoses,” on page 6-4. Have shop
rags handy to soak up any oil spills.

6-50
5. If the motor is being replaced, or if a fitting is defective, notice the placement (angle)
of the hydraulic fittings, then remove them and thread them into the new motor (or
replace) (See Figure 6-35).
Immediately plug the ports in the steer motor and the tubing to prevent oil spills. For
tubing, use # 06 male O-ring face seal plugs.
6. Remove the pinion screw and hardware and the retainer plate.
7. Using a pry bar (or possibly two), “evenly” and carefully pry the gear upwards
(working in a circular motion around the underside of the gear) until the gear is
removed from the motor shaft (See Figure 6-35).
Note: The motor shaft is keyed. DO NOT lose the woodruff key.
8. Remove the four screws (½-20 hex head) and hardware securing the motor to the
motor mounting plate.
If the support bearing is being replaced, from underneath, “evenly” tap out the
existing bearing and discard.
9. Install the new motor and/or bearing and reassemble the truck by following the
preceding steps in reverse order.
Hints
· Adequately grease the new motor support bearing before inserting.
· Clean and/or replace the woodruff key in the motor shaft before installing the
pinion gear.
· When installing the pinion gear and mounting hardware, make certain to tighten
and torque the screw accordingly (See Table 4-3).
As the pinion screw is tightened, the gear is pressed downward insuring proper
alignment with the spur gear.
· Check oil level in the hydraulic tank and fill as needed (See ‘Check Hydraulic Oil
Level,’ on page 4-18).
To Service the Motor

To service the steer motor, see the Appendix, index tab Q - Z 'Steer System'.

6-51
Drive wheel gear box, motor

and brake assembly
Parking brake
assembly
Steer pump
Lift electric
motor
Steer electric
motor
Lift pump
Front of
truck
Drive wheel gear

box, motor and
frmwell brake assembly
Figure 6-36 Rear Frame Well
Steer Pump and Motor

The steer pump and the electric motor are located in the rear frame well compartment of
the truck, below the battery compartment (See Figure 6-36).
To repair and/or replace the motor you will need an assistant to help plug hydraulic lines,
avoiding excessive oil leakage, and an overhead crane to support the weight of the
electric motor. The pump is removable by hand as a single unit.

6-52
To Replace the Pump and/or Motor

4. Relieve pressure in the system by turning the steering wheel two times to the left,
then two times to the right and move the joysticks in both directions.
5. Remove the battery, the battery tray and guides (See “Replacing the Battery,” page
2-12).
6. If the electric motor is being serviced, remove the two electrical wires from the motor
- tag the wires for identification (See Figure 6-37).
IMPORTANT !
If the pump requires servicing, disconnecting the suction line hose will cause ex-
cessive oil drainage from the hydraulic tank.
To limit the amount of drainage:

· Slide a drain pan under the truck and center it around the vent opening in
the bottom plate of the well frame (See Figure 4-24 on page 4-30).
· You could empty the hydraulic tank, especially if an oil and oil filter change
is near or if dirty oil could be suspect in a pump failure.
· You could remove the oil filter cap and oil filter, located below the driver’s
floor panel. See section ‘Floor Access Panel - Removal,’ on page 4-9. Also
see “ Change Hydraulic Oil Filter,” on page 4-32.
Then have a helper hold an operating shop vac over the filler opening to
create a “partial” vacuum in the tank. It is not necessary to seal the opening
tight. Wrapping your hand around the opening is sufficient.
7. If the electric motor is being serviced only, proceed to Step 9, “Electric Motor Service
Only” , beginning on page 6-54.
8. If the pump is being service only, proceed to Step 10, “Steer Pump Service Only” ,

6-53
ck of
tru ck
Back wall of truck frame
Ba
Motor mounting hardware (4)
Electric motor
Electrical
connections (2)
Low pressure line -

suction hose
Pump/motor
mounting plate
Steer pump
High pressure line

(tube)
Oil filter/
Strainer - located
filler cap
inside hydraulic tank
strpump
Figure 6-37 Steer Pump and Motor
9. Electric motor service only

· Connect an overhead crane and strap around the motor and apply slight tension
to stabilize the motor when the mounting bolts are removed.
· Disconnect the pump high pressure line (tube) from the steer pump fitting (See
Figure 6-37).
Note: Immediately plug and cap all tube ends and pump ports and tag each for
identification. Have shop rags handy to soak up any oil spills.
Use # 16 male O-ring face seal for suction line; # 08 for high pressure line.
· Remove the pump/motor mounting screws and hardware (3/8”-24). Slide the
pump shaft from the motor and carefully loop the suction hose back to lay the
pump assembly over the drive motor. Avoid kinking the hose.
· Remove the four hex bolts (½”-13) and hardware securing the motor mounting
plate assembly to the frame back wall (See Figure 6-37).
· Lift the motor assembly from the truck and place on a work bench for repair and/or
replace. Be careful of electrical wire harness and other tubing/hose lines in the
area to avoid unnecessary damage and repair.
· Wipe clean any oil spills in the bottom of the frame well compartment.
· Install the electric motor assembly to the truck by following the preceding steps in
reverse order.
· Tighten and torque all screws (See Table 4-3 on page 4-4).

6-54
· Make sure the electrical wires are connected correctly and tight.
· Check fluid in the hydraulic tank (See ‘Check Hydraulic Oil Level,’ on page 4-18).
10. Steer Pump Service Only
· Disconnect the pump high pressure line (tube) from the steer pump fitting (See
Figure 6-37).
· Disconnect the suction low pressure line (hose) from the steer pump fitting.
Note: Immediately plug and cap all hose/tube ends and pump ports and tag each
for identification. Have shop rags handy to soak up any oil spills.
Use # 16 male O-ring face seal for suction line; #08 for high pressure line.
pump shaft from the motor and remove the pump assembly to a workbench.
Be careful of electrical wire harness and other tubing/hose lines in the area to
avoid unnecessary damage and repair.
· Notice the placement (angle) of the pump fittings, then remove the fittings and
install them in the new pump - if the pump is being replaced.
· Apply graphite grease to the pump shaft before inserting into the electric motor.
· Install the new pump to the electric motor, making sure the hydraulic fittings are
properly aligned, and install the assembly to the truck by following the preceding
steps in reverse order.
· Check fluid in the hydraulic tank (See ‘Check Hydraulic Oil Level,’ page 4-18).
To Service the Steer Pump

To service (rebuild) the steer pump, see the Appendix, index tab Q-Z 'Steer System'.

6-55
Lift Circuit
Satisfactory performance of any hydraulic system requires a well-engineered installation.
The hydraulics must meet the design features of the vehicle and contribute to the
operation for which the vehicle was built.
Make no changes to the lift circuit without first consulting qualified Landoll factory service
personnel.
This procedure replaces the lift pump, electric motor and control valve levers.
· Before disassembling or disconnecting any part of the system, thoroughly clean off
all outside dirt, especially from around fittings and tube connections.
· First, review “Before You Begin,” page 6-2.
· Apply the hand brake and disconnect the battery. Make sure all wheels are
The lift pump and the electric motor are also located in the rear frame well compartment
of the truck, below the battery compartment (See Figure 6-36).
To repair and/or replace the motor you will need an assistant to help plug hydraulic lines,
avoiding excessive oil leakage, and an overhead crane to support the weight of the
electric motor. The pump is removable by hand as a single unit.
To Replace the Pump and/or Motor

2-12).
6. If the electric motor is being serviced, remove the two electrical wires from the motor
- tag the wires for identification (See Figure 6-38).

6-56
F r truc
on k
to
f
Figure 6-38 Main Pump and Motor
IMPORTANT !
If the pump requires servicing, disconnecting the suction line hose will cause ex-
cessive oil drainage from the hydraulic tank.
To limit the amount of drainage:

· Slide a drain pan under the truck and center it around the vent opening in
the bottom plate of the well frame. Remove the pipe plug and set aside (See
Figure 4-24).
· You could empty the hydraulic tank, especially if an oil and oil filter change
is near or if dirty oil could be suspect in a pump failure.
· You could remove the oil filter cap and oil filter, located below the driver’s
floor panel. See ‘Floor Access Panel - Removal,’ on page 4-9. Also, see “
Change Hydraulic Oil Filter,” on page 4-32.
Then have a helper hold an operating shop vac over the filler opening to
create a “partial” vacuum in the tank. It is not necessary to seal the opening
tight. Wrapping your hand around the opening is sufficient.

6-57
7. If the electric motor is being serviced only, proceed to Step 9, “Electric Motor Service
Only” , beginning on page 6-58.
8. If the pump is being service only, proceed to Step 10, “Lift Pump Service Only” ,
9. Electric motor service only
· Connect an overhead crane and strap around the motor and apply slight tension
to stabilize the motor when the mounting bolts are removed.
· Disconnect the pump high pressure line (tube) from the lift pump fitting (See
Figure 6-38).
Note: Immediately plug and cap all tube ends and pump ports and tag each for
identification. Have shop rags handy to soak up any oil spills.
pump shaft from the motor and carefully position the pump out of your way. Avoid
kinking the suction hose.
· Remove the four hex bolts (3/8”-16) and hardware securing the motor mounting
plate assembly to the frame bottom wall (See Figure 6-38).
· Lift the motor assembly from the truck and place on a work bench for repair and/or
replace. Be careful of electrical wire harness and other tubing/hose lines in the
area to avoid unnecessary damage and repair.
· Install the electric motor assembly to the truck by following the preceding steps in
reverse order.
· Tighten and torque all screws (See Table 4-3).
· Make sure the electrical wires are connected correctly and tight.

6-58
10. Lift pump service only

· Disconnect the pump high pressure line (tube) from the lift pump fitting (See
Figure 6-38).
· Disconnect the suction low pressure line (hose) from the pump fitting.
Note: Immediately plug and cap all hose/tube ends and pump ports and tag each
for identification. Have shop rags handy to soak up any oil spills.
pump shaft from the motor and remove the pump assembly to a workbench.
Be careful of electrical wire harness and other tubing/hose lines in the area to
avoid unnecessary damage and repair.
· Notice the placement (angle) of the pump fittings, then remove the fittings and
install them in the new pump - if the pump is being replaced.
· Apply graphite grease to the pump shaft before inserting into the electric motor.
· Install the new pump to the electric motor, making sure the hydraulic fittings are
properly aligned, and install the assembly to the truck by following the preceding
steps in reverse order.
To Service the Lift Pump

To service (rebuild) the lift pump, see the Appendix, index tab I - P 'Lift circuit'.

6-59
Traction Drive - Rear

This section explains servicing the gear box unit and the electric drive motor.
For an overview of the traction drive assembly, see Figure 6-36.
To Begin…
3. Apply the hand brake and disconnect the battery. Make sure all wheels are securely
blocked so that the truck cannot move.
4. Relieve hydraulic pressure in the system by turning the steering wheel two times to
the left, then two times to the right and move the control levers in both directions.
2-12).
6. Raise the side of the truck being serviced 6” to 8” (15 - 20 cm) off the floor surface
and support the truck in this position. Review previous section “Lifting the Truck,” on
page 6-3.
7. Remove the drive wheel assembly on the side being serviced. Also see “Replacing
Tires/Wheels,” on page 6-41.
To Replace Gear Unit / Motor

The traction drive assembly is very heavy and awkward to handle. It must be supported
using and overhead crane as it is being removed from the truck (See Figure 6-39).
2. If the gear box is being serviced only, proceed to Step 4. “Gear box” , beginning on
page 6-61.
3. If the electric motor is being serviced, proceed to Step 5. “Electric drive motor” ,

6-60
Figure 6-39 Traction Drive Assembly
4. Gear box
· Connect an overhead crane and strap around the gear box and apply slight
tension to stabilize the unit as the mounting bolts are removed.
· Remove the eight M16-2 socket head bolts and hardware holding the gear box to
the truck frame (See Figure 6-39).
· Adjust the overhead crane to evenly support the gear box and allow the shaft to
slide free of the motor.
· Place the gear box on a sturdy work bench. Use wood planks to balance and
support the assembly while on the workbench.
· To service the gear box, see the Appendix, index tab A-H 'Drive system'.
Also see Bendi Series IV Parts List (p/n F-371-____) for an overview and
replacement parts.
· Reassemble the gear box to the truck by following the preceding steps in reverse
order.
· Tighten and torque the screws (See Table 4-5 on page 4-6).

6-61
CAUTION
When installing a new gear box unit, it is shipped from the factory
without oil, therefore you must add oil before putting the unit into op-
eration (See Table 4-2).
For proper oil fill instructions, see “Check Planetary Gear Box,” be-
ginning on page 4-26.
5. Electric drive motor
· Repeat preceding steps to remove the gear box - see Step 4. “Gear box” ,
· Remove the Brake caliper - see “Replace the Brake Caliper Assembly,” beginning
on page 6-23. Also see “Disc Brake Rotors,” beginning on page 6-25.
· Connect an overhead crane and strap around the drive motor and apply slight
tension to stabilize the unit as the mounting bolts are removed.
· Remove the twelve ½”-20 socket head bolts and hardware holding the motor to
the truck frame (See Figure 6-39).
· With the motor supported by the overhead crane, rotate the motor to align the
electrical connecting ports to the slots machined in the truck frame side plate (See
Figure 6-39).
· Slide the motor out the side of the truck far enough to install a second strap
around the motor. This strap is to support the motor from outside the truck frame.
· Place the assembly on a sturdy work bench. Use wood planks to balance and
support the assembly while on the workbench.
· Assemble the new motor by following the preceding steps in reverse.
· Tighten and torque the screws (See Table 4-3).
· To service the shaft drive motor, see Bendi Series IV Parts List (p/n
F-371-____) for an overview and replacement parts.

6-62
Hydraulic Valve Assemblies

Individual directional control, pressure valve assemblies and gauge ports (for psi
readings) are located on two manifolds:
· Hydraulic control valve manifold, located in front of the driver’s arm rest, under the
control levers (See Figure 6-6 on page 6-11).
· Steering control valve manifold, located in the frame well in the driver’s
compartment, under the floor access panel (See Figure 6-34 on page 6-49).
The following procedure explains how to replace a specific valve should a sluggish or
sticking valve spool be suspect.
IMPORTANT !
If you remove the manifold from the truck for servicing (hex head screws and
hardware), when reinstalling the manifold be certain to tighten the mounting
screws in a staggering fashion while applying equal pressure to all four screws.
If the screws are not tightened and torqued evenly, you could create a stress
crack, thus internal oil leaks, rendering the manifold defective.
Steer Control Valve

4. Relieve pressure in the system by
turning the steering wheel two Check valves
times to the left, then two times to
the right and move the control Gauge pressure port
levers in both directions. (test port)
5. Remove the driver’s floor access
panel to expose the steer
manifold (See ‘ Floor Access
Panel - Removal,’ on page 4-9).
6. Determine the suspected valve
cartridge and remove it from the
manifold assembly (locate where
the leak is occurring and/or
determine which valve spool is Counterbalance
defective) (See Figure 6-40). valve
Have shop rags handy to clean Relief valve

any oil spills. stermfld
Note: Two check valve cartridges
are located on the bottom of the Figure 6-40 Steer Control Valve Manifold
manifold (not shown).

6-63
7. All valves include external O-ring seals which are serviceable. However, on pressure
valves, the internal mechanism is not serviceable and must be replaced as compete
unit.
8. If the valve manifold is being replaced,
Note: When ordering a new valve, you must provide the date (mm/dd/yy) the
truck was manufactured.
· Disconnect tubing at the fittings and immediately plug/cap all lines. Have shop
rags handy to clean any oil spills.
· Remove the fittings from the defective manifold and note their alignment, then
remove the mounting hardware and replace the manifold.
· Clean the mating surfaces of the valve spools and make sure the O-ring seal is
properly seated before sealing the parts together.
· When installing fittings, apply a light film of oil to the O-ring seal and do not
overtighten. Excessive pressure could damage the seals.
· Install manifold - see “IMPORTANT !,” beginning on page 6-63.
· Adjust system pressure to factory specifications (See ‘Steer Pump Relief Valve,’
on page 6-14).
· Reassemble in reverse order.
9. Before placing the truck back into operation, test it to make sure all functions are
operating properly and that there are no oil leaks.
Hydraulic Control Valve and Switches

5. Remove the control valve access cover to expose the hydraulic control valve
manifold. (See ‘Main Pump Relief Valve,’ on page 6-11).
6. Determine the suspect valve or solenoid cartridge and remove it from the hydraulic
control valve manifold (locate where the leak is occurring and/or determine which
valve spool is defective) (See Figure 6-41).
All valves/solenoids include external O-ring seals which are serviceable. However, on
pressure valves, the internal mechanism is not serviceable and must be replaced as
compete unit.
7. Disconnect the control lever extension rods (three) from the valves. Tag the rods for
identification.
8. Disconnect the three limit switch wire harnesses. It is not necessary to disconnect the
wire leads from the individual switches.

6-64
LIFT spool sensor Shift lever
TILT switch Lift lever

(Sw15)
Tilt lever
SHIFT switch
(Sw16) Plug
Pressure relief valve
Port tubing arrangement
1. Pressure gauge
2. Lift spool to bulkhead
3. Tilt back to bulkhead
4. Sideshift RH to bulkhhead
5. Lift pump
6. Tilt forward to bulkhead
7. Sideshift LH to bulkhead
Figure 6-41 Hydraulic Control Valve Manifold
9. Remove the two hex nuts and hardware holding the valve assembly to the truck
base. Lift the valve from the truck and place it on your workbench. It is heavy - be
prepared.
10. Disassemble the switch bracket from the valve by:
· removing all limit switches (2 screws and hardware each)
· removing the eight Allen head screws holding the bracket to the valve.
If a valve spool is being replaced, remove the hydraulic fittings from the defective
valve and note how the fittings are arranged.
11. To service the control valve, see the Appendix, index tab A-H, 'Lift circuit'. Vendor
instructions are found in alphabetical order behind the appropriate index tab,
separated by colored slip-sheets.
12. Before placing the truck back into operation, test it to make sure all functions are
operating properly and that there are no oil leaks.

6-65
13. If the hydraulic control valve manifold is being replaced,

· Clean the mating surfaces of the valve spools and make sure the O-ring seal is
properly seated before sealing the parts together.
· Disconnect tubing at the fittings and immediately plug/cap all lines. Have shop
rags handy to clean any oil spills.
· Remove the fittings from the defective manifold and note their alignment, then
remove the mounting hardware and replace the manifold.
· Install the fittings in the replacement manifold maintaining proper alignment - see
“IMPORTANT !,” beginning on page 6-63.
· When installing fittings, apply a light film of oil to the O-ring seal and do not
overtighten. Excessive pressure could damage the seals.
· When installing the limit switch bracket and switches, each must be adjusted. See
Appendix, index tab I-P 'Lift Circuit'.
· If the pressure relief valve is being replaced, you must Readjust the pressure
setting before operating the truck (See ‘Main Pump Relief Valve,’ on page 6-11).
· Reassemble in reverse order.
Hydraulic Lift Pot

General
The hydraulic lift pot is replaced as a complete unit with the wiring harness. It is
electrically charged by using the Pro-bit handset of the SRE Controls. See Appendix,
index tab A-H "Electrical System".
To Adjust and/or Replace

4. Remove control valve cover (See Figure 6-6 on page 6-11).
5. Should it become necessary to replace the 3 spool valve or the lift spool
potentiometer (pot) set this pot to the following settings:
Valve in neutral and handle centered: 3.5 k Ohms
Valve fully stroked and handle pulled toward operator: 5 k Ohms
These resistance valves should be measured between pins 2 and 3 on the 8-pin
connector of the valve wire harness.
6. Adjust setting by rotating pot shaft in its lever arm. Loosen set screw locking arm onto
shaft and use a screwdriver to rotate shaft. Once properly set, tighten set screw and
reassemble valve cover.
7. To recalibrate the hydraulic lift pot, use the Pro-bit handset for the SRE controls.
Refer to the setup procedure in the Appendix, index tab A-H "Electrical System".

6-66
Linear Accelerator Module

The accelerator assembly Accelerator pedal
consists of the linear assembly
accelerator and
interconnecting cable and the
accelerator pedal (See Figure
6-42).
Fr Accelerator
o
tru nt of pivot bracket
Module and ck
Cable Assembly
1. First, review “Before You
Begin,” page 6-2.
2. Set the key switch to Floor mat
OFF and place the key in
your pocket. RH Floor
plate
3. Apply the hand brake,
disconnect the battery and
block all wheels.
4. Remove the driver’s cab Actuation rod
floor access panel. (See ‘ Hex jam nut Linear
Floor Access Panel - accelerator
Removal,’ on page 4-9). Accelerator
mount bracket
5. Raise the floor panel as
far as possible and Accelerator
cable
disconnect the accelerator
acceler
cable connector from the
main harness. Figure 6-42 Accelerator Module Assembly
6. Remove the round head
screws (¼”-20 [2]) and hardware securing the accelerator mount bracket to the floor
panel (See Figure 6-42).
7. Disassemble the linear accelerator from the mounting bracket and install the
replacement module in its place.
8. Note the adjustment setting of the jam nut on the existing linear accelerator actuation
rod, then remove the rod and jam nut and install them on the new linear accelerator
maintaining the adjustment setting.
9. Install the new linear accelerator assembly to the truck by reversing the preceding
steps.
10. Adjust the actuation rod so it just makes contact with the accelerator pedal in its
raised, resting, position then tighten the jam nut.
11. Recalibrate PSM Module using SRE Control Panel Setup Procedure Step 3
Calibration Procedure for PSM Module. See Appendix, index tab A-H "Electrical
System".

6-67
Accelerator
Pedal
Pin
Return spring
Retaining
ring (2)
acelpedl
Figure 6-43 Accelerator Module Assembly
Limit Switch
and cable
Figure 6-44 Seat Switch

6-68
Pedal Spring
1. Repeat Steps 1, 2 and 3 of preceding section “Module and Cable Assembly” ,
2. Remove one of the pin shaft retaining rings (See Figure 6-43).
3. While applying slight pressure to the pedal, slide the pin from the assembly.
4. Ease up on the accelerator pedal and slide the pin out to replace the return spring.
5. Replace return spring and put back together by reversing preceding steps.
Seat Switch
The driver’s seat micro switch and cable assembly are mounted to the bottom of the seat
cushion.

6-69
Replace the Switch

and Cable
page 6-2.
3. Apply the hand brake, disconnect
the battery and block all wheels.
4. Release the battery/seat cover
latch and raise the cover to
expose the underside. Make sure
the cover is secured in the fully
raised position (See Figure 2-2 on
page 2-9).
5. Remove the hardware securing
the front portion of the seat slide
Figure 6-45 Hose Bulkhead Support
rails to the cover. Then loosen the
back two sets of hardware (See
Figure 6-44).
6. Lower the battery/seat cover, then raise the front of the seat up to expose the switch
and cable mounting.
Have a helper disconnect the switch cable from the main harness, then unscrew the
switch assembly.
7. Install the new switch and cable by performing the preceding steps in reverse.
8. Before placing the truck back into operation, test it to be sure the switch functions
properly (See ‘Check Driver’s Seat Switch,’ on page 4-17).
Front End Assembly

This section explains servicing the:
· Front rotation spur gear (large), seals and bearing and race assemblies - see
“Rotation Seals, Bearings or Spur Gear,” beginning on page 6-72.
· Mast assembly - see “The Mast,” beginning on page 6-76.
· Tilt cylinder - see “Tilt Cylinders,” beginning on page 6-77.
· Sideshifter - see “Sideshifter,” beginning on page 6-82.
· Articulation bearing and seal - see “Articulation Bearing and Seal,” beginning
on page 6-83.
· Stop blocks - see “Stop Block,” beginning on page 6-84.
You will need an approximate 2 to 3 ton (1,814-2,722 kg.) overhead crane to support the
mast and/or the front end assembly when you separate it from the truck rotation arm
assembly. You will also need hydraulic jacks or large block of wood and a portable
hydraulic press (come-along).

6-70
Mounting screws Switch activator cam

(1/2”-20)
Slotted hex nut and
cotter pin
Bearing cone Upper bearing spacer
Rotation shaft Large spur gear
Cotter pin Seal

Hex nut and screw hole
(3/4”-16)
Front Position sensor switch
rotation assembly
Bearing cone stop
Small spur gear
Seal
Lower bearing spacer
Front plate
weldment,
mast mount
Place support stands
Note: Mast or blocks of wood
removed for under frame on both
clarity. sides of truck for support
and to maintain “level.
Steer motor assembly
spurgear Grease fittings (2)
Figure 6-46 Front End Assembly
This service is best performed at your service center as opposed to the customer facility.

6-71
To Begin…
2. Park the truck on a clean, flat, level surface with enough room to work in the area
safely.
3. Apply the hand parking brake and block all wheels.
4. Relieve hydraulic pressure in the system by turning the steering wheel two times to
the left, then two times to the right and move both joysticks in both directions.
7. Support the front end of the truck (between the rotation arm and the truck frame)
using support stands or blocks of wood capable of handling the weight. Review
“Lifting the Truck,” page 6-3.
8. Tag for identification, then disconnect the mast (1), tilt (2) and sideshift (2) hoses
from the bulkhead support bracket, located below the steer motor. Make sure you
identify both the hose and the bulkhead fitting (See Figure 6-45).
Immediately plug/cap the lines and have rags handy to clean up any oil spills.
9. Connect a strap from the overhead crane around the top center cross member of the
mast and apply slight tension only (See Figure 6-48). Also see “Removing the Mast
From the Truck,” on page 6-77.
Rotation Seals, Bearings or Spur Gear

1. Repeat “To Begin...” , beginning on page 6-72.
2. Remove the:
· Switch activator cam - 3/8”-16 setscrew
· Cotter pin and slotted hex nut - 2”-12
· Upper bearing spacer - use flatblade screw driver to pry bearing upwards (See
Figure 6-46).

6-72
To Remove Spur Gear Only

Note: For other than gear service, the spur gear does not have to be separated
from the front mounting plate (See Figure 6-46).
1. Remove the eight spur gear/mounting screws (½”-20) and hardware securing the
gear to the front plate weldment.
2. Replace or repair the gear and reassemble in reverse order.

6-73
Tilt cylinder
assembly
Mast assembly
Tilt cylinder
mounting
Seal
Trunnion pin
bolt 5/8”-11
Trunnion pin
Seal
Bushing
Articulate seal
assembly
Mast trunnion
pin assembly
Front mounting
plate
Tilt cylinder mount

mastremv Mast trunnion mount
Figure 6-47 Removing the Mast

6-74
Rotation Seals and Bearings

1. Slide a medium sized, long handled Phillips head screw driver through the cotter pin
hole into threaded portion of the rotation shaft. This prevents the shaft from dropping
out the bottom and provides a handle for lifting (See Figure 6-46).
2. From the bottom, remove the front rotation shaft hex screw (¾”-16) and hardware.
This single screw secures the shaft to the bottom of the front plate weldment
yoke (See Figure 6-46).
3. To remove the rotation shaft from the rotation arm assembly you must align all the
parts to allow the shaft to be pulled up and out. The overhead crane on the mast may
have to be raised or lowered a fraction of an inch to free the shaft.
4. With the shaft removed, roll the front plate weldment, mast assembly far enough
away from the rotation arm assembly to allow for safe working conditions while
servicing the bearings and seals.
CAUTION
Make sure the front plate weldment, mast assembly is stable in its lo-
cation and secured to the overhead crane.
5. As you separate the front plate from the rotation arm, the lower bearing spacer may
fall out. Immediately put in a safe place to avoid damage.
6. Remove the upper and lower seals and bearings (See Figure 6-46).
7. Use solvent to remove all traces of old grease from
the bearings, rotation arm inner race and the Strap
rotation shaft. Allow the parts to air dry.
8. Carefully inspect the bearings for cracks, heat
discoloration, worn rollers, etc. Check the upper
and lower bearing races for wear and/or damage.
IMPORTANT!
If a race is damaged it must be replaced and it is
good practice to replace both the upper and lower
at the same time. A portable hydraulic press 50D series
(come-along) is preferred. The new race
installation must be done carefully to maintain a
Figure 6-48 Supporting the Mast
level, parallel alignment between the upper and
lower race.

6-75
Hints for reassembly

· Pack the bearings with high-temperature bearing grease making sure the grease
penetrates the rollers, cone and cage from the back side.
Apply a thin coat of grease to the upper and lower inner race surfaces and ample
grease to the seal outer surfaces.
· If the races are replaced make sure they are properly seated against their
machined stop within the rotation arm frame.
· To install the rotation shaft, you must align all parts. The overhead crane may have
to be adjusted a fraction of an inch to allow the shaft to slide in place.
· Remember to install the bottom spacer before you roll the front mounting
plate/mast assembly back into place.
· Starting at the top of the assembly, carefully install the rotation shaft. Align the
shaft bottom through hole to the hole in the front plate weldment yoke (See Figure
6-46).
Install the hex screw and hardware. Tighten and torque accordingly (See Table 4-5
on page 4-6).
· Install the top portion of the assembly. Tighten and torque accordingly (See Table
4-5 on page 4-6).
· Apply additional grease at the two grease fittings (See ‘Front Column Rotation
Bearings / Gears,’ on page 4-24).
The Mast
WARNING
Only trained and experienced technicians or your Landoll service
representative must be allowed to service the mast assembly.
Never place any part of one’s body into the working area of the mast.
Never work on the mast while it is loaded; remove the load first.
Observe all safety precautions while operating the overhead crane

and lifting apparatus.

6-76
Tilt cylinder mount
Mast assembly
Lock nut
(B) Bearing
(A) Lock
Cylinder end plate
(hub)
Ring
Tube
Pin
Setscrew
(A)
Tilt cylinder (B)
Front Spacers
mounting
plate Keeper pin mounting
tilt cylinder
tiltrepr
Figure 6-49 Removing Tilt Cylinders
Removing the Mast From the Truck

To remove the mast, the work area must be clean and clear of obstacles, large enough to
lay the mast horizontally, have a concrete floor and an overhead crane and frame rated
to at least three (3) tons and three or four 6” x 6” x 48” (53 mm x 53 mm x 1,219 mm)
solid planks of wood.
It is recommended to thoroughly steam clean the mast, removing all dirt, debris and
grease.
Record the roller clearances and chain adjustments before removing the carriage or rails
(See ‘Inspect Lift Chains, Triplex,’ and “Chain and Roller Adjustment,” on page 6-10).
Make notes as you disassemble the mast while referring to the Appendix section of this
manual, index tab I-P 'Mast'. A separate manual is available for the triplex (3-stage) and
quad masts.
1. Review “To Begin...,” on page 6-72. Also review and keep handy the Mast
Service Manual, found in the Appendix, index I-P.
2. Remove the forks. Review “Removing Forks,” on page 6-38.

6-77
3. Remove the four bolts and hardware holding the backrest to the mast. Carefully
remove the backrest; it can be heavy - use adequate lifting apparatus or ask for a
helper.
4. At the mast, disconnect the lift cylinder hose (1) and both sideshift hoses (2) from the
bulkhead (See Figure 6-45).
5. Oil will drain from the cylinder lines and the hoses. Have shop rags handy to clean oil
spills. Plug and/or cap the cylinder ports and hoses to prevent further oil drainage.
Tag each hose for identification.
6. Attach an overhead crane and strap, rated to 3 tons, and apply slight lift to the
mast (See Figure 6-48).
7. Disconnect the two tilt cylinders from the mast - see “Tilt Cylinders,” beginning on
page 6-77 (See Figure 6-47).
8. With the tilt cylinders disconnect from the mast, move the overhead crane forward
slightly to provide a gap between the mast and the front mounting plate (See Figure
6-47).

6-78
CAUTION
Wedge a block of wood between the mast and the front mounting
plate to insure that the mast cannot be accidentally move backwards
while you are disconnecting the pivot pin assemblies.
9. Remove the trunnion pin bolts (5/8”-11) and hardware (See Figure 6-47).
10. Remove the wedged block of wood between the mast and front mounting plate and
slowly slide the mast backwards.
Raise the mast enough to release the trunnion pins from their supports.
Sideshift
assembly
Left sideshift
(Right)
(Left)
Right sideshift
sideshift
Figure 6-50 Sideshift Assembly
WARNING
The mast may swing from the lift truck, be alert and cautious!
11. Lay the mast horizontally, carriage side facing up, across three or four 6” x 6” x 48”
(53 mm x 153 mm x 1,220 mm) planks of wood.
12. Dismantle, clean and inspect the mast assemblies and subassemblies as instructed
in the Service Manual.
13. Reassemble the mast in reverse order, using your notes as necessary and the
enclosed Mast Service Manuals.
14. Before returning the mast to service, perform all adjustment procedures listed in
enclosed Mast Service Manuals. Refer to the Appendix, index tab I-P 'Mast'.

6-79
Articulation bearing and

seal assembly - front
Load wheel axle

assembly
Trunnion bearing
Trunnion cover
o-ring
Mounting block
Hex head cap screw,

1”-8 x 5 Hex head cap
screw, 1/4-20 x 1/2
articula Trunnion cover

Figure 6-51 Articulation Bearing and Seal
Tilt Cylinders
1. Repeat “To Begin...,” on page 6-72.
2. If the cylinder is being removed, disconnect the two hydraulic hoses (A and B) from
the cylinder being serviced. Cap and plug the hoses and cylinder ports. Also tag the
hoses for identification. Have rags handy to soak up oil spills (See Figure 6-49).
3. Mark the location of the cylinder locknut for reassembly to the new cylinder.
4. On the mast end of the cylinder, remove the bolt and hardware from the keeper pin
assembly and lift the cylinder free from the mast assembly (See Figure 6-49).
Do not lose the cylinder spacers (6) and note how many spacers are on each side of
the cylinder hub.

6-80
5. If the cylinder is being removed, loosen set screw

from the cylinder end, then remove the tilt cylinder Hex head cap
pin. screw 3/8-16
6. Lift the cylinder from the front plate mount and

Rotation
remove the tube spacers from each side of the stop
cylinder hub.
7. If the cylinder is being replaced, (See Figure
6-49)
Rotation stop assembly
· Mark the location of the cylinder lock nut on the
shaft. stopblck
· Bend the lock plate tabs back from the cylinder

lock nut. Figure 6-52 Front Rotation Stop
· Loosen the cylinder shaft lock nut and thread
the cylinder from the end hub.
· To repair the tilt cylinder, replace seals, wiper, O-rings, etc., see Bendi Series IV
Parts List (p/n F-371-___).
· Install the lock nut, lock plate and cylinder end (hub) to the new cylinder shaft and
set the lock nut in the approximate same position as on the old cylinder.
· Continued from Step 13., beginning on page 6-81.
8. To service the cylinder end (hub) bearing, (See Figure 6-49)
Note: It is not necessary to disassemble the cylinder end from the shaft and dis-
turb the lock nut setting. Simply support the cylinder in a vise making sure not
to damage or crimp the cylinder casing.
· Remove both retaining rings from within Horn button
the cylinder hub.
· Remove the old bearing and thoroughly Direction control
clean the cylinder end (hub).
· Coat the new bearing with grease, then
install it and both retaining rings.
· Insert both tube spacers to each side of
the assembly, then position the cylinder
end between the front plate mounts.
· Insert the cylinder pin, flush on both
side. Tighten the locking setscrew to
secure the assembly.
· Continued from Step 13., beginning on
page 6-81. Arm rest
horn
9. When tilt cylinder installation is complete
(cylinder is connected to the mast and Figure 6-53 Horn Button/Direction
front plate), remove the strap securing the Switch
mast to the overhead guard.
10. Readjust tilt cylinder/mast racking (See ‘Check Tilt Cylinder Racking,’ on page 4-20).

6-81
Sideshifter Cable
connector
Horn
2. Park the truck on a clean, flat, level surface with
enough room to work in the area safely.
3. Apply the hand parking brake and block all wheels.
4. Relieve hydraulic pressure in the system by
turning the steering wheel two times to the left,
then two times to the right and move both joysticks
in both directions. horn-2
5. Set the key switch to OFF and place the key in
Figure 6-54 Horn Location
your pocket.
7. Disconnect the two hydraulic hoses (Left and Right) at the sideshift cylinder (See
Figure 6-50).
The hoses feed back to the bulkhead should they require replacement (See Figure
6-45 on page 6-70).
8. Cap and plug the hoses and cylinder ports. Also tag the hoses for identification. Have
rags handy to soak up oil spills.
9. To remove the sideshift assembly from the truck and/or service sideshift components,
see Appendix, index tab Q - Z 'Sideshift'.

6-82
Fan and
Fan grill hardware
Floor
compartment
Frame
well area
Fan Mounting
plate
Hardware
fanbotm
Figure 6-55 Cooling Fan Service, Front and Rear
Articulation Bearing and Seal

1. Repeat “To Begin...,” on page 6-72.
Omit Step 8. No hydraulic hoses need be removed.

2. With the truck and the mast support, remove the trunnion cover (four ¼”-20 hex
screws) (See Figure 6-51).
3. Remove the O-ring seal and clean off all grease. Examine seal for damage - replace
accordingly.
4. Remove the mounting block from the front axle (two 1”-8 hex screws) (See Figure
6-51).
5. At your work bench, remove the bearing from the block and examine for damage -
replace accordingly.
6. Clean all grease from the axle trunnion shaft, bearing and mounting block.
7. When reassembling, apply sufficient grease to all parts. Also be certain the O-ring
seals are properly installed (See Figure 6-51).

6-83
Headlight
option
Half strobe
light cover
Strobe and
reverse light
option
12v Tail light

option
Rear view
mirror option
Voice backup
alarm option
Beeper backup
alarm option
options
Figure 6-56 OHG Alarms and Lighting Options
Stop Block
The rotation stop acts as a cushion when the front end is turned the full 180° in either
direction (See Figure 6-52).
The rotation stop is replaced by simply removing the hex screw (3/8”-16).

6-84
Horn and Direction Control

The horn push button and directional control switch (forward-neutral-reverse) are located
on the driver’s arm rest panel. Each assembly is available as a complete unit only (See
Figure 6-53). The horn is located under the plastic front rotation cover.
Horn/Horn Pushbutton
1. Make sure the key switch is OFF and in your pocket and that the battery is
disconnected.
2. The horn push button is removed by -
· Remove the mushroom cap (setscrew) (See Figure 6-53).
· Remove the locknut.
· Open the top cover to its full opened and locked position.
· Note wire color and connection terminals and tag for identification. Disconnect
electrical leads to the pushbutton.
· Install the new horn pushbutton by reversing the preceding steps.
· Connect the battery and test the horn.

6-85
3. The horn (48VDC) is removed by -

· Make sure the key switch is OFF, placed in your pocket and that the battery
is disconnected.
· Removing the front rotation plastic cover (button head screws and hardware) to
expose the horn (See Figure 6-54).
· Disconnect the electrical cable.
· Remove the hex screws and hardware to separate the horn from the mounting
bracket attached to the frame (See Figure 6-54).
· Install the new horn by reversing the preceding steps.
· Connect the battery and test the horn.
Direction Control Switch

1. Make sure the key switch is OFF and in your pocket and that the battery is
disconnected.
2. Remove the switch locknut cap (See Figure 6-53).
3. Open the top cover to its full opened and locked position.
4. Note wire color and connection terminals and tag for identification. Disconnect
electrical leads to the switch.
5. Install the new horn by reversing the preceding steps. The switch and arm rest
casing are notched to insure proper installation.
6. Connect the battery and test the switch for forward and reverse travel.

6-86
Fans
Cooling fans (2 at 48VDC) are provided - one to circulate air within the frame well that
houses the pumps and motors (rear fan), the other to circulate air in the well below the
driver’s cab floor plate (front fan) (See Figure 6-55).
To Replace a Fan
1. Park the truck on a clean, flat surface with enough room to work in the area safely.
3. Apply the hand brake, disconnect the battery and block all wheels.
4. The front fan is accessed by removing the floor panel in the driver’ cab - see “Floor
Access Panel - Removal,” beginning on page 4-9.
5. The rear fan is accessed from underneath the truck (See Figure 6-55).
6. Either fan is replaced by removing the mounting hardware and disconnecting the
appropriate cable connector.
The front fan includes removing the protective grill; the rear fan must be separated
from its mounting bracket (See Figure 6-55).

6-87
Options
Trucks equipped with optional flood / headlights, tail and stop lights, flashing or spot lights
(strobe lights), etc. contain replaceable bulbs. Bulb replacement varies according to
manufacturer (See Figure 6-56).
Additional options can include rear view mirror, backup alarms, etc (See Figure 6-56).

6-88
Lights
WARNING
Make sure electrical power to the item being serviced is turned OFF
and that the battery is disconnected. Wear eye protection.
4. To replace a light bulb, in most cases a plastic lens must be removed to expose the
bulb (two or three screw and hardware).
5. Remove the bulb by pushing in while turning to the left (counterclockwise). Push the
new bulb into the socket, and turn it to the right (clockwise).
For certain assemblies, wiggle and pull-up on the light tube to remove it from the
base. Be careful to avoid breaking the glass tube in your hand.
Align the base of the new light tube over the base connector and press down to
install the tube. Handle the new bulb carefully to avoid breaking the glass tube.
6. To replace the light assembly, simply disconnect the cable connector and remove the
mounting hardware holding the light to its mounting bracket.
7. Where shielding (guard cover) is involved, make certain to replace the guard and
reassemble the light.
Back Up Alarms
Two types of back up alarm are offered - beeping and voice (See Figure 6-56).
WARNING
Make sure electrical power to the alarm is turned OFF and that the
battery is disconnected. Wear eye protection.
4. To replace the alarm assembly, simple disconnect the cable connector and remove
the mounting hardware holding the alarm to its mounting bracket (See Figure 6-56).

6-89
Notes

6-90
Appendix A - H
This section contains additional service/repair manuals, in
alphabetical order, for the following systems:
· Brake System
· Drive System
· Electrical System
If information is not provided for a component you wish to
service, contact your Landoll service representative. Information
may not be provided due to the sensitive nature of the product,
be it safety or technical requirements, or may not have been
available at time of publication.

Appendix I - P
This section contains additional service/repair manuals, in
alphabetical order, for the following systems:
· Lift System
· Mast
If information is not provided for a component you wish to

service, contact your Landoll service representative. Information
may not be provided due to the sensitive nature of the product,
be it safety or technical requirements, or may not have been
available at time of publication.

Bendi IV Service Manual F-378-0804 1-11,2012

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Bendi Series IV Forklift Operator’s Manual

Truck Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Bendi Series IV Forklift Operator’s Manual

Receiving and Inspection . . . . . . . . . . . . . . . . . . . . . . . 2-1

Bendi Series IV Forklift Operator’s Manual

Bendi Series IV Forklift Operator’s Manual

Corrective Maintenance. . . . . . . . . . . . . . . . . . . . . . . . 6-1

Bendi Series IV Forklift Operator’s Manual

Bendi Series IV Forklift Operator’s Manual

Bendi Series IV Forklift Operator’s Manual

Bendi Series IV Forklift Operator’s Manual

Using This Manual

Warranty and Parts

Receiving and Inspection

Bendi Series IV Forklift Service Manual

When applicable, special customer option operating instructions may also be

Bendi Series IV Forklift Service Manual

Mast IPB (illustrated parts breakdown)

Base IPB (illustrated parts breakdown)

Bendi Series IV Forklift Service Manual

* Landoll and Bendi are trademarks of the Landoll Corporation.

Bendi Series IV Forklift Operator’s Manual

Bendi Series IV Forklift Service Manual

To avoid personal injury when operating the truck, be extremely

Know the location of and be especially careful of all pinch points, as

Be especially careful when there are other people or moving or fixed

NEVER lift, lower or transport people. NEVER allow anyone on or un-

Bendi Series IV Forklift Service Manual

· Do not indulge in stunt driving or horseplay.

Bendi Series IV Forklift Service Manual

Seat Safety Switch

Emergency STOP Button

· in case of fire, smoke or

Figure S-1 Emergency STOP Button

Bendi Series IV Forklift Service Manual

Longitudinal Tipping Can Occur When:

Bendi Series IV Forklift Service Manual

Lateral Tipping Can Occur When:

Traveling and Load Handling

· Pay particular attention when

Bendi Series IV Forklift Service Manual

Bendi Series IV Forklift Service Manual

Consult the label on your battery for information on cell-type,

Packaged with every battery are specific instructions for battery

Always disconnect the battery before performing any truck mainte-

Neutralize acid spills immediately with Bicarbonate of soda! If acid

Use caution when changing battery connectors to ensure that the

Bendi Series IV Forklift Service Manual

Be sure to replace, close and/or retighten any battery restraints

Bendi Series IV Forklift Service Manual

Bendi Series IV Forklift Service Manual

Bendi Series IV Forklift Service Manual

Figure S-4 Safety Label Location

Bendi Series IV Forklift Service Manual

Figure S-5 Safety Decal Identification

Bendi Series IV Forklift Service Manual

Figure S-6 Safety Decal Identification

Bendi Series IV Forklift Service Manual

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

NEVER reach through the backrest or between the fork positioner

Daily, check the upper hook engagement, the

Figure S-7 Fork Check Points

Bendi Series IV Forklift Service Manual